Chevrolet - Element EX - Wiring Diagram - 2000 - 2003

Diagram Information and Instructions 4WD Control Unit: Diagram Information and Instructions How to Identify Wiring Color-Coded Insulation Wire Color Wire Color Coding Page 8211 3. Remove the screw while pulling the inside lever toward you and then remove the inside handle. 4. Remove the speaker grille (3). - Pull out the front side of the grille. 5. Remove the speaker assembly (2). 6. Remove the door mirror cover. 7. Remove the grip cover. Accelerator Pedal Assembly/Sensor - Adjustment Update Accelerator Pedal Position Sensor: All Technical Service Bulletins Accelerator Pedal Assembly/Sensor - Adjustment Update 00-045 August 14, 2001 Applies To: 2000-02 Passport - ALL Service Manual Update: Accelerator Pedal Position Sensor (APPS) (Supersedes 00-045, dated May 23, 2000) Updated information is shown by asterisks and black bars. BACKGROUND When the accelerator pedal position sensor (APPS) or the accelerator pedal assembly is replaced for any reason, you must adjust the APPS. *This procedure is missing in the 2000 service manual and is wrong in the 2001 and 2002 service manuals. Make a note on page 6E2-539 of the 2000 Passport Fuel and Emissions manual, on page 6E2-553 of the 2001 Passport Fuel and Emissions manual, and on page 6E2-545 of the 2002 Passport Fuel and Emissions manual to refer to this bulletin.* ADJUSTMENT PROCEDURE 1. Replace the APPS or the accelerator pedal assembly, and leave the mounting screws for the APPS loose. 2. Connect the PGM Tester to the data link connector (DLC), and turn the ignition switch to ON (II). *3. While watching the APP Sensor values in the Engine Data List, adjust the APPS by turning it until the values are within the ranges shown at closed pushed all the way down), then tighten the throttle and wide open throttle (accelerator pedal mounting screws and recheck the values. ^ If all three sensors are within range, go to step 12. ^ If APP Sensor 1, APP Sensor 2, and/or APP Sensor 3 cannot be brought into range, go to step 4. 4. Troubleshoot for an open circuit or a PCM malfunction. ^ If APP Sensor 1 has a value of 0% or APP Sensor 2 and/or APP Sensor 3 have a value of 99%, an open circuit exists or the PCM is malfunctioning. Repair the circuit or replace the PCM, and repeat step 3. ^ If you don't find a problem, go to step 5. 5. Disconnect the 10P connector from the APPS. 6. View the APP Sensor values in the Engine Data List. ^ If APP Sensor 1 has a value of 0% or APP Sensor 2 and/or APP Sensor 3 have a value of 99%, go to step 7. ^ If APP Sensor 1 has a value other than 0%, or APP Sensor 2 and/or APP Sensor 3 have a value other than 99%, a short circuit exists or the PCM is malfunctioning. Repair the circuit or replace the PCM, and repeat step 3. Page 3064 Canister Purge Solenoid: Service and Repair REMOVAL PROCEDURE 1. Disconnect the electrical connector from the EVAP canister purge solenoid. 2. Disconnect the vacuum hoses from the EVAP canister purge solenoid. 3. Remove the EVAP canister purge solenoid retaining bolt from the common chamber. 4. Remove the EVAP canister purge solenoid. INSTALLATION PROCEDURE 1. Install the EVAP canister purge solenoid on the upper intake manifold. 2. Install the EVAP canister purge solenoid retaining bolt. Tighten Tighten the bolts to 20 N.m (16 lb ft.). Page 2192 4. Remove the fuel pressure regulator from the fuel rail. 5. Remove the fuel return line from the regulator. 6. Install the new fuel pressure regulator in the reverse order of removal. 7. Use the Smart Cable to reprogram the PCM with the latest software from the June 2001 or later HONDANET CD-ROM. Refer to Service Bulletin 99-005, Updating the Passport PCM, filed under Tools. 8. Use the PGM Tester to clear any DTCs. 9. Use the PGM Tester to check the broadcast code. Make sure the broadcast code matches the one you selected from the CD-ROM. WARRANTY CLAIM INFORMATION In warranty: The normal warranty applies. Failed Part: P/N 8-17113-398-0 H/C 5504386 Defect Code: 092 Contention Code: C99 Skill Level: Repair Technician Out of warranty: Any repair performed after warranty expiration may be eligible for goodwill consideration by the District Service Manager or your Zone Office. You must request consideration, and get a decision, before starting work. REPAIR PROCEDURE - POWER STEERING SWITCH 1. Drain the power steering fluid out of the system. 2. Remove the power steering fluid reservoir. Clean the reservoir with solvent, then with soap and water. Rinse and dry it thoroughly. 3. Reinstall the reservoir. Do not connect the return hose. 4. Remove the power steering pressure switch, then clean it with brake cleaner and a scraper. Reinstall the switch, and torque it to 20 N.m (14 lb-ft). 5. Cover the unconnected end of the reservoir with your finger, then fill the reservoir with Dexron III ATF Page 6150 Wires Wire insulation can be one color, or one color with another color stripe. (The second color is the stripe.) This circuit continues on another image. (The arrow shows direction of current flow.) To follow the RED/BLK wire in this example, you would turn to "Fuel and Emissions" and look for the "A" arrow. Service and Repair Output Shaft: Service and Repair For further information regarding this component and the system that it is a part of, please refer to Automatic Transmission/Transaxle; Service and Repair; Unit Overhaul Page 3568 Testing For A Short With A Self-Powered Test Light or DVOM 1. Remove the blown fuse and disconnect the battery and load. 2. Connect one lead of a self-powered test light or digital volt/ohmmeter (DVOM) (switched to the lowest "OHMS" range) to the fuse terminal on the load side. 3. Connect the other lead to a known good ground. 4. Beginning near the fuse box, wiggle the harness. Continue this at convenient points about six inches apart while watching the test light or DVOM. 5. If the self-powered test light goes on or the DVOM displays a low reading or no reading (zero), there is a short to ground in the wiring near that point. Testing for a Short with a Test Light or DVOM 1. Remove the blown fuse and disconnect the load. 2. Connect a test light or digital volt/ohmmeter (DVOM), switched to the appropriate DC volts range, across the fuse terminals to make sure voltage is present. You might have to turn the ignition switch to ON; check the schematic to see. 3. Beginning near the fuse box, wiggle the harness. Continue this at convenient points about six inches apart while watching the test light or DVOM. 4. Where the test light goes , or the DVOM voltage drops to zero, there is a short to ground in the wiring near that point. NOTE: Always use a DVOM on high impedance circuits. A test light may not glow (even with battery voltage present). Testing For A Short With A Short Circuit Locator (Short Finder) 1. Remove the blown fuse. Leave the battery connected. Page 3544 Ignition Coil: Service and Repair Inspection and Repair Check the ignition coil assembly for insulation. Check terminals for corrosion or damage, and replace as necessary. Measuring resistance of ignition coil assembly. Measure resistance of ignition coil assembly,and replace the ignition coil assembly if its value exceeds the standard. Page 1192 FLUID CONDITION - Fluid should be changed according to maintenance schedule. Page 7893 Part 1 Of 3 Page 5847 3. Photocopy the template that is shown. Cut out the template. Page 5796 ^ If this is your first time using the pop nut installer, or if you haven't used it in a while, practice installing one or two pop nuts onto the pop nut test plate: - Place a pop nut at the tip of installer's threaded mandrel. Make sure to keep your fingers away from the gap between the pop nut and the base of the mandrel. Squeeze the installer's trigger; the pop nut threads onto the mandrel. - Insert the pop nut into a hole on the pop nut test plate. Make sure the pop nut is seated against the plate. - Squeeze and hold the installer's trigger until the mandrel reverses and unthreads the pop nut. - Measure the diameter of the expanded (crush) section of the installed pop nut; it should be at least 15 mm. If you need more practice, install another pop nut on the test plate. 34. Install a pop nut in each of the 32 holes you drilled on the frame rails (16 per bracket). Make sure each pop nut is seated against the frame before you pull the trigger. Continue holding the trigger until the mandrel reverses direction. Once reversed, pull back slightly, and the mandrel unthreads the pop nut. Page 5393 ^ If the wheels are pointed to the right, shorten the driver's side tie-rod, and lengthen the passenger's side. ^ If the wheels are pointed to the left, shorten the passenger's side tie-rod, and lengthen the driver's side. ^ Each 360° turn of the tie-rod equals about 8 mm of steering wheel adjustment. For example, a steering wheel is off-center by 4 mm with the front wheels pointed right (when the steering wheel is centered). To correct the off-center, shorten the driver's side tie-rod by a half-turn, and lengthen the passenger's side tie-rod by a half-turn. 4. Use your diagnosis worksheet to fill in the following table and build your 15-digit DTC. Specifications Convertible Top: Specifications Main Data And Specifications Main Data And Specifications Torque Specification Application N.m lb.ft lb.in Sunroof Glass Fixing Screws (LWB) 4 35 Sunroof Handle Plate Fixing Nuts (SWB) 8 69 Resin Top Assembly Fixing Bolts and Nuts 15 11 Rear Seat Belt Anchor Bolts 39 29 Seat Belt Cross Bar Assembly Fixing Bolts 19 14 Page 4555 Wires Wire insulation can be one color, or one color with another color stripe. (The second color is the stripe.) This circuit continues on another image. (The arrow shows direction of current flow.) To follow the RED/BLK wire in this example, you would turn to "Fuel and Emissions" and look for the "A" arrow. Page 511 Parking Brake Warning Switch: Description and Operation The brake system warning light goes on to alert the driver that the parking brake is applied or that the brake fluid is low. It also lights as a bulb test when the engine is cranked. With the ignition switch in ON or START, battery voltage is applied through fuse 11 to the brake system warning light. When the parking brake is applied, the parking brake switch closes and provides a ground for the light. The brake system warning light goes on to remind the driver that the parking brake is applied. Page 1100 Compression Check: Testing and Inspection Engine Compression Test Procedure 1. Start and run the engine until the engine reaches normal operating temperature. 2. Turn the engine off. 3. Remove all the spark plugs. 4. Remove ignition coil fuse (15A) and disable the ignition system. 5. Remove the fuel pump relay from the relay and fuse box. 6. Engage the starter and check that the cranking speed is approximately 300 rpm. 7. Install cylinder compression gauge into spark plug hole. 8. With the throttle valve opened fully, keep the starter engaged until the compression gage needle reaches the maximum level. Note the reading. 9. Repeat the test with each cylinder. If the compression pressure obtained falls below the limit, engine overhaul is necessary. Limit: 1000 kPa (145 psi) Page 2765 it is located, and what it connects to. Use the Connector Views to help locate the proper cavity when you need to probe a connector. It can be especially helpful if the connector has more than one wire of the same color. A dash symbol (-) indicates that the cavity is empty. Connector views can also be used to help diagnose multiple symptoms in separate circuits which could be caused by a single problem in a connector shared by those circuits. Here's an example: 1. Pick one of the multiple symptoms and look up the schematic for that circuit. 2. Make a list of all the in-line and fuse box connectors in that schematic , 3. Then, in the Connector Views, look up each connector on your list to see if circuits related to the other symptoms run through one of them. If they do, inspect that connector for the problem. Example: The blower, rear window defogger, and the windshield wiper don't work. List all in-line and fuse box connectors in the blower controls circuit and then check the Connector View (see the sample). You find that C324 is common to the blower controls, rear window defogger, and wiper/washer, so you inspect C324 and find the problem, bent terminals. Finding Component/Connector Locations Finding Component/Connector Locations To see where a component or connector is located on the car, look up its photo number in the "Component Location". The photo will also tell you the color of the connector, and how many cavities it has. Page 5532 4. Remove the fuel pressure regulator from the fuel rail. 5. Remove the fuel return line from the regulator. 6. Install the new fuel pressure regulator in the reverse order of removal. 7. Use the Smart Cable to reprogram the PCM with the latest software from the June 2001 or later HONDANET CD-ROM. Refer to Service Bulletin 99-005, Updating the Passport PCM, filed under Tools. 8. Use the PGM Tester to clear any DTCs. 9. Use the PGM Tester to check the broadcast code. Make sure the broadcast code matches the one you selected from the CD-ROM. WARRANTY CLAIM INFORMATION In warranty: The normal warranty applies. Failed Part: P/N 8-17113-398-0 H/C 5504386 Defect Code: 092 Contention Code: C99 Skill Level: Repair Technician Out of warranty: Any repair performed after warranty expiration may be eligible for goodwill consideration by the District Service Manager or your Zone Office. You must request consideration, and get a decision, before starting work. REPAIR PROCEDURE - POWER STEERING SWITCH 1. Drain the power steering fluid out of the system. 2. Remove the power steering fluid reservoir. Clean the reservoir with solvent, then with soap and water. Rinse and dry it thoroughly. 3. Reinstall the reservoir. Do not connect the return hose. 4. Remove the power steering pressure switch, then clean it with brake cleaner and a scraper. Reinstall the switch, and torque it to 20 N.m (14 lb-ft). 5. Cover the unconnected end of the reservoir with your finger, then fill the reservoir with Dexron III ATF Page 6510 Front And Rear Seat Belts Specifications Steering Wheel: Specifications Steering wheel Rotational play measured at outside edge With engine running ............................................................................................................................................................ 0 - 30 mm (0 - 1.18 inch) Page 8117 Power Window Switch: Service and Repair Master Switch Replacement Removal 1. Disconnect the battery ground cable. 2. Remove the switch (1). - Pull out the switch by pushing the spring with the tip of a screwdriver. - Disconnect the connector. Installation To install, follow the removal steps in the reverse order. Page 1552 1. Install cylinder head cover. - Clean the sealing surface of cylinder head and cylinder head cover to remove oil and sealing materials completely. - Apply sealant (TB-1207B or equivalent) of bead diameter 2-3 mm at eight place of arched area of camshaft bracket on front and rear sides. - The cylinder head cover must be installed with in 5 minutes after sealant application to prevent hardening of sealant. - Tighten bolts to the specified torque. Torque: 9 Nm (80 inch lbs.) 2. Install fuel injection harness bracket and tighten bolt to the specified torque. Torque: 9 Nm (80 inch lbs.) 3. Connect ignition coil connector and ignition coil, then tighten bolt to the specified torque. Torque: 4 Nm (35 inch lbs.) 4. Connect ground cable and tighten bolts to the specified torque. Torque: 9 Nm (80 inch lbs.) 5. Connect camshaft angle sensor connector. 6. Install positive crankcase ventilation hose. 7. Install air cleaner duct assembly. Page 2569 Ground - "G" Shielding Sheilding This represents RFI (Radio Frequency Interference) shielding around a wire. The shielding is always connected to ground. Splices Page 4464 4. If the trouble occurs after the above test, charge the Axle Disconnect controller to the new one. Page 3420 3. Install the fuse and relay box cover. Page 6207 O-ring(2) must be fitted in the groove (1) of refrigerant line Insert the nut into the union. First, tighten the nut by hand as much as possible, then tighten the nut to the specified torque. Specifications Stabilizer Bar: Specifications Stabilizer Bar Front Link Attaching Nut 50 Nm Bracket Bolts 25 Nm Rear Link Nuts 31 Nm Bracket Bolts 25 Nm Page 3351 Fuel Tank Unit: Service and Repair Removal 1. Disconnect the battery ground cable. 2. Remove the fuel tank (1). 3. Remove the fuel tank unit (2). - Disconnect the connector. - Remove the five fixing screws. Installation To install, follow the removal steps in the reverse order. Locations Relay Box: Locations Page 3344 Wire Color Abbreviations The following abbreviations are used to identify wire colors in the circuit schematics: WHT................................... White YEL................................... Yellow BLK................................... Black BLU................................... Blue GRN................................... Green RED................................... Red ORN................................... Orange PNK................................... Pink BRN................................... Brown GRY................................... Gray PUR................................... Purple LT BLU................................... Light Blue LT GRN................................... Light Green Page 2042 the component if the component only has one connector, or by a capital letter (A, B, C, etc.) if the component has more than one connector. Below most connector numbers and component names are PHOTO and VIEW numbers. The PHOTO number refers to a photo in the back of the book that shows the connector's location on the car. The VIEW number refers to an illustration in the back of the book that shows the connector face, wire colors, connector cavity numbers, and other details. The connector cavity numbering sequence begins at the top left corner of the connector. Disregard any numbers molded into the connector housing. Wires Wires are identified by the abbreviated names of their colors; the second color is the color of the stripe. Wires are also identified by their location in a connector. The number "2" next to the male and female wire terminals at C416, for example, means those terminals join in cavity 2 of connector C416. Symbols A complete description of schematic symbols is given under wire color abbreviation. Power Distribution Schematics Power Distribution schematics show how power is supplied from the positive battery terminal to various circuits in the car. Refer to the Power Distribution section to get a more detailed picture of how power is supplied to the circuit you're working on. From Battery to Ignition Switch, Fuses, and Relays Individual circuit schematics begin with a fuse. The first half of Power Distribution, however, shows the wiring "upstream" between the battery Page 631 3. Connect the electrical connector. 4. Fill the radiator with coolant. Refer to Draining and Refilling Cooling System. 5. Connect the negative battery cable. Description and Operation Brake Proportioning/Combination Valve: Description and Operation The P&B; valve contains two sections, each serving a different function. The proportioning section of the P&B; valve proportions outlet pressure to the rear brakes after a predetermined rear input pressure has been reached. This is done to prevent rear wheel lock up on the vehicles with light rear wheel loads. The valve has a by-pass feature which assures full system pressure to the rear brakes in the event of front brake system malfunction. Also full front pressure is retained in the event of rear brake malfunction. The P&B; valve is not repairable and must be replaced as complete assembly. Page 7306 Tailgate Lock (SWB) And Associated Parts Locations Parking Brake Warning Switch: Locations Under Center Console Page 7353 Cruise Control Switch: Service and Repair Removal 1. Disconnect the battery ground cable. 2. Remove the meter cluster assembly (1). 3. Remove the rear defogger switch (2). - Disconnect the switch connector. - To remove the switch, push the lock from the back side of the instrument panel cluster assembly. Installation To install, follow the removal steps in the reverse order. Description and Operation Ignition Cable: Description and Operation Spark Plug Cables Spark Plug Cables The cable contains a synthetic conductor which is easily damaged. Never stretch or kink the cable. Disconnect the cable from spark plug and the ignition coil. The original equipment cables and the ignition coil are marked to show correct location of the cables. If spark plug cables or the ignition coil are replaced previously, before cables are removed from the ignition coil, mark the cables and the coil so they can be reconnected in the same position. Page 671 96. Rear of Right Catalytic Converter Rear of right catalytic converter 94. Rear of Left Catalytic Converter Rear of Left Catalytic Converter Page 611 Accelerator Pedal Position Sensor: Adjustments Accelerator Position Sensor Adjustment AP sensor is controlled three multiple control system, and adjust the idle position and WOT position are between A and B for AP sensor 1, AP sensor 2, and AP sensor 3. Refer to "How to adjust for AP sensor". How To Adjust For AP Sensor 1. Connect the Tech 2 to DLC on vehicle. 2. Ignition "ON," engine "OFF". 3. Display the APS date list. Check the following item for AP position (%). 4. If the problem was found, adjust as necessary. Page 8155 1. Install the regulator handle as shown in the figure, if equipped without Dower windows. 2. Check to see that the window regulator operates smoothly and the glass opens and closes properly. 3. Install the waterproof sheet tightly against the door panel. Page 7783 and the fuses. From Fuses to Relays and Components The second half of Power Distribution shows the wiring "From Fuses to Relays and Components." This can speed your troubleshooting by showing which circuits share fuses. If Power Distribution shows that an inoperative circuit and another circuit share a fuse, check a component in the other circuit. If it works, you know the fuse is good and power is available to the inoperative circuit. Ground Distribution Schematics Page 3850 identify it.) 3. Connect the PC adapter end of the PC interface kit to the 9P serial port on the DCS workstation. NOTES: It the workstation you're using isn't the same one used for updating PGM Tester program cards, you'll need to disconnect the interface kit from one workstation, and then connect it to the 9P serial port on the other workstation. To avoid this extra step, get a PC interface kit for each workstation. 4. Connect the 110 VAC/12 VAC power supply to the Smart Cable box and to 110 VAC power. 5. Log in to HONDANET 2000. 6. At the top of the HONDANET 2000 screen, click on Service Bay, then click on Smart Cable from the drop-down menu. This brings up the Smart Cable Welcome screen. 7. Retrieve the PCM broadcast code with the Smart Cable or the PGM Tester. ^ To retrieve the code with the Smart Cable, go to step 8. ^ To retrieve the code with the PGM Tester, go to step 14. 8. From the Smart Cable Welcome screen, click on Get ID. When the "Smart Cable is programmed to Get ID" message appears, disconnect the cable from the workstation.* 9. *Disconnect the Smart Cable from the DCS workstation, then take it to the vehicle. Turn the ignition switch ON (II), and connect the Smart Cable to the vehicle's DLC. 10. When the green and yellow lights on the Smart Cable glow steadily, disconnect it from the DLC. 11. Reconnect the Smart Cable to the DCS workstation (steps 2 thru 4 above). 12. From the Smart Cable Welcome screen, click on View ID. The broadcast code needed by the PCM will be highlighted. 13. Click on the highlighted broadcast code, and follow the instructions to reprogram the Smart Cable with the broadcast code needed for the PCM update. When the Smart Cable has been reprogrammed, go to step 21. 14. Connect the Tester to the vehicle's DLC, then turn the ignition switch ON (II). 15. From the System Select menu, press 1: ENGINE 16. From the Test Mode menu, press 6: MISC TEST 17. From the MISC TEST menu, press 6: BROADCAST CODE 18. Write down the 4-digit broadcast code; you'll need it to reprogram the Smart Cable. 19. Write down the 4-digit broadcast code; you'll need it to reprogram the Smart Cable. 20. Go back to the DOS workstation. From the Smart Cable Welcome menu, click on Select. 21. Follow the instructions to reprogram the Smart Cable with the broadcast code needed for the PCM update. 22. Now that the Smart Cable is programmed to update the PCM, go to USING A PROGRAMMED SMART CABLE.* Page 6624 5. Click Warranty Audio Order to view the Warranty Audio Order form. 6. Enter the VIN and the mileage, then click the Submit button to view the Warranty Audio Order form. Use the completed Audio/Navigation/RES Worksheet to help you answer the questions on the Warranty Audio Order form. Questions with a red asterisk (*) are required fields that you must answer to submit the form. Make sure the information is complete (17-digit VIN, etc.). This information is critical to the remanufacturing process. Screen # 2 of the form contains the problem description, condition information, and shared functions. Fill this section out with as much information as possible. Select one part number from the list provided, then click Submit. It is your responsibility to ensure the correct part number is selected based on color and application information. Page 7162 Roof Rack Frame: Service and Repair Removal 1. Remove the front and rear of roof rail cover. - Pry the roof rail covers. 2. Remove the roof rail sub assembly. - Remove the four fixing bolts at each roof rail. Installation To install, follow the removal steps in the reverse order, noting the following points. 1. Tighten the roof rail sub assembly fixing bolts to the specified torque. Torque 8 Nm (69 lb in) Locations Page 8118 Power Window Switch: Service and Repair Passenger's Window Switch Replacement Removal 1. Disconnect the battery ground cable. 2. Remove the switch (1). - Pull out the switch by pushing the spring with the tip of a screwdriver. - Disconnect the connector. Installation To install, follow the removal steps in the reverse order. Page 6398 The following procedure requires use of J-42986 Supplemental Restraint System (SRS) Deployment Harness with the appropriate pigtail adapter. The procedure also requires the use of J-41497 Driver Side SRS Deployment Fixture. Do not attempt this procedure without J-42986 and fixture J-41497. WARNING: FAILURE TO FOLLOW PROCEDURES IN THE ORDER LISTED MAY RESULT IN PERSONAL INJURY. NEVER CONNECT DEPLOYMENT HARNESS TO ANY POWER SOURCE BEFORE CONNECTING DEPLOYMENT HARNESS TO THE DRIVER AIR BAG ASSEMBLY. DEPLOYMENT HARNESS SHALL REMAIN SHORTED AND NOT BE CONNECTED TO A POWER SOURCE UNTIL THE AIR BAG IS TO BE DEPLOYED. THE AIR BAG ASSEMBLY WILL IMMEDIATELY DEPLOY THE AIR BAG WHEN A POWER SOURCE IS CONNECTED TO IT. WEAR SAFETY GLASSES THROUGHOUT THIS ENTIRE DEPLOYMENT AND DISPOSAL PROCEDURE. NOTE: This information applies only to driver air bag assembly Refer to "Deployment Outside Vehicle (Passenger Air Bag Assembly)" for information on passenger air bag assembly scrapping. 1. Turn ignition switch to "LOCK", remove key and put on safety glasses. 2. Inspect J-41434 SRS Deployment Harness and appropriate pigtail adapter for damage. If harness or pigtail adapter is damaged, discard and obtain a replacement. 3. Short the two SRS deployment harness leads together by fully seating one banana plug into the other. SRS deployment harness shall remain shorted and not be connected to a power source until the air bag is to be deployed. Page 289 If there is no photo number below or beside a component name or a connector, ground, or terminal number, look up that name or number in the appropriate Connector Identification Chart. The chart lists how many cavities a connector has, where it's located, and what it connects to. The related illustration shows the connector's location on the harness, and the harness routing. NOTE: Photos listed by number are located at Locations / Components / Photograohs. See: Locations/Component Locations/Photographs Circuit Schematics Page 6697 Radio/Stereo: Service and Repair Removal 1. Disconnect the battery ground cable. 2. Remove the lower cluster assembly (1). 3. Remove the radio (5). - Remove the two fixing screws. - Disconnect the connector (3) and the antenna cable (4). Installation To install, follow the removal steps in the reverse order, noting the following point: General Precautions Air Bag(s) Arming and Disarming: Service Precautions General Precautions General Precautions Please read the following precautions carefully before performing the airbag system service. Observe the instructions described or the airbags could accidentally deploy and cause damage or injuries. Except when performing electrical inspections, always turn the ignition switch OFF and disconnect the negative cable from the battery, and wait at least three minutes before beginning work. NOTE: The contents in the memory is not erased even if the ignition switch is turned OFF or the battery cables are disconnected from the battery. Use the replacement parts which are manufactured to the same standards as the original parts and quality. Do not install used SRS parts from another vehicle. Use only new parts when making SRS repairs. Carefully inspect any SRS part before you install it. Do not install any part that shows signs of being dropped or improperly handled, such as dents, cracks or deformation. Before removing any of the SRS parts (including the disconnection of the connectors), always disconnect the SRS connector. Use only a digital multimeter to check the system. If it is not a Honda multimeter, make sure its output is 10 mA (0.01 A) or less when switched to the lowest value in the ohmmeter range. A tester with a higher output could cause accidental deployment and possible injury. Do not put objects on the front passenger's airbag. The original radio has a coded theft protection circuit. Be sure to get the customer's radio code before disconnecting the battery cable. Page 6855 To install, follow the removal steps in the reverse order, noting the following points: 1. Install the regulator handle as shown in the figure, if equipped without power windows. 2. Check to see that the window regulator operates smoothly and the glass opens and closes properly. 3. Install the waterproof sheet tightly against the door panel. Page 2155 Manifold Pressure/Vacuum Sensor: Service and Repair MANIFOLD ABSOLUTE PRESSURE (MAP) SENSOR REMOVAL PROCEDURE 1. Disconnect the negative battery cable. 2. Disconnect the electrical connector from the MAP sensor. 3. Remove the bolt securing the MAP sensor to the mounting bracket on the common chamber. 4. Remove the MAP sensor from the mounting bracket. INSTALLATION PROCEDURE 1. Install the MAP sensor in the mounting bracket. 2. Install the mounting bracket retaining bolt on the common chamber. Page 1307 Page 7720 The wire insulation has one color or one color with another color stripe. The second color is the stripe. Diagram Information and Instructions Axle Disconnect Control Control Unit: Diagram Information and Instructions How to Identify Wiring Color-Coded Insulation Wire Color Wire Color Coding Page 5324 Fuse: Diagrams Instrument Panel Bleeding Brake Hydraulic System Brake Bleeding: Service and Repair Bleeding Brake Hydraulic System This procedure has been updated by TSB Manual Update # 01-016 dated January 30, 2001. BRAKE SYSTEM BLEEDING A bleeding operation is necessary to remove air from the hydraulic brake system whenever air is introduced into the hydraulic system. It may be necessary to bleed the hydraulic system at all four brakes if air has been introduced through a low fluid level or by disconnecting brake pipes at the master cylinder. If a brake pipe is disconnected at one wheel, only that wheel cylinder/caliper needs to be bled. If the pipes are disconnected at any fitting located between the master cylinder and brakes, then the brake system served by the disconnected pipe must be bled. 1. For 4-Wheel Antilock Brake System (ABS) equipped vehicle, be sure to remove the ABS main fuse 60A located at the relay and fuse box before bleeding air. If you attempt to bleed air without removing the main fuse, air cannot be let out thoroughly, and this may cause damage to the hydraulic unit. After bleeding air, be sure to replace the ABS main fuse back to its original position. 2. Set the parking brake completely, then start the engine. NOTE: The vacuum booster will be damaged if the bleeding operation is performed with the engine off. NOTE: To avoid trapping air bubbles in the ABS hydraulic unit while bleeding the brakes, the hydraulic unit must be tilted forward at a 15-degree angle or greater. Before bleeding, check the angle of the ABS hydraulic unit with an angle locator level. If needed, raise the rear of the vehicle to get the proper angle. The angle locator level (P/N SUN-YA328A) is available through the Honda Tool and Equipment Program. 3. Remove the master cylinder reservoir cap. 4. Fill the master cylinder reservoir with brake fluid. Keep the reservoir at least half full during the air bleeding operation 5. Always use new brake fluid for replenishment. 6. In replenishing brake fluid, take care that air bubbles do not enter the brake fluid. When the master cylinder is replaced or overhauled, first bleed the air from the master cylinder, then from each wheel cylinder and caliper following the procedures. BLEEDING THE MASTER CYLINDER 7. Disconnect the rear wheel brake pipe (1) from the master cylinder. Page 1361 Tires: Description and Operation GENERAL DESCRIPTION Replacement wheels or tires must be equivalent to the originals in load capacity, specified dimension and mounting configuration. Improper size or type may affect bearing life, brake performance, speedometer/odometer calibration, vehicle ground clearance and tire clearance to the body and chassis. All model are equipped with metric sized tubeless steel belted radial tires. Correct tire pressures and driving habits have an important influence on tire life. Heavy cornering, excessively rapid acceleration and unnecessary sharp braking increase premature and uneven wear. TREAD WEAR INDICATORS The original equipment tires have built-in tread wear indicators (1) to show when tires need replacement. These indicators may appear as wide bands. When the indicators appear in two or more grooves at three locations, tire replacement is recommended. Page 6873 Fuel Fill Door Page 5073 NOTE: Confirm that a white line marked on the cable is not twisted when connecting the speed sensor cable. 5. Install speed sensor connector. Page 7411 Splices Splices are shown as a dot. Their location and the number of wires may vary depending on the harness manufacturer. Switches Switches These switches move together; the broken straight line between them means they are mechanically connected. Other types of switches are controlled by a coil or a solid state circuit. Unless otherwise noted, all switches are shown in their normal (rest) position, with power off. Terminal "T" Page 163 it is located, and what it connects to. Use the Connector Views to help locate the proper cavity when you need to probe a connector. It can be especially helpful if the connector has more than one wire of the same color. A dash symbol (-) indicates that the cavity is empty. Connector views can also be used to help diagnose multiple symptoms in separate circuits which could be caused by a single problem in a connector shared by those circuits. Here's an example: 1. Pick one of the multiple symptoms and look up the schematic for that circuit. 2. Make a list of all the in-line and fuse box connectors in that schematic , 3. Then, in the Connector Views, look up each connector on your list to see if circuits related to the other symptoms run through one of them. If they do, inspect that connector for the problem. Example: The blower, rear window defogger, and the windshield wiper don't work. List all in-line and fuse box connectors in the blower controls circuit and then check the Connector View (see the sample). You find that C324 is common to the blower controls, rear window defogger, and wiper/washer, so you inspect C324 and find the problem, bent terminals. Finding Component/Connector Locations Finding Component/Connector Locations To see where a component or connector is located on the car, look up its photo number in the "Component Location". The photo will also tell you the color of the connector, and how many cavities it has. Specifications Brake Fluid: Specifications Fluid Type DOT 3 or 4 Page 6234 1. Before adding any leak-detection dye, check to see if there is dye in the system now. ^ Check for a label in the engine compartment indicating that fluorescent leak-detection dye has been added to the system. ^ Dye may have been added even though no label is present. To confirm this: - Put on the fluorescence-enhancing glasses, and remove the low-side service port sealing cap. - Direct the ultraviolet lamp into the valve stem area. If dye has been previously added, the lubricant traces will have a bright yellow fluorescent glow. You may need to press the port's valve stem briefly to release some lubricant and dye from the system. ^ If there is no dye in the system, go to step 2. ^ If there is dye in the system, go to step 5. Do not add more dye. 2. Add the dye. NOTE: Air and moisture must be evacuated from the universal connect set if it is being used for the first time, or if it has been stored with the control valve open. If the air and moisture have been evacuated, go to step 3; otherwise do the following: (a) Attach the empty dye capsule (provided in the dye kit) to the control valve fitting. (b) Attach the service valve fitting (provided in the kit) to the empty dye capsule. (c) Attach the low-side hose of the A/C recovery and charging station, and open the quick coupler's hand-wheel valve. Then open the control valve (black knob) on the universal connect set. (d) Following the manufacturer's instructions for your recovery and charging station, evacuate the universal connect set for approximately 3 minutes. (e) When evacuation is complete, be sure the set's control valve is closed (finger tight), and disconnect the NC recovery and charging station. (f) Remove the service valve fitting and the empty dye capsule from the set, and store them for future use. NOTE: ^ Check the refrigerant charge level. There must be enough refrigerant in the system to operate the A/C compressor and to circulate refrigerant oil. ^ If the refrigerant charge is too low, recover the remaining amount and recharge the system before adding any dye. (g) Start the vehicle and operate the A/C system. Follow your A/C refrigerant recovery and charging station's operating instructions for low-side charging to install the dye. * NOTE: Only 0.05 lb (0.02 kg) of refrigerant is needed to push the dye into the A/C system.* (h) Once the refrigerant charge is programmed, open the control valve on the set to allow the dye to enter the system. (i) After the dye capsule clears, allow the low-side of the A/C system to reach its lowest operating pressure, then quickly close both the service equipment's low-side coupler valve and the control valve on the set. (j) Remove the set from the vehicle by releasing its quick coupler. Remove the empty dye capsule from the service valve fitting. Return the hose, control valve, and service-valve fitting to the storage case. * NOTE: Store the hose with the control valve closed. This will retain a small amount of refrigerant in the hose so it does not have to be evacuated the next time you use it.* (k) Fill out an identification label (provided in the kit), and attach it to a location near the A/C charge label. Locations Air Flow Meter/Sensor: Locations 28. Left Side of Engine Compartment Left Side Of Engine Compartment Page 3369 This means the branch of the wire connects to another circuit. The arrow points to the name of the circuit branch where the wire continues. Page 6435 13. Install Air Bag (6) into steering wheel and tighten bolts (8) to specified sequence as figure. Torque: 8.8 N.m (0.9 kg.m / 78 lb.in) CAUTION: Never use the air bag assembly from another vehicle. Use only the air bag assembly for Rodeo Models Only. 14. Enable the SRS. Page 4286 Page 8127 Front Door Window Motor: Service and Repair Removal 1. Disconnect the battery ground cable. 2. Remove the window regulator assembly (2). 3. Remove the power window motor (1). - Remove three screws. Installation To install, follow the removal steps in the reverse order. Engine Controls - High/Erratic Engine Idle Power Steering Pressure Switch: Customer Interest Engine Controls - High/Erratic Engine Idle 01-080 August 14, 2001 Applies To: 2000-02 Passport - ALL 2000-02 Passport: High or Erratic Idle SYMPTOM The engine occasionally idles at too high a speed, or the idle speed fluctuates. PROBABLE CAUSES The symptom could be the result of any of these conditions: ^ Loose or corroded engine or body ground ^ High resistance in the APPS ground circuit ^ PSP (power steering pressure) switch is internally shorted to ground ^ Fuel pressure regulator is leaking fuel into the intake manifold CORRECTIVE ACTION Diagnose the cause of the idle condition, and select the proper REPAIR PROCEDURE. PARTS INFORMATION REQUIRED MATERIALS REQUIRED SOFTWARE Each REPAIR PROCEDURE requires you to use the Smart Cable to reprogram the PCM with the latest software. To select the latest software from the CDROM, enter the year, model, engine, transmission, and emissions type (49-state or California). This gives you a list of broadcast codes. Select the broadcast code at the top of the list. WARRANTY CLAIM INFORMATION Refer to the Warranty Claim Information for each Repair Procedure. DIAGNOSIS 1. Find out from the customer when the high or erratic idle condition occurs and what the RPM range is: ^ Within 20 minutes of a cold start ^ After braking to a stop ^ All the time ^ Intermittently, with no set pattern Page 7576 Wires Wire insulation can be one color, or one color with another color stripe. (The second color is the stripe.) This circuit continues on another image. (The arrow shows direction of current flow.) To follow the RED/BLK wire in this example, you would turn to "Fuel and Emissions" and look for the "A" arrow. Page 1964 Wires Wire insulation can be one color, or one color with another color stripe. (The second color is the stripe.) This circuit continues on another image. (The arrow shows direction of current flow.) To follow the RED/BLK wire in this example, you would turn to "Fuel and Emissions" and look for the "A" arrow. Page 6740 Wires Wire insulation can be one color, or one color with another color stripe. (The second color is the stripe.) This circuit continues on another image. (The arrow shows direction of current flow.) To follow the RED/BLK wire in this example, you would turn to "Fuel and Emissions" and look for the "A" arrow. Page 3500 4. Select F6: Variable Intake Manifold Solenoid Test. 5. Push "On" or "Off" of soft key. 6. Control VIM Solenoid check data list. - If data list changes, the VIM Solenoid is normal. Locations Air Flow Meter/Sensor: Locations 28. Left Side of Engine Compartment Left Side Of Engine Compartment Page 2643 Powertrain Control Module: Description and Operation Electrically Erasable Programmable Read Only Memory (EEPROM) Electrically Erasable Programmable Read Only Memory (EEPROM) The electrically erasable programmable read only memory (EEPROM) is a permanent memory chip that is physically soldered within the PCM. The EEPROM contains the program and the calibration information that the PCM needs to control powertrain operation. Unlike the PROM used in past applications, the EEPROM is not replaceable. If the PCM is replaced, the new PCM will need to be programmed. Equipment containing the correct program and calibration for the vehicle is required to program the PCM. Page 7880 The connector cavity number is listed next to each terminal on the circuit schematic. The cavity / terminal shown is # 6. Diodes A rectifier diode works like a one way valve. It allows current to flow only in the direction of the arrow. A Zener diode blocks reverse current at normal voltages just like a rectifier diode. At high voltages, however, a Zener diode allows current to flow in reverse. Fuses Page 3293 This sample Ground Distribution schematic shows all of the components that share two ground points. Components A solid border line means the entire component is shown. A broken border line indicates that only part of the component is shown. Adjustments Clutch Switch: Adjustments 1. Turn the clutch switch (1) until the switch plunger is fully retracted against the clutch pedal arm. 2. Adjust clutch switch by backing it out half a turn and measure the clearance (4) between the clutch pedal arm (3) and the clutch switch. 3. Lock the lock nut (2). 4. Connect clutch switch connector. Clutch Switch (bolt) and Clutch Pedal Clearance 0.5 - 1.5 mm (0.020 - 0.059 in) SRS Component Replacement/Inspection After Deployment Repairs and Inspections Required After a Collision: Service and Repair SRS Component Replacement/Inspection After Deployment REPAIRS AND INSPECTIONS REQUIRED AFTER AN ACCIDENT NOTE: If any SRS components are damaged, they must be replaced. If SRS component mounting points are damaged, they must be replaced. Never use SRS parts from another vehicle. This does not include remanufactured parts purchased from an authorized dealer; they may be used for SRS repairs. Do not attempt to service the SDM, the SRS coil assembly, or the air bag assembly. Service of these items is by replacement only. Verify the part number of replacement air bag assembly. CAUTION: Never use the air bag assembly from another vehicle and difference model year air bag assembly. The air bag assembly has identification colors on the bar code label from 00-02 models as follows. - Light blue color for driver air bag assembly. - Light blue color for passenger air bag assembly. - Use only the air bag assembly for Rodeo (UE) models. CAUTION: Proper operation of the sensors and Supplemental Restraint System (SRS) requires that any repairs to the vehicle structure return it to the original production configuration. Deployment requires, at a minimum, replacement of the SDM, air bag assembly and dimensional inspection of the steering column. Any visible damage to the SDM mounting bracket (s) requires replacement, and the steering column must be dimensionally inspected, whether deployment occurred or not. ACCIDENT WITH DEPLOYMENT COMPONENT REPLACEMENT AND INSPECTIONS Certain SRS components must be replaced or inspected for damage after a frontal crash involving air bag deployment. Those components are: - Air bag assembly - SDM - CAUTION: Refer to SDM Replacement Guidelines below for important information on SDM replacement in both deployment and non deployment crashes. - SRS coil assembly Inspect wiring and connector for any signs of scorching, melting, or damage due to excessive heat. Replace if damaged. Refer to SRS coil assembly. ACCIDENT WITH OR WITHOUT DEPLOYMENT - COMPONENT INSPECTION Certain SRS and restraint system components must be inspected after any crash, whether the air bag deployed or not. Those components are: - Steering column dimensionally inspect. Refer to Checking Steering Column for Accident Damage. - Knee bolsters and mounting points Inspect for any distortion, bending, cracking, or other damage. - I/P steering column reinforcement plate Inspect for any distortion, bending, cracking, or other damage. - I/P braces. Inspect for any distortion, bending, cracking, or other damage. - Seat belts and mounting points Refer to Seat Belts. SDM REPLACEMENT GUIDELINES SDM replacement policy requires replacement of SDM, after crash involving air bag deployment when SRS Warning Lamp turn ON, SRS Diagnosis should be done. WIRING DAMAGE If any SRS wire harness is damaged, it should be replaced. Don't repair SRS. It is replace only be replaced. Dont repair SRS. It is replace only SRS CONNECTOR DAMAGE (Plastic Body And Terminal Metal Pin) If any connector or terminal in the SRS wire harness (except pigtails) is damaged, it should be replaced. SRS WIRE PIGTAIL DAMAGE If the wiring pigtail (a wire or wires attached directly to the device, not by a connector) is damaged, the entire component (with pigtail) must be replaced. Examples of pigtail components are the driver air bag assembly, the passenger air bag assembly, and the SRS coil assembly. Page 6753 Trailer Connector: Description and Operation With the converter jumper installed, a power wire must be spliced into the RED/WHT wire above the cargo area light to ensure that the converter is powered with 12 V at all times. Page 4833 angle. The angle locator level (P/N SUN-YA328A) is available through the Honda Tool and Equipment Program. To order one, call 888-424-6857. DISCLAIMER Page 855 INSTALLATION 1. Install lock cylinder assembly. 2. Install shift lock cable (for A/T). 3. Install cushion rubber. 4. Install snap ring. 5. Install Combination switch and SRS coil assembly. After installation of combination switch assembly, connect the combination switch wiring harness connector and the SRS 2-way connector located under the steering column. 6. Turn the SRS coil counterclockwise to full, return about 3 turns and align the neutral mark. CAUTION: When turning the SRS coil counterclockwise to full, stop turning if resistance is felt. Forced further turning may damage to the cable in the SRS coil. Page 6629 ^ Online, enter keyword AUDIO, NAVI, or RES, and select the appropriate removal procedure from the list. NOTE: If the customer's media (CD, CD magazine, DVD, DVD-A, cassette tape, navigation DVD, etc.) is stuck in the unit, leave it there. The manufacturer will remove and return it. 3. Obtain an Out-of-Warranty/New Replacement component repair form, and complete the Technician section.To obtain the form, do this: ^ On ISIS, click on Technical Library, then click on Job Aids. ^ Select the applicable form from the list, and print it out: - Out-of-Warranty/New Replacement Audio System Component Repair Form - Out-of-Warranty/New Replacement Navigation System Component Repair Form - Out-of-Warranty/New Replacement Rear Entertainment System Component Repair Form Parts Manager: 4. Complete the parts manager's section of the Out-of-Warranty/New Replacement component repair form. Make sure you include your name, department, and dealership phone number on the form. 5. Identify the manufacturer. Units sent to the wrong manufacturer may not be shipped back within the usual 5-7 days. ^ Look for the number code on the face of the unit. ^ If the unit has no number code on its face, check the label on the unit housing, and compare the first two or three letters of the radio reference number (or the audio unit model number) to this list: Alpine - CM, CD, MR, or MF Clarion - PH Fujitsu Ten - CE or SD Panasonic - CQ or CR Pioneer KEH or DEH 6. Contact the manufacturer (see step 9) to request an estimate for the cost of the repair plus shipping. 7. Complete the required paperwork: ^ Paying by check - Make a dealership check out to the manufacturer for the cost of repair and return shipping. Make sure to include the check number on the form. NOTE: For all Panasonic products, make your check out to Komtec Electronics. ^ Paying by credit card (Visa or Mastercard only) - When you use a credit card, fill in all of these fields on the component repair form: - Credit card number - Credit card expiration date Page 3563 This means the branch of the wire connects to another circuit. The arrow points to the name of the circuit branch where the wire continues. Page 5434 DIAGNOSTIC WORKSHEET REPAIR PROCEDURE A Page 818 Air Flow Meter/Sensor: Service and Repair Mass Air Flow (MAF) Sensor REMOVAL PROCEDURE 1. Disconnect the negative battery cable. 2. Disconnect the electrical connector from the MAF sensor. 3. Loosen the clamps which secure the intake air duct and the air cleaner to the MAF sensor. 4. Remove the intake air duct from the MAF sensor. 5. Remove the MAF sensor from the air cleaner. INSTALLATION PROCEDURE SRS Operation Air Bag(s) Arming and Disarming: Description and Operation SRS Operation The SRS is a safety device which, when used in conjunction with the seat belt, is designed to help protect the driver (and front passenger) in a frontal impact exceeding a certain set limit. The system consists of the SRS unit (including safing sensor and impact sensor), the cable reel, the driver's airbag (and front passenger's airbag). Operation The main circuit in the SRS unit senses and judges the force of impact and, if necessary, ignites the inflator charge(s). If battery voltage is too low or power is disconnected due to the impact, the voltage regulator and the back-up power circuit respectively will keep voltage at a constant level. For the SRS to operate: 1. The impact sensor must activate, and send electric signals to the microprocessor. 2. The microprocessor must compute the signals, and must send signals to the airbag inflator(s). 3. The inflator(s) must ignite and deploy the airbag(s). Self-diagnosis System A self-diagnosis circuit is built into the SRS unit; when the ignition switch is turned ON (II), the SRS indicator light comes on and goes off after about six seconds if the system is operating normally. If the light does not come on, or does not go off after six seconds, or if it comes on while driving, it indicates an abnormality in the system. The system must be inspected and repaired as soon as possible. For better serviceability, the memory will store the cause of the malfunction, and the data link circuit passes on the information from the memory to the data link connector (DLC). This information can be read with the Honda PGM Tester connected to the DLC (16P). Page 8204 To install, follow the removal steps in the reverse order, noting the following points: 1. Install the regulator handle as shown in the figure, if equipped without power windows. 2. Check to see that the window regulator operates smoothly and the glass opens and closes properly. 3. Install the waterproof sheet tightly against the door panel. Page 7461 - Refer to the scrapping procedures for disposal of the damaged airbag. Mechanical Specifications Power Steering Pump: Mechanical Specifications Power Steering Pump Bracket Bolts 46 Nm Flexible Hose Bolt 54 Nm Suction Pipe Bolts 10 Nm Pressure Switch 18 Nm Connector 59 Nm Rear Housing Bolts 24 Nm Page 4270 and the fuses. From Fuses to Relays and Components The second half of Power Distribution shows the wiring "From Fuses to Relays and Components." This can speed your troubleshooting by showing which circuits share fuses. If Power Distribution shows that an inoperative circuit and another circuit share a fuse, check a component in the other circuit. If it works, you know the fuse is good and power is available to the inoperative circuit. Ground Distribution Schematics Page 1415 Compression Check: Testing and Inspection Engine Compression Test Procedure 1. Start and run the engine until the engine reaches normal operating temperature. 2. Turn the engine off. 3. Remove all the spark plugs. 4. Remove ignition coil fuse (15A) and disable the ignition system. 5. Remove the fuel pump relay from the relay and fuse box. 6. Engage the starter and check that the cranking speed is approximately 300 rpm. 7. Install cylinder compression gauge into spark plug hole. 8. With the throttle valve opened fully, keep the starter engaged until the compression gage needle reaches the maximum level. Note the reading. 9. Repeat the test with each cylinder. If the compression pressure obtained falls below the limit, engine overhaul is necessary. Limit: 1000 kPa (145 psi) Page 5170 Magnetic Switch Check for continuity of shunt coil between terminals S and M. Replace, if there is no continuity (i.e., coil is disconnected). Continuity of Series Coil Check for continuity between terminals S and M. Replace, if there is no continuity (i.e., coil is disconnected). Page 7014 2. To install the sunroof finisher (1), first fit it in at one place with the headlining (3) close to the sunroof frame (2), then install the entire finisher tightly by hitting it with a plastic hammer, not allowing it to move up. Page 4662 5. Remove the meter assembly. - Push the metal cover (6) with the screw driver (7). 6. Remove the meter rear cover. 7. Remove the meter circuit board. 8. Remove the A/T shift indicator bulb. Installation To install, follow the removal steps in the reverse order. Page 6169 8. Remove lower case. - Slit the case parting face with a knife since the lining is separated when removing the evaporator. - Lift to remove the upper case. 9. Remove evaporator core. 10. Remove expansion valve. Page 5584 Terminals - "T" Each "T" terminal (ring type) is numbered for reference and location. A "T" terminal is secured with a screw or bolt. Wires Audio Unit with CD Player/Changer - Error Codes Compact Disc Player (CD): Customer Interest Audio Unit with CD Player/Changer - Error Codes 00-015 March 14, 2000 Applies To: All with CD Player/Changer Audio Unit Error Codes (Replaces 91-007, dated October 6, 1997) *If the audio unit displays an error code, use the troubleshooting tables in this service bulletin to troubleshoot the problem. Refer to service bulletin 98-019 for CD Player/Changer exchange information.* Service and Repair Ring Gear: Service and Repair For further information regarding this component and the system that it is a part of, please refer to Differential; Service and Repair; Unit Overhaul Page 7961 Parking Lamp: Electrical Diagrams Part 1 Of 2 Page 5865 Tires: Testing and Inspection Radial Tire Waddle Waddle is side-to-side movement at the front and/or rear of the car. It can be caused by the steel belt not being straight within the tire, or by excessive lateral runout of the tire or wheel. It is most noticeable at low speed, about 8 to 48 km/h (5 to 30 mph). It may also cause rough ride at 80 to 113 km/h (50 to 70 mph). The car can be road tested to see which end of the car has the faulty tire. If the tire causing the waddle is on the rear, the rear end of the car will "waddle". From the driver's seat, it feels as if someone is pushing on the side of the car. If the faulty tire is on the front, the waddle is more easily seen. The front sheet metal appears to be moving back and forth. It feels as if the driver's seat is the pivot point in the car. Another more time-consuming method of determining the faulty tire is substituting tire and wheel assemblies that are known to be good. Follow these steps: 1. Drive the car to determine if the waddle is coming from the front or rear. 2. Install tire and wheel assemblies known to be good (from a similar car) in place of those on the end of the car which is waddling. If the waddle cannot be isolated to front or rear, start with the rear tires. 3. Road test again. If improvement is noted, install the original tire and wheel assemblies one at a time until the faulty tire is found. If no improvement is noted, install tires known to be good in place of all four. Then, install the originals one at a time until the faulty tire is found. Page 8154 10. Remove the 2 screws through the access hole and pull out the glass upward. 11. Remove the window regulator. - Disconnect the window regulator motor harness connector, if equipped with power windows. 12. Remove the glass run. - Pull the glass run (6) out from the door frame groove. Installation To install, follow the removal steps in the reverse order, noting the following points: Page 1810 Coolant: Fluid Type Specifications Mixture of water and good quality ethylene glycol base type antifreeze mixed 50/50. Page 2684 Idle Speed/Throttle Actuator - Electronic: Diagnostic Aids Before Troubleshooting Before Troubleshooting See: Service Precautions/Vehicle Damage Warnings/Tips and Precautions 1. Check applicable fuses in the appropriate fuse/relay box. 2. Check the battery for damage, state of charge, and clean and tight connections. CAUTION: Do not quick-charge a battery unless the battery ground cable has been disconnected, otherwise you will damage the alternator diodes. - Do not attempt to crank the engine with the battery ground cable loosely connected or you will severely damage the wiring. While You're Working 1. Make sure connectors are clean, and have no loose terminals or receptacles. 2. Make sure that connectors without wire seals are packed with dielectric (silicone) grease. Part Number: 08798-9001. 3. When connecting a connector, push it until it "clicks" into place. CAUTION: Do not pull on the wires when disconnecting a connector. Pull only on the connector housings. - Most circuits include solid-state devices. Test the voltages in these circuits only with a 10-megaohm or higher impedance digital multi meter. Never use a test light or analog meter on circuits that contain solid-state devices. Damage to the devices may result. Five-Step Troubleshooting 1. Verify The Complaint Turn on all the components in the problem circuit to check the accuracy of the customer complaint. Note the symptoms. Do not begin disassembly or testing until you have narrowed down the problem area. 2. Analyze The Schematic Look up the schematic for the problem circuit. Determine how the circuit is supposed to work by tracing the current paths from the power source through the circuit components to ground. Also, trace circuits that share wiring with the problem circuit. The names of circuits that share the same fuse, ground, or switch, and so on, are referred to in each circuit schematic. Try to operate any shared circuits you didn't check in step 1. If the shared circuits work, the shared wiring is OK, and the cause must be in the wiring used only by the problem circuit. If several circuits fail at the same time, the fuse or ground is a likely cause. Based on the symptoms and your understanding of the circuit's operation, identify one or more possible causes. 3. Isolate The Problem By Testing The Circuit Make circuit tests to check the diagnosis you made in step 2. Keep in mind that a logical, simple procedure is the key to efficient troubleshooting. Test for the most likely cause of failure first. Try to make tests at points that are easily accessible. 4. Fix The Problem Once the specific problem is identified, make the repair. Be sure to use proper tools and safe procedures. 5. Make Sure The Circuit Works Turn on all components in the repaired circuit in all modes to make sure you've fixed the entire problem. If the problem was a blown fuse, be sure to test all of the circuits on that fuse. Make sure no new problems turn up and the original problem does not recur. Page 663 Steps 1 - 3 Steps 4 - 7 Test Description IMPORTANT: Be sure to used the same diagnostic test equipment for all measurements. The Number(s) below refer to the step number(s) on the Diagnostic Chart. 2. Applying 34 kPa (10 Hg) vacuum to the MAP sensor should cause the voltage to be 1.5 - 2.1 volts less than the voltage at step 1. Upon applying vacuum to the sensor, the change in voltage should be instantaneous. A slow voltage change indicates a faulty sensor. Page 5876 Tires: Service and Repair Spare Tire Spare Tire Hanger Removal 1. Open the hatch gate and tail gate. 2. Remove the spare tire (3). - Put the spare tire handle (1) to the center of upper side of rear bumper (2) and turn counterclockwise. Put spare tire down. 3. Remove the spare tire support. - Remove the four bolts that are fixed to frame cross member. 4. Remove the spare tire hanger assembly. - Remove the two fixing bolts. Installation To install, follow the removal steps in the reverse order, noting the following points. 1. Install the spare tire firmly. 2. Tighten the spare tire support fixing bolts to the specified torque. Torque: 40 Nm (4.1 kg.m) 3. Tighten the spare tire hanger fixing bolts to the specified torque. Torque: 19 Nm (1.9 kg.m) Page 7760 Wires Wire insulation can be one color, or one color with another color stripe. (The second color is the stripe.) This circuit continues on another image. (The arrow shows direction of current flow.) To follow the RED/BLK wire in this example, you would turn to "Fuel and Emissions" and look for the "A" arrow. Page 2942 Power Steering Pressure Switch: Locations 27. Left Side of Engine Left Side Of Engine Page 6378 Splices Splices are shown as a dot. Their location and the number of wires may vary depending on the harness manufacturer. Switches Switches These switches move together; the broken straight line between them means they are mechanically connected. Other types of switches are controlled by a coil or a solid state circuit. Unless otherwise noted, all switches are shown in their normal (rest) position, with power off. Terminal "T" Locations Resin Top Assembly And Associated Parts Page 198 Distinct Of Circuit By Wire Base Color All wires have color-coded insulation. Wires belonging to a system's main harness will have a single color. Wires belonging to a system's sub-circuits will have a colored stripe. Striped wires use the codes found in the chart to show wire size and colors. Abbreviations are used to indicate wire color within a circuit diagram. How to Identify Connector Terminals How to Identify Connector Terminals Cavity Numbering System The cavities (and wire terminals) in each connector are numbered starting from the upper left, looking at the male terminals from the terminal side (or looking at the female terminals from the wire side. Both views are in the same direction so the numbers are the same.) All actual cavities are numbered, even if they have no wire terminals in them. NOTE: Data Link Connector (DLC) terminals are numbered according to SAE standard J1962, not the Honda standard. The numbers of the four end terminals are molded into the corners of the connector face. The connector cavity number is listed next to each terminal on the circuit schematic. The cavity / terminal shown is # 6. Using/Identifying Connector Terminal Views How to Use Connector Terminal Views To see the configuration of a connector's cavities, look up its view number in the Connector Views. Each view includes the color of the connector, where A/T - Vehicle Speed Sensor Installation Precautions Transmission Speed Sensor: Technical Service Bulletins A/T - Vehicle Speed Sensor Installation Precautions Install VSS Properly to Avoid Reman A/T Damage We can't emphasize enough how important it is to follow, to the letter, the installation instructions that come with a reman A/T. These instructions help ensure that you avoid damaging the A/T and score a successful repair. This is particularly true when it comes to installing the vehicle speed sensor (VSS). Step 6 of the instructions tells you to make sure its gear is fully engaged and the VSS is fully seated before you tighten the retaining bolt. If you don't install the VSS properly, the speed sensor gear will get stripped and the A/T will be seriously damaged. So don't take risks with your customer's vehicle. Always follow these instructions to the letter. You can rest assured you're doing the job right. Page 4726 Test Equipment CAUTION: Most circuits include solid-state devices. Test the voltages in these circuits only with a 10-megaohm or higher impedance digital multimeter. Never use a test light or analog meter on circuits that contain solid-state devices. Damage to the devices may result. Test Light and DVOM On circuits without solid-state devices, use a test light to check for voltage. A test light is made up of a 12 volt bulb with a pair of leads attached. After grounding one lead, touch the other lead to various points along the circuit where voltage should be present. The bulb will go on if there is voltage at the point being tested. If you need to know how much voltage is present, use a digital volt/ohmmeter (DVOM). Self-Powered Test Light and DVOM Use a self-powered test light to check for continuity. This tool is made up of a light bulb, battery, and two leads. To test it, touch the leads together: the light should go on. Use a self-powered test light only on an unpowered circuit. First, disconnect the battery, or remove the fuse that feeds the circuit you are working on. Select two points in the circuit between which you want to check continuity. Connect one lead of the self-powered test light to each point. If there is continuity, the test light's circuit will be completed, and the light will go on. If, in addition, you need to know exactly how much resistance there is between two points, use a digital volt/ohmmeter (DVOM). In the "OHMS" range, the DVOM will measure resistance between two points along a circuit. Low resistance means good continuity. Diodes and solid-state devices in a circuit can make a DVOM give a false reading. To check a reading, reverse the leads, and take a second reading. If the readings differ, the component is affecting the measurement. Jumper Wire Use a jumper wire to bypass an open circuit. A jumper wire is made up of an in-line fuse holder connected to a set of test leads. It should have a five ampere fuse. Never connect a jumper wire across a short circuit. The direct battery short will blow the fuse. Short Finder (Short Circuit Locator) Short finders are available to locate shorts to ground. The short finder creates a pulsing magnetic field in the shorted circuit which you can follow to the location of the short. To order any test equipment shown above, contact your local tool supplier. For a list of suppliers and tool numbers, refer to Honda Required Special Tools and Equipment Service Bulletin. Page 7993 8. Apply a setting mark (1) across the steering wheel and shaft so parts can be reassembled in their original position. Move the front wheels to the straight ahead position, then use steering wheel remover J-29752 to remove the steering wheel. CAUTION: Never apply force to the steering wheel in direction of the shaft by using a hammer or other impact tools in an attempt to remove the steering wheel. The steering shaft is designed as an energy absorbing unit. 9. Remove steering column cover. 10. Disconnect the wiring harness connectors located under the steering column, then remove combination switch and SRS coil assembly. NOTE: The SRS coil is a part of the combination switch assembly, which can not be replaced separately. Therefore, be sure not to remove the SRS coil from the combination switch assembly. INSTALLATION Page 2373 Spark Plug: Testing and Inspection Inspection and Repair The spark plug affects entire engine performance and therefore its inspection is very important. - Check electrode and insulator for presence of cracks, and replace if any. - Check electrode for wear, and replace if necessary.. - Check gasket for damage, and replace if necessary. - Measure insulation resistance with an ohmmeter, and replace if faulty. - Adjust spark plug gap to 1.0 mm (0.040 in) to 1.1 mm (0.043 in). - Check fuel and electrical systems if spark plug is extremely dirty. - Use spark plugs having low heat value (hot type plug) if fuel and electrical systems are normal. - Use spark plugs having high heat value (cold type plug) if insulator and electrode are extremely burned. Sooty Spark Plugs Much deposit of carbon or oil on the electrode and insulator of spark plug reduces the engine performance. Possible causes: - Too rich mixture - Presence of oil in combustion chamber - Incorrectly adjusted spark plug gap Burning Electrodes This fault is characterized by scorched or heavily oxidized electrode or blistered insulator nose. Possible causes: - Too lean mixture - Improper heat value Measuring Insulation Resistance - Measure insulation resistance using a 500 volt megaohm meter. - Replace spark plugs if measured value is out of standard. Insulation resistance: 50 Mohm or more. Page 1383 Wheels: Service and Repair REMOVAL 1. Loosen wheel lug nut by approximately 180 g (half a rotation), then raise the vehicle and remove the nuts. 2. Remove wheel and tire. NOTE: Never use heat to loosen a tight wheel lug nut. The application of heat to the hub can shorten the life of the wheel and may cause damage to wheel bearings. INSTALLATION 1. Install wheel and tire. 2. Install wheel lug nut, and lower the vehicle. Tighten the wheel lug nuts to the specified torque in numerical order. Torque to 118 Nm (87 ft. lbs.). CAUTION: Before installing wheels, remove any build-up of corrosion on the wheel mounting surface and brake disc mounting surface by scraping and wire brushing. Installing wheels without good metal-to-metal contact at mounting surfaces can cause wheel nuts to loosen, which can later allow a wheel to come off while the vehicle is moving. NOTE: Valve caps should be on the valve stems to keep dust and water out. Page 4601 Wire Color Abbreviations The following abbreviations are used to identify wire colors in the circuit schematics: WHT................................... White YEL................................... Yellow BLK................................... Black BLU................................... Blue GRN................................... Green RED................................... Red ORN................................... Orange PNK................................... Pink BRN................................... Brown GRY................................... Gray PUR................................... Purple LT BLU................................... Light Blue LT GRN................................... Light Green Page 650 Fuel Tank Pressure Sensor: Description and Operation Fuel Tank Pressure Sensor The fuel tank pressure sensor is a three-wire strain gauge sensor similar to a common MAP sensor. However, the fuel tank pressure sensor has very different electrical characteristics due to its pressure differential design. The sensor measures the difference between the air pressure (or vacuum) in the fuel tank and the outside air pressure. The sensor mounts at the top of the fuel pump assembly. A three-wire electrical harness connects it to the PCM. The PCM supplies a five-volt reference voltage and a ground to the sensor. The sensor will return a voltage between 0.1 and 4.9 volts. When the air pressure in the fuel tank is equal to the outside air pressure, such as when the fuel cap is removed, the output voltage of the sensor will be 1.3 to 1.7 volts. When the air pressure in the fuel tank is 4.5 in. H2O (1.25 kPa), the sensor output voltage will be 0.5 ± 0.2 V. When there is neither vacuum nor pressure in the fuel tank, the sensor voltage will be 1.5 V. At -14 in. H2O (-3.75 kPa), the sensor voltage will be 4.5 ± 0.2 V. Page 2846 Accelerator Pedal Position Sensor: Adjustments Accelerator Position Sensor Adjustment AP sensor is controlled three multiple control system, and adjust the idle position and WOT position are between A and B for AP sensor 1, AP sensor 2, and AP sensor 3. Refer to "How to adjust for AP sensor". How To Adjust For AP Sensor 1. Connect the Tech 2 to DLC on vehicle. 2. Ignition "ON," engine "OFF". 3. Display the APS date list. Check the following item for AP position (%). 4. If the problem was found, adjust as necessary. Page 3700 and the fuses. From Fuses to Relays and Components The second half of Power Distribution shows the wiring "From Fuses to Relays and Components." This can speed your troubleshooting by showing which circuits share fuses. If Power Distribution shows that an inoperative circuit and another circuit share a fuse, check a component in the other circuit. If it works, you know the fuse is good and power is available to the inoperative circuit. Ground Distribution Schematics Page 4241 6. Install the hose of the shift on the fly (1). 7. Install the shift switch connector (2) of the shift on the fly. 8. Install the tie-rod end of the power steering unit to the knuckle, tighten the nut to the specified torque. Torque: 118 Nm (87 ft. lbs.) 9. Install lower bolts and nuts of the shock absorber, tighten it to the specified torque. Torque: 93 Nm (69 ft. lbs.) 10. Install lower nuts of the stabilizer link, tighten it to the specified torque. 11. Install the suspension crossmember. 12. Install the torsion bar. 13. Install the front propeller shaft. 14. Install the hub and disc assembly and adjust the bearing preload. 15. Install the wheel sensor of the antilock brake system. 16. Install the brake caliper. Tighten the bolt of the caliper bracket to the specified torque. Torque: 50 Nm (37 ft. lbs.) 17. Install the stone guard. 18. Install the tire and wheel. 19. Lower the vehicle, adjust the trim height. 20. Tighten the bolts and nuts of the lower control arm to the specified torque. Page 5904 Fan Control Switch Page 6674 it is located, and what it connects to. Use the Connector Views to help locate the proper cavity when you need to probe a connector. It can be especially helpful if the connector has more than one wire of the same color. A dash symbol (-) indicates that the cavity is empty. Connector views can also be used to help diagnose multiple symptoms in separate circuits which could be caused by a single problem in a connector shared by those circuits. Here's an example: 1. Pick one of the multiple symptoms and look up the schematic for that circuit. 2. Make a list of all the in-line and fuse box connectors in that schematic , 3. Then, in the Connector Views, look up each connector on your list to see if circuits related to the other symptoms run through one of them. If they do, inspect that connector for the problem. Example: The blower, rear window defogger, and the windshield wiper don't work. List all in-line and fuse box connectors in the blower controls circuit and then check the Connector View (see the sample). You find that C324 is common to the blower controls, rear window defogger, and wiper/washer, so you inspect C324 and find the problem, bent terminals. Finding Component/Connector Locations Finding Component/Connector Locations To see where a component or connector is located on the car, look up its photo number in the "Component Location". The photo will also tell you the color of the connector, and how many cavities it has. Page 7524 Splices Splices are shown as a dot. Their location and the number of wires may vary depending on the harness manufacturer. Switches Switches These switches move together; the broken straight line between them means they are mechanically connected. Other types of switches are controlled by a coil or a solid state circuit. Unless otherwise noted, all switches are shown in their normal (rest) position, with power off. Terminal "T" Description and Operation Windshield Washer Spray Nozzle: Description and Operation Rear Washer Spray Pattern Page 472 Part 2 Of 2 Page 2208 Transmission Position Switch/Sensor: Service and Repair REMOVAL 1. Place selector lever in neutral. 2. Disconnect battery ground cable. 3. Remove mode switch cover (1). 4. Disconnect selector lever (2) from the mode switch. 5. Remove bracket with cable (3). 6. Disconnect transmission harness from the mode switch connector (4). 7. Remove bracket with mode switch connector from the transmission case. 8. Remove mode switch connector (4) from the bracket (5). 9. Remove two mode switch bolts and nut then remove mode switch (6). INSTALLATION To install, follow the removal steps in the reverse order, noting the following points; 1. Torque Mode switch bolt: 13 Nm (113 inch lbs.) Selector lever nut: 23 Nm (17 ft. lbs.) 2. Mode switch setting procedure. Perform either of the following adjustment procedures: Procedure 1 a. Place selector lever in neutral. b. Remove selector lever from the mode switch. c. Remove the mode switch cover. d. Loosen the two 10 mm screws. e. Rotate the mode switch until the slot in the mode switch housing aligns with the selector shaft bushing, and insert a 3/32 inch (2.4 mm) drill bit or punch (1) into the slot. f. Tighten the screws to 13 Nm (113 inch lbs.). g. After completing adjustment, snap the mode switch cover into place. h. Reinstall the selector lever. Procedure 2 a. Place selector lever in neutral. b. Disconnect transmission harness connector from mode switch connector. Page 7949 Ground - "G" Shielding Sheilding This represents RFI (Radio Frequency Interference) shielding around a wire. The shielding is always connected to ground. Splices Page 2650 Powertrain Control Module: Component Tests and General Diagnostics Powertrain Control Module (PCM) Diagnosis To read and clear diagnostic trouble codes, use a Tech 2. IMPORTANT: Use of a Tech 2 is recommended to clear diagnostic trouble codes from the PCM memory. Diagnostic trouble codes can also be cleared by turning the ignition "OFF" and disconnecting the battery power from the PCM for 30 seconds. Turning off the ignition and disconnecting the battery power from the PCM will cause all diagnostic information in the PCM memory to be cleared. Therefore, all the diagnostic tests will have to be re-run. Since the PCM can have a failure which may affect only one circuit, following the diagnostic procedures will determine which circuit has a problem and where it is. If a diagnostic chart indicates that the PCM connections or the PCM is the cause of a problem, and the PCM is replaced, but this does not correct the problem, one of the following may be the reason: - There is a problem with the PCM terminal connections. The terminals may have to be removed from the connector in order to check them properly. - EEPROM program is not correct for the application. Incorrect components or reprogramming the PCM with the wrong EEPROM program may cause a malfunction and may or may not set a DTC. - The problem is intermittent. This means that the problem is not present at the time the system is being checked. In this case, refer to Symptom Diagnosis and make a careful physical inspection of all component and wiring associated with the affected system. - There is a shorted solenoid, relay coil, or harness. Solenoids and relays are turned "ON" and "OFF" by the PCM using internal electronic switches called drivers. A shorted solenoid, relay coil, or harness will not damage the PCM but will cause the solenoid or relay to be inoperative. Page 6062 - Tighten the outlet line connector fixing bolt to the specified torque. Torque: 6 Nm (52 lb in) - 0-ring cannot be reused. Always replace with new ones. - Be sure to apply new compressor oil to the O-ring when connecting the refrigerant line. 3. Connect pressure switch connector. 4. Install engine hood lock. 5. Install engine hood front end stay. 6. Install radiator grille. Locations Procedures Fuel Door: Procedures Removal 1. Open the fuel filler door. 2. Remove the fuel filler door. - Remove the two fixing screws. 3. Pull out the fuel filler door buffer. 4. Pull out the fuel filler hinge buffer. Installation To install follow the removal steps in the reverse order, noting the following points. 1. Install the fuel filler door to match the basic hole. 2. Adjust the clearance between quarter outer panel (1) and fuel filler door (2). Page 6774 Wires Wire insulation can be one color, or one color with another color stripe. (The second color is the stripe.) This circuit continues on another image. (The arrow shows direction of current flow.) To follow the RED/BLK wire in this example, you would turn to "Fuel and Emissions" and look for the "A" arrow. Page 7903 the component if the component only has one connector, or by a capital letter (A, B, C, etc.) if the component has more than one connector. Below most connector numbers and component names are PHOTO and VIEW numbers. The PHOTO number refers to a photo in the back of the book that shows the connector's location on the car. The VIEW number refers to an illustration in the back of the book that shows the connector face, wire colors, connector cavity numbers, and other details. The connector cavity numbering sequence begins at the top left corner of the connector. Disregard any numbers molded into the connector housing. Wires Wires are identified by the abbreviated names of their colors; the second color is the color of the stripe. Wires are also identified by their location in a connector. The number "2" next to the male and female wire terminals at C416, for example, means those terminals join in cavity 2 of connector C416. Symbols A complete description of schematic symbols is given under wire color abbreviation. Power Distribution Schematics Power Distribution schematics show how power is supplied from the positive battery terminal to various circuits in the car. Refer to the Power Distribution section to get a more detailed picture of how power is supplied to the circuit you're working on. From Battery to Ignition Switch, Fuses, and Relays Individual circuit schematics begin with a fuse. The first half of Power Distribution, however, shows the wiring "upstream" between the battery Page 5558 - Refer to the scrapping procedures for disposal of the damaged airbag. On Vehicle Service Valve Body: Service and Repair On Vehicle Service Valve Body Assembly (Main Case) REMOVAL 1. Raise the vehicle and support it on jack stands. 2. Disconnect battery ground cable. 3. Drain fluid. 4. Remove sixteen 10 mm screws, main case oil pan, magnet and gasket. 5. Remove three 13 mm oil filter fixing screws, then remove oil filter. 6. Remove two 13 mm manual detent fixing screws, then remove roller and spring assembly. 7. Disconnect wiring harness from band control solenoid and shift solenoids. Pull only on connectors, not on wiring harness. 8. Remove four 13 mm servo cover fixing screws, then remove servo cover and gasket. 9. Remove seven 13 mm valve body fixing screws. 10. Remove main case valve body with manual valve link and transfer plate. Note the position of the link (long end into valve, short end into range selector lever). 11. Remove transfer plate gasket from main case. 12. Remove two check balls from main case. INSTALLATION 1. Install two check balls to main case. 2. Inspect electrical 7 pin connector and seal of main case. Replace if necessary. 3. Use two J-25025-B guide pin to install main case. - Install valve body complete assembly and manual valve link. NOTE: Valve must be extended as the short end of manual valve link is connected to the range selector lever. Long end of link goes into valve. Page 6550 SURROUNDING AREAS OF THE DRIVER AIR BAG ASSEMBLY WILL BE VERY HOT. DO NOT TOUCH THE METAL AREAS OF THE DRIVER AIR BAG ASSEMBLY FOR ABOUT TEN MINUTES AFTER DEPLOYMENT. IF THE DEPLOYED DRIVER AIR BAG ASSEMBLY MUST BE MOVED BEFORE IT IS COOL, WEAR GLOVES AND HANDLE BY THE AIR BAG OR TRIM COVER. 21. Disconnect the pigtail adapter from the driver airbag assembly immediately after deployment. This will prevent damage to the pigtail adapter or SRS deployment harness due to possible contact with the hot driver air bag assembly canister. The pigtail adapter can be reused. They should, however, be inspected for damage after each deployment and replaced If necessary. 22. Dispose of the deployed driver air bag assembly through normal refuse channels after it has cooled for at least 30 minutes. 23. Wash your hands with mild soap and water afterward. NOTE: The remaining steps are to be followed in the unlikely event that the driver air bag assembly did not deploy after following these procedures. 24. Ensure that the SRS deployment harness has been disconnected from the power source and that its two banana plugs have been shorted together by fully seating one banana plug into the other. 25. Disconnect the pigtail adapter from the driver air bag assembly. WARNING: WHEN STORING A LIVE AIR BAG ASSEMBLY OR WHEN LEAVING A LIVE INFLATOR MODULE UNATTENDED ON A BENCH OR OTHER SURFACE, ALWAYS FACE THE BAG AND TRIM COVER UP AND AWAY FROM THE SURFACE. THIS IS NECESSARY SO THAT A FREE SPACE IS PROVIDED TO ALLOW THE AIR BAG TO EXPAND IN THE UNLIKELY EVENT OF ACCIDENTAL DEPLOYMENT. FAILURE TO FOLLOW PROCEDURES MAY RESULT IN PERSONAL INJURY. 26. Temporarily store the driver air bag assembly with its trim cover facing up. Brakes - Revised Brake Bleeding Procedure Brake Bleeding: By Symptom Brakes - Revised Brake Bleeding Procedure 01-016 January 30, 2001 Applies To: 1998-01 Passport - ALL Service Manual Update: Revised Brake Bleeding Procedure BACKGROUND The brake bleeding procedure in the 1998 thru 2001 Passport Service Manuals is incomplete. Use this service bulletin to update the manuals. WARRANTY INFORMATION None. CORRECTIVE ACTION 1. In the 1998, 1999, 2000, and 2001 Passport Service Manuals, on pages 5A-21 and 5A-22, cross out the entire Tech 2 Service Bleed procedure. 2. In each manual, on page 5A-21, write this note: See page 5C-10 for the brake bleeding procedure 3. In each manual, on page 5C-10, between steps 1 and 2, write this note: For important additional information, see Service Bulletin 01-016, Service Manual Update: Revised Brake Bleeding Procedure, Filed under Brakes. SERVICE MANUAL UPDATE INFORMATION To avoid trapping air bubbles in the ABS hydraulic unit while bleeding the brakes, the hydraulic unit must be tilted forward at a 15-degree angle or greater. Before bleeding, check the angle of the ABS hydraulic unit with an angle locator level. If needed, raise the rear of the vehicle to get the proper Page 4249 Fluid - Differential: Fluid Type Specifications Front and Rear Differential Grade ................................................................................................................................................... ................................................................... API GL-5 Viscosity: Below 50° F (10° C) Front ................................................................................................................... ............................................................................... SAE 75W-90 synthetic Rear ................................ .............................................................................................................................................................. ........... SAE 80 or 80W-90 From 0° F to 90° F (-18° C to 32° C) Front .......................................................................................... ........................................................................................................ SAE 75W-90 synthetic Rear ....... .............................................................................................................................................................. .................................... SAE 90 or 80W-90 Above 50° F (10° C) consistently Front ............................................................................................... ...................................................................................... SAE 80W-90 or SAE 80W-140 Rear ............ .............................................................................................................................................................. ............................................... SAE 140 If your vehicle is equipped with the optional Limited Slip differential (on the rear axle), use GL-5 Limited Slip Differential Gear Lubricant together with Limited Slip Differential Gear Lubricant Additive (Part No. 8-01052-358-0) or equivalent. Use the correct viscosity for the existing ambient temperatures. Service and Repair Case: Service and Repair For further information regarding this component and the system that it is a part of, please refer to Automatic Transmission/Transaxle; Service and Repair; Unit Overhaul Diagram Information and Instructions Headlamp Switch: Diagram Information and Instructions How to Identify Wiring Color-Coded Insulation Wire Color Wire Color Coding Page 5469 6. Place the end of the return hose in a container. Have someone start the engine, then pour ATF into the reservoir while you watch the fluid coming out of the return hose. When the fluid coming out is the same color as the new fluid, turn off the engine. 7. Reconnect the return hose to the reservoir. 8. Start the engine. Fill the power steering reservoir to the proper level with ATF then turn off the engine. 9. Use the Smart Cable to reprogram the PCM with the latest software from the June 2001 or later HONDANET CD-ROM. Refer to Service Bulletin 99-005, Updating the Passport PCM, filed under Tools. 10. Use the PGM Tester to clear any DTCs. 11. Use the PGM Tester to check the broadcast code. Make sure the broadcast code matches the one you selected from the CD-ROM. WARRANTY CLAIM INFORMATION In warranty: The normal warranty applies. Failed Part: P/N 8-97181-590-0 H/C 5698030 Defect Code: 064 Contention Code: C01 Skill Level: Repair Technician Out of warranty: Any repair performed after warranty expiration may be eligible for goodwill consideration by the District Service Manager or your Zone Office. You must request consideration, and get a decision, before starting work. REPAIR PROCEDURE - APPS GROUND 1. Unclamp the air cleaner housing cover, and move it to the side for access to connector C123 (16P BLK). Page 7246 Hood Sensor/Switch (For Alarm): Service and Repair Removal 1. Disconnect the battery ground cable. 2. Disconnect the connector. 3. Remove the engine hood switch (1). Installation To install, follow the removal steps in the reverse order. Page 3313 3. Install the fuse and relay box cover. Page 4274 Ground - "G" Shielding Sheilding This represents RFI (Radio Frequency Interference) shielding around a wire. The shielding is always connected to ground. Splices Description and Operation Acceleration/Deceleration Sensor: Description and Operation DESCRIPTION/OPERATION The G-sensor installed inside the EHCU detects the vehicle deceleration speed and sends a signal to the EHCU. In 4WD operation, all four wheels may be decelerated in almost the same phase, since all wheels are connected mechanically. This tendency is noticeable particularly on roads with low friction coefficient, and the ABS control is adversely affected. The G-sensor judges whether the friction coefficient of road surface is low or high, and changes the EHCU's operating system to ensure ABS control. Page 5979 Blower Motor: Locations Page 3739 Wires Wire insulation can be one color, or one color with another color stripe. (The second color is the stripe.) This circuit continues on another image. (The arrow shows direction of current flow.) To follow the RED/BLK wire in this example, you would turn to "Fuel and Emissions" and look for the "A" arrow. Specifications Valve: Specifications Valve Clearance Intake 0.28 mm Exhaust 0.30 mm Locations Page 4496 Part 3 Of 3 Page 5443 Alignment: Description and Operation GENERAL DESCRIPTION "Front End Alignment" refers to the angular relationship between the front wheels, the front suspension attaching parts and the ground. Proper front end alignment must be maintained in order to insure efficient steering, good directional stability and to prevent abnormal tire wear. The most important factors of front end alignment are wheel toe-in, wheel camber and axle caster. CAMBER: Camber is the vertical tilting inward or outward of the front wheels. When the wheels tilt outward at the top, the camber is positive (+). When the wheels tilt inward at the top, the camber is negative (-). The amount of tilt measured in degrees from the vertical is called the camber angle (1). If camber is extreme or unequal between the wheels, improper steering and excessive tire wear will result. Negative camber causes wear on the inside of the tire, while positive camber causes wear to the outside. CASTER: This illustration shows view from the side of the vehicle. Caster (1) is the vertical tilting of the wheel axis either forward or backward (when viewed from the side of the vehicle). A backward tilt is positive (+) and a forward tilt is negative (-). On the short and long arm type suspension you cannot see a caster angle without a special instrument, but if you look straight down from the top of the upper control arm to the ground, the ball joints do not line up (fore and aft) when a caster angle other than 0 degree is present. With a positive angle, the lower ball joint would be slightly ahead (toward the front of the vehicle) of the upper ball joint center line. Page 3380 11. Remove common chamber four bolts and four nuts then remove the common chamber. Installation 1. Install common chamber and tighten bolts and nuts to the specified torque. Torque: Bolt: 25 Nm (18 ft. lbs.) Nut: 25 Nm (18 ft. lbs.) 2. Install fuel hose bracket and tighten bolts to specified torque. Torque: 10 Nm (89 inch lbs.) 3. Install exhaust gas recirculation valve assembly and tighten bolt and nut to the specified torque. Torque: 25 Nm (18 ft. lbs.) 4. Install throttle body and tighten bolts to the specified torque. Torque: 25 Nm (18 ft. lbs.) 5. Install ventilating hose to throttle valve and intake duct. 6. Connect vacuum hoses on canister VSV and positive crankcase ventilation hose. Tighten bolts for fuel rail assembly with pressure control valve bracket. Torque: 25 Nm (18 ft. lbs.) 7. Connect each connector without fail. 8. Connect vacuum booster hose. 9. Connect accelerator pedal cable. Page 7424 Cigarette Lighter: Service and Repair Removal 1. Disconnect the battery ground cable. 2. Remove the lower cluster assembly (1). 3. Remove the cigarette lighter assembly (2). - Disconnect the connectors. - Remove the socket (3). Installation To install, follow the removal steps in the reverse order, noting the following point: 1. When installing the bezel, align the projected portion of the socket with the notch of the bezel. Locations Fuse Block: Locations Page 3573 Ion Sensing Module: Service and Repair ION Sensing Module REMOVAL PROCEDURE 1. Disconnect the negative battery cable. 2. Disconnect the ION sensing module connector. 3. Remove the bolts and the ION sensing module from the common chamber. INSTALLATION PROCEDURE 1. Install the ION sensing module on the common chamber with the bolts. Tighten Tighten the ION sensing module to 4 N.m (35 lb in.). 2. Connect the ION sensing module connectors as shown in the illustration. Page 802 20. Using a DVOM, check the voltage between the reference voltage pin for each sensor and ground. ^ If the sensor circuits all read 5.0 volts, go to step 22. ^ If any sensor circuit is above or below 5.0 volts, go to step 21. 21. Troubleshoot for an internal short in another sensor or a PCM malfunction. ^ To find the sensor with an internal short, monitor the reference voltage, and disconnect each sensor (FTPS, EGR, MAP TPS, CKP and CMP) one at a time until the reference voltage reads 5.0 volts. Replace that sensor, and repeat step 14. ^ To find a malfunctioning PCM, replace it with a known-good PCM. If all three sensors (APP Sensor 1, APP Sensor 2, and APP Sensor 3) are within range, the original PCM is faulty; replace it and repeat step 14. 22. Using a jumper wire, connect the reference voltage of each circuit to its signal input, and view the APP Sensor values in the Engine Data List. APP Sensor 1 should have a value of 99%, and APP Sensor 2 and APP Sensor 3 should each have a value of 0%. ^ If the values are not as specified, troubleshoot for high resistance on the signal input or a PCM malfunction. Repair the circuit or replace the PCM, then repeat step 14. ^ If the values are as specified, the problem may be intermittent. Disconnect the 10 P connector from the modified APPS, and connect it to the new APPS; then repeat step 14. Wiggle the APPS wires as you go through the adjustment procedure to find the intermittent problem. 23. Install the accelerator pedal assembly, and torque the bolts to 10 N.m (7 lb-ft). Page 3034 2. Secure the VSS in place with the clamp and the bolt. 3. Tighten the bolt to 27 Nm (20 lb ft.). 4. Connect the VSS electrical connector. 5. Check the transfer case oil level. Add fluid if necessary. 6. Connect the negative battery cable. Page 2624 Splices Splices are shown as a dot. Their location and the number of wires may vary depending on the harness manufacturer. Switches Switches These switches move together; the broken straight line between them means they are mechanically connected. Other types of switches are controlled by a coil or a solid state circuit. Unless otherwise noted, all switches are shown in their normal (rest) position, with power off. Terminal "T" Page 6487 Child Seat Tether Attachment: Service and Repair Child Seat Lower Anchorage Striker And Associated Parts REMOVAL 1. Raise the seat cushion assembly (2). - Pull the strap (1) of the rear seat lock assembly to release the seat lock. 2. Remove the head rests. 3. Pull the release knobs and fall down the seat back assembly forward. 4. Remove the front luggage floor carpets. - Pull the nine carpet fixing clips at each from the backside of the seat back assembly. 5. Remove the tour lower anchorage strikers. - Remove the two fixing bolts of each lower anchorage striker. INSTALLATION Page 496 Terminals - "T" Each "T" terminal (ring type) is numbered for reference and location. A "T" terminal is secured with a screw or bolt. Wires Page 187 Fuel Pump Relay: Service and Repair REMOVAL PROCEDURE 1. Remove the fuse and relay box cover from under the hood. 2. Consult the diagram on the cover to determine which is the correct relay. 3. Insert a small screwdriver into the catch slot on the forward side of the fuel pump relay. 4. The screwdriver blade will release the catch inside. 5. Pull the relay straight up and out of the fuse and relay box. INSTALLATION PROCEDURE 1. Insert the relay into the correct place in the fuse and relay box with the catch slot facing forward. 2. Press down until the catch engages. - An audible "click" will be heard. Page 173 Terminals - "T" Each "T" terminal (ring type) is numbered for reference and location. A "T" terminal is secured with a screw or bolt. Wires Service and Repair Shift Indicator: Service and Repair Removal 1. Disconnect the battery ground cable. 3. Remove the meter lens (3) from the meter visor (4). 4. Remove the meter visor from the meter case(5). Page 294 The name of the component appears next to it followed by notes about its function along with any photo and connector view references. Connector "C" How to Identify Connector Terminals Cavity Numbering System The cavities (and wire terminals) in each connector are numbered starting from the upper left, looking at the male terminals from the terminal side (or looking at the female terminals from the wire side. Both views are in the same direction so the numbers are the same.) All actual cavities are numbered, even if they have no wire terminals in them. NOTE: Data Link Connector (DLC) terminals are numbered according to SAE standard J1962, not the Honda standard. The numbers of the four end terminals are molded into the corners of the connector face. Page 2183 2. Unfasten C123 from the side of the engine compartment using a 90-degree pick. 3. Disconnect C123, and clean the terminals on both sides of the connector with contact cleaner. Shake the residue out of the connector. Allow the contact cleaner to evaporate for at least 3 minutes, then reconnect C123. 4. Fasten C123 to the left side of the engine compartment, and reinstall the air cleaner housing cover. 5. Remove the connector position assurance (CPA) clip from the APPS connector. 6. Disconnect the lop connector from the APPS. 7. Clean the terminals of the 10P APPS connector (harness side) with contact cleaner. Shake out residue from the connector, and allow the contact cleaner to evaporate for at least 3 minutes, then reconnect it. 8. Use the Smart Cable to reprogram the PCM with the latest software from the June 2001 or later HONDANET CD-ROM. Refer to Service Bulletin 99-005, Updating the Passport PCM, filed under Tools. 9. Use the PGM Tester to clear any DTCs. Page 7432 Each schematic represents one circuit. A circuit's wires and components are arranged to show current flow, from power at the top of the page, to ground, at the bottom. Shared Circuits Other circuits may share power or ground terminals or wiring with the circuit shown. A wire that connects one circuit to another, for example, is cut short and has an arrowhead at the end of it pointing in the direction of current flow. Next to the arrowhead is the name of the circuit or component which shares that wiring. To quickly check shared wiring, check the operation of a component it serves. If that component works, you know the shared wiring is OK. Connectors All in-line and junction connectors are numbered (C725, C416, etc.). Component connectors are not numbered but are identified either by the name of Page 6769 The name of the component appears next to it followed by notes about its function along with any photo and connector view references. Connector "C" How to Identify Connector Terminals Cavity Numbering System The cavities (and wire terminals) in each connector are numbered starting from the upper left, looking at the male terminals from the terminal side (or looking at the female terminals from the wire side. Both views are in the same direction so the numbers are the same.) All actual cavities are numbered, even if they have no wire terminals in them. NOTE: Data Link Connector (DLC) terminals are numbered according to SAE standard J1962, not the Honda standard. The numbers of the four end terminals are molded into the corners of the connector face. Page 3435 14. While watching the APP Sensor values in the Engine Data List, adjust the APPS by turning it until the values are within the ranges shown at closed throttle and wide open throttle (accelerator pedal pushed all the way down), then tighten the mounting screws and recheck the values. ^ If all three sensors are within range, go to step 23. ^ If APP Sensor 1 APP Sensor 2, and/or APP Sensor 3 cannot be brought into range, go to step 15. 15. Troubleshoot for an open circuit or a PCM malfunction. ^ If APP Sensor 1 has a value of 0% or APP Sensor 2 and/or APP Sensor 3 have a value of 99%, an open circuit exists or the PCM is malfunctioning. Repair the circuit or replace the PCM, and repeat step 14. ^ If you don't find a problem, go to step 16. 16. Disconnect the 10 P connector from the APPS. 17. View the APP Sensor values in the Engine Data List. ^ If APP Sensor 1 has a value of 0% or APP Sensor 2 and/or APP Sensor 3 have a value of 99%, go to step 18. ^ If APP Sensor 1 has a value other than 0%, or APP Sensor 2 and/or APP Sensor 3 have a value other than 99%, a short circuit exists or the PCM is malfunctioning. Repair the circuit or replace the PCM, and repeat step 14. 18. Modify the original APPS by cutting the connector housing off of the sensor. 19. Connect the 10 P connector to the modified APPS connector housing. Page 2764 Distinct Of Circuit By Wire Base Color All wires have color-coded insulation. Wires belonging to a system's main harness will have a single color. Wires belonging to a system's sub-circuits will have a colored stripe. Striped wires use the codes found in the chart to show wire size and colors. Abbreviations are used to indicate wire color within a circuit diagram. How to Identify Connector Terminals How to Identify Connector Terminals Cavity Numbering System The cavities (and wire terminals) in each connector are numbered starting from the upper left, looking at the male terminals from the terminal side (or looking at the female terminals from the wire side. Both views are in the same direction so the numbers are the same.) All actual cavities are numbered, even if they have no wire terminals in them. NOTE: Data Link Connector (DLC) terminals are numbered according to SAE standard J1962, not the Honda standard. The numbers of the four end terminals are molded into the corners of the connector face. The connector cavity number is listed next to each terminal on the circuit schematic. The cavity / terminal shown is # 6. Using/Identifying Connector Terminal Views How to Use Connector Terminal Views To see the configuration of a connector's cavities, look up its view number in the Connector Views. Each view includes the color of the connector, where Page 7786 The connector cavity number is listed next to each terminal on the circuit schematic. The cavity / terminal shown is # 6. Diodes A rectifier diode works like a one way valve. It allows current to flow only in the direction of the arrow. A Zener diode blocks reverse current at normal voltages just like a rectifier diode. At high voltages, however, a Zener diode allows current to flow in reverse. Fuses Component Locations Page 1463 - Push the ring by the piston, at a right angle to the wall, into the point at which the cylinder bore diameter is the smallest. - Measure the ring end gap. - Positioning mark (1) is painted as shown in the illustration. Marked T: No.1 Compression ring Marked T2: No.2 Compression ring 2. Measure the clearance between the piston ring groove and the piston ring with a feeler gauge. If the piston ring groove/piston ring clearance exceeds the specified limit, the piston must be replaced. Compression Ring Clearance Standard: 0.025 mm - 0.065 mm (0.0006 inch - 0.0015 inch) Limit: 0.1mm (0.0059 inch) Piston Pin Note: Do not reuse the old piston pin. 1. Use a micrometer to measure the new piston pin outside diameter in both directions at three different positions. Page 1389 - Disc - Caliper - Shift on the fly system parts (Cap, Hub flange, Shim, Snap ring) - ABS sensor ring For inspection and servicing of disc caliper and related parts, refer to Brakes and Traction Control; Brakes; Disc Brake System. REASSEMBLY 1. Install wheel pin. - Place the hub on a wood workbench or a block of wood approx. 6" by 6" to protect the wheel stud ends and threads. - Insert a wheel stud using a hammer. Be sure the wheel stud is started squarely and seats completely. 2. Align scribe marks (1) and attach the hub to the disc, then tighten the bolts to the specified torque. Torque: 103 Nm (76 ft. lbs.) 3. Use installer J-36829 and grip J-8092, then install the inner bearing by driving it into the hub. Page 6459 Air Bag Control Module: Service and Repair WARNING: DURING SERVICE PROCEDURES, BE VERY CAREFUL WHEN HANDLING SDM. NEVER STRIKE OR JAR SDM. UNDER SOME CIRCUMSTANCES, IT COULD CAUSE DEPLOYMENT AND RESULT IN PERSONAL INJURY OR IMPROPER OPERATION OF THE SUPPLEMENTAL RESTRAINT SYSTEM (SRS). SDM MOUNTING BRACKET BOLTS MUST BE CAREFULLY TORQUED TO ASSURE PROPER OPERATION. THE SRS SHOULD ONLY BE CONNECTED TO A POWER SOURCE WHEN IT IS INSTALLED SECURELY IN THE VEHICLE. THE SDM MAY SUDDENLY DEPLOY THE AIRBAGS CAUSING PERSONAL INJURY WARNING: PROPER OPERATION OF THE SENSING AND DIAGNOSTIC MODULE (SDM) REQUIRES THE SDM TO BE SECURELY INSTALLED ON THE VEHICLE AND THE ARROW ON THE SENSOR MUST BE POINTING TOWARD THE FRONT OF THE VEHICLE. SDM is specifically calibrated and is keyed to the SDM location SRS wiring harness. Caution should be used to ensure proper location of the SDM. The keying of the SDM to its location and wiring harness connectors should never be modified in the field. Removal 1. Disable the SRS. 2. Remove dressing panel around the radio and disconnect cigar lighter harness 3. Remove the transfer sift lever knob. 4. Remove the center console. 5. Remove three connector from Powertrain Control Module (PCM). (Y22SE 2.2L Engine only) 6. Remove PCM with bracket. (Fixed tour bolts) (Y22SE 2.2L Engine only) 7. Remove right side stay between instrument panel and floor. 8. Remove driver and passenger seat. 9. Turn over carpet to rear side. 10. Remove air conditioning duct for rear seat. (Transform the duct during removing it) 11. Pull CPA (2) (Connector Position Assurance-red color) out and push connector lock down to disconnect the SDM harness connector (3). Page 4285 2. Connect one lead of a self-powered test light or DVOM to one end of the part of the circuit you want to test. 3. Connect the other lead to the other end. 4. If the self-powered test light glows, there is continuity. If you're using a DVOM, a low reading or no reading (zero), means good continuity. Testing For Voltage When testing for voltage at a connector without wire seals, you do not have to separate the two halves of the connector. Instead, probe the connector from the back. Always check both sides of the connector because dirty, corroded, and bent terminals can cause problems (no electrical contact = an open). 1. Connect one lead of the lest light to a known good ground, or, if you're using a digital volt ohmmeter (DVOM), place it in the appropriate DC volts range, and connect its negative lead to ground. 2. Connect the other lead of the test light or DVOM to the point you want to check. 3. If the test light glows, there is voltage present. If you're using a DVOM, note the voltage reading. It should be within one volt of measured battery voltage. A loss of more than one volt indicates a problem. NOTE: Always use a DVOM on high impedance circuits. A test light may not glow (even with battery voltage present). Testing For Voltage Drop Wires, connectors, and switches are designed to conduct current with a minimum loss of voltage. A voltage drop of more than one volt indicates a problem. 1. Place the digital volt/ohmmeter (DVOM) in the appropriate DC volts range. Connect the positive lead to the end of the wire (or to the connector or switch) closest to the battery. 2. Connect the negative lead to the other end of the wire (or the other side of the connector or switch). 3. Turn on the components in the circuit. 4. The DVOM will show the difference in voltage between the two points. A difference, or drop, of more than one volt indicates a problem. Check the circuit for loose, dirty, or bent terminals. Page 8170 Quarter Window Glass: Diagrams Rear Quarter Glass (LWB) Description and Operation Transmission Mode Indicator - A/T: Description and Operation With the ignition switch in ON or START battery voltage is applied to the A/T gear position switch through fuse 14. The A/T gear position switch sends a signal to the PCM which communicates this information to the multiplex control unit which in turn controls the A/T gear position indicator corresponding to the gear selected. The multiplex control unit applies voltage to the appropriate A/T gear position indicator light in the meter assembly, causing it to come on. Page 3745 Testing For A Short With A Self-Powered Test Light or DVOM 1. Remove the blown fuse and disconnect the battery and load. 2. Connect one lead of a self-powered test light or digital volt/ohmmeter (DVOM) (switched to the lowest "OHMS" range) to the fuse terminal on the load side. 3. Connect the other lead to a known good ground. 4. Beginning near the fuse box, wiggle the harness. Continue this at convenient points about six inches apart while watching the test light or DVOM. 5. If the self-powered test light goes on or the DVOM displays a low reading or no reading (zero), there is a short to ground in the wiring near that point. Testing for a Short with a Test Light or DVOM 1. Remove the blown fuse and disconnect the load. 2. Connect a test light or digital volt/ohmmeter (DVOM), switched to the appropriate DC volts range, across the fuse terminals to make sure voltage is present. You might have to turn the ignition switch to ON; check the schematic to see. 3. Beginning near the fuse box, wiggle the harness. Continue this at convenient points about six inches apart while watching the test light or DVOM. 4. Where the test light goes , or the DVOM voltage drops to zero, there is a short to ground in the wiring near that point. NOTE: Always use a DVOM on high impedance circuits. A test light may not glow (even with battery voltage present). Testing For A Short With A Short Circuit Locator (Short Finder) 1. Remove the blown fuse. Leave the battery connected. Page 3302 The wire insulation has one color or one color with another color stripe. The second color is the stripe. Page 5113 Disassembled View Page 6083 This means the branch of the wire connects to another circuit. The arrow points to the name of the circuit branch where the wire continues. Page 3305 Testing For A Short With A Self-Powered Test Light or DVOM 1. Remove the blown fuse and disconnect the battery and load. 2. Connect one lead of a self-powered test light or digital volt/ohmmeter (DVOM) (switched to the lowest "OHMS" range) to the fuse terminal on the load side. 3. Connect the other lead to a known good ground. 4. Beginning near the fuse box, wiggle the harness. Continue this at convenient points about six inches apart while watching the test light or DVOM. 5. If the self-powered test light goes on or the DVOM displays a low reading or no reading (zero), there is a short to ground in the wiring near that point. Testing for a Short with a Test Light or DVOM 1. Remove the blown fuse and disconnect the load. 2. Connect a test light or digital volt/ohmmeter (DVOM), switched to the appropriate DC volts range, across the fuse terminals to make sure voltage is present. You might have to turn the ignition switch to ON; check the schematic to see. 3. Beginning near the fuse box, wiggle the harness. Continue this at convenient points about six inches apart while watching the test light or DVOM. 4. Where the test light goes , or the DVOM voltage drops to zero, there is a short to ground in the wiring near that point. NOTE: Always use a DVOM on high impedance circuits. A test light may not glow (even with battery voltage present). Testing For A Short With A Short Circuit Locator (Short Finder) 1. Remove the blown fuse. Leave the battery connected. Page 5346 10. Use the PGM Tester to check the broadcast code. Make sure the broadcast code matches the one you selected from the CD-ROM. WARRANTY CLAIM INFORMATION In warranty: The normal warranty applies. Failed Part: P/N 8-17087-655-0 H/C 4375820 Defect Code: 064 Contention Code: C01 Skill Level: Repair Technician Out of warranty: Any repair performed after warranty expiration may be eligible for goodwill consideration by the District Service Manager or your Zone Office. You must request consideration, and get a decision, before starting work. REPAIR PROCEDURE - ENGINE/BODY GROUND 1. Use the ETM for the appropriate year to locate these ground connectors: G101, G104, G105, G106 and G160. 2. Inspect each connector for corrosion or looseness. 3. Remove the bolt from any connector that is corroded or loose. Clean the terminal connector with a wire brush. File flat any solder bumps on the connector. 4. Clean the contact surface on the engine or body with a wire brush. 5. Replace the bolt if it is heavily corroded. Otherwise, clean it with a wire brush. 6. Apply lithium dielectric grease to both sides of the terminal connector. 7. Reinstall the bolt, torque it to 14 N.m (10 lb-ft). 8. Use the Smart Cable to reprogram the PCM with the latest software from the June 2001 or later HONDANET CD-ROM. Refer to Service Bulletin 99-005, Updating the Passport PCM, filed under Tools. 9. Use the PGM Tester to clear any DTCs. 10. Use the PGM Tester to check the broadcast code. Make sure the broadcast code matches the one you selected from the CD-ROM. WARRANTY CLAIM INFORMATION In warranty: The normal warranty applies. Failed Part: P/N 8-97086-823-0 Page 7527 This means the branch of the wire connects to another circuit. The arrow points to the name of the circuit branch where the wire continues. Page 4716 The name of the component appears next to it followed by notes about its function along with any photo and connector view references. Connector "C" How to Identify Connector Terminals Cavity Numbering System The cavities (and wire terminals) in each connector are numbered starting from the upper left, looking at the male terminals from the terminal side (or looking at the female terminals from the wire side. Both views are in the same direction so the numbers are the same.) All actual cavities are numbered, even if they have no wire terminals in them. NOTE: Data Link Connector (DLC) terminals are numbered according to SAE standard J1962, not the Honda standard. The numbers of the four end terminals are molded into the corners of the connector face. Page 3155 6. Remove the connector position assurance (CPA) clip from the APPS connector. 7. Disconnect the 10 P connector from the APPS. 8. Remove the bolts, the APPS, the spacer, and the accelerator link from the accelerator pedal assembly. 9. Separate the spacer from the APPS. Clean the grease off the spacer and the accelerator link with a clean shop towel. 10. Clean the terminals of the 10 P APPS connector (harness side) with contact cleaner. Shake the residue out of the connector, and allow the contact cleaner to evaporate for at least 3 minutes before reconnecting the connector. 11. Install a new APPS, the spacer, and the accelerator link onto the accelerator pedal assembly. Leave the mounting screws loose so the sensor can be adjusted. 12. Connect the 10 P connector to the new APPS, and lock the connector in place with the CPA. 13. Connect the PGM Tester to the data link connector (DLC), and turn the ignition switch to ON (II). Page 5429 ^ If the wheels are pointed to the right, shorten the driver's side tie-rod, and lengthen the passenger's side. ^ If the wheels are pointed to the left, shorten the passenger's side tie-rod, and lengthen the driver's side. ^ Each 360° turn of the tie-rod equals about 8 mm of steering wheel adjustment. For example, a steering wheel is off-center by 4 mm with the front wheels pointed right (when the steering wheel is centered). To correct the off-center, shorten the driver's side tie-rod by a half-turn, and lengthen the passenger's side tie-rod by a half-turn. 4. Use your diagnosis worksheet to fill in the following table and build your 15-digit DTC. Technical Service Bulletin # SN030915 Date: 030901 Suspension - Drifting & Pulling At Highway Speeds SOURCE: Honda Service News September 2003 TITLE: Drifting and Pulling at Highway Speeds APPLIES TO: All Models SERVICE TIP: Got a customer complaining that the vehicle drifts or pulls when driving at highway speeds? Use this handy procedure to diagnose and repair the problem. NOTE: Before doing the procedure in this article, check ISIS for related S/Bs and other S/N articles for the model you're working on. 1. Check if your customer has original equipment wheels and tires and that the ride height hasn't been modified. - If the wheels, tires, and ride height are OK, go to step 2. - If the wheels or tires aren't original equipment or the ride height was modified, stop here. Aftermarket wheels or tires or a ride height that's been modified pose challenges that this article doesn't cover. Resolve these issues with your customer before going further. 2. Set the tire pressures to the recommended cold inflation values listed on the doorjamb sticker. 3. Find a straight stretch of 4-lane road where you can safely (and legally) go 60 mph for several minutes. Ideally, you want a road that's perfectly flat, but most roads have a crown that¡C■s anywhere from 1.5° to 1.75° so they can drain. Flat Road - While driving at 60 mph, use a stopwatch to time how long it takes to drift one full lane from center to center. Record the time. Repeat this, driving in the opposite direction to cancel the effects of wind, then average the two times you recorded. If the vehicle drifts one full lane from center to center in less than 6 seconds, go to step 4. If not, return the vehicle to your customer. Crowned Road - While driving at 60 mph, check if the vehicle climbs the crown. Do this for both a left- and right-crowned road. A drift to the right on a right-crowned road and a drift to the left on left-crowned road are considered normal. If the vehicle climbs the crown or it drifts to the right on a left crowned road, go to step 4. 4. Record the original toe, camber, and caster readings. On Passports, set the ride height to spec if needed. Refer to Ride Height Adjustment in S/B 99-043, Steering Wheel Shimmy or Chassis Vibration. 5. Loosen the subframe mounting bolts, and move the rear beam (it¡C■s the entire front subframe on some models) to get the maximum amount of caster and equal side-to-side camber. (As little as 0.4° of camber stagger can cause the vehicle to pull.) 6. Make sure the steering wheel is centered, then set the front and rear toe to the maximum toe-in spec. (Toe-in improves vehicle stability and reduces the tendency to drift or pull.) 7. Test-drive the vehicle on the same road you used earlier. - If the drift is now within spec, return the vehicle to your customer. - If the drift is still out of spec, go to step 8. 8. Swap the front and rear tires on each side of the vehicle, then adjust the tire pressures to the recommended cold inflation values listed on the doorjamb sticker. Page 5544 6. Place the end of the return hose in a container. Have someone start the engine, then pour ATF into the reservoir while you watch the fluid coming out of the return hose. When the fluid coming out is the same color as the new fluid, turn off the engine. 7. Reconnect the return hose to the reservoir. 8. Start the engine. Fill the power steering reservoir to the proper level with ATF then turn off the engine. 9. Use the Smart Cable to reprogram the PCM with the latest software from the June 2001 or later HONDANET CD-ROM. Refer to Service Bulletin 99-005, Updating the Passport PCM, filed under Tools. 10. Use the PGM Tester to clear any DTCs. 11. Use the PGM Tester to check the broadcast code. Make sure the broadcast code matches the one you selected from the CD-ROM. WARRANTY CLAIM INFORMATION In warranty: The normal warranty applies. Failed Part: P/N 8-97181-590-0 H/C 5698030 Defect Code: 064 Contention Code: C01 Skill Level: Repair Technician Out of warranty: Any repair performed after warranty expiration may be eligible for goodwill consideration by the District Service Manager or your Zone Office. You must request consideration, and get a decision, before starting work. REPAIR PROCEDURE - APPS GROUND 1. Unclamp the air cleaner housing cover, and move it to the side for access to connector C123 (16P BLK). Page 7957 Test Equipment CAUTION: Most circuits include solid-state devices. Test the voltages in these circuits only with a 10-megaohm or higher impedance digital multimeter. Never use a test light or analog meter on circuits that contain solid-state devices. Damage to the devices may result. Test Light and DVOM On circuits without solid-state devices, use a test light to check for voltage. A test light is made up of a 12 volt bulb with a pair of leads attached. After grounding one lead, touch the other lead to various points along the circuit where voltage should be present. The bulb will go on if there is voltage at the point being tested. If you need to know how much voltage is present, use a digital volt/ohmmeter (DVOM). Self-Powered Test Light and DVOM Use a self-powered test light to check for continuity. This tool is made up of a light bulb, battery, and two leads. To test it, touch the leads together: the light should go on. Use a self-powered test light only on an unpowered circuit. First, disconnect the battery, or remove the fuse that feeds the circuit you are working on. Select two points in the circuit between which you want to check continuity. Connect one lead of the self-powered test light to each point. If there is continuity, the test light's circuit will be completed, and the light will go on. If, in addition, you need to know exactly how much resistance there is between two points, use a digital volt/ohmmeter (DVOM). In the "OHMS" range, the DVOM will measure resistance between two points along a circuit. Low resistance means good continuity. Diodes and solid-state devices in a circuit can make a DVOM give a false reading. To check a reading, reverse the leads, and take a second reading. If the readings differ, the component is affecting the measurement. Jumper Wire Use a jumper wire to bypass an open circuit. A jumper wire is made up of an in-line fuse holder connected to a set of test leads. It should have a five ampere fuse. Never connect a jumper wire across a short circuit. The direct battery short will blow the fuse. Short Finder (Short Circuit Locator) Short finders are available to locate shorts to ground. The short finder creates a pulsing magnetic field in the shorted circuit which you can follow to the location of the short. To order any test equipment shown above, contact your local tool supplier. For a list of suppliers and tool numbers, refer to Honda Required Special Tools and Equipment Service Bulletin. Page 214 Ion Sensing Module: Diagnostic Aids Before Troubleshooting Before Troubleshooting See: Service Precautions/Vehicle Damage Warnings/Tips and Precautions 1. Check applicable fuses in the appropriate fuse/relay box. 2. Check the battery for damage, state of charge, and clean and tight connections. CAUTION: Do not quick-charge a battery unless the battery ground cable has been disconnected, otherwise you will damage the alternator diodes. - Do not attempt to crank the engine with the battery ground cable loosely connected or you will severely damage the wiring. While You're Working 1. Make sure connectors are clean, and have no loose terminals or receptacles. 2. Make sure that connectors without wire seals are packed with dielectric (silicone) grease. Part Number: 08798-9001. 3. When connecting a connector, push it until it "clicks" into place. CAUTION: Do not pull on the wires when disconnecting a connector. Pull only on the connector housings. - Most circuits include solid-state devices. Test the voltages in these circuits only with a 10-megaohm or higher impedance digital multi meter. Never use a test light or analog meter on circuits that contain solid-state devices. Damage to the devices may result. Five-Step Troubleshooting 1. Verify The Complaint Turn on all the components in the problem circuit to check the accuracy of the customer complaint. Note the symptoms. Do not begin disassembly or testing until you have narrowed down the problem area. 2. Analyze The Schematic Look up the schematic for the problem circuit. Determine how the circuit is supposed to work by tracing the current paths from the power source through the circuit components to ground. Also, trace circuits that share wiring with the problem circuit. The names of circuits that share the same fuse, ground, or switch, and so on, are referred to in each circuit schematic. Try to operate any shared circuits you didn't check in step 1. If the shared circuits work, the shared wiring is OK, and the cause must be in the wiring used only by the problem circuit. If several circuits fail at the same time, the fuse or ground is a likely cause. Based on the symptoms and your understanding of the circuit's operation, identify one or more possible causes. 3. Isolate The Problem By Testing The Circuit Make circuit tests to check the diagnosis you made in step 2. Keep in mind that a logical, simple procedure is the key to efficient troubleshooting. Test for the most likely cause of failure first. Try to make tests at points that are easily accessible. 4. Fix The Problem Once the specific problem is identified, make the repair. Be sure to use proper tools and safe procedures. 5. Make Sure The Circuit Works Turn on all components in the repaired circuit in all modes to make sure you've fixed the entire problem. If the problem was a blown fuse, be sure to test all of the circuits on that fuse. Make sure no new problems turn up and the original problem does not recur. Page 6526 - Remove the three bolts and three screws, and then remove quarter side molding (Soft top model). 6. Remove the tailgate weather strip. 7. Remove the rear end floor trim cover. 8. Remove the luggage side trim cover (RH). - Remove the lack & tool lid and remove the tool. - Remove fixing screw and pry the trim cover retainers free from the body panel. 9. Remove the luggage side trim cover (LH). - Remove fixing screw and pry the trim cover retainers free from the body panel. - Disconnect the accessory socket connectors. 10. Remove the anchor cover and seat belt lower anchor bolt. Page 3124 Accelerator Pedal And Associated Parts Specifications Torque Specifications Page 4275 Splices Splices are shown as a dot. Their location and the number of wires may vary depending on the harness manufacturer. Switches Switches These switches move together; the broken straight line between them means they are mechanically connected. Other types of switches are controlled by a coil or a solid state circuit. Unless otherwise noted, all switches are shown in their normal (rest) position, with power off. Terminal "T" Suspension - Drifting & Pulling At Highway Speeds Alignment: All Technical Service Bulletins Suspension - Drifting & Pulling At Highway Speeds SOURCE: Honda Service News September 2003 TITLE: Drifting and Pulling at Highway Speeds APPLIES TO: All Models SERVICE TIP: Got a customer complaining that the vehicle drifts or pulls when driving at highway speeds? Use this handy procedure to diagnose and repair the problem. NOTE: Before doing the procedure in this article, check ISIS for related S/Bs and other S/N articles for the model you're working on. 1. Check if your customer has original equipment wheels and tires and that the ride height hasn't been modified. - If the wheels, tires, and ride height are OK, go to step 2. - If the wheels or tires aren't original equipment or the ride height was modified, stop here. Aftermarket wheels or tires or a ride height that's been modified pose challenges that this article doesn't cover. Resolve these issues with your customer before going further. 2. Set the tire pressures to the recommended cold inflation values listed on the doorjamb sticker. 3. Find a straight stretch of 4-lane road where you can safely (and legally) go 60 mph for several minutes. Ideally, you want a road that's perfectly flat, but most roads have a crown that¡C■s anywhere from 1.5° to 1.75° so they can drain. Flat Road - While driving at 60 mph, use a stopwatch to time how long it takes to drift one full lane from center to center. Record the time. Repeat this, driving in the opposite direction to cancel the effects of wind, then average the two times you recorded. If the vehicle drifts one full lane from center to center in less than 6 seconds, go to step 4. If not, return the vehicle to your customer. Crowned Road - While driving at 60 mph, check if the vehicle climbs the crown. Do this for both a left- and right-crowned road. A drift to the right on a right-crowned road and a drift to the left on left-crowned road are considered normal. If the vehicle climbs the crown or it drifts to the right on a left crowned road, go to step 4. 4. Record the original toe, camber, and caster readings. On Passports, set the ride height to spec if needed. Refer to Ride Height Adjustment in S/B 99-043, Steering Wheel Shimmy or Chassis Vibration. 5. Loosen the subframe mounting bolts, and move the rear beam (it¡C■s the entire front subframe on some models) to get the maximum amount of caster and equal side-to-side camber. (As little as 0.4° of camber stagger can cause the vehicle to pull.) 6. Make sure the steering wheel is centered, then set the front and rear toe to the maximum toe-in spec. (Toe-in improves vehicle stability and reduces the tendency to drift or pull.) 7. Test-drive the vehicle on the same road you used earlier. - If the drift is now within spec, return the vehicle to your customer. - If the drift is still out of spec, go to step 8. 8. Swap the front and rear tires on each side of the vehicle, then adjust the tire pressures to the recommended cold inflation values listed on the doorjamb sticker. 9. Test-drive the vehicle on the same road you used earlier. - If the drift is now within spec, swap each rear tire back to the front, one at a time, and test-drive the vehicle on the same road you used earlier. Replace the bad tire, then return the vehicle to your customer. - If the drift is still out of spec after swapping the front and rear tires, go to step 10. 10. Test-drive a known-good donor vehicle on the same road you used earlier, and check its pull. 11. Swap all four tires from the donor vehicle with the tires on your customer¡C■s vehicle. Page 5050 Brake Fluid Level Sensor/Switch: Description and Operation The brake system warning light goes on to alert the driver that the parking brake is applied or that the brake fluid is low. It also lights as a bulb test when the engine is cranked. With the ignition switch in ON or START, battery voltage is applied to fuse 11 and to the brake system warning light. If the brake fluid is low, the brake fluid level switch closes and provides a ground for the light. The brake system warning light comes on to warn the driver of low brake fluid level in the brake master cylinder. (Note: Check brake pad wear before adding fluid). Page 3602 Ion Sensing Module: Description and Operation ION Sensing Module ION Sensing Module This module has the function to energize and de-energize the primary ignition coil in response to signals from the PCM. Page 4300 Seals and Gaskets: Service and Repair Rear Differential PINION OIL SEAL AND ASSOCIATED PARTS REMOVAL 1. Remove the rear drive/propeller shaft. 2. Drain the rear axle oil. 3. Check and record preload with an inch pound torque wrench. This will give combined pinion bearing, seal, carrier bearing, axle bearing and seal preload. Page 4656 Page 6841 Rear Door Exterior Handle: Service and Repair Removal 1. Disconnect the battery ground cable. 2. Remove the door trim panel. 3. Remove the waterproof sheet. - Taking notice of the door harness, peel the waterproof sheet off the door panel carefully. 4. Disconnect the locking link and remove fixing bolts to remove the outside handle. Installation To install, follow the removal steps in the reverse order, noting the following points. 1. Check that the outside handle operates smoothly. 2. Tighten the outside handle fixing bolts to the specified torque. Torque 9 Nm (78 lb in) Page 1724 11. Remove the timing belt covers in this order: right, left, then lower. 12. Loosen (don't remove) the tensioner pulley bolt. 13. Remove the idler pulley bolt, and let the idler pulley pivot towards the crankshaft timing pulley. 14. Remove the lower tensioner bolt and the tensioner pusher. 15. Carefully remove the timing belt from the pulleys. ENGINE TIMING 1. Turn the crankshaft timing pulley until its notch aligns with the mark on the oil pump housing. NOTE: The crankshaft timing pulley may have a green mark 150 degrees from its keyway. Do not use this mark to set the crankshaft position. 2. Turn the right cylinder bank's camshaft pulley clockwise with a socket and ratchet. (The pulley clicks and stops several times.) Stop the pulley when its green mark aligns with the valve cover timing mark. NOTE: You may need to rotate the camshaft pulley up to four complete turns before its green mark aligns directly with the valve cover timing mark. 3. Turn the left cylinder bank's camshaft pulley clockwise with a socket and ratchet. (The pulley clicks and stops several times.) Stop the pulley when its green mark aligns with the timing belt cover bolt hole. Page 938 Transmission Speed Sensor: Locations Top Of Transfer Case Page 6408 To install the connector, hold the socket insulator(l) and insert it. The cover insulator slides and connector will be locked. Do not hold the cover insulator(2). Removal and Installation WARNING: SAFETY PRECAUTIONS MUST BE FOLLOWED WHEN HANDLING A DEPLOYED AIR BAG ASSEMBLY. AFTER DEPLOYMENT, THE AIR BAG ASSEMBLY SURFACE MAY CONTAIN A SMALL AMOUNT OF SODIUM HYDROXIDE, A BY-PRODUCT OF THE DEPLOYMENT REACTION, THAT IS IRRITATING TO THE SKIN AND EYES. MOST OF THE POWDER ON THE AIR BAG ASSEMBLY IS HARMLESS. AS A PRECAUTION, WEAR GLOVES AND SAFETY GLASSES WHEN HANDLING A DEPLOYED AIR BAG ASSEMBLY AND WASH YOUR HANDS WITH MILD SOAP AND WATER AFTERWARDS. WARNING: WHEN CARRYING A LIVE AIR BAG ASSEMBLY, MAKE SURE THE BAG AND TRIM COVER ARE POINTED AWAY FROM YOU. NEVER CARRY AIR BAG ASSEMBLY BY THE WIRES OR CONNECTOR ON THE UNDERSIDE OF MODULE. IN THE CASE OF AN ACCIDENTAL DEPLOYMENT, THE BAG WILL THEN DEPLOY WITH MINIMAL CHANCE OF INJURY. WHEN PLACING A LIVE AIR BAG ASSEMBLY ON A BENCH OR OTHER SURFACE, ALWAYS FACE BAG AND TRIM COVER UP, AWAY FROM THE SURFACE. NEVER REST A STEERING COLUMN ASSEMBLY ON THE STEERING WHEEL WITH THE AIR BAG ASSEMBLY FACE DOWN AND COLUMN VERTICAL. THIS IS NECESSARY SO THAT A FREE SPACE IS PROVIDED TO ALLOW THE AIR BAG ASSEMBLY TO EXPAND IN THE UNLIKELY EVENT OF ACCIDENTAL DEPLOYMENT. OTHERWISE, PERSONAL INJURY COULD RESULT. NOTE: In the event deployment has occurred, inspect coil assembly wire for any signs of scorching. Melting or any other damage due to excessive heat. If the coil has been damaged, replace it. Removal 1. Disable the SRS. 2. Remove glove box assembly. 3. Disconnect passenger air bag assembly harness connector. 4. Remove air bag assembly fixing bolts and nuts. 5. Remove reinforcement. Page 1780 Cleaning Spark Plugs - Clean spark plugs with a spark plug cleaner. - Raise the ground electrode to an position of 45 to 60 degrees. If electrode is wet, dry it before cleaning. - After spark plug is thoroughly cleaned, check insulator for presence of cracks. - Clean threads and metal body with a wire brush. - File the electrode tip if electrode is extremely worn. - Bend the ground electrode to adjust the spark plug gap. Page 1852 Coolant Temperature Sensor/Switch (For Computer): Description and Operation Engine Coolant Temperature (ECT) Sensor The engine coolant temperature (ECT) sensor is a thermistor (a resistor which changes value based on temperature) mounted in the engine coolant stream. Low coolant temperature produces a high resistance of 100,000 ohms at -40 °C (-40 °F). High temperature causes a low resistance of 70 ohms at 130 °C (266 °F). The PCM supplies a 5-volt signal to the ECT sensor through resistors in the PCM and measures the voltage. The signal voltage will be high when the engine is cold and low when the engine is hot. By measuring the voltage, the PCM calculates the engine coolant temperature. Engine coolant temperature affects most of the systems that the PCM controls. The Tech 2 displays engine coolant temperature in degrees. After engine start-up, the temperature should rise steadily to about 85 °C (185 °F). It then stabilizes when the thermostat opens. If the engine has not been run for several hours (overnight), the engine coolant temperature and intake air temperature displays should be close to each other. A hard fault in the engine coolant sensor circuit will set DTC P0177 or DTC P0118. An intermittent fault will set a DTC P1114 or P1115. Page 7565 it is located, and what it connects to. Use the Connector Views to help locate the proper cavity when you need to probe a connector. It can be especially helpful if the connector has more than one wire of the same color. A dash symbol (-) indicates that the cavity is empty. Connector views can also be used to help diagnose multiple symptoms in separate circuits which could be caused by a single problem in a connector shared by those circuits. Here's an example: 1. Pick one of the multiple symptoms and look up the schematic for that circuit. 2. Make a list of all the in-line and fuse box connectors in that schematic , 3. Then, in the Connector Views, look up each connector on your list to see if circuits related to the other symptoms run through one of them. If they do, inspect that connector for the problem. Example: The blower, rear window defogger, and the windshield wiper don't work. List all in-line and fuse box connectors in the blower controls circuit and then check the Connector View (see the sample). You find that C324 is common to the blower controls, rear window defogger, and wiper/washer, so you inspect C324 and find the problem, bent terminals. Finding Component/Connector Locations Finding Component/Connector Locations To see where a component or connector is located on the car, look up its photo number in the "Component Location". The photo will also tell you the color of the connector, and how many cavities it has. Engine Controls - High/Erratic Engine Idle Power Steering Pressure Switch: Customer Interest Engine Controls - High/Erratic Engine Idle 01-080 August 14, 2001 Applies To: 2000-02 Passport - ALL 2000-02 Passport: High or Erratic Idle SYMPTOM The engine occasionally idles at too high a speed, or the idle speed fluctuates. PROBABLE CAUSES The symptom could be the result of any of these conditions: ^ Loose or corroded engine or body ground ^ High resistance in the APPS ground circuit ^ PSP (power steering pressure) switch is internally shorted to ground ^ Fuel pressure regulator is leaking fuel into the intake manifold CORRECTIVE ACTION Diagnose the cause of the idle condition, and select the proper REPAIR PROCEDURE. PARTS INFORMATION REQUIRED MATERIALS REQUIRED SOFTWARE Each REPAIR PROCEDURE requires you to use the Smart Cable to reprogram the PCM with the latest software. To select the latest software from the CDROM, enter the year, model, engine, transmission, and emissions type (49-state or California). This gives you a list of broadcast codes. Select the broadcast code at the top of the list. WARRANTY CLAIM INFORMATION Refer to the Warranty Claim Information for each Repair Procedure. DIAGNOSIS 1. Find out from the customer when the high or erratic idle condition occurs and what the RPM range is: ^ Within 20 minutes of a cold start ^ After braking to a stop ^ All the time ^ Intermittently, with no set pattern Page 8015 The name of the component appears next to it followed by notes about its function along with any photo and connector view references. Connector "C" How to Identify Connector Terminals Cavity Numbering System The cavities (and wire terminals) in each connector are numbered starting from the upper left, looking at the male terminals from the terminal side (or looking at the female terminals from the wire side. Both views are in the same direction so the numbers are the same.) All actual cavities are numbered, even if they have no wire terminals in them. NOTE: Data Link Connector (DLC) terminals are numbered according to SAE standard J1962, not the Honda standard. The numbers of the four end terminals are molded into the corners of the connector face. Page 5576 Each schematic represents one circuit. A circuit's wires and components are arranged to show current flow, from power at the top of the page, to ground, at the bottom. Shared Circuits Other circuits may share power or ground terminals or wiring with the circuit shown. A wire that connects one circuit to another, for example, is cut short and has an arrowhead at the end of it pointing in the direction of current flow. Next to the arrowhead is the name of the circuit or component which shares that wiring. To quickly check shared wiring, check the operation of a component it serves. If that component works, you know the shared wiring is OK. Connectors All in-line and junction connectors are numbered (C725, C416, etc.). Component connectors are not numbered but are identified either by the name of Page 8270 Torque: 10 Nm (87 lb in) 4. Tighten the wiper arm nut to the specified torque. Torque: 14 Nm (122 lb in) Rear Wiper Blade Rubber Removal 1. Remove the wiper blade from the wiper arm. 2. Push out the wiper rubber from the wiper blade by sliding it horizontally while holding down the rubber on the wiper blade convex (1) side. CAUTION: When the wiper blade has been removed, wrap the tip of the wiper arm with cloth, to avoid damaging the glass. Installation 1. Install the wiper blade rubber. - Insert the tip of wiper rubber (2) from the opposite side of removal in the arrow direction. Page 5345 2. Unfasten C123 from the side of the engine compartment using a 90-degree pick. 3. Disconnect C123, and clean the terminals on both sides of the connector with contact cleaner. Shake the residue out of the connector. Allow the contact cleaner to evaporate for at least 3 minutes, then reconnect C123. 4. Fasten C123 to the left side of the engine compartment, and reinstall the air cleaner housing cover. 5. Remove the connector position assurance (CPA) clip from the APPS connector. 6. Disconnect the lop connector from the APPS. 7. Clean the terminals of the 10P APPS connector (harness side) with contact cleaner. Shake out residue from the connector, and allow the contact cleaner to evaporate for at least 3 minutes, then reconnect it. 8. Use the Smart Cable to reprogram the PCM with the latest software from the June 2001 or later HONDANET CD-ROM. Refer to Service Bulletin 99-005, Updating the Passport PCM, filed under Tools. 9. Use the PGM Tester to clear any DTCs. Page 1391 Grease Amount - Hub: 35 g (1.23 oz.) - Outer bearing: 10 g (0.35 oz.) - Inner bearing: 15 g (0.53 oz.) 8. Install hub nut. Turn to the place where there is a chamfer in the tapped hole to the outer side, then attach the nut by using front hub nut wrench J-36827. PRELOAD ADJUSTMENT 1. Tighten the hub nut to 29 Nm (22 ft. lbs.), then fully loosen the nut. Page 267 Wires Wire insulation can be one color, or one color with another color stripe. (The second color is the stripe.) This circuit continues on another image. (The arrow shows direction of current flow.) To follow the RED/BLK wire in this example, you would turn to "Fuel and Emissions" and look for the "A" arrow. Page 8013 and the fuses. From Fuses to Relays and Components The second half of Power Distribution shows the wiring "From Fuses to Relays and Components." This can speed your troubleshooting by showing which circuits share fuses. If Power Distribution shows that an inoperative circuit and another circuit share a fuse, check a component in the other circuit. If it works, you know the fuse is good and power is available to the inoperative circuit. Ground Distribution Schematics Locations Evaporator Temperature Sensor / Switch: Locations Electronic Thermostat, Evaporator Core And/Or Expansion Valve - Disassembled View Page 5300 Splices Splices are shown as a dot. Their location and the number of wires may vary depending on the harness manufacturer. Switches Switches These switches move together; the broken straight line between them means they are mechanically connected. Other types of switches are controlled by a coil or a solid state circuit. Unless otherwise noted, all switches are shown in their normal (rest) position, with power off. Terminal "T" Page 2702 Manifold Pressure/Vacuum Sensor: Service and Repair MANIFOLD ABSOLUTE PRESSURE (MAP) SENSOR REMOVAL PROCEDURE 1. Disconnect the negative battery cable. 2. Disconnect the electrical connector from the MAP sensor. 3. Remove the bolt securing the MAP sensor to the mounting bracket on the common chamber. 4. Remove the MAP sensor from the mounting bracket. INSTALLATION PROCEDURE 1. Install the MAP sensor in the mounting bracket. 2. Install the mounting bracket retaining bolt on the common chamber. Page 3394 Distinct Of Circuit By Wire Base Color All wires have color-coded insulation. Wires belonging to a system's main harness will have a single color. Wires belonging to a system's sub-circuits will have a colored stripe. Striped wires use the codes found in the chart to show wire size and colors. Abbreviations are used to indicate wire color within a circuit diagram. How to Identify Connector Terminals How to Identify Connector Terminals Cavity Numbering System The cavities (and wire terminals) in each connector are numbered starting from the upper left, looking at the male terminals from the terminal side (or looking at the female terminals from the wire side. Both views are in the same direction so the numbers are the same.) All actual cavities are numbered, even if they have no wire terminals in them. NOTE: Data Link Connector (DLC) terminals are numbered according to SAE standard J1962, not the Honda standard. The numbers of the four end terminals are molded into the corners of the connector face. The connector cavity number is listed next to each terminal on the circuit schematic. The cavity / terminal shown is # 6. Using/Identifying Connector Terminal Views How to Use Connector Terminal Views To see the configuration of a connector's cavities, look up its view number in the Connector Views. Each view includes the color of the connector, where Page 7497 Dimmer Switch: Electrical Diagrams Part 1 Of 2 Page 3356 Distinct Of Circuit By Wire Base Color All wires have color-coded insulation. Wires belonging to a system's main harness will have a single color. Wires belonging to a system's sub-circuits will have a colored stripe. Striped wires use the codes found in the chart to show wire size and colors. Abbreviations are used to indicate wire color within a circuit diagram. How to Identify Connector Terminals How to Identify Connector Terminals Cavity Numbering System The cavities (and wire terminals) in each connector are numbered starting from the upper left, looking at the male terminals from the terminal side (or looking at the female terminals from the wire side. Both views are in the same direction so the numbers are the same.) All actual cavities are numbered, even if they have no wire terminals in them. NOTE: Data Link Connector (DLC) terminals are numbered according to SAE standard J1962, not the Honda standard. The numbers of the four end terminals are molded into the corners of the connector face. The connector cavity number is listed next to each terminal on the circuit schematic. The cavity / terminal shown is # 6. Using/Identifying Connector Terminal Views How to Use Connector Terminal Views To see the configuration of a connector's cavities, look up its view number in the Connector Views. Each view includes the color of the connector, where Page 6811 Front Door Panel: Service and Repair Front Door Trim Panel And Associated Parts Front Door Trim Panel Removal 1. Disconnect the battery ground cable. 2. Remove the door mirror assembly. Diagrams Diagram Information and Instructions Transmission Shift Position Indicator Lamp: Diagram Information and Instructions How to Identify Wiring Color-Coded Insulation Wire Color Wire Color Coding Page 7564 Distinct Of Circuit By Wire Base Color All wires have color-coded insulation. Wires belonging to a system's main harness will have a single color. Wires belonging to a system's sub-circuits will have a colored stripe. Striped wires use the codes found in the chart to show wire size and colors. Abbreviations are used to indicate wire color within a circuit diagram. How to Identify Connector Terminals How to Identify Connector Terminals Cavity Numbering System The cavities (and wire terminals) in each connector are numbered starting from the upper left, looking at the male terminals from the terminal side (or looking at the female terminals from the wire side. Both views are in the same direction so the numbers are the same.) All actual cavities are numbered, even if they have no wire terminals in them. NOTE: Data Link Connector (DLC) terminals are numbered according to SAE standard J1962, not the Honda standard. The numbers of the four end terminals are molded into the corners of the connector face. The connector cavity number is listed next to each terminal on the circuit schematic. The cavity / terminal shown is # 6. Using/Identifying Connector Terminal Views How to Use Connector Terminal Views To see the configuration of a connector's cavities, look up its view number in the Connector Views. Each view includes the color of the connector, where Page 1894 Exhaust Manifold: Service and Repair Exhaust Manifold RH Removal 1. Disconnect battery ground cable. 2. Remove torsion bar. 3. Remove exhaust front pipe three stud nuts and two nuts then disconnect exhaust front pipe. 4. Remove heat protector two fixing bolts then the heat protector. 5. Remove Exhaust Gas Recirculation (EGR) pipe fixing bolt and nut from exhaust manifold, remove a nut from EGR valve and a bolt from rear side of cylinder head for bracket of EGR pipe then remove the EGR pipe. 6. Remove exhaust manifold eight fixing nuts then the exhaust manifold. Installation Page 3311 - If the data list changes, the Fuel Pump Relay is normal. Page 4611 Part 3 Of 3 Page 4329 7. Measure and mark the band with a felt-tip pen at the specified distance from the clip: ^ If you are installing a new boot, mark the band approximately 10 to 14 mm (0.4 to 0.6 in.) from the clip. ^ If you are reinstalling the original boot, mark the band 10 mm (0.4 in.) from the clip. 8. Thread the free end of the band through the nose section of the boot band tool and into the slot on the winding mandrel. 9. Take up the slack in the boot band by hand, then slowly turn the winding mandrel with a wrench. Tighten the band until the mark you made in step 7 meets the edge of the clip. 10. Raise up the boot band tool to bend the free end of the band 90 degrees, then center-punch the clip to hold the band temporarily. Accelerator Pedal Assembly/Sensor - Adjustment Update Accelerator Pedal Position Sensor: All Technical Service Bulletins Accelerator Pedal Assembly/Sensor - Adjustment Update 00-045 August 14, 2001 Applies To: 2000-02 Passport - ALL Service Manual Update: Accelerator Pedal Position Sensor (APPS) (Supersedes 00-045, dated May 23, 2000) Updated information is shown by asterisks and black bars. BACKGROUND When the accelerator pedal position sensor (APPS) or the accelerator pedal assembly is replaced for any reason, you must adjust the APPS. *This procedure is missing in the 2000 service manual and is wrong in the 2001 and 2002 service manuals. Make a note on page 6E2-539 of the 2000 Passport Fuel and Emissions manual, on page 6E2-553 of the 2001 Passport Fuel and Emissions manual, and on page 6E2-545 of the 2002 Passport Fuel and Emissions manual to refer to this bulletin.* ADJUSTMENT PROCEDURE 1. Replace the APPS or the accelerator pedal assembly, and leave the mounting screws for the APPS loose. 2. Connect the PGM Tester to the data link connector (DLC), and turn the ignition switch to ON (II). *3. While watching the APP Sensor values in the Engine Data List, adjust the APPS by turning it until the values are within the ranges shown at closed pushed all the way down), then tighten the throttle and wide open throttle (accelerator pedal mounting screws and recheck the values. ^ If all three sensors are within range, go to step 12. ^ If APP Sensor 1, APP Sensor 2, and/or APP Sensor 3 cannot be brought into range, go to step 4. 4. Troubleshoot for an open circuit or a PCM malfunction. ^ If APP Sensor 1 has a value of 0% or APP Sensor 2 and/or APP Sensor 3 have a value of 99%, an open circuit exists or the PCM is malfunctioning. Repair the circuit or replace the PCM, and repeat step 3. ^ If you don't find a problem, go to step 5. 5. Disconnect the 10P connector from the APPS. 6. View the APP Sensor values in the Engine Data List. ^ If APP Sensor 1 has a value of 0% or APP Sensor 2 and/or APP Sensor 3 have a value of 99%, go to step 7. ^ If APP Sensor 1 has a value other than 0%, or APP Sensor 2 and/or APP Sensor 3 have a value other than 99%, a short circuit exists or the PCM is malfunctioning. Repair the circuit or replace the PCM, and repeat step 3. Page 5179 21. Remove internal gear and planet gear(3) (22). 22. Remove an E-ring(23) from the pinion shaft using a flat blade screwdriver. 23. Holding the pinion shaft, push pinion toward the center bracket and turn the pinion clockwise or counterclockwise by one tooth of spline, then pull OFF the pinion. 24. Remove thrust washer(24). 25. Remove center bracket Service and Repair Vehicle Lifting: Service and Repair CAUTION: - If a lifting device other than the original jack is used, it is most important that the device be applied only to the correct lifting points. Raising the vehicle from any other point may result in serious damage. - When jacking or lifting a vehicle at the frame side rail or other prescribed lift points, be certain that lift pads do not contact the catalytic converter, brake pipes or cables, or fuel lines. Such contact may result in damage or unsatisfactory vehicle performance. Lifting Points And Supportive Point Locations Lifting Points and Supportable Point Locations Lifting Point: Front - When using a floor jack, lift on the Convex portion of the skid plate. Page 5577 the component if the component only has one connector, or by a capital letter (A, B, C, etc.) if the component has more than one connector. Below most connector numbers and component names are PHOTO and VIEW numbers. The PHOTO number refers to a photo in the back of the book that shows the connector's location on the car. The VIEW number refers to an illustration in the back of the book that shows the connector face, wire colors, connector cavity numbers, and other details. The connector cavity numbering sequence begins at the top left corner of the connector. Disregard any numbers molded into the connector housing. Wires Wires are identified by the abbreviated names of their colors; the second color is the color of the stripe. Wires are also identified by their location in a connector. The number "2" next to the male and female wire terminals at C416, for example, means those terminals join in cavity 2 of connector C416. Symbols A complete description of schematic symbols is given under wire color abbreviation. Power Distribution Schematics Power Distribution schematics show how power is supplied from the positive battery terminal to various circuits in the car. Refer to the Power Distribution section to get a more detailed picture of how power is supplied to the circuit you're working on. From Battery to Ignition Switch, Fuses, and Relays Individual circuit schematics begin with a fuse. The first half of Power Distribution, however, shows the wiring "upstream" between the battery Page 6218 7. Pull out the mode door while raising up the catch of door lever. 8. Remove sub-lever. 9. Remove door lever. Installation To install, follow the removal steps in the reverse order, noting the following points: 1. Apply grease to the door lever and to the abrasive surface of the upper case. 2. Apply an adhesive to the parting face of the lining when assembling the upper case. Page 7466 Air Bag(s) Arming and Disarming: Description and Operation General Description General Description Restraint Devices The Supplemental Restraint System (SRS) helps supplement the protection offered by the driver and front passenger seat belts by deploying an air bag from the center of the steering wheel and from the top of the right side of the instrument panel. The air bag deploys when the vehicle is involved in a frontal crash of sufficient force up to 30 degrees off the centerline of the vehicle; To further absorb the crash energy there is a knee bolster located beneath the instrument panel for both the driver and passenger, and the steering column is collapsible. Locations Diagrams Page 6745 Test Equipment CAUTION: Most circuits include solid-state devices. Test the voltages in these circuits only with a 10-megaohm or higher impedance digital multimeter. Never use a test light or analog meter on circuits that contain solid-state devices. Damage to the devices may result. Test Light and DVOM On circuits without solid-state devices, use a test light to check for voltage. A test light is made up of a 12 volt bulb with a pair of leads attached. After grounding one lead, touch the other lead to various points along the circuit where voltage should be present. The bulb will go on if there is voltage at the point being tested. If you need to know how much voltage is present, use a digital volt/ohmmeter (DVOM). Self-Powered Test Light and DVOM Use a self-powered test light to check for continuity. This tool is made up of a light bulb, battery, and two leads. To test it, touch the leads together: the light should go on. Use a self-powered test light only on an unpowered circuit. First, disconnect the battery, or remove the fuse that feeds the circuit you are working on. Select two points in the circuit between which you want to check continuity. Connect one lead of the self-powered test light to each point. If there is continuity, the test light's circuit will be completed, and the light will go on. If, in addition, you need to know exactly how much resistance there is between two points, use a digital volt/ohmmeter (DVOM). In the "OHMS" range, the DVOM will measure resistance between two points along a circuit. Low resistance means good continuity. Diodes and solid-state devices in a circuit can make a DVOM give a false reading. To check a reading, reverse the leads, and take a second reading. If the readings differ, the component is affecting the measurement. Jumper Wire Use a jumper wire to bypass an open circuit. A jumper wire is made up of an in-line fuse holder connected to a set of test leads. It should have a five ampere fuse. Never connect a jumper wire across a short circuit. The direct battery short will blow the fuse. Short Finder (Short Circuit Locator) Short finders are available to locate shorts to ground. The short finder creates a pulsing magnetic field in the shorted circuit which you can follow to the location of the short. To order any test equipment shown above, contact your local tool supplier. For a list of suppliers and tool numbers, refer to Honda Required Special Tools and Equipment Service Bulletin. Page 5282 L4 Engine Room Page 7941 it is located, and what it connects to. Use the Connector Views to help locate the proper cavity when you need to probe a connector. It can be especially helpful if the connector has more than one wire of the same color. A dash symbol (-) indicates that the cavity is empty. Connector views can also be used to help diagnose multiple symptoms in separate circuits which could be caused by a single problem in a connector shared by those circuits. Here's an example: 1. Pick one of the multiple symptoms and look up the schematic for that circuit. 2. Make a list of all the in-line and fuse box connectors in that schematic , 3. Then, in the Connector Views, look up each connector on your list to see if circuits related to the other symptoms run through one of them. If they do, inspect that connector for the problem. Example: The blower, rear window defogger, and the windshield wiper don't work. List all in-line and fuse box connectors in the blower controls circuit and then check the Connector View (see the sample). You find that C324 is common to the blower controls, rear window defogger, and wiper/washer, so you inspect C324 and find the problem, bent terminals. Finding Component/Connector Locations Finding Component/Connector Locations To see where a component or connector is located on the car, look up its photo number in the "Component Location". The photo will also tell you the color of the connector, and how many cavities it has. Page 6380 Wires Wire insulation can be one color, or one color with another color stripe. (The second color is the stripe.) This circuit continues on another image. (The arrow shows direction of current flow.) To follow the RED/BLK wire in this example, you would turn to "Fuel and Emissions" and look for the "A" arrow. Page 1125 8. Remove the bolts used to hold the preload of the camshaft subgears. 9. If not already done, inspect the camshaft thrust clearances. If any clearances are not within specification, replace the cylinder head(s). Page 555 The connector cavity number is listed next to each terminal on the circuit schematic. The cavity / terminal shown is # 6. Diodes A rectifier diode works like a one way valve. It allows current to flow only in the direction of the arrow. A Zener diode blocks reverse current at normal voltages just like a rectifier diode. At high voltages, however, a Zener diode allows current to flow in reverse. Fuses Page 5866 Tires: Testing and Inspection Irregular and Premature Wear Irregular and/or premature wear has many causes. Some of them are incorrect inflation pressures, lack of tire rotation, poor driving habits or improper wheel alignment. Incorrect inflation is common cause of tire premature wear. NOTE: Due to their design, radial tires tend to wear faster in the shoulder area, particularly on the front tires. This makes regular rotation especially necessary. After rotation, be sure to check wheel nut torque, and set tire pressures. Tread Wear Indicators Tread Wear Indicators The original equipment tires have built-in tread wear indicators (l) to show when tires need replacement. These indicators may appear as wide bands. When the indicators appear in two or more grooves at three locations, tire replacement is recommended. Diagnosis List If the following conditions are noted, rotation is required. 1. Front tire wear is different from rear. 2. Uneven wear exists across the tread of any tire. 3. Left and right front tire wear is unequal. 4. Left and right rear tire wear is unequal. If the following conditions are noted, check the wheel alignment. 1. Left and right front tire wear is unequal. 2. Uneven wear exists across the tread of any tire. 3. Front tire treads have scuffed appearance with "feather" edges on one side of tread ribs or blocks. 4. There is cupping, flat spotting etc. Higher than recommended pressure can cause: 1. Hard ride. Page 6957 1. Remove the storage cover. 2. Remove and discard the original lock knob. 3. Push the new lock knob into place, and turn the knob until the lock tabs secure it. Disclaimer Locations Main Relay (Computer/Fuel System): Locations 9. Fuse/Relay Box (Cover Removed) Fuse/Relay Box (Cover Removed) Antitheft & Keyless Entry Controller Alarm/Immobilizer Control Unit: Service and Repair Antitheft & Keyless Entry Controller Anti-Theft & Keyless Entry Controller Removal 1. Disconnect the battery ground cable. 2. Remove the glove box from the instrument panel assembly (1). - Refer to the Instrument Panel Assembly in Body Structure section. 3. Remove the anti-theft & keyless entry controller (2). - Disconnect the connector. Remove two fixing screws. Installation To install, follow the removal steps in the reverse order. Page 1518 Piston Ring: Diagrams Piston, Connecting Rod and Associate Parts Locations Parking Brake Warning Switch: Locations Under Center Console Page 3046 Catalytic Converter: Description and Operation Catalyst Monitor Heated Oxygen Sensors Three-way catalytic converters are used to control emissions of hydrocarbons (HC), carbon monoxide (CO), and oxides of nitrogen (NOx). The catalyst within the converters promotes a chemical reaction. This reaction oxidizes the HC and CO present in the exhaust gas and converts them into harmless water vapor and carbon dioxide. The catalyst also reduces NOx by converting it to nitrogen. The PCM can monitor this process using the Bank 1 HO2S 2 and the Bank 2 HO2S 2 heated oxygen sensors. The Bank 1 HO2S 1 and the Bank 2 HO2S 1 sensors produce an output signal which indicates the amount of oxygen present in the exhaust gas entering the three-way catalytic converter. The Bank 1 HO2S 2 and the Bank 2 HO2S 2 sensors produce an output signal which indicates the oxygen storage capacity of the catalyst. This indicates the catalyst's ability to efficiently convert exhaust gases. If the Page 6032 Blower Motor Resistor: Testing and Inspection 1. Disconnect the resistor (C-41) connector. 2. Check for continuity and resistance between the terminals of the resistor. Page 6141 Each schematic represents one circuit. A circuit's wires and components are arranged to show current flow, from power at the top of the page, to ground, at the bottom. Shared Circuits Other circuits may share power or ground terminals or wiring with the circuit shown. A wire that connects one circuit to another, for example, is cut short and has an arrowhead at the end of it pointing in the direction of current flow. Next to the arrowhead is the name of the circuit or component which shares that wiring. To quickly check shared wiring, check the operation of a component it serves. If that component works, you know the shared wiring is OK. Connectors All in-line and junction connectors are numbered (C725, C416, etc.). Component connectors are not numbered but are identified either by the name of Page 5439 ^ If the wheels are pointed to the right, shorten the driver's side tie-rod, and lengthen the passenger's side. ^ If the wheels are pointed to the left, shorten the passenger's side tie-rod, and lengthen the driver's side. ^ Each 360° turn of the tie-rod equals about 8 mm of steering wheel adjustment. For example, a steering wheel is off-center by 4 mm with the front wheels pointed right (when the steering wheel is centered). To correct the off-center, shorten the driver's side tie-rod by a half-turn, and lengthen the passenger's side tie-rod by a half-turn. 4. Use your diagnosis worksheet to fill in the following table and build your 15-digit DTC. Page 3403 Ground - "G" Shielding Sheilding This represents RFI (Radio Frequency Interference) shielding around a wire. The shielding is always connected to ground. Splices Page 6371 Each schematic represents one circuit. A circuit's wires and components are arranged to show current flow, from power at the top of the page, to ground, at the bottom. Shared Circuits Other circuits may share power or ground terminals or wiring with the circuit shown. A wire that connects one circuit to another, for example, is cut short and has an arrowhead at the end of it pointing in the direction of current flow. Next to the arrowhead is the name of the circuit or component which shares that wiring. To quickly check shared wiring, check the operation of a component it serves. If that component works, you know the shared wiring is OK. Connectors All in-line and junction connectors are numbered (C725, C416, etc.). Component connectors are not numbered but are identified either by the name of Page 2440 6. Remove the connector position assurance (CPA) clip from the APPS connector. 7. Disconnect the 10 P connector from the APPS. 8. Remove the bolts, the APPS, the spacer, and the accelerator link from the accelerator pedal assembly. 9. Separate the spacer from the APPS. Clean the grease off the spacer and the accelerator link with a clean shop towel. 10. Clean the terminals of the 10 P APPS connector (harness side) with contact cleaner. Shake the residue out of the connector, and allow the contact cleaner to evaporate for at least 3 minutes before reconnecting the connector. 11. Install a new APPS, the spacer, and the accelerator link onto the accelerator pedal assembly. Leave the mounting screws loose so the sensor can be adjusted. 12. Connect the 10 P connector to the new APPS, and lock the connector in place with the CPA. 13. Connect the PGM Tester to the data link connector (DLC), and turn the ignition switch to ON (II). Page 1704 2. Measure the valve spring squareness with a steel square and replace the valve springs if the measured value exceeds the specified limit. Limit: 2 mm (0.079 inch) 3. Using a spring tester to compress the springs to the installed height, measure the compressed spring tension, and replace the springs if the measured tension is below the specified limit. At installed height: 35.0 mm (1.38 inch) Standard: 196 N (44 lbs.) Limit: Less than 181 N (41 lbs.) Valve Guide Caution: Take care not to damage the valve seat contact surface, when removing carbon adhering to the valve head. Carefully inspect the valve stem for scratches or abnormal wear. If these conditions are present, the valve and the valve guide must be replaced as a set 1. Measure the valve stem diameter with a micrometer. If the valve stem diameter is less than the specified limit, the valve and the valve guide must be replaced as a set. Diameter of Valve Stem Intake Standard: 5.977 mm - 5.959 mm (0.2353 in 0.2346 inch) Limit: 5.90 mm (0.2323 inch) Exhaust Standard: 5.952 mm - 5.970 mm (0.2343 in 0.2350 inch) Limit: 5.90 mm (0.2323 inch) 2. Measure the inside diameter of the valve guide with a micrometer. Subtract the measured outer diameter of the valve stem from the measured inner diameter of the valve guide. If the value exceeds the specified limit, the valve and the valve guide must be replaced as a set. Inside Diameter of the Valve Guide Inlet clearance Standard: 0.023 mm - 0.056 mm (0.0009 in - 0.0002 inch) Limit: 0.20 mm (0.00787 inch) Exhaust clearance Standard: 0.030 mm - 0.063 mm (0.0012 in - 0.0025 inch) Limit: 0.20 mm (0.00787 inch) Locations 105. Left Side of Driver's Seat Page 4568 4WD Control Unit: Service and Repair 4WD CONTROL UNIT ASSOCIATED PARTS REMOVAL 1. Remove center console assembly. 2. Remove two screws and harness connector (1) from 4WD control unit. INSTALLATION 1. Connect harness connector, then install 4WD control unit. 2. Install center console assembly. Page 1883 Catalytic Converter: Description and Operation Catalyst Monitor Heated Oxygen Sensors Three-way catalytic converters are used to control emissions of hydrocarbons (HC), carbon monoxide (CO), and oxides of nitrogen (NOx). The catalyst within the converters promotes a chemical reaction. This reaction oxidizes the HC and CO present in the exhaust gas and converts them into harmless water vapor and carbon dioxide. The catalyst also reduces NOx by converting it to nitrogen. The PCM can monitor this process using the Bank 1 HO2S 2 and the Bank 2 HO2S 2 heated oxygen sensors. The Bank 1 HO2S 1 and the Bank 2 HO2S 1 sensors produce an output signal which indicates the amount of oxygen present in the exhaust gas entering the three-way catalytic converter. The Bank 1 HO2S 2 and the Bank 2 HO2S 2 sensors produce an output signal which indicates the oxygen storage capacity of the catalyst. This indicates the catalyst's ability to efficiently convert exhaust gases. If the Page 6520 7. Remove the rear speaker (2). - Remove the speaker grille (1) and remove the speaker fixing screws. - Disconnect the connector (3). 8. Remove the lower quarter trim cover. - Pry the trim cover retainers free from the body panel. 9. Remove the dome light. - Remove the dome light lens and the fixing screws. - Disconnect the dome light connector. 10. Remove the soft top latch (Soft top model). - Remove two bolts. Page 6087 Test Equipment CAUTION: Most circuits include solid-state devices. Test the voltages in these circuits only with a 10-megaohm or higher impedance digital multimeter. Never use a test light or analog meter on circuits that contain solid-state devices. Damage to the devices may result. Test Light and DVOM On circuits without solid-state devices, use a test light to check for voltage. A test light is made up of a 12 volt bulb with a pair of leads attached. After grounding one lead, touch the other lead to various points along the circuit where voltage should be present. The bulb will go on if there is voltage at the point being tested. If you need to know how much voltage is present, use a digital volt/ohmmeter (DVOM). Self-Powered Test Light and DVOM Use a self-powered test light to check for continuity. This tool is made up of a light bulb, battery, and two leads. To test it, touch the leads together: the light should go on. Use a self-powered test light only on an unpowered circuit. First, disconnect the battery, or remove the fuse that feeds the circuit you are working on. Select two points in the circuit between which you want to check continuity. Connect one lead of the self-powered test light to each point. If there is continuity, the test light's circuit will be completed, and the light will go on. If, in addition, you need to know exactly how much resistance there is between two points, use a digital volt/ohmmeter (DVOM). In the "OHMS" range, the DVOM will measure resistance between two points along a circuit. Low resistance means good continuity. Diodes and solid-state devices in a circuit can make a DVOM give a false reading. To check a reading, reverse the leads, and take a second reading. If the readings differ, the component is affecting the measurement. Jumper Wire Use a jumper wire to bypass an open circuit. A jumper wire is made up of an in-line fuse holder connected to a set of test leads. It should have a five ampere fuse. Never connect a jumper wire across a short circuit. The direct battery short will blow the fuse. Short Finder (Short Circuit Locator) Short finders are available to locate shorts to ground. The short finder creates a pulsing magnetic field in the shorted circuit which you can follow to the location of the short. To order any test equipment shown above, contact your local tool supplier. For a list of suppliers and tool numbers, refer to Honda Required Special Tools and Equipment Service Bulletin. Page 690 ^ If the idle speed ever exceeds 1,300 rpm 2. Remove the vacuum hose from the fuel pressure regulator, then start the engine. ^ If fuel comes out of the fuel pressure regulator vacuum hose connection, go to REPAIR PROCEDURE FUEL PRESSURE REGULATOR. ^ If no fuel comes out of the regulator, reconnect the vacuum hose and continue to step 3. 3. Connect the PGM Tester. Set it to Engine Data List. 4. Have an assistant drive the vehicle under the conditions described by the customer. 5. If the high or erratic idle condition occurs, note the values of the PSP Switch and APP Sensor 1 when it is occurring. ^ If the PSP Switch is HIGH, and you are not turning, go to REPAIR PROCEDURE POWER STEERING SWITCH. ^ If the APP Sensor 1 is greater than 15% and APP Sensor 2 and/or APP Sensor 3 are less than 85%, and the accelerator pedal is not depressed, go to REPAIR PROCEDURE APPS GROUND. ^ If the PSP Switch is reading LOW when not turning and HIGH when turning, and the APP Sensors are reading within the range shown, discontinue the test-drive and go to step 6. 6. Do these repairs: ^ REPAIR PROCEDURE APPS GROUND ^ REPAIR PROCEDURE ENGINE/BODY GROUND REPAIR PROCEDURE - FUEL PRESSURE REGULATOR 1. Relieve fuel system pressure: ^ Remove the fuel fill cap. ^ Remove the fuel pump relay. ^ Start the engine and run it until it stalls. ^ Crank the engine for 3 seconds. 2. Remove the vacuum hose from the fuel pressure regulator. 3. Remove the fuel pressure regulator shield from the common chamber (two bolts). Page 3971 FLUID CONDITION - Fluid should be changed according to maintenance schedule. Page 6301 Test Equipment CAUTION: Most circuits include solid-state devices. Test the voltages in these circuits only with a 10-megaohm or higher impedance digital multimeter. Never use a test light or analog meter on circuits that contain solid-state devices. Damage to the devices may result. Test Light and DVOM On circuits without solid-state devices, use a test light to check for voltage. A test light is made up of a 12 volt bulb with a pair of leads attached. After grounding one lead, touch the other lead to various points along the circuit where voltage should be present. The bulb will go on if there is voltage at the point being tested. If you need to know how much voltage is present, use a digital volt/ohmmeter (DVOM). Self-Powered Test Light and DVOM Use a self-powered test light to check for continuity. This tool is made up of a light bulb, battery, and two leads. To test it, touch the leads together: the light should go on. Use a self-powered test light only on an unpowered circuit. First, disconnect the battery, or remove the fuse that feeds the circuit you are working on. Select two points in the circuit between which you want to check continuity. Connect one lead of the self-powered test light to each point. If there is continuity, the test light's circuit will be completed, and the light will go on. If, in addition, you need to know exactly how much resistance there is between two points, use a digital volt/ohmmeter (DVOM). In the "OHMS" range, the DVOM will measure resistance between two points along a circuit. Low resistance means good continuity. Diodes and solid-state devices in a circuit can make a DVOM give a false reading. To check a reading, reverse the leads, and take a second reading. If the readings differ, the component is affecting the measurement. Jumper Wire Use a jumper wire to bypass an open circuit. A jumper wire is made up of an in-line fuse holder connected to a set of test leads. It should have a five ampere fuse. Never connect a jumper wire across a short circuit. The direct battery short will blow the fuse. Short Finder (Short Circuit Locator) Short finders are available to locate shorts to ground. The short finder creates a pulsing magnetic field in the shorted circuit which you can follow to the location of the short. To order any test equipment shown above, contact your local tool supplier. For a list of suppliers and tool numbers, refer to Honda Required Special Tools and Equipment Service Bulletin. Page 6217 Housing Assembly HVAC: Service and Repair Blower Link Unit and/or Mode Door Blower Link Unit and/or Mode Door Blower Link Unit and/or Mode Door Removal 1. Disconnect the battery ground cable. 2. Discharge and recover refrigerant (with air conditioning). 3. Remove blower assembly. 4. Remove intake actuator. 5. Remove lower case. 6. Separate the upper case and slit the lining parting face with a knife. Page 4623 4WD Motor Actuator: Connector Locations Beneath Center of Vehicle, on Transfer Case (A/T) Testing and Inspection Seat Belt Retractor: Testing and Inspection 1. ELR (Emergency Locking Retractor) lock inclining angle check. - The seat belt should not lock when pulled gently at a 15 degree angle. Also, the seat belt should lock when pulled at a 45 degree angle or higher. 2. ELR lock check. - The seat belt should not lock when pulled slowly, however, the seat belt should lock when pulled quickly. 3. ALR (Automatic Locking Retractor) / ELR check (Except for driver's seat). - Make sure the seat belt is locked when pulled out fully. - Make sure the seat belt can be pulled out and retracts after when rewound fully. CAUTION: Do not disassemble the retractor. Page 8267 1. Push the wiper blade lock(1) while pulling the wiper blade in the arrow direction as shown in the figure. CAUTION: When the wiper blade has been removed, wrap the tip of the wiper arm with cloth, to avoid damaging the glass. 2. Pull the end of rubber and remove the projection(3) from the click of the blade stay (2). 3. Pull the rubber out in the same direction. Installation To install, follow the removal steps in the reverse order, noting the following points: 1. Install the click of the blade stay in the groove of the new rubber and slide it in. Complete wiper blade installation by pushing the click. Music Link(R) - System Information/Diagnostics Technical Service Bulletin # 07-012 Date: 070216 Music Link(R) - System Information/Diagnostics 07-012 February 16, 2007 Applies To: ALL - with accessory Music Link installed Music Link (For iPod) General Information and Symptom Troubleshooting BACKGROUND Honda Music Link is a Honda accessory designed to let the customer play music from an Apple(R) ipod(R) through the vehicle's audio system. The basic Music Link kit includes the Music Link interface unit, an audio unit bus cable, the Music Link harness, a CD-ROM, and the Quick Reference Guide. The CD-ROM includes a detailed User's Guide and some optional ITS (text-to-speech) software that lets the customer play music by playlist, artist, album, or genre. ^ The CD-ROM is for home computer use only. Do not insert it into a vehicle CD player. ^ Quick Reference Guides, User's Guides, and the latest TTS software versions can be downloaded from http://musiclink.honda.com. ^ For customer assistance and questions regarding TTS software loading, have the customer contact American Honda's Automobile Customer Service Department. The GENERAL INFORMATION section of this service bulletin covers these subjects: ^ Music Link iPod Information Resources ^ Resources for Installation Instructions ^ Music Link First-Use Information ^ iPod Reset Procedure Information The TROUBLESHOOTING section includes troubleshooting for these symptoms: ^ Check mark is not shown on the iPod display screen, radio will not switch to CD-C or CD-4 mode. ^ Static, or weak or no volume over speakers only in Music Link mode. ^ Music Link has no sound, check mark is shown on the iPod display screen. ^ Music Link has no sound, the disc number and track number flashes on the audio display. ^ Check mark is shown on the iPod display screen, radio will not switch to CD-C or CD-4 mode. ^ iPod music and XM radio music play at the same time (Pilot). ^ Music Link will not do Disc 1-4 search functions. ^ Artist is not categorized in the correct grouping when using (Disc 2) search function. ^ Song/artist is not categorized in the correct grouping when using Disc 1-4 search functions. PARTS INFORMATION Bus Harness: P/N 08-8-1H1-10030, H/C 8387060 Music Link Harness: P/N 08-8-1H1-10031, H/C 8387052 2-Port Bus Harness: Page 7599 The connector cavity number is listed next to each terminal on the circuit schematic. The cavity / terminal shown is # 6. Diodes A rectifier diode works like a one way valve. It allows current to flow only in the direction of the arrow. A Zener diode blocks reverse current at normal voltages just like a rectifier diode. At high voltages, however, a Zener diode allows current to flow in reverse. Fuses Page 754 Splices Splices are shown as a dot. Their location and the number of wires may vary depending on the harness manufacturer. Switches Switches These switches move together; the broken straight line between them means they are mechanically connected. Other types of switches are controlled by a coil or a solid state circuit. Unless otherwise noted, all switches are shown in their normal (rest) position, with power off. Terminal "T" Page 4869 2. Connect the short finder across the battery terminals and the load (component) side of the fuse terminal. 3. Close all switches in the circuit you're testing. 4. Turn on the short finder. This creates a pulsing magnetic field around the wiring between the fuse box and the short. 5. Beginning at the fuse box, slowly move the short finder along the circuit wiring. The meter will read current pulses through sheet metal and body trim. As long as the meter is between the fuse and the short, the needle will move with each current pulse. Once you move the meter past the point of the short, the needle will stop moving. Check the wiring and connectors in this area to locate the cause of the short. Testing For Continuity When testing for continuity at a connector without wire seals, you do not have to separate the two halves of the connector. Instead, probe the connector from the back. Always check both sides of the connector because dirty, corroded, and bent terminals can cause problems (no electrical contact = an open). 1. Disconnect the negative cable from the car battery. If you're using a DVOM, place it in the lowest "OHMS" range. Page 8258 Wiper Arm: Service and Repair Rear Wiper Arm/Blade Rear Wiper Arm/Blade Removal 1. Remove the arm nut (2). 2. Remove the wiper arm/blade (1). Installation To install, follow the removal steps in the reverse order, noting the following points: 1. Before installing the wiper arm/blade to the motor shaft, confirm that the motor stops at the autostop position. 2. Install the wiper arm/blade so that the wiper arm (2) contact with the stopper portion (3) on the hatch gate cover (1) as shown in the figure. 3. Tighten the motor shaft nut to the specified torque. Torque: 10 Nm (87 lb in) Accelerator Pedal Assembly/Sensor - Adjustment Update Accelerator Pedal Position Sensor: All Technical Service Bulletins Accelerator Pedal Assembly/Sensor - Adjustment Update 00-045 August 14, 2001 Applies To: 2000-02 Passport - ALL Service Manual Update: Accelerator Pedal Position Sensor (APPS) (Supersedes 00-045, dated May 23, 2000) Updated information is shown by asterisks and black bars. BACKGROUND When the accelerator pedal position sensor (APPS) or the accelerator pedal assembly is replaced for any reason, you must adjust the APPS. *This procedure is missing in the 2000 service manual and is wrong in the 2001 and 2002 service manuals. Make a note on page 6E2-539 of the 2000 Passport Fuel and Emissions manual, on page 6E2-553 of the 2001 Passport Fuel and Emissions manual, and on page 6E2-545 of the 2002 Passport Fuel and Emissions manual to refer to this bulletin.* ADJUSTMENT PROCEDURE 1. Replace the APPS or the accelerator pedal assembly, and leave the mounting screws for the APPS loose. 2. Connect the PGM Tester to the data link connector (DLC), and turn the ignition switch to ON (II). *3. While watching the APP Sensor values in the Engine Data List, adjust the APPS by turning it until the values are within the ranges shown at closed pushed all the way down), then tighten the throttle and wide open throttle (accelerator pedal mounting screws and recheck the values. ^ If all three sensors are within range, go to step 12. ^ If APP Sensor 1, APP Sensor 2, and/or APP Sensor 3 cannot be brought into range, go to step 4. 4. Troubleshoot for an open circuit or a PCM malfunction. ^ If APP Sensor 1 has a value of 0% or APP Sensor 2 and/or APP Sensor 3 have a value of 99%, an open circuit exists or the PCM is malfunctioning. Repair the circuit or replace the PCM, and repeat step 3. ^ If you don't find a problem, go to step 5. 5. Disconnect the 10P connector from the APPS. 6. View the APP Sensor values in the Engine Data List. ^ If APP Sensor 1 has a value of 0% or APP Sensor 2 and/or APP Sensor 3 have a value of 99%, go to step 7. ^ If APP Sensor 1 has a value other than 0%, or APP Sensor 2 and/or APP Sensor 3 have a value other than 99%, a short circuit exists or the PCM is malfunctioning. Repair the circuit or replace the PCM, and repeat step 3. Page 7837 Dimmer Switch: Service and Repair Removal 1. Disconnect the battery ground cable. 2. Remove the instrument panel driver lower cover assembly (3). 3. Remove the illumination controller (2). - Disconnect the controller connector. - Remove the controller knob (1). - Remove the nut. - Remove the controller from the back side of the instrument panel driver lower cover assembly. Installation To install, follow the removal steps in the reverse order. Page 6686 This means the branch of the wire connects to another circuit. The arrow points to the name of the circuit branch where the wire continues. Unit Overhaul Clutch Slave Cylinder: Service and Repair Unit Overhaul DISASSEMBLED VIEW DISASSEMBLY 1. Disassemble boot (1), push rod (2), piston and piston cup (3), and spring (4) from cylinder body (5). INSPECTION AND REPAIR Make the necessary adjustments, repairs, and part replacements if excessive wear or damage is discovered during inspection. Cylinder Body 1. Clean the cylinder body. 2. Check the fluid return port for restrictions and clean it if necessary. Piston And Piston Cup Page 6221 To install, follow the removal steps in the reverse order, noting the following point: 1. Check that each mode door operates properly. Description and Operation ABS Light: Description and Operation ABS Warning Light Vehicles equipped with the Anti-lock Brake System (ABS) have an amber "ABS" warning light in the instrument panel. The "ABS" warning light will illuminate if a malfunction in the Anti-lock Brake System is detected by the Electronic Hydraulic Control Unit (EHCU). In case of an electronic malfunction, the EHCU will turn "ON" the "ABS" warning light and disable the Anti-lock braking function. The "ABS" light will turn "ON" for approximately three seconds after the ignition switch is turned to the "ON" position. If the "ABS" light stays "ON" after the ignition switch is turned to the "ON" position, or comes "ON" and stays "ON" while driving, the Anti-lock Brake System should be inspected for a malfunction according to the diagnosis procedure. When Anti-lock Brake System (ABS) trouble occurs to actuate "ABS" warning light, the trouble code corresponding to the trouble is stored in the Electronic Hydraulic Control Unit (EHCU). Only ordinary brake is available with ABS being unactuated. Even when "ABS" warning light is actuated, if the starter switch is set ON after setting it OFF once, the EHCU checks up on the entire system and, if there is no abnormality, judges ABS to work currently and the warning light is lit normally even though the trouble code is stored. NOTE: Illumination of the "ABS" warning light indicates that anti-lock braking is no longer available. Power assisted braking without anti-lock control is still available. Page 8185 - Remove the fixing screws from back side of the rear door trim panel. 8. Remove the bracket. 9. Disconnect the speaker harness connector. 10. Remove the speaker with the speaker harness connector from the door inner panel. 11. Remove the waterproof sheet (1). - Taking notice of the door harness, peel the waterproof sheet off the door panel carefully. 12. Remove the speaker bracket. - Remove the six fixing screws. 13. Remove the fixing glass. - Remove one bolt and screw as shown in the figure, then pull it upward. Page 5366 L4 Engine Room Service and Repair Shift Cable: Service and Repair SELECT CABLE Removal 1. Set selector lever in "P" position. 2. Remove transfer control lever knob, lower cluster assembly, rear console, center console, selector lever knob and cover. 3. Disconnect inner cable by pulling projection on pin. 4. Press down claws and disconnect cable assembly. 5. Disconnect PCM harness connectors and remove nuts that fasten grommet in select cable assembly. 6. Disconnect inner cable. 7. Slide sleeve and disconnect cable assembly. Page 4696 2. Connect the short finder across the battery terminals and the load (component) side of the fuse terminal. 3. Close all switches in the circuit you're testing. 4. Turn on the short finder. This creates a pulsing magnetic field around the wiring between the fuse box and the short. 5. Beginning at the fuse box, slowly move the short finder along the circuit wiring. The meter will read current pulses through sheet metal and body trim. As long as the meter is between the fuse and the short, the needle will move with each current pulse. Once you move the meter past the point of the short, the needle will stop moving. Check the wiring and connectors in this area to locate the cause of the short. Testing For Continuity When testing for continuity at a connector without wire seals, you do not have to separate the two halves of the connector. Instead, probe the connector from the back. Always check both sides of the connector because dirty, corroded, and bent terminals can cause problems (no electrical contact = an open). 1. Disconnect the negative cable from the car battery. If you're using a DVOM, place it in the lowest "OHMS" range. Page 1559 Valve Guide: Service and Repair Disassembly, Inspection and Assembly Valve Spring, Oil Controller, Valve, Valve Guide Disassembly 1. Remove camshaft bracket fixing bolts (1). 2. Remove camshaft assembly (intake). 3. Remove camshaft assembly (Exhaust side). 4. Remove shim (4) and tappet (5). Accelerator Pedal Position Sensor - MIL ON/DTC's Set Technical Service Bulletin # 01-047 Date: 010814 Accelerator Pedal Position Sensor - MIL ON/DTC's Set 01-047 August 14, 2001 Applies To: 2000-01 Passport - ALL MIL Comes On With Accelerator Pedal Position Sensor DTC(s) P1271, P1273, P1275, P1280, and/or P1285 SYMPTOM The MIL is on with DTC P1271, P1273, P1275, P1280, or P1285 (various accelerator pedal position sensor problems) stored. The REDUCED POWER indicator may also be on; and the engine may occasionally idle too high, or the idle may fluctuate. PROBABLE CAUSE Contaminated grease on the potentiometer circuit board of the accelerator pedal position sensor (APPS) causes high resistance in the APPS circuit. CORRECTIVE ACTION Replace and adjust the APPS, remove all grease from the accelerator link, and clean the APPS harness connector and connector C123. PARTS INFORMATION Accelerator Pedal Position Sensor: P/N 8-97193-713-0, H/C 6198311 REQUIRED MATERIALS CAIG DeoxIT D5-S6 Contact Cleaner: P/N 341-200 (available from www.partsexpress.com) or Permatex Electrical Contact Cleaner: Permatex P/N 24379 WARRANTY CLAIM INFORMATION In warranty: The normal warranty applies. Operation Number: 122114 Flat Rate Time: 0.5 hour Failed Part: P/N 8-97220-540-0 H/C 6202436 Defect Code: 091 Contention Code: C99 Template ID: 01-047A Skill Level: Repair Technician Out of warranty: Any repair performed after warranty expiration may be eligible for goodwill consideration by the District Service Manager or your Zone Office. You must request consideration, and get a decision, before starting work. Page 6777 The wire insulation has one color or one color with another color stripe. The second color is the stripe. Page 4362 2. Set the yoke in the arbor press with a piece of tube stock beneath it. Place a solid plug on the upper bearing assembly and press it through to release the lower bearing assembly. 3. If the bearing assembly will not pull out by hand after pressing, tap the base of the lug near the bearing assembly to dislodge it. 4. To remove the opposite bearing, turn the yoke over and straighten the spider in the open hole. Then carefully press on the end of the spider so the remaining bearing moves straight out of the bearing spider hole. If the spider or bearing are cocked, the bearing will score the walls of the spider hole and ruin the yoke. 5. Repeat this procedure on the remaining bearing to remove the spider from the yoke. 6. Make sure of proper position for reinstallation by applying setting marks, then remove spider. INSPECTION AND REPAIR Make necessary correction or parts replacement if wear, damage, corrosion or any other abnormal condition is found through inspection. NOTE: When any part of the journal assembly (spider, needle roller bearing) requires replacement, be sure to replace the entire assembly. Check the following parts for wear, damage, noise or any other abnormal conditions. 1. Spider 2. Needle roller bearing 3. Yoke 4. Flange 5. Boot Spider Pin For Wear Spider pin should be smooth and free from fretting or galling. Visible signs of needle presence is normal, but wear should not be felt. Propeller Shaft Run-Out Specifications Axle Nut: Specifications 1. Tighten the hub nut to 29 Nm (22 lb. ft.), then fully loosen the nut. 2. Tighten the hub nut to the value given below, using a spring scale on the wheel pin. New Bearing and New Oil Seal Bearing Preload: 20 N - 25 N (4.4 lb. - 5.5 lb.) Used Bearing New Oil Seal Bearing Preload: 12 N - 18 N (2.6 lb. - 4.0 lb.) If the measured bearing preload is outside the specificatoins, adjust it by loosening or tightening the bearing nut. Diagram Information and Instructions Trailer Connector: Diagram Information and Instructions How to Identify Wiring Color-Coded Insulation Wire Color Wire Color Coding Page 1864 Thermostat: Service and Repair Thermostat Removal 1. Disconnect battery ground cable. 2. Drain engine coolant from the radiator and engine. 3. Disconnect radiator hose from the inlet pipe. 4. Remove thermostat housing. 5. Remove thermostat (2). Inspection Suspend the thermostat in a water-filled container using thin wire. Place a thermometer next to the thermostat. Do not directly heat the thermostat. Specifications Fluid Pan: Specifications Pan Bottom, Main Case 11 Nm Pan Bottom, Adapter Case 11 Nm Page 125 This means the branch of the wire connects to another circuit. The arrow points to the name of the circuit branch where the wire continues. Page 7549 Air Bag(s) Arming and Disarming: Description and Operation Definitions Air Bag An inflatable cloth cushion designed to deploy in certain frontal crashes. It supplements the protection offered by the seat belts by distributing the impact load more evenly over the vehicle occupant's head and torso. Asynchronous Performed in a nonperiodic fashion, (i.e., no defined time or interval). (B+) Battery voltage, (B+) The voltage available at the battery at the time of the indicated measurement. With the key "ON" and the engine not running, the system voltage will likely be between 12 and 12.5 volts. At idle the voltage may be 14 to 16 volts. The voltage could be as low as 10 volts during engine cranking. Bulb Check The SDM will cause the "AIR BAG" warning lamp to flash seven times and then go "OFF" whenever the ignition switch transitions to the ON position from any other ignition switch position and no malfunctions are detected. "CONTINUOUS MONITORING" Tests performed by the SDM on the SRS every 100 milliseconds while "Ignition 1" voltage is in the normal operating voltage range at the SDM. Data Link Connector (DLC) Formerly "DLC" a connector which allows communication with an external computer, such as a scan tool. Datum Line A base line parallel to the plane of the underbody or frame from which all vertical measurements originate. Deploy To inflate the air bag. Deployment Loops The circuits which supply current to the air bag assemblies to deploy the air bag. Diagnostic Trouble Code (DTC) Formerly "Code", a numerical designator used by the SDM to indicate specific SRS malfunctions. Driver Current Source An output of the SDM which applies current into the driver air bag assembly circuit during the "Initiator Assembly Resistance Test". Driver Air Bag Assembly An assembly located in the steering wheel hub consisting of an inflatable bag, an inflator and an initiator. EEPROM Electronically Erasable Programmable Read Only Memory. Memory which retains its contents when power is removed from the SDM. Ignition Cycle The voltage at the SDM "Ignition 1" inputs, with ignition switch "ON", is within the normal operating voltage range for at least ten seconds before turning ignition switch "OFF". Ignition 1 Specifications Power Steering Line/Hose: Specifications Power Steering Unit Lines 13 Nm Page 7642 Dimmer Switch: Diagnostic Aids Before Troubleshooting Before Troubleshooting See: Service Precautions/Vehicle Damage Warnings/Tips and Precautions 1. Check applicable fuses in the appropriate fuse/relay box. 2. Check the battery for damage, state of charge, and clean and tight connections. CAUTION: Do not quick-charge a battery unless the battery ground cable has been disconnected, otherwise you will damage the alternator diodes. - Do not attempt to crank the engine with the battery ground cable loosely connected or you will severely damage the wiring. While You're Working 1. Make sure connectors are clean, and have no loose terminals or receptacles. 2. Make sure that connectors without wire seals are packed with dielectric (silicone) grease. Part Number: 08798-9001. 3. When connecting a connector, push it until it "clicks" into place. CAUTION: Do not pull on the wires when disconnecting a connector. Pull only on the connector housings. - Most circuits include solid-state devices. Test the voltages in these circuits only with a 10-megaohm or higher impedance digital multi meter. Never use a test light or analog meter on circuits that contain solid-state devices. Damage to the devices may result. Five-Step Troubleshooting 1. Verify The Complaint Turn on all the components in the problem circuit to check the accuracy of the customer complaint. Note the symptoms. Do not begin disassembly or testing until you have narrowed down the problem area. 2. Analyze The Schematic Look up the schematic for the problem circuit. Determine how the circuit is supposed to work by tracing the current paths from the power source through the circuit components to ground. Also, trace circuits that share wiring with the problem circuit. The names of circuits that share the same fuse, ground, or switch, and so on, are referred to in each circuit schematic. Try to operate any shared circuits you didn't check in step 1. If the shared circuits work, the shared wiring is OK, and the cause must be in the wiring used only by the problem circuit. If several circuits fail at the same time, the fuse or ground is a likely cause. Based on the symptoms and your understanding of the circuit's operation, identify one or more possible causes. 3. Isolate The Problem By Testing The Circuit Make circuit tests to check the diagnosis you made in step 2. Keep in mind that a logical, simple procedure is the key to efficient troubleshooting. Test for the most likely cause of failure first. Try to make tests at points that are easily accessible. 4. Fix The Problem Once the specific problem is identified, make the repair. Be sure to use proper tools and safe procedures. 5. Make Sure The Circuit Works Turn on all components in the repaired circuit in all modes to make sure you've fixed the entire problem. If the problem was a blown fuse, be sure to test all of the circuits on that fuse. Make sure no new problems turn up and the original problem does not recur. Page 1914 2. Loosen the two flange nuts holding the transmission mount to the third crossmember. 3. Use a pry bar to shift the engine assembly all the way forward. 4. Hold the prybar in place, and torque the flange nuts to 50 N.m (37 lb-ft). 5. Lower the vehicle. 6. Start the engine, and check for vibration. Make sure the chassis is not touching the lift during this check. ^ If the vibration is gone, no further action is required. ^ If the vibration is still there, go to REPAIR PROCEDURE B. REPAIR PROCEDURE B 1. Write down your customer's radio station presets and mode settings. 2. Disconnect the negative cable from the battery. 3. Raise the vehicle on a lift. 4. Remove both front wheels. 5. Models With 4WD: Remove the front skid plate (four bolts, four lock washers, four washers). Service and Repair Band Control Solenoid Valve: Service and Repair REMOVAL 1. Raise the vehicle and support it on jack stands. 2. Disconnect battery ground cable. 3. Drain fluid. 4. Remove sixteen 10 mm screws, main case oil pan, magnet, and gasket. 5. Remove three 13 mm screws, oil filter. 6. Disconnect wiring harness from band control solenoid and shift solenoids. Pull only on connectors, not on wiring harness. 7. Remove spring pin for shift solenoid A, shift solenoid B, and band control solenoid respectively, using suitable pliers taking care not to damage solenoids. 8. Remove shift solenoid A, shift solenoid B, band control solenoid, and gaskets from main case valve body. Do not pull on wiring harness. Remove solenoids by grasping the metal tip. INSTALLATION 1. Install shift solenoid A, shift solenoid B, band control solenoid with new gaskets to main case valve body respectively. 2. Carefully install spring pin with hammer to avoid damage to valve body, etc. 3. Connect wiring harness to solenoids. 4. Install oil filter with a new gasket and the three 13 mm screws, tighten to the specified torque. Torque: 20 Nm (15 Ft. lbs.) Page 1234 Low ambient light conditions (a dark work area) will aid in locating the leak. NOTE: Not all UV lamps work well with all types of fluorescent dye. Use only the lamp provided in the kit to inspect for leaks. (c) Inspect the entire system. Be sure to check these locations: ^ damaged and corroded areas ^ fittings ^ hose-to-line couplings ^ refrigerant controls ^ service ports ^ brazed or welded areas ^ areas near attachment points (d) Check for evaporator leaks by illuminating the evaporator drain tube area with the UV lamp and glasses. (e) After repairing a leak, remove any fluorescent residue using the GLO-AWAY dye cleaner from the kit and hot water (follow the instructions on the bottle). Disclaimer Page 1368 2. Poor steering stability. 3. Rapid and uneven wear at center of the tread. Lower than recommended pressure can cause: 1. Tire squeal on turns. 2. Hard steering. 3. Rapid and uneven wear on the edges of the tread. 4. Tire rim bruises and rupture. 5. Tire cord breakage. 6. High tire temperatures. 7. Reduced handling. 8. Reduced fuel economy. Unequal pressure on same axle can cause: 1. Uneven braking. 2. Steering lead. 3. Reduced handling. 4. Swerve on acceleration. Radial Tire Waddle Waddle is side-to-side movement at the front and/or rear of the car. It can be caused by the steel belt not being straight within the tire, or by excessive lateral runout of the tire or wheel. It is most noticeable at low speed, about 8 to 48 km/h (5 to 30 mph). It may also cause rough ride at 80 to 113 km/h (50 to 70 mph). The car can be road tested to see which end of the car has the faulty tire. If the tire causing the waddle is on the rear, the rear end of the car will "waddle". From the driver's seat, it feels as if someone is pushing on the side of the car. If the faulty tire is on the front, the waddle is more easily seen. The front sheet metal appears to be moving back and forth. It feels as if the driver's seat is the pivot point in the car. Another more time-consuming method of determining the faulty tire is substituting tire and wheel assemblies that are known to be good. Follow these steps: 1. Drive the car to determine if the waddle is coming from the front or rear. 2. Install tire and wheel assemblies known to be good (from a similar car) in place of those on the end of the car which is waddling. If the waddle cannot be isolated to front or rear, start with the rear tires. 3. Road test again. If improvement is noted, install the original tire and wheel assemblies one at a time until the faulty tire is found. If no improvement is noted, install tires known to be good in place of all four. Then, install the originals one at a time until the faulty tire is found. Radial Tire Lead/Pull "Lead/Pull" is vehicle deviation from a straight path, on a level road with no pressure on the steering wheel. Lead is usually caused by: 1. Poorly manufactured radial tires. 2. Uneven brake adjustment. 3. Wheel alignment. The way in which a tire is built can produce lead in a car. An example of this is placement of the belt. Off-center belts on radial tires can cause the tire to develop a side force while rolling straight down the road and the tire will tend to roll like a cone. The "Radial Tire Lead/Pull Correction" chart should be used to make sure that front wheel alignment is not mistaken for tire lead. Rear tires will not cause lead/pull. Page 4605 Testing For A Short With A Self-Powered Test Light or DVOM 1. Remove the blown fuse and disconnect the battery and load. 2. Connect one lead of a self-powered test light or digital volt/ohmmeter (DVOM) (switched to the lowest "OHMS" range) to the fuse terminal on the load side. 3. Connect the other lead to a known good ground. 4. Beginning near the fuse box, wiggle the harness. Continue this at convenient points about six inches apart while watching the test light or DVOM. 5. If the self-powered test light goes on or the DVOM displays a low reading or no reading (zero), there is a short to ground in the wiring near that point. Testing for a Short with a Test Light or DVOM 1. Remove the blown fuse and disconnect the load. 2. Connect a test light or digital volt/ohmmeter (DVOM), switched to the appropriate DC volts range, across the fuse terminals to make sure voltage is present. You might have to turn the ignition switch to ON; check the schematic to see. 3. Beginning near the fuse box, wiggle the harness. Continue this at convenient points about six inches apart while watching the test light or DVOM. 4. Where the test light goes , or the DVOM voltage drops to zero, there is a short to ground in the wiring near that point. NOTE: Always use a DVOM on high impedance circuits. A test light may not glow (even with battery voltage present). Testing For A Short With A Short Circuit Locator (Short Finder) 1. Remove the blown fuse. Leave the battery connected. Page 166 the component if the component only has one connector, or by a capital letter (A, B, C, etc.) if the component has more than one connector. Below most connector numbers and component names are PHOTO and VIEW numbers. The PHOTO number refers to a photo in the back of the book that shows the connector's location on the car. The VIEW number refers to an illustration in the back of the book that shows the connector face, wire colors, connector cavity numbers, and other details. The connector cavity numbering sequence begins at the top left corner of the connector. Disregard any numbers molded into the connector housing. Wires Wires are identified by the abbreviated names of their colors; the second color is the color of the stripe. Wires are also identified by their location in a connector. The number "2" next to the male and female wire terminals at C416, for example, means those terminals join in cavity 2 of connector C416. Symbols A complete description of schematic symbols is given under wire color abbreviation. Power Distribution Schematics Power Distribution schematics show how power is supplied from the positive battery terminal to various circuits in the car. Refer to the Power Distribution section to get a more detailed picture of how power is supplied to the circuit you're working on. From Battery to Ignition Switch, Fuses, and Relays Individual circuit schematics begin with a fuse. The first half of Power Distribution, however, shows the wiring "upstream" between the battery Page 4485 This means the branch of the wire connects to another circuit. The arrow points to the name of the circuit branch where the wire continues. Page 7754 This sample Ground Distribution schematic shows all of the components that share two ground points. Components A solid border line means the entire component is shown. A broken border line indicates that only part of the component is shown. Page 4212 Each schematic represents one circuit. A circuit's wires and components are arranged to show current flow, from power at the top of the page, to ground, at the bottom. Shared Circuits Other circuits may share power or ground terminals or wiring with the circuit shown. A wire that connects one circuit to another, for example, is cut short and has an arrowhead at the end of it pointing in the direction of current flow. Next to the arrowhead is the name of the circuit or component which shares that wiring. To quickly check shared wiring, check the operation of a component it serves. If that component works, you know the shared wiring is OK. Connectors All in-line and junction connectors are numbered (C725, C416, etc.). Component connectors are not numbered but are identified either by the name of Page 6294 Splices Splices are shown as a dot. Their location and the number of wires may vary depending on the harness manufacturer. Switches Switches These switches move together; the broken straight line between them means they are mechanically connected. Other types of switches are controlled by a coil or a solid state circuit. Unless otherwise noted, all switches are shown in their normal (rest) position, with power off. Terminal "T" Page 5800 Page 1925 6. Working from under the vehicle, unplug the 3P connector from the crankshaft position sensor. 7. Remove the crankshaft position sensor (one flange bolt). 8. Remove the crankshaft position sensor harness clamp from the engine (one flange nut). 9. Models With A/T: Remove the front and rear clamps for the ATF cooler lines. 10. Support the engine with a block of wood and a powertrain lift or commercially available jack as shown. Page 7829 The wire insulation has one color or one color with another color stripe. The second color is the stripe. Preliminary Checks Alignment: Service and Repair Preliminary Checks INSPECTION Before making any adjustments affecting caster, camber or toe-in, the following front end inspection should be made. 1. Inspect the tires for proper inflation pressure. 2. Make sure that the vehicle is unladen condition (With no passenger or loading). 3. Make sure that the spare tire is installed at the normal position. 4. Inspect the front wheel bearings for proper adjustment. 5. Inspect the ball joints and tie rod ends. If excessive looseness is noted, correct before adjusting. 6. Inspect the wheel and tires for run-out. 7. Inspect the trim height. If not within specifications, the correction must be made before adjusting caster. 8. Inspect the steering unit for looseness at the frame. 9. Inspect shock absorbers for leaks or any noticeable noise. 10. Inspect the control arms or stabilizer bar attachment for looseness. 11. Inspect the front end alignment using alignment equipment. Follow the manufacturer's instructions. 12. Park the vehicle on a level surface. Page 8026 Testing For A Short With A Self-Powered Test Light or DVOM 1. Remove the blown fuse and disconnect the battery and load. 2. Connect one lead of a self-powered test light or digital volt/ohmmeter (DVOM) (switched to the lowest "OHMS" range) to the fuse terminal on the load side. 3. Connect the other lead to a known good ground. 4. Beginning near the fuse box, wiggle the harness. Continue this at convenient points about six inches apart while watching the test light or DVOM. 5. If the self-powered test light goes on or the DVOM displays a low reading or no reading (zero), there is a short to ground in the wiring near that point. Testing for a Short with a Test Light or DVOM 1. Remove the blown fuse and disconnect the load. 2. Connect a test light or digital volt/ohmmeter (DVOM), switched to the appropriate DC volts range, across the fuse terminals to make sure voltage is present. You might have to turn the ignition switch to ON; check the schematic to see. 3. Beginning near the fuse box, wiggle the harness. Continue this at convenient points about six inches apart while watching the test light or DVOM. 4. Where the test light goes , or the DVOM voltage drops to zero, there is a short to ground in the wiring near that point. NOTE: Always use a DVOM on high impedance circuits. A test light may not glow (even with battery voltage present). Testing For A Short With A Short Circuit Locator (Short Finder) 1. Remove the blown fuse. Leave the battery connected. Page 5917 and the fuses. From Fuses to Relays and Components The second half of Power Distribution shows the wiring "From Fuses to Relays and Components." This can speed your troubleshooting by showing which circuits share fuses. If Power Distribution shows that an inoperative circuit and another circuit share a fuse, check a component in the other circuit. If it works, you know the fuse is good and power is available to the inoperative circuit. Ground Distribution Schematics Technician Safety Information Air Bag Control Module: Technician Safety Information Service Precautions WARNING: DURING SERVICE PROCEDURES, BE VERY CAREFUL WHEN HANDLING SDM. NEVER STRIKE OR JAR SDM. UNDER SOME CIRCUMSTANCES, IT COULD CAUSE DEPLOYMENT AND RESULT IN PERSONAL INJURY OR IMPROPER OPERATION OF THE SUPPLEMENTAL RESTRAINT SYSTEM (SRS). SDM MOUNTING BRACKET BOLTS MUST BE CAREFULLY TORQUED TO ASSURE PROPER OPERATION. THE SRS SHOULD ONLY BE CONNECTED TO A POWER SOURCE WHEN IT IS INSTALLED SECURELY IN THE VEHICLE. THE SDM MAY SUDDENLY DEPLOY THE AIRBAGS CAUSING PERSONAL INJURY WARNING: PROPER OPERATION OF THE SENSING AND DIAGNOSTIC MODULE (SDM) REQUIRES THE SDM TO BE SECURELY INSTALLED ON THE VEHICLE AND THE ARROW ON THE SENSOR MUST BE POINTING TOWARD THE FRONT OF THE VEHICLE. SDM is specifically calibrated and is keyed to the SDM location SRS wiring harness. Caution should be used to ensure proper location of the SDM. The keying of the SDM to its location and wiring harness connectors should never be modified in the field. Be careful not to bump or impact the SRS unit or the side impact sensors whenever the ignition switch is ON (II), or at least for three minutes after the ignition switch is turned OFF. During installation or replacement, be careful not to bump (by impact wrench, hammer, etc.) the area around the SRS unit and the side impact sensor. The airbags could accidentally deploy and cause damage or injury. After a collision in which the airbags were deployed, replace the SRS unit. After a collision in which the side airbag was deployed, replace the side impact sensor on the side where the side airbag deployed and the SRS unit. After a collision in which the airbags or the side airbags did not deploy, inspect for any damage or any deformation on the SRS unit and the side impact sensors. If there is any damage, replace the SRS unit and/or the side impact sensors. Do not disassemble the SRS unit or the side impact sensors. Turn the ignition switch OFF, disconnect the battery negative cable and wait at least three minutes before beginning installation or replacement of the SRS unit, and disconnect the connectors from the SRS unit. Be sure the SRS unit and side impact sensors are installed securely with the mounting bolts torqued to 9.8 Nm (1.0 kg.m, 7.2 lb.ft) Do not spill water or oil on the SRS unit or the side impact sensors and keep them away from dust. Store the SRS unit and the side impact sensors in a cool (less than 104°F / 40°C) and dry (less than 80% relative humidity, no moisture) area. Locations Page 2261 24. Verify APP Sensor 1 is between 11 and 15 percent, and APP Sensor 2 and APP Sensor 3 are between 89 and 85 percent with the pedal up (closed throttle). If not, loosen the mounting screws on the APPS sensor, and go to step 14. 25. Clear all DTCs with the PGM Tester. 26. Turn off the ignition switch, and disconnect the PGM Tester. PCM- Smart Cable Programming Procedures PROM - Programmable Read Only Memory: All Technical Service Bulletins PCM- Smart Cable Programming Procedures 99-005 May 11, 1999 *Applies To: 1996 and Later Passports* Updating the Passport PCM *(Supersedes 99-005 dated February 2, 1999, which was sent only to dealers who participated in the Smart Cable pilot test programs.)* The procedures in this service bulletin will be used end referenced in other service bulletins. PCMs (powertrain control modules) in 1996 and later Passports are programmable. The tool used to reprogram (update) Passport PCMs is a portable programming device called the Smart Cable. *When correctly programmed, the Smart Cable can read a Passport's current PCM broadcast code, decide if the code is correct, and if needed, update the PCM with another code. If the PCM broadcast code stored in the Smart Cable is different than the code needed by the PCM, you can reprogram the Smart Cable using your DCS workstation. This bulletin describes: ^ Updating a PCM with a programmed Smart Cable ^ Reprogramming a Smart Cable if its broadcast code is different than the one needed by the PCM ^ Smart Cable diagnosis ^ Who to contact for questions or problems when using the Smart Cable* WARRANTY CLAIM INFORMATION Refer to the bulletin for the symptom you are repairing. Skill level: Repair Technician REQUIRED TOOLS AND EQUIPMENT ^ Smart Cable Kit: P/N PTS-B001 *Includes cable, box, a copy of this bulletin (99-005), and a sheet on interpreting Smart Cable LED patterns.* ^ *PC Interface Kit: P/N VET01002582* This is the same kit used to connect the PGM Tester to the DCS computer when you update the Tester's program card. The kit includes a cable with an attached adapter. ^ *110 VAC/12 VDC Power Supply: P/N VET02001723* Starting System - Unable To Key In Ignition Switch Ignition Switch Lock Cylinder: Technical Service Bulletins Starting System - Unable To Key In Ignition Switch Can't Turn Ignition Switch? Check for Locked Steering Got a service customer complaining he or she can't turn the ignition switch to start the engine? The reason could just be the steering column lock pin is engaged with the front wheels turned. Here's what typically happens: Some folks use the steering wheel to help support themselves while climbing in or out of the vehicle. This is very common among elderly or disabled drivers. Doing this turns the front wheels, which twists the tires against the ground. The twisted tires apply torque to the steering column. With the ignition switch in LOCK (0), the steering column lock pin is engaged. But the applied torque on the steering column binds the lock pin, making it tough to turn the ignition switch. The ignition switch won't turn to ON (II) if the lock pin isn't disengaged from the steering column. Tell your customer there's nothing wrong with the ignition switch itself. All he or she needs to do is turn the steering wheel from side to side while turning the switch. This usually releases the lock pin so the engine can be started. In some cases, though, your customer may need to give a good tug on the wheel. This could easily happen when parking on a hill and the wheels are turned sharply before the engine is shut off. Page 4124 Clutch Fluid: Service and Repair For further information regarding this component and the system that it is a part of, please refer to Clutch, M/T; Service and Repair; Hydraulic System Bleed. Specifications Crankshaft Gear/Sprocket: Specifications Camshaft Drive Gear ........................................................................................................................... ....................................................... 98 Nm (72 lb. ft.) Page 6365 Passenger's Inflator Module Connector Page 616 Air Flow Meter/Sensor: Description and Operation Mass Air Flow (MAF) Sensor The mass air flow (MAF) sensor measures the difference between the volume and the quantity of air that enters the engine. "Volume" means the size of the space to be filled. "Quantity" means the number of air molecules that will fit into the space. This information is important to the PCM because heavier, denser air will hold more fuel than lighter, thinner air. The PCM adjusts the air/fuel ratio as needed depending on the MAF value. The Tech 2 reads the MAF value and displays it in terms of grams per second (g/sec). At idle, the Tech 2 should read between 4 - 7 g/sec on a fully warmed up engine. Values should change quickly on acceleration. Values should remain stable at any given RPM. A failure in the MAF sensor or circuit will set DTC P0101, DTC P0102, or DTC P0103. Page 2912 amount of oxygen present in the exhaust gas entering the three-way catalytic converter. The Bank 1 HO2S 2 and the Bank 2 HO2S 2 sensors produce an output signal which indicates the oxygen storage capacity of the catalyst. This indicates the catalyst's ability to efficiently convert exhaust gases. If the catalyst is operating efficiently, the Bank 1 HO2S 1 and the Bank 2 HO2S 1 signals will be more active than the signals produced by the Bank 1 HO2S 2 and the Bank 2 HO2S 2 sensors. The catalyst monitor sensors operate the same as the fuel control sensors. The Bank 1 HO2S 2 and the Bank 2 HO2S 2 sensors" main function is catalyst monitoring, but they also have a limited role in fuel control. If a sensor output indicates a voltage either above or below the 450 mV bias voltage for an extended period of time, the PCM will make a slight adjustment to fuel trim to ensure that fuel delivery is correct for catalyst monitoring. A problem with the Bank 1 HO2S 2 signal circuit will set DTC P0137, P0138, or P0140, depending on the specific condition. A problem with the Bank 2 HO2S 2 signal circuit will set DTC P0157, P0158, or P0160, depending on the specific condition. A fault in the heated oxygen sensor heater element or its ignition feed or ground will result in lower sensor response. This may cause incorrect catalyst monitor diagnostic results. Service and Repair Extension Housing: Service and Repair Extension Housing Seal REMOVAL 1. Remove transfer case assembly from the vehicle (4x4). 2. Remove rear oil seal from transmission extension housing. INSTALLATION 1. Use J-36797 extension housing oil seal installer, and install the rear oil seal to the transmission extension housing. 2. Install the transfer case assembly to the vehicle (4x4). Page 7676 The wire insulation has one color or one color with another color stripe. The second color is the stripe. Locations Acceleration Sensor: Locations Below Left Side of Dash Page 5543 4. Remove the fuel pressure regulator from the fuel rail. 5. Remove the fuel return line from the regulator. 6. Install the new fuel pressure regulator in the reverse order of removal. 7. Use the Smart Cable to reprogram the PCM with the latest software from the June 2001 or later HONDANET CD-ROM. Refer to Service Bulletin 99-005, Updating the Passport PCM, filed under Tools. 8. Use the PGM Tester to clear any DTCs. 9. Use the PGM Tester to check the broadcast code. Make sure the broadcast code matches the one you selected from the CD-ROM. WARRANTY CLAIM INFORMATION In warranty: The normal warranty applies. Failed Part: P/N 8-17113-398-0 H/C 5504386 Defect Code: 092 Contention Code: C99 Skill Level: Repair Technician Out of warranty: Any repair performed after warranty expiration may be eligible for goodwill consideration by the District Service Manager or your Zone Office. You must request consideration, and get a decision, before starting work. REPAIR PROCEDURE - POWER STEERING SWITCH 1. Drain the power steering fluid out of the system. 2. Remove the power steering fluid reservoir. Clean the reservoir with solvent, then with soap and water. Rinse and dry it thoroughly. 3. Reinstall the reservoir. Do not connect the return hose. 4. Remove the power steering pressure switch, then clean it with brake cleaner and a scraper. Reinstall the switch, and torque it to 20 N.m (14 lb-ft). 5. Cover the unconnected end of the reservoir with your finger, then fill the reservoir with Dexron III ATF Fan Control Lever (Fan Switch) Blower Motor Switch: Testing and Inspection Fan Control Lever (Fan Switch) 1. Check for continuity between the terminals of the fan switch. Page 764 2. Connect one lead of a self-powered test light or DVOM to one end of the part of the circuit you want to test. 3. Connect the other lead to the other end. 4. If the self-powered test light glows, there is continuity. If you're using a DVOM, a low reading or no reading (zero), means good continuity. Testing For Voltage When testing for voltage at a connector without wire seals, you do not have to separate the two halves of the connector. Instead, probe the connector from the back. Always check both sides of the connector because dirty, corroded, and bent terminals can cause problems (no electrical contact = an open). 1. Connect one lead of the lest light to a known good ground, or, if you're using a digital volt ohmmeter (DVOM), place it in the appropriate DC volts range, and connect its negative lead to ground. 2. Connect the other lead of the test light or DVOM to the point you want to check. 3. If the test light glows, there is voltage present. If you're using a DVOM, note the voltage reading. It should be within one volt of measured battery voltage. A loss of more than one volt indicates a problem. NOTE: Always use a DVOM on high impedance circuits. A test light may not glow (even with battery voltage present). Testing For Voltage Drop Wires, connectors, and switches are designed to conduct current with a minimum loss of voltage. A voltage drop of more than one volt indicates a problem. 1. Place the digital volt/ohmmeter (DVOM) in the appropriate DC volts range. Connect the positive lead to the end of the wire (or to the connector or switch) closest to the battery. 2. Connect the negative lead to the other end of the wire (or the other side of the connector or switch). 3. Turn on the components in the circuit. 4. The DVOM will show the difference in voltage between the two points. A difference, or drop, of more than one volt indicates a problem. Check the circuit for loose, dirty, or bent terminals. Locations Shift Interlock Relay: Locations Under Center Console Page 5739 1. Using a wire brush and a scraper, remove any loose frame coating and rust from the outside frame rail and the lower trailing link frame bracket in the 20-inch (500 mm) section shown below. 2. Use a dry rag to remove any remaining dust or debris. If the area is wet, dry it with an air nozzle. 3. Spray a coat of Noxudol 300 onto the lower trailing link frame brackets, and on the outside of the frame rails in the area you just cleaned. The total spray area is about 20 inches (500 mm). Be careful not to overspray onto the exhaust system or body painted areas. 4. Fill out the information on a campaign completion label. Stick this label to the back edge of the driver's door, just below the door latch. *NOTE: If you need more labels, order them from Helm using reorder number Y0895.* Stage 2 Repair STAGE 2 REPAIR NOTE: ^ Do this repair on both sides of the vehicle. ^ Noxudol spray is highly flammable. Keep away from ignition sources (no smoking). Keep at a temperature not exceeding 120°F (50°C). ^ Wear hand and eye protection to avoid direct contact with the Noxudol spray. Spraying should be done in an area with adequate ventilation. 1. Remove the frame rail side hole plug from the driver's and passenger's side frame rails. 2. Using a hammer, knock on the outside of the frame rail around the lower trailing link bracket area to loosen any rust on the inside of the frame. Page 2163 96. Rear of Right Catalytic Converter Rear of right catalytic converter 94. Rear of Left Catalytic Converter Rear of Left Catalytic Converter Page 4723 Wire Color Abbreviations The following abbreviations are used to identify wire colors in the circuit schematics: WHT................................... White YEL................................... Yellow BLK................................... Black BLU................................... Blue GRN................................... Green RED................................... Red ORN................................... Orange PNK................................... Pink BRN................................... Brown GRY................................... Gray PUR................................... Purple LT BLU................................... Light Blue LT GRN................................... Light Green Air Bag Disarming and Arming Air Bag(s) Arming and Disarming: Service and Repair Air Bag Disarming and Arming Disabling The SRS Removal Turn the ignition switch to "lock" and remove key. 1. Remove SRS fuse "METER" and "SRS", from left dash side lower fuse block or disconnect battery. 2. Disconnect yellow 2 - pin connector at the base of steering column. 3. Remove glove box assembly, Refer to "Passenger Air Bag Assembly Replacement". 4. Disconnect yellow 2 - pin connector behind the glove box assembly. CAUTION: With the "SRS" fuse removed and ignition switch "ON", "AIR BAG" warning lamp will be "ON". This is normal operation and does not indicate an SRS malfunction. Enabling The SRS Installation CAUTION: Never use the air bag assembly from another vehicle. Use only the air bag assembly. Turn ignition switch to "LOCK" and remove key. 1. Connect yellow 2 - pin connector passenger air bag assembly. 2. Install glove box assembly, refer to "Passenger Air Bag Assembly Replacement". 3. Connect yellow 2 - pin connector at the base of steering column. 4. Install "AIR BAG" fuse "METER" and "SRS" to left dash side lower fuse block or connect battery. Turn ignition switch to "ON" and verify that the "AIR BAG" warning lamp flashes seven times and then turns "OFF". If it does not operate as described, perform the "Supplemental Restraint System (SRS) Diagnostic System Check". Page 4087 TOOL DESCRIPTION CLEANING PROCEDURE The cleaning procedure involves hot fluid under high pressure. Check the security of all hoses and connections. Always wear safety glasses or a face shield, gloves, and protective clothing. If you get ATF in your eyes or on your skin, rinse with water immediately. Improper use of the ATF cooler cleaner can result in burns and other serious injuries. Always wear eye protection and protective clothing, and follow all instructions in this bulletin. 1. Plug the ATF cooler cleaner into a 110 V grounded electrical outlet. NOTICE Make sure the outlet has no other appliances (light fixtures, drop lights, extension cords) plugged into it. Also, never plug the cooler cleaner into an extension cord or drop light cord; you would damage the unit. 2. Flip the HEAT toggle switch to ON. Wait 1 hour for the cooler cleaner to reach its operating temperature. (The cooler cleaner is ready to use when the temperature gauge reads 140° to 150°F.) Page 3702 The name of the component appears next to it followed by notes about its function along with any photo and connector view references. Connector "C" How to Identify Connector Terminals Cavity Numbering System The cavities (and wire terminals) in each connector are numbered starting from the upper left, looking at the male terminals from the terminal side (or looking at the female terminals from the wire side. Both views are in the same direction so the numbers are the same.) All actual cavities are numbered, even if they have no wire terminals in them. NOTE: Data Link Connector (DLC) terminals are numbered according to SAE standard J1962, not the Honda standard. The numbers of the four end terminals are molded into the corners of the connector face. Specifications Idle Speed: Specifications Idle speed is PCM controlled Page 1537 7. Turn the valve tappet with a pick or a small screwdriver until the tappet notch is within the indentation in the head. 8. Turn the crankshaft (or camshaft) pulley clockwise until the cam lobe presses the valve fully open. 9. On the tappet side closest to the bearing cap, insert the valve adjuster holder (T/N J-42659-AH) between the camshaft and the tappet. The tool should rest on the edge of the tappet without touching the shim. 10. Slowly turn the crankshaft (or camshaft) pulley counterclockwise so that when the valve closes, the tool catches between the camshaft and the tappet, holding the valve slightly open. NOTE: Do not turn the crankshaft (or camshaft) pulley too far or in the wrong direction. If you do, you might break the tool, or worse yet, damage the cylinder head. 11. Insert a pick or a small screwdriver into the tappet notch, and pry out the shim. 12. Wipe off the shim, then write its number on the Valve Inspection Chart for that valve and cylinder. If there is no number on the shim, measure its thickness with a micrometer, and write down the measurement on the Valve Inspection Chart. 13. Follow the directions on the Valve Shim Replacement Chart to select the correct shim. 14. Insert the correct shim, number side down, into the tappet. Make sure the shim is fully seated. 15. Release and remove the tool by turning the crankshaft (or camshaft) pulley clockwise. 16. Turn the crankshaft (or camshaft) pulley clockwise until the cam lobe again points away from the valve. Page 2449 7. Modify the original APPS by cutting the connector housing off of the sensor. 8. Connect the 10P connector to the modified APPS connector housing. 9. Using a DVOM, check the voltage between the reference voltage pin for each sensor and ground. ^ If the sensor circuits all read 5.0 volts, go to step 11. ^ If any sensor circuit is above or below 5.0 volts, go to step 10. 10. Troubleshoot for an internal short in another sensor or a PCM malfunction. ^ To find the sensor with an internal short, monitor the incorrect reference voltage, and disconnect each sensor (FTPS, EGR, MAP, TPS, CKP, and CMP) one at a time until the reference voltage reads 5.0 volts. Replace that sensor, and repeat step 3. ^ To find a malfunctioning PCM, replace it with a known-good PCM. If all three sensors (APP Sensor 1, APP Sensor 2, and APP Sensor 3) are within range, the original PCM is faulty; replace it and repeat step 3. Page 6298 Wire Color Abbreviations The following abbreviations are used to identify wire colors in the circuit schematics: WHT................................... White YEL................................... Yellow BLK................................... Black BLU................................... Blue GRN................................... Green RED................................... Red ORN................................... Orange PNK................................... Pink BRN................................... Brown GRY................................... Gray PUR................................... Purple LT BLU................................... Light Blue LT GRN................................... Light Green B-9 Pump Motor Failure (DTC 32/C0267, C0268) Page 1566 spring compressor and J42898 valve spring compressor adapter to install the split collars. 6. Install tappet with shim. 7. Install camshaft assembly. - Refer to installation procedure for Camshaft. Valve Clearance Adjustments Note: To adjust valve clearance, apply engine oil to the cam as well as to the adjusting shim (2) with the cylinder head built on the cylinder block, give a few turns to the camshaft by means of timing pulley tightening bolt, and measure valve clearance when the nose of cam is just opposite to maximum cam lift (1) as shown in illustration. Valve Clearance Standard Value (cold) Intake: 0.23 mm - 0.33 mm (0.0091 inch - 0.01 30 inch) Exhaust: 0.25 mm-0.35 mm (0.0098 in-0.0138 inch) Selection of Adjusting Shim Shim to be selected = (Thickness of removed shim) + (Valve clearance measurement - Standard value) Based on the above formula, the best suited shim should be selected from 41 sorts of shim (differently thick at 0.02 mm (0.0008 inch) intervals from 2.40 mm (0.0945 inch) through 3.2 mm (0.1260 inch) thick). Install the shim and check valve clearance. Replacement of Shim Page 1675 3. Install the new intake manifold gaskets. 4. Reinstall the intake manifold with the new EGR valve gasket and the new throttle body gasket. Disclaimer Page 7484 The connector cavity number is listed next to each terminal on the circuit schematic. The cavity / terminal shown is # 6. Diodes A rectifier diode works like a one way valve. It allows current to flow only in the direction of the arrow. A Zener diode blocks reverse current at normal voltages just like a rectifier diode. At high voltages, however, a Zener diode allows current to flow in reverse. Fuses Page 4265 Distinct Of Circuit By Wire Base Color All wires have color-coded insulation. Wires belonging to a system's main harness will have a single color. Wires belonging to a system's sub-circuits will have a colored stripe. Striped wires use the codes found in the chart to show wire size and colors. Abbreviations are used to indicate wire color within a circuit diagram. How to Identify Connector Terminals How to Identify Connector Terminals Cavity Numbering System The cavities (and wire terminals) in each connector are numbered starting from the upper left, looking at the male terminals from the terminal side (or looking at the female terminals from the wire side. Both views are in the same direction so the numbers are the same.) All actual cavities are numbered, even if they have no wire terminals in them. NOTE: Data Link Connector (DLC) terminals are numbered according to SAE standard J1962, not the Honda standard. The numbers of the four end terminals are molded into the corners of the connector face. The connector cavity number is listed next to each terminal on the circuit schematic. The cavity / terminal shown is # 6. Using/Identifying Connector Terminal Views How to Use Connector Terminal Views To see the configuration of a connector's cavities, look up its view number in the Connector Views. Each view includes the color of the connector, where Service and Repair Case: Service and Repair For further information regarding this component and the system that it is a part of, please refer to Manual Transmission/Transaxle; Service and Repair; Unit Overhaul Page 2407 14. While watching the APP Sensor values in the Engine Data List, adjust the APPS by turning it until the values are within the ranges shown at closed throttle and wide open throttle (accelerator pedal pushed all the way down), then tighten the mounting screws and recheck the values. ^ If all three sensors are within range, go to step 23. ^ If APP Sensor 1 APP Sensor 2, and/or APP Sensor 3 cannot be brought into range, go to step 15. 15. Troubleshoot for an open circuit or a PCM malfunction. ^ If APP Sensor 1 has a value of 0% or APP Sensor 2 and/or APP Sensor 3 have a value of 99%, an open circuit exists or the PCM is malfunctioning. Repair the circuit or replace the PCM, and repeat step 14. ^ If you don't find a problem, go to step 16. 16. Disconnect the 10 P connector from the APPS. 17. View the APP Sensor values in the Engine Data List. ^ If APP Sensor 1 has a value of 0% or APP Sensor 2 and/or APP Sensor 3 have a value of 99%, go to step 18. ^ If APP Sensor 1 has a value other than 0%, or APP Sensor 2 and/or APP Sensor 3 have a value other than 99%, a short circuit exists or the PCM is malfunctioning. Repair the circuit or replace the PCM, and repeat step 14. 18. Modify the original APPS by cutting the connector housing off of the sensor. 19. Connect the 10 P connector to the modified APPS connector housing. Initial Inspection and Diagnostic Overview Powertrain Control Module: Initial Inspection and Diagnostic Overview 1. Perform the On-Board Diagnostic System Check. 2. Start the engine and run for one minute. 3. Scan for DTCs using the Tech 2. Page 7709 the component if the component only has one connector, or by a capital letter (A, B, C, etc.) if the component has more than one connector. Below most connector numbers and component names are PHOTO and VIEW numbers. The PHOTO number refers to a photo in the back of the book that shows the connector's location on the car. The VIEW number refers to an illustration in the back of the book that shows the connector face, wire colors, connector cavity numbers, and other details. The connector cavity numbering sequence begins at the top left corner of the connector. Disregard any numbers molded into the connector housing. Wires Wires are identified by the abbreviated names of their colors; the second color is the color of the stripe. Wires are also identified by their location in a connector. The number "2" next to the male and female wire terminals at C416, for example, means those terminals join in cavity 2 of connector C416. Symbols A complete description of schematic symbols is given under wire color abbreviation. Power Distribution Schematics Power Distribution schematics show how power is supplied from the positive battery terminal to various circuits in the car. Refer to the Power Distribution section to get a more detailed picture of how power is supplied to the circuit you're working on. From Battery to Ignition Switch, Fuses, and Relays Individual circuit schematics begin with a fuse. The first half of Power Distribution, however, shows the wiring "upstream" between the battery Page 2974 Terminals - "T" Each "T" terminal (ring type) is numbered for reference and location. A "T" terminal is secured with a screw or bolt. Wires Page 5786 20. Install the passenger's side type A reinforcement bracket using the hardware in the kit: Install the trailing link front mounting nut and bolt hand-tight, then torque the remaining bolts and nuts, in the order shown on the illustration below: ^ Torque the bracket bolts to 35 Nm (25 Ib-ft). ^ Torque the body mount stud and nut to 30 Nm (22 Ib-ft). 21. Remove the driver's side lower trailing link front mounting bolt: ^ Push the bolt out toward the fuel tank as far as possible. ^ Cut off the bolt head with a reciprocating saw. ^ Push the bolt out through the opposite side of the bracket. 22. * Install the driver's side type A reinforcement bracket using the hardware in the kit. The required parts vary, depending on the vehicle model year and frame design. To correctly install the driver's side type A reinforcement bracket, use the illustrations below for reference.* All 1998-99 models and some 2000 models require three bolts and one body mount stud and nut; some 2000 models require three bolts, one body mount stud and nut, plus one washer; all 2001-02 models require three bolts, one body mount stud and nut, plus one fuel tank protector bolt. Locations Gear Sensor/Switch: Locations Top Right Side Of Transfer Case Page 5456 View A REMOVAL 1. Disconnect the battery ground cable. 2. Remove the front console assembly. 3. Disconnect the connector from the control unit. 4. Remove 4 nuts. 5. Disconnect the control unit with brackets. 6. Remove 4 screws. 7. Disconnect the control unit from brackets. INSTALLATION To install, follow the removal steps in the reverse order, noting the following points. Torque: Nut (1) 8 Nm (69 inch lbs.) Page 4865 The wire insulation has one color or one color with another color stripe. The second color is the stripe. Page 7749 it is located, and what it connects to. Use the Connector Views to help locate the proper cavity when you need to probe a connector. It can be especially helpful if the connector has more than one wire of the same color. A dash symbol (-) indicates that the cavity is empty. Connector views can also be used to help diagnose multiple symptoms in separate circuits which could be caused by a single problem in a connector shared by those circuits. Here's an example: 1. Pick one of the multiple symptoms and look up the schematic for that circuit. 2. Make a list of all the in-line and fuse box connectors in that schematic , 3. Then, in the Connector Views, look up each connector on your list to see if circuits related to the other symptoms run through one of them. If they do, inspect that connector for the problem. Example: The blower, rear window defogger, and the windshield wiper don't work. List all in-line and fuse box connectors in the blower controls circuit and then check the Connector View (see the sample). You find that C324 is common to the blower controls, rear window defogger, and wiper/washer, so you inspect C324 and find the problem, bent terminals. Finding Component/Connector Locations Finding Component/Connector Locations To see where a component or connector is located on the car, look up its photo number in the "Component Location". The photo will also tell you the color of the connector, and how many cavities it has. Page 2053 The wire insulation has one color or one color with another color stripe. The second color is the stripe. Testing and Inspection Wheel Bearing: Testing and Inspection FRONT HUB BEARING PRELOAD CHECK Check the hub bearing preload at the wheel pin. New bearing and New oil seal: 19.6 - 24.5 N (4.4 - 5.5 lbs.) Used bearing and New oil seal: 11.8 17.7 N (2.6 - 4.0 lbs.) Page 6092 Condenser Fan: Description and Operation With the engine running, battery voltage is applied to the A/C switch. When you press the A/C switch button or the air selector knob is in the FOOT/DEFROST or DEFROST position, battery voltage is applied to the A/C triple pressure switch. If the A/C pressure is above 1471.5 ± 98.1 kPa (213.3 ± 14.2 psi) the switch will close and apply voltage to the coil side of the condenser fan relay, which is continually grounded. Once the relay is energized, the contacts close, allowing battery voltage from the COND. FAN fuse to be applied to the condenser fan. The motor, being grounded continually, is energized, and the fan comes on. Quarter Glass Quarter Window Glass: Service and Repair Quarter Glass Rear Quarter Glass (LWB) Removal 1. Disconnect the battery ground cable. 2. Remove the rear quarter trim panel. 3. Remove the rear quarter glass. Installation 1. Rear quarter glass. - Clean the bonding surfaces of both the glass and the body panel. - Be absolutely sure to apply glass primer to the side glass. - Be absolutely sure to apply body primer fully to the body. NOTE: Immediately wipe off the primer left on the body or extruded sealant. Attach the fastener to the indicated position of body with sealant as shown in the figure. - Apply the sealant to the circumference of glass as shown in the figure. - Insert the location pins on glass into the panel, push the glass against the panel, and bond them. - Attach the molding to the body with sealant. - Cure the bonding at a temperature of 20 °C - 30 °C (68 °F - 86 °F) for 24 hours. - Check that the rear quarter glass does not leak water. 2. Install the rear quarter trim panel. Rear Quarter Glass (Resin Top) Removal 1. Disconnect the battery ground cable. 2. Remove the rear quarter glass assembly. Installation 1. Use alcohol or the like to wipe clean the areas of the resin top and glass assembly that are to be affixed to each other. 2. Apply the primer (2) to the area of the resin top to which the glass is to be affixed. - Top edge (1) and bottom edge (3) primer coat areas. 3. Stick the fasteners tape to the body in the specified locations. Page 3401 The name of the component appears next to it followed by notes about its function along with any photo and connector view references. Connector "C" How to Identify Connector Terminals Cavity Numbering System The cavities (and wire terminals) in each connector are numbered starting from the upper left, looking at the male terminals from the terminal side (or looking at the female terminals from the wire side. Both views are in the same direction so the numbers are the same.) All actual cavities are numbered, even if they have no wire terminals in them. NOTE: Data Link Connector (DLC) terminals are numbered according to SAE standard J1962, not the Honda standard. The numbers of the four end terminals are molded into the corners of the connector face. Page 2987 Vehicle Speed Sensor: Service and Repair REMOVAL CAUTION: The VSS is located on the right side of the transfer case just ahead of the rear propeller shaft and very close to the exhaust pipes for 4WD and on the extension cover for 2WD. Be sure that the exhaust pipes are cool enough to touch before trying to remove the VSS. If the pipes are hot, you could be burned. 1. Disconnect the negative battery cable. 2. Disconnect the VSS electrical connector. 3. Remove the bolt and the clamp securing the VSS in place. IMPORTANT: Have a container ready to catch any fluid that leaks out when the VSS is removed from the transfer case for 4WD and on the extension cover for 2WD. 4. Remove the VSS from the transfer case by wiggling it slightly and pulling it straight out. INSTALLATION 1. Install the VSS in the transfer case with the notch for the connector facing the rear. Service and Repair Fuel Pressure Release: Service and Repair CAUTION: To reduce the risk of fire and personal injury, there are necessary to relieve the fuel system pressure filler and gauge unit before servicing the fuel system components. CAUTION: After relieving the system pressure, a small amount of fuel may be released when servicing fuel lines or connections. Reduce the chance of personal injury by covering the fuel line fittings with a shop towel before you disconnect the fittings. The towels will absorb any fuel that may leak out. When the disconnection is completed, place the towel in an approved container. 1. Remove the fuel cap. 2. Remove the fuel pump relay from the underhood relay box. 3. Start the engine and allow it to stall. 4. Crank the engine for 30 seconds. 5. Disconnect the negative battery cable. Page 3331 it is located, and what it connects to. Use the Connector Views to help locate the proper cavity when you need to probe a connector. It can be especially helpful if the connector has more than one wire of the same color. A dash symbol (-) indicates that the cavity is empty. Connector views can also be used to help diagnose multiple symptoms in separate circuits which could be caused by a single problem in a connector shared by those circuits. Here's an example: 1. Pick one of the multiple symptoms and look up the schematic for that circuit. 2. Make a list of all the in-line and fuse box connectors in that schematic , 3. Then, in the Connector Views, look up each connector on your list to see if circuits related to the other symptoms run through one of them. If they do, inspect that connector for the problem. Example: The blower, rear window defogger, and the windshield wiper don't work. List all in-line and fuse box connectors in the blower controls circuit and then check the Connector View (see the sample). You find that C324 is common to the blower controls, rear window defogger, and wiper/washer, so you inspect C324 and find the problem, bent terminals. Finding Component/Connector Locations Finding Component/Connector Locations To see where a component or connector is located on the car, look up its photo number in the "Component Location". The photo will also tell you the color of the connector, and how many cavities it has. Page 2054 Ion Sensing Module: Diagnostic Aids Before Troubleshooting Before Troubleshooting See: Service Precautions/Vehicle Damage Warnings/Tips and Precautions 1. Check applicable fuses in the appropriate fuse/relay box. 2. Check the battery for damage, state of charge, and clean and tight connections. CAUTION: Do not quick-charge a battery unless the battery ground cable has been disconnected, otherwise you will damage the alternator diodes. - Do not attempt to crank the engine with the battery ground cable loosely connected or you will severely damage the wiring. While You're Working 1. Make sure connectors are clean, and have no loose terminals or receptacles. 2. Make sure that connectors without wire seals are packed with dielectric (silicone) grease. Part Number: 08798-9001. 3. When connecting a connector, push it until it "clicks" into place. CAUTION: Do not pull on the wires when disconnecting a connector. Pull only on the connector housings. - Most circuits include solid-state devices. Test the voltages in these circuits only with a 10-megaohm or higher impedance digital multi meter. Never use a test light or analog meter on circuits that contain solid-state devices. Damage to the devices may result. Five-Step Troubleshooting 1. Verify The Complaint Turn on all the components in the problem circuit to check the accuracy of the customer complaint. Note the symptoms. Do not begin disassembly or testing until you have narrowed down the problem area. 2. Analyze The Schematic Look up the schematic for the problem circuit. Determine how the circuit is supposed to work by tracing the current paths from the power source through the circuit components to ground. Also, trace circuits that share wiring with the problem circuit. The names of circuits that share the same fuse, ground, or switch, and so on, are referred to in each circuit schematic. Try to operate any shared circuits you didn't check in step 1. If the shared circuits work, the shared wiring is OK, and the cause must be in the wiring used only by the problem circuit. If several circuits fail at the same time, the fuse or ground is a likely cause. Based on the symptoms and your understanding of the circuit's operation, identify one or more possible causes. 3. Isolate The Problem By Testing The Circuit Make circuit tests to check the diagnosis you made in step 2. Keep in mind that a logical, simple procedure is the key to efficient troubleshooting. Test for the most likely cause of failure first. Try to make tests at points that are easily accessible. 4. Fix The Problem Once the specific problem is identified, make the repair. Be sure to use proper tools and safe procedures. 5. Make Sure The Circuit Works Turn on all components in the repaired circuit in all modes to make sure you've fixed the entire problem. If the problem was a blown fuse, be sure to test all of the circuits on that fuse. Make sure no new problems turn up and the original problem does not recur. Page 4101 Transmission Position Switch/Sensor: Service and Repair REMOVAL 1. Place selector lever in neutral. 2. Disconnect battery ground cable. 3. Remove mode switch cover (1). 4. Disconnect selector lever (2) from the mode switch. 5. Remove bracket with cable (3). 6. Disconnect transmission harness from the mode switch connector (4). 7. Remove bracket with mode switch connector from the transmission case. 8. Remove mode switch connector (4) from the bracket (5). 9. Remove two mode switch bolts and nut then remove mode switch (6). INSTALLATION To install, follow the removal steps in the reverse order, noting the following points; 1. Torque Mode switch bolt: 13 Nm (113 inch lbs.) Selector lever nut: 23 Nm (17 ft. lbs.) 2. Mode switch setting procedure. Perform either of the following adjustment procedures: Procedure 1 a. Place selector lever in neutral. b. Remove selector lever from the mode switch. c. Remove the mode switch cover. d. Loosen the two 10 mm screws. e. Rotate the mode switch until the slot in the mode switch housing aligns with the selector shaft bushing, and insert a 3/32 inch (2.4 mm) drill bit or punch (1) into the slot. f. Tighten the screws to 13 Nm (113 inch lbs.). g. After completing adjustment, snap the mode switch cover into place. h. Reinstall the selector lever. Procedure 2 a. Place selector lever in neutral. b. Disconnect transmission harness connector from mode switch connector. Page 4612 4WD Control Unit: Service and Repair 4WD CONTROL UNIT ASSOCIATED PARTS REMOVAL 1. Remove center console assembly. 2. Remove two screws and harness connector (1) from 4WD control unit. INSTALLATION 1. Connect harness connector, then install 4WD control unit. 2. Install center console assembly. Page 4863 This means the branch of the wire connects to another circuit. The arrow points to the name of the circuit branch where the wire continues. Diagram Information and Instructions Idle Speed/Throttle Actuator - Electronic: Diagram Information and Instructions How to Identify Wiring Color-Coded Insulation Wire Color Wire Color Coding Page 1275 Check the fluid level and replenish as necessary. If replenished, leave the system for at least one minute. 8. Depress the brake pedal slowly once and hold it depressed. 9. Completely seal the delivery port of the master cylinder with your finger, where the pipe was disconnected then release the brake pedal slowly. 10. Release your finger from the delivery port when the brake pedal returns completely. 11. Repeat steps 8 through 10 until the brake fluid comes out of the delivery port during step 8. NOTE: Do not allow the fluid level in the reservoir to go below the half-way mark. 12. Reconnect the brake pipe (1) to the master cylinder and tighten the pipe. 13. Depress the brake pedal slowly once and hold it depressed. 14. Loosen the rear wheel brake pipe (1) at the master cylinder. 15. Retighten the brake pipe, then release the brake pedal slowly. 16. Repeat steps 13 through 15 until no air comes out of the port when the brake pipe is loosened NOTE: Be very careful not to allow the brake fluid to come in contact with painted surfaces. 17. Bleed the air from the front wheel brake pipe connection (2) by repeating steps 7 through 16. BLEEDING THE CALIPER 18. Bleed the air from each wheel in the order listed: - Right rear caliper or wheel cylinder - Left rear caliper or wheel cylinder - Right front caliper - Left front caliper Conduct air bleeding from the wheels in the above order. If no brake fluid comes out, it suggests that air is mixed in the master cylinder. In this case, bleed air from the master cylinder. In this case, bleed air from the master cylinder in accordance with steps 7 through 17, and then bleed air from the caliper or wheel cylinder. 19. Place the proper size box end wrench over the bleeder screw. 20. Cover the bleeder screw with a transparent tube, and submerge the free end of the transparent tube in a transparent container containing brake fluid . 21. Pump the brake pedal slowly three (3) times (once/second), then hold it depressed. 22. Loosen the bleeder screw until fluid flows through the tube. 23. Retighten the bleeder screw. 24. Release the brake pedal slowly. 25. Repeat steps 21 through 24 until the air is completely removed. It may be necessary to repeat the bleeding procedure 10 or more times for front wheels and 15 or more times for rear wheels. 26. Go to the next wheel in the sequence after each wheel is bled. Be sure to monitor reservoir fluid level. 27. Depress the brake pedal to check if you feel "sponginess" after the air has been removed from all wheel cylinders and calipers. If the pedal feels "spongy", the entire bleeding procedure must be repeated. 28. After the bleeding operation is completed on the each individual wheel, check the level of the brake fluid in the reservoir and replenish up to the "MAX" level as necessary. 29. Attach the reservoir cap. If the diaphragm inside the cap is deformed, reform it and install. 30. Stop the engine. Page 2257 Disclaimer Repair Procedure 1. Unclamp the air cleaner housing cover, and move it to the side for access to connector C123 (16P BLK). 2. Unfasten C123 from the side of the engine compartment using a 90-degree pick. 3. Disconnect C123, and clean the terminals on both sides of the connector with contact cleaner. Shake the residue out of the connector. Allow the contact cleaner to evaporate for at least 3 minutes, then reconnect C123. 4. Fasten C123 to the left side of the engine compartment, then reinstall the air cleaner housing cover. 5. While supporting the accelerator pedal assembly, remove the two bolts that secure the assembly to the bulkhead. Carefully lower the assembly to gain access to the connector. Page 7019 Interior Trim Panels (SWB) And Associated Parts Locations Behind Glove Box Page 6154 Control Module HVAC: Diagnostic Aids Before Troubleshooting Before Troubleshooting See: Service Precautions/Vehicle Damage Warnings/Tips and Precautions 1. Check applicable fuses in the appropriate fuse/relay box. 2. Check the battery for damage, state of charge, and clean and tight connections. CAUTION: Do not quick-charge a battery unless the battery ground cable has been disconnected, otherwise you will damage the alternator diodes. - Do not attempt to crank the engine with the battery ground cable loosely connected or you will severely damage the wiring. While You're Working 1. Make sure connectors are clean, and have no loose terminals or receptacles. 2. Make sure that connectors without wire seals are packed with dielectric (silicone) grease. Part Number: 08798-9001. 3. When connecting a connector, push it until it "clicks" into place. CAUTION: Do not pull on the wires when disconnecting a connector. Pull only on the connector housings. - Most circuits include solid-state devices. Test the voltages in these circuits only with a 10-megaohm or higher impedance digital multi meter. Never use a test light or analog meter on circuits that contain solid-state devices. Damage to the devices may result. Five-Step Troubleshooting 1. Verify The Complaint Turn on all the components in the problem circuit to check the accuracy of the customer complaint. Note the symptoms. Do not begin disassembly or testing until you have narrowed down the problem area. 2. Analyze The Schematic Look up the schematic for the problem circuit. Determine how the circuit is supposed to work by tracing the current paths from the power source through the circuit components to ground. Also, trace circuits that share wiring with the problem circuit. The names of circuits that share the same fuse, ground, or switch, and so on, are referred to in each circuit schematic. Try to operate any shared circuits you didn't check in step 1. If the shared circuits work, the shared wiring is OK, and the cause must be in the wiring used only by the problem circuit. If several circuits fail at the same time, the fuse or ground is a likely cause. Based on the symptoms and your understanding of the circuit's operation, identify one or more possible causes. 3. Isolate The Problem By Testing The Circuit Make circuit tests to check the diagnosis you made in step 2. Keep in mind that a logical, simple procedure is the key to efficient troubleshooting. Test for the most likely cause of failure first. Try to make tests at points that are easily accessible. 4. Fix The Problem Once the specific problem is identified, make the repair. Be sure to use proper tools and safe procedures. 5. Make Sure The Circuit Works Turn on all components in the repaired circuit in all modes to make sure you've fixed the entire problem. If the problem was a blown fuse, be sure to test all of the circuits on that fuse. Make sure no new problems turn up and the original problem does not recur. Page 1844 Radiator: Service and Repair Radiator Removal 1. Disconnect battery ground cable. 2. Loosen a drain plug (2) to drain coolant. 3. Disconnect oil cooler hose (1) on Automatic Transmission (A/T). 4. Disconnect radiator inlet hose and outlet hose from the engine. 5. Remove fan guide (1), clips (3) on both sides and the bottom lock, then remove fan guide lower (3) with fan shroud (4). 6. Disconnect the reserve tank hose (4) from radiator. 7. Lift up and remove the radiator assembly with hose, taking care not to damage the radiator core with a fan blade. 8. Remove rubber cushions on both sides at the bottom. Inspection Radiator Cap Measure the valve opening pressure of the pressurizing valve with a radiator filler cap tester. Replace the cap if the valve opening pressure is outside the standard range. Valve opening pressure kPa (psi) 93.3 - 122.7 (13.5 - 17.8) Cap tester: J-24460-01 Page 5426 1. Place the vehicle on a commercially available, computerized, four-wheel alignment rack, and record the following measurements. Follow the equipment manufacturer's instructions. NOTE: Enter each reading in decimal degrees. Example 30' = 0.50. 2. If any measurement is out of specification, inspect the front suspension for any damage. Repair any damaged parts before continuing your diagnosis. 3. Determine how the front wheel camber is affecting the pull. Pick the combination of left- and right-front camber that best matches the vehicle you are repairing, then note the camber thrust direction for that combination: NOTE: ^ If the camber of both front wheels is negative, but one wheel is grossly more negative than the other, the camber thrust direction will be opposite the wheel with more negative camber (for example, if the left-front wheel is more negative, the camber thrust direction is right). ^ If the camber of both front wheels is positive, but one wheel is grossly more positive than the other, the camber thrust direction will be the same as the wheel with more positive camber (for example, if the left-front wheel is more positive, the camber thrust direction is left). 4. Determine how the camber needs to be adjusted. 5. Adjust the camber as needed. Front Camber Adjustment, Double Wishbone Suspension Page 8077 Ground - "G" Shielding Sheilding This represents RFI (Radio Frequency Interference) shielding around a wire. The shielding is always connected to ground. Splices Page 4851 it is located, and what it connects to. Use the Connector Views to help locate the proper cavity when you need to probe a connector. It can be especially helpful if the connector has more than one wire of the same color. A dash symbol (-) indicates that the cavity is empty. Connector views can also be used to help diagnose multiple symptoms in separate circuits which could be caused by a single problem in a connector shared by those circuits. Here's an example: 1. Pick one of the multiple symptoms and look up the schematic for that circuit. 2. Make a list of all the in-line and fuse box connectors in that schematic , 3. Then, in the Connector Views, look up each connector on your list to see if circuits related to the other symptoms run through one of them. If they do, inspect that connector for the problem. Example: The blower, rear window defogger, and the windshield wiper don't work. List all in-line and fuse box connectors in the blower controls circuit and then check the Connector View (see the sample). You find that C324 is common to the blower controls, rear window defogger, and wiper/washer, so you inspect C324 and find the problem, bent terminals. Finding Component/Connector Locations Finding Component/Connector Locations To see where a component or connector is located on the car, look up its photo number in the "Component Location". The photo will also tell you the color of the connector, and how many cavities it has. Page 3480 Throttle Position Sensor: Testing and Inspection Function Check Use a Tech 2 to check the TP sensor output voltage at closed throttle. - The voltage should be under 0.85 volt. - If the reading is greater than 0.85 volt, check the throttle shaft to see if it is binding. Page 5942 Air Door Cable: Service and Repair Control Assembly / Control Cable Removal 1. Disconnect the battery ground cable. 2. Remove instrument panel driver lower cover assembly. 3. Remove meter cluster assembly. 4. Remove glove box. 5. Remove the control lever attaching screws. Page 2952 Transmission Position Switch/Sensor: Description and Operation Transmission Range Switch IMPORTANT: The vehicle should not be driven with the transmission range switch disconnected; idle quality will be affected. The four inputs from the transmission range switch indicate to the PCM which position is selected by the transmission selector lever. This information is used for ignition timing, EVAP canister purge, EGR operation. For more information on the transmission on the transmission range switch, refer to Transmission Control System Diagnosis. See: Transmission Control Systems/Testing and Inspection Page 4461 Specifications Idle Speed: Specifications Idle speed is PCM controlled Page 3372 Idle Speed/Throttle Actuator - Electronic: Diagnostic Aids Before Troubleshooting Before Troubleshooting See: Service Precautions/Vehicle Damage Warnings/Tips and Precautions 1. Check applicable fuses in the appropriate fuse/relay box. 2. Check the battery for damage, state of charge, and clean and tight connections. CAUTION: Do not quick-charge a battery unless the battery ground cable has been disconnected, otherwise you will damage the alternator diodes. - Do not attempt to crank the engine with the battery ground cable loosely connected or you will severely damage the wiring. While You're Working 1. Make sure connectors are clean, and have no loose terminals or receptacles. 2. Make sure that connectors without wire seals are packed with dielectric (silicone) grease. Part Number: 08798-9001. 3. When connecting a connector, push it until it "clicks" into place. CAUTION: Do not pull on the wires when disconnecting a connector. Pull only on the connector housings. - Most circuits include solid-state devices. Test the voltages in these circuits only with a 10-megaohm or higher impedance digital multi meter. Never use a test light or analog meter on circuits that contain solid-state devices. Damage to the devices may result. Five-Step Troubleshooting 1. Verify The Complaint Turn on all the components in the problem circuit to check the accuracy of the customer complaint. Note the symptoms. Do not begin disassembly or testing until you have narrowed down the problem area. 2. Analyze The Schematic Look up the schematic for the problem circuit. Determine how the circuit is supposed to work by tracing the current paths from the power source through the circuit components to ground. Also, trace circuits that share wiring with the problem circuit. The names of circuits that share the same fuse, ground, or switch, and so on, are referred to in each circuit schematic. Try to operate any shared circuits you didn't check in step 1. If the shared circuits work, the shared wiring is OK, and the cause must be in the wiring used only by the problem circuit. If several circuits fail at the same time, the fuse or ground is a likely cause. Based on the symptoms and your understanding of the circuit's operation, identify one or more possible causes. 3. Isolate The Problem By Testing The Circuit Make circuit tests to check the diagnosis you made in step 2. Keep in mind that a logical, simple procedure is the key to efficient troubleshooting. Test for the most likely cause of failure first. Try to make tests at points that are easily accessible. 4. Fix The Problem Once the specific problem is identified, make the repair. Be sure to use proper tools and safe procedures. 5. Make Sure The Circuit Works Turn on all components in the repaired circuit in all modes to make sure you've fixed the entire problem. If the problem was a blown fuse, be sure to test all of the circuits on that fuse. Make sure no new problems turn up and the original problem does not recur. Page 2717 - Bank 2 sensor 1 is mounted on the exhaust pipe ahead of the left-hand catalytic converter. - Bank 2 sensor 2 is mounted behind the left-hand catalytic converter. 3. Disconnect the pigtail from the wiring harness. IMPORTANT: The pigtail is permanently attached to the sensor. Be careful not to pull the wires out. NOTE: Do not use a torch to remove an HO2S unless the sensor is being replaced. Using a torch could damage the sensor. Page 2237 2. Connect the short finder across the battery terminals and the load (component) side of the fuse terminal. 3. Close all switches in the circuit you're testing. 4. Turn on the short finder. This creates a pulsing magnetic field around the wiring between the fuse box and the short. 5. Beginning at the fuse box, slowly move the short finder along the circuit wiring. The meter will read current pulses through sheet metal and body trim. As long as the meter is between the fuse and the short, the needle will move with each current pulse. Once you move the meter past the point of the short, the needle will stop moving. Check the wiring and connectors in this area to locate the cause of the short. Testing For Continuity When testing for continuity at a connector without wire seals, you do not have to separate the two halves of the connector. Instead, probe the connector from the back. Always check both sides of the connector because dirty, corroded, and bent terminals can cause problems (no electrical contact = an open). 1. Disconnect the negative cable from the car battery. If you're using a DVOM, place it in the lowest "OHMS" range. Service and Repair Tail Light Bulb: Service and Repair Removal 1. Disconnect the battery ground cable. 2. Remove the rear combination light assembly (1). - Remove three screws. - Pull out the rear combination light assembly to ward you. 3. Remove the bulb (1). - Remove the taillight socket by turning it counterclockwise. - Remove the bulb by turning it counterclockwise while pushing it at the same time. Installation To install, follow the removal steps in the reverse order. Locations Door Switch: Locations Page 2913 Oxygen Sensor: Testing and Inspection Heated Oxygen Sensor (HO2S) All four sensors are identical. Inspect each in the same way. 1. Inspect the pigtail and the electrical connector for grease, dirt, corrosion, and bare wires or worn insulation. 2. Inspect the lowered end of the sensor for grease, dirt, or other contaminations. Page 5738 ^ If the flat punch doesn't poke a hole in any of the X-marked areas on the frame, go to STAGE 2 REPAIR. ^ * If the flat punch pokes a hole in any of the X-marked areas, or if there are pre-existing holes in the frame above the lower trailing link front bracket, go to the next step.* 5. Using the 3/16 in. x 9 in. flat punch and the 12-16-oz. hammer, strike the radius of the frame corners on each of the X-marked areas shown below. Again, swing the hammer with a 10 to 12 inch stroke to be sure enough force is applied to the flat punch. ^ If the flat punch doesn't poke a hole in any of the X-marked areas, go to STAGE 3 REPAIR. ^ If the flat punch pokes a hole in any of the X-marked areas, go to STAGE 4 REPAIR. Stage 1 Repair STAGE 1 REPAIR NOTE: ^ Do this repair on both sides of the vehicle. ^ Noxudol spray is highly flammable. Keep away from ignition sources (no smoking). Keep at a temperature not exceeding 120°F (50°C). ^ Wear hand and eye protection to avoid direct contact with the Noxudol spray. Spraying should be done in an area with adequate ventilation. Page 5514 Power Steering Pump: Diagrams Disassembled View Page 2259 14. While watching the APP Sensor values in the Engine Data List, adjust the APPS by turning it until the values are within the ranges shown at closed throttle and wide open throttle (accelerator pedal pushed all the way down), then tighten the mounting screws and recheck the values. ^ If all three sensors are within range, go to step 23. ^ If APP Sensor 1 APP Sensor 2, and/or APP Sensor 3 cannot be brought into range, go to step 15. 15. Troubleshoot for an open circuit or a PCM malfunction. ^ If APP Sensor 1 has a value of 0% or APP Sensor 2 and/or APP Sensor 3 have a value of 99%, an open circuit exists or the PCM is malfunctioning. Repair the circuit or replace the PCM, and repeat step 14. ^ If you don't find a problem, go to step 16. 16. Disconnect the 10 P connector from the APPS. 17. View the APP Sensor values in the Engine Data List. ^ If APP Sensor 1 has a value of 0% or APP Sensor 2 and/or APP Sensor 3 have a value of 99%, go to step 18. ^ If APP Sensor 1 has a value other than 0%, or APP Sensor 2 and/or APP Sensor 3 have a value other than 99%, a short circuit exists or the PCM is malfunctioning. Repair the circuit or replace the PCM, and repeat step 14. 18. Modify the original APPS by cutting the connector housing off of the sensor. 19. Connect the 10 P connector to the modified APPS connector housing. Page 3122 7. Modify the original APPS by cutting the connector housing off of the sensor. 8. Connect the 10P connector to the modified APPS connector housing. 9. Using a DVOM, check the voltage between the reference voltage pin for each sensor and ground. ^ If the sensor circuits all read 5.0 volts, go to step 11. ^ If any sensor circuit is above or below 5.0 volts, go to step 10. 10. Troubleshoot for an internal short in another sensor or a PCM malfunction. ^ To find the sensor with an internal short, monitor the incorrect reference voltage, and disconnect each sensor (FTPS, EGR, MAP, TPS, CKP, and CMP) one at a time until the reference voltage reads 5.0 volts. Replace that sensor, and repeat step 3. ^ To find a malfunctioning PCM, replace it with a known-good PCM. If all three sensors (APP Sensor 1, APP Sensor 2, and APP Sensor 3) are within range, the original PCM is faulty; replace it and repeat step 3. Page 7663 If there is no photo number below or beside a component name or a connector, ground, or terminal number, look up that name or number in the appropriate Connector Identification Chart. The chart lists how many cavities a connector has, where it's located, and what it connects to. The related illustration shows the connector's location on the harness, and the harness routing. NOTE: Photos listed by number are located at Locations / Components / Photograohs. See: Locations/Component Locations/Photographs Circuit Schematics Page 5662 NOTE: Torque lower control arm nut after adjusting buffer clearance . Buffer clearance: 22 mm (0.87 inch). Torque to 190 Nm (140 ft. lbs.). NOTE: Adjust the trim height. Page 5124 Alternator: Service and Repair Disassembly and Reassembly Disassembly 1. Remove the through bolt. Insert the tip of a pry bar into the gaps between the front cover and the stator core. Pry apart and separate the front cover, rotor, the rear cover and stator. NOTE: Take care not to scratch or otherwise damage the stator coil with pry bar. 2. Clamp the rotor in a vise and then remove the nut and pulley. 3. Remove the rotor assembly from front cover. Locations Page 6005 Blower Motor: Description and Operation With the engine running, voltage is applied to the coil of the heater-A/C relay. The heater-A/C relay energizes and allows battery voltage from fuse 16 through fuse 5 and fuse 6 to the blower motor. The fan control switch then applies ground to the blower resistor for the desired blower motor speed. As the fan control switch is moved from OFF to position 4, segments of the blower resistor are bypassed. This increases the blower motor speed. When the blower switch is in position 4, the entire resistor is bypassed and the blower motor runs at the highest speed. Page 423 Air Conditioning Switch: Testing and Inspection 1. Check for continuity between the fan switch and the A/C switch side connector terminals. Page 8159 Rear Hatchgate (LWB) Page 812 Accelerator Pedal Position Sensor: Adjustments Accelerator Position Sensor Adjustment AP sensor is controlled three multiple control system, and adjust the idle position and WOT position are between A and B for AP sensor 1, AP sensor 2, and AP sensor 3. Refer to "How to adjust for AP sensor". How To Adjust For AP Sensor 1. Connect the Tech 2 to DLC on vehicle. 2. Ignition "ON," engine "OFF". 3. Display the APS date list. Check the following item for AP position (%). 4. If the problem was found, adjust as necessary. Page 6747 2. Connect the short finder across the battery terminals and the load (component) side of the fuse terminal. 3. Close all switches in the circuit you're testing. 4. Turn on the short finder. This creates a pulsing magnetic field around the wiring between the fuse box and the short. 5. Beginning at the fuse box, slowly move the short finder along the circuit wiring. The meter will read current pulses through sheet metal and body trim. As long as the meter is between the fuse and the short, the needle will move with each current pulse. Once you move the meter past the point of the short, the needle will stop moving. Check the wiring and connectors in this area to locate the cause of the short. Testing For Continuity When testing for continuity at a connector without wire seals, you do not have to separate the two halves of the connector. Instead, probe the connector from the back. Always check both sides of the connector because dirty, corroded, and bent terminals can cause problems (no electrical contact = an open). 1. Disconnect the negative cable from the car battery. If you're using a DVOM, place it in the lowest "OHMS" range. Locations A/T - Vehicle Speed Sensor Installation Precautions Transmission Speed Sensor: Technical Service Bulletins A/T - Vehicle Speed Sensor Installation Precautions Install VSS Properly to Avoid Reman A/T Damage We can't emphasize enough how important it is to follow, to the letter, the installation instructions that come with a reman A/T. These instructions help ensure that you avoid damaging the A/T and score a successful repair. This is particularly true when it comes to installing the vehicle speed sensor (VSS). Step 6 of the instructions tells you to make sure its gear is fully engaged and the VSS is fully seated before you tighten the retaining bolt. If you don't install the VSS properly, the speed sensor gear will get stripped and the A/T will be seriously damaged. So don't take risks with your customer's vehicle. Always follow these instructions to the letter. You can rest assured you're doing the job right. Page 3309 Fuel Pump Relay: Testing and Inspection Relays Test This test is conducted to check Fuel Pump Relay and A/C Clutch for proper operation. Tech 2 must be used for this test. Test Procedure: 1. Connect Tech 2 to the vehicle DLC. 2. Ignition SW is "On". 3. Select F3 : Miscellaneous Test in the Application Menu. 4. Select F1 : Relay Test in the Miscellaneous Test. Locations Door Switch: Locations Page 871 Ignition Switch Lock Cylinder: Testing and Inspection TESTING AND INSPECTION Turn the ignition switch to "ON" while watching warning light. The light should flash 7 times and then go off. Specifications Compression Check: Specifications Compression Pressure 145 psi. kg/cm2 at 300 rpm Diagram Information and Instructions Headlamp Switch: Diagram Information and Instructions How to Identify Wiring Color-Coded Insulation Wire Color Wire Color Coding Service and Repair Constant Velocity Joint: Service and Repair Right Front Drive Shaft FRONT AXLE DRIVE SHAFT AND ASSOCIATED PARTS DISASSEMBLY NOTE: For the left side, follow the same steps as right side. Page 2126 Crankshaft Position Sensor: Testing and Inspection 1. Inspect the sensor O-ring for cracks or leaks. 2. Replace the O-ring if it is worn or damaged. 3. Lubricate the new O-ring with engine oil. 4. Install the lubricated O-ring. Page 4699 Part 3 Of 3 Page 6084 Wire Color Abbreviations The following abbreviations are used to identify wire colors in the circuit schematics: WHT................................... White YEL................................... Yellow BLK................................... Black BLU................................... Blue GRN................................... Green RED................................... Red ORN................................... Orange PNK................................... Pink BRN................................... Brown GRY................................... Gray PUR................................... Purple LT BLU................................... Light Blue LT GRN................................... Light Green Page 7583 2. Connect the short finder across the battery terminals and the load (component) side of the fuse terminal. 3. Close all switches in the circuit you're testing. 4. Turn on the short finder. This creates a pulsing magnetic field around the wiring between the fuse box and the short. 5. Beginning at the fuse box, slowly move the short finder along the circuit wiring. The meter will read current pulses through sheet metal and body trim. As long as the meter is between the fuse and the short, the needle will move with each current pulse. Once you move the meter past the point of the short, the needle will stop moving. Check the wiring and connectors in this area to locate the cause of the short. Testing For Continuity When testing for continuity at a connector without wire seals, you do not have to separate the two halves of the connector. Instead, probe the connector from the back. Always check both sides of the connector because dirty, corroded, and bent terminals can cause problems (no electrical contact = an open). 1. Disconnect the negative cable from the car battery. If you're using a DVOM, place it in the lowest "OHMS" range. Diagrams Front Door Trim Panel Locations A/T - Vehicle Speed Sensor Installation Precautions Vehicle Speed Sensor: Technical Service Bulletins A/T - Vehicle Speed Sensor Installation Precautions Install VSS Properly to Avoid Reman A/T Damage We can't emphasize enough how important it is to follow, to the letter, the installation instructions that come with a reman A/T. These instructions help ensure that you avoid damaging the A/T and score a successful repair. This is particularly true when it comes to installing the vehicle speed sensor (VSS). Step 6 of the instructions tells you to make sure its gear is fully engaged and the VSS is fully seated before you tighten the retaining bolt. If you don't install the VSS properly, the speed sensor gear will get stripped and the A/T will be seriously damaged. So don't take risks with your customer's vehicle. Always follow these instructions to the letter. You can rest assured you're doing the job right. Page 6088 Testing For A Short With A Self-Powered Test Light or DVOM 1. Remove the blown fuse and disconnect the battery and load. 2. Connect one lead of a self-powered test light or digital volt/ohmmeter (DVOM) (switched to the lowest "OHMS" range) to the fuse terminal on the load side. 3. Connect the other lead to a known good ground. 4. Beginning near the fuse box, wiggle the harness. Continue this at convenient points about six inches apart while watching the test light or DVOM. 5. If the self-powered test light goes on or the DVOM displays a low reading or no reading (zero), there is a short to ground in the wiring near that point. Testing for a Short with a Test Light or DVOM 1. Remove the blown fuse and disconnect the load. 2. Connect a test light or digital volt/ohmmeter (DVOM), switched to the appropriate DC volts range, across the fuse terminals to make sure voltage is present. You might have to turn the ignition switch to ON; check the schematic to see. 3. Beginning near the fuse box, wiggle the harness. Continue this at convenient points about six inches apart while watching the test light or DVOM. 4. Where the test light goes , or the DVOM voltage drops to zero, there is a short to ground in the wiring near that point. NOTE: Always use a DVOM on high impedance circuits. A test light may not glow (even with battery voltage present). Testing For A Short With A Short Circuit Locator (Short Finder) 1. Remove the blown fuse. Leave the battery connected. Page 4072 7. Connect inner cable to select lever. 8. Push lock into adjust end fitting attachment. 9. Install grommet. Component Locations Wheel Speed Sensor: Component Locations Under Rear of Vehicle (On Differential) Checking Pedal Height Brake Pedal Assy: Testing and Inspection Checking Pedal Height Checking Pedal Height The push rod serves as the brake pedal stopper when the pedal is fully released. Brake pedal height adjustment should be performed as follows: Adjust Brake Pedal 1. Measure the brake pedal height after making sure the pedal is fully returned by the pedal return spring. Pedal height must be measured after starting the engine and receiving it several times. Pedal Free Play: 6 - 10 mm (0.23 - 0.39 inch) Pedal Free Play: 173 - 185 mm (6.81 - 7.28 inch) NOTE: Pedal free play must be measured after turning off the engine and stepping on the brake pedal firmly five times or more. 2. If the measured value is not within the above range, adjust the brake pedal as follows: a. Disconnect the stoplight switch connector. b. Loosen the stoplight switch lock nut. c. Rotate the stoplight switch so that it moves away from the brake pedal. d. Loosen the lock nut (1) on the push rod. e. Adjust the brake pedal to the specified height by rotating the push rod in the appropriate direction. f. Tighten the lock nut to the specified torque. Torque: 20 Nm (15 ft. lbs.) g. Adjust the stoplight switch (2) to the specified clearance (between the switch housing and the brake pedal) by rotating the switch housing. Clearance: 0.5 - 1.0 mm (0.02 - 0.04 inch) NOTE: While adjusting the stoplight switch, make sure that the threaded part of the stoplight switch does not push the brake pedal. h. Tighten the stoplight switch lock nut. i. Connect the stoplight switch connector. Page 3022 This means the branch of the wire connects to another circuit. The arrow points to the name of the circuit branch where the wire continues. Page 6037 Fan Control Switch Page 1522 2. Install oil gallery and tighten the bolts in two steps, in the order shown in illustration. Torque: 1st step: 29 Nm (21 ft. lbs.) 2nd step: 55° - 65° 3. Install oil pipe with O-ring. - Torque: 10 Nm (89 inch lbs.) 4. Install oil strainer assembly with O-ring. Torque: 25 Nm (18 ft. lbs.) 5. Install crankcase with oil pan. Refer to installation procedure for Oil Pan and Crankcase. 6. Install cylinder head assembly. Refer to installation procedure for Cylinder Head. Page 5427 ^ Loosen the front subframe bolts. See the applicable service manual for more information. NOTE: The front wheels are being viewed from the rear of the vehicle. ^ Depending which way you need to shift the subframe, insert a pry bar between the subframe and body at both the front and rear positions of the subframe. NOTE: Be careful not to damage the vehicle. You could bend and damage the frame and/or body if you apply too much pressure. ^ Press on both pry bars to shift the subframe. It will move only a few millimeters. This should adjust the camber about 0.2-0.5°. ^ While holding the subframe in place, have an assistant torque the subframe bolts to their proper torque. Front Camber Adjustment, Strut Suspension ^ Raise the vehicle, and remove the front tires. ^ Loosen the damper pinch bolts and the flange nuts. ^ Adjust the camber by moving the bottom of the damper within the range of the damper pinch bolt free play. NOTE: Some vehicles have special pinch bolts that allow more adjustment. For more information, refer to the parts catalog. ^ Tighten the damper pinch bolts to the specified torque. ^ Reinstall the front wheels and lower the vehicle. Bounce the front of the vehicle several times to stabilize the suspension. Page 5265 10. Use the PGM Tester to check the broadcast code. Make sure the broadcast code matches the one you selected from the CD-ROM. WARRANTY CLAIM INFORMATION In warranty: The normal warranty applies. Failed Part: P/N 8-17087-655-0 H/C 4375820 Defect Code: 064 Contention Code: C01 Skill Level: Repair Technician Out of warranty: Any repair performed after warranty expiration may be eligible for goodwill consideration by the District Service Manager or your Zone Office. You must request consideration, and get a decision, before starting work. REPAIR PROCEDURE - ENGINE/BODY GROUND 1. Use the ETM for the appropriate year to locate these ground connectors: G101, G104, G105, G106 and G160. 2. Inspect each connector for corrosion or looseness. 3. Remove the bolt from any connector that is corroded or loose. Clean the terminal connector with a wire brush. File flat any solder bumps on the connector. 4. Clean the contact surface on the engine or body with a wire brush. 5. Replace the bolt if it is heavily corroded. Otherwise, clean it with a wire brush. 6. Apply lithium dielectric grease to both sides of the terminal connector. 7. Reinstall the bolt, torque it to 14 N.m (10 lb-ft). 8. Use the Smart Cable to reprogram the PCM with the latest software from the June 2001 or later HONDANET CD-ROM. Refer to Service Bulletin 99-005, Updating the Passport PCM, filed under Tools. 9. Use the PGM Tester to clear any DTCs. 10. Use the PGM Tester to check the broadcast code. Make sure the broadcast code matches the one you selected from the CD-ROM. WARRANTY CLAIM INFORMATION In warranty: The normal warranty applies. Failed Part: P/N 8-97086-823-0 Page 1621 6. Working from under the vehicle, unplug the 3P connector from the crankshaft position sensor. 7. Remove the crankshaft position sensor (one flange bolt). 8. Remove the crankshaft position sensor harness clamp from the engine (one flange nut). 9. Models With A/T: Remove the front and rear clamps for the ATF cooler lines. 10. Support the engine with a block of wood and a powertrain lift or commercially available jack as shown. Page 7944 the component if the component only has one connector, or by a capital letter (A, B, C, etc.) if the component has more than one connector. Below most connector numbers and component names are PHOTO and VIEW numbers. The PHOTO number refers to a photo in the back of the book that shows the connector's location on the car. The VIEW number refers to an illustration in the back of the book that shows the connector face, wire colors, connector cavity numbers, and other details. The connector cavity numbering sequence begins at the top left corner of the connector. Disregard any numbers molded into the connector housing. Wires Wires are identified by the abbreviated names of their colors; the second color is the color of the stripe. Wires are also identified by their location in a connector. The number "2" next to the male and female wire terminals at C416, for example, means those terminals join in cavity 2 of connector C416. Symbols A complete description of schematic symbols is given under wire color abbreviation. Power Distribution Schematics Power Distribution schematics show how power is supplied from the positive battery terminal to various circuits in the car. Refer to the Power Distribution section to get a more detailed picture of how power is supplied to the circuit you're working on. From Battery to Ignition Switch, Fuses, and Relays Individual circuit schematics begin with a fuse. The first half of Power Distribution, however, shows the wiring "upstream" between the battery Page 1167 Brake Fluid: Service and Repair Leakage of Brake Fluid Leakage of Brake Fluid With engine idling, set shift lever in the neutral position and continue to depress brake pedal at a constant pedal application force. Should the pedal stroke become deeper gradually, a leakage from the hydraulic pressure system is possible. Make sure by visual check that there is no leak. Page 5295 and the fuses. From Fuses to Relays and Components The second half of Power Distribution shows the wiring "From Fuses to Relays and Components." This can speed your troubleshooting by showing which circuits share fuses. If Power Distribution shows that an inoperative circuit and another circuit share a fuse, check a component in the other circuit. If it works, you know the fuse is good and power is available to the inoperative circuit. Ground Distribution Schematics Page 3743 4WD Control Unit: Diagnostic Aids Before Troubleshooting Before Troubleshooting See: Service Precautions/Vehicle Damage Warnings/Tips and Precautions 1. Check applicable fuses in the appropriate fuse/relay box. 2. Check the battery for damage, state of charge, and clean and tight connections. CAUTION: Do not quick-charge a battery unless the battery ground cable has been disconnected, otherwise you will damage the alternator diodes. - Do not attempt to crank the engine with the battery ground cable loosely connected or you will severely damage the wiring. While You're Working 1. Make sure connectors are clean, and have no loose terminals or receptacles. 2. Make sure that connectors without wire seals are packed with dielectric (silicone) grease. Part Number: 08798-9001. 3. When connecting a connector, push it until it "clicks" into place. CAUTION: Do not pull on the wires when disconnecting a connector. Pull only on the connector housings. - Most circuits include solid-state devices. Test the voltages in these circuits only with a 10-megaohm or higher impedance digital multi meter. Never use a test light or analog meter on circuits that contain solid-state devices. Damage to the devices may result. Five-Step Troubleshooting 1. Verify The Complaint Turn on all the components in the problem circuit to check the accuracy of the customer complaint. Note the symptoms. Do not begin disassembly or testing until you have narrowed down the problem area. 2. Analyze The Schematic Look up the schematic for the problem circuit. Determine how the circuit is supposed to work by tracing the current paths from the power source through the circuit components to ground. Also, trace circuits that share wiring with the problem circuit. The names of circuits that share the same fuse, ground, or switch, and so on, are referred to in each circuit schematic. Try to operate any shared circuits you didn't check in step 1. If the shared circuits work, the shared wiring is OK, and the cause must be in the wiring used only by the problem circuit. If several circuits fail at the same time, the fuse or ground is a likely cause. Based on the symptoms and your understanding of the circuit's operation, identify one or more possible causes. 3. Isolate The Problem By Testing The Circuit Make circuit tests to check the diagnosis you made in step 2. Keep in mind that a logical, simple procedure is the key to efficient troubleshooting. Test for the most likely cause of failure first. Try to make tests at points that are easily accessible. 4. Fix The Problem Once the specific problem is identified, make the repair. Be sure to use proper tools and safe procedures. 5. Make Sure The Circuit Works Turn on all components in the repaired circuit in all modes to make sure you've fixed the entire problem. If the problem was a blown fuse, be sure to test all of the circuits on that fuse. Make sure no new problems turn up and the original problem does not recur. Page 2508 This sample Ground Distribution schematic shows all of the components that share two ground points. Components A solid border line means the entire component is shown. A broken border line indicates that only part of the component is shown. Page 932 Transmission Position Switch/Sensor: Service and Repair REMOVAL 1. Place selector lever in neutral. 2. Disconnect battery ground cable. 3. Remove mode switch cover (1). 4. Disconnect selector lever (2) from the mode switch. 5. Remove bracket with cable (3). 6. Disconnect transmission harness from the mode switch connector (4). 7. Remove bracket with mode switch connector from the transmission case. 8. Remove mode switch connector (4) from the bracket (5). 9. Remove two mode switch bolts and nut then remove mode switch (6). INSTALLATION To install, follow the removal steps in the reverse order, noting the following points; 1. Torque Mode switch bolt: 13 Nm (113 inch lbs.) Selector lever nut: 23 Nm (17 ft. lbs.) 2. Mode switch setting procedure. Perform either of the following adjustment procedures: Procedure 1 a. Place selector lever in neutral. b. Remove selector lever from the mode switch. c. Remove the mode switch cover. d. Loosen the two 10 mm screws. e. Rotate the mode switch until the slot in the mode switch housing aligns with the selector shaft bushing, and insert a 3/32 inch (2.4 mm) drill bit or punch (1) into the slot. f. Tighten the screws to 13 Nm (113 inch lbs.). g. After completing adjustment, snap the mode switch cover into place. h. Reinstall the selector lever. Procedure 2 a. Place selector lever in neutral. b. Disconnect transmission harness connector from mode switch connector. Description and Operation Clutch Master Cylinder: Description and Operation MASTER CYLINDER The master cylinder converts mechanical energy into hydraulic energy. Depressing the clutch pedal causes the push rod to move against the piston to close the return port. Clutch fluid is forced out of the master cylinder. Releasing the clutch pedal causes the return spring to force the piston back to its original position. Page 8241 Page 71 2. Connect the short finder across the battery terminals and the load (component) side of the fuse terminal. 3. Close all switches in the circuit you're testing. 4. Turn on the short finder. This creates a pulsing magnetic field around the wiring between the fuse box and the short. 5. Beginning at the fuse box, slowly move the short finder along the circuit wiring. The meter will read current pulses through sheet metal and body trim. As long as the meter is between the fuse and the short, the needle will move with each current pulse. Once you move the meter past the point of the short, the needle will stop moving. Check the wiring and connectors in this area to locate the cause of the short. Testing For Continuity When testing for continuity at a connector without wire seals, you do not have to separate the two halves of the connector. Instead, probe the connector from the back. Always check both sides of the connector because dirty, corroded, and bent terminals can cause problems (no electrical contact = an open). 1. Disconnect the negative cable from the car battery. If you're using a DVOM, place it in the lowest "OHMS" range. Page 278 Axle Disconnect Control Control Unit: Testing and Inspection AXLE DISCONNECT CONTROLLER 1. Connect 12 V with terminal (3) and the ground with the terminal (6). 2. Send the signal to the terminal (4). 2WD - 4WD less than 2.4 V 4WD - 2WD more than 9.0 V 3. Confirm the output signal from the terminals (1) & (2) (2 seconds output). Page 6115 Ground - "G" Shielding Sheilding This represents RFI (Radio Frequency Interference) shielding around a wire. The shielding is always connected to ground. Splices Page 1064 Air Filter Element: Service and Repair Cleaning Method Air Cleaner Element Tap the air cleaner filter gently so as not to damage the paper filter, or clean the element by blowing with compressed air of about 490 kPa (71 psi) from the clean side if it is extremely dirty. Page 2795 Powertrain Control Module: Description and Operation PCM Function PCM Function The PCM supplies either 5 or 12 volts to power various sensors or switches. The power is supplied through resistances in the PCM which are so high in value that a test light will not light when connected to the circuit. In some cases, even an ordinary shop voltmeter will not give an accurate reading because its resistance is too low. Therefore, a digital voltmeter with at least 10 megohms input impedance is required to ensure accurate voltage readings. Tool J 39200 meets this requirement. The PCM controls output circuits such as the injectors, fan relays, etc., by controlling the ground or the power feed circuit through transistors or through either of the following two devices: - Output Driver Module (0DM) - Quad Driver Module (QDM) Deterioration of Brake Fluid Brake Fluid: Service and Repair Deterioration of Brake Fluid Deterioration of Brake Fluid Using any other brake fluid than specified or brake fluid with mineral oil or water mixed in will drop the boiling point of brake fluid. It may, in turn, result in vapor lock or deteriorated rubber parts of the hydraulic system. Be sure to change the brake fluid at specified intervals. If the rubber parts are deteriorated, remove all the system parts and clean them with alcohol. Prior to reassembly, dry the cleaned parts with air to remove the alcohol. Replace all the hoses and rubber parts of the system. Page 601 20. Using a DVOM, check the voltage between the reference voltage pin for each sensor and ground. ^ If the sensor circuits all read 5.0 volts, go to step 22. ^ If any sensor circuit is above or below 5.0 volts, go to step 21. 21. Troubleshoot for an internal short in another sensor or a PCM malfunction. ^ To find the sensor with an internal short, monitor the reference voltage, and disconnect each sensor (FTPS, EGR, MAP TPS, CKP and CMP) one at a time until the reference voltage reads 5.0 volts. Replace that sensor, and repeat step 14. ^ To find a malfunctioning PCM, replace it with a known-good PCM. If all three sensors (APP Sensor 1, APP Sensor 2, and APP Sensor 3) are within range, the original PCM is faulty; replace it and repeat step 14. 22. Using a jumper wire, connect the reference voltage of each circuit to its signal input, and view the APP Sensor values in the Engine Data List. APP Sensor 1 should have a value of 99%, and APP Sensor 2 and APP Sensor 3 should each have a value of 0%. ^ If the values are not as specified, troubleshoot for high resistance on the signal input or a PCM malfunction. Repair the circuit or replace the PCM, then repeat step 14. ^ If the values are as specified, the problem may be intermittent. Disconnect the 10 P connector from the modified APPS, and connect it to the new APPS; then repeat step 14. Wiggle the APPS wires as you go through the adjustment procedure to find the intermittent problem. 23. Install the accelerator pedal assembly, and torque the bolts to 10 N.m (7 lb-ft). Page 7377 Each schematic represents one circuit. A circuit's wires and components are arranged to show current flow, from power at the top of the page, to ground, at the bottom. Shared Circuits Other circuits may share power or ground terminals or wiring with the circuit shown. A wire that connects one circuit to another, for example, is cut short and has an arrowhead at the end of it pointing in the direction of current flow. Next to the arrowhead is the name of the circuit or component which shares that wiring. To quickly check shared wiring, check the operation of a component it serves. If that component works, you know the shared wiring is OK. Connectors All in-line and junction connectors are numbered (C725, C416, etc.). Component connectors are not numbered but are identified either by the name of Locations Diode: Locations Component Locations Oxygen Sensor: Component Locations 95. Right Front Exhaust Downpipe Right Front Exhaust Downpipe 93. Left Front Exhaust Downpipe Left Front Exhaust Downpipe Page 3616 Crankshaft Position Sensor: Testing and Inspection 1. Inspect the sensor O-ring for cracks or leaks. 2. Replace the O-ring if it is worn or damaged. 3. Lubricate the new O-ring with engine oil. 4. Install the lubricated O-ring. Page 5748 - Insert the pop nut into a hole on the pop nut test plate. Make sure the pop nut is seated against the plate. - Squeeze and hold the installer's trigger until the mandrel reverses and unthreads the pop nut. - Measure the diameter of the expanded (crush) section of the installed pop nut; it should be at least 15 mm. If you need more practice, install another pop nut on the test plate. 15. Install pop nuts in the holes you drilled on the frame (six holes for all 1998-99 models and some 2000 models, five holes for some 2000 models and all 2001-02 models). Make sure each pop nut is seated against the frame before you pull the trigger. Continue holding the trigger until the mandrel reverses direction. Once reversed, pull back slightly, and the mandrel unthreads the pop-nut. Diagrams License Plate Garnish Locations Fuel Fill Door Page 6820 10. Remove the 2 screws through the access hole and pull out the glass upward. 11. Remove the window regulator. - Disconnect the window regulator motor harness connector, if equipped with power windows. 12. Remove the glass run. - Pull the glass run (6) out from the door frame groove. Installation To install, follow the removal steps in the reverse order, noting the following points: Page 1589 5. Use the J-8062 valve spring compressor and J-42898 valve spring compressor adapter to remove split collar. 6. Remove valve spring. 7. Remove valve. 8. Remove oil controller and spring lower seat. 9. Remove the valve guide using the J-42899 valve guide replacer. Inspection and Repair Valve Spring Caution: Visually inspect the valve springs and replace them if damage or abnormal wear is evident. 1. Measure the free height of the springs. The springs must be replaced if the free height is below the specified limit. Standard: 44.6 mm (1.756 inch) Limit: 43.6 mm (1.717 inch) Accelerator Pedal Position Sensor - MIL ON/DTC's Set Technical Service Bulletin # 01-047 Date: 010814 Accelerator Pedal Position Sensor - MIL ON/DTC's Set 01-047 August 14, 2001 Applies To: 2000-01 Passport - ALL MIL Comes On With Accelerator Pedal Position Sensor DTC(s) P1271, P1273, P1275, P1280, and/or P1285 SYMPTOM The MIL is on with DTC P1271, P1273, P1275, P1280, or P1285 (various accelerator pedal position sensor problems) stored. The REDUCED POWER indicator may also be on; and the engine may occasionally idle too high, or the idle may fluctuate. PROBABLE CAUSE Contaminated grease on the potentiometer circuit board of the accelerator pedal position sensor (APPS) causes high resistance in the APPS circuit. CORRECTIVE ACTION Replace and adjust the APPS, remove all grease from the accelerator link, and clean the APPS harness connector and connector C123. PARTS INFORMATION Accelerator Pedal Position Sensor: P/N 8-97193-713-0, H/C 6198311 REQUIRED MATERIALS CAIG DeoxIT D5-S6 Contact Cleaner: P/N 341-200 (available from www.partsexpress.com) or Permatex Electrical Contact Cleaner: Permatex P/N 24379 WARRANTY CLAIM INFORMATION In warranty: The normal warranty applies. Operation Number: 122114 Flat Rate Time: 0.5 hour Failed Part: P/N 8-97220-540-0 H/C 6202436 Defect Code: 091 Contention Code: C99 Template ID: 01-047A Skill Level: Repair Technician Out of warranty: Any repair performed after warranty expiration may be eligible for goodwill consideration by the District Service Manager or your Zone Office. You must request consideration, and get a decision, before starting work. Page 3338 The connector cavity number is listed next to each terminal on the circuit schematic. The cavity / terminal shown is # 6. Diodes A rectifier diode works like a one way valve. It allows current to flow only in the direction of the arrow. A Zener diode blocks reverse current at normal voltages just like a rectifier diode. At high voltages, however, a Zener diode allows current to flow in reverse. Fuses Locations Auto Light Sensor Connector Ambient Light Sensor: Locations Auto Light Sensor Connector Behind Gauge Assembly Page 6229 Receiver Dryer: Service and Repair Removal 1. Disconnect the battery ground cable. 2. Discharge and recover refrigerant. 3. Remove radiator grille. 4. Disconnect pressure switch connector. 5. Disconnect refrigerant line. - When removing the line connected pant, the connecting part should immediately be plugged or capped to prevent foreign matter from being mixed into the line. 6. Remove bracket bolt. 7. Remove receiver/drier. - Loosen the bolt, then, using care not to touch or bend the refrigerant line, carefully pull out the receiver/drier. Installation To install, follow the removal steps in the reverse order, noting the following points: 1. If installing a new receiver/drier, be sure to add 30cc (1.0 fl.oz.) of new compressor oil to a new one. 2. Put the receiver/drier in the bracket and connect with the refrigerant line. Check that no excessive force is imposed on the line. Fasten the bracket bolt to the receiver/drier. 3. Tighten the refrigerant line to the specified torque. Torque: 6 Nm (52 lb in) 4. 0-rings cannot be reused. Always replace with new ones. 5. Be sure to apply new compressor oil to the O-ring when connecting the refrigerant line. Page 6911 3. Remove the waterproof sheet. - Remove the waterproof sheet, taking special care so as not to break it. 4. Remove the hatchgate lock. - Disconnect the lock link and connector and remove the 3 fixing bolts. 5. Remove the key cylinder. - Disconnect the lock links. - Remove the key cylinder retaining clip with screw driver to remove the key cylinder. 6. Remove the hatchgate lock actuator assembly. - Disconnect the actuator harness connector. - Remove the 2 bolts holding hatchgate lock actuator assembly from inside. 7. Remove the outside handle. - Remove the 2 bolts holding the outside handle from inside. 8. Remove the tailgate lock assembly. - Remove the 3 screws holding the lock assembly. Installation To install, follow the removal steps in the reverse order, noting the following points: Component Locations Page 7486 Splices Splices are shown as a dot. Their location and the number of wires may vary depending on the harness manufacturer. Switches Switches These switches move together; the broken straight line between them means they are mechanically connected. Other types of switches are controlled by a coil or a solid state circuit. Unless otherwise noted, all switches are shown in their normal (rest) position, with power off. Terminal "T" Page 5294 the component if the component only has one connector, or by a capital letter (A, B, C, etc.) if the component has more than one connector. Below most connector numbers and component names are PHOTO and VIEW numbers. The PHOTO number refers to a photo in the back of the book that shows the connector's location on the car. The VIEW number refers to an illustration in the back of the book that shows the connector face, wire colors, connector cavity numbers, and other details. The connector cavity numbering sequence begins at the top left corner of the connector. Disregard any numbers molded into the connector housing. Wires Wires are identified by the abbreviated names of their colors; the second color is the color of the stripe. Wires are also identified by their location in a connector. The number "2" next to the male and female wire terminals at C416, for example, means those terminals join in cavity 2 of connector C416. Symbols A complete description of schematic symbols is given under wire color abbreviation. Power Distribution Schematics Power Distribution schematics show how power is supplied from the positive battery terminal to various circuits in the car. Refer to the Power Distribution section to get a more detailed picture of how power is supplied to the circuit you're working on. From Battery to Ignition Switch, Fuses, and Relays Individual circuit schematics begin with a fuse. The first half of Power Distribution, however, shows the wiring "upstream" between the battery Page 2019 Test Equipment CAUTION: Most circuits include solid-state devices. Test the voltages in these circuits only with a 10-megaohm or higher impedance digital multimeter. Never use a test light or analog meter on circuits that contain solid-state devices. Damage to the devices may result. Test Light and DVOM On circuits without solid-state devices, use a test light to check for voltage. A test light is made up of a 12 volt bulb with a pair of leads attached. After grounding one lead, touch the other lead to various points along the circuit where voltage should be present. The bulb will go on if there is voltage at the point being tested. If you need to know how much voltage is present, use a digital volt/ohmmeter (DVOM). Self-Powered Test Light and DVOM Use a self-powered test light to check for continuity. This tool is made up of a light bulb, battery, and two leads. To test it, touch the leads together: the light should go on. Use a self-powered test light only on an unpowered circuit. First, disconnect the battery, or remove the fuse that feeds the circuit you are working on. Select two points in the circuit between which you want to check continuity. Connect one lead of the self-powered test light to each point. If there is continuity, the test light's circuit will be completed, and the light will go on. If, in addition, you need to know exactly how much resistance there is between two points, use a digital volt/ohmmeter (DVOM). In the "OHMS" range, the DVOM will measure resistance between two points along a circuit. Low resistance means good continuity. Diodes and solid-state devices in a circuit can make a DVOM give a false reading. To check a reading, reverse the leads, and take a second reading. If the readings differ, the component is affecting the measurement. Jumper Wire Use a jumper wire to bypass an open circuit. A jumper wire is made up of an in-line fuse holder connected to a set of test leads. It should have a five ampere fuse. Never connect a jumper wire across a short circuit. The direct battery short will blow the fuse. Short Finder (Short Circuit Locator) Short finders are available to locate shorts to ground. The short finder creates a pulsing magnetic field in the shorted circuit which you can follow to the location of the short. To order any test equipment shown above, contact your local tool supplier. For a list of suppliers and tool numbers, refer to Honda Required Special Tools and Equipment Service Bulletin. Page 2698 Manifold Pressure/Vacuum Sensor: Description and Operation Manifold Absolute Pressure (MAP) Sensor The manifold absolute pressure (MAP) sensor responds to changes in intake manifold pressure (vacuum). The MAP sensor signal voltage to the PCM varies from below 2 volts at idle (high vacuum) to above 4 volts with the ignition ON, engine not running or at wide-open throttle (low vacuum). The MAP sensor is used to determine the following: - Manifold pressure changes while the linear EGR flow test diagnostic is being run. Refer to DTC P0401. - Barometric pressure (BARO). If the PCM detects a voltage that is lower than the possible range of the MAP sensor, DTC P0107 will be set. A signal voltage higher than the possible range of the sensor will set DTC P0108. An intermittent low or high voltage will set DTC P1107, respectively. The PCM can detect a shifted MAP sensor. The PCM compares the MAP sensor signal to a calculated MAP based on throttle position and various engine load factors. If the PCM detects a MAP signal that varies excessively above or below the calculated value, DTC P0106 will set. Page 723 Power Steering Pressure Switch: Locations 27. Left Side of Engine Left Side Of Engine Page 4330 11. Unwind the boot band tool, and cut off the excess 5 to 10 mm (0.2 to 0.4 in.) from the clip. 12. Secure the end of the boot band by tapping it down over the clip with a hammer. 13. Make sure that the boot band and clip do not interfere with anything and that the band does not move. 14. If necessary, repeat steps 5 through 13 to install the boot band on the small end of the boot. Disclaimer Upper Ball Joint: Service and Repair Upper Ball Joint Removal REMOVAL 1. Raise the vehicle and support the frame with suitable safety stands. 2. Remove the speed sensor from the knuckle. 3. Remove upper ball joint nut and cotter pin, then use remover J-36831 to remove the upper ball joint from the knuckle. CAUTION: Be careful not to damage the ball joint boot. 4. Remove bolt and nut. Alignment Hatchgate Lock Trunk / Liftgate Lock Cylinder: Service and Repair Hatchgate Lock Tailgate Lock and Hatchgate Lock (LWB) Removal 1. Disconnect the battery ground cable. 2. Remove the tailgate trim cover assembly (3). - Remove the 2 screws (2) holding the hatch gate lock assembly (1) first, and pull up the trim cover while detaching the clips from tailgate panel. 3. Remove the waterproof sheet. - Remove the waterproof sheet, taking special care so as not to break it. 4. Remove the hatchgate lock. - Disconnect the lock link and connector and remove the 3 fixing bolts. 5. Remove the key cylinder. - Disconnect the lock links. - Remove the key cylinder retaining clip with screw driver to remove the key cylinder. 6. Remove the hatchgate lock actuator assembly. - Disconnect the actuator harness connector. - Remove the 2 bolts holding hatchgate lock actuator assembly from inside. 7. Remove the outside handle. - Remove the 2 bolts holding the outside handle from inside. Removal and Installation Valve: Service and Repair Removal and Installation Valve Stem Oil Controller, Valve Spring and Valve Guide Removal 1. Disconnect battery ground cable. 2. Drain engine oil. - Drain engine coolant. 3. Remove cylinder head assembly. Refer to removal procedure for Cylinder Head. 4. Remove camshaft. Refer to removal procedure for Camshaft. 5. Remove tappets with shim. Note: Do not damage shim surface. 6. Remove valve springs using J-8062 valve spring compressor and J-42898 valve spring compressor adapter then remove upper valve spring seat and lower seat. 7. Remove oil controller using J-37281 oil controller remover, remove each valve stem oil controller. 8. Remove valve guide using J-37985 valve guide replacer. Installation 1. Install valve guide using J-42899 valve guide installer. 2. Install oil controller using J-38537 oil controller installer. 3. Install lower valve spring seat, valve spring and upper valve spring seat then put split collars on the upper spring seat, using J-8062 valve spring compressor and J-42898 valve spring compressor adapter to install the split collars. 4. Install tappet with shim. 5. Install camshaft assembly. Refer to installation procedure for Camshaft. 6. Install cylinder head assembly. Refer to installation procedure for Cylinder Head. 7. Fill engine oil until full level. 8. Fill engine coolant. Locations Page 6972 Air Bag(s) Arming and Disarming: Service Precautions Wiring Precautions Wiring Precautions SRS wiring can be identified by special yellow outer covering (except the SRS indicator light circuit). Never attempt to modify, splice, or repair SRS wiring. If there is an open or damage in SRS wiring, replace the harness. Be sure to install the harness wires so that they are not pinched, or interfere with other parts. Make sure all SRS ground locations are clean, and grounds are securely fastened for optimum metal-to-metal contact. Poor grounding can cause intermittent problems that are difficult to diagnose. Page 113 it is located, and what it connects to. Use the Connector Views to help locate the proper cavity when you need to probe a connector. It can be especially helpful if the connector has more than one wire of the same color. A dash symbol (-) indicates that the cavity is empty. Connector views can also be used to help diagnose multiple symptoms in separate circuits which could be caused by a single problem in a connector shared by those circuits. Here's an example: 1. Pick one of the multiple symptoms and look up the schematic for that circuit. 2. Make a list of all the in-line and fuse box connectors in that schematic , 3. Then, in the Connector Views, look up each connector on your list to see if circuits related to the other symptoms run through one of them. If they do, inspect that connector for the problem. Example: The blower, rear window defogger, and the windshield wiper don't work. List all in-line and fuse box connectors in the blower controls circuit and then check the Connector View (see the sample). You find that C324 is common to the blower controls, rear window defogger, and wiper/washer, so you inspect C324 and find the problem, bent terminals. Finding Component/Connector Locations Finding Component/Connector Locations To see where a component or connector is located on the car, look up its photo number in the "Component Location". The photo will also tell you the color of the connector, and how many cavities it has. Page 1348 3. Photocopy the template that is shown. Cut out the template. Page 766 Vehicle Speed Sensor: Description and Operation Vehicle Speed Sensor (VSS) The PCM determines the speed of the vehicle by converting a plusing voltage signal from the vehicle speed sensor (VSS) into miles per hour. The PCM uses this signal to operate the cruise control, speedometer, and the TCC and shift solenoids in the transmission. For more information on the TCC and shift solenoids, refer to 4L30-E Automatic Transmission (Transmission Control System Diagnosis). How the Circuit Works The VSS generates a signal for the speedometer. The speedometer consists of its own speed sensor, an ammeter (to move the needle), stepper motor (to turn the odometer), and a driving circuit (printed circuit board). The VSS is mounted to the transmission. The transmission pinion shaft generates four pulses per one rotation. The rate at which the pulses are generated indicates the vehicle speed. The speed sensor in the speedometer uses the pulses to control how far and fast the needle moves and to send vehicle speed information (4096 pulses per mile) to the ECM or PCM. Locations Relay Box: Locations Page 3306 2. Connect the short finder across the battery terminals and the load (component) side of the fuse terminal. 3. Close all switches in the circuit you're testing. 4. Turn on the short finder. This creates a pulsing magnetic field around the wiring between the fuse box and the short. 5. Beginning at the fuse box, slowly move the short finder along the circuit wiring. The meter will read current pulses through sheet metal and body trim. As long as the meter is between the fuse and the short, the needle will move with each current pulse. Once you move the meter past the point of the short, the needle will stop moving. Check the wiring and connectors in this area to locate the cause of the short. Testing For Continuity When testing for continuity at a connector without wire seals, you do not have to separate the two halves of the connector. Instead, probe the connector from the back. Always check both sides of the connector because dirty, corroded, and bent terminals can cause problems (no electrical contact = an open). 1. Disconnect the negative cable from the car battery. If you're using a DVOM, place it in the lowest "OHMS" range. Page 5405 ^ Loosen the front subframe bolts. See the applicable service manual for more information. NOTE: The front wheels are being viewed from the rear of the vehicle. ^ Depending which way you need to shift the subframe, insert a pry bar between the subframe and body at both the front and rear positions of the subframe. NOTE: Be careful not to damage the vehicle. You could bend and damage the frame and/or body if you apply too much pressure. ^ Press on both pry bars to shift the subframe. It will move only a few millimeters. This should adjust the camber about 0.2-0.5°. ^ While holding the subframe in place, have an assistant torque the subframe bolts to their proper torque. Front Camber Adjustment, Strut Suspension ^ Raise the vehicle, and remove the front tires. ^ Loosen the damper pinch bolts and the flange nuts. ^ Adjust the camber by moving the bottom of the damper within the range of the damper pinch bolt free play. NOTE: Some vehicles have special pinch bolts that allow more adjustment. For more information, refer to the parts catalog. ^ Tighten the damper pinch bolts to the specified torque. ^ Reinstall the front wheels and lower the vehicle. Bounce the front of the vehicle several times to stabilize the suspension. Page 5468 4. Remove the fuel pressure regulator from the fuel rail. 5. Remove the fuel return line from the regulator. 6. Install the new fuel pressure regulator in the reverse order of removal. 7. Use the Smart Cable to reprogram the PCM with the latest software from the June 2001 or later HONDANET CD-ROM. Refer to Service Bulletin 99-005, Updating the Passport PCM, filed under Tools. 8. Use the PGM Tester to clear any DTCs. 9. Use the PGM Tester to check the broadcast code. Make sure the broadcast code matches the one you selected from the CD-ROM. WARRANTY CLAIM INFORMATION In warranty: The normal warranty applies. Failed Part: P/N 8-17113-398-0 H/C 5504386 Defect Code: 092 Contention Code: C99 Skill Level: Repair Technician Out of warranty: Any repair performed after warranty expiration may be eligible for goodwill consideration by the District Service Manager or your Zone Office. You must request consideration, and get a decision, before starting work. REPAIR PROCEDURE - POWER STEERING SWITCH 1. Drain the power steering fluid out of the system. 2. Remove the power steering fluid reservoir. Clean the reservoir with solvent, then with soap and water. Rinse and dry it thoroughly. 3. Reinstall the reservoir. Do not connect the return hose. 4. Remove the power steering pressure switch, then clean it with brake cleaner and a scraper. Reinstall the switch, and torque it to 20 N.m (14 lb-ft). 5. Cover the unconnected end of the reservoir with your finger, then fill the reservoir with Dexron III ATF Page 145 - Engine Coolant Temperature - Crankshaft Position - Exhaust Oxygen Content - Electronic Ignition - Manifold Absolute Pressure - Battery Voltage - Throttle Position - Vehicle Speed - Fuel Pump Voltage - Power Steering Pressure - Intake Air Temperature - Mass Air Flow - Engine knock - Camshaft Position Outputs - Systems Controlled - EVAP Canister Purge - Exhaust Gas Recirculation (EGR) - Ignition Control - Fuel Control - ION Sensing Module - Electric Fuel Pump - Air Conditioning - Diagnostics Malfunction Indicator Lamp - Data Link Connector (DLC) - Data Output - Transmission Control Module PCM Voltage Description PCM Voltage Description The PCM supplies a buffered voltage to various switches and sensors. It can do this because resistance in the PCM is so high in value that a test light may not illuminate when connected to the circuit. An ordinary shop voltmeter may not give an accurate reading because the voltmeter input impedance is too low. Use a 10 megohms input impedance digital voltmeter (such as J 39200) to assure accurate voltage readings. The input/output devices in the PCM include analog-to-digital converters, signal buffers, counters, and special drivers. The PCM controls most components with electronic switches which complete a ground circuit when turned "ON." These switches are arranged in groups of 4 and 7, called either a surface-mounted quad driver module (QDM), which can independently control up to 4 output terminals, or QDMs which can independently control up to 7 outputs. Not all outputs are always used. Powertrain Control Module (PCM) Powertrain Control Module (PCM) The powertrain control module (PCM) is located in the passenger compartment below the center console. The PCM controls the following: - Fuel metering system. - Transmission shifting (automatic transmission only). - Ignition timing. - On-board diagnostics for powertrain functions. The PCM constantly observes the information from various sensors. The PCM controls the systems that affect vehicle performance. The PCM performs the diagnostic function of the system. It can recognize operational problems, alert the driver through the MIL (Check Engine lamp), and store diagnostic trouble codes (DTCs). DTCs identify the problem areas to aid the technician in making repairs. 58X Reference PCM Input 58X Reference PCM Input The powertrain control module (PCM) uses this signal from the crankshaft position (CKP) sensor to calculate engine RPM and crankshaft position at all engine speeds. The PCM also uses the pulses on this circuit to initiate injector pulses. If the PCM receives no pulses on this circuit, DTC P0337 will set. The engine will not start and run without using the 58X reference signal. Page 3459 7. Modify the original APPS by cutting the connector housing off of the sensor. 8. Connect the 10P connector to the modified APPS connector housing. 9. Using a DVOM, check the voltage between the reference voltage pin for each sensor and ground. ^ If the sensor circuits all read 5.0 volts, go to step 11. ^ If any sensor circuit is above or below 5.0 volts, go to step 10. 10. Troubleshoot for an internal short in another sensor or a PCM malfunction. ^ To find the sensor with an internal short, monitor the incorrect reference voltage, and disconnect each sensor (FTPS, EGR, MAP, TPS, CKP, and CMP) one at a time until the reference voltage reads 5.0 volts. Replace that sensor, and repeat step 3. ^ To find a malfunctioning PCM, replace it with a known-good PCM. If all three sensors (APP Sensor 1, APP Sensor 2, and APP Sensor 3) are within range, the original PCM is faulty; replace it and repeat step 3. Page 6647 Manually Removing a Jammed Magazine (Passport only) One-piece door model: 1. Open the changer door. 2. Check to see if all the trays are in the magazine. ^ If a tray is stuck in the changer, replace the changer. ^ If all the trays are in the magazine, place the changer in a horizontal position, and insert a thin stainless steel ruler or a "Slim Jim" under the magazine, about 1/2" from the right side of the opening. 3. Push the ruler in until it presses against the eject lever at the back of the unit. 4. Slowly remove the ruler and magazine at the same time. Two-piece door model: 1. Remove the changer from the vehicle. 2. Remove the top cover plate from the changer, and inspect for a jammed tray. ^ If a tray is stuck in the changer, replace the changer. ^ If all the trays are in the magazine, place the changer in a horizontal position, and insert a thin stainless steel ruler or a "Slim Jim" under the magazine, about 1/2" from the right side of the opening. 3. Push the ruler in until it presses against the eject lever at the back of the unit. 4. Slowly remove the ruler and magazine at the same time. Handling and Inspecting Compact Discs Page 6909 8. Remove the tailgate lock assembly. - Remove the 3 screws holding the lock assembly. Installation To install, follow the removal steps in the reverse order, noting the following points: 1. When setting up links, pay attention to the position and direction of the links. 2. Apply chassis grease to the lock assembly and striker moving surface. 3. Check that the tailgate lock operates correctly after installing it. 4. Tighten the hatchgate lock assembly fixing bolts to the specified torque. Torque 7 Nm (61 lb in) Page 373 Parking Brake Warning Switch: Description and Operation The brake system warning light goes on to alert the driver that the parking brake is applied or that the brake fluid is low. It also lights as a bulb test when the engine is cranked. With the ignition switch in ON or START, battery voltage is applied through fuse 11 to the brake system warning light. When the parking brake is applied, the parking brake switch closes and provides a ground for the light. The brake system warning light goes on to remind the driver that the parking brake is applied. Page 553 This sample Ground Distribution schematic shows all of the components that share two ground points. Components A solid border line means the entire component is shown. A broken border line indicates that only part of the component is shown. Page 7825 Terminals - "T" Each "T" terminal (ring type) is numbered for reference and location. A "T" terminal is secured with a screw or bolt. Wires Adjustments Clutch Switch: Adjustments 1. Turn the clutch switch (1) until the switch plunger is fully retracted against the clutch pedal arm. 2. Adjust clutch switch by backing it out half a turn and measure the clearance (4) between the clutch pedal arm (3) and the clutch switch. 3. Lock the lock nut (2). 4. Connect clutch switch connector. Clutch Switch (bolt) and Clutch Pedal Clearance 0.5 - 1.5 mm (0.020 - 0.059 in) Locations Relay Box: Locations Locations Page 67 The wire insulation has one color or one color with another color stripe. The second color is the stripe. Specifications Exhaust Manifold: Specifications Exhaust Manifold LH 57 Nm RH 57 Nm Page 819 1. Install the MAF sensor on the air cleaner with the clamp. 2. Install the intake air duct and the clamp on the MAF sensor. 3. Tighten the clamps to secure the MAF sensor to the intake air duct and the air cleaner. 4. Connect the MAF electrical connector. 5. Connect the negative battery cable. Page 7013 4. Remove me sunroof switch (With sunroof). - Pry the clip positions free from the sunroof switch bracket and disconnect the connector. 5. Remove the sunvisors. - Remove the fixing screws and pull out the sunvisor holder (1) to remove it. - Disconnect the vanity mirror illumination connector, (if so equipped) 6. Remove the sunroof finisher (With sunroof). 7. Remove the headlining. - Remove the headlining fixing clips. Installation To install, follow the removal steps in the reverse order, noting the following points. 1. Install the headlining so that the fixing clips will not come off. Page 6893 Rear Hatchgate (LWB) Page 4593 This sample Ground Distribution schematic shows all of the components that share two ground points. Components A solid border line means the entire component is shown. A broken border line indicates that only part of the component is shown. Page 1508 The size mark (1) for piston outside diameter is represented as shown in Figure. Outside Diameter Size Mark A: 93.360 mm - 93.370 mm (3.6756 inch - 3.6760 inch) Size Mark B: 93.371 mm 93.380 mm (3.6760 inch - 3.6764 inch) Size Mark C: 93.381 mm - 93.390 mm (3.6764 inch 3.6768 inch) Measure the cylinder bore inside diameter (refer to Cylinder Block). Piston Rings (8) Any worn or damaged part discovered during engine overhaul must be replaced with a new one. 1. Ring end gap measurement - Insert the piston ring into the bore. Blower Motor - Will Not Run In One Or More Settings Blower Motor: Customer Interest Blower Motor - Will Not Run In One Or More Settings 01-007 October 16, 2001 Applies To: 1998-01 Passport - ALL Blower Does Not Run in One or More Settings (Supersedes 01-007, dated July 3, 2001) SYMPTOM The blower does not run in one or more fan control lever positions. PROBABLE CAUSE A high current draw on the blower resistor causes it overheat and to become electrically "open." This high current draw is usually caused by high friction in the blower motor bearings and/or debris in the blower assembly housing, which jams or slows the blower motor and damages its commutator. CORRECTIVE ACTION Replace the blower resistor and the blower motor assembly. Clean out all debris from inside the blower assembly housing. PARTS INFORMATION Blower Resistor (1998-99 models): P/N 8-97078-452-1, H/C 4906202 Blower Resistor (2000-01 models): P/N 8-97260-283-0, H/C 6633390 Blower Motor Assembly (1998-99 models): P/N 8-97231-642-0, H/C 6447544 Blower Motor Assembly (2000-01 models): P/N 8-97229-613-1, H/C 6262083 WARRANTY CLAIM INFORMATION In warranty: The normal warranty applies. Operation Number: 612109 Flat Rate Time: 0.4 hour Failed Part: P/N 8-97046-497-0 H/C 4402186 Defect Code: 032 Contention Code: B01 Template ID: 01-007A (1998-99 models) 01-007B (2000-01 models) Skill Level: Repair Technician Out of warranty: Any repair performed after warranty expiration may be eligible for goodwill consideration by the District Service Manager or your Zone Office. You must request consideration, and get a decision, before starting work. REPAIR PROCEDURE Page 7119 5. Check your work by running your fingers over the cleaned and lubricated surface to feel for any remaining contamination. ^ If you feel any particles on the cleaned surface fold the clay in half, knead it back into a disk shape, clean the section again, and recheck your work. ^ If the cleaned surface feels smooth, fold the clay in half, knead it back into a disk shape, and go to step 6. NOTE: You must carefully fold and knead the clay to keep a clean side next to the paint surface. Never use clay that has fallen on the ground. Any small pieces of dirt or sand that imbed in the clay will scratch the paint surface. If the clay falls on the ground, discard it and get a fresh piece. 6. Clean the remaining sections of the sprayed area (repeat steps 4 and 5). 7. Wipe the lubricant from all the cleaned sections with a clean terry cloth towel. 8. Clean the rest of the affected panel and any additional panels that need cleaning (repeat steps 3 thru 7). 9. Apply the manufacturer's recommended wax or glaze to all the cleaned panels. Disclaimer Page 3202 it is located, and what it connects to. Use the Connector Views to help locate the proper cavity when you need to probe a connector. It can be especially helpful if the connector has more than one wire of the same color. A dash symbol (-) indicates that the cavity is empty. Connector views can also be used to help diagnose multiple symptoms in separate circuits which could be caused by a single problem in a connector shared by those circuits. Here's an example: 1. Pick one of the multiple symptoms and look up the schematic for that circuit. 2. Make a list of all the in-line and fuse box connectors in that schematic , 3. Then, in the Connector Views, look up each connector on your list to see if circuits related to the other symptoms run through one of them. If they do, inspect that connector for the problem. Example: The blower, rear window defogger, and the windshield wiper don't work. List all in-line and fuse box connectors in the blower controls circuit and then check the Connector View (see the sample). You find that C324 is common to the blower controls, rear window defogger, and wiper/washer, so you inspect C324 and find the problem, bent terminals. Finding Component/Connector Locations Finding Component/Connector Locations To see where a component or connector is located on the car, look up its photo number in the "Component Location". The photo will also tell you the color of the connector, and how many cavities it has. Page 1092 Cleaning Spark Plugs - Clean spark plugs with a spark plug cleaner. - Raise the ground electrode to an position of 45 to 60 degrees. If electrode is wet, dry it before cleaning. - After spark plug is thoroughly cleaned, check insulator for presence of cracks. - Clean threads and metal body with a wire brush. - File the electrode tip if electrode is extremely worn. - Bend the ground electrode to adjust the spark plug gap. Component Tests and General Diagnostics Electronic Brake Control Module: Component Tests and General Diagnostics Page 5119 2. Check for continuity across one of the stator coils and stator core. If a continuity exists, replace the coil. Standard: More than 1 M ohms Brush Measure the brush length. If more than limit, replace the brush. Standard: 18.0 mm (0.709 in) Limit: 5.5 mm (0.217 in) Rectifier Assembly Page 7990 Page 691 4. Remove the fuel pressure regulator from the fuel rail. 5. Remove the fuel return line from the regulator. 6. Install the new fuel pressure regulator in the reverse order of removal. 7. Use the Smart Cable to reprogram the PCM with the latest software from the June 2001 or later HONDANET CD-ROM. Refer to Service Bulletin 99-005, Updating the Passport PCM, filed under Tools. 8. Use the PGM Tester to clear any DTCs. 9. Use the PGM Tester to check the broadcast code. Make sure the broadcast code matches the one you selected from the CD-ROM. WARRANTY CLAIM INFORMATION In warranty: The normal warranty applies. Failed Part: P/N 8-17113-398-0 H/C 5504386 Defect Code: 092 Contention Code: C99 Skill Level: Repair Technician Out of warranty: Any repair performed after warranty expiration may be eligible for goodwill consideration by the District Service Manager or your Zone Office. You must request consideration, and get a decision, before starting work. REPAIR PROCEDURE - POWER STEERING SWITCH 1. Drain the power steering fluid out of the system. 2. Remove the power steering fluid reservoir. Clean the reservoir with solvent, then with soap and water. Rinse and dry it thoroughly. 3. Reinstall the reservoir. Do not connect the return hose. 4. Remove the power steering pressure switch, then clean it with brake cleaner and a scraper. Reinstall the switch, and torque it to 20 N.m (14 lb-ft). 5. Cover the unconnected end of the reservoir with your finger, then fill the reservoir with Dexron III ATF Page 6506 4. Clean and dry the seat belt guide, then put a piece of teflon tape on the inside. Use the teflon tape specified in this service bulletin; other brands or types of tape may eventually peel off and restrict seat belt movement. 5. Install the seat belt guide and the door panel. 6. Test the belt for proper retraction by pulling the latch plate down to the floor of the vehicle and then releasing it. The belt should retract fully in four seconds or less. Disclaimer Specifications Clutch Pedal Assembly: Specifications Clutch Pedal Free Play 5 - 15 mm Stroke 165.5 - 175.5 mm Height 178 - 188 mm Page 63 Terminals - "T" Each "T" terminal (ring type) is numbered for reference and location. A "T" terminal is secured with a screw or bolt. Wires Locations 4WD Control Unit: Locations Under Center Console Page 2507 and the fuses. From Fuses to Relays and Components The second half of Power Distribution shows the wiring "From Fuses to Relays and Components." This can speed your troubleshooting by showing which circuits share fuses. If Power Distribution shows that an inoperative circuit and another circuit share a fuse, check a component in the other circuit. If it works, you know the fuse is good and power is available to the inoperative circuit. Ground Distribution Schematics Page 2986 Vehicle Speed Sensor: Testing and Inspection 1. Inspect the electrical connector for signs of corrosion or warping. Replace the VSS if the electrical connector is corroded or warped. 2. Inspect the VSS driven gear for chips, breaks, or worn condition. Replace the VSS if the driven gear is chipped, broken or worn. 3. Inspect the O-ring for wear, nicks, tears, or looseness. Replace the O-ring if necessary. Page 810 11. Using a jumper wire, connect the reference voltage of each circuit to its signal input and view the APP Sensor values in the Engine Data List. APP Sensor 1 should have a value of 99%, and APP Sensor 2 and APP Sensor 3 should each have a value of 0%. ^ If the values are not as specified, troubleshoot for high resistance on the signal input or a PCM malfunction. Repair the circuit or replace the PCM, then repeat step 3. ^ If the values are as specified, the problem may be intermittent. Disconnect the 10P connector from the modified APPS, and connect it to the new APPS; then repeat step 3. Wiggle the APPS wires as you go through the adjustment procedure to find the intermittent problem. 12. Turn off the ignition switch, and disconnect the PGM Tester.* DISCLAIMER Page 5403 NOTE: Do this repair procedure if, after doing step 10 of the test-drive, the vehicle pulled in the opposite direction after you swapped the front tires. 1. Swap wheels 2 and 4 on the passenger's side of the vehicle, and test-drive again. ^ If the pull goes away, replace the tire on wheel 2, then go to step 3. ^ If the pull does not go away, put wheels 2 and 4 back to their original positions, and go to step 2. 2. Swap wheels 1 and 3 on the driver's side of the vehicle, and test-drive again. ^ If the pull goes away, replace the tire on wheel 1, then go to step 3. ^ If the pull does not go away, use a known-good tire in position 1 and continue diagnosis. 3. Use your diagnosis worksheet to fill in the following table and build your 15-digit DTC. REPAIR PROCEDURE B Page 5063 Wheel Speed Sensor: Testing and Inspection Related Diagnostic Procedures B-19 Rear Speed Sensor Open or Shorted (DTC 53/C0235) Chart B-19 Rear Speed Sensor Open Or Shorted (DTC 53 (Flash Out) / C0235 (Serial Communications)) Page 3585 and the fuses. From Fuses to Relays and Components The second half of Power Distribution shows the wiring "From Fuses to Relays and Components." This can speed your troubleshooting by showing which circuits share fuses. If Power Distribution shows that an inoperative circuit and another circuit share a fuse, check a component in the other circuit. If it works, you know the fuse is good and power is available to the inoperative circuit. Ground Distribution Schematics Diagram Information and Instructions Vehicle Speed Sensor: Diagram Information and Instructions How to Identify Wiring Color-Coded Insulation Wire Color Wire Color Coding Accelerator Pedal Position Sensor - MIL ON/DTC's Set Technical Service Bulletin # 01-047 Date: 010814 Accelerator Pedal Position Sensor - MIL ON/DTC's Set 01-047 August 14, 2001 Applies To: 2000-01 Passport - ALL MIL Comes On With Accelerator Pedal Position Sensor DTC(s) P1271, P1273, P1275, P1280, and/or P1285 SYMPTOM The MIL is on with DTC P1271, P1273, P1275, P1280, or P1285 (various accelerator pedal position sensor problems) stored. The REDUCED POWER indicator may also be on; and the engine may occasionally idle too high, or the idle may fluctuate. PROBABLE CAUSE Contaminated grease on the potentiometer circuit board of the accelerator pedal position sensor (APPS) causes high resistance in the APPS circuit. CORRECTIVE ACTION Replace and adjust the APPS, remove all grease from the accelerator link, and clean the APPS harness connector and connector C123. PARTS INFORMATION Accelerator Pedal Position Sensor: P/N 8-97193-713-0, H/C 6198311 REQUIRED MATERIALS CAIG DeoxIT D5-S6 Contact Cleaner: P/N 341-200 (available from www.partsexpress.com) or Permatex Electrical Contact Cleaner: Permatex P/N 24379 WARRANTY CLAIM INFORMATION In warranty: The normal warranty applies. Operation Number: 122114 Flat Rate Time: 0.5 hour Failed Part: P/N 8-97220-540-0 H/C 6202436 Defect Code: 091 Contention Code: C99 Template ID: 01-047A Skill Level: Repair Technician Out of warranty: Any repair performed after warranty expiration may be eligible for goodwill consideration by the District Service Manager or your Zone Office. You must request consideration, and get a decision, before starting work. Page 2439 Disclaimer Repair Procedure 1. Unclamp the air cleaner housing cover, and move it to the side for access to connector C123 (16P BLK). 2. Unfasten C123 from the side of the engine compartment using a 90-degree pick. 3. Disconnect C123, and clean the terminals on both sides of the connector with contact cleaner. Shake the residue out of the connector. Allow the contact cleaner to evaporate for at least 3 minutes, then reconnect C123. 4. Fasten C123 to the left side of the engine compartment, then reinstall the air cleaner housing cover. 5. While supporting the accelerator pedal assembly, remove the two bolts that secure the assembly to the bulkhead. Carefully lower the assembly to gain access to the connector. A/T - ATF Cooler Cleaner Information Transmission Cooler: Technical Service Bulletins A/T - ATF Cooler Cleaner Information Use Worm-Style Clamps With the ATF Cooler Cleaner The spring-style clamps used on the ATF cooler lines are made to hold the cooler lines to the ATF cooler under normal operating conditions. The ATF Cooler Cleaner (P/N GHTTTCF6H) uses high pressure (100 psi) to do its job. With the pump motor running, the spring-style clamps can walk off or disconnect, and you'll wind up with a real mess to clean up in your shop. In March of this year, we sent each Honda dealership a pair of high-quality worm-style clamps to replace the original spring-style clamps. These clamps were part of a cooler cleaner update kit, and securely hold the cooler line in place. They've got a blue cap for easy identification. Need some more? Just call G-TFC, Inc. Page 3805 2. Compare the retrieved code with the codes shown. ^ If the code you retrieved is not in the list, the PCM has already been updated. Troubleshoot other causes for the PCM to reset. ^ If the code you retrieved is in the list, go to step 3. 3. If not already done, load the May 2001 or later HONDANET 2000 CD onto your HONDANET 2000 master terminal. Loading instructions are included in the CD's mailing. 4. Update the PCM software with the Smart Cable and the broadcast code information on the HONDANET 2000 CD. For updating instructions, refer to Service Bulletin 99-005, Updating the Passport PCM, filed under Tools. NOTE: ^ Since the Smart Cable may need to be cleared from a previous PCM update or the Smart Cable firmware may need to be reprogrammed, always begin each vehicle's PCM software update at the HONDANET 2000 workstation. ^ Make sure you select the most recent broadcast code from the list on the HONDANET screen. (This code is not necessarily at the top of the list. The most recent code is the last one in alphabetical sequence, letter by letter.) For example, among the codes DJTF, DDNN, and DCLY the most recent code is DJTF. 5. Use the PGM Tester to clear any DTCs. 6. After you update the PCM, retrieve the PCM broadcast code with the PGM Tester. Make sure the code does not match any from the list in step 2. DISCLAIMER Service and Repair Torque Converter Clutch Solenoid: Service and Repair REMOVAL 1. Raise the vehicle and support it on jack stands. 2. Disconnect battery ground cable. 3. Drain fluid. 4. Remove twelve 10 mm adapter case oil pan fixing screws, adapter case oil pan, and gasket. NOTE: Oil pan still contains transmission fluid. Place a large drain container under the oil pan. Drain the fluid carefully. 5. Disconnect wiring harness from force motor solenoid and converter clutch solenoid. Pull only on connectors, not on wiring harness. 6. Remove seven 13 mm screws from adapter case valve body assembly, then remove transfer plate, two gaskets, and adapter case valve body. INSTALLATION 1. Inspect electrical 4 pin connector and seal of adapter case. Replace if necessary. 2. Install gasket, transfer plate, and gasket. 3. Install adapter case valve body and seven 13 mm screws. Tighten the screws to the specified torque. Torque: 20 Nm (15 Ft. lbs.) 4. Connect wiring harness assembly to converter clutch solenoid and force motor. 5. Install oil pan gasket, oil pan, and twelve 10 mm screws. Tighten the screws to the specified torque. Torque: 11 Nm (96 Ft. lbs.) 6. Fill transmission through the overfill screw hole of oil pan, using ATF DEXRON III. 7. Connect battery ground cable. Page 1812 Coolant: Description and Operation Anti Freeze Solution Relation between the mixing ratio and freezing temperature of the Engine Coolant varies with the ratio of anti-freeze solution in water. Proper mixing ratio can be determined by referring to the chart. Supplemental inhibitors or additives claiming to increase cooling capability that have not been specifically approved by Isuzu are not recommended for addition to the cooling system. - Calculating mixing ratio Notice: Antifreeze solution + Water = Total cooling system capacity. Mixing Ratio Check the specific gravity of engine coolant in the cooling system temperature ranges from O°C to 50°C using a suction type hydrometer, then determine the density of the engine coolant by referring to the table. Notice: 1. Even in the areas where the atmospheric temperature is higher than 0°C, be sure not to use antifreeze solution at a mixing ratio lower than 20% so that the inside of the engine may not be corroded. Page 4135 - Master cylinder to dash panel: 16 Nm (12 ft. lbs.) - Clutch pedal to dash panel: 15 Nm (11 ft. lbs.) - Master cylinder push rod to yoke: 17 Nm (12 ft. lbs.) - Clutch pipe to master cylinder: 20 Nm (14 ft. lbs.) - Clutch pipe to flex, hose: 20 Nm (14 ft. lbs.) - Slave cylinder to case: 43 Nm (32 ft. lbs.) - Slave cylinder bleeder screw: 8 Nm (69 inch lbs.) - Clutch pipe to slave cylinder: 20 Nm (14 ft. lbs.) Page 6175 8. Remove lower case. - Slit the case parting face with a knife since the lining is separated when removing the evaporator. - Lift to remove the upper case. 9. Remove evaporator core. 10. Remove expansion valve. Page 7485 Ground - "G" Shielding Sheilding This represents RFI (Radio Frequency Interference) shielding around a wire. The shielding is always connected to ground. Splices Page 6057 Compressor Clutch Relay: Testing and Inspection 1. Disconnect relays and check for continuity and resistance between relay terminals. - For handling of these relays, refer to Heater Relay. Page 3666 Actuator: Testing and Inspection MOTOR ACTUATOR ASSEMBLY Inspect the function of the motor actuator assembly as follows: 1. Disassemble the motor actuator from transfer rear case. 2. Connect the terminals as shown in figure. Shift rod of the motor actuator moves and stops at 4WD position. Page 5100 Jump Starting: Service and Repair 1. Set the vehicle parking brake. If the vehicle is equipped with an automatic transmission, place the selector level in the "PARK" position. If the vehicle is equipped with a manual transmission, place the shift lever in the "NEUTRAL" position. Turn "OFF" the ignition. Turn "OFF" all lights and any other accessory requiring electrical power. 2. Look at the built-in hydrometer. If the indication area of the built-in hydrometer is completely clear, do not try to jump start. 3. Attach the end of one jumper cable to the positive terminal of the booster battery. Attach the other end of the same cable to the positive terminal of the discharged battery. Do not allow the vehicles to touch each other. This wilt cause a ground connection, effectively neutralizing the charging procedure. Be sure that the booster battery has a 12 volt rating. 4. Attach one end of the remaining cable to the negative terminal of the booster battery. Attach the other end of the same cable to a solid engine ground (such as the air conditioning compressor bracket or the generator mounting bracket) of the vehicle with the discharged battery. The ground connection must be at least 450 mm (18 in.) from the battery of the vehicle whose battery is being charged. WARNING: NEVER ATTACH THE END OF THE JUMPER CABLE DIRECTLY TO THE NEGATIVE TERMINAL OF THE DEAD BATTERY. 5. Start the engine of the vehicle with the good battery. Make sure that all unnecessary electrical accessories have been turned "OFF". 6. Start the engine of the vehicle with the dead battery. 7. To remove the jumper cables, follow the above directions in reverse order. Be sure to first disconnect the negative cable from the vehicle with the discharged battery. Locations Page 2478 ^ Handle a CD by its edges; never touch the flat surfaces. Contamination from fingerprints, liquids, felt-tip pens, and labels can cause the CD to not play properly, or possibly jam in the drive. ^ When cleaning a disc, use a clean soft cloth. Wipe across the disc from the center to the outside. Do not wipe the disc in a circular motion. ^ A new CD may be rough on the inner and outer edges. The small plastic pieces causing this roughness can flake off and fall on the recording surface of the disc, causing skipping or other problems. Remove these pieces by rubbing the inner and outer edges with the side of a pencil or pen. ^ Various accessories are available to protect CDs and improve the sound quality of CDs. These accessories increase the thickness or diameter of the discs, and should not be used in CD changers. Disclaimer Service and Repair Fuel Pressure Release: Service and Repair CAUTION: To reduce the risk of fire and personal injury, there are necessary to relieve the fuel system pressure filler and gauge unit before servicing the fuel system components. CAUTION: After relieving the system pressure, a small amount of fuel may be released when servicing fuel lines or connections. Reduce the chance of personal injury by covering the fuel line fittings with a shop towel before you disconnect the fittings. The towels will absorb any fuel that may leak out. When the disconnection is completed, place the towel in an approved container. 1. Remove the fuel cap. 2. Remove the fuel pump relay from the underhood relay box. 3. Start the engine and allow it to stall. 4. Crank the engine for 30 seconds. 5. Disconnect the negative battery cable. Diagram Information and Instructions Heated Element: Diagram Information and Instructions How to Identify Wiring Color-Coded Insulation Wire Color Wire Color Coding Page 8281 3. Tighten the motor shaft nut to the specified torque. Torque: 10 Nm (87 lb in) 4. Tighten the wiper arm nut to the specified torque. Torque: 14 Nm (122 lb in) Page 7052 Keyless Entry Module: Service and Repair Anti-Theft & Keyless Entry Controller Removal 1. Disconnect the battery ground cable. 2. Remove the glove box from the instrument panel assembly (1). - Refer to the Instrument Panel Assembly in Body Structure section. 3. Remove the anti-theft & keyless entry controller (2). - Disconnect the connector. Remove two fixing screws. Installation To install, follow the removal steps in the reverse order. Page 4495 Part 2 Of 3 Page 4810 Part 1 of 2 Part 2 of 2 B-23 Simultaneous Drop-Out of FT Spd Sensor Sig. (DTC 64/C0229) Chart B-23 Simultaneous Drop-Out Of Front Speed Sensor Signal (DTC 64 (Flash Out) / C0229 (Serial Communications)) Page 4130 Clutch Master Cylinder: Service and Repair Hydraulic System Bleed For further information regarding this component and the system that it is a part of, please refer to Clutch, M/T; Service and Repair; Hydraulic System Bleed. Page 2783 2. Connect the short finder across the battery terminals and the load (component) side of the fuse terminal. 3. Close all switches in the circuit you're testing. 4. Turn on the short finder. This creates a pulsing magnetic field around the wiring between the fuse box and the short. 5. Beginning at the fuse box, slowly move the short finder along the circuit wiring. The meter will read current pulses through sheet metal and body trim. As long as the meter is between the fuse and the short, the needle will move with each current pulse. Once you move the meter past the point of the short, the needle will stop moving. Check the wiring and connectors in this area to locate the cause of the short. Testing For Continuity When testing for continuity at a connector without wire seals, you do not have to separate the two halves of the connector. Instead, probe the connector from the back. Always check both sides of the connector because dirty, corroded, and bent terminals can cause problems (no electrical contact = an open). 1. Disconnect the negative cable from the car battery. If you're using a DVOM, place it in the lowest "OHMS" range. Page 6123 Test Equipment CAUTION: Most circuits include solid-state devices. Test the voltages in these circuits only with a 10-megaohm or higher impedance digital multimeter. Never use a test light or analog meter on circuits that contain solid-state devices. Damage to the devices may result. Test Light and DVOM On circuits without solid-state devices, use a test light to check for voltage. A test light is made up of a 12 volt bulb with a pair of leads attached. After grounding one lead, touch the other lead to various points along the circuit where voltage should be present. The bulb will go on if there is voltage at the point being tested. If you need to know how much voltage is present, use a digital volt/ohmmeter (DVOM). Self-Powered Test Light and DVOM Use a self-powered test light to check for continuity. This tool is made up of a light bulb, battery, and two leads. To test it, touch the leads together: the light should go on. Use a self-powered test light only on an unpowered circuit. First, disconnect the battery, or remove the fuse that feeds the circuit you are working on. Select two points in the circuit between which you want to check continuity. Connect one lead of the self-powered test light to each point. If there is continuity, the test light's circuit will be completed, and the light will go on. If, in addition, you need to know exactly how much resistance there is between two points, use a digital volt/ohmmeter (DVOM). In the "OHMS" range, the DVOM will measure resistance between two points along a circuit. Low resistance means good continuity. Diodes and solid-state devices in a circuit can make a DVOM give a false reading. To check a reading, reverse the leads, and take a second reading. If the readings differ, the component is affecting the measurement. Jumper Wire Use a jumper wire to bypass an open circuit. A jumper wire is made up of an in-line fuse holder connected to a set of test leads. It should have a five ampere fuse. Never connect a jumper wire across a short circuit. The direct battery short will blow the fuse. Short Finder (Short Circuit Locator) Short finders are available to locate shorts to ground. The short finder creates a pulsing magnetic field in the shorted circuit which you can follow to the location of the short. To order any test equipment shown above, contact your local tool supplier. For a list of suppliers and tool numbers, refer to Honda Required Special Tools and Equipment Service Bulletin. Page 876 7. When installing the steering column cover, be sure to wire (through each harness) as illustrated so that the harnesses starter switch, combination switch and SRS coil may not catch wiring. 8. Install steering wheel by aligning the setting marks made during removal. CAUTION: Never apply force to the steering wheel in direction of the shaft by using a hammer or other impact tools in an attempt to remove the steering wheel. The steering shaft is designed as an energy absorbing unit. 9. Tighten the steering wheel fixing nut to the specified torque. Torque: 34 Nm (25 ft. lbs.) 10. Support inflator module and carefully connect the SRS connector and horn lead, then install inflator module. NOTE: Pass the lead wire through the tabs on the plastic cover (wire protector) of inflator to prevent lead wire from being pinched. 11. Tighten fixing bolts to specified torque. Torque: 9 Nm (78 inch lbs.) 12. Install driver knee bolster (reinforcement). 13. Install instrument panel lower cover, then install the engine hood opening lever. 14. Connect the yellow 2-way SRS connector located under the steering column. 15. Connect the battery "-" terminal cable. Page 2872 Crankshaft Position Sensor: Service and Repair REMOVAL 1. Disconnect the negative battery cable. 2. Disconnect the wiring connector from crankshaft position sensor. 3. Remove one bolt and remove the CKP sensor from the right side of the engine block, just behind the mount. NOTE: Use caution to avoid any hot oil that might drip out. INSTALLATION 1. Apply a small amount of engine oil to the O-ring and install the CKP sensor in the engine block. 2. Install the CKP sensor mounting bolt. 3. Tighten the mounting bolt to 10 Nm (89 lb in.). 4. Connect the wiring connector to the CKP sensor. 5. Connect the negative battery cable. Ignition Switch - Won't Turn To The Lock Position Technical Service Bulletin # 02-005 Date: 020212 Ignition Switch - Won't Turn To The Lock Position 02-005 February 12, 2002 Applies To: 1998-02 Passport - ALL with A/T Ignition Switch Does Not Turn to the LOCK Position SYMPTOM The ignition switch does not turn to the LOCK position; as if the shift lever is not in Park. The ignition key cannot be removed. PROBABLE CAUSE The shift lock cable between the lock cylinder assembly (ignition lock assembly) and the shift lever is out of adjustment. CORRECTIVE ACTION Check and, if necessary, adjust the shift lock cable. WARRANTY CLAIM INFORMATION In warranty: The normal warranty applies. Operation Number: 745301 Flat Rate Time: 0.3 hour Failed Part: P/N 8-97178-564-0 H/C 5650262 Defect Code: 032 Contention Code: B01 Template ID: 02-005A Skill Level: Repair Technician Out of warranty: Any repair performed after warranty expiration may be eligible for goodwill consideration by the District Service Manager or your Zone Office. You must request consideration, and get a decision, before starting work. Disclaimer Repair Procedure 1. Remove the driver's kick panel (two clips). 2. Remove the driver's dashboard lower cover: ^ Remove the two mounting screws for the hood release lever and the mounting screw on the lower right corner of the cover. ^ Pull the hood release lever forward, and turn it sideways to unclip it from the cover. Page 4988 Hydraulic Control Assembly - Antilock Brakes: Testing and Inspection B-11 FL Isolation Solenoid Valve Failure (DTC 41/C0245, C0247) Chart B-11 FL Isolation Solenoid Coil Failure (DTC 41 (Flash Out) / C0245, C0247 (Serial Communications)) Part 1 of 2 Page 2954 c. Remove mode switch connector with bracket from the transmission case. d. Connect multimeter (resistance mode) to terminals 1(E) and 4(H) on mode switch connector. e. Loosen two mounting screws. f. Rotate mode switch slightly in both directions to determine the range (approx. 5 degrees) of electrical contact. g. Position mode switch in middle of contact range. h. Tighten two mounting screws. i. Remove multimeter and install mode switch harness connector with bracket to the transmission case. j. Connect transmission harness connector to mode switch connector. Page 5254 10. Use the PGM Tester to check the broadcast code. Make sure the broadcast code matches the one you selected from the CD-ROM. WARRANTY CLAIM INFORMATION In warranty: The normal warranty applies. Failed Part: P/N 8-17087-655-0 H/C 4375820 Defect Code: 064 Contention Code: C01 Skill Level: Repair Technician Out of warranty: Any repair performed after warranty expiration may be eligible for goodwill consideration by the District Service Manager or your Zone Office. You must request consideration, and get a decision, before starting work. REPAIR PROCEDURE - ENGINE/BODY GROUND 1. Use the ETM for the appropriate year to locate these ground connectors: G101, G104, G105, G106 and G160. 2. Inspect each connector for corrosion or looseness. 3. Remove the bolt from any connector that is corroded or loose. Clean the terminal connector with a wire brush. File flat any solder bumps on the connector. 4. Clean the contact surface on the engine or body with a wire brush. 5. Replace the bolt if it is heavily corroded. Otherwise, clean it with a wire brush. 6. Apply lithium dielectric grease to both sides of the terminal connector. 7. Reinstall the bolt, torque it to 14 N.m (10 lb-ft). 8. Use the Smart Cable to reprogram the PCM with the latest software from the June 2001 or later HONDANET CD-ROM. Refer to Service Bulletin 99-005, Updating the Passport PCM, filed under Tools. 9. Use the PGM Tester to clear any DTCs. 10. Use the PGM Tester to check the broadcast code. Make sure the broadcast code matches the one you selected from the CD-ROM. WARRANTY CLAIM INFORMATION In warranty: The normal warranty applies. Failed Part: P/N 8-97086-823-0 Page 4287 Part 3 Of 3 Page 2009 The name of the component appears next to it followed by notes about its function along with any photo and connector view references. Connector "C" How to Identify Connector Terminals Cavity Numbering System The cavities (and wire terminals) in each connector are numbered starting from the upper left, looking at the male terminals from the terminal side (or looking at the female terminals from the wire side. Both views are in the same direction so the numbers are the same.) All actual cavities are numbered, even if they have no wire terminals in them. NOTE: Data Link Connector (DLC) terminals are numbered according to SAE standard J1962, not the Honda standard. The numbers of the four end terminals are molded into the corners of the connector face. Page 7611 2. Connect one lead of a self-powered test light or DVOM to one end of the part of the circuit you want to test. 3. Connect the other lead to the other end. 4. If the self-powered test light glows, there is continuity. If you're using a DVOM, a low reading or no reading (zero), means good continuity. Testing For Voltage When testing for voltage at a connector without wire seals, you do not have to separate the two halves of the connector. Instead, probe the connector from the back. Always check both sides of the connector because dirty, corroded, and bent terminals can cause problems (no electrical contact = an open). 1. Connect one lead of the lest light to a known good ground, or, if you're using a digital volt ohmmeter (DVOM), place it in the appropriate DC volts range, and connect its negative lead to ground. 2. Connect the other lead of the test light or DVOM to the point you want to check. 3. If the test light glows, there is voltage present. If you're using a DVOM, note the voltage reading. It should be within one volt of measured battery voltage. A loss of more than one volt indicates a problem. NOTE: Always use a DVOM on high impedance circuits. A test light may not glow (even with battery voltage present). Testing For Voltage Drop Wires, connectors, and switches are designed to conduct current with a minimum loss of voltage. A voltage drop of more than one volt indicates a problem. 1. Place the digital volt/ohmmeter (DVOM) in the appropriate DC volts range. Connect the positive lead to the end of the wire (or to the connector or switch) closest to the battery. 2. Connect the negative lead to the other end of the wire (or the other side of the connector or switch). 3. Turn on the components in the circuit. 4. The DVOM will show the difference in voltage between the two points. A difference, or drop, of more than one volt indicates a problem. Check the circuit for loose, dirty, or bent terminals. Page 6033 Blower Motor Resistor: Service and Repair Resistor And Associated Parts Removal 1. Disconnect the battery ground cable. 2. Remove glove box. 3. Remove resistor connector. 4. Remove duct (heater only). 5. Remove resistor. Installation To install, follow the removal steps in the reverse order. Page 1433 3. Install camshaft assembly and camshaft brackets, tighten twenty bolts on one side bank to the specified torque. 1. Apply engine oil to camshaft journal and bearing surface of camshaft bracket. 2. Align timing mark on intake camshaft (one dot for right bank, two dots for left bank) and exhaust camshaft (one dot for right bank, two dots for left bank) to timing mark on camshaft drive gear (one dot). 3. Tighten twenty bolts in numerical order on one side bank as shown in the illustration. Torque: 10 Nm (89 inch lbs.) 4. If the oil seal requires replacement, use the J-42985 to install the oil seal. Page 7328 14. Remove the glass. - First, align the height of regulator to the access hole. Remove 2 screws attaching bottom channel and regulator, then remove the glass. - Remove the window glass by tilting it as necessary. 15. Remove the window regulator. - Remove the window regulator fixing bolts and pull the regulator out from the lower hole of the door panel. 16. Remove the glass run. - Pull the glass run out from the door frame. Installation Page 2777 This means the branch of the wire connects to another circuit. The arrow points to the name of the circuit branch where the wire continues. Page 3433 Disclaimer Repair Procedure 1. Unclamp the air cleaner housing cover, and move it to the side for access to connector C123 (16P BLK). 2. Unfasten C123 from the side of the engine compartment using a 90-degree pick. 3. Disconnect C123, and clean the terminals on both sides of the connector with contact cleaner. Shake the residue out of the connector. Allow the contact cleaner to evaporate for at least 3 minutes, then reconnect C123. 4. Fasten C123 to the left side of the engine compartment, then reinstall the air cleaner housing cover. 5. While supporting the accelerator pedal assembly, remove the two bolts that secure the assembly to the bulkhead. Carefully lower the assembly to gain access to the connector. Page 7416 The wire insulation has one color or one color with another color stripe. The second color is the stripe. Page 1956 the component if the component only has one connector, or by a capital letter (A, B, C, etc.) if the component has more than one connector. Below most connector numbers and component names are PHOTO and VIEW numbers. The PHOTO number refers to a photo in the back of the book that shows the connector's location on the car. The VIEW number refers to an illustration in the back of the book that shows the connector face, wire colors, connector cavity numbers, and other details. The connector cavity numbering sequence begins at the top left corner of the connector. Disregard any numbers molded into the connector housing. Wires Wires are identified by the abbreviated names of their colors; the second color is the color of the stripe. Wires are also identified by their location in a connector. The number "2" next to the male and female wire terminals at C416, for example, means those terminals join in cavity 2 of connector C416. Symbols A complete description of schematic symbols is given under wire color abbreviation. Power Distribution Schematics Power Distribution schematics show how power is supplied from the positive battery terminal to various circuits in the car. Refer to the Power Distribution section to get a more detailed picture of how power is supplied to the circuit you're working on. From Battery to Ignition Switch, Fuses, and Relays Individual circuit schematics begin with a fuse. The first half of Power Distribution, however, shows the wiring "upstream" between the battery Page 6866 3. Remove the window regulator handle. - Remove the clip on the rear side of the regulator handle using a wire. 4. Remove the screw while pulling the inside lever toward you and then remove the inside handle. 5. Remove the 1 screw at the pull case. 6. Pull out the trim panel at the 8 clip positions. - Disconnect the power window switch connector. 7. Remove the power window switch and pull case, if equipped. Page 1300 Fuse: Diagrams Instrument Panel Engine Controls - High/Erratic Engine Idle Power Steering Pressure Switch: Customer Interest Engine Controls - High/Erratic Engine Idle 01-080 August 14, 2001 Applies To: 2000-02 Passport - ALL 2000-02 Passport: High or Erratic Idle SYMPTOM The engine occasionally idles at too high a speed, or the idle speed fluctuates. PROBABLE CAUSES The symptom could be the result of any of these conditions: ^ Loose or corroded engine or body ground ^ High resistance in the APPS ground circuit ^ PSP (power steering pressure) switch is internally shorted to ground ^ Fuel pressure regulator is leaking fuel into the intake manifold CORRECTIVE ACTION Diagnose the cause of the idle condition, and select the proper REPAIR PROCEDURE. PARTS INFORMATION REQUIRED MATERIALS REQUIRED SOFTWARE Each REPAIR PROCEDURE requires you to use the Smart Cable to reprogram the PCM with the latest software. To select the latest software from the CDROM, enter the year, model, engine, transmission, and emissions type (49-state or California). This gives you a list of broadcast codes. Select the broadcast code at the top of the list. WARRANTY CLAIM INFORMATION Refer to the Warranty Claim Information for each Repair Procedure. DIAGNOSIS 1. Find out from the customer when the high or erratic idle condition occurs and what the RPM range is: ^ Within 20 minutes of a cold start ^ After braking to a stop ^ All the time ^ Intermittently, with no set pattern Page 7708 Each schematic represents one circuit. A circuit's wires and components are arranged to show current flow, from power at the top of the page, to ground, at the bottom. Shared Circuits Other circuits may share power or ground terminals or wiring with the circuit shown. A wire that connects one circuit to another, for example, is cut short and has an arrowhead at the end of it pointing in the direction of current flow. Next to the arrowhead is the name of the circuit or component which shares that wiring. To quickly check shared wiring, check the operation of a component it serves. If that component works, you know the shared wiring is OK. Connectors All in-line and junction connectors are numbered (C725, C416, etc.). Component connectors are not numbered but are identified either by the name of Page 4231 Part 3 Of 3 Locations Page 5713 Page 734 Transmission Position Switch/Sensor: Service and Repair REMOVAL 1. Place selector lever in neutral. 2. Disconnect battery ground cable. 3. Remove mode switch cover (1). 4. Disconnect selector lever (2) from the mode switch. 5. Remove bracket with cable (3). 6. Disconnect transmission harness from the mode switch connector (4). 7. Remove bracket with mode switch connector from the transmission case. 8. Remove mode switch connector (4) from the bracket (5). 9. Remove two mode switch bolts and nut then remove mode switch (6). INSTALLATION To install, follow the removal steps in the reverse order, noting the following points; 1. Torque Mode switch bolt: 13 Nm (113 inch lbs.) Selector lever nut: 23 Nm (17 ft. lbs.) 2. Mode switch setting procedure. Perform either of the following adjustment procedures: Procedure 1 a. Place selector lever in neutral. b. Remove selector lever from the mode switch. c. Remove the mode switch cover. d. Loosen the two 10 mm screws. e. Rotate the mode switch until the slot in the mode switch housing aligns with the selector shaft bushing, and insert a 3/32 inch (2.4 mm) drill bit or punch (1) into the slot. f. Tighten the screws to 13 Nm (113 inch lbs.). g. After completing adjustment, snap the mode switch cover into place. h. Reinstall the selector lever. Procedure 2 a. Place selector lever in neutral. b. Disconnect transmission harness connector from mode switch connector. Page 7413 Wires Wire insulation can be one color, or one color with another color stripe. (The second color is the stripe.) This circuit continues on another image. (The arrow shows direction of current flow.) To follow the RED/BLK wire in this example, you would turn to "Fuel and Emissions" and look for the "A" arrow. Page 5521 4. Install rotor and vanes to cam. 5. Install pin to front housing. 6. Install two new O-rings to front housing. Be sure to discard used O-ring. 7. Install side plate. CAUTION: When installing side plate, be careful not to damage its inner surface. Damaged side plate may cause poor pump performance, pump seizure or oil leakage. 8. Install pump cartridge assembly to front housing. 9. Install snap ring to shaft end. 10. Install rear housing with a new O-ring. Be sure to discard used O-ring. Then install bolt and tighten it to specified torque. Torque to 24 Nm (17 ft. lbs.). 11. Install suction pipe with a new O-ring. Be sure to discard used O-ring. Then install bolt and tighten it to specified torque. Torque to 10 Nm (87 inch lbs.). 12. Install relief valve and spring. 13. Install connector with a new O-ring. Be sure to discard used O-ring. Tighten the connector to specified torque. Torque to 59 Nm (43 ft. lbs.). 14. Install pressure switch assembly and tighten it to specified torque. Torque to 18 Nm (13 ft. lbs.). Page 2191 ^ If the idle speed ever exceeds 1,300 rpm 2. Remove the vacuum hose from the fuel pressure regulator, then start the engine. ^ If fuel comes out of the fuel pressure regulator vacuum hose connection, go to REPAIR PROCEDURE FUEL PRESSURE REGULATOR. ^ If no fuel comes out of the regulator, reconnect the vacuum hose and continue to step 3. 3. Connect the PGM Tester. Set it to Engine Data List. 4. Have an assistant drive the vehicle under the conditions described by the customer. 5. If the high or erratic idle condition occurs, note the values of the PSP Switch and APP Sensor 1 when it is occurring. ^ If the PSP Switch is HIGH, and you are not turning, go to REPAIR PROCEDURE POWER STEERING SWITCH. ^ If the APP Sensor 1 is greater than 15% and APP Sensor 2 and/or APP Sensor 3 are less than 85%, and the accelerator pedal is not depressed, go to REPAIR PROCEDURE APPS GROUND. ^ If the PSP Switch is reading LOW when not turning and HIGH when turning, and the APP Sensors are reading within the range shown, discontinue the test-drive and go to step 6. 6. Do these repairs: ^ REPAIR PROCEDURE APPS GROUND ^ REPAIR PROCEDURE ENGINE/BODY GROUND REPAIR PROCEDURE - FUEL PRESSURE REGULATOR 1. Relieve fuel system pressure: ^ Remove the fuel fill cap. ^ Remove the fuel pump relay. ^ Start the engine and run it until it stalls. ^ Crank the engine for 3 seconds. 2. Remove the vacuum hose from the fuel pressure regulator. 3. Remove the fuel pressure regulator shield from the common chamber (two bolts). Page 7664 Each schematic represents one circuit. A circuit's wires and components are arranged to show current flow, from power at the top of the page, to ground, at the bottom. Shared Circuits Other circuits may share power or ground terminals or wiring with the circuit shown. A wire that connects one circuit to another, for example, is cut short and has an arrowhead at the end of it pointing in the direction of current flow. Next to the arrowhead is the name of the circuit or component which shares that wiring. To quickly check shared wiring, check the operation of a component it serves. If that component works, you know the shared wiring is OK. Connectors All in-line and junction connectors are numbered (C725, C416, etc.). Component connectors are not numbered but are identified either by the name of Page 904 2. Unfasten C123 from the side of the engine compartment using a 90-degree pick. 3. Disconnect C123, and clean the terminals on both sides of the connector with contact cleaner. Shake the residue out of the connector. Allow the contact cleaner to evaporate for at least 3 minutes, then reconnect C123. 4. Fasten C123 to the left side of the engine compartment, and reinstall the air cleaner housing cover. 5. Remove the connector position assurance (CPA) clip from the APPS connector. 6. Disconnect the lop connector from the APPS. 7. Clean the terminals of the 10P APPS connector (harness side) with contact cleaner. Shake out residue from the connector, and allow the contact cleaner to evaporate for at least 3 minutes, then reconnect it. 8. Use the Smart Cable to reprogram the PCM with the latest software from the June 2001 or later HONDANET CD-ROM. Refer to Service Bulletin 99-005, Updating the Passport PCM, filed under Tools. 9. Use the PGM Tester to clear any DTCs. Page 3968 Fluid - A/T: Fluid Type Specifications A/T Fluid Type ..................................................................................................................................................... .............................................. ATF DEXRON (R) III Page 811 129 - Below Left Side Of I/P Page 462 Wires Wire insulation can be one color, or one color with another color stripe. (The second color is the stripe.) This circuit continues on another image. (The arrow shows direction of current flow.) To follow the RED/BLK wire in this example, you would turn to "Fuel and Emissions" and look for the "A" arrow. Service and Repair Heated Glass Element Switch: Service and Repair Removal 1. Disconnect the battery ground cable. 2. Remove the meter cluster assembly (1). 3. Remove the rear defogger switch (2). - Disconnect the switch connector. - To remove the switch, push the lock from the back side of the meter cluster assembly. Installation To install, follow the removal steps in the reverse order. Page 3601 Page 1784 Cleaning Spark Plugs - Clean spark plugs with a spark plug cleaner. - Raise the ground electrode to an position of 45 to 60 degrees. If electrode is wet, dry it before cleaning. - After spark plug is thoroughly cleaned, check insulator for presence of cracks. - Clean threads and metal body with a wire brush. - File the electrode tip if electrode is extremely worn. - Bend the ground electrode to adjust the spark plug gap. Locations Shift Interlock Solenoid: Locations Under Center Console Page 6331 Refrigerant Pressure Sensor / Switch: Service and Repair Removal 1. Disconnect the battery ground cable. 2. Discharge and recover refrigerant. 3. Remove radiator grille. 4. Disconnect pressure switch connector. 5. Disconnect pressure switch. - When removing the switch connected part, the connecting part should immediately be plugged or capped to prevent foreign matter from being mixed into the line. Installation To install, follow the removal steps in the reverse order, noting the following point: 1. O-ring cannot be reused. Always replace with a new one. 2. Be sure to apply new compressor oil to the O-ring when connecting pressure switch. 3. Tighten the pressure switch to the specified torque. Torque: 13 Nm (113 lb in) Page 7790 Wires Wire insulation can be one color, or one color with another color stripe. (The second color is the stripe.) This circuit continues on another image. (The arrow shows direction of current flow.) To follow the RED/BLK wire in this example, you would turn to "Fuel and Emissions" and look for the "A" arrow. Page 2818 6. Remove the connector position assurance (CPA) clip from the APPS connector. 7. Disconnect the 10 P connector from the APPS. 8. Remove the bolts, the APPS, the spacer, and the accelerator link from the accelerator pedal assembly. 9. Separate the spacer from the APPS. Clean the grease off the spacer and the accelerator link with a clean shop towel. 10. Clean the terminals of the 10 P APPS connector (harness side) with contact cleaner. Shake the residue out of the connector, and allow the contact cleaner to evaporate for at least 3 minutes before reconnecting the connector. 11. Install a new APPS, the spacer, and the accelerator link onto the accelerator pedal assembly. Leave the mounting screws loose so the sensor can be adjusted. 12. Connect the 10 P connector to the new APPS, and lock the connector in place with the CPA. 13. Connect the PGM Tester to the data link connector (DLC), and turn the ignition switch to ON (II). Page 2524 Compact Disc Player (CD): Diagrams Deterioration of Brake Fluid Brake Fluid: Service and Repair Deterioration of Brake Fluid Deterioration of Brake Fluid Using any other brake fluid than specified or brake fluid with mineral oil or water mixed in will drop the boiling point of brake fluid. It may, in turn, result in vapor lock or deteriorated rubber parts of the hydraulic system. Be sure to change the brake fluid at specified intervals. If the rubber parts are deteriorated, remove all the system parts and clean them with alcohol. Prior to reassembly, dry the cleaned parts with air to remove the alcohol. Replace all the hoses and rubber parts of the system. Description and Operation Transmission Mode Indicator - A/T: Description and Operation With the ignition switch in ON or START battery voltage is applied to the A/T gear position switch through fuse 14. The A/T gear position switch sends a signal to the PCM which communicates this information to the multiplex control unit which in turn controls the A/T gear position indicator corresponding to the gear selected. The multiplex control unit applies voltage to the appropriate A/T gear position indicator light in the meter assembly, causing it to come on. Page 3021 Wires Wire insulation can be one color, or one color with another color stripe. (The second color is the stripe.) This circuit continues on another image. (The arrow shows direction of current flow.) To follow the RED/BLK wire in this example, you would turn to "Fuel and Emissions" and look for the "A" arrow. Page 677 amount of oxygen present in the exhaust gas entering the three-way catalytic converter. The Bank 1 HO2S 2 and the Bank 2 HO2S 2 sensors produce an output signal which indicates the oxygen storage capacity of the catalyst. This indicates the catalyst's ability to efficiently convert exhaust gases. If the catalyst is operating efficiently, the Bank 1 HO2S 1 and the Bank 2 HO2S 1 signals will be more active than the signals produced by the Bank 1 HO2S 2 and the Bank 2 HO2S 2 sensors. The catalyst monitor sensors operate the same as the fuel control sensors. The Bank 1 HO2S 2 and the Bank 2 HO2S 2 sensors" main function is catalyst monitoring, but they also have a limited role in fuel control. If a sensor output indicates a voltage either above or below the 450 mV bias voltage for an extended period of time, the PCM will make a slight adjustment to fuel trim to ensure that fuel delivery is correct for catalyst monitoring. A problem with the Bank 1 HO2S 2 signal circuit will set DTC P0137, P0138, or P0140, depending on the specific condition. A problem with the Bank 2 HO2S 2 signal circuit will set DTC P0157, P0158, or P0160, depending on the specific condition. A fault in the heated oxygen sensor heater element or its ignition feed or ground will result in lower sensor response. This may cause incorrect catalyst monitor diagnostic results. Page 6607 5. Click Warranty Audio Order to view the Warranty Audio Order form. 6. Enter the VIN and the mileage, then click the Submit button to view the Warranty Audio Order form. Use the completed Audio/Navigation/RES Worksheet to help you answer the questions on the Warranty Audio Order form. Questions with a red asterisk (*) are required fields that you must answer to submit the form. Make sure the information is complete (17-digit VIN, etc.). This information is critical to the remanufacturing process. Screen # 2 of the form contains the problem description, condition information, and shared functions. Fill this section out with as much information as possible. Select one part number from the list provided, then click Submit. It is your responsibility to ensure the correct part number is selected based on color and application information. Description and Operation Solenoid Valve Page 4600 This means the branch of the wire connects to another circuit. The arrow points to the name of the circuit branch where the wire continues. Page 5555 Air Bag(s) Arming and Disarming: Service Precautions Precautions For Electrical Inspections Precautions For Electrical Inspections When using electrical test equipment, insert the probe of the tester into the wire side of the connector. Do not insert the probe of the tester into the terminal side of the connector, and do not tamper with the connector. Use a U-shaped probe. Do not insert the probe forcibly. Use specified service connectors in troubleshooting. Using improper tools could cause an error in inspection due to poor metal-to-metal contact. Page 1315 Relay Box: Diagrams Instrument Panel Page 8084 Vanity Lamp: Diagnostic Aids Before Troubleshooting Before Troubleshooting See: Service Precautions/Vehicle Damage Warnings/Tips and Precautions 1. Check applicable fuses in the appropriate fuse/relay box. 2. Check the battery for damage, state of charge, and clean and tight connections. CAUTION: Do not quick-charge a battery unless the battery ground cable has been disconnected, otherwise you will damage the alternator diodes. - Do not attempt to crank the engine with the battery ground cable loosely connected or you will severely damage the wiring. While You're Working 1. Make sure connectors are clean, and have no loose terminals or receptacles. 2. Make sure that connectors without wire seals are packed with dielectric (silicone) grease. Part Number: 08798-9001. 3. When connecting a connector, push it until it "clicks" into place. CAUTION: Do not pull on the wires when disconnecting a connector. Pull only on the connector housings. - Most circuits include solid-state devices. Test the voltages in these circuits only with a 10-megaohm or higher impedance digital multi meter. Never use a test light or analog meter on circuits that contain solid-state devices. Damage to the devices may result. Five-Step Troubleshooting 1. Verify The Complaint Turn on all the components in the problem circuit to check the accuracy of the customer complaint. Note the symptoms. Do not begin disassembly or testing until you have narrowed down the problem area. 2. Analyze The Schematic Look up the schematic for the problem circuit. Determine how the circuit is supposed to work by tracing the current paths from the power source through the circuit components to ground. Also, trace circuits that share wiring with the problem circuit. The names of circuits that share the same fuse, ground, or switch, and so on, are referred to in each circuit schematic. Try to operate any shared circuits you didn't check in step 1. If the shared circuits work, the shared wiring is OK, and the cause must be in the wiring used only by the problem circuit. If several circuits fail at the same time, the fuse or ground is a likely cause. Based on the symptoms and your understanding of the circuit's operation, identify one or more possible causes. 3. Isolate The Problem By Testing The Circuit Make circuit tests to check the diagnosis you made in step 2. Keep in mind that a logical, simple procedure is the key to efficient troubleshooting. Test for the most likely cause of failure first. Try to make tests at points that are easily accessible. 4. Fix The Problem Once the specific problem is identified, make the repair. Be sure to use proper tools and safe procedures. 5. Make Sure The Circuit Works Turn on all components in the repaired circuit in all modes to make sure you've fixed the entire problem. If the problem was a blown fuse, be sure to test all of the circuits on that fuse. Make sure no new problems turn up and the original problem does not recur. Page 1792 7. Turn the valve tappet with a pick or a small screwdriver until the tappet notch is within the indentation in the head. 8. Turn the crankshaft (or camshaft) pulley clockwise until the cam lobe presses the valve fully open. 9. On the tappet side closest to the bearing cap, insert the valve adjuster holder (T/N J-42659-AH) between the camshaft and the tappet. The tool should rest on the edge of the tappet without touching the shim. 10. Slowly turn the crankshaft (or camshaft) pulley counterclockwise so that when the valve closes, the tool catches between the camshaft and the tappet, holding the valve slightly open. NOTE: Do not turn the crankshaft (or camshaft) pulley too far or in the wrong direction. If you do, you might break the tool, or worse yet, damage the cylinder head. 11. Insert a pick or a small screwdriver into the tappet notch, and pry out the shim. 12. Wipe off the shim, then write its number on the Valve Inspection Chart for that valve and cylinder. If there is no number on the shim, measure its thickness with a micrometer, and write down the measurement on the Valve Inspection Chart. 13. Follow the directions on the Valve Shim Replacement Chart to select the correct shim. 14. Insert the correct shim, number side down, into the tappet. Make sure the shim is fully seated. 15. Release and remove the tool by turning the crankshaft (or camshaft) pulley clockwise. 16. Turn the crankshaft (or camshaft) pulley clockwise until the cam lobe again points away from the valve. Page 6812 3. Remove the regulator handle (1). - Pull the hook (2) out and remove the regulator handle. 4. Remove the power window switch (1). - Pry the power window switch out and disconnect the switch connector. 5. Remove the speaker cover. 6. Remove the front speaker. - Remove the front speaker fixing screws in order to disconnect the speaker connector. 7. Remove the inside handle fixing screw. Page 304 Test Equipment CAUTION: Most circuits include solid-state devices. Test the voltages in these circuits only with a 10-megaohm or higher impedance digital multimeter. Never use a test light or analog meter on circuits that contain solid-state devices. Damage to the devices may result. Test Light and DVOM On circuits without solid-state devices, use a test light to check for voltage. A test light is made up of a 12 volt bulb with a pair of leads attached. After grounding one lead, touch the other lead to various points along the circuit where voltage should be present. The bulb will go on if there is voltage at the point being tested. If you need to know how much voltage is present, use a digital volt/ohmmeter (DVOM). Self-Powered Test Light and DVOM Use a self-powered test light to check for continuity. This tool is made up of a light bulb, battery, and two leads. To test it, touch the leads together: the light should go on. Use a self-powered test light only on an unpowered circuit. First, disconnect the battery, or remove the fuse that feeds the circuit you are working on. Select two points in the circuit between which you want to check continuity. Connect one lead of the self-powered test light to each point. If there is continuity, the test light's circuit will be completed, and the light will go on. If, in addition, you need to know exactly how much resistance there is between two points, use a digital volt/ohmmeter (DVOM). In the "OHMS" range, the DVOM will measure resistance between two points along a circuit. Low resistance means good continuity. Diodes and solid-state devices in a circuit can make a DVOM give a false reading. To check a reading, reverse the leads, and take a second reading. If the readings differ, the component is affecting the measurement. Jumper Wire Use a jumper wire to bypass an open circuit. A jumper wire is made up of an in-line fuse holder connected to a set of test leads. It should have a five ampere fuse. Never connect a jumper wire across a short circuit. The direct battery short will blow the fuse. Short Finder (Short Circuit Locator) Short finders are available to locate shorts to ground. The short finder creates a pulsing magnetic field in the shorted circuit which you can follow to the location of the short. To order any test equipment shown above, contact your local tool supplier. For a list of suppliers and tool numbers, refer to Honda Required Special Tools and Equipment Service Bulletin. Page 6309 Fan Control Switch Page 2670 If there is no photo number below or beside a component name or a connector, ground, or terminal number, look up that name or number in the appropriate Connector Identification Chart. The chart lists how many cavities a connector has, where it's located, and what it connects to. The related illustration shows the connector's location on the harness, and the harness routing. NOTE: Photos listed by number are located at Locations / Components / Photograohs. See: Locations/Component Locations/Photographs Circuit Schematics Page 2653 2. Connect the PCM electrical connectors. 3. Install the two screws to PCM electrical connectors. Page 1924 2. Loosen the two flange nuts holding the transmission mount to the third crossmember. 3. Use a pry bar to shift the engine assembly all the way forward. 4. Hold the prybar in place, and torque the flange nuts to 50 N.m (37 lb-ft). 5. Lower the vehicle. 6. Start the engine, and check for vibration. Make sure the chassis is not touching the lift during this check. ^ If the vibration is gone, no further action is required. ^ If the vibration is still there, go to REPAIR PROCEDURE B. REPAIR PROCEDURE B 1. Write down your customer's radio station presets and mode settings. 2. Disconnect the negative cable from the battery. 3. Raise the vehicle on a lift. 4. Remove both front wheels. 5. Models With 4WD: Remove the front skid plate (four bolts, four lock washers, four washers). A/T - Vehicle Speed Sensor Installation Precautions Transmission Speed Sensor: Technical Service Bulletins A/T - Vehicle Speed Sensor Installation Precautions Install VSS Properly to Avoid Reman A/T Damage We can't emphasize enough how important it is to follow, to the letter, the installation instructions that come with a reman A/T. These instructions help ensure that you avoid damaging the A/T and score a successful repair. This is particularly true when it comes to installing the vehicle speed sensor (VSS). Step 6 of the instructions tells you to make sure its gear is fully engaged and the VSS is fully seated before you tighten the retaining bolt. If you don't install the VSS properly, the speed sensor gear will get stripped and the A/T will be seriously damaged. So don't take risks with your customer's vehicle. Always follow these instructions to the letter. You can rest assured you're doing the job right. Page 4979 Brake Proportioning/Combination Valve: Service and Repair REMOVAL 1. The P&B; valve is not repairable and must be replaced as a complete assembly. Care must be taken to prevent brake fluid from contacting any painted surface. 2. Remove hydraulic pipes (1) and plug the pipes (1) to prevent the loss of fluid or the entrance of dirt. 3. Remove bolt (3). 4. Remove P&B; valve (2). INSTALLATION 1. Install P&B; valve (2). 2. Install bolt (3) and tighten the bolt to the specified torches Torque: 22 Nm (16 ft. lbs.) 3. Install hydraulic pipes (1) and tighten the bolt to the specified torque. Torque: 12 Nm (104 inch lbs.) 4. After installing the brake pipes, bleed the brakes. Locations Front Outside Handle And Associated Parts Page 1500 Piston: Diagrams Piston, Connecting Rod and Associate Parts Page 3761 Transmission Position Switch/Sensor: Description and Operation Transmission Range Switch IMPORTANT: The vehicle should not be driven with the transmission range switch disconnected; idle quality will be affected. The four inputs from the transmission range switch indicate to the PCM which position is selected by the transmission selector lever. This information is used for ignition timing, EVAP canister purge, EGR operation. For more information on the transmission on the transmission range switch, refer to Transmission Control System Diagnosis. See: Testing and Inspection Page 4901 Reinstall the tool bed on the brake lathe with the top of the cutting bits facing up and the feed knobs facing down. Adjust the tool bed until the brake disc is centered between the cutting bits. For proper refinishing, the brake disc must turn toward the top of the cutting bits. Do not set the cutting depth on the brake lathe to more than 0.2 mm (0.008 in.). This is two divisions on the cutting knob. Make sure you start your cut at least 3 mm (0.12 in.) beyond the worn area on the brake disc. If you are cutting larger diameter brake discs, make sure you use the 150 cutting bit holders. These bit holders, available through the Honda Tool and Equipment Program (see ORDERING INFORMATION), supersede the original bit holders and provide better cutting coverage for larger diameter brake discs. Each bit holder is clearly marked for proper installation on the tool holder. Cutting the Brake Disc To get the smoothest cut and the best brake disc finish, always use the slowest feed speed on the tool bed feed motor. Place the drive belt on the smallest pulley of the feed motor and on the largest pulley of the hand wheel. Make sure the lower toggle switch on the power drive system drive motor assembly is set to the proper rotation to turn the brake disc toward the top of the cutting bits. Plug the tool bed feed motor into the power outlet on the drive motor assembly, then turn on the drive motor with the upper toggle switch on the assembly. If you are not using the power drive system, make sure the transmission is in 1st gear (2nd gear on Preludes with ATTS) or Reverse and the engine is idling, but not at a fast idle. If the transmission and engine are at higher gears and speeds, you will damage the cutting bits. Turn on the tool bed feed motor, and snap it into place; there should be tension on the feed belt. Cut the brake disc until the cutting bits clear the outer edge of the disc. The cutting bits should produce a smooth, consistent finish with no chatter marks or grooves. If the disc did not clean up entirely on the first pass, reset the brake lathe and make a second pass. Page 1526 The size mark (1) for piston outside diameter is represented as shown in Figure. Outside Diameter Size Mark A: 93.360 mm - 93.370 mm (3.6756 inch - 3.6760 inch) Size Mark B: 93.371 mm 93.380 mm (3.6760 inch - 3.6764 inch) Size Mark C: 93.381 mm - 93.390 mm (3.6764 inch 3.6768 inch) Measure the cylinder bore inside diameter (refer to Cylinder Block). Piston Rings (8) Any worn or damaged part discovered during engine overhaul must be replaced with a new one. 1. Ring end gap measurement - Insert the piston ring into the bore. Page 325 Hood Sensor/Switch (For Alarm): Service and Repair Removal 1. Disconnect the battery ground cable. 2. Disconnect the connector. 3. Remove the engine hood switch (1). Installation To install, follow the removal steps in the reverse order. Page 4458 Testing For A Short With A Self-Powered Test Light or DVOM 1. Remove the blown fuse and disconnect the battery and load. 2. Connect one lead of a self-powered test light or digital volt/ohmmeter (DVOM) (switched to the lowest "OHMS" range) to the fuse terminal on the load side. 3. Connect the other lead to a known good ground. 4. Beginning near the fuse box, wiggle the harness. Continue this at convenient points about six inches apart while watching the test light or DVOM. 5. If the self-powered test light goes on or the DVOM displays a low reading or no reading (zero), there is a short to ground in the wiring near that point. Testing for a Short with a Test Light or DVOM 1. Remove the blown fuse and disconnect the load. 2. Connect a test light or digital volt/ohmmeter (DVOM), switched to the appropriate DC volts range, across the fuse terminals to make sure voltage is present. You might have to turn the ignition switch to ON; check the schematic to see. 3. Beginning near the fuse box, wiggle the harness. Continue this at convenient points about six inches apart while watching the test light or DVOM. 4. Where the test light goes , or the DVOM voltage drops to zero, there is a short to ground in the wiring near that point. NOTE: Always use a DVOM on high impedance circuits. A test light may not glow (even with battery voltage present). Testing For A Short With A Short Circuit Locator (Short Finder) 1. Remove the blown fuse. Leave the battery connected. Page 4336 - Disc - Caliper - Shift on the fly system parts (Cap, Hub flange, Shim, Snap ring) - ABS sensor ring For inspection and servicing of disc caliper and related parts, refer to Brakes and Traction Control; Brakes; Disc Brake System. REASSEMBLY 1. Install wheel pin. - Place the hub on a wood workbench or a block of wood approx. 6" by 6" to protect the wheel stud ends and threads. - Insert a wheel stud using a hammer. Be sure the wheel stud is started squarely and seats completely. 2. Align scribe marks (1) and attach the hub to the disc, then tighten the bolts to the specified torque. Torque: 103 Nm (76 ft. lbs.) 3. Use installer J-36829 and grip J-8092, then install the inner bearing by driving it into the hub. Page 4871 Page 6382 Wire Color Abbreviations The following abbreviations are used to identify wire colors in the circuit schematics: WHT................................... White YEL................................... Yellow BLK................................... Black BLU................................... Blue GRN................................... Green RED................................... Red ORN................................... Orange PNK................................... Pink BRN................................... Brown GRY................................... Gray PUR................................... Purple LT BLU................................... Light Blue LT GRN................................... Light Green Page 1543 Valve Shim Replacement Chart Page 3738 Terminals - "T" Each "T" terminal (ring type) is numbered for reference and location. A "T" terminal is secured with a screw or bolt. Wires Page 5273 Relay Box: Diagrams Instrument Panel Page 7593 If there is no photo number below or beside a component name or a connector, ground, or terminal number, look up that name or number in the appropriate Connector Identification Chart. The chart lists how many cavities a connector has, where it's located, and what it connects to. The related illustration shows the connector's location on the harness, and the harness routing. NOTE: Photos listed by number are located at Locations / Components / Photograohs. See: Locations/Component Locations/Photographs Circuit Schematics Diagrams Transmission Mode Switch: Diagrams Page 4769 ABS Light: Testing and Inspection Chart B-1 With The Key In The ON Position (Before Starting The Engine). Waring Light (W/L) Is Not Activated. Part 1 of 2 Part 2 of 2 Page 3040 Catalytic Converter: Technical Service Bulletins Catalytic Converter - Rotten Egg Smell SOURCE: Honda Service News July 2003 TITLE: Rotten Egg Smell? Could Be the Catalytic Converter APPLIES TO: All Models SERVICE TIP: Are customers complaining of a rotten egg smell, but you can't find anything wrong with their vehicles to account for it [there's no DTC(s) set, no driveability problems reported, nothing damaged or broken]? Then it could well be coming from the catalytic converter. That smell is a release of built up hydrogen sulfide (H2S) from the reaction of organic sulfur compounds in the gasoline with the catalyst in the converter. Almost all gasoline contains some amount of organic sulfur compounds, and that amount varies by region. The more sulfur there is in the gasoline, the more H2S is built up and released by the catalytic converter, so the stronger the smell. In California, where low-sulfur gasoline is actually required by state law, sulfur smell complaints are few and far between. The folks at the Environmental Protection Agency have issued a requirement for the phasing-in of low-sulfur gasoline nationwide between 2004 and 2006. This low-sulfur gasoline should go a long way toward making complaints of rotten egg smell a thing of the past. Page 7042 7. Pull out the trim panel at the 8 clip positions. - Disconnect the power window switch connector and courtesy light connector. 8. Remove the power window switch, if equipped. 9. Remove the bracket. 10. Remove the waterproof sheet. - Taking notice of the door harness, peel the waterproof sheet off the door panel carefully. 11. Disconnect the locking links and remove the door lock assembly fixing screws to remove the door lock assembly. Installation To install, follow the removal steps in the reverse order, noting the following points. 1. Apply chassis grease to the lock assembly and striker moving surface. Page 7683 Seat Belt, Lights-ON and Ignition Key Reminders Part 2 Of 2 Page 7009 2. To install the sunroof finisher (1), first fit it in at one place with the headlining (3) close to the sunroof frame complete (2), then install the entire finisher tightly by hitting it with a plastic hammer, not allowing it to move up. SWB Removal 1. Disconnect the battery ground cable. 2. Remove the soft top latch (Soft top model). - Remove two bolts. Checking/Adjusting Oil For New Compressor Refrigerant Oil: Service and Repair Checking/Adjusting Oil For New Compressor 150 cc (5.0 fl.oz.) of oil is charged in compressor (service parts). So it is necessary to drain the proper amount of oil from the new compressor. 1. Perform oil return operation. 2. Discharge and recover the refrigerant and remove the compressor. 3. Drain the compressor oil and measure the extracted oil. 4. Check the compressor oil for contamination. 5. Adjust the oil level as required. 6. Evacuate, charge and perform the oil return operation. 7. Check the system operation. Page 8082 Wire Color Abbreviations The following abbreviations are used to identify wire colors in the circuit schematics: WHT................................... White YEL................................... Yellow BLK................................... Black BLU................................... Blue GRN................................... Green RED................................... Red ORN................................... Orange PNK................................... Pink BRN................................... Brown GRY................................... Gray PUR................................... Purple LT BLU................................... Light Blue LT GRN................................... Light Green Page 5210 Wires Wire insulation can be one color, or one color with another color stripe. (The second color is the stripe.) This circuit continues on another image. (The arrow shows direction of current flow.) To follow the RED/BLK wire in this example, you would turn to "Fuel and Emissions" and look for the "A" arrow. Locations 46 - Top Front Of 3.2L Engine (Intake Duct Removed) Page 312 4WD Control Unit: Service and Repair 4WD CONTROL UNIT ASSOCIATED PARTS REMOVAL 1. Remove center console assembly. 2. Remove two screws and harness connector (1) from 4WD control unit. INSTALLATION 1. Connect harness connector, then install 4WD control unit. 2. Install center console assembly. Page 1929 Muffler: Diagrams Exhaust Silencer and Associated Parts Page 2107 Air Flow Meter/Sensor: Service and Repair Mass Air Flow (MAF) Sensor REMOVAL PROCEDURE 1. Disconnect the negative battery cable. 2. Disconnect the electrical connector from the MAF sensor. 3. Loosen the clamps which secure the intake air duct and the air cleaner to the MAF sensor. 4. Remove the intake air duct from the MAF sensor. 5. Remove the MAF sensor from the air cleaner. INSTALLATION PROCEDURE Diagram Information and Instructions Air Door Actuator / Motor: Diagram Information and Instructions How to Identify Wiring Color-Coded Insulation Wire Color Wire Color Coding Page 291 the component if the component only has one connector, or by a capital letter (A, B, C, etc.) if the component has more than one connector. Below most connector numbers and component names are PHOTO and VIEW numbers. The PHOTO number refers to a photo in the back of the book that shows the connector's location on the car. The VIEW number refers to an illustration in the back of the book that shows the connector face, wire colors, connector cavity numbers, and other details. The connector cavity numbering sequence begins at the top left corner of the connector. Disregard any numbers molded into the connector housing. Wires Wires are identified by the abbreviated names of their colors; the second color is the color of the stripe. Wires are also identified by their location in a connector. The number "2" next to the male and female wire terminals at C416, for example, means those terminals join in cavity 2 of connector C416. Symbols A complete description of schematic symbols is given under wire color abbreviation. Power Distribution Schematics Power Distribution schematics show how power is supplied from the positive battery terminal to various circuits in the car. Refer to the Power Distribution section to get a more detailed picture of how power is supplied to the circuit you're working on. From Battery to Ignition Switch, Fuses, and Relays Individual circuit schematics begin with a fuse. The first half of Power Distribution, however, shows the wiring "upstream" between the battery Dual Pressure Switch Refrigerant Pressure Sensor / Switch: Testing and Inspection Dual Pressure Switch 1. Disconnect pressure switch connector and check for continuity between pressure switch side connector terminals (1) and (2). Diagram Information and Instructions Dimmer Switch: Diagram Information and Instructions How to Identify Wiring Color-Coded Insulation Wire Color Wire Color Coding Page 3719 4. If the trouble occurs after the above test, charge the Axle Disconnect controller to the new one. Page 5003 "0" Line - Checks port into the atmospheric pressure chamber "5" Line - Checks air tightness of the pressure chamber NOTE: 1. Do not use an air compressor, as the air from the compressor is mixed with compressor oil. 2. When installing the master cylinder onto the vacuum booster, always adjust the vacuum booster push rod. 3. After the master cylinder is installed onto the vehicle, check for leakage, pedal travel and pedal free play. INSTALLATION 1. Install spacer and the 2 gaskets. 2. Install master cylinder. When replacing the master cylinder or vacuum booster or both, always measure the vacuum booster push rod protrusion and adjust it as necessary. 3. Install P&B; valve and bracket. 4. Install 2 attaching nuts and tighten the attaching nuts to the specified torque. Torque: 13 Nm (113 inch lbs.) 5. Install brake pipes and tighten the brake pipe to the specified torque. Master cylinder and P & B valve sides Torque: 12 Nm (104 inch lbs.) Others Torque: 16 Nm (12 inch lbs.) 6. Connect electrical connector. Specifications Firing Order: Specifications Firing Order Firing Order Firing Order 1-2-3-4-5-6 Page 4689 Wires Wire insulation can be one color, or one color with another color stripe. (The second color is the stripe.) This circuit continues on another image. (The arrow shows direction of current flow.) To follow the RED/BLK wire in this example, you would turn to "Fuel and Emissions" and look for the "A" arrow. Adjustments Clutch Switch: Adjustments 1. Turn the clutch switch (1) until the switch plunger is fully retracted against the clutch pedal arm. 2. Adjust clutch switch by backing it out half a turn and measure the clearance (4) between the clutch pedal arm (3) and the clutch switch. 3. Lock the lock nut (2). 4. Connect clutch switch connector. Clutch Switch (bolt) and Clutch Pedal Clearance 0.5 - 1.5 mm (0.020 - 0.059 in) Page 2370 Spark Plug: Application and ID Plug Types: K16PR-P11 RC10PYPP4 PK16PR11 Page 1408 Supportable Point: Front - Position the chassis stands at the bottom of the frame sidemember, behind the front wheel. Lifting Point: Rear - Position the floor jack at the center of the rear axle case when lifting the vehicle. Supportable Point: Rear - Position the chassis stands at the bottom of the frame sidemember, just behind the trailing link bracket. Page 3203 If there is no photo number below or beside a component name or a connector, ground, or terminal number, look up that name or number in the appropriate Connector Identification Chart. The chart lists how many cavities a connector has, where it's located, and what it connects to. The related illustration shows the connector's location on the harness, and the harness routing. NOTE: Photos listed by number are located at Locations / Components / Photograohs. See: Locations/Component Locations/Photographs Circuit Schematics Drivetrain - Revised CV Joint Boot Band/Installation Constant Velocity Joint Boot: Technical Service Bulletins Drivetrain - Revised CV Joint Boot Band/Installation 98-018 July 22, 2003 Applies To: ALL Models Driveshaft Boot Band Tool (Supersedes 98-018, Boot Band Tool, dated April 14, 1998) Updated information is shown by asterisks. The replacement boot bands for the driveshaft CV joint boots have changed. The replacement bands are a double loop type that require a special tool for proper installation. * TOOL INFORMATION Boot Band Tool: T/N KD-3191 This tool is already at your dealership. To order additional tools, call the Honda Tool and Equipment Program at 1-888-424-6857. Phone lines are open Monday through Friday from 7:30 a.m. to 7:00 p.m. CT.* REPAIR PROCEDURE 1. Remove the old boot band(s). Take care not to damage the boot. 2. Remove and inspect the boot. Replace the boot if it is worn or damaged. 3. Install the boot, and fill it with the specified amount and type of grease. Refer to section 16 of the appropriate service manual for the grease amount and type. 4. Adjust the driveshaft to the proper length. Refer to section 16 of the appropriate service manual. 5. Install the replacement boot band onto the large end of the boot with the end of the band facing toward the front of the vehicle. 6. Take up the slack in the boot band by hand, and hold the boot band in place. Page 6748 2. Connect one lead of a self-powered test light or DVOM to one end of the part of the circuit you want to test. 3. Connect the other lead to the other end. 4. If the self-powered test light glows, there is continuity. If you're using a DVOM, a low reading or no reading (zero), means good continuity. Testing For Voltage When testing for voltage at a connector without wire seals, you do not have to separate the two halves of the connector. Instead, probe the connector from the back. Always check both sides of the connector because dirty, corroded, and bent terminals can cause problems (no electrical contact = an open). 1. Connect one lead of the lest light to a known good ground, or, if you're using a digital volt ohmmeter (DVOM), place it in the appropriate DC volts range, and connect its negative lead to ground. 2. Connect the other lead of the test light or DVOM to the point you want to check. 3. If the test light glows, there is voltage present. If you're using a DVOM, note the voltage reading. It should be within one volt of measured battery voltage. A loss of more than one volt indicates a problem. NOTE: Always use a DVOM on high impedance circuits. A test light may not glow (even with battery voltage present). Testing For Voltage Drop Wires, connectors, and switches are designed to conduct current with a minimum loss of voltage. A voltage drop of more than one volt indicates a problem. 1. Place the digital volt/ohmmeter (DVOM) in the appropriate DC volts range. Connect the positive lead to the end of the wire (or to the connector or switch) closest to the battery. 2. Connect the negative lead to the other end of the wire (or the other side of the connector or switch). 3. Turn on the components in the circuit. 4. The DVOM will show the difference in voltage between the two points. A difference, or drop, of more than one volt indicates a problem. Check the circuit for loose, dirty, or bent terminals. Page 7620 Parking Brake Warning Switch: Description and Operation The brake system warning light goes on to alert the driver that the parking brake is applied or that the brake fluid is low. It also lights as a bulb test when the engine is cranked. With the ignition switch in ON or START, battery voltage is applied through fuse 11 to the brake system warning light. When the parking brake is applied, the parking brake switch closes and provides a ground for the light. The brake system warning light goes on to remind the driver that the parking brake is applied. Specifications Water Pump: Specifications Water Pump Bolts 25 Nm Engine Coolant Pump Centrifugal Impeller Type Page 7126 Page 7467 The SRS consists of the Sensing and Diagnostic Module (SDM), the driver air bag assembly, the SRS coil assembly, the passenger air bag assembly, and the "AIR BAG" warning lamp in the instrument cluster. The SDM, SRS coil assembly (driver side only), driver air bag assembly, passenger air bag assembly and connector wire make up the deployment loops. The function of the deployment loops is to supply current through air bag assembly, which will cause deployment of the air bags in the event of a frontal crash of sufficient force, up to 30 degrees off the centerline of the vehicle. The air bag assemblies are only supplied enough current to deploy when the SDM detects vehicle velocity changes severe enough to warrant deployment. The SDM contains a sensing device which converts vehicle velocity change to an electrical signal. The electrical signal generated is processed by the SDM and then compared to a value stored in memory. When the generated signal exceeds the stored value, the SDM will cause current to flow through the air bag assembly deploying the air bags. Page 2661 Fuel Tank Pressure Sensor: Description and Operation Fuel Tank Pressure Sensor The fuel tank pressure sensor is a three-wire strain gauge sensor similar to a common MAP sensor. However, the fuel tank pressure sensor has very different electrical characteristics due to its pressure differential design. The sensor measures the difference between the air pressure (or vacuum) in the fuel tank and the outside air pressure. The sensor mounts at the top of the fuel pump assembly. A three-wire electrical harness connects it to the PCM. The PCM supplies a five-volt reference voltage and a ground to the sensor. The sensor will return a voltage between 0.1 and 4.9 volts. When the air pressure in the fuel tank is equal to the outside air pressure, such as when the fuel cap is removed, the output voltage of the sensor will be 1.3 to 1.7 volts. When the air pressure in the fuel tank is 4.5 in. H2O (1.25 kPa), the sensor output voltage will be 0.5 ± 0.2 V. When there is neither vacuum nor pressure in the fuel tank, the sensor voltage will be 1.5 V. At -14 in. H2O (-3.75 kPa), the sensor voltage will be 4.5 ± 0.2 V. Page 4900 3. Attach the driveshaft on the drive motor assembly to the mounting yoke, making sure the center line of the driveshaft is level with the spindle nut on the wheel hub. 4. Set the lower toggle switch on the drive motor assembly to FWD (counterclockwise rotation) or REV (clockwise rotation). Setting Up and Adjusting the Brake Lathe Use Kwik-Way cutting bits, P/N KWY-109109223, and the holding screws that come with them. These bits are stamped KW and are available through the Honda Tool and Equipment Program (see ORDERING INFORMATION). Before you use the brake lathe, inspect the tips of the cutting bits with a magnifying glass to make sure the tips are not worn out. Each bit has three tips. If a tip is worn, rotate the bit, and use a new tip. A worn tip produces a poor finish and may cause chattering. Page 2450 11. Using a jumper wire, connect the reference voltage of each circuit to its signal input and view the APP Sensor values in the Engine Data List. APP Sensor 1 should have a value of 99%, and APP Sensor 2 and APP Sensor 3 should each have a value of 0%. ^ If the values are not as specified, troubleshoot for high resistance on the signal input or a PCM malfunction. Repair the circuit or replace the PCM, then repeat step 3. ^ If the values are as specified, the problem may be intermittent. Disconnect the 10P connector from the modified APPS, and connect it to the new APPS; then repeat step 3. Wiggle the APPS wires as you go through the adjustment procedure to find the intermittent problem. 12. Turn off the ignition switch, and disconnect the PGM Tester.* DISCLAIMER Page 5921 Ground - "G" Shielding Sheilding This represents RFI (Radio Frequency Interference) shielding around a wire. The shielding is always connected to ground. Splices Page 7041 Door Locks: Service and Repair Rear Door Lock Removal 1. Disconnect the battery ground cable. 2. Remove the rear corner garnish. 3. Remove the courtesy light lens. 4. Remove the window regulator handle. - Remove the clip on the rear side of the regulator handle using a wire. 5. Remove the screw while pulling the inside lever toward you and then remove the inside handle. 6. Remove the 2 screws at the pull case and courtesy light. Page 7515 it is located, and what it connects to. Use the Connector Views to help locate the proper cavity when you need to probe a connector. It can be especially helpful if the connector has more than one wire of the same color. A dash symbol (-) indicates that the cavity is empty. Connector views can also be used to help diagnose multiple symptoms in separate circuits which could be caused by a single problem in a connector shared by those circuits. Here's an example: 1. Pick one of the multiple symptoms and look up the schematic for that circuit. 2. Make a list of all the in-line and fuse box connectors in that schematic , 3. Then, in the Connector Views, look up each connector on your list to see if circuits related to the other symptoms run through one of them. If they do, inspect that connector for the problem. Example: The blower, rear window defogger, and the windshield wiper don't work. List all in-line and fuse box connectors in the blower controls circuit and then check the Connector View (see the sample). You find that C324 is common to the blower controls, rear window defogger, and wiper/washer, so you inspect C324 and find the problem, bent terminals. Finding Component/Connector Locations Finding Component/Connector Locations To see where a component or connector is located on the car, look up its photo number in the "Component Location". The photo will also tell you the color of the connector, and how many cavities it has. Page 4382 Universal Joint: Specifications Rear Propeller Shaft REAR PROPELLER SHAFT General Specifications Torque Specifications Page 7578 Wire Color Abbreviations The following abbreviations are used to identify wire colors in the circuit schematics: WHT................................... White YEL................................... Yellow BLK................................... Black BLU................................... Blue GRN................................... Green RED................................... Red ORN................................... Orange PNK................................... Pink BRN................................... Brown GRY................................... Gray PUR................................... Purple LT BLU................................... Light Blue LT GRN................................... Light Green Engine Controls - High/Erratic Engine Idle Power Steering Pressure Switch: All Technical Service Bulletins Engine Controls - High/Erratic Engine Idle 01-080 August 14, 2001 Applies To: 2000-02 Passport - ALL 2000-02 Passport: High or Erratic Idle SYMPTOM The engine occasionally idles at too high a speed, or the idle speed fluctuates. PROBABLE CAUSES The symptom could be the result of any of these conditions: ^ Loose or corroded engine or body ground ^ High resistance in the APPS ground circuit ^ PSP (power steering pressure) switch is internally shorted to ground ^ Fuel pressure regulator is leaking fuel into the intake manifold CORRECTIVE ACTION Diagnose the cause of the idle condition, and select the proper REPAIR PROCEDURE. PARTS INFORMATION REQUIRED MATERIALS REQUIRED SOFTWARE Each REPAIR PROCEDURE requires you to use the Smart Cable to reprogram the PCM with the latest software. To select the latest software from the CDROM, enter the year, model, engine, transmission, and emissions type (49-state or California). This gives you a list of broadcast codes. Select the broadcast code at the top of the list. WARRANTY CLAIM INFORMATION Refer to the Warranty Claim Information for each Repair Procedure. DIAGNOSIS 1. Find out from the customer when the high or erratic idle condition occurs and what the RPM range is: ^ Within 20 minutes of a cold start ^ After braking to a stop ^ All the time ^ Intermittently, with no set pattern Accelerator Pedal Position Sensor - MIL ON/DTC's Set Technical Service Bulletin # 01-047 Date: 010814 Accelerator Pedal Position Sensor - MIL ON/DTC's Set 01-047 August 14, 2001 Applies To: 2000-01 Passport - ALL MIL Comes On With Accelerator Pedal Position Sensor DTC(s) P1271, P1273, P1275, P1280, and/or P1285 SYMPTOM The MIL is on with DTC P1271, P1273, P1275, P1280, or P1285 (various accelerator pedal position sensor problems) stored. The REDUCED POWER indicator may also be on; and the engine may occasionally idle too high, or the idle may fluctuate. PROBABLE CAUSE Contaminated grease on the potentiometer circuit board of the accelerator pedal position sensor (APPS) causes high resistance in the APPS circuit. CORRECTIVE ACTION Replace and adjust the APPS, remove all grease from the accelerator link, and clean the APPS harness connector and connector C123. PARTS INFORMATION Accelerator Pedal Position Sensor: P/N 8-97193-713-0, H/C 6198311 REQUIRED MATERIALS CAIG DeoxIT D5-S6 Contact Cleaner: P/N 341-200 (available from www.partsexpress.com) or Permatex Electrical Contact Cleaner: Permatex P/N 24379 WARRANTY CLAIM INFORMATION In warranty: The normal warranty applies. Operation Number: 122114 Flat Rate Time: 0.5 hour Failed Part: P/N 8-97220-540-0 H/C 6202436 Defect Code: 091 Contention Code: C99 Template ID: 01-047A Skill Level: Repair Technician Out of warranty: Any repair performed after warranty expiration may be eligible for goodwill consideration by the District Service Manager or your Zone Office. You must request consideration, and get a decision, before starting work. Page 8178 - Top edge (1) and bottom edge (3) primer coat areas. 3. Stick the fasteners tape to the body in the specified locations. 4. Install the rear quarter glass assembly (1). - Apply the primer (4) to the rear quarter glass as shown in the figure. - Stick the dam seal (2) in place and then apply adhesive (3), as shown in the figure. - Allow a 20 mm (0.79 in) overlap at the ends of the adhesive. - Insert the glass clips into the hole in the panel and then push the glass against the panel to affix it in place. Page 5112 Alternator: Locations Page 1527 - Push the ring by the piston, at a right angle to the wall, into the point at which the cylinder bore diameter is the smallest. - Measure the ring end gap. - Positioning mark (1) is painted as shown in the illustration. Marked T: No.1 Compression ring Marked T2: No.2 Compression ring 2. Measure the clearance between the piston ring groove and the piston ring with a feeler gauge. If the piston ring groove/piston ring clearance exceeds the specified limit, the piston must be replaced. Compression Ring Clearance Standard: 0.025 mm - 0.065 mm (0.0006 inch - 0.0015 inch) Limit: 0.1mm (0.0059 inch) Piston Pin Note: Do not reuse the old piston pin. 1. Use a micrometer to measure the new piston pin outside diameter in both directions at three different positions. Circuit Operation Powertrain Control Module: Description and Operation Circuit Operation The engine or powertrain control module (ECM or PCM) receives inputs from the engine sensors and switches, controlling the functions of the engine. It also turns on the malfunction indicator "check engine" light whenever a malfunction or abnormal engine performance is detected, and allows for diagnostic testing through the data link connector (DLC). Page 5318 Page 7716 Terminals - "T" Each "T" terminal (ring type) is numbered for reference and location. A "T" terminal is secured with a screw or bolt. Wires Page 3623 Ignition Switch Lock Cylinder: Testing and Inspection TESTING AND INSPECTION Turn the ignition switch to "ON" while watching warning light. The light should flash 7 times and then go off. Locations Ignition Coil: Locations Right Side Of Engine Left Side Of Engine Right Side Of Engine Page 7670 Ground - "G" Shielding Sheilding This represents RFI (Radio Frequency Interference) shielding around a wire. The shielding is always connected to ground. Splices Page 1882 TWC LH and Forked Exhaust Pipe and Associated Parts Locations Heater Core: Locations Page 7006 Headlining (LWB) Front Differential Differential Axle Housing: Service and Repair Front Differential FRONT DRIVE AXLE ASSEMBLY AND ASSOCIATED PARTS REMOVAL 1. Jack up the vehicle and support it using jack stands. 2. Remove the tire and wheel. 3. Remove the stone guard. 4. Remove the brake caliper fixing bolt and hang the caliper. 5. Remove the antilock brake system speed sensor. 6. Remove the hub and disc assembly, refer to Wheel Hub; Service and Repair. 7. Remove propeller shaft, refer to Drive/Propeller Shaft; Service and Repair. 8. Loosen the height control arm of the torsion bar, then remove the torsion bar from lower control arm. 9. Remove suspension crossmember. Page 4162 Pressure Plate: Description and Operation PRESSURE PLATE ASSEMBLY X22SE engine, MUA transmissions 6VD1 engine, MUA transmission The pressure plate assembly consists of the clutch cover, the pressure plate with diaphragm spring. Operating the clutch pedal causes the pressure plate to move in an axial direction to engage and disengage the clutch. Page 2522 2. Connect one lead of a self-powered test light or DVOM to one end of the part of the circuit you want to test. 3. Connect the other lead to the other end. 4. If the self-powered test light glows, there is continuity. If you're using a DVOM, a low reading or no reading (zero), means good continuity. Testing For Voltage When testing for voltage at a connector without wire seals, you do not have to separate the two halves of the connector. Instead, probe the connector from the back. Always check both sides of the connector because dirty, corroded, and bent terminals can cause problems (no electrical contact = an open). 1. Connect one lead of the lest light to a known good ground, or, if you're using a digital volt ohmmeter (DVOM), place it in the appropriate DC volts range, and connect its negative lead to ground. 2. Connect the other lead of the test light or DVOM to the point you want to check. 3. If the test light glows, there is voltage present. If you're using a DVOM, note the voltage reading. It should be within one volt of measured battery voltage. A loss of more than one volt indicates a problem. NOTE: Always use a DVOM on high impedance circuits. A test light may not glow (even with battery voltage present). Testing For Voltage Drop Wires, connectors, and switches are designed to conduct current with a minimum loss of voltage. A voltage drop of more than one volt indicates a problem. 1. Place the digital volt/ohmmeter (DVOM) in the appropriate DC volts range. Connect the positive lead to the end of the wire (or to the connector or switch) closest to the battery. 2. Connect the negative lead to the other end of the wire (or the other side of the connector or switch). 3. Turn on the components in the circuit. 4. The DVOM will show the difference in voltage between the two points. A difference, or drop, of more than one volt indicates a problem. Check the circuit for loose, dirty, or bent terminals. Page 7228 105. Left Side of Driver's Seat Page 5638 Make necessary parts replacement if wear, damage, corrosion or any other abnormal condition are found through inspection. Inspect the lower end boot for damage or grease leak. Move the ball joint as shown in the figure to confirm its normal movement . - Inspect screw/taper area of ball for damage. - If any defects are found by the above inspections, replace the ball joint assembly with new one. - After moving the ball joint 4 or 5 times, attach nut the measure the preload. Starting torque: 0.5-6.4 Nm (0.4-4.7 ft. lbs.) - If the above limits specified are exceeded, replace the ball joint assembly. INSTALLATION 1. Install lower ball joint. 2. Install bolt. 3. Install nut and tighten it to the specified torque. Torque to 116 Nm (85 ft. lbs.). 4. Install ball joint nut, then tighten it to the specified torque with just enough additional torque to align cotter pin holes. Install new cotter pin. Torque to 147 Nm (108 ft. lbs.). Bleeding Brake Hydraulic System Brake Bleeding: Service and Repair Bleeding Brake Hydraulic System This procedure has been updated by TSB Manual Update # 01-016 dated January 30, 2001. BRAKE SYSTEM BLEEDING A bleeding operation is necessary to remove air from the hydraulic brake system whenever air is introduced into the hydraulic system. It may be necessary to bleed the hydraulic system at all four brakes if air has been introduced through a low fluid level or by disconnecting brake pipes at the master cylinder. If a brake pipe is disconnected at one wheel, only that wheel cylinder/caliper needs to be bled. If the pipes are disconnected at any fitting located between the master cylinder and brakes, then the brake system served by the disconnected pipe must be bled. 1. For 4-Wheel Antilock Brake System (ABS) equipped vehicle, be sure to remove the ABS main fuse 60A located at the relay and fuse box before bleeding air. If you attempt to bleed air without removing the main fuse, air cannot be let out thoroughly, and this may cause damage to the hydraulic unit. After bleeding air, be sure to replace the ABS main fuse back to its original position. 2. Set the parking brake completely, then start the engine. NOTE: The vacuum booster will be damaged if the bleeding operation is performed with the engine off. NOTE: To avoid trapping air bubbles in the ABS hydraulic unit while bleeding the brakes, the hydraulic unit must be tilted forward at a 15-degree angle or greater. Before bleeding, check the angle of the ABS hydraulic unit with an angle locator level. If needed, raise the rear of the vehicle to get the proper angle. The angle locator level (P/N SUN-YA328A) is available through the Honda Tool and Equipment Program. 3. Remove the master cylinder reservoir cap. 4. Fill the master cylinder reservoir with brake fluid. Keep the reservoir at least half full during the air bleeding operation 5. Always use new brake fluid for replenishment. 6. In replenishing brake fluid, take care that air bubbles do not enter the brake fluid. When the master cylinder is replaced or overhauled, first bleed the air from the master cylinder, then from each wheel cylinder and caliper following the procedures. BLEEDING THE MASTER CYLINDER 7. Disconnect the rear wheel brake pipe (1) from the master cylinder. Page 170 The connector cavity number is listed next to each terminal on the circuit schematic. The cavity / terminal shown is # 6. Diodes A rectifier diode works like a one way valve. It allows current to flow only in the direction of the arrow. A Zener diode blocks reverse current at normal voltages just like a rectifier diode. At high voltages, however, a Zener diode allows current to flow in reverse. Fuses Page 2043 and the fuses. From Fuses to Relays and Components The second half of Power Distribution shows the wiring "From Fuses to Relays and Components." This can speed your troubleshooting by showing which circuits share fuses. If Power Distribution shows that an inoperative circuit and another circuit share a fuse, check a component in the other circuit. If it works, you know the fuse is good and power is available to the inoperative circuit. Ground Distribution Schematics Component Locations Oxygen Sensor: Component Locations 95. Right Front Exhaust Downpipe Right Front Exhaust Downpipe 93. Left Front Exhaust Downpipe Left Front Exhaust Downpipe Page 4363 Support the propeller shaft on V-blocks (2) and check for run-out by holding the probe of a dial indicator (1) in contact with the shaft. Static run-out limit: 0.13 mm (0.005 inch) TIR on the neck of the slip tube shaft (with a boot). 0.25 mm (0.010 inch) TIR on the ends of the tubing 3 inch from the welds. 0.38 mm (0.015 inch) TIR at the linear center of the tube. 0.38 mm (0.015 inch) TIR for the full length of tube with 30" or less of tubing. (TIR: Total Indicator Reading) Spline The nylon-coated spline should be free from nicks and dings and the underlying steel spline should not be visible. After cleaning the nylon coating spline, the coating should exhibit only slight indicator of wear. Grease volume is approximately 10 grams of grease in total. Grease should be evenly applied to both the female and the male slip splines using a small brush. After assembly of the slip joint, the sliding joint should be fully worked from the full collapsed to the full extended position. Play In The Universal Joint Limit: Less than 0.15 mm (0.006 inch) Preload Of The Universal Joint Page 3821 ^ If the idle speed ever exceeds 1,300 rpm 2. Remove the vacuum hose from the fuel pressure regulator, then start the engine. ^ If fuel comes out of the fuel pressure regulator vacuum hose connection, go to REPAIR PROCEDURE FUEL PRESSURE REGULATOR. ^ If no fuel comes out of the regulator, reconnect the vacuum hose and continue to step 3. 3. Connect the PGM Tester. Set it to Engine Data List. 4. Have an assistant drive the vehicle under the conditions described by the customer. 5. If the high or erratic idle condition occurs, note the values of the PSP Switch and APP Sensor 1 when it is occurring. ^ If the PSP Switch is HIGH, and you are not turning, go to REPAIR PROCEDURE POWER STEERING SWITCH. ^ If the APP Sensor 1 is greater than 15% and APP Sensor 2 and/or APP Sensor 3 are less than 85%, and the accelerator pedal is not depressed, go to REPAIR PROCEDURE APPS GROUND. ^ If the PSP Switch is reading LOW when not turning and HIGH when turning, and the APP Sensors are reading within the range shown, discontinue the test-drive and go to step 6. 6. Do these repairs: ^ REPAIR PROCEDURE APPS GROUND ^ REPAIR PROCEDURE ENGINE/BODY GROUND REPAIR PROCEDURE - FUEL PRESSURE REGULATOR 1. Relieve fuel system pressure: ^ Remove the fuel fill cap. ^ Remove the fuel pump relay. ^ Start the engine and run it until it stalls. ^ Crank the engine for 3 seconds. 2. Remove the vacuum hose from the fuel pressure regulator. 3. Remove the fuel pressure regulator shield from the common chamber (two bolts). Page 5146 Ignition Switch Lock Cylinder: Testing and Inspection TESTING AND INSPECTION Turn the ignition switch to "ON" while watching warning light. The light should flash 7 times and then go off. Page 656 Intake Air Temperature Sensor: Description and Operation Intake Air Temperature (IAT) Sensor The intake air temperature (IAT) sensor is a thermistor which changes its resistance based on the temperature of air entering the engine. Low temperature produces a high resistance of 100,000 ohms at -40 °C (-40 °F). High temperature causes low resistance of 70 ohms at 130 °C (266 °F). The PCM supplies a 5-volt signal to the sensor through a resistor in the PCM and monitors the signal voltage. The voltage will be high when the incoming air is cold. The voltage will be low when the incoming air is hot. By measuring the voltage, the PCM calculates the incoming air temperature. The IAT sensor signal is used to adjust spark timing according to the incoming air density. The Tech 2 displays the temperature of the air entering the engine. The temperature should read close to the ambient air temperature when the engine is cold and rise as underhood temperature increases. If the engine has not been run for several hours (overnight), the IAT sensor temperature and engine coolant temperature should read close to each other. A fault in the IAT sensor circuit will set DTC P0112 or DTC P0113. Description and Operation EGR Valve Position Sensor: Description and Operation EGR Pintle Position Sensor The PCM monitors the EGR valve pintle position input to endure that the valve responds properly to commands from the PCM and to detect a fault if the pintle position sensor and control circuits are open or shorted. If the PCM detects a pintle position signal voltage outside the normal range of the pintle position sensor, or a signal voltage that is not within a tolerance considered acceptable for proper EGR system operation, the PCM will set DTC P1406. Page 355 Sunroof/Moonroof Limit Switch: Service and Repair Limit Switch Removal 1. Disconnect the battery ground cable. 2. Remove the sunroof drive unit assembly (1) to remove the limit switch (2). Installation To install, follow the removal steps in the reverse order. Page 467 Test Equipment CAUTION: Most circuits include solid-state devices. Test the voltages in these circuits only with a 10-megaohm or higher impedance digital multimeter. Never use a test light or analog meter on circuits that contain solid-state devices. Damage to the devices may result. Test Light and DVOM On circuits without solid-state devices, use a test light to check for voltage. A test light is made up of a 12 volt bulb with a pair of leads attached. After grounding one lead, touch the other lead to various points along the circuit where voltage should be present. The bulb will go on if there is voltage at the point being tested. If you need to know how much voltage is present, use a digital volt/ohmmeter (DVOM). Self-Powered Test Light and DVOM Use a self-powered test light to check for continuity. This tool is made up of a light bulb, battery, and two leads. To test it, touch the leads together: the light should go on. Use a self-powered test light only on an unpowered circuit. First, disconnect the battery, or remove the fuse that feeds the circuit you are working on. Select two points in the circuit between which you want to check continuity. Connect one lead of the self-powered test light to each point. If there is continuity, the test light's circuit will be completed, and the light will go on. If, in addition, you need to know exactly how much resistance there is between two points, use a digital volt/ohmmeter (DVOM). In the "OHMS" range, the DVOM will measure resistance between two points along a circuit. Low resistance means good continuity. Diodes and solid-state devices in a circuit can make a DVOM give a false reading. To check a reading, reverse the leads, and take a second reading. If the readings differ, the component is affecting the measurement. Jumper Wire Use a jumper wire to bypass an open circuit. A jumper wire is made up of an in-line fuse holder connected to a set of test leads. It should have a five ampere fuse. Never connect a jumper wire across a short circuit. The direct battery short will blow the fuse. Short Finder (Short Circuit Locator) Short finders are available to locate shorts to ground. The short finder creates a pulsing magnetic field in the shorted circuit which you can follow to the location of the short. To order any test equipment shown above, contact your local tool supplier. For a list of suppliers and tool numbers, refer to Honda Required Special Tools and Equipment Service Bulletin. Page 1431 Limit: 0.11 mm (0.0043 inch) 5. Replace the cylinder head and/or camshaft if the measured oil clearance exceeds the specified limit. 1. Carefully clean the camshaft journal, the camshaft bracket, and the cylinder head. 2. Install camshaft assembly and camshaft brackets (2), tighten twenty bolts (1) on one side bank to the specified torque. Torque: 10 Nm (89 inch lbs.) 3. Measure the camshaft thrust clearance with a dial indicator. Replace the camshaft and/or the cylinder head if the camshaft thrust clearance exceeds the specified limit. Camshaft thrust Clearance Standard: 0.03 mm - 0.08 mm (0.0012 inch - 0.0031 inch) Limit: 0.12 mm (0.0047 mm) REASSEMBLY 1. Install camshaft drive gear assembly and tighten three bolts to specified torque. Torque: 10 Nm (89 inch lbs.) Page 7470 Air Bag(s) Arming and Disarming: Service and Repair Connector Disconnection / Connection REMOVAL To remove the connector, hold the cover insulator(l) and pull it. The cover insulator slides and lock will be released. Do not hold the socket insulator(2). INSTALLATION Page 5365 Relay Box: Diagrams Instrument Panel Page 6321 Evaporator Temperature Sensor / Switch: Service and Repair Electronic Thermostat, Evaporator Core and/or Expansion Valve Electronic Thermostat, Evaporator Core And/Or Expansion Valve - Disassembled View Removal 1. Disconnect the battery ground cable. 2. Discharge and recover refrigerant. 3. Remove evaporator assembly. 4. Remove the electronic thermostat sensor fixing clip. Pull the sensor from the evaporator assembly. 5. Remove clip. 6. Remove attaching screw. 7. Remove upper case. Page 2741 2. Unfasten C123 from the side of the engine compartment using a 90-degree pick. 3. Disconnect C123, and clean the terminals on both sides of the connector with contact cleaner. Shake the residue out of the connector. Allow the contact cleaner to evaporate for at least 3 minutes, then reconnect C123. 4. Fasten C123 to the left side of the engine compartment, and reinstall the air cleaner housing cover. 5. Remove the connector position assurance (CPA) clip from the APPS connector. 6. Disconnect the lop connector from the APPS. 7. Clean the terminals of the 10P APPS connector (harness side) with contact cleaner. Shake out residue from the connector, and allow the contact cleaner to evaporate for at least 3 minutes, then reconnect it. 8. Use the Smart Cable to reprogram the PCM with the latest software from the June 2001 or later HONDANET CD-ROM. Refer to Service Bulletin 99-005, Updating the Passport PCM, filed under Tools. 9. Use the PGM Tester to clear any DTCs. Page 8231 9. Install side molding. - Use alcohol wipe or equivalent cleaner with soft cloth to wipe away any excess adhesive. - Cure the bonding at a temperature of 20 °C - 30 °C (68 °F - 86 °F) for 24 hours. - Check the windshield for any signs of water leak. 10. Install windshield wiper arm. Page 8174 4. Install the rear quarter glass assembly (1). - Apply the primer (4) to the rear quarter glass as shown in the figure. - Stick the dam seal (2) in place and then apply adhesive (3), as shown in the figure. - Allow a 20mm (0.7g in) overlap at the ends of the adhesive. - Insert the glass clips into the hole in the panel and then push the glass against the panel to affix it in place. On-Vehicle Inspection Alternator: Testing and Inspection On-Vehicle Inspection 1. Disconnect the wiring connector from generator. 2. With the engine stopped, turn starter switch to "ON" and connect a voltmeter between connector terminal L (1) and ground or between terminal IG (2) and ground. If voltage is not present, the line between battery and connector is disconnected and so requires repair. 3. Reconnect the wiring connector to the generator, run the engine at middle speed, and turn OFF all electrical devices other than engine. 4. Measure battery voltage. If it exceeds 16 V, repair or replace the generator. 5. Connect an ammeter to output terminal of generator, and measure output current under load by turning on the other electrical devices (eg., headlights). At this time the amperes must not be less than 15 A and the voltage must not be less than 13 V. Page 1854 3. Connect the electrical connector. 4. Fill the radiator with coolant. Refer to Draining and Refilling Cooling System. 5. Connect the negative battery cable. Page 5184 Polish the commutator surface with sandpaper #500 to #600 if it is rough. Measure the depth of insulator in commutator. Repair,if it is below the limit. Standard: 0.5 mm to 0.8 mm (0.02 in to 0.03 in) Limit: 0.2 mm (0.008 in) Page 6616 Testing and Inspection Interior - Rear Beverage Holder Swing Arm Won't Lock Drink Holders: All Technical Service Bulletins Interior - Rear Beverage Holder Swing Arm Won't Lock 02-022 April 9, 2002 Applies To: 1999-02 Passport - ALL Rear Beverage Holder Swing Arm Does Not Lock SYMPTOM The rear beverage holder swing arm does not firmly stay in an open or closed position because the detents do not hold. PROBABLE CAUSE One or both metal detent clips are out of place or missing. CORRECTIVE ACTION Replace both detent clips. PARTS INFORMATION Rear Beverage Holder Detent Clip (two required): P/N 8-97212-275-0, H/C 7084197 WARRANTY CLAIM INFORMATION In warranty: The normal warranty applies. Operation Number: 044104 Flat Rate Time: 0.3 hour Failed Part: P/N 8-97292-133-3 H/C 6193379 Defect Code: 030 Contention Code: B02 Template ID: 02-022A Skill Level: Repair Technician Out of warranty: Any repair performed after warranty expiration may be eligible for goodwill consideration by the District Service Manager or your Zone Office. You must request consideration, and get a decision, before starting work. REPAIR PROCEDURE Page 3395 it is located, and what it connects to. Use the Connector Views to help locate the proper cavity when you need to probe a connector. It can be especially helpful if the connector has more than one wire of the same color. A dash symbol (-) indicates that the cavity is empty. Connector views can also be used to help diagnose multiple symptoms in separate circuits which could be caused by a single problem in a connector shared by those circuits. Here's an example: 1. Pick one of the multiple symptoms and look up the schematic for that circuit. 2. Make a list of all the in-line and fuse box connectors in that schematic , 3. Then, in the Connector Views, look up each connector on your list to see if circuits related to the other symptoms run through one of them. If they do, inspect that connector for the problem. Example: The blower, rear window defogger, and the windshield wiper don't work. List all in-line and fuse box connectors in the blower controls circuit and then check the Connector View (see the sample). You find that C324 is common to the blower controls, rear window defogger, and wiper/washer, so you inspect C324 and find the problem, bent terminals. Finding Component/Connector Locations Finding Component/Connector Locations To see where a component or connector is located on the car, look up its photo number in the "Component Location". The photo will also tell you the color of the connector, and how many cavities it has. Page 7902 Each schematic represents one circuit. A circuit's wires and components are arranged to show current flow, from power at the top of the page, to ground, at the bottom. Shared Circuits Other circuits may share power or ground terminals or wiring with the circuit shown. A wire that connects one circuit to another, for example, is cut short and has an arrowhead at the end of it pointing in the direction of current flow. Next to the arrowhead is the name of the circuit or component which shares that wiring. To quickly check shared wiring, check the operation of a component it serves. If that component works, you know the shared wiring is OK. Connectors All in-line and junction connectors are numbered (C725, C416, etc.). Component connectors are not numbered but are identified either by the name of Front Tires - Rub On Mud Flap On Sharp Turns Tires: Customer Interest Front Tires - Rub On Mud Flap On Sharp Turns 01-088 September 11, 2001 Applies To: 1998-01 Passport - ALL Front Tire Rubs Against the Mud Flap PROBLEM The front tire rubs against the mud flap when the wheel is turned to full lock. CORRECTIVE ACTION Trim away part of the mud flap. WARRANTY CLAIM INFORMATION In warranty: The normal warranty applies. Operation Number: 031005 Flat Rate Time: 0.3 hour Failed Part: P/N 8-97261-990-0 H/C 6633416 Defect Code: 042 Contention Code: B07 Template ID: 01-088A Skill Level: Repair Technician Out of warranty: Any repair performed after warranty expiration may be eligible for goodwill consideration by the District Service Manager or your Zone Office. You must request consideration, and get a decision, before starting work. REPAIR PROCEDURE 1. Remove the mud flaps from the front fenders (four screws each). 2. Wipe off the mud flaps. Page 4452 Wires Wire insulation can be one color, or one color with another color stripe. (The second color is the stripe.) This circuit continues on another image. (The arrow shows direction of current flow.) To follow the RED/BLK wire in this example, you would turn to "Fuel and Emissions" and look for the "A" arrow. Page 3519 Camshaft Position Sensor: Testing and Inspection 1. Inspect the sensor O-ring for cracks or leaks. 2. Replace the O-ring if it is worn or damaged. 3. Lubricate the new O-ring with engine oil. 4. Install the lubricated O-ring. Capacity Specifications Fluid - A/T: Capacity Specifications A/T Fluid Capacity ............................................................................................................................................... ........................................................................... 8.6L Page 489 the component if the component only has one connector, or by a capital letter (A, B, C, etc.) if the component has more than one connector. Below most connector numbers and component names are PHOTO and VIEW numbers. The PHOTO number refers to a photo in the back of the book that shows the connector's location on the car. The VIEW number refers to an illustration in the back of the book that shows the connector face, wire colors, connector cavity numbers, and other details. The connector cavity numbering sequence begins at the top left corner of the connector. Disregard any numbers molded into the connector housing. Wires Wires are identified by the abbreviated names of their colors; the second color is the color of the stripe. Wires are also identified by their location in a connector. The number "2" next to the male and female wire terminals at C416, for example, means those terminals join in cavity 2 of connector C416. Symbols A complete description of schematic symbols is given under wire color abbreviation. Power Distribution Schematics Power Distribution schematics show how power is supplied from the positive battery terminal to various circuits in the car. Refer to the Power Distribution section to get a more detailed picture of how power is supplied to the circuit you're working on. From Battery to Ignition Switch, Fuses, and Relays Individual circuit schematics begin with a fuse. The first half of Power Distribution, however, shows the wiring "upstream" between the battery Front Door Lock Door Locks: Service and Repair Front Door Lock Removal 1. Disconnect the battery ground cable. 2. Remove the power window switch (1)/regulator handle. - Pry out the power window switch and remove the connectors. - To remove the regulator handle (1), remove the clip (2), at the root of the handle by using wire with hook. Page 872 Ignition Switch Lock Cylinder: Service and Repair REMOVAL 1. Turn the steering wheel so that the vehicle's wheels are pointing straight ahead. 2. Turn the ignition switch to "LOCK". 3. Disconnect the battery "-" terminal cable, and wait at least 5 minutes. 4. Disconnect the yellow 2-way SRS connector located under the steering column. CAUTION: The wheels of the vehicle must be straight ahead and the steering column in the "LOCK" position before disconnecting the steering wheel. Failure to do so will cause the coil assembly to become uncentered which will cause damage to the coil assembly. 5. Remove the engine hood opening lever and steering lower cover. 6. Remove knee bolster (reinforcement). Windshield Wiper Arm/Blade Wiper Arm: Service and Repair Windshield Wiper Arm/Blade Windshield Wiper Arm/Blade Removal 1. Pry the cap(2) off with the tip of a screwdriver. 2. Remove the nut. 3. Remove the wiper arm/blade(1). Installation To install, follow the removal steps in the reverse order, noting the following points: 1. Before installing the wiper arm/blade to the shaft, confirm that the motor stops at the autostop position. 2. Set the wiper arm/blade so that the tips of both blades are positioned about 40 mm (1.57 in) from the upper edge of the cowl cover as shown in the figure. 3. Tighten the nuts to the specified torque. Torque: 23 Nm (17 lb.ft) Page 2784 2. Connect one lead of a self-powered test light or DVOM to one end of the part of the circuit you want to test. 3. Connect the other lead to the other end. 4. If the self-powered test light glows, there is continuity. If you're using a DVOM, a low reading or no reading (zero), means good continuity. Testing For Voltage When testing for voltage at a connector without wire seals, you do not have to separate the two halves of the connector. Instead, probe the connector from the back. Always check both sides of the connector because dirty, corroded, and bent terminals can cause problems (no electrical contact = an open). 1. Connect one lead of the lest light to a known good ground, or, if you're using a digital volt ohmmeter (DVOM), place it in the appropriate DC volts range, and connect its negative lead to ground. 2. Connect the other lead of the test light or DVOM to the point you want to check. 3. If the test light glows, there is voltage present. If you're using a DVOM, note the voltage reading. It should be within one volt of measured battery voltage. A loss of more than one volt indicates a problem. NOTE: Always use a DVOM on high impedance circuits. A test light may not glow (even with battery voltage present). Testing For Voltage Drop Wires, connectors, and switches are designed to conduct current with a minimum loss of voltage. A voltage drop of more than one volt indicates a problem. 1. Place the digital volt/ohmmeter (DVOM) in the appropriate DC volts range. Connect the positive lead to the end of the wire (or to the connector or switch) closest to the battery. 2. Connect the negative lead to the other end of the wire (or the other side of the connector or switch). 3. Turn on the components in the circuit. 4. The DVOM will show the difference in voltage between the two points. A difference, or drop, of more than one volt indicates a problem. Check the circuit for loose, dirty, or bent terminals. Page 4557 Wire Color Abbreviations The following abbreviations are used to identify wire colors in the circuit schematics: WHT................................... White YEL................................... Yellow BLK................................... Black BLU................................... Blue GRN................................... Green RED................................... Red ORN................................... Orange PNK................................... Pink BRN................................... Brown GRY................................... Gray PUR................................... Purple LT BLU................................... Light Blue LT GRN................................... Light Green Locations Page 2701 3. Check the vacuum hose to the sensor for leaking or restriction, Be sure that no other vacuum devices are connected to the MAP hose. IMPORTANT: Make sure the electrical connector remains securely fastened. 4. Disconnect the sensor from the bracket. Twist the sensor with your hand to check for an intermittent connection. Output changes greater than 0.10 volt indicate a bad sensor. Page 2489 CD Player/Changer Troubleshooting (Passport only) Manually Removing a Jammed Magazine (All except Passport) One-piece door model: 1. Remove the changer from the vehicle. 2. Remove the rear cover plate from the changer, and look for a jammed disc. 3. If a disc is jammed between the player and the magazine, turn the loading gear until the disc returns to the player mechanism. Do not attempt to reload the disc back into the magazine. 4. After the disc is loaded into the player mechanism, turn the changer so that the front is facing you. Page 5513 Moonroof - Visor Sags in The Middle Sun Shade: All Technical Service Bulletins Moonroof - Visor Sags in The Middle 00-061 August 22, 2000 Applies To: 1998-00 Passport - ALL Accessory Moonroof Visor Appearance PROBLEM The rear edge of the moonroof visor sags in the middle, and/or the roof seal is distorted. CORRECTIVE ACTION Replace the moonroof visor and the roof seal with a new assembly. PARTS INFORMATION Accessory Moonroof Visor Kit: P/N 08R01-ED1101, H/C 6483838 WARRANTY CLAIM INFORMATION In warranty: The normal warranty applies. Out of warranty: Any repair performed after warranty expiration may be eligible for goodwill consideration by the District Service Manager or your Zone Office. You must request consideration, and get a decision, before starting work. REPAIR PROCEDURE 1. Remove the moonroof visor, the roof seal, and all related hardware. 2. Install the new moonroof visor kit. Refer to the Accessory Installation Instructions binder for the installation instructions. Disclaimer Specifications Torsion Bar: Specifications Torsion Bar Attaching Bolts 116 Nm A/T - Vehicle Speed Sensor Installation Precautions Transmission Speed Sensor: Technical Service Bulletins A/T - Vehicle Speed Sensor Installation Precautions Install VSS Properly to Avoid Reman A/T Damage We can't emphasize enough how important it is to follow, to the letter, the installation instructions that come with a reman A/T. These instructions help ensure that you avoid damaging the A/T and score a successful repair. This is particularly true when it comes to installing the vehicle speed sensor (VSS). Step 6 of the instructions tells you to make sure its gear is fully engaged and the VSS is fully seated before you tighten the retaining bolt. If you don't install the VSS properly, the speed sensor gear will get stripped and the A/T will be seriously damaged. So don't take risks with your customer's vehicle. Always follow these instructions to the letter. You can rest assured you're doing the job right. Page 7586 Seat Belt, Lights-ON and Ignition Key Reminders Part 2 Of 2 Page 3920 12. Install the new cover using the accumulator cover installation tool. 13. Reinstall the snap ring. 14. 2002 only: Reconnect the cooler return line, and tighten the bracket that secures the ATF cooler line. 15. Check the transmission fluid level, and refill as necessary with Dexron III ATF. Refer to the Automatic Transmission section of the appropriate Passport Service Manual. Disclaimer Component Tests Wheel Speed Sensor: Testing and Inspection Component Tests Front INSPECTION AND REPAIR 1. Check the speed sensor pole piece for presence of foreign materials; remove any dirt, etc. 2. Check the pole piece for damage; replace speed sensor if necessary. 3. Check the speed sensor cable for short or open circuit, and replace with a new one if necessary. To check for cable short or open, bend or stretch the cable while checking for continuity. 4. Check the sensor ring for damage including tooth chipping, and if damaged, replace the sensor ring assembly. Rear INSPECTION AND REPAIR 1. Check speed sensor pole piece for presence of foreign materials; remove any dirt, etc. 2. Check the pole piece for damage, and replace speed sensor if necessary. 3. Check speed sensor cable for short or open, and replace with a new one if necessary. To check for cable short or open, bend or stretch the cable while checking for continuity. 4. Check the sensor ring for damage including tooth chipping, and if damaged, replace the axle shaft assembly. Page 1243 Refrigerant: Service and Repair System Charging There are various methods of charging refrigerant into the air conditioning system. These include using J-39500 (ACR(4):HFC-134a Refrigerant Recovery / Recycling / Recharging / System) or equivalent and direct charging with a weight scale charging station. Charging Procedure - ACR(4)(or equivalent) Method For the charging of refrigerant recovered by ACR(4)(or equivalent), follow the manufacturer's instruction. - Direct charging with a weight scale charging station method 1. Make sure the evacuation process is correctly completed. 2. Connect the center hose of the manifold gauge to the weight scale. 3. Connect the low pressure charging hose of the manifold gauge to the low pressure side service valve of the vehicle. Front Tires - Rub On Mud Flap On Sharp Turns Tires: All Technical Service Bulletins Front Tires - Rub On Mud Flap On Sharp Turns 01-088 September 11, 2001 Applies To: 1998-01 Passport - ALL Front Tire Rubs Against the Mud Flap PROBLEM The front tire rubs against the mud flap when the wheel is turned to full lock. CORRECTIVE ACTION Trim away part of the mud flap. WARRANTY CLAIM INFORMATION In warranty: The normal warranty applies. Operation Number: 031005 Flat Rate Time: 0.3 hour Failed Part: P/N 8-97261-990-0 H/C 6633416 Defect Code: 042 Contention Code: B07 Template ID: 01-088A Skill Level: Repair Technician Out of warranty: Any repair performed after warranty expiration may be eligible for goodwill consideration by the District Service Manager or your Zone Office. You must request consideration, and get a decision, before starting work. REPAIR PROCEDURE 1. Remove the mud flaps from the front fenders (four screws each). 2. Wipe off the mud flaps. Page 6475 A battery voltage (B+) circuit which is only powered with the ignition switch in the ON, or START positions. Initiator The electrical component inside the air bag assembly which, when sufficient current flows, sets off the chemical reaction that inflates the air bag. "Initiator Assembly Resistance Test" Tests performed once each ignition cycle when no malfunctions are detected during "Turn-ON" or "Continuous Monitoring." This test checks for the correct SDM configuration for the vehicle, shorts to "Ignition 1 in the deployment loops, high resistance or opens in the "Driver Side High", "Driver Side Low", "Passenger Side High" and "Passenger Side Low" circuits and measures the resistance of the inflator assembly consisting of: 1. Initiators. 2. SRS coil assembly (driver side only). 3. Connectors and associated wiring. Normal Operating Voltage Range The voltage measured between the SDM "Ignition 1" terminals and "Ground" terminals is between 9 and 16 volts. Passenger Current Source An output of the SDM which applies current into the passenger air bag assembly circuit during the "Initiator Assembly Resistance Test". Passenger Air Bag Assembly An assembly located in the right side of the instrument panel consisting of an inflatable bag, an inflator and an initiator. Scan Tool An external computer used to read diagnostic information from on-board computers via the data link connector. SDM Sensing and Diagnostic Module which provides reserve energy to the deployment loops, deploys the air bags when required and performs diagnostic monitoring of all SRS components. Serial Data Information representing the status of the SRS. SRS Supplemental Restraint System. SRS Coil Assembly An assembly of two current-carrying coils in the driver deployment loop that allows the rotation of the steering wheel while maintaining the continuous contact of the driver deployment loop to the driver air bag assembly. SRS Wiring Harness The wires and connectors that electrically connect the components in the SRS. "Turn-ON" Test which the SDM performs on the SRS once during each ignition cycle immediately after "Ignition 1" voltage is applied to the SDM and before "Continuous Monitoring". Page 25 Sunroof / Moonroof Module: Service and Repair Removal 1. Disconnect the battery ground cable. 2. Remove the headlining (2). 3. Remove the sunroof control unit (1). - Disconnect two connectors. - Remove two screws. Installation To install, follow the removal steps in the reverse order. Page 2170 - Bank 2 sensor 1 is mounted on the exhaust pipe ahead of the left-hand catalytic converter. - Bank 2 sensor 2 is mounted behind the left-hand catalytic converter. 3. Disconnect the pigtail from the wiring harness. IMPORTANT: The pigtail is permanently attached to the sensor. Be careful not to pull the wires out. NOTE: Do not use a torch to remove an HO2S unless the sensor is being replaced. Using a torch could damage the sensor. Specifications Timing Belt: Specifications Replace Timing Belt every 75,000 miles (120,000 km) Capacity Specifications Fluid - M/T: Capacity Specifications M/T Fluid Capacity ............................................................................................................................................... ......................................................................... 2.95L Page 6369 it is located, and what it connects to. Use the Connector Views to help locate the proper cavity when you need to probe a connector. It can be especially helpful if the connector has more than one wire of the same color. A dash symbol (-) indicates that the cavity is empty. Connector views can also be used to help diagnose multiple symptoms in separate circuits which could be caused by a single problem in a connector shared by those circuits. Here's an example: 1. Pick one of the multiple symptoms and look up the schematic for that circuit. 2. Make a list of all the in-line and fuse box connectors in that schematic , 3. Then, in the Connector Views, look up each connector on your list to see if circuits related to the other symptoms run through one of them. If they do, inspect that connector for the problem. Example: The blower, rear window defogger, and the windshield wiper don't work. List all in-line and fuse box connectors in the blower controls circuit and then check the Connector View (see the sample). You find that C324 is common to the blower controls, rear window defogger, and wiper/washer, so you inspect C324 and find the problem, bent terminals. Finding Component/Connector Locations Finding Component/Connector Locations To see where a component or connector is located on the car, look up its photo number in the "Component Location". The photo will also tell you the color of the connector, and how many cavities it has. RH TWC and Forked Exhaust Pipe and Associated Parts Catalytic Converter: Diagrams RH TWC and Forked Exhaust Pipe and Associated Parts TWC RH and Forked Exhaust Pipe and Associated Parts Locations Front Window Regulator, Glass And Glass Run Page 4465 Axle Disconnect Control Control Unit: Service and Repair SHIFT ON THE FLY CONTROLLER AND ASSOCIATED PARTS REMOVAL 1. Disconnect the battery ground cable. 2. Remove the front console assembly. 3. Disconnect the connector from the controller. 4. Remove the nut. 5. Remove the controller. INSTALLATION 1. To install, follow the removal steps in the reverse order, noting the following points. Torque: Nut (1) 8 Nm (69 inch lbs.) Page 6196 7. Remove case (Temperature control) separate two halves of core case. 8. Remove heater core (1). 9. Pull out the mode door while raising up the catch of the door lever. Installation Page 6693 2. Connect one lead of a self-powered test light or DVOM to one end of the part of the circuit you want to test. 3. Connect the other lead to the other end. 4. If the self-powered test light glows, there is continuity. If you're using a DVOM, a low reading or no reading (zero), means good continuity. Testing For Voltage When testing for voltage at a connector without wire seals, you do not have to separate the two halves of the connector. Instead, probe the connector from the back. Always check both sides of the connector because dirty, corroded, and bent terminals can cause problems (no electrical contact = an open). 1. Connect one lead of the lest light to a known good ground, or, if you're using a digital volt ohmmeter (DVOM), place it in the appropriate DC volts range, and connect its negative lead to ground. 2. Connect the other lead of the test light or DVOM to the point you want to check. 3. If the test light glows, there is voltage present. If you're using a DVOM, note the voltage reading. It should be within one volt of measured battery voltage. A loss of more than one volt indicates a problem. NOTE: Always use a DVOM on high impedance circuits. A test light may not glow (even with battery voltage present). Testing For Voltage Drop Wires, connectors, and switches are designed to conduct current with a minimum loss of voltage. A voltage drop of more than one volt indicates a problem. 1. Place the digital volt/ohmmeter (DVOM) in the appropriate DC volts range. Connect the positive lead to the end of the wire (or to the connector or switch) closest to the battery. 2. Connect the negative lead to the other end of the wire (or the other side of the connector or switch). 3. Turn on the components in the circuit. 4. The DVOM will show the difference in voltage between the two points. A difference, or drop, of more than one volt indicates a problem. Check the circuit for loose, dirty, or bent terminals. Service and Repair Mainshaft: Service and Repair For further information regarding this component and the system that it is a part of, please refer to Automatic Transmission/Transaxle; Service and Repair; Unit Overhaul Page 7147 Convertible Top: Service and Repair Removal 1. Remove the quarter window assembly (LH & RH). - Peel off the velcro fasteners and unzip the zippers. 2. Remove the back window assembly (2). -Peel off the velcro fasteners (3), unzip the zipper (1) and pull the back window assembly toward the rear together with the support bar assembly (4). Then slide the back window out to the side. NOTE: After removing the side windows and back window, be careful not to bend then or place other objects on top of them as this could scratch or crack them. Exercise caution when handling and storing the windows. 3. Press the lock button (2) of the soft top latch assembly (1) and lower the lock knob to disengage the lock. Then remove the hooks of the tarpaulin frame assembly (LH & RH). 4. Remove the tarpaulin assembly. - Disengage the 14 hocks. 5. Remove the tarpaulin frame assembly. - Remove the four fixing bolts. Installation To install, follow the removal steps in the reverse order, noting the following point. Page 7180 6. Pull out the sunshade (4) up to the guide rail edge. Lift the front of sunshade and clear the projection (3) of sunshade through the notch (2) of guide rail edge, then draw the sunshade out of the roof. Installation To install, follow the removal steps in the reverse order. Page 2203 Throttle Position Sensor: Service and Repair REMOVAL PROCEDURE 1. Disconnect the negative battery cable. 2. Disconnect the TPS electrical connector. 3. Remove the bolts and the TP sensor from the throttle body. NOTE: Do not clean the TP sensor by soaking it in solvent. The sensor will be damaged as a result. INSTALLATION PROCEDURE 1. Install the TP sensor on the throttle body with the bolts. 2. Connect the TP electrical connector. 3. Install the negative battery cable. Page 3291 the component if the component only has one connector, or by a capital letter (A, B, C, etc.) if the component has more than one connector. Below most connector numbers and component names are PHOTO and VIEW numbers. The PHOTO number refers to a photo in the back of the book that shows the connector's location on the car. The VIEW number refers to an illustration in the back of the book that shows the connector face, wire colors, connector cavity numbers, and other details. The connector cavity numbering sequence begins at the top left corner of the connector. Disregard any numbers molded into the connector housing. Wires Wires are identified by the abbreviated names of their colors; the second color is the color of the stripe. Wires are also identified by their location in a connector. The number "2" next to the male and female wire terminals at C416, for example, means those terminals join in cavity 2 of connector C416. Symbols A complete description of schematic symbols is given under wire color abbreviation. Power Distribution Schematics Power Distribution schematics show how power is supplied from the positive battery terminal to various circuits in the car. Refer to the Power Distribution section to get a more detailed picture of how power is supplied to the circuit you're working on. From Battery to Ignition Switch, Fuses, and Relays Individual circuit schematics begin with a fuse. The first half of Power Distribution, however, shows the wiring "upstream" between the battery Page 6480 Air Bag(s) Arming and Disarming: Service and Repair Connector Disconnection / Connection REMOVAL To remove the connector, hold the cover insulator(l) and pull it. The cover insulator slides and lock will be released. Do not hold the socket insulator(2). INSTALLATION Page 209 Terminals - "T" Each "T" terminal (ring type) is numbered for reference and location. A "T" terminal is secured with a screw or bolt. Wires Page 1306 Page 5914 If there is no photo number below or beside a component name or a connector, ground, or terminal number, look up that name or number in the appropriate Connector Identification Chart. The chart lists how many cavities a connector has, where it's located, and what it connects to. The related illustration shows the connector's location on the harness, and the harness routing. NOTE: Photos listed by number are located at Locations / Components / Photograohs. See: Locations/Component Locations/Photographs Circuit Schematics Page 24 Page 5333 Page 201 Each schematic represents one circuit. A circuit's wires and components are arranged to show current flow, from power at the top of the page, to ground, at the bottom. Shared Circuits Other circuits may share power or ground terminals or wiring with the circuit shown. A wire that connects one circuit to another, for example, is cut short and has an arrowhead at the end of it pointing in the direction of current flow. Next to the arrowhead is the name of the circuit or component which shares that wiring. To quickly check shared wiring, check the operation of a component it serves. If that component works, you know the shared wiring is OK. Connectors All in-line and junction connectors are numbered (C725, C416, etc.). Component connectors are not numbered but are identified either by the name of Page 1592 Limit: 39.47 mm (1.5539 inch) Exhaust Standard: 39.3 mm (1.5472 inch) Limit: 39.45 mm (1.5531 inch) 2. Measure the valve seat contact width. Make the necessary corrections if the seat contact surface is damaged or rough or if the contact width wear exceeds the limit. Valve seat contact width Standard: 1.1 mm (0.0433 inch) Limit: 1.7 mm (0.0669 inch) Contact Surface Angle on Valve Seat on Valve 1. Measure contact surface angle on valve seat. 2. If the measured value exceeds the limit, replace valve, valve guide and valve seat as a set. Valve contact surface angle: 45° Valve Seat Insert Correction 1. Remove the carbon from the valve seat insert surface. Diagram Information and Instructions Axle Disconnect Control Control Unit: Diagram Information and Instructions How to Identify Wiring Color-Coded Insulation Wire Color Wire Color Coding Page 7364 Cruise Control Switch: Service and Repair Removal 1. Disconnect the battery ground cable. 2. Remove the meter cluster assembly (1). 3. Remove the rear defogger switch (2). - Disconnect the switch connector. - To remove the switch, push the lock from the back side of the instrument panel cluster assembly. Installation To install, follow the removal steps in the reverse order. Page 3089 EGR Valve: Testing and Inspection EGR Control Test This test is conducted check EGR valve for proper operation. Tech 2 must be used for this test. Test Procedure: 1. Connect Tech 2 to the vehicle DLC. 2. Run the Engine at idle. 3. Select F3: Miscellaneous Test in the Application Menu. 4. Select F5: EGR Control Test in the Miscellaneous Test. Page 3071 Canister Vent Valve: Service and Repair REMOVAL PROCEDURE 1. Disconnect the negative battery cable. 2. Slide out the EVAP canister vent solenoid from mounting bracket. 3. Disconnect the connector and hose. INSTALLATION PROCEDURE 1. Connect the connector and hose. Page 664 3. Check the vacuum hose to the sensor for leaking or restriction, Be sure that no other vacuum devices are connected to the MAP hose. IMPORTANT: Make sure the electrical connector remains securely fastened. 4. Disconnect the sensor from the bracket. Twist the sensor with your hand to check for an intermittent connection. Output changes greater than 0.10 volt indicate a bad sensor. Page 1869 Page 6317 Blower Motor Switch: Testing and Inspection Fan Control Knob (Fan Switch) 1. Check for continuity between the fan switch and the A/C switch side connector terminals. Locations Camshaft Position Sensor Diagram Information and Instructions Clock: Diagram Information and Instructions How to Identify Wiring Color-Coded Insulation Wire Color Wire Color Coding Page 3921 Accumulator: Service and Repair For further information regarding this component and the system that it is a part of, please refer to Automatic Transmission/Transaxle; Service and Repair; Unit Overhaul Component Locations Service and Repair Input Shaft: Service and Repair For further information regarding this component and the system that it is a part of, please refer to Transfer Case; Service and Repair; Unit Overhaul Page 4276 Terminals - "T" Each "T" terminal (ring type) is numbered for reference and location. A "T" terminal is secured with a screw or bolt. Wires Page 6716 Keyless Entry Module: Service and Repair Anti-Theft & Keyless Entry Controller Removal 1. Disconnect the battery ground cable. 2. Remove the glove box from the instrument panel assembly (1). - Refer to the Instrument Panel Assembly in Body Structure section. 3. Remove the anti-theft & keyless entry controller (2). - Disconnect the connector. Remove two fixing screws. Installation To install, follow the removal steps in the reverse order. Page 6695 Radio/Stereo: Electrical Diagrams Part 1 Of 2 Page 6712 Alarm/Immobilizer Control Unit: Service and Repair Alarm and Relay Control Unit Removal 1. Disconnect the battery ground cable. 2. Remove the instrument panel (1). 3. Remove the alarm and relay control unit (2). Disconnect the connector. Installation To install, follow the removal steps in the reverse order. Page 1382 Wheels: Description and Operation Replacement wheels or tires must be equivalent to the originals in load capacity, specified dimension and mounting configuration. Improper size or type may affect bearing life, brake performance, speedometer/odometer calibration, vehicle ground clearance and tire clearance to the body and chassis. All model are equipped with metric sized tubeless steel belted radial tires. Correct tire pressures and driving habits have an important influence on tire life. Heavy cornering, excessively rapid acceleration and unnecessary sharp braking increase premature and uneven wear. Diagram Information and Instructions Auxiliary Power Outlet: Diagram Information and Instructions How to Identify Wiring Color-Coded Insulation Wire Color Wire Color Coding Page 5042 Electronic Brake Control Module: Pinout Values and Diagnostic Parameters EHCU Connector Pin-Out Checks Part 1 of 2 Part 2 of 2 - Disconnect Electronic Hydraulic Control Module. - Perform checks with high impedance digital multimeter J-39200 or equivalent. Page 2911 Oxygen Sensor: Description and Operation Catalyst Monitor Heated Oxygen Sensors Catalyst Monitor Heated Oxygen Sensors Three-way catalytic converters are used to control emissions of hydrocarbons (HC), carbon monoxide (CO), and oxides of nitrogen (NOx). The catalyst within the converters promotes a chemical reaction. This reaction oxidizes the HC and CO present in the exhaust gas and converts them into harmless water vapor and carbon dioxide. The catalyst also reduces NOx by converting it to nitrogen. The PCM can monitor this process using the Bank 1 HO2S 2 and the Bank 2 HO2S 2 heated oxygen sensors. The Bank 1 HO2S 1 and the Bank 2 HO2S 1 sensors produce an output signal which indicates the Page 4545 If there is no photo number below or beside a component name or a connector, ground, or terminal number, look up that name or number in the appropriate Connector Identification Chart. The chart lists how many cavities a connector has, where it's located, and what it connects to. The related illustration shows the connector's location on the harness, and the harness routing. NOTE: Photos listed by number are located at Locations / Components / Photograohs. See: Locations/Component Locations/Photographs Circuit Schematics Page 1693 4. Remove the fuel pressure regulator from the fuel rail. 5. Remove the fuel return line from the regulator. 6. Install the new fuel pressure regulator in the reverse order of removal. 7. Use the Smart Cable to reprogram the PCM with the latest software from the June 2001 or later HONDANET CD-ROM. Refer to Service Bulletin 99-005, Updating the Passport PCM, filed under Tools. 8. Use the PGM Tester to clear any DTCs. 9. Use the PGM Tester to check the broadcast code. Make sure the broadcast code matches the one you selected from the CD-ROM. WARRANTY CLAIM INFORMATION In warranty: The normal warranty applies. Failed Part: P/N 8-17113-398-0 H/C 5504386 Defect Code: 092 Contention Code: C99 Skill Level: Repair Technician Out of warranty: Any repair performed after warranty expiration may be eligible for goodwill consideration by the District Service Manager or your Zone Office. You must request consideration, and get a decision, before starting work. REPAIR PROCEDURE - POWER STEERING SWITCH 1. Drain the power steering fluid out of the system. 2. Remove the power steering fluid reservoir. Clean the reservoir with solvent, then with soap and water. Rinse and dry it thoroughly. 3. Reinstall the reservoir. Do not connect the return hose. 4. Remove the power steering pressure switch, then clean it with brake cleaner and a scraper. Reinstall the switch, and torque it to 20 N.m (14 lb-ft). 5. Cover the unconnected end of the reservoir with your finger, then fill the reservoir with Dexron III ATF Page 2463 6. Remove the connector position assurance (CPA) clip from the APPS connector. 7. Disconnect the 10 P connector from the APPS. 8. Remove the bolts, the APPS, the spacer, and the accelerator link from the accelerator pedal assembly. 9. Separate the spacer from the APPS. Clean the grease off the spacer and the accelerator link with a clean shop towel. 10. Clean the terminals of the 10 P APPS connector (harness side) with contact cleaner. Shake the residue out of the connector, and allow the contact cleaner to evaporate for at least 3 minutes before reconnecting the connector. 11. Install a new APPS, the spacer, and the accelerator link onto the accelerator pedal assembly. Leave the mounting screws loose so the sensor can be adjusted. 12. Connect the 10 P connector to the new APPS, and lock the connector in place with the CPA. 13. Connect the PGM Tester to the data link connector (DLC), and turn the ignition switch to ON (II). Page 3024 The wire insulation has one color or one color with another color stripe. The second color is the stripe. Capacity Specifications Fluid - Transfer Case: Capacity Specifications Transfer Case Fluid Capacity ............................................................................................................................................... .......................................................... 1.45 L (1.5 Qt) Page 297 Splices Splices are shown as a dot. Their location and the number of wires may vary depending on the harness manufacturer. Switches Switches These switches move together; the broken straight line between them means they are mechanically connected. Other types of switches are controlled by a coil or a solid state circuit. Unless otherwise noted, all switches are shown in their normal (rest) position, with power off. Terminal "T" Page 5774 ^ If the flat punch doesn't poke a hole in any of the X-marked areas on the frame, go to STAGE 2 REPAIR. ^ * If the flat punch pokes a hole in any of the X-marked areas, or if there are pre-existing holes in the frame above the lower trailing link front bracket, go to the next step.* 5. Using the 3/16 in. x 9 in. flat punch and the 12-16-oz. hammer, strike the radius of the frame corners on each of the X-marked areas shown below. Again, swing the hammer with a 10 to 12 inch stroke to be sure enough force is applied to the flat punch. ^ If the flat punch doesn't poke a hole in any of the X-marked areas, go to STAGE 3 REPAIR. ^ If the flat punch pokes a hole in any of the X-marked areas, go to STAGE 4 REPAIR. Stage 1 Repair STAGE 1 REPAIR NOTE: ^ Do this repair on both sides of the vehicle. ^ Noxudol spray is highly flammable. Keep away from ignition sources (no smoking). Keep at a temperature not exceeding 120°F (50°C). ^ Wear hand and eye protection to avoid direct contact with the Noxudol spray. Spraying should be done in an area with adequate ventilation. Locations Gear Sensor/Switch: Locations Top Right Side Of Transfer Case Accelerator Pedal Assembly/Sensor - Adjustment Update Accelerator Pedal Position Sensor: All Technical Service Bulletins Accelerator Pedal Assembly/Sensor - Adjustment Update 00-045 August 14, 2001 Applies To: 2000-02 Passport - ALL Service Manual Update: Accelerator Pedal Position Sensor (APPS) (Supersedes 00-045, dated May 23, 2000) Updated information is shown by asterisks and black bars. BACKGROUND When the accelerator pedal position sensor (APPS) or the accelerator pedal assembly is replaced for any reason, you must adjust the APPS. *This procedure is missing in the 2000 service manual and is wrong in the 2001 and 2002 service manuals. Make a note on page 6E2-539 of the 2000 Passport Fuel and Emissions manual, on page 6E2-553 of the 2001 Passport Fuel and Emissions manual, and on page 6E2-545 of the 2002 Passport Fuel and Emissions manual to refer to this bulletin.* ADJUSTMENT PROCEDURE 1. Replace the APPS or the accelerator pedal assembly, and leave the mounting screws for the APPS loose. 2. Connect the PGM Tester to the data link connector (DLC), and turn the ignition switch to ON (II). *3. While watching the APP Sensor values in the Engine Data List, adjust the APPS by turning it until the values are within the ranges shown at closed pushed all the way down), then tighten the throttle and wide open throttle (accelerator pedal mounting screws and recheck the values. ^ If all three sensors are within range, go to step 12. ^ If APP Sensor 1, APP Sensor 2, and/or APP Sensor 3 cannot be brought into range, go to step 4. 4. Troubleshoot for an open circuit or a PCM malfunction. ^ If APP Sensor 1 has a value of 0% or APP Sensor 2 and/or APP Sensor 3 have a value of 99%, an open circuit exists or the PCM is malfunctioning. Repair the circuit or replace the PCM, and repeat step 3. ^ If you don't find a problem, go to step 5. 5. Disconnect the 10P connector from the APPS. 6. View the APP Sensor values in the Engine Data List. ^ If APP Sensor 1 has a value of 0% or APP Sensor 2 and/or APP Sensor 3 have a value of 99%, go to step 7. ^ If APP Sensor 1 has a value other than 0%, or APP Sensor 2 and/or APP Sensor 3 have a value other than 99%, a short circuit exists or the PCM is malfunctioning. Repair the circuit or replace the PCM, and repeat step 3. Page 4282 Test Equipment CAUTION: Most circuits include solid-state devices. Test the voltages in these circuits only with a 10-megaohm or higher impedance digital multimeter. Never use a test light or analog meter on circuits that contain solid-state devices. Damage to the devices may result. Test Light and DVOM On circuits without solid-state devices, use a test light to check for voltage. A test light is made up of a 12 volt bulb with a pair of leads attached. After grounding one lead, touch the other lead to various points along the circuit where voltage should be present. The bulb will go on if there is voltage at the point being tested. If you need to know how much voltage is present, use a digital volt/ohmmeter (DVOM). Self-Powered Test Light and DVOM Use a self-powered test light to check for continuity. This tool is made up of a light bulb, battery, and two leads. To test it, touch the leads together: the light should go on. Use a self-powered test light only on an unpowered circuit. First, disconnect the battery, or remove the fuse that feeds the circuit you are working on. Select two points in the circuit between which you want to check continuity. Connect one lead of the self-powered test light to each point. If there is continuity, the test light's circuit will be completed, and the light will go on. If, in addition, you need to know exactly how much resistance there is between two points, use a digital volt/ohmmeter (DVOM). In the "OHMS" range, the DVOM will measure resistance between two points along a circuit. Low resistance means good continuity. Diodes and solid-state devices in a circuit can make a DVOM give a false reading. To check a reading, reverse the leads, and take a second reading. If the readings differ, the component is affecting the measurement. Jumper Wire Use a jumper wire to bypass an open circuit. A jumper wire is made up of an in-line fuse holder connected to a set of test leads. It should have a five ampere fuse. Never connect a jumper wire across a short circuit. The direct battery short will blow the fuse. Short Finder (Short Circuit Locator) Short finders are available to locate shorts to ground. The short finder creates a pulsing magnetic field in the shorted circuit which you can follow to the location of the short. To order any test equipment shown above, contact your local tool supplier. For a list of suppliers and tool numbers, refer to Honda Required Special Tools and Equipment Service Bulletin. Page 2614 Distinct Of Circuit By Wire Base Color All wires have color-coded insulation. Wires belonging to a system's main harness will have a single color. Wires belonging to a system's sub-circuits will have a colored stripe. Striped wires use the codes found in the chart to show wire size and colors. Abbreviations are used to indicate wire color within a circuit diagram. How to Identify Connector Terminals How to Identify Connector Terminals Cavity Numbering System The cavities (and wire terminals) in each connector are numbered starting from the upper left, looking at the male terminals from the terminal side (or looking at the female terminals from the wire side. Both views are in the same direction so the numbers are the same.) All actual cavities are numbered, even if they have no wire terminals in them. NOTE: Data Link Connector (DLC) terminals are numbered according to SAE standard J1962, not the Honda standard. The numbers of the four end terminals are molded into the corners of the connector face. The connector cavity number is listed next to each terminal on the circuit schematic. The cavity / terminal shown is # 6. Using/Identifying Connector Terminal Views How to Use Connector Terminal Views To see the configuration of a connector's cavities, look up its view number in the Connector Views. Each view includes the color of the connector, where Page 458 The connector cavity number is listed next to each terminal on the circuit schematic. The cavity / terminal shown is # 6. Diodes A rectifier diode works like a one way valve. It allows current to flow only in the direction of the arrow. A Zener diode blocks reverse current at normal voltages just like a rectifier diode. At high voltages, however, a Zener diode allows current to flow in reverse. Fuses Page 389 Chart B-24 Wheel Speed Input Abnormality (DTC 65 (Flash Out) / C0238 (Serial Communications)) Sensor Signal Abnormality Criteria Using TECH 2 1. While driving, the speed of one or two wheels is 25% or more higher than that of the other wheels. 2. The speed of one or two wheels is 10 km/h (6 mph) or more higher than that of the other wheels. 3. During steady driving, wheel speed changes abruptly. NOTE: Even after repairing the faulty part the Warning Light (W/L) does not go out if the vehicle is at a stop. Turn the ignition switch to the ON position and drive the vehicle at 12 km/h (8 mph) or higher to make sure that the warning light goes out. It is important to verify that the correct tires are installed on vehicle. Page 5228 Locations Parking Brake Warning Switch: Locations Under Center Console Locations Page 6089 2. Connect the short finder across the battery terminals and the load (component) side of the fuse terminal. 3. Close all switches in the circuit you're testing. 4. Turn on the short finder. This creates a pulsing magnetic field around the wiring between the fuse box and the short. 5. Beginning at the fuse box, slowly move the short finder along the circuit wiring. The meter will read current pulses through sheet metal and body trim. As long as the meter is between the fuse and the short, the needle will move with each current pulse. Once you move the meter past the point of the short, the needle will stop moving. Check the wiring and connectors in this area to locate the cause of the short. Testing For Continuity When testing for continuity at a connector without wire seals, you do not have to separate the two halves of the connector. Instead, probe the connector from the back. Always check both sides of the connector because dirty, corroded, and bent terminals can cause problems (no electrical contact = an open). 1. Disconnect the negative cable from the car battery. If you're using a DVOM, place it in the lowest "OHMS" range. Page 5070 Chart B-24 Wheel Speed Input Abnormality (DTC 65 (Flash Out) / C0238 (Serial Communications)) Sensor Signal Abnormality Criteria Using TECH 2 1. While driving, the speed of one or two wheels is 25% or more higher than that of the other wheels. 2. The speed of one or two wheels is 10 km/h (6 mph) or more higher than that of the other wheels. 3. During steady driving, wheel speed changes abruptly. NOTE: Even after repairing the faulty part the Warning Light (W/L) does not go out if the vehicle is at a stop. Turn the ignition switch to the ON position and drive the vehicle at 12 km/h (8 mph) or higher to make sure that the warning light goes out. It is important to verify that the correct tires are installed on vehicle. Page 2151 Manifold Pressure/Vacuum Sensor: Description and Operation Manifold Absolute Pressure (MAP) Sensor The manifold absolute pressure (MAP) sensor responds to changes in intake manifold pressure (vacuum). The MAP sensor signal voltage to the PCM varies from below 2 volts at idle (high vacuum) to above 4 volts with the ignition ON, engine not running or at wide-open throttle (low vacuum). The MAP sensor is used to determine the following: - Manifold pressure changes while the linear EGR flow test diagnostic is being run. Refer to DTC P0401. - Barometric pressure (BARO). If the PCM detects a voltage that is lower than the possible range of the MAP sensor, DTC P0107 will be set. A signal voltage higher than the possible range of the sensor will set DTC P0108. An intermittent low or high voltage will set DTC P1107, respectively. The PCM can detect a shifted MAP sensor. The PCM compares the MAP sensor signal to a calculated MAP based on throttle position and various engine load factors. If the PCM detects a MAP signal that varies excessively above or below the calculated value, DTC P0106 will set. Diagram Information and Instructions Powertrain Control Module: Diagram Information and Instructions How to Identify Wiring Color-Coded Insulation Wire Color Wire Color Coding Page 5478 ^ If the idle speed ever exceeds 1,300 rpm 2. Remove the vacuum hose from the fuel pressure regulator, then start the engine. ^ If fuel comes out of the fuel pressure regulator vacuum hose connection, go to REPAIR PROCEDURE FUEL PRESSURE REGULATOR. ^ If no fuel comes out of the regulator, reconnect the vacuum hose and continue to step 3. 3. Connect the PGM Tester. Set it to Engine Data List. 4. Have an assistant drive the vehicle under the conditions described by the customer. 5. If the high or erratic idle condition occurs, note the values of the PSP Switch and APP Sensor 1 when it is occurring. ^ If the PSP Switch is HIGH, and you are not turning, go to REPAIR PROCEDURE POWER STEERING SWITCH. ^ If the APP Sensor 1 is greater than 15% and APP Sensor 2 and/or APP Sensor 3 are less than 85%, and the accelerator pedal is not depressed, go to REPAIR PROCEDURE APPS GROUND. ^ If the PSP Switch is reading LOW when not turning and HIGH when turning, and the APP Sensors are reading within the range shown, discontinue the test-drive and go to step 6. 6. Do these repairs: ^ REPAIR PROCEDURE APPS GROUND ^ REPAIR PROCEDURE ENGINE/BODY GROUND REPAIR PROCEDURE - FUEL PRESSURE REGULATOR 1. Relieve fuel system pressure: ^ Remove the fuel fill cap. ^ Remove the fuel pump relay. ^ Start the engine and run it until it stalls. ^ Crank the engine for 3 seconds. 2. Remove the vacuum hose from the fuel pressure regulator. 3. Remove the fuel pressure regulator shield from the common chamber (two bolts). Page 4273 The connector cavity number is listed next to each terminal on the circuit schematic. The cavity / terminal shown is # 6. Diodes A rectifier diode works like a one way valve. It allows current to flow only in the direction of the arrow. A Zener diode blocks reverse current at normal voltages just like a rectifier diode. At high voltages, however, a Zener diode allows current to flow in reverse. Fuses Page 3206 and the fuses. From Fuses to Relays and Components The second half of Power Distribution shows the wiring "From Fuses to Relays and Components." This can speed your troubleshooting by showing which circuits share fuses. If Power Distribution shows that an inoperative circuit and another circuit share a fuse, check a component in the other circuit. If it works, you know the fuse is good and power is available to the inoperative circuit. Ground Distribution Schematics Page 4880 Brake Caliper: Service and Repair Disassembly and Reassembly DISASSEMBLY 1. Remove guide bolt. 2. Remove lock bolt. 3. Remove dust boot; guide bolt and lock bolt. 4. Remove dust boot ring, using a small screwdriver. Page 4233 4. If the trouble occurs after the above test, charge the Axle Disconnect controller to the new one. Page 2999 Transmission Position Switch/Sensor: Service and Repair REMOVAL 1. Place selector lever in neutral. 2. Disconnect battery ground cable. 3. Remove mode switch cover (1). 4. Disconnect selector lever (2) from the mode switch. 5. Remove bracket with cable (3). 6. Disconnect transmission harness from the mode switch connector (4). 7. Remove bracket with mode switch connector from the transmission case. 8. Remove mode switch connector (4) from the bracket (5). 9. Remove two mode switch bolts and nut then remove mode switch (6). INSTALLATION To install, follow the removal steps in the reverse order, noting the following points; 1. Torque Mode switch bolt: 13 Nm (113 inch lbs.) Selector lever nut: 23 Nm (17 ft. lbs.) 2. Mode switch setting procedure. Perform either of the following adjustment procedures: Procedure 1 a. Place selector lever in neutral. b. Remove selector lever from the mode switch. c. Remove the mode switch cover. d. Loosen the two 10 mm screws. e. Rotate the mode switch until the slot in the mode switch housing aligns with the selector shaft bushing, and insert a 3/32 inch (2.4 mm) drill bit or punch (1) into the slot. f. Tighten the screws to 13 Nm (113 inch lbs.). g. After completing adjustment, snap the mode switch cover into place. h. Reinstall the selector lever. Procedure 2 a. Place selector lever in neutral. b. Disconnect transmission harness connector from mode switch connector. Page 464 Wire Color Abbreviations The following abbreviations are used to identify wire colors in the circuit schematics: WHT................................... White YEL................................... Yellow BLK................................... Black BLU................................... Blue GRN................................... Green RED................................... Red ORN................................... Orange PNK................................... Pink BRN................................... Brown GRY................................... Gray PUR................................... Purple LT BLU................................... Light Blue LT GRN................................... Light Green Page 1202 Fluid - M/T: Fluid Type Specifications M/T Fluid Grade ................................................................................................................................................... ...................................... Engine oil labeled SG or SF SAE Viscosity: Above 90° F (32° C) ........................................................................................................................................................ SAE 15W-40, 20W-40 or 20W-50 Other areas ................................................................................... ............................................................................................................................... 5W-30 Page 1776 Spark Plug: Application and ID Plug Types: K16PR-P11 RC10PYPP4 PK16PR11 Page 2668 Distinct Of Circuit By Wire Base Color All wires have color-coded insulation. Wires belonging to a system's main harness will have a single color. Wires belonging to a system's sub-circuits will have a colored stripe. Striped wires use the codes found in the chart to show wire size and colors. Abbreviations are used to indicate wire color within a circuit diagram. How to Identify Connector Terminals How to Identify Connector Terminals Cavity Numbering System The cavities (and wire terminals) in each connector are numbered starting from the upper left, looking at the male terminals from the terminal side (or looking at the female terminals from the wire side. Both views are in the same direction so the numbers are the same.) All actual cavities are numbered, even if they have no wire terminals in them. NOTE: Data Link Connector (DLC) terminals are numbered according to SAE standard J1962, not the Honda standard. The numbers of the four end terminals are molded into the corners of the connector face. The connector cavity number is listed next to each terminal on the circuit schematic. The cavity / terminal shown is # 6. Using/Identifying Connector Terminal Views How to Use Connector Terminal Views To see the configuration of a connector's cavities, look up its view number in the Connector Views. Each view includes the color of the connector, where Page 1798 Valve Shim Replacement Chart Locations Brake Light Switch: Locations Below Left Side of Dash Page 2845 129 - Below Left Side Of I/P Page 7385 Terminals - "T" Each "T" terminal (ring type) is numbered for reference and location. A "T" terminal is secured with a screw or bolt. Wires Page 5358 H/C 4408092 Defect Code: 017 Contention Code: C99 Skill Level: Repair Technician Out of warranty: Any repair performed after warranty expiration may be eligible for goodwill consideration by the District Service Manager or your Zone Office. You must request consideration, and get a decision, before starting work. DISCLAIMER Page 7320 5. Remove the speaker assembly (2). - Remove the 4 screws and disconnect the speaker harness connector (1). 6. Remove the door mirror cover. 7. Remove the grip cover. 8. Remove the 5 screws (1), (3) and pull out the trim panel at the 6 clip positions (2). 9. Remove the waterproof sheet. Page 3209 The connector cavity number is listed next to each terminal on the circuit schematic. The cavity / terminal shown is # 6. Diodes A rectifier diode works like a one way valve. It allows current to flow only in the direction of the arrow. A Zener diode blocks reverse current at normal voltages just like a rectifier diode. At high voltages, however, a Zener diode allows current to flow in reverse. Fuses Page 7326 3. Remove the window regulator handle. - Remove the clip on the rear side of the regulator handle using a wire. 4. Remove the screw while pulling the inside lever toward you and then remove the inside handle. 5. Remove the 1 screw at the pull case. 6. Pull out the trim panel at the 8 clip positions. - Disconnect the power window switch connector. 7. Remove the power window switch and pull case, if equipped. Page 7490 Wire Color Abbreviations The following abbreviations are used to identify wire colors in the circuit schematics: WHT................................... White YEL................................... Yellow BLK................................... Black BLU................................... Blue GRN................................... Green RED................................... Red ORN................................... Orange PNK................................... Pink BRN................................... Brown GRY................................... Gray PUR................................... Purple LT BLU................................... Light Blue LT GRN................................... Light Green Torque Converter Oil Seal - Installation Tool Seals and Gaskets: Technical Service Bulletins Torque Converter Oil Seal - Installation Tool 00-022 March 7, 2000 Applies To: ALL Models With L4 or V6 Engine and A/T With 44 mm I.D. Torque Converter Oil Seal Torque Converter Oil Seal Installation Tool The service manual procedure for installing the torque converter oil seal requires you to disassemble the transmission. A new required special tool, which attaches to your existing 40 mm l.D. driver, lets you install this seal without removing the main shaft or disassembling the transmission. REQUIRED SPECIAL TOOLS Seal Driver Attachment: T/N O7XAD-001000A (Shipped to all dealers March 2000 as a required special tool) 40 mm I.D. Driver: T/N 07746-0030100 ORDERING INFORMATION Additional seal driver attachments are available from American Honda using normal parts ordering procedures. WARRANTY CLAIM INFORMATION None. This service bulletin is for information only. PROCEDURE 1. Remove the transmission (see section 14 of the appropriate service manual). 2. Remove and discard the torque converter oil seal. Be careful not to damage the torque converter housing. 3. Select the appropriate replacement seal. 4. Press the long end of the seal driver attachment into the driver. Press the new seal onto the short end. Do not apply any type of sealer to the seal or Locations Variable Induction Control Valve: Locations Left Side Of Engine Page 5264 2. Unfasten C123 from the side of the engine compartment using a 90-degree pick. 3. Disconnect C123, and clean the terminals on both sides of the connector with contact cleaner. Shake the residue out of the connector. Allow the contact cleaner to evaporate for at least 3 minutes, then reconnect C123. 4. Fasten C123 to the left side of the engine compartment, and reinstall the air cleaner housing cover. 5. Remove the connector position assurance (CPA) clip from the APPS connector. 6. Disconnect the lop connector from the APPS. 7. Clean the terminals of the 10P APPS connector (harness side) with contact cleaner. Shake out residue from the connector, and allow the contact cleaner to evaporate for at least 3 minutes, then reconnect it. 8. Use the Smart Cable to reprogram the PCM with the latest software from the June 2001 or later HONDANET CD-ROM. Refer to Service Bulletin 99-005, Updating the Passport PCM, filed under Tools. 9. Use the PGM Tester to clear any DTCs. Locations Page 4714 and the fuses. From Fuses to Relays and Components The second half of Power Distribution shows the wiring "From Fuses to Relays and Components." This can speed your troubleshooting by showing which circuits share fuses. If Power Distribution shows that an inoperative circuit and another circuit share a fuse, check a component in the other circuit. If it works, you know the fuse is good and power is available to the inoperative circuit. Ground Distribution Schematics Removal and Installation Valve Guide Seal: Service and Repair Removal and Installation Valve Stem Oil Controller, Valve Spring and Valve Guide Removal 1. Disconnect battery ground cable. 2. Drain engine oil. - Drain engine coolant. 3. Remove cylinder head assembly. Refer to removal procedure for Cylinder Head. 4. Remove camshaft. Refer to removal procedure for Camshaft. 5. Remove tappets with shim. Note: Do not damage shim surface. 6. Remove valve springs using J-8062 valve spring compressor and J-42898 valve spring compressor adapter then remove upper valve spring seat and lower seat. 7. Remove oil controller using J-37281 oil controller remover, remove each valve stem oil controller. 8. Remove valve guide using J-37985 valve guide replacer. Installation 1. Install valve guide using J-42899 valve guide installer. 2. Install oil controller using J-38537 oil controller installer. 3. Install lower valve spring seat, valve spring and upper valve spring seat then put split collars on the upper spring seat, using J-8062 valve spring compressor and J-42898 valve spring compressor adapter to install the split collars. 4. Install tappet with shim. 5. Install camshaft assembly. Refer to installation procedure for Camshaft. 6. Install cylinder head assembly. Refer to installation procedure for Cylinder Head. 7. Fill engine oil until full level. 8. Fill engine coolant. Page 8053 8. Apply a setting mark (1) across the steering wheel and shaft so parts can be reassembled in their original position. Move the front wheels to the straight ahead position, then use steering wheel remover J-29752 to remove the steering wheel. CAUTION: Never apply force to the steering wheel in direction of the shaft by using a hammer or other impact tools in an attempt to remove the steering wheel. The steering shaft is designed as an energy absorbing unit. 9. Remove steering column cover. 10. Disconnect the wiring harness connectors located under the steering column, then remove combination switch and SRS coil assembly. NOTE: The SRS coil is a part of the combination switch assembly, which can not be replaced separately. Therefore, be sure not to remove the SRS coil from the combination switch assembly. INSTALLATION Page 4476 the component if the component only has one connector, or by a capital letter (A, B, C, etc.) if the component has more than one connector. Below most connector numbers and component names are PHOTO and VIEW numbers. The PHOTO number refers to a photo in the back of the book that shows the connector's location on the car. The VIEW number refers to an illustration in the back of the book that shows the connector face, wire colors, connector cavity numbers, and other details. The connector cavity numbering sequence begins at the top left corner of the connector. Disregard any numbers molded into the connector housing. Wires Wires are identified by the abbreviated names of their colors; the second color is the color of the stripe. Wires are also identified by their location in a connector. The number "2" next to the male and female wire terminals at C416, for example, means those terminals join in cavity 2 of connector C416. Symbols A complete description of schematic symbols is given under wire color abbreviation. Power Distribution Schematics Power Distribution schematics show how power is supplied from the positive battery terminal to various circuits in the car. Refer to the Power Distribution section to get a more detailed picture of how power is supplied to the circuit you're working on. From Battery to Ignition Switch, Fuses, and Relays Individual circuit schematics begin with a fuse. The first half of Power Distribution, however, shows the wiring "upstream" between the battery Starting System - Unable To Key In Ignition Switch Key: Technical Service Bulletins Starting System - Unable To Key In Ignition Switch Can't Turn Ignition Switch? Check for Locked Steering Got a service customer complaining he or she can't turn the ignition switch to start the engine? The reason could just be the steering column lock pin is engaged with the front wheels turned. Here's what typically happens: Some folks use the steering wheel to help support themselves while climbing in or out of the vehicle. This is very common among elderly or disabled drivers. Doing this turns the front wheels, which twists the tires against the ground. The twisted tires apply torque to the steering column. With the ignition switch in LOCK (0), the steering column lock pin is engaged. But the applied torque on the steering column binds the lock pin, making it tough to turn the ignition switch. The ignition switch won't turn to ON (II) if the lock pin isn't disengaged from the steering column. Tell your customer there's nothing wrong with the ignition switch itself. All he or she needs to do is turn the steering wheel from side to side while turning the switch. This usually releases the lock pin so the engine can be started. In some cases, though, your customer may need to give a good tug on the wheel. This could easily happen when parking on a hill and the wheels are turned sharply before the engine is shut off. Page 8194 5. Remove the speaker assembly (2). - Remove the 4 screws and disconnect the speaker harness connector (1). 6. Remove the door mirror cover. 7. Remove the grip cover. 8. Remove the 5 screws (1), (3) and pull out the trim panel at the 6 clip positions (2). 9. Remove the waterproof sheet. Page 5305 The wire insulation has one color or one color with another color stripe. The second color is the stripe. Page 3919 6. Screw the accumulator cover removal tool clockwise into the accumulator cover. 7. Using a 22 mm wrench, continue turning the tool clockwise until the accumulator cover turns in the housing. 8. Position a drain pan under the transmission. 9. Using the 22 mm wrench as a lever and the transmission case as the fulcrum, pry the accumulator cover out of the housing. NOTE: For maximum leverage, do not fully seat the 22 mm wrench against the removal tool. Line up the end of the wrench with the center of the tool. 10. Clean the accumulator housing. 11. Lubricate the accumulator housing and the accumulator cover with clean ATF. NOTE: The accumulator cover is rubber coated and does not require an 0-ring or sealant. Page 4229 2. Connect one lead of a self-powered test light or DVOM to one end of the part of the circuit you want to test. 3. Connect the other lead to the other end. 4. If the self-powered test light glows, there is continuity. If you're using a DVOM, a low reading or no reading (zero), means good continuity. Testing For Voltage When testing for voltage at a connector without wire seals, you do not have to separate the two halves of the connector. Instead, probe the connector from the back. Always check both sides of the connector because dirty, corroded, and bent terminals can cause problems (no electrical contact = an open). 1. Connect one lead of the lest light to a known good ground, or, if you're using a digital volt ohmmeter (DVOM), place it in the appropriate DC volts range, and connect its negative lead to ground. 2. Connect the other lead of the test light or DVOM to the point you want to check. 3. If the test light glows, there is voltage present. If you're using a DVOM, note the voltage reading. It should be within one volt of measured battery voltage. A loss of more than one volt indicates a problem. NOTE: Always use a DVOM on high impedance circuits. A test light may not glow (even with battery voltage present). Testing For Voltage Drop Wires, connectors, and switches are designed to conduct current with a minimum loss of voltage. A voltage drop of more than one volt indicates a problem. 1. Place the digital volt/ohmmeter (DVOM) in the appropriate DC volts range. Connect the positive lead to the end of the wire (or to the connector or switch) closest to the battery. 2. Connect the negative lead to the other end of the wire (or the other side of the connector or switch). 3. Turn on the components in the circuit. 4. The DVOM will show the difference in voltage between the two points. A difference, or drop, of more than one volt indicates a problem. Check the circuit for loose, dirty, or bent terminals. Page 703 6. Place the end of the return hose in a container. Have someone start the engine, then pour ATF into the reservoir while you watch the fluid coming out of the return hose. When the fluid coming out is the same color as the new fluid, turn off the engine. 7. Reconnect the return hose to the reservoir. 8. Start the engine. Fill the power steering reservoir to the proper level with ATF then turn off the engine. 9. Use the Smart Cable to reprogram the PCM with the latest software from the June 2001 or later HONDANET CD-ROM. Refer to Service Bulletin 99-005, Updating the Passport PCM, filed under Tools. 10. Use the PGM Tester to clear any DTCs. 11. Use the PGM Tester to check the broadcast code. Make sure the broadcast code matches the one you selected from the CD-ROM. WARRANTY CLAIM INFORMATION In warranty: The normal warranty applies. Failed Part: P/N 8-97181-590-0 H/C 5698030 Defect Code: 064 Contention Code: C01 Skill Level: Repair Technician Out of warranty: Any repair performed after warranty expiration may be eligible for goodwill consideration by the District Service Manager or your Zone Office. You must request consideration, and get a decision, before starting work. REPAIR PROCEDURE - APPS GROUND 1. Unclamp the air cleaner housing cover, and move it to the side for access to connector C123 (16P BLK). Page 6399 4. Connect the appropriate pigtail adapter to the SRS deployment harness. 5. Remove the driver air bag assembly from vehicle. Refer to driver air bag assembly Removal. WARNING: WHEN STORING A LIVE AIR BAG ASSEMBLY OR WHEN LEAVING A LIVE AIR BAG ASSEMBLY UNATTENDED ON A BENCH OR OTHER SURFACE, ALWAYS FACE THE AIR BAG AND TRIM COVER UP AND AWAY FROM THE SURFACE. THIS IS NECESSARY SO THAT A FREE SPACE IS PROVIDED TO ALLOW THE AIR BAG TO EXPAND IN THE UNLIKELY EVENT OF ACCIDENTAL DEPLOYMENT. FAILURE TO FOLLOW PROCEDURES MAY RESULT IN PERSONAL INJURY. 6. Clear a space on the ground about 183 cm (8 feet) in clearance where the driver air bag assembly is to be deployed. A paved, outdoor location where there is no activity is preferred. If an outdoor location is not available, a space on the shop floor where there is no activity and sufficient ventilation is recommended. Ensure no loose or flammable objects are within the deployment area. 7. Place the J-41497 on the bench vice. This is necessary to provide sufficient stabilization of the fixture during deployment. 8. Attach the driver airbag assembly in the J-41497. Airbag assembly must be mounted facing upward on J-41497. SECURELY HAND-TIGHTEN ALL FASTENERS PRIOR TO DEPLOYMENT. 9. The double pole extension cord must be atleast 10 m (33 feet) away from the airbag assembly. Page 7799 Cargo Lamp: Electrical Diagrams Part 1 Of 2 Page 1669 3. Install the new intake manifold gaskets. 4. Reinstall the intake manifold with the new EGR valve gasket and the new throttle body gasket. Disclaimer Page 1404 Jump Starting: Service and Repair 1. Set the vehicle parking brake. If the vehicle is equipped with an automatic transmission, place the selector level in the "PARK" position. If the vehicle is equipped with a manual transmission, place the shift lever in the "NEUTRAL" position. Turn "OFF" the ignition. Turn "OFF" all lights and any other accessory requiring electrical power. 2. Look at the built-in hydrometer. If the indication area of the built-in hydrometer is completely clear, do not try to jump start. 3. Attach the end of one jumper cable to the positive terminal of the booster battery. Attach the other end of the same cable to the positive terminal of the discharged battery. Do not allow the vehicles to touch each other. This wilt cause a ground connection, effectively neutralizing the charging procedure. Be sure that the booster battery has a 12 volt rating. 4. Attach one end of the remaining cable to the negative terminal of the booster battery. Attach the other end of the same cable to a solid engine ground (such as the air conditioning compressor bracket or the generator mounting bracket) of the vehicle with the discharged battery. The ground connection must be at least 450 mm (18 in.) from the battery of the vehicle whose battery is being charged. WARNING: NEVER ATTACH THE END OF THE JUMPER CABLE DIRECTLY TO THE NEGATIVE TERMINAL OF THE DEAD BATTERY. 5. Start the engine of the vehicle with the good battery. Make sure that all unnecessary electrical accessories have been turned "OFF". 6. Start the engine of the vehicle with the dead battery. 7. To remove the jumper cables, follow the above directions in reverse order. Be sure to first disconnect the negative cable from the vehicle with the discharged battery. Page 8214 Window Track: Service and Repair Rear Door Rear Window Regulator, Glass and Glass Run Removal 1. Disconnect the battery ground cable. 2. Remove the rear corner garnish. 3. Remove the window regulator handle. - Remove the clip on the rear side of the regulator handle using a wire. 4. Remove the screw while pulling the inside lever toward you and then remove the inside handle. 5. Remove the 1 screw at the pull case. 6. Remove the rear corner garnish. Page 2800 Powertrain Control Module: Component Tests and General Diagnostics Powertrain Control Module (PCM) Diagnosis To read and clear diagnostic trouble codes, use a Tech 2. IMPORTANT: Use of a Tech 2 is recommended to clear diagnostic trouble codes from the PCM memory. Diagnostic trouble codes can also be cleared by turning the ignition "OFF" and disconnecting the battery power from the PCM for 30 seconds. Turning off the ignition and disconnecting the battery power from the PCM will cause all diagnostic information in the PCM memory to be cleared. Therefore, all the diagnostic tests will have to be re-run. Since the PCM can have a failure which may affect only one circuit, following the diagnostic procedures will determine which circuit has a problem and where it is. If a diagnostic chart indicates that the PCM connections or the PCM is the cause of a problem, and the PCM is replaced, but this does not correct the problem, one of the following may be the reason: - There is a problem with the PCM terminal connections. The terminals may have to be removed from the connector in order to check them properly. - EEPROM program is not correct for the application. Incorrect components or reprogramming the PCM with the wrong EEPROM program may cause a malfunction and may or may not set a DTC. - The problem is intermittent. This means that the problem is not present at the time the system is being checked. In this case, refer to Symptom Diagnosis and make a careful physical inspection of all component and wiring associated with the affected system. - There is a shorted solenoid, relay coil, or harness. Solenoids and relays are turned "ON" and "OFF" by the PCM using internal electronic switches called drivers. A shorted solenoid, relay coil, or harness will not damage the PCM but will cause the solenoid or relay to be inoperative. Page 3341 Terminals - "T" Each "T" terminal (ring type) is numbered for reference and location. A "T" terminal is secured with a screw or bolt. Wires Page 4507 Transmission Position Switch/Sensor: Service and Repair REMOVAL 1. Place selector lever in neutral. 2. Disconnect battery ground cable. 3. Remove mode switch cover (1). 4. Disconnect selector lever (2) from the mode switch. 5. Remove bracket with cable (3). 6. Disconnect transmission harness from the mode switch connector (4). 7. Remove bracket with mode switch connector from the transmission case. 8. Remove mode switch connector (4) from the bracket (5). 9. Remove two mode switch bolts and nut then remove mode switch (6). INSTALLATION To install, follow the removal steps in the reverse order, noting the following points; 1. Torque Mode switch bolt: 13 Nm (113 inch lbs.) Selector lever nut: 23 Nm (17 ft. lbs.) 2. Mode switch setting procedure. Perform either of the following adjustment procedures: Procedure 1 a. Place selector lever in neutral. b. Remove selector lever from the mode switch. c. Remove the mode switch cover. d. Loosen the two 10 mm screws. e. Rotate the mode switch until the slot in the mode switch housing aligns with the selector shaft bushing, and insert a 3/32 inch (2.4 mm) drill bit or punch (1) into the slot. f. Tighten the screws to 13 Nm (113 inch lbs.). g. After completing adjustment, snap the mode switch cover into place. h. Reinstall the selector lever. Procedure 2 a. Place selector lever in neutral. b. Disconnect transmission harness connector from mode switch connector. Page 4489 Test Equipment CAUTION: Most circuits include solid-state devices. Test the voltages in these circuits only with a 10-megaohm or higher impedance digital multimeter. Never use a test light or analog meter on circuits that contain solid-state devices. Damage to the devices may result. Test Light and DVOM On circuits without solid-state devices, use a test light to check for voltage. A test light is made up of a 12 volt bulb with a pair of leads attached. After grounding one lead, touch the other lead to various points along the circuit where voltage should be present. The bulb will go on if there is voltage at the point being tested. If you need to know how much voltage is present, use a digital volt/ohmmeter (DVOM). Self-Powered Test Light and DVOM Use a self-powered test light to check for continuity. This tool is made up of a light bulb, battery, and two leads. To test it, touch the leads together: the light should go on. Use a self-powered test light only on an unpowered circuit. First, disconnect the battery, or remove the fuse that feeds the circuit you are working on. Select two points in the circuit between which you want to check continuity. Connect one lead of the self-powered test light to each point. If there is continuity, the test light's circuit will be completed, and the light will go on. If, in addition, you need to know exactly how much resistance there is between two points, use a digital volt/ohmmeter (DVOM). In the "OHMS" range, the DVOM will measure resistance between two points along a circuit. Low resistance means good continuity. Diodes and solid-state devices in a circuit can make a DVOM give a false reading. To check a reading, reverse the leads, and take a second reading. If the readings differ, the component is affecting the measurement. Jumper Wire Use a jumper wire to bypass an open circuit. A jumper wire is made up of an in-line fuse holder connected to a set of test leads. It should have a five ampere fuse. Never connect a jumper wire across a short circuit. The direct battery short will blow the fuse. Short Finder (Short Circuit Locator) Short finders are available to locate shorts to ground. The short finder creates a pulsing magnetic field in the shorted circuit which you can follow to the location of the short. To order any test equipment shown above, contact your local tool supplier. For a list of suppliers and tool numbers, refer to Honda Required Special Tools and Equipment Service Bulletin. Page 7766 Testing For A Short With A Self-Powered Test Light or DVOM 1. Remove the blown fuse and disconnect the battery and load. 2. Connect one lead of a self-powered test light or digital volt/ohmmeter (DVOM) (switched to the lowest "OHMS" range) to the fuse terminal on the load side. 3. Connect the other lead to a known good ground. 4. Beginning near the fuse box, wiggle the harness. Continue this at convenient points about six inches apart while watching the test light or DVOM. 5. If the self-powered test light goes on or the DVOM displays a low reading or no reading (zero), there is a short to ground in the wiring near that point. Testing for a Short with a Test Light or DVOM 1. Remove the blown fuse and disconnect the load. 2. Connect a test light or digital volt/ohmmeter (DVOM), switched to the appropriate DC volts range, across the fuse terminals to make sure voltage is present. You might have to turn the ignition switch to ON; check the schematic to see. 3. Beginning near the fuse box, wiggle the harness. Continue this at convenient points about six inches apart while watching the test light or DVOM. 4. Where the test light goes , or the DVOM voltage drops to zero, there is a short to ground in the wiring near that point. NOTE: Always use a DVOM on high impedance circuits. A test light may not glow (even with battery voltage present). Testing For A Short With A Short Circuit Locator (Short Finder) 1. Remove the blown fuse. Leave the battery connected. Page 1242 Refrigerant: Service and Repair System Evacuation Evacuation Of The Refrigerant System NOTE: Explained below is a method using a vacuum pump. Refer to the ACR(4)(or equivalent) manufacturer's instructions when evacuating the system with a ACR(4)(or equivalent). Air and moisture in the refrigerant will cause problems in the air conditioning system. Therefore, before charging the refrigerant, be sure to evacuate air and moisture thoroughly from the system. 1. Connect the gauge manifold. - High-pressure valve (HI) - Discharge-side. - Low-pressure valve (LOW) - Suction-side. 2. Discharge and recover the refrigerant. 3. Connect the center hose of the gauge manifold set to the vacuum pump inlet. 4. Operate the vacuum pump, open shutoff valve and then open both hand valves. 5. When the low-pressure gauge indicates approximately 750 mmHg (30 inHg), continue the evacuation for 5 minutes or more. 6. Close both hand valves and stop the vacuum pump. 7. Check to ensure that the pressure does not change after 10 minutes or more. - If the pressure changes, check the system for leaks. - If leaks occur, retighten the refrigerant line connections and repeat the evacuation steps. 8. If no leaks are found, again operate the vacuum pump for 20 minutes or more. After confirming that the gauge manifold pressure is at 750 mmHg (30 inHg), close both hand valves. 9. Close positive shutoff valve. Stop the vacuum pump and disconnect the center hose from the vacuum pump. Page 1963 Terminals - "T" Each "T" terminal (ring type) is numbered for reference and location. A "T" terminal is secured with a screw or bolt. Wires Diagrams Vibration When Idling Muffler: Customer Interest Vibration When Idling 00-040 April 11, 2000 Applies To: 1998-99 Passport - ALL 2000 Passport-From VIN 4S6..58W.Y4400001 thru 4S6..58W.Y4400051 Vibration When Idling SYMPTOM Harsh vibration comes from the body, the steering wheel, the seats, or the floor when the transmission is in Drive with the engine idling. The vibration is worse when the engine is cold. Sometimes, you can hear banging while starting the engine. PROBABLE CAUSE The right engine mount cover hits the chassis side of the engine mount. CORRECTIVE ACTION Shift the engine assembly slightly forward using REPAIR PROCEDURE A. If the vibration is still there, replace the right engine mount cover using REPAIR PROCEDURE B. PARTS INFORMATION Engine Mount Cover: P/N 8-97241-056-0, H/C 6362701 WARRANTY CLAIM INFORMATION In warranty: The normal warranty applies. REPAIR PROCEDURE A Operation Number: 112010 Flat Rate Time: 0.2 hour Failed Part: P/N 8-97125-561-7 H/C 6360812 Detect Code: 045 Contention Code: B99 Template ID: 00-040A Skill Level: Repair Technician REPAIR PROCEDURE B Operation Number: 112125 Flat Rate Time: 1.5 hours Failed Part: P/N 8-97125-306-0 H/C 5508981 Defect Code: 045 Contention Code: B99 Template ID: 00-040B Skill Level: Repair Technician Out of warranty: Any repair performed after warranty expiration may be eligible for goodwill consideration by the District Service Manager or your Zone Office. You must request consideration, and get a decision, before starting work. REPAIR PROCEDURE A 1. Raise the vehicle on a lift. Page 6157 2. Connect the short finder across the battery terminals and the load (component) side of the fuse terminal. 3. Close all switches in the circuit you're testing. 4. Turn on the short finder. This creates a pulsing magnetic field around the wiring between the fuse box and the short. 5. Beginning at the fuse box, slowly move the short finder along the circuit wiring. The meter will read current pulses through sheet metal and body trim. As long as the meter is between the fuse and the short, the needle will move with each current pulse. Once you move the meter past the point of the short, the needle will stop moving. Check the wiring and connectors in this area to locate the cause of the short. Testing For Continuity When testing for continuity at a connector without wire seals, you do not have to separate the two halves of the connector. Instead, probe the connector from the back. Always check both sides of the connector because dirty, corroded, and bent terminals can cause problems (no electrical contact = an open). 1. Disconnect the negative cable from the car battery. If you're using a DVOM, place it in the lowest "OHMS" range. Page 7020 Rear Door Trim Panel And Associated Parts Page 2754 2. Compare the retrieved code with the listed codes. ^ If the code is in the list, go to step 3. ^ If the code is not in the list, the PCM has already been updated. Troubleshoot other causes for the detonation. NOTE: Since the Smart Cable may need to be cleared from a previous PCM update or the Smart Cable firmware may need to be reprogrammed, always begin each PCM update at the iN workstation. 3. Update the PCM software with the Smart Cable. For instructions, refer to Service Bulletin 99-005. NOTE: Make sure you select the most recent broadcast code from the list on the iN screen that applies to the model year, transmission type, and emission level. This code is not necessarily at the top of the list since the most recent code is the last one in the alphabetical sequence, letter by letter. 4. Use the PGM Tester to clear any DTCs set during programming. 5. Retrieve the broadcast code. Make sure it does not match any of the codes in the list in step 2 (indicating the PCM has been updated) and that it applies to the model year, transmission type, and emission level for the vehicle. The broadcast code should match a code in the list below. Disclaimer Page 1775 Spark Plug: Specifications Plug Torque 13 ft lb (18 Nm) Locations Parking Brake Warning Switch: Locations Under Center Console Page 7516 If there is no photo number below or beside a component name or a connector, ground, or terminal number, look up that name or number in the appropriate Connector Identification Chart. The chart lists how many cavities a connector has, where it's located, and what it connects to. The related illustration shows the connector's location on the harness, and the harness routing. NOTE: Photos listed by number are located at Locations / Components / Photograohs. See: Locations/Component Locations/Photographs Circuit Schematics Description and Operation Fuel Pump Pickup Filter: Description and Operation The filter is located on the lower end of fuel pickup tube in the fuel tank. It prevents dirt from entering the fuel pipe and also stops water unless the filter is completely submerged in the water. It is a self cleaning type, not requiring scheduled maintenance. Excess water and sediment in the tank restricts fuel supply to the engine, resulting in engine stoppage. In such a case, the tank must be cleaned thoroughly. Page 7300 3. Photocopy the template that is shown. Cut out the template. Accelerator Pedal Assembly/Sensor - Adjustment Update Accelerator Pedal Position Sensor: All Technical Service Bulletins Accelerator Pedal Assembly/Sensor - Adjustment Update 00-045 August 14, 2001 Applies To: 2000-02 Passport - ALL Service Manual Update: Accelerator Pedal Position Sensor (APPS) (Supersedes 00-045, dated May 23, 2000) Updated information is shown by asterisks and black bars. BACKGROUND When the accelerator pedal position sensor (APPS) or the accelerator pedal assembly is replaced for any reason, you must adjust the APPS. *This procedure is missing in the 2000 service manual and is wrong in the 2001 and 2002 service manuals. Make a note on page 6E2-539 of the 2000 Passport Fuel and Emissions manual, on page 6E2-553 of the 2001 Passport Fuel and Emissions manual, and on page 6E2-545 of the 2002 Passport Fuel and Emissions manual to refer to this bulletin.* ADJUSTMENT PROCEDURE 1. Replace the APPS or the accelerator pedal assembly, and leave the mounting screws for the APPS loose. 2. Connect the PGM Tester to the data link connector (DLC), and turn the ignition switch to ON (II). *3. While watching the APP Sensor values in the Engine Data List, adjust the APPS by turning it until the values are within the ranges shown at closed pushed all the way down), then tighten the throttle and wide open throttle (accelerator pedal mounting screws and recheck the values. ^ If all three sensors are within range, go to step 12. ^ If APP Sensor 1, APP Sensor 2, and/or APP Sensor 3 cannot be brought into range, go to step 4. 4. Troubleshoot for an open circuit or a PCM malfunction. ^ If APP Sensor 1 has a value of 0% or APP Sensor 2 and/or APP Sensor 3 have a value of 99%, an open circuit exists or the PCM is malfunctioning. Repair the circuit or replace the PCM, and repeat step 3. ^ If you don't find a problem, go to step 5. 5. Disconnect the 10P connector from the APPS. 6. View the APP Sensor values in the Engine Data List. ^ If APP Sensor 1 has a value of 0% or APP Sensor 2 and/or APP Sensor 3 have a value of 99%, go to step 7. ^ If APP Sensor 1 has a value other than 0%, or APP Sensor 2 and/or APP Sensor 3 have a value other than 99%, a short circuit exists or the PCM is malfunctioning. Repair the circuit or replace the PCM, and repeat step 3. Page 6511 Seat Belt: Service Precautions WARNING: THIS VEHICLE HAS A SUPPLEMENTAL RESTRAINT SYSTEM (SRS). REFER TO THE SRS COMPONENT AND WIRING LOCATION VIEW IN ORDER TO DETERMINE WHETHER YOU ARE PERFORMING SERVICE ON OR NEAR THE SRS COMPONENTS OR THE SRS WIRING. WHEN YOU ARE PERFORMING SERVICE ON OR NEAR THE SRS COMPONENTS OR THE SRS WIRING, REFER TO THE SRS SERVICE INFORMATION. FAILURE TO FOLLOW WARNINGS COULD RESULT IN POSSIBLE AIR BAG DEPLOYMENT, PERSONAL INJURY, OR OTHERWISE UNNEEDED SRS SYSTEM REPAIRS. CAUTION: Always use the correct fastener in the proper location. When you replace a fastener, use ONLY the exact part number for that application. ISUZU will call out those fasteners that require a replacement after removal. ISUZU will also call out the fasteners that require thread lockers or thread sealant. UNLESS OTHERWISE SPECIFIED, do not use supplemental coatings (Paints, greases, or other corrosion inhibitors) on threaded fasteners or fastener joint interfaces. Generally, such coatings adversely affect the fastener torque and the joint clamping force, and may damage the fastener. When you install fasteners, use the correct tightening sequence and specifications. Following these instructions can help you avoid damage to parts and systems. Page 6819 5. Remove the speaker assembly (2). - Remove the 4 screws and disconnect the speaker harness connector (1). 6. Remove the door mirror cover. 7. Remove the grip cover. 8. Remove the 5 screws (1), (3) and pull out the trim panel at the 6 clip positions (2). 9. Remove the waterproof sheet. Audio/Navigation/RES - Warr. Exchange/Non-Warr Repair Navigation System: Technical Service Bulletins Audio/Navigation/RES - Warr. Exchange/Non-Warr Repair 06-001 February 26, 2010 Applies To: 1998 and Later Models - ALL Audio, Navigation, and RES Unit In-Warranty Exchange and Out-of-Warranty Repair (Supersedes 06-601, dated March 4, 2009, to revise the information marked by the black bars and asterisks) *REVISION SUMMARY Under OUT-OF-WARRANTY REPAIR, the address for Pioneer Electronics Service was changed.* COVERAGE This bulletin applies to all Honda audio units, CD players/changers, cassette tape players, navigation units, and rear entertainment system (RES) units, both in warranty and out of warranty. COMPONENT REPLACEMENT POLICY Use only remanufactured components for warranty repairs on customer vehicles. Follow the warranty information and procedures given in this service bulletin. ^ Remanufactured audio, navigation, and RES units are not available for non-warranty repairs. ^ Use new components to repair new, unsold vehicles. ^ A new component may be used to repair a customer's vehicle only if the remanufactured component is currently unavailable from American Honda. ^ You must receive authorization from your District Parts and Service Manager (DPSM) before ordering a new component. WARRANTY CLAIM INFORMATION In warranty: The normal warranty applies. Operation Number: From the Flat Rate Manual Flat Rate Time: From the Flat Rate Manual Failed Part: Use the RM part number from the repair order without the RM (example: 08A06-341-110) Defect Code: From the Flat Rate Manual Symptom Code: From Audio Customer Contention Codes in the Flat Rate Manual Part used for repair: Use the RM part number from the repair order (example: 08A06-341-110RM) IN-WARRANTY DIAGNOSIS Service Advisor: Interview the customer to get as much information as possible. Information like where and when the problem occurs is vital to your diagnosis. This information also helps you to determine if the audio, navigation, or RES system is operating normally, or if a problem exists. Write the complaint on the repair order. NOTE: For CD/DVD related problems, you must verify if the customer used discs with adhesive labels. Service Technician: Locations Fuse Block: Locations Page 5172 Yoke Assembly Check a magnet inside the yoke. Replace the yoke assembly if it is broken. Ball Bearing Clamp the inner race of the ball bearing with your finger, and check for sticking or play when rotating the outer race. Replace, if abnormality is found. Page 6436 Clockspring Assembly / Spiral Cable: Service and Repair Horn Terminals How to Disconnect the horn terminal 1. Lift the white part of black connector with a screw driver (-) and release connector terminal lock. 2. Pull out the terminal of lead wire coming to black connector NO.12 while lifting the lock part with a screw driver (-). How to Connect Horn Terminal Page 4309 5. Install retainer ring, using installer and press. 6. Install snap ring. 7. Install axle shaft assembly into housing. 8. Install bolts, lockwashers, and nuts. Tighten the retainer nuts to the specified torque. Torque: 75 Nm (55 ft. lbs.) Service and Repair Antenna Mast: Service and Repair Removal 1. Disconnect the battery ground cable. 2. Turn the antenna rod (1) counterclockwise to remove it. 3. Remove three screws and nine clips to remove the fender inner liner (2). 4. Disconnect the feeder cable connector (3) at the inside of the vehicle, remove the housing bracket screw, turn the lock nut counterclockwise to remove it together with the base mold and then remove the housing. Installation To install, follow the removal steps in the reverse order, noting the following point: Page 5813 4. Use installer J-36828 and grip J-8092 then install the outer bearing by driving it into the hub. 5. Apply grease (NLG1 No.2 or equivalent) to the lip portion, then install oil seal by using installer J-36830 and grip J-8092. 6. Install ABS sensor ring, then tighten the bolts to the specified torque. Torque: 18 Nm (13 ft. lbs.) 7. Install hub and disc assembly. - Apply grease in the hub. - Apply wheel bearing type grease NLGI No. 2 or equivalent to the outer and inner bearing. Page 293 This sample Ground Distribution schematic shows all of the components that share two ground points. Components A solid border line means the entire component is shown. A broken border line indicates that only part of the component is shown. Diagram Information and Instructions Brake Warning Indicator: Diagram Information and Instructions How to Identify Wiring Color-Coded Insulation Wire Color Wire Color Coding Page 5608 REASSEMBLY 1. Install mounting rubber and dust cover (If removed). 2. Install oil line. Torque to 13 Nm (113 inch lbs.) 3. Install tie-rod assembly with tab washer. Apply grease to ball joint, install tie-rod and tab washer, then tighten to specified torque. Torque to 83 Nm (61 ft. lbs.). After tightening, bend tab washer against width across flat of inner ball joint. 4. Apply a thin coat of grease to the shaft for smooth installation. Then install bellows. 5. Install band and clip. 6. Install tie-rod end and tighten lock nut. Torque to 98 Nm (72 ft. lbs.) Page 7927 License Plate Bulb: Service and Repair Tailgate Type Removal 1. Disconnect the battery ground cable. 2. Remove the lens cover (3). - Remove two screws. 3. Remove the bulb (2). - Pull out the bulb from the socket (1). Installation To install, follow the removal steps in the reverse order. Description and Operation EGR Valve Position Sensor: Description and Operation EGR Pintle Position Sensor The PCM monitors the EGR valve pintle position input to endure that the valve responds properly to commands from the PCM and to detect a fault if the pintle position sensor and control circuits are open or shorted. If the PCM detects a pintle position signal voltage outside the normal range of the pintle position sensor, or a signal voltage that is not within a tolerance considered acceptable for proper EGR system operation, the PCM will set DTC P1406. Locations Camshaft Position Sensor Inspection and Repair Starter Motor: Testing and Inspection Inspection and Repair Repair or replace necessary parts if extreme wear or damage is found during inspection. Armature Measure the outer diameter of commutator, and replace with a new one if it is out of the limit. Standard: 33.0 mm (1.30 in) Limit: 32.0 mm (1.26 in) Check for continuity between commutator and segment. Replace commutator if there is no continuity (i.e., disconnected). Component Locations Page 8196 1. Install the regulator handle as shown in the figure, if equipped without Dower windows. 2. Check to see that the window regulator operates smoothly and the glass opens and closes properly. 3. Install the waterproof sheet tightly against the door panel. Page 554 The name of the component appears next to it followed by notes about its function along with any photo and connector view references. Connector "C" How to Identify Connector Terminals Cavity Numbering System The cavities (and wire terminals) in each connector are numbered starting from the upper left, looking at the male terminals from the terminal side (or looking at the female terminals from the wire side. Both views are in the same direction so the numbers are the same.) All actual cavities are numbered, even if they have no wire terminals in them. NOTE: Data Link Connector (DLC) terminals are numbered according to SAE standard J1962, not the Honda standard. The numbers of the four end terminals are molded into the corners of the connector face. Page 6142 the component if the component only has one connector, or by a capital letter (A, B, C, etc.) if the component has more than one connector. Below most connector numbers and component names are PHOTO and VIEW numbers. The PHOTO number refers to a photo in the back of the book that shows the connector's location on the car. The VIEW number refers to an illustration in the back of the book that shows the connector face, wire colors, connector cavity numbers, and other details. The connector cavity numbering sequence begins at the top left corner of the connector. Disregard any numbers molded into the connector housing. Wires Wires are identified by the abbreviated names of their colors; the second color is the color of the stripe. Wires are also identified by their location in a connector. The number "2" next to the male and female wire terminals at C416, for example, means those terminals join in cavity 2 of connector C416. Symbols A complete description of schematic symbols is given under wire color abbreviation. Power Distribution Schematics Power Distribution schematics show how power is supplied from the positive battery terminal to various circuits in the car. Refer to the Power Distribution section to get a more detailed picture of how power is supplied to the circuit you're working on. From Battery to Ignition Switch, Fuses, and Relays Individual circuit schematics begin with a fuse. The first half of Power Distribution, however, shows the wiring "upstream" between the battery Specifications Timing Belt: Specifications Replace Timing Belt every 75,000 miles (120,000 km) Description and Operation Temperature Gauge: Description and Operation The engine coolant temperature gauge consists of two intersecting coils wound around a permanent magnet rotor. When voltage from fuse 11 is applied to the coils, a magnetic field is generated. This causes the rotor to rotate and the gauge needle to move. The magnetic field is controlled by the sender. As the resistance in the sender varies, current through the gauge coils changes. The gauge needle moves according to the changing magnetic field. Locations Gear Sensor/Switch: Locations Top Right Side Of Transfer Case Page 7446 Test Equipment CAUTION: Most circuits include solid-state devices. Test the voltages in these circuits only with a 10-megaohm or higher impedance digital multimeter. Never use a test light or analog meter on circuits that contain solid-state devices. Damage to the devices may result. Test Light and DVOM On circuits without solid-state devices, use a test light to check for voltage. A test light is made up of a 12 volt bulb with a pair of leads attached. After grounding one lead, touch the other lead to various points along the circuit where voltage should be present. The bulb will go on if there is voltage at the point being tested. If you need to know how much voltage is present, use a digital volt/ohmmeter (DVOM). Self-Powered Test Light and DVOM Use a self-powered test light to check for continuity. This tool is made up of a light bulb, battery, and two leads. To test it, touch the leads together: the light should go on. Use a self-powered test light only on an unpowered circuit. First, disconnect the battery, or remove the fuse that feeds the circuit you are working on. Select two points in the circuit between which you want to check continuity. Connect one lead of the self-powered test light to each point. If there is continuity, the test light's circuit will be completed, and the light will go on. If, in addition, you need to know exactly how much resistance there is between two points, use a digital volt/ohmmeter (DVOM). In the "OHMS" range, the DVOM will measure resistance between two points along a circuit. Low resistance means good continuity. Diodes and solid-state devices in a circuit can make a DVOM give a false reading. To check a reading, reverse the leads, and take a second reading. If the readings differ, the component is affecting the measurement. Jumper Wire Use a jumper wire to bypass an open circuit. A jumper wire is made up of an in-line fuse holder connected to a set of test leads. It should have a five ampere fuse. Never connect a jumper wire across a short circuit. The direct battery short will blow the fuse. Short Finder (Short Circuit Locator) Short finders are available to locate shorts to ground. The short finder creates a pulsing magnetic field in the shorted circuit which you can follow to the location of the short. To order any test equipment shown above, contact your local tool supplier. For a list of suppliers and tool numbers, refer to Honda Required Special Tools and Equipment Service Bulletin. Page 4440 Distinct Of Circuit By Wire Base Color All wires have color-coded insulation. Wires belonging to a system's main harness will have a single color. Wires belonging to a system's sub-circuits will have a colored stripe. Striped wires use the codes found in the chart to show wire size and colors. Abbreviations are used to indicate wire color within a circuit diagram. How to Identify Connector Terminals How to Identify Connector Terminals Cavity Numbering System The cavities (and wire terminals) in each connector are numbered starting from the upper left, looking at the male terminals from the terminal side (or looking at the female terminals from the wire side. Both views are in the same direction so the numbers are the same.) All actual cavities are numbered, even if they have no wire terminals in them. NOTE: Data Link Connector (DLC) terminals are numbered according to SAE standard J1962, not the Honda standard. The numbers of the four end terminals are molded into the corners of the connector face. The connector cavity number is listed next to each terminal on the circuit schematic. The cavity / terminal shown is # 6. Using/Identifying Connector Terminal Views How to Use Connector Terminal Views To see the configuration of a connector's cavities, look up its view number in the Connector Views. Each view includes the color of the connector, where Page 1899 Page 2865 Coolant Temperature Sensor/Switch (For Computer): Service and Repair ENGINE COOLANT TEMPERATURE (ECT) SENSOR REMOVAL PROCEDURE NOTE: Care must be taken when handling the engine coolant temperature (ECT) sensor. Damage to the ECT sensor will affect proper operation of the fuel injection system. 1. Disconnect the negative battery cable. 2. Drain the radiator coolant. Refer to Draining and Refilling Cooling System. 3. Disconnect the electrical connector. 4. Remove the ECT sensor from the coolant crossover. INSTALLATION PROCEDURE 1. Apply sealer or the equivalent to the threads of the ECT sensor. 2. Install the ECT sensor in the coolant crossover. Tighten Tighten the ECT sensor to 30 N.m (22 lb ft.). Page 1684 2. Unfasten C123 from the side of the engine compartment using a 90-degree pick. 3. Disconnect C123, and clean the terminals on both sides of the connector with contact cleaner. Shake the residue out of the connector. Allow the contact cleaner to evaporate for at least 3 minutes, then reconnect C123. 4. Fasten C123 to the left side of the engine compartment, and reinstall the air cleaner housing cover. 5. Remove the connector position assurance (CPA) clip from the APPS connector. 6. Disconnect the lop connector from the APPS. 7. Clean the terminals of the 10P APPS connector (harness side) with contact cleaner. Shake out residue from the connector, and allow the contact cleaner to evaporate for at least 3 minutes, then reconnect it. 8. Use the Smart Cable to reprogram the PCM with the latest software from the June 2001 or later HONDANET CD-ROM. Refer to Service Bulletin 99-005, Updating the Passport PCM, filed under Tools. 9. Use the PGM Tester to clear any DTCs. Page 1682 4. Remove the fuel pressure regulator from the fuel rail. 5. Remove the fuel return line from the regulator. 6. Install the new fuel pressure regulator in the reverse order of removal. 7. Use the Smart Cable to reprogram the PCM with the latest software from the June 2001 or later HONDANET CD-ROM. Refer to Service Bulletin 99-005, Updating the Passport PCM, filed under Tools. 8. Use the PGM Tester to clear any DTCs. 9. Use the PGM Tester to check the broadcast code. Make sure the broadcast code matches the one you selected from the CD-ROM. WARRANTY CLAIM INFORMATION In warranty: The normal warranty applies. Failed Part: P/N 8-17113-398-0 H/C 5504386 Defect Code: 092 Contention Code: C99 Skill Level: Repair Technician Out of warranty: Any repair performed after warranty expiration may be eligible for goodwill consideration by the District Service Manager or your Zone Office. You must request consideration, and get a decision, before starting work. REPAIR PROCEDURE - POWER STEERING SWITCH 1. Drain the power steering fluid out of the system. 2. Remove the power steering fluid reservoir. Clean the reservoir with solvent, then with soap and water. Rinse and dry it thoroughly. 3. Reinstall the reservoir. Do not connect the return hose. 4. Remove the power steering pressure switch, then clean it with brake cleaner and a scraper. Reinstall the switch, and torque it to 20 N.m (14 lb-ft). 5. Cover the unconnected end of the reservoir with your finger, then fill the reservoir with Dexron III ATF Page 525 Brake Light Switch: Service and Repair REMOVAL 1. Disconnect connector (1) 2. Remove lock nut (3). 3. Remove switch (2). INSTALLATION 1. Adjust the stop light switch to the specified clearance (between switch housing and brake pedal) by rotating the switch housing. NOTE: Do not attempt to force the push rod into position during the stop light switch installation and adjustment procedure. 2. Connect connector (1). 3. Install lock nut (3). Page 1237 HVAC / Heating Page 6075 and the fuses. From Fuses to Relays and Components The second half of Power Distribution shows the wiring "From Fuses to Relays and Components." This can speed your troubleshooting by showing which circuits share fuses. If Power Distribution shows that an inoperative circuit and another circuit share a fuse, check a component in the other circuit. If it works, you know the fuse is good and power is available to the inoperative circuit. Ground Distribution Schematics Page 6813 CAUTION: Do not apply excessive force on the inside handle link or damage may occur, which could make the inside handle difficult to operate. 8. Remove the door trim panel. - Remove 5 fixing screws (1), (3) in order to take off 6 clips (2) from the door panel. - Disconnect the tweeter and courtesy light connectors to lift the door trim panel and unlock the engagement of the waist seal section. Then, pass the inside handle through the mounting hole of the trim panel, and detach the trim panel. 9. Remove the inside handle. 10. Remove the tweeter. Installation To install, follow the removal steps in the reverse order. Page 5775 1. Using a wire brush and a scraper, remove any loose frame coating and rust from the outside frame rail and the lower trailing link frame bracket in the 20-inch (500 mm) section shown below. 2. Use a dry rag to remove any remaining dust or debris. If the area is wet, dry it with an air nozzle. 3. Spray a coat of Noxudol 300 onto the lower trailing link frame brackets, and on the outside of the frame rails in the area you just cleaned. The total spray area is about 20 inches (500 mm). Be careful not to overspray onto the exhaust system or body painted areas. 4. Fill out the information on a campaign completion label. Stick this label to the back edge of the driver's door, just below the door latch. *NOTE: If you need more labels, order them from Helm using reorder number Y0895.* Stage 2 Repair STAGE 2 REPAIR NOTE: ^ Do this repair on both sides of the vehicle. ^ Noxudol spray is highly flammable. Keep away from ignition sources (no smoking). Keep at a temperature not exceeding 120°F (50°C). ^ Wear hand and eye protection to avoid direct contact with the Noxudol spray. Spraying should be done in an area with adequate ventilation. 1. Remove the frame rail side hole plug from the driver's and passenger's side frame rails. 2. Using a hammer, knock on the outside of the frame rail around the lower trailing link bracket area to loosen any rust on the inside of the frame. Description and Operation EGR Valve Position Sensor: Description and Operation EGR Pintle Position Sensor The PCM monitors the EGR valve pintle position input to endure that the valve responds properly to commands from the PCM and to detect a fault if the pintle position sensor and control circuits are open or shorted. If the PCM detects a pintle position signal voltage outside the normal range of the pintle position sensor, or a signal voltage that is not within a tolerance considered acceptable for proper EGR system operation, the PCM will set DTC P1406. Page 5481 2. Unfasten C123 from the side of the engine compartment using a 90-degree pick. 3. Disconnect C123, and clean the terminals on both sides of the connector with contact cleaner. Shake the residue out of the connector. Allow the contact cleaner to evaporate for at least 3 minutes, then reconnect C123. 4. Fasten C123 to the left side of the engine compartment, and reinstall the air cleaner housing cover. 5. Remove the connector position assurance (CPA) clip from the APPS connector. 6. Disconnect the lop connector from the APPS. 7. Clean the terminals of the 10P APPS connector (harness side) with contact cleaner. Shake out residue from the connector, and allow the contact cleaner to evaporate for at least 3 minutes, then reconnect it. 8. Use the Smart Cable to reprogram the PCM with the latest software from the June 2001 or later HONDANET CD-ROM. Refer to Service Bulletin 99-005, Updating the Passport PCM, filed under Tools. 9. Use the PGM Tester to clear any DTCs. Description and Operation Electric Load Sensor: Description and Operation Electrical Load Detector (ELD) Since the early ’90s, Honda vehicles have come with an electrical load detector (ELD) unit in the under-hood fuse/relay box. This unit allows the ECM/PCM to regulate the alternator (switch it between high output and low output) to provide the best combination of fuel economy and electrical system operation. The ELD sends a signal to the ECM/PCM that is proportional to the electrical demand. The ECM/PCM switches the alternator between high output and low output depending on several factors, which include electrical demand, battery charge level, and the driving cycle. When the alternator is in low output, the engine load is reduced and fuel economy improves. Page 5128 Alternator: Service and Repair Inspection and Repair Repair or replace necessary parts if extreme wear or damage is found during inspection. Rotor Assembly 1. Check the face of the slip rings for contamination and roughness. If found to be scored, dress with a fine sandpaper (#500-600). If found to be contaminated, clean with a cloth saturated with alcohol. 2. Measure the outside diameter of the slip rings. Standard: 27 mm (1.06 in) Limit: 26 mm (1.02 in) 3. Check resistance between slip rings, and replace if there is no continuity. Standard: 3.75 ohms or less Page 1948 2. Compare the retrieved code with the listed codes. ^ If the code is in the list, go to step 3. ^ If the code is not in the list, the PCM has already been updated. Troubleshoot other causes for the detonation. NOTE: Since the Smart Cable may need to be cleared from a previous PCM update or the Smart Cable firmware may need to be reprogrammed, always begin each PCM update at the iN workstation. 3. Update the PCM software with the Smart Cable. For instructions, refer to Service Bulletin 99-005. NOTE: Make sure you select the most recent broadcast code from the list on the iN screen that applies to the model year, transmission type, and emission level. This code is not necessarily at the top of the list since the most recent code is the last one in the alphabetical sequence, letter by letter. 4. Use the PGM Tester to clear any DTCs set during programming. 5. Retrieve the broadcast code. Make sure it does not match any of the codes in the list in step 2 (indicating the PCM has been updated) and that it applies to the model year, transmission type, and emission level for the vehicle. The broadcast code should match a code in the list below. Disclaimer Page 6197 To install, follow the removal steps in the reverse order, noting the following point: 1. Check that each mode door operates properly. Locations Air Flow Meter/Sensor: Locations 28. Left Side of Engine Compartment Left Side Of Engine Compartment Page 3416 Fuel Pump Relay: Testing and Inspection Relays Test This test is conducted to check Fuel Pump Relay and A/C Clutch for proper operation. Tech 2 must be used for this test. Test Procedure: 1. Connect Tech 2 to the vehicle DLC. 2. Ignition SW is "On". 3. Select F3 : Miscellaneous Test in the Application Menu. 4. Select F1 : Relay Test in the Miscellaneous Test. Page 7104 2. Connect one lead of a self-powered test light or DVOM to one end of the part of the circuit you want to test. 3. Connect the other lead to the other end. 4. If the self-powered test light glows, there is continuity. If you're using a DVOM, a low reading or no reading (zero), means good continuity. Testing For Voltage When testing for voltage at a connector without wire seals, you do not have to separate the two halves of the connector. Instead, probe the connector from the back. Always check both sides of the connector because dirty, corroded, and bent terminals can cause problems (no electrical contact = an open). 1. Connect one lead of the lest light to a known good ground, or, if you're using a digital volt ohmmeter (DVOM), place it in the appropriate DC volts range, and connect its negative lead to ground. 2. Connect the other lead of the test light or DVOM to the point you want to check. 3. If the test light glows, there is voltage present. If you're using a DVOM, note the voltage reading. It should be within one volt of measured battery voltage. A loss of more than one volt indicates a problem. NOTE: Always use a DVOM on high impedance circuits. A test light may not glow (even with battery voltage present). Testing For Voltage Drop Wires, connectors, and switches are designed to conduct current with a minimum loss of voltage. A voltage drop of more than one volt indicates a problem. 1. Place the digital volt/ohmmeter (DVOM) in the appropriate DC volts range. Connect the positive lead to the end of the wire (or to the connector or switch) closest to the battery. 2. Connect the negative lead to the other end of the wire (or the other side of the connector or switch). 3. Turn on the components in the circuit. 4. The DVOM will show the difference in voltage between the two points. A difference, or drop, of more than one volt indicates a problem. Check the circuit for loose, dirty, or bent terminals. Page 2185 H/C 4408092 Defect Code: 017 Contention Code: C99 Skill Level: Repair Technician Out of warranty: Any repair performed after warranty expiration may be eligible for goodwill consideration by the District Service Manager or your Zone Office. You must request consideration, and get a decision, before starting work. DISCLAIMER Diagram Information and Instructions Fuel Pump Relay: Diagram Information and Instructions How to Identify Wiring Color-Coded Insulation Wire Color Wire Color Coding Page 2241 Vehicle Speed Sensor: Testing and Inspection 1. Inspect the electrical connector for signs of corrosion or warping. Replace the VSS if the electrical connector is corroded or warped. 2. Inspect the VSS driven gear for chips, breaks, or worn condition. Replace the VSS if the driven gear is chipped, broken or worn. 3. Inspect the O-ring for wear, nicks, tears, or looseness. Replace the O-ring if necessary. Page 3617 Crankshaft Position Sensor: Service and Repair REMOVAL 1. Disconnect the negative battery cable. 2. Disconnect the wiring connector from crankshaft position sensor. 3. Remove one bolt and remove the CKP sensor from the right side of the engine block, just behind the mount. NOTE: Use caution to avoid any hot oil that might drip out. INSTALLATION 1. Apply a small amount of engine oil to the O-ring and install the CKP sensor in the engine block. 2. Install the CKP sensor mounting bolt. 3. Tighten the mounting bolt to 10 Nm (89 lb in.). 4. Connect the wiring connector to the CKP sensor. 5. Connect the negative battery cable. Page 3363 The name of the component appears next to it followed by notes about its function along with any photo and connector view references. Connector "C" How to Identify Connector Terminals Cavity Numbering System The cavities (and wire terminals) in each connector are numbered starting from the upper left, looking at the male terminals from the terminal side (or looking at the female terminals from the wire side. Both views are in the same direction so the numbers are the same.) All actual cavities are numbered, even if they have no wire terminals in them. NOTE: Data Link Connector (DLC) terminals are numbered according to SAE standard J1962, not the Honda standard. The numbers of the four end terminals are molded into the corners of the connector face. Page 6979 Air Bag(s) Arming and Disarming: Description and Operation General Description General Description Restraint Devices The Supplemental Restraint System (SRS) helps supplement the protection offered by the driver and front passenger seat belts by deploying an air bag from the center of the steering wheel and from the top of the right side of the instrument panel. The air bag deploys when the vehicle is involved in a frontal crash of sufficient force up to 30 degrees off the centerline of the vehicle; To further absorb the crash energy there is a knee bolster located beneath the instrument panel for both the driver and passenger, and the steering column is collapsible. Page 2546 Coolant Temperature Sensor/Switch (For Computer): Description and Operation Engine Coolant Temperature (ECT) Sensor The engine coolant temperature (ECT) sensor is a thermistor (a resistor which changes value based on temperature) mounted in the engine coolant stream. Low coolant temperature produces a high resistance of 100,000 ohms at -40 °C (-40 °F). High temperature causes a low resistance of 70 ohms at 130 °C (266 °F). The PCM supplies a 5-volt signal to the ECT sensor through resistors in the PCM and measures the voltage. The signal voltage will be high when the engine is cold and low when the engine is hot. By measuring the voltage, the PCM calculates the engine coolant temperature. Engine coolant temperature affects most of the systems that the PCM controls. The Tech 2 displays engine coolant temperature in degrees. After engine start-up, the temperature should rise steadily to about 85 °C (185 °F). It then stabilizes when the thermostat opens. If the engine has not been run for several hours (overnight), the engine coolant temperature and intake air temperature displays should be close to each other. A hard fault in the engine coolant sensor circuit will set DTC P0177 or DTC P0118. An intermittent fault will set a DTC P1114 or P1115. Page 5433 NOTE: You must calibrate the gauge with the same weight in the vehicle that you will use for the test-drive. If you plan to have an assistant help you during the test-drive, calibrate the gauge while both of you are sitting in the vehicle. The steering wheel offset gauge is a sticker that attaches to the steering wheel and the steering column cover. Place the sticker on the steering wheel when the steering wheel is straight. When you test-drive the vehicle, you can read how many millimeters the steering wheel is off-center. NOTE: If the vehicle is pulling, repairing the pull may correct the steering wheel offset. Page 7575 Terminals - "T" Each "T" terminal (ring type) is numbered for reference and location. A "T" terminal is secured with a screw or bolt. Wires Page 1369 Abnormal Tire Ahead Wear and Major Causes TYPICAL EXAMPLES OF ABNORMAL TIRE AHEAD WEAR AND MAJOR CAUSES: CAUTION: Similar wear patterns can be caused by worn suspension parts, misalignment of wheels and tires, and other suspension related problems. Spotty Wear Wear localized on shoulder sections, and in an extreme cases, the tire becomes polygonal in shape. 1. Tire or wheel out of round or distorted. 2. Hub or knuckle out of round or distorted. 3. Play in hub bearings or ball joint. 4. Rotating parts out of balance. Tread Wear One-Sided 1. Rotating parts out of balance. 2. Tire or wheel out of round. 3. Hub or knuckle out of round or distorted. Page 272 Test Equipment CAUTION: Most circuits include solid-state devices. Test the voltages in these circuits only with a 10-megaohm or higher impedance digital multimeter. Never use a test light or analog meter on circuits that contain solid-state devices. Damage to the devices may result. Test Light and DVOM On circuits without solid-state devices, use a test light to check for voltage. A test light is made up of a 12 volt bulb with a pair of leads attached. After grounding one lead, touch the other lead to various points along the circuit where voltage should be present. The bulb will go on if there is voltage at the point being tested. If you need to know how much voltage is present, use a digital volt/ohmmeter (DVOM). Self-Powered Test Light and DVOM Use a self-powered test light to check for continuity. This tool is made up of a light bulb, battery, and two leads. To test it, touch the leads together: the light should go on. Use a self-powered test light only on an unpowered circuit. First, disconnect the battery, or remove the fuse that feeds the circuit you are working on. Select two points in the circuit between which you want to check continuity. Connect one lead of the self-powered test light to each point. If there is continuity, the test light's circuit will be completed, and the light will go on. If, in addition, you need to know exactly how much resistance there is between two points, use a digital volt/ohmmeter (DVOM). In the "OHMS" range, the DVOM will measure resistance between two points along a circuit. Low resistance means good continuity. Diodes and solid-state devices in a circuit can make a DVOM give a false reading. To check a reading, reverse the leads, and take a second reading. If the readings differ, the component is affecting the measurement. Jumper Wire Use a jumper wire to bypass an open circuit. A jumper wire is made up of an in-line fuse holder connected to a set of test leads. It should have a five ampere fuse. Never connect a jumper wire across a short circuit. The direct battery short will blow the fuse. Short Finder (Short Circuit Locator) Short finders are available to locate shorts to ground. The short finder creates a pulsing magnetic field in the shorted circuit which you can follow to the location of the short. To order any test equipment shown above, contact your local tool supplier. For a list of suppliers and tool numbers, refer to Honda Required Special Tools and Equipment Service Bulletin. Page 6370 If there is no photo number below or beside a component name or a connector, ground, or terminal number, look up that name or number in the appropriate Connector Identification Chart. The chart lists how many cavities a connector has, where it's located, and what it connects to. The related illustration shows the connector's location on the harness, and the harness routing. NOTE: Photos listed by number are located at Locations / Components / Photograohs. See: Locations/Component Locations/Photographs Circuit Schematics Locations Quarter Window Glass: Locations Rear Quarter Glass (LWB) Page 6877 2. Adjust the clearance between outer quarter panel (1) and fuel filler door (2). Page 5793 16. Remove the top of body mount No. 4 from the left and right sides. Refer to step 11. 17. Insert wood blocks at the No. 4 and 5 body mounts to support the body off of the frame, and provide access for the following steps. The No. 4 body mount should be about 7 inches (175 mm) above the frame, and the No. 5 body mounts should be about 10.25 inches (260 mm) above the frame. 18. Remove both lower trailing link front mounting nuts and bolts. Discard the nuts and the bolts; new ones are included in the bracket kit. 19. Raise the vehicle on a lift. 20. Cut off the driver's side and the passenger's side lower trailing link front brackets from the frame: ^ Using a cutting wheel, cut just below or through the bracket weld to remove the bracket. ^ Once the bracket is removed, use a disk grinder to remove any excess material and smooth out the frame. Locations Trunk / Liftgate Lock Cylinder: Locations Tailgate Lock, Hatchgate (LWB) Lock And Associated Parts Component Locations Condenser Fan: Component Locations Page 5578 and the fuses. From Fuses to Relays and Components The second half of Power Distribution shows the wiring "From Fuses to Relays and Components." This can speed your troubleshooting by showing which circuits share fuses. If Power Distribution shows that an inoperative circuit and another circuit share a fuse, check a component in the other circuit. If it works, you know the fuse is good and power is available to the inoperative circuit. Ground Distribution Schematics Page 5091 INSTALLATION 1. Install lock cylinder assembly. 2. Install shift lock cable (for A/T). 3. Install cushion rubber. 4. Install snap ring. 5. Install Combination switch and SRS coil assembly. After installation of combination switch assembly, connect the combination switch wiring harness connector and the SRS 2-way connector located under the steering column. 6. Turn the SRS coil counterclockwise to full, return about 3 turns and align the neutral mark. CAUTION: When turning the SRS coil counterclockwise to full, stop turning if resistance is felt. Forced further turning may damage to the cable in the SRS coil. Page 4917 4. Outer Bearing Outer Race. Install the outer race; outer bearing by driving it into the hub. - Installer: J-36828. - Grip: J-8092. 5. Oil Seal. Apply grease (Besco L-2 or equivalent) to the lip portion. - Installer: J-36830. - Grip: J-8092. 6. ABS Sensor Ring (if so equipped). Tighten the bolts to the specified torque. - Torque 18 Nm (13 ft. lbs.). 7. Hub and Disc Assembly: a. Apply grease in the hub. b. Apply wheel bearing type grease NLGI No. 2 or equivalent to the other and inner bearing. Grease Amount: - Hub 35 g (1.23 oz) - Outer bearing 10 g (0.35 oz) - Inner bearing 15 g (0.53 oz) Locations Crankshaft Position Sensor: Locations CKP Sensor 36. Bottom Right Side of Engine Bottom Right Side of Engine Page 7982 Backup Lamp Switch: Service and Repair Removal 1. Disconnect the battery ground cable. 2. Remove the backup light switch (1). - Disconnect the connector (2). Installation To install, follow the removal steps in the reverse order, noting the following point. 1. Apply liquid gasket to the screw portion of the switch to prevent oil leak. Specifications Page 5274 L4 Engine Room Page 4523 Gear Sensor/Switch: Testing and Inspection TRANSFER POSITION SWITCH 1. With ball being free. A-B: There is continuity. 2. With ball forced into the switch. A-B: No continuity. 3. If 1) and 2) fail, replace with a new switch. Page 6347 Air Bag(s) Arming and Disarming: Service Precautions Airbag Handling and Storage Airbag Handling and Storage Do not disassemble an airbag. It has no serviceable parts. Once an airbag has been deployed, it cannot be repaired or reused. For temporary storage of the airbag during service, please observe the following precautions. - Store the removed airbag with the pad surface up. Never put anything on the removed airbag. - Keep free from any oil, grease, detergent, or water to prevent damage to the airbag assembly. - Store the removed airbag on a secure, flat surface away from any high heat source (exceeding 200 °F/93 °C). - Never perform electrical inspections to the airbags, such as measuring resistance. - Do not position yourself in front of the airbag assembly during removal, inspection, or replacement. Locations EGR Control Solenoid: Locations Right Side of Engine Page 1710 Let the cam push down the edge of tappet by using J-42689 valve clearance adjusting tool and push out the shim with a flat blade screw driver as shown in illustrations. Description and Operation Ignition Cable: Description and Operation Spark Plug Cables Spark Plug Cables The cable contains a synthetic conductor which is easily damaged. Never stretch or kink the cable. Disconnect the cable from spark plug and the ignition coil. The original equipment cables and the ignition coil are marked to show correct location of the cables. If spark plug cables or the ignition coil are replaced previously, before cables are removed from the ignition coil, mark the cables and the coil so they can be reconnected in the same position. Locations Intake Air Temperature Sensor: Locations 26. Left Front of Engine Left Front Of Engine Page 6782 2. Connect one lead of a self-powered test light or DVOM to one end of the part of the circuit you want to test. 3. Connect the other lead to the other end. 4. If the self-powered test light glows, there is continuity. If you're using a DVOM, a low reading or no reading (zero), means good continuity. Testing For Voltage When testing for voltage at a connector without wire seals, you do not have to separate the two halves of the connector. Instead, probe the connector from the back. Always check both sides of the connector because dirty, corroded, and bent terminals can cause problems (no electrical contact = an open). 1. Connect one lead of the lest light to a known good ground, or, if you're using a digital volt ohmmeter (DVOM), place it in the appropriate DC volts range, and connect its negative lead to ground. 2. Connect the other lead of the test light or DVOM to the point you want to check. 3. If the test light glows, there is voltage present. If you're using a DVOM, note the voltage reading. It should be within one volt of measured battery voltage. A loss of more than one volt indicates a problem. NOTE: Always use a DVOM on high impedance circuits. A test light may not glow (even with battery voltage present). Testing For Voltage Drop Wires, connectors, and switches are designed to conduct current with a minimum loss of voltage. A voltage drop of more than one volt indicates a problem. 1. Place the digital volt/ohmmeter (DVOM) in the appropriate DC volts range. Connect the positive lead to the end of the wire (or to the connector or switch) closest to the battery. 2. Connect the negative lead to the other end of the wire (or the other side of the connector or switch). 3. Turn on the components in the circuit. 4. The DVOM will show the difference in voltage between the two points. A difference, or drop, of more than one volt indicates a problem. Check the circuit for loose, dirty, or bent terminals. Page 6419 Air Bag Control Module: Description and Operation SRS Component and Wiring Location View SDM (Sensing and Diagnostic Module) WARNING: DURING SERVICE PROCEDURES, BE VERY CAREFUL WHEN HANDLING A SDM. NEVER STRIKE OR JAR THE SDM. NEVER POWER UP THE SRS WHEN THE SDM IS NOT RIGIDLY ATTACHED TO THE VEHICLE. ALL SDM AND MOUNTING BRACKET FASTENERS MUST BE CAREFULLY TORQUED AND THE ARROW MUST BE POINTED TOWARD THE FRONT OF THE VEHICLE TO ENSURE PROPER OPERATION OF THE SRS. THE SDM COULD BE ACTIVATED WHEN POWERED WHILE NOT RIGIDLY ATTACHED TO THE VEHICLE WHICH COULD CAUSE DEPLOYMENT AND RESULT IN PERSONAL INJURY. The SDM is designed to perform the following functions in the Supplemental Restraint System (SRS). 1. Energy Reserve -The SDM maintains 24 - Volt Loop Reserve (24 VLR) energy supply to provide deployment energy when ignition voltage is lost in a frontal crash. 2. Frontal Crash Detection - The SDM monitors vehicle velocity changes to detect frontal crashes which are severe enough to warrant deployment. 3. Air Bag Deployment - When a frontal crash of sufficient force is detected, the SDM will cause enough current to flow through the air bag assembly to deploy the air bag. 4. Malfunction Detection - The SDM performs diagnostic monitoring of SRS electrical components and sets a diagnostic trouble code when a malfunction is detected. 5. Frontal Crash Recording - The SDM records information regarding SRS status during frontal crash. 6. Malfunction Diagnosis - The SDM displays SRS diagnostic trouble codes and system status information through the use of a scan tool. 7. Driver notification - The SDM warns the vehicle driver of SRS malfunctions by controlling the "Air Bag" warning lamp. Page 3019 Splices Splices are shown as a dot. Their location and the number of wires may vary depending on the harness manufacturer. Switches Switches These switches move together; the broken straight line between them means they are mechanically connected. Other types of switches are controlled by a coil or a solid state circuit. Unless otherwise noted, all switches are shown in their normal (rest) position, with power off. Terminal "T" Page 7818 the component if the component only has one connector, or by a capital letter (A, B, C, etc.) if the component has more than one connector. Below most connector numbers and component names are PHOTO and VIEW numbers. The PHOTO number refers to a photo in the back of the book that shows the connector's location on the car. The VIEW number refers to an illustration in the back of the book that shows the connector face, wire colors, connector cavity numbers, and other details. The connector cavity numbering sequence begins at the top left corner of the connector. Disregard any numbers molded into the connector housing. Wires Wires are identified by the abbreviated names of their colors; the second color is the color of the stripe. Wires are also identified by their location in a connector. The number "2" next to the male and female wire terminals at C416, for example, means those terminals join in cavity 2 of connector C416. Symbols A complete description of schematic symbols is given under wire color abbreviation. Power Distribution Schematics Power Distribution schematics show how power is supplied from the positive battery terminal to various circuits in the car. Refer to the Power Distribution section to get a more detailed picture of how power is supplied to the circuit you're working on. From Battery to Ignition Switch, Fuses, and Relays Individual circuit schematics begin with a fuse. The first half of Power Distribution, however, shows the wiring "upstream" between the battery Specifications Wheel Fastener: Specifications Wheel Fastener 118 Nm Page 4559 4WD Control Unit: Diagnostic Aids Before Troubleshooting Before Troubleshooting See: Service Precautions/Vehicle Damage Warnings/Tips and Precautions 1. Check applicable fuses in the appropriate fuse/relay box. 2. Check the battery for damage, state of charge, and clean and tight connections. CAUTION: Do not quick-charge a battery unless the battery ground cable has been disconnected, otherwise you will damage the alternator diodes. - Do not attempt to crank the engine with the battery ground cable loosely connected or you will severely damage the wiring. While You're Working 1. Make sure connectors are clean, and have no loose terminals or receptacles. 2. Make sure that connectors without wire seals are packed with dielectric (silicone) grease. Part Number: 08798-9001. 3. When connecting a connector, push it until it "clicks" into place. CAUTION: Do not pull on the wires when disconnecting a connector. Pull only on the connector housings. - Most circuits include solid-state devices. Test the voltages in these circuits only with a 10-megaohm or higher impedance digital multi meter. Never use a test light or analog meter on circuits that contain solid-state devices. Damage to the devices may result. Five-Step Troubleshooting 1. Verify The Complaint Turn on all the components in the problem circuit to check the accuracy of the customer complaint. Note the symptoms. Do not begin disassembly or testing until you have narrowed down the problem area. 2. Analyze The Schematic Look up the schematic for the problem circuit. Determine how the circuit is supposed to work by tracing the current paths from the power source through the circuit components to ground. Also, trace circuits that share wiring with the problem circuit. The names of circuits that share the same fuse, ground, or switch, and so on, are referred to in each circuit schematic. Try to operate any shared circuits you didn't check in step 1. If the shared circuits work, the shared wiring is OK, and the cause must be in the wiring used only by the problem circuit. If several circuits fail at the same time, the fuse or ground is a likely cause. Based on the symptoms and your understanding of the circuit's operation, identify one or more possible causes. 3. Isolate The Problem By Testing The Circuit Make circuit tests to check the diagnosis you made in step 2. Keep in mind that a logical, simple procedure is the key to efficient troubleshooting. Test for the most likely cause of failure first. Try to make tests at points that are easily accessible. 4. Fix The Problem Once the specific problem is identified, make the repair. Be sure to use proper tools and safe procedures. 5. Make Sure The Circuit Works Turn on all components in the repaired circuit in all modes to make sure you've fixed the entire problem. If the problem was a blown fuse, be sure to test all of the circuits on that fuse. Make sure no new problems turn up and the original problem does not recur. Page 3257 6. Place the end of the return hose in a container. Have someone start the engine, then pour ATF into the reservoir while you watch the fluid coming out of the return hose. When the fluid coming out is the same color as the new fluid, turn off the engine. 7. Reconnect the return hose to the reservoir. 8. Start the engine. Fill the power steering reservoir to the proper level with ATF then turn off the engine. 9. Use the Smart Cable to reprogram the PCM with the latest software from the June 2001 or later HONDANET CD-ROM. Refer to Service Bulletin 99-005, Updating the Passport PCM, filed under Tools. 10. Use the PGM Tester to clear any DTCs. 11. Use the PGM Tester to check the broadcast code. Make sure the broadcast code matches the one you selected from the CD-ROM. WARRANTY CLAIM INFORMATION In warranty: The normal warranty applies. Failed Part: P/N 8-97181-590-0 H/C 5698030 Defect Code: 064 Contention Code: C01 Skill Level: Repair Technician Out of warranty: Any repair performed after warranty expiration may be eligible for goodwill consideration by the District Service Manager or your Zone Office. You must request consideration, and get a decision, before starting work. REPAIR PROCEDURE - APPS GROUND 1. Unclamp the air cleaner housing cover, and move it to the side for access to connector C123 (16P BLK). Page 6201 Heater Core Case: Service and Repair Removal 1. Disconnect the battery ground cable. 2. Drain the engine coolant. 3. Discharge and recover refrigerant (with air conditioning). 4. Remove the Instrument panel assembly. 5. Remove instrument panel bracket. 6. Cross Beam Assembly. 7. Disconnect resistor connector. 8. Remove duct. 9. Remove evaporator assembly (A/C only). 10. Remove ventilation lower duct. 11. Remove rear heater duct. - Remove foot rest, carpet and 3 clips. 12. Remove heater unit assembly. - Disconnect heater hoses at heater unit. Installation To install, follow the removal steps in the reverse order, noting the following points: 1. When handling the PCM and the control unit, be careful not to make any improper connection of the connectors. 2. Adjust the control cables. 3. When installing the heater unit, defroster nozzle and center vent duct, be sure that the proper seal is made, without any gap between them. Removal and Installation Piston: Service and Repair Removal and Installation Piston, Piston Ring and Connecting Rod Removal 1. Remove cylinder head assembly. - Refer to removal procedure for Cylinder Head. 2. Remove crankcase with oil pan. - Refer to removal procedure for Oil Pan and Crankcase. Page 7946 This sample Ground Distribution schematic shows all of the components that share two ground points. Components A solid border line means the entire component is shown. A broken border line indicates that only part of the component is shown. Page 338 Power Door Lock Switch: Diagrams Page 1435 Camshaft: Service and Repair Camshaft Subgear Preloading, Gear Timing & Camshaft Install. THIS ARTICLE HAS BEEN UPDATED BY TSB 02-047 CAMSHAFT SUBGEAR PRELOADING, GEAR TIMING, AND CAMSHAFT INSTALLATION NOTE: - The V6 engine has a "non-interference" design. This means the valves never contact the pistons, even when the valves or camshafts are not correctly timed, or even if a valve is fully open and its piston is at top dead center (TDC). - The ratio between the camshaft drive gear and the camshaft gears is 1.33 to 1. This means the timing dots on a correctly timed camshaft will only align with the dots on the camshaft drive gears every 4th turn of the camshaft pulley. - The left and right intake camshafts are different. On the cam lobe side of the camshaft gear, the left intake camshaft is marked "LI," and it has dual timing dots; the right intake camshaft is marked "RI," and it has a single timing dot. - The left and right exhaust camshafts are the same. On the cam lobe side of the camshaft gear, both camshafts are marked "LE" and "RE and both have dual timing dots and a single dot. 1. Before you install the camshafts, preload the subgears (preloading must be done whenever you remove the bearing caps from a camshaft): - Make sure the spring is installed between the camshaft gear and the subgear. - With the camshaft held in a soft-jawed vise, attach the gear spring lever (T/N J-42656) to the subgear, then turn the subgear until its threaded hole lines up with the hole in the camshaft gear. - Lock the subgear to the camshaft gear with a 5 x 0.5 mm bolt through either side of the gear hole. - Preload the subgears on the other camshafts. Interior - Storage Cover Lock Knob Loose/Missing Cargo Cover: All Technical Service Bulletins Interior - Storage Cover Lock Knob Loose/Missing 02-033 June 11, 2002 Applies To: 2000-02 Passport - ALL Loose or Missing Lock Knob on the Storage Cover SYMPTOM The knob on the storage cover in the cargo area separates from the cover, or it is missing. PROBABLE CAUSE The stop tabs on the lock knob are broken. CORRECTIVE ACTION Replace the storage cover lock knob with the appropriate color knob, either gray or beige. PARTS INFORMATION Lock Knob, Gray: P/N 8-97394-481-1 H/C 7117617 Lock Knob, Beige: P/N 8-97394-482-1 H/C 7117625 WARRANTY CLAIM INFORMATION In warranty: The normal warranty applies. Operation Number: 523117 Flat Rate Time: 0.2 hour Failed Part: P/N 5-97195-525-2 H/C 5756554 Defect Code: 075 Contention Code: A99 Template ID: 02-033A (Lock Knob, Gray) 02-033B (Lock Knob, Beige) Skill Level: Repair Technician Out of warranty: Any repair performed after warranty expiration may be eligible for goodwill consideration by the District Parts and Service Manager or your Zone Office. You must request consideration, and get a decision, before starting work. REPAIR PROCEDURE Page 5375 V6 Engine Room Page 4817 Wheel Speed Sensor: Service and Repair Rear REMOVAL 1. Disconnect harness connector (1). 2. Remove sensor fixing bolt (2). 3. Remove speed sensor (3). Page 5279 Page 6028 1. Make sure the ignition key is not in the ignition switch. 2. Open the glove box, and empty out its contents. Gently squeeze the sides of the glove box together to release the stops, then lower it all the way. 3. 2000-01 Models: Slide the intake actuator relay off its mounting bracket, and move it out of the way. 4. Unplug the 6P connector from the blower resistor, then remove and discard the resistor (two screws). 5. Unplug the 2P connector from the blower motor, then remove and discard the blower motor assembly (four screws). Page 2623 Ground - "G" Shielding Sheilding This represents RFI (Radio Frequency Interference) shielding around a wire. The shielding is always connected to ground. Splices Page 4548 and the fuses. From Fuses to Relays and Components The second half of Power Distribution shows the wiring "From Fuses to Relays and Components." This can speed your troubleshooting by showing which circuits share fuses. If Power Distribution shows that an inoperative circuit and another circuit share a fuse, check a component in the other circuit. If it works, you know the fuse is good and power is available to the inoperative circuit. Ground Distribution Schematics Page 7418 Test Equipment CAUTION: Most circuits include solid-state devices. Test the voltages in these circuits only with a 10-megaohm or higher impedance digital multimeter. Never use a test light or analog meter on circuits that contain solid-state devices. Damage to the devices may result. Test Light and DVOM On circuits without solid-state devices, use a test light to check for voltage. A test light is made up of a 12 volt bulb with a pair of leads attached. After grounding one lead, touch the other lead to various points along the circuit where voltage should be present. The bulb will go on if there is voltage at the point being tested. If you need to know how much voltage is present, use a digital volt/ohmmeter (DVOM). Self-Powered Test Light and DVOM Use a self-powered test light to check for continuity. This tool is made up of a light bulb, battery, and two leads. To test it, touch the leads together: the light should go on. Use a self-powered test light only on an unpowered circuit. First, disconnect the battery, or remove the fuse that feeds the circuit you are working on. Select two points in the circuit between which you want to check continuity. Connect one lead of the self-powered test light to each point. If there is continuity, the test light's circuit will be completed, and the light will go on. If, in addition, you need to know exactly how much resistance there is between two points, use a digital volt/ohmmeter (DVOM). In the "OHMS" range, the DVOM will measure resistance between two points along a circuit. Low resistance means good continuity. Diodes and solid-state devices in a circuit can make a DVOM give a false reading. To check a reading, reverse the leads, and take a second reading. If the readings differ, the component is affecting the measurement. Jumper Wire Use a jumper wire to bypass an open circuit. A jumper wire is made up of an in-line fuse holder connected to a set of test leads. It should have a five ampere fuse. Never connect a jumper wire across a short circuit. The direct battery short will blow the fuse. Short Finder (Short Circuit Locator) Short finders are available to locate shorts to ground. The short finder creates a pulsing magnetic field in the shorted circuit which you can follow to the location of the short. To order any test equipment shown above, contact your local tool supplier. For a list of suppliers and tool numbers, refer to Honda Required Special Tools and Equipment Service Bulletin. Page 5794 21. Remove and discard the frame rail side hole plug from both frame rails. 22. Using a hammer, knock on the outside of both frame rails to loosen any rust on the inside of the frame. 23. Using a wire brush and a scraper, remove any loose frame coating and rust from the outside frame rail. Clean 10 inches (250 mm) forward and rearward of the bracket area. 24. Use a dry rag to remove any remaining dust or debris. 25. Temporarily install both type B reinforcement brackets using new body mount studs and nuts, and C-clamps: ^ Secure the bracket to the frame using the new body mount stud and nut at the upper link bracket. ^ Firmly push the bracket up against the frame, and clamp it into place with a C-clamp. Make sure the C-clamp compresses the bracket against the frame so there is no possibility of bracket movement when drilling pilot holes into the frame. Page 6289 and the fuses. From Fuses to Relays and Components The second half of Power Distribution shows the wiring "From Fuses to Relays and Components." This can speed your troubleshooting by showing which circuits share fuses. If Power Distribution shows that an inoperative circuit and another circuit share a fuse, check a component in the other circuit. If it works, you know the fuse is good and power is available to the inoperative circuit. Ground Distribution Schematics Page 4408 Gear Sensor/Switch: Testing and Inspection TRANSFER POSITION SWITCH 1. With ball being free. A-B: There is continuity. 2. With ball forced into the switch. A-B: No continuity. 3. If 1) and 2) fail, replace with a new switch. Page 6457 Air Bag Control Module: Description and Operation SRS Component and Wiring Location View SDM (Sensing and Diagnostic Module) WARNING: DURING SERVICE PROCEDURES, BE VERY CAREFUL WHEN HANDLING A SDM. NEVER STRIKE OR JAR THE SDM. NEVER POWER UP THE SRS WHEN THE SDM IS NOT RIGIDLY ATTACHED TO THE VEHICLE. ALL SDM AND MOUNTING BRACKET FASTENERS MUST BE CAREFULLY TORQUED AND THE ARROW MUST BE POINTED TOWARD THE FRONT OF THE VEHICLE TO ENSURE PROPER OPERATION OF THE SRS. THE SDM COULD BE ACTIVATED WHEN POWERED WHILE NOT RIGIDLY ATTACHED TO THE VEHICLE WHICH COULD CAUSE DEPLOYMENT AND RESULT IN PERSONAL INJURY. The SDM is designed to perform the following functions in the Supplemental Restraint System (SRS). 1. Energy Reserve -The SDM maintains 24 - Volt Loop Reserve (24 VLR) energy supply to provide deployment energy when ignition voltage is lost in a frontal crash. 2. Frontal Crash Detection - The SDM monitors vehicle velocity changes to detect frontal crashes which are severe enough to warrant deployment. 3. Air Bag Deployment - When a frontal crash of sufficient force is detected, the SDM will cause enough current to flow through the air bag assembly to deploy the air bag. 4. Malfunction Detection - The SDM performs diagnostic monitoring of SRS electrical components and sets a diagnostic trouble code when a malfunction is detected. 5. Frontal Crash Recording - The SDM records information regarding SRS status during frontal crash. 6. Malfunction Diagnosis - The SDM displays SRS diagnostic trouble codes and system status information through the use of a scan tool. 7. Driver notification - The SDM warns the vehicle driver of SRS malfunctions by controlling the "Air Bag" warning lamp. Page 1048 CAUTION: Left and right side must be equal within 30'. NOTE: Overall thickness of caster shim and camber shim should be 10.8 mm (0.425 inch) or less. Tighten the fulcrum pin bolt to the specified torque. Torque to 152 Nm (112 ft. lbs.) TOE-IN 1. To adjust the toe-in angle, loosen the lock nuts (2) on the tie rod (1) and turn the tie rod. Turn both rods the same amount, to keep the steering wheel centered . Toe-in: 0 ± 2 mm (0 ± 0.08 inch) 2. Tighten the lock nut to the specified torque. Torque to 98 Nm (72 ft. lbs.) Page 5169 Brush Measure the length of brush. Replace with a new one, if it is below the limit. Standard: 16 mm (0.63 in) Limit: 11 mm (0.43 in) Brush Holder Check for continuity between brush holder (+) (4) and base (-). Replace, if there is continuity (i.e., insulation is broken). Page 2051 This means the branch of the wire connects to another circuit. The arrow points to the name of the circuit branch where the wire continues. Page 1695 2. Unfasten C123 from the side of the engine compartment using a 90-degree pick. 3. Disconnect C123, and clean the terminals on both sides of the connector with contact cleaner. Shake the residue out of the connector. Allow the contact cleaner to evaporate for at least 3 minutes, then reconnect C123. 4. Fasten C123 to the left side of the engine compartment, and reinstall the air cleaner housing cover. 5. Remove the connector position assurance (CPA) clip from the APPS connector. 6. Disconnect the lop connector from the APPS. 7. Clean the terminals of the 10P APPS connector (harness side) with contact cleaner. Shake out residue from the connector, and allow the contact cleaner to evaporate for at least 3 minutes, then reconnect it. 8. Use the Smart Cable to reprogram the PCM with the latest software from the June 2001 or later HONDANET CD-ROM. Refer to Service Bulletin 99-005, Updating the Passport PCM, filed under Tools. 9. Use the PGM Tester to clear any DTCs. Page 5791 8. On the passenger's side of the frame, loosen the four brake line clips. 9. Loosen the ABS speed sensor harness bracket bolts and clip from both front fenderwells. 10. Loosen the EVAP canister line from the bulkhead (three clips). Page 5737 WARRANTY CLAIM INFORMATION INSPECTION PROCEDURE NOTE: Do this inspection on both sides of the vehicle. 1. Raise the vehicle on a lift. To allow enough clearance for the inspection, make sure the rear lifting points are at least 12 inches (300 mm) ahead of the rear trailing link front mounting brackets. 2. Visually inspect the lower trailing link front bracket area at the red circle in the photo below: ^ If the vehicle's bracket area is rusted to a similar or lesser degree than that in the photo, go to STAGE 1 REPAIR. ^ If the vehicle's bracket area is rusted to a greater degree than that in the photo, go to the next step. ^ * If the vehicle had a prior repair resulting in a modification to the lower trailing link front brackets, stop the inspection, call Tech Line to open a case, then take photos of the area, and send them to Tech Line.* 3. If the vehicle has side steps or running boards, remove them. 4. Use a 3/16 in. x 9 in. flat punch and a 12-16-oz. hammer to strike the frame areas marked X in the illustration below. Swing the hammer with a 10 to 12 inch stroke to be sure enough force is applied to the punch. Page 4567 Part 3 Of 3 Page 6293 Ground - "G" Shielding Sheilding This represents RFI (Radio Frequency Interference) shielding around a wire. The shielding is always connected to ground. Splices Page 1484 1. Carefully set the crankshaft on the V-blocks. Slowly rotate the crankshaft and measure the runout. If the crankshaft runout exceeds the specified limit, the crankshaft must be replaced. Runout: 0.04 mm (0.0016 inch) 2. Measure the diameter and the uneven wear of main journal and crank pin. If the crankshaft wear exceeds the specified limit, crankshaft must be replaced. Main journal diameter: 63.918 mm - 63.933 mm (2.5165 inch - 2.5170 inch) Crank pin diameter: 53.922 mm - 53.937 mm (2.1229 inch - 2.1235 inch) Uneven wear limit: 0.005 mm (0.0002 inch) Crankshaft Bearing Selection When installing new crankshaft bearings or replacing bearings, refer to the selection table below. Select and install the new crankshaft bearings, paying close attention to the cylinder block journal hole. 1. Diameter size mark (1) and the crankshaft journal. Page 2236 Testing For A Short With A Self-Powered Test Light or DVOM 1. Remove the blown fuse and disconnect the battery and load. 2. Connect one lead of a self-powered test light or digital volt/ohmmeter (DVOM) (switched to the lowest "OHMS" range) to the fuse terminal on the load side. 3. Connect the other lead to a known good ground. 4. Beginning near the fuse box, wiggle the harness. Continue this at convenient points about six inches apart while watching the test light or DVOM. 5. If the self-powered test light goes on or the DVOM displays a low reading or no reading (zero), there is a short to ground in the wiring near that point. Testing for a Short with a Test Light or DVOM 1. Remove the blown fuse and disconnect the load. 2. Connect a test light or digital volt/ohmmeter (DVOM), switched to the appropriate DC volts range, across the fuse terminals to make sure voltage is present. You might have to turn the ignition switch to ON; check the schematic to see. 3. Beginning near the fuse box, wiggle the harness. Continue this at convenient points about six inches apart while watching the test light or DVOM. 4. Where the test light goes , or the DVOM voltage drops to zero, there is a short to ground in the wiring near that point. NOTE: Always use a DVOM on high impedance circuits. A test light may not glow (even with battery voltage present). Testing For A Short With A Short Circuit Locator (Short Finder) 1. Remove the blown fuse. Leave the battery connected. Page 556 Ground - "G" Shielding Sheilding This represents RFI (Radio Frequency Interference) shielding around a wire. The shielding is always connected to ground. Splices Page 2844 11. Using a jumper wire, connect the reference voltage of each circuit to its signal input and view the APP Sensor values in the Engine Data List. APP Sensor 1 should have a value of 99%, and APP Sensor 2 and APP Sensor 3 should each have a value of 0%. ^ If the values are not as specified, troubleshoot for high resistance on the signal input or a PCM malfunction. Repair the circuit or replace the PCM, then repeat step 3. ^ If the values are as specified, the problem may be intermittent. Disconnect the 10P connector from the modified APPS, and connect it to the new APPS; then repeat step 3. Wiggle the APPS wires as you go through the adjustment procedure to find the intermittent problem. 12. Turn off the ignition switch, and disconnect the PGM Tester.* DISCLAIMER Page 3310 5. Select F0 : Fuel Pump Relay. 6. Push "On" soft key. 7. Control Fuel Pump Relay and check data list. - If the data list changes, the Fuel Pump Relay is normal. 8. Select F1 : A/C Clutch Relay. 9. Run the Engine at idle. 10. Turn on Air Conditioning. 11. Turn "On" and "Off" A/C Switch. 12. Control A/C Clutch Relay and check data list. Page 786 20. Using a DVOM, check the voltage between the reference voltage pin for each sensor and ground. ^ If the sensor circuits all read 5.0 volts, go to step 22. ^ If any sensor circuit is above or below 5.0 volts, go to step 21. 21. Troubleshoot for an internal short in another sensor or a PCM malfunction. ^ To find the sensor with an internal short, monitor the reference voltage, and disconnect each sensor (FTPS, EGR, MAP TPS, CKP and CMP) one at a time until the reference voltage reads 5.0 volts. Replace that sensor, and repeat step 14. ^ To find a malfunctioning PCM, replace it with a known-good PCM. If all three sensors (APP Sensor 1, APP Sensor 2, and APP Sensor 3) are within range, the original PCM is faulty; replace it and repeat step 14. 22. Using a jumper wire, connect the reference voltage of each circuit to its signal input, and view the APP Sensor values in the Engine Data List. APP Sensor 1 should have a value of 99%, and APP Sensor 2 and APP Sensor 3 should each have a value of 0%. ^ If the values are not as specified, troubleshoot for high resistance on the signal input or a PCM malfunction. Repair the circuit or replace the PCM, then repeat step 14. ^ If the values are as specified, the problem may be intermittent. Disconnect the 10 P connector from the modified APPS, and connect it to the new APPS; then repeat step 14. Wiggle the APPS wires as you go through the adjustment procedure to find the intermittent problem. 23. Install the accelerator pedal assembly, and torque the bolts to 10 N.m (7 lb-ft). Page 2793 Powertrain Control Module: Description and Operation Electrically Erasable Programmable Read Only Memory (EEPROM) Electrically Erasable Programmable Read Only Memory (EEPROM) The electrically erasable programmable read only memory (EEPROM) is a permanent memory chip that is physically soldered within the PCM. The EEPROM contains the program and the calibration information that the PCM needs to control powertrain operation. Unlike the PROM used in past applications, the EEPROM is not replaceable. If the PCM is replaced, the new PCM will need to be programmed. Equipment containing the correct program and calibration for the vehicle is required to program the PCM. Page 901 ^ If the idle speed ever exceeds 1,300 rpm 2. Remove the vacuum hose from the fuel pressure regulator, then start the engine. ^ If fuel comes out of the fuel pressure regulator vacuum hose connection, go to REPAIR PROCEDURE FUEL PRESSURE REGULATOR. ^ If no fuel comes out of the regulator, reconnect the vacuum hose and continue to step 3. 3. Connect the PGM Tester. Set it to Engine Data List. 4. Have an assistant drive the vehicle under the conditions described by the customer. 5. If the high or erratic idle condition occurs, note the values of the PSP Switch and APP Sensor 1 when it is occurring. ^ If the PSP Switch is HIGH, and you are not turning, go to REPAIR PROCEDURE POWER STEERING SWITCH. ^ If the APP Sensor 1 is greater than 15% and APP Sensor 2 and/or APP Sensor 3 are less than 85%, and the accelerator pedal is not depressed, go to REPAIR PROCEDURE APPS GROUND. ^ If the PSP Switch is reading LOW when not turning and HIGH when turning, and the APP Sensors are reading within the range shown, discontinue the test-drive and go to step 6. 6. Do these repairs: ^ REPAIR PROCEDURE APPS GROUND ^ REPAIR PROCEDURE ENGINE/BODY GROUND REPAIR PROCEDURE - FUEL PRESSURE REGULATOR 1. Relieve fuel system pressure: ^ Remove the fuel fill cap. ^ Remove the fuel pump relay. ^ Start the engine and run it until it stalls. ^ Crank the engine for 3 seconds. 2. Remove the vacuum hose from the fuel pressure regulator. 3. Remove the fuel pressure regulator shield from the common chamber (two bolts). Audio Unit with CD Player/Changer - Error Codes Compact Disc Player (CD): All Technical Service Bulletins Audio Unit with CD Player/Changer Error Codes 00-015 March 14, 2000 Applies To: All with CD Player/Changer Audio Unit Error Codes (Replaces 91-007, dated October 6, 1997) *If the audio unit displays an error code, use the troubleshooting tables in this service bulletin to troubleshoot the problem. Refer to service bulletin 98-019 for CD Player/Changer exchange information.* Page 7178 Sunshade (LWB) - Disassembled View Page 3592 Wires Wire insulation can be one color, or one color with another color stripe. (The second color is the stripe.) This circuit continues on another image. (The arrow shows direction of current flow.) To follow the RED/BLK wire in this example, you would turn to "Fuel and Emissions" and look for the "A" arrow. Page 500 The wire insulation has one color or one color with another color stripe. The second color is the stripe. General Precautions Air Bag(s) Arming and Disarming: Service Precautions General Precautions General Precautions Please read the following precautions carefully before performing the airbag system service. Observe the instructions described or the airbags could accidentally deploy and cause damage or injuries. Except when performing electrical inspections, always turn the ignition switch OFF and disconnect the negative cable from the battery, and wait at least three minutes before beginning work. NOTE: The contents in the memory is not erased even if the ignition switch is turned OFF or the battery cables are disconnected from the battery. Use the replacement parts which are manufactured to the same standards as the original parts and quality. Do not install used SRS parts from another vehicle. Use only new parts when making SRS repairs. Carefully inspect any SRS part before you install it. Do not install any part that shows signs of being dropped or improperly handled, such as dents, cracks or deformation. Before removing any of the SRS parts (including the disconnection of the connectors), always disconnect the SRS connector. Use only a digital multimeter to check the system. If it is not a Honda multimeter, make sure its output is 10 mA (0.01 A) or less when switched to the lowest value in the ohmmeter range. A tester with a higher output could cause accidental deployment and possible injury. Do not put objects on the front passenger's airbag. The original radio has a coded theft protection circuit. Be sure to get the customer's radio code before disconnecting the battery cable. Page 7905 This sample Ground Distribution schematic shows all of the components that share two ground points. Components A solid border line means the entire component is shown. A broken border line indicates that only part of the component is shown. Page 7909 Splices Splices are shown as a dot. Their location and the number of wires may vary depending on the harness manufacturer. Switches Switches These switches move together; the broken straight line between them means they are mechanically connected. Other types of switches are controlled by a coil or a solid state circuit. Unless otherwise noted, all switches are shown in their normal (rest) position, with power off. Terminal "T" Page 7679 Testing For A Short With A Self-Powered Test Light or DVOM 1. Remove the blown fuse and disconnect the battery and load. 2. Connect one lead of a self-powered test light or digital volt/ohmmeter (DVOM) (switched to the lowest "OHMS" range) to the fuse terminal on the load side. 3. Connect the other lead to a known good ground. 4. Beginning near the fuse box, wiggle the harness. Continue this at convenient points about six inches apart while watching the test light or DVOM. 5. If the self-powered test light goes on or the DVOM displays a low reading or no reading (zero), there is a short to ground in the wiring near that point. Testing for a Short with a Test Light or DVOM 1. Remove the blown fuse and disconnect the load. 2. Connect a test light or digital volt/ohmmeter (DVOM), switched to the appropriate DC volts range, across the fuse terminals to make sure voltage is present. You might have to turn the ignition switch to ON; check the schematic to see. 3. Beginning near the fuse box, wiggle the harness. Continue this at convenient points about six inches apart while watching the test light or DVOM. 4. Where the test light goes , or the DVOM voltage drops to zero, there is a short to ground in the wiring near that point. NOTE: Always use a DVOM on high impedance circuits. A test light may not glow (even with battery voltage present). Testing For A Short With A Short Circuit Locator (Short Finder) 1. Remove the blown fuse. Leave the battery connected. Page 1504 2. Install oil gallery and tighten the bolts in two steps, in the order shown in illustration. Torque: 1st step: 29 Nm (21 ft. lbs.) 2nd step: 55° - 65° 3. Install oil pipe with O-ring. - Torque: 10 Nm (89 inch lbs.) 4. Install oil strainer assembly with O-ring. Torque: 25 Nm (18 ft. lbs.) 5. Install crankcase with oil pan. Refer to installation procedure for Oil Pan and Crankcase. 6. Install cylinder head assembly. Refer to installation procedure for Cylinder Head. Page 3937 3. Start the engine, and let it warm up to normal operating temperature. 4. Move the selector lever through all shift positions, then apply the brakes, and move the lever to Park. 5. Check the drain plug and fill plug for signs of leakage. ^ If you see signs of leakage, turn off the engine. Remove and discard both plugs and gaskets. Let the oil pan drain completely, then install the new drain plug. Torque the drain plug to 38 N.m (28 lb-ft). Add DEXRON III ATF until it runs out the fill hole. Install the new fill plug hand tight. Go to step 6. ^ If you do not see signs of leakage, look for other possible causes of the leak. 6. Connect the PGM Tester to the 16P data link connector to measure ATF temperature. Start the engine. 7. Remove the fill plug, and add ATF until it runs out the fill hole. Reinstall the fill plug. 8. Move the selector lever through all shift positions, then apply the brakes, and move the lever to Park. 9. Remove the fill plug. 10. Let the engine idle until the ATF temperature is between 90° and 135° F (32° and 57° C). As the temperature increases, ATF drips out the fill hole until the correct fluid level is reached. 11. Reinstall the fill plug. Torque the fill plug to 38 N.m (28 lb-ft). 12. Turn off the engine, and disconnect the PGM Tester. Lower the vehicle. DISCLAIMER Locations Relay Box: Locations Page 473 Dimmer Switch: Service and Repair Removal 1. Disconnect the battery ground cable. 2. Remove the instrument panel driver lower cover assembly (3). 3. Remove the illumination controller (2). - Disconnect the controller connector. - Remove the controller knob (1). - Remove the nut. - Remove the controller from the back side of the instrument panel driver lower cover assembly. Installation To install, follow the removal steps in the reverse order. Page 2529 Air Flow Meter/Sensor: Service and Repair Mass Air Flow (MAF) Sensor REMOVAL PROCEDURE 1. Disconnect the negative battery cable. 2. Disconnect the electrical connector from the MAF sensor. 3. Loosen the clamps which secure the intake air duct and the air cleaner to the MAF sensor. 4. Remove the intake air duct from the MAF sensor. 5. Remove the MAF sensor from the air cleaner. INSTALLATION PROCEDURE Locations Page 2916 4. Remove the sensor from the exhaust pipe. Because of the expansion and contraction of the metal in the exhaust system over time, this may be difficult if the engine temperature is below 48 ° C (120 °F). INSTALLATION PROCEDURE IMPORTANT: - A special anti-seize compound on the HO2S threads. This compound consists of glass beads suspended in a liquid graphite solution. The graphite burns away with engine heat, but the glass beads will remain, making the sensor easier to remove. - New or service sensors will already have the compound applied to the threads. If a sensor is removed and is to be reinstalled for any reason, the threads must have anti-seize compound applied. 1. Apply anti-seize compound or the equivalent to the threads of the oxygen sensor, if necessary. 2. Install the oxygen sensor on the exhaust pipe in its original position. Tighten Tighten the oxygen sensor to 55 N.m (40 lb ft.). 3. Connect the pigtail to the wiring harness. 4. Connect the negative battery cable. Page 5941 1. Adjust the control cable. - Temperature control cable. 1. Turn the control knob to the left ("MAX COLD" position). 2. Connect the control cable at the "COLD" position of the temperature control link of the heater unit and secure it with the clip. - Air select control cable 1. Turn the control knob to the right ("DEFROST" position). 2. Connect the control cable at the "DEFROST" position of the mode control link of the heater unit and secure it with the clip. 2. Check the control cable operation. Page 6322 8. Remove lower case. - Slit the case parting face with a knife since the lining is separated when removing the evaporator. - Lift to remove the upper case. 9. Remove evaporator core. 10. Remove expansion valve. Locations Blower Motor Switch: Locations Fan Control Switch Fan Control Switch Page 2982 2. Connect the short finder across the battery terminals and the load (component) side of the fuse terminal. 3. Close all switches in the circuit you're testing. 4. Turn on the short finder. This creates a pulsing magnetic field around the wiring between the fuse box and the short. 5. Beginning at the fuse box, slowly move the short finder along the circuit wiring. The meter will read current pulses through sheet metal and body trim. As long as the meter is between the fuse and the short, the needle will move with each current pulse. Once you move the meter past the point of the short, the needle will stop moving. Check the wiring and connectors in this area to locate the cause of the short. Testing For Continuity When testing for continuity at a connector without wire seals, you do not have to separate the two halves of the connector. Instead, probe the connector from the back. Always check both sides of the connector because dirty, corroded, and bent terminals can cause problems (no electrical contact = an open). 1. Disconnect the negative cable from the car battery. If you're using a DVOM, place it in the lowest "OHMS" range. Page 6833 5. Remove the speaker assembly (2). - Remove the 4 screws and disconnect the speaker harness connector (1). 6. Remove the door mirror cover. 7. Remove the grip cover. 8. Remove the 5 screws (1), (3) and pull out the trim panel at the 6 clip positions (2). 9. Remove the waterproof sheet. Page 2579 2. Connect the short finder across the battery terminals and the load (component) side of the fuse terminal. 3. Close all switches in the circuit you're testing. 4. Turn on the short finder. This creates a pulsing magnetic field around the wiring between the fuse box and the short. 5. Beginning at the fuse box, slowly move the short finder along the circuit wiring. The meter will read current pulses through sheet metal and body trim. As long as the meter is between the fuse and the short, the needle will move with each current pulse. Once you move the meter past the point of the short, the needle will stop moving. Check the wiring and connectors in this area to locate the cause of the short. Testing For Continuity When testing for continuity at a connector without wire seals, you do not have to separate the two halves of the connector. Instead, probe the connector from the back. Always check both sides of the connector because dirty, corroded, and bent terminals can cause problems (no electrical contact = an open). 1. Disconnect the negative cable from the car battery. If you're using a DVOM, place it in the lowest "OHMS" range. Page 6662 ^ Handle a CD by its edges; never touch the flat surfaces. Contamination from fingerprints, liquids, felt-tip pens, and labels can cause the CD to not play properly, or possibly jam in the drive. ^ When cleaning a disc, use a clean soft cloth. Wipe across the disc from the center to the outside. Do not wipe the disc in a circular motion. ^ A new CD may be rough on the inner and outer edges. The small plastic pieces causing this roughness can flake off and fall on the recording surface of the disc, causing skipping or other problems. Remove these pieces by rubbing the inner and outer edges with the side of a pencil or pen. ^ Various accessories are available to protect CDs and improve the sound quality of CDs. These accessories increase the thickness or diameter of the discs, and should not be used in CD changers. Disclaimer Page 2744 Power Steering Pressure Switch: Locations 27. Left Side of Engine Left Side Of Engine Page 722 12. Install the new cover using the accumulator cover installation tool. 13. Reinstall the snap ring. 14. 2002 only: Reconnect the cooler return line, and tighten the bracket that secures the ATF cooler line. 15. Check the transmission fluid level, and refill as necessary with Dexron III ATF. Refer to the Automatic Transmission section of the appropriate Passport Service Manual. Disclaimer Page 517 Specifications Crankshaft Gear/Sprocket: Specifications Camshaft Drive Gear ........................................................................................................................... ....................................................... 98 Nm (72 lb. ft.) Page 1969 Test Equipment CAUTION: Most circuits include solid-state devices. Test the voltages in these circuits only with a 10-megaohm or higher impedance digital multimeter. Never use a test light or analog meter on circuits that contain solid-state devices. Damage to the devices may result. Test Light and DVOM On circuits without solid-state devices, use a test light to check for voltage. A test light is made up of a 12 volt bulb with a pair of leads attached. After grounding one lead, touch the other lead to various points along the circuit where voltage should be present. The bulb will go on if there is voltage at the point being tested. If you need to know how much voltage is present, use a digital volt/ohmmeter (DVOM). Self-Powered Test Light and DVOM Use a self-powered test light to check for continuity. This tool is made up of a light bulb, battery, and two leads. To test it, touch the leads together: the light should go on. Use a self-powered test light only on an unpowered circuit. First, disconnect the battery, or remove the fuse that feeds the circuit you are working on. Select two points in the circuit between which you want to check continuity. Connect one lead of the self-powered test light to each point. If there is continuity, the test light's circuit will be completed, and the light will go on. If, in addition, you need to know exactly how much resistance there is between two points, use a digital volt/ohmmeter (DVOM). In the "OHMS" range, the DVOM will measure resistance between two points along a circuit. Low resistance means good continuity. Diodes and solid-state devices in a circuit can make a DVOM give a false reading. To check a reading, reverse the leads, and take a second reading. If the readings differ, the component is affecting the measurement. Jumper Wire Use a jumper wire to bypass an open circuit. A jumper wire is made up of an in-line fuse holder connected to a set of test leads. It should have a five ampere fuse. Never connect a jumper wire across a short circuit. The direct battery short will blow the fuse. Short Finder (Short Circuit Locator) Short finders are available to locate shorts to ground. The short finder creates a pulsing magnetic field in the shorted circuit which you can follow to the location of the short. To order any test equipment shown above, contact your local tool supplier. For a list of suppliers and tool numbers, refer to Honda Required Special Tools and Equipment Service Bulletin. Page 7379 and the fuses. From Fuses to Relays and Components The second half of Power Distribution shows the wiring "From Fuses to Relays and Components." This can speed your troubleshooting by showing which circuits share fuses. If Power Distribution shows that an inoperative circuit and another circuit share a fuse, check a component in the other circuit. If it works, you know the fuse is good and power is available to the inoperative circuit. Ground Distribution Schematics Page 1290 Air Bag(s) Arming and Disarming: Description and Operation General Description General Description Restraint Devices The Supplemental Restraint System (SRS) helps supplement the protection offered by the driver and front passenger seat belts by deploying an air bag from the center of the steering wheel and from the top of the right side of the instrument panel. The air bag deploys when the vehicle is involved in a frontal crash of sufficient force up to 30 degrees off the centerline of the vehicle; To further absorb the crash energy there is a knee bolster located beneath the instrument panel for both the driver and passenger, and the steering column is collapsible. Page 6420 The SDM is connected to the SRS wiring harness by a 24 - pin connector. This harness connector uses a shorting clip across certain terminals in the contact area. This shorting clip connects the "AIR BAG" warning lamp to ground when the SDM harness connector is disconnected or Connector Position Assurance (CPA) is not inserted even If completely connected. This will cause the "AIR BAG" warning lamp to come "ON" steady whenever the ignition switch is at the ON or START positions with the SDM disconnected. Page 8081 This means the branch of the wire connects to another circuit. The arrow points to the name of the circuit branch where the wire continues. Page 3045 TWC LH and Forked Exhaust Pipe and Associated Parts Page 7369 ABS Light: Testing and Inspection Chart B-1 With The Key In The ON Position (Before Starting The Engine). Waring Light (W/L) Is Not Activated. Part 1 of 2 Part 2 of 2 Page 1973 Powertrain Control Module: Connector Views Page 4277 Wires Wire insulation can be one color, or one color with another color stripe. (The second color is the stripe.) This circuit continues on another image. (The arrow shows direction of current flow.) To follow the RED/BLK wire in this example, you would turn to "Fuel and Emissions" and look for the "A" arrow. Page 3712 Test Equipment CAUTION: Most circuits include solid-state devices. Test the voltages in these circuits only with a 10-megaohm or higher impedance digital multimeter. Never use a test light or analog meter on circuits that contain solid-state devices. Damage to the devices may result. Test Light and DVOM On circuits without solid-state devices, use a test light to check for voltage. A test light is made up of a 12 volt bulb with a pair of leads attached. After grounding one lead, touch the other lead to various points along the circuit where voltage should be present. The bulb will go on if there is voltage at the point being tested. If you need to know how much voltage is present, use a digital volt/ohmmeter (DVOM). Self-Powered Test Light and DVOM Use a self-powered test light to check for continuity. This tool is made up of a light bulb, battery, and two leads. To test it, touch the leads together: the light should go on. Use a self-powered test light only on an unpowered circuit. First, disconnect the battery, or remove the fuse that feeds the circuit you are working on. Select two points in the circuit between which you want to check continuity. Connect one lead of the self-powered test light to each point. If there is continuity, the test light's circuit will be completed, and the light will go on. If, in addition, you need to know exactly how much resistance there is between two points, use a digital volt/ohmmeter (DVOM). In the "OHMS" range, the DVOM will measure resistance between two points along a circuit. Low resistance means good continuity. Diodes and solid-state devices in a circuit can make a DVOM give a false reading. To check a reading, reverse the leads, and take a second reading. If the readings differ, the component is affecting the measurement. Jumper Wire Use a jumper wire to bypass an open circuit. A jumper wire is made up of an in-line fuse holder connected to a set of test leads. It should have a five ampere fuse. Never connect a jumper wire across a short circuit. The direct battery short will blow the fuse. Short Finder (Short Circuit Locator) Short finders are available to locate shorts to ground. The short finder creates a pulsing magnetic field in the shorted circuit which you can follow to the location of the short. To order any test equipment shown above, contact your local tool supplier. For a list of suppliers and tool numbers, refer to Honda Required Special Tools and Equipment Service Bulletin. Page 119 The name of the component appears next to it followed by notes about its function along with any photo and connector view references. Connector "C" How to Identify Connector Terminals Cavity Numbering System The cavities (and wire terminals) in each connector are numbered starting from the upper left, looking at the male terminals from the terminal side (or looking at the female terminals from the wire side. Both views are in the same direction so the numbers are the same.) All actual cavities are numbered, even if they have no wire terminals in them. NOTE: Data Link Connector (DLC) terminals are numbered according to SAE standard J1962, not the Honda standard. The numbers of the four end terminals are molded into the corners of the connector face. Page 6051 - Align the located portion (1) of the field coil and compressor. - Tighten the mounting screw to the specified torque Torque: 5 Nm (44 lb in) 2. Connect the lead wire connector with the rubber hold and tighten the screw. 3. Install pulley assembly by using pulley installer J-33940-A (2) and drive handle J-8092 (1). 4. Install snap ring. 5. Install shim (s). 6. Install the drive plate to the compressor drive shaft together with the original shim(s)(1). Press the drive plate by hand. Page 3550 Distinct Of Circuit By Wire Base Color All wires have color-coded insulation. Wires belonging to a system's main harness will have a single color. Wires belonging to a system's sub-circuits will have a colored stripe. Striped wires use the codes found in the chart to show wire size and colors. Abbreviations are used to indicate wire color within a circuit diagram. How to Identify Connector Terminals How to Identify Connector Terminals Cavity Numbering System The cavities (and wire terminals) in each connector are numbered starting from the upper left, looking at the male terminals from the terminal side (or looking at the female terminals from the wire side. Both views are in the same direction so the numbers are the same.) All actual cavities are numbered, even if they have no wire terminals in them. NOTE: Data Link Connector (DLC) terminals are numbered according to SAE standard J1962, not the Honda standard. The numbers of the four end terminals are molded into the corners of the connector face. The connector cavity number is listed next to each terminal on the circuit schematic. The cavity / terminal shown is # 6. Using/Identifying Connector Terminal Views How to Use Connector Terminal Views To see the configuration of a connector's cavities, look up its view number in the Connector Views. Each view includes the color of the connector, where Page 5533 6. Place the end of the return hose in a container. Have someone start the engine, then pour ATF into the reservoir while you watch the fluid coming out of the return hose. When the fluid coming out is the same color as the new fluid, turn off the engine. 7. Reconnect the return hose to the reservoir. 8. Start the engine. Fill the power steering reservoir to the proper level with ATF then turn off the engine. 9. Use the Smart Cable to reprogram the PCM with the latest software from the June 2001 or later HONDANET CD-ROM. Refer to Service Bulletin 99-005, Updating the Passport PCM, filed under Tools. 10. Use the PGM Tester to clear any DTCs. 11. Use the PGM Tester to check the broadcast code. Make sure the broadcast code matches the one you selected from the CD-ROM. WARRANTY CLAIM INFORMATION In warranty: The normal warranty applies. Failed Part: P/N 8-97181-590-0 H/C 5698030 Defect Code: 064 Contention Code: C01 Skill Level: Repair Technician Out of warranty: Any repair performed after warranty expiration may be eligible for goodwill consideration by the District Service Manager or your Zone Office. You must request consideration, and get a decision, before starting work. REPAIR PROCEDURE - APPS GROUND 1. Unclamp the air cleaner housing cover, and move it to the side for access to connector C123 (16P BLK). Page 5150 INSTALLATION 1. Install lock cylinder assembly. 2. Install shift lock cable (for A/T). 3. Install cushion rubber. 4. Install snap ring. 5. Install Combination switch and SRS coil assembly. After installation of combination switch assembly, connect the combination switch wiring harness connector and the SRS 2-way connector located under the steering column. 6. Turn the SRS coil counterclockwise to full, return about 3 turns and align the neutral mark. CAUTION: When turning the SRS coil counterclockwise to full, stop turning if resistance is felt. Forced further turning may damage to the cable in the SRS coil. Page 7915 Horn: Diagnostic Aids Before Troubleshooting Before Troubleshooting See: Service Precautions/Vehicle Damage Warnings/Tips and Precautions 1. Check applicable fuses in the appropriate fuse/relay box. 2. Check the battery for damage, state of charge, and clean and tight connections. CAUTION: Do not quick-charge a battery unless the battery ground cable has been disconnected, otherwise you will damage the alternator diodes. - Do not attempt to crank the engine with the battery ground cable loosely connected or you will severely damage the wiring. While You're Working 1. Make sure connectors are clean, and have no loose terminals or receptacles. 2. Make sure that connectors without wire seals are packed with dielectric (silicone) grease. Part Number: 08798-9001. 3. When connecting a connector, push it until it "clicks" into place. CAUTION: Do not pull on the wires when disconnecting a connector. Pull only on the connector housings. - Most circuits include solid-state devices. Test the voltages in these circuits only with a 10-megaohm or higher impedance digital multi meter. Never use a test light or analog meter on circuits that contain solid-state devices. Damage to the devices may result. Five-Step Troubleshooting 1. Verify The Complaint Turn on all the components in the problem circuit to check the accuracy of the customer complaint. Note the symptoms. Do not begin disassembly or testing until you have narrowed down the problem area. 2. Analyze The Schematic Look up the schematic for the problem circuit. Determine how the circuit is supposed to work by tracing the current paths from the power source through the circuit components to ground. Also, trace circuits that share wiring with the problem circuit. The names of circuits that share the same fuse, ground, or switch, and so on, are referred to in each circuit schematic. Try to operate any shared circuits you didn't check in step 1. If the shared circuits work, the shared wiring is OK, and the cause must be in the wiring used only by the problem circuit. If several circuits fail at the same time, the fuse or ground is a likely cause. Based on the symptoms and your understanding of the circuit's operation, identify one or more possible causes. 3. Isolate The Problem By Testing The Circuit Make circuit tests to check the diagnosis you made in step 2. Keep in mind that a logical, simple procedure is the key to efficient troubleshooting. Test for the most likely cause of failure first. Try to make tests at points that are easily accessible. 4. Fix The Problem Once the specific problem is identified, make the repair. Be sure to use proper tools and safe procedures. 5. Make Sure The Circuit Works Turn on all components in the repaired circuit in all modes to make sure you've fixed the entire problem. If the problem was a blown fuse, be sure to test all of the circuits on that fuse. Make sure no new problems turn up and the original problem does not recur. B-9 Pump Motor Failure (DTC 32/C0267, C0268) Diagram Information and Instructions Axle Disconnect Control Control Unit: Diagram Information and Instructions How to Identify Wiring Color-Coded Insulation Wire Color Wire Color Coding Page 2202 Throttle Position Sensor: Testing and Inspection Function Check Use a Tech 2 to check the TP sensor output voltage at closed throttle. - The voltage should be under 0.85 volt. - If the reading is greater than 0.85 volt, check the throttle shaft to see if it is binding. Locations Heater Core: Locations Page 5848 4. Align the template on the mud flap. Mark the area on the mud flap that needs to be cut away with a pencil or scribe. 5. Use a utility knife to remove the marked area. 6. Repeat steps 4 and 5 on the other mud flap. 7. Reinstall the mud flaps on the vehicle. DISCLAIMER Page 4357 Page 6572 Alarm/Immobilizer Control Unit: Service and Repair Alarm and Relay Control Unit Removal 1. Disconnect the battery ground cable. 2. Remove the instrument panel (1). 3. Remove the alarm and relay control unit (2). Disconnect the connector. Installation To install, follow the removal steps in the reverse order. Adjustments Valve Clearance: Adjustments THIS ARTICLE HAS BEEN UPDATED BY TSB 02-047 NOTE: - Valve adjustment can be done either on-vehicle or off-vehicle. - To measure exhaust valves, you need a 0.25 mm and a 0.35 mm feeler gauge. - To measure intake valves, you need a 0.23 mm and a 0.33 mm feeler gauge. Since these are odd sizes, you may need to stack two gauges (for example, 0.11 mm and 0.12 mm to make 0.23 mm). If you do this, make sure the gauges are clean and in good condition. If you're not sure the gauge stack is correct, measure it with a micrometer. On-Vehicle Valve Adjustment 1. Make a copy of the Valve Inspection Chart. 2. Make a copy of the Valve Shim Replacement Chart, then tape the pages together, side-by-side. 3. Remove the cylinder head covers. 4. Measure the valve clearances using the Go/No-Go method (see the note below). The clearances must be - Intake valves: 0.25 mm +/- 0.05 mm - Exhaust valves: 0.30 mm +/- 0.05 mm NOTE: - To measure with the Go/No-Go method, use two feeler gauges, one to measure the smallest allowable clearance, and the other to measure the largest. - If the small gauge fits and the large gauge doesn't, the valve adjustment is OK. - If the small gauge doesn't fit, or if the large gauge slides easily, the valve needs adjustment. - The feeler gauges slide through the clearance gap at a slight angle, making the drag a little more than it would be on other engines. 5. For valves with the correct clearance, draw an "X" in the appropriate circle on the Valve Inspection Chart. For valves with incorrect clearances, write down the clearance you measured in the circle. 6. If you need to replace a valve shim, turn the crankshaft (or camshaft) until the cam lobe for the valve points away from the valve. Page 3343 This means the branch of the wire connects to another circuit. The arrow points to the name of the circuit branch where the wire continues. Page 2100 129 - Below Left Side Of I/P Page 3598 Testing For A Short With A Self-Powered Test Light or DVOM 1. Remove the blown fuse and disconnect the battery and load. 2. Connect one lead of a self-powered test light or digital volt/ohmmeter (DVOM) (switched to the lowest "OHMS" range) to the fuse terminal on the load side. 3. Connect the other lead to a known good ground. 4. Beginning near the fuse box, wiggle the harness. Continue this at convenient points about six inches apart while watching the test light or DVOM. 5. If the self-powered test light goes on or the DVOM displays a low reading or no reading (zero), there is a short to ground in the wiring near that point. Testing for a Short with a Test Light or DVOM 1. Remove the blown fuse and disconnect the load. 2. Connect a test light or digital volt/ohmmeter (DVOM), switched to the appropriate DC volts range, across the fuse terminals to make sure voltage is present. You might have to turn the ignition switch to ON; check the schematic to see. 3. Beginning near the fuse box, wiggle the harness. Continue this at convenient points about six inches apart while watching the test light or DVOM. 4. Where the test light goes , or the DVOM voltage drops to zero, there is a short to ground in the wiring near that point. NOTE: Always use a DVOM on high impedance circuits. A test light may not glow (even with battery voltage present). Testing For A Short With A Short Circuit Locator (Short Finder) 1. Remove the blown fuse. Leave the battery connected. Page 4443 Each schematic represents one circuit. A circuit's wires and components are arranged to show current flow, from power at the top of the page, to ground, at the bottom. Shared Circuits Other circuits may share power or ground terminals or wiring with the circuit shown. A wire that connects one circuit to another, for example, is cut short and has an arrowhead at the end of it pointing in the direction of current flow. Next to the arrowhead is the name of the circuit or component which shares that wiring. To quickly check shared wiring, check the operation of a component it serves. If that component works, you know the shared wiring is OK. Connectors All in-line and junction connectors are numbered (C725, C416, etc.). Component connectors are not numbered but are identified either by the name of Page 4987 Page 8276 Wiper Motor: Connector Locations Page 4791 Part 2 of 2 Page 5484 Power Steering Pressure Switch: Locations 27. Left Side of Engine Left Side Of Engine Page 7533 2. Connect the short finder across the battery terminals and the load (component) side of the fuse terminal. 3. Close all switches in the circuit you're testing. 4. Turn on the short finder. This creates a pulsing magnetic field around the wiring between the fuse box and the short. 5. Beginning at the fuse box, slowly move the short finder along the circuit wiring. The meter will read current pulses through sheet metal and body trim. As long as the meter is between the fuse and the short, the needle will move with each current pulse. Once you move the meter past the point of the short, the needle will stop moving. Check the wiring and connectors in this area to locate the cause of the short. Testing For Continuity When testing for continuity at a connector without wire seals, you do not have to separate the two halves of the connector. Instead, probe the connector from the back. Always check both sides of the connector because dirty, corroded, and bent terminals can cause problems (no electrical contact = an open). 1. Disconnect the negative cable from the car battery. If you're using a DVOM, place it in the lowest "OHMS" range. Page 6195 Heater Core: Service and Repair Removal 1. Disconnect the battery ground cable. 2. Drain the engine coolant. 3. Discharge and recover refrigerant (with air conditioning). 4. Remove heater unit. 5. Remove duct. 6. Remove case (Mode control) and do not remove link unit at this step. Service and Repair Fuel Pressure Release: Service and Repair CAUTION: To reduce the risk of fire and personal injury, there are necessary to relieve the fuel system pressure filler and gauge unit before servicing the fuel system components. CAUTION: After relieving the system pressure, a small amount of fuel may be released when servicing fuel lines or connections. Reduce the chance of personal injury by covering the fuel line fittings with a shop towel before you disconnect the fittings. The towels will absorb any fuel that may leak out. When the disconnection is completed, place the towel in an approved container. 1. Remove the fuel cap. 2. Remove the fuel pump relay from the underhood relay box. 3. Start the engine and allow it to stall. 4. Crank the engine for 30 seconds. 5. Disconnect the negative battery cable. Page 5778 12. Insert the Noxudol 700 spray nozzle into the frame rail side hole, pointing down, until it touches the bottom of the frame. Spray the Noxudol downward while pulling out the nozzle. Spray two times. 13. Remove the long spray nozzle from the Noxudol 700 can, and attach the regular spray valve. Spray a coat of Noxudol 700 on the outside of both lower trailing link frame brackets and frame rails in the 20-inch (500 mm) section shown below. Be careful not to overspray onto the exhaust system or body painted areas. 14. Spray a coat of Noxudol 300 on the same areas you sprayed in step 13. Be careful not to overspray onto the exhaust system or painted areas on the body. 15. Reinstall both frame rail side hole plugs. If either plug was damaged or missing, install a new one. 16. If the side steps or the running boards were removed, reinstall them. Page 7536 Seat Belt, Lights-ON and Ignition Key Reminders Part 2 Of 2 Removal and Installation Spark Plug: Service and Repair Removal and Installation Removal 1. Remove spark plugs. Installation 1. Spark plugs - Tighten spark plugs to the specified torque. Torque: 18 Nm (13 lb.ft) Page 7711 This sample Ground Distribution schematic shows all of the components that share two ground points. Components A solid border line means the entire component is shown. A broken border line indicates that only part of the component is shown. Page 4036 ^ If the cover is OK, release the shift lever pushbutton, and go to step 11. 11. Push the white plastic cable slider toward the cable until it stops, then release the slider. 12. Try turning the ignition switch to LOCK. ^ If you cannot turn the switch to LOCK because the cable slider is blocking the white plastic interlock pin, go to step 13 Page 7608 Test Equipment CAUTION: Most circuits include solid-state devices. Test the voltages in these circuits only with a 10-megaohm or higher impedance digital multimeter. Never use a test light or analog meter on circuits that contain solid-state devices. Damage to the devices may result. Test Light and DVOM On circuits without solid-state devices, use a test light to check for voltage. A test light is made up of a 12 volt bulb with a pair of leads attached. After grounding one lead, touch the other lead to various points along the circuit where voltage should be present. The bulb will go on if there is voltage at the point being tested. If you need to know how much voltage is present, use a digital volt/ohmmeter (DVOM). Self-Powered Test Light and DVOM Use a self-powered test light to check for continuity. This tool is made up of a light bulb, battery, and two leads. To test it, touch the leads together: the light should go on. Use a self-powered test light only on an unpowered circuit. First, disconnect the battery, or remove the fuse that feeds the circuit you are working on. Select two points in the circuit between which you want to check continuity. Connect one lead of the self-powered test light to each point. If there is continuity, the test light's circuit will be completed, and the light will go on. If, in addition, you need to know exactly how much resistance there is between two points, use a digital volt/ohmmeter (DVOM). In the "OHMS" range, the DVOM will measure resistance between two points along a circuit. Low resistance means good continuity. Diodes and solid-state devices in a circuit can make a DVOM give a false reading. To check a reading, reverse the leads, and take a second reading. If the readings differ, the component is affecting the measurement. Jumper Wire Use a jumper wire to bypass an open circuit. A jumper wire is made up of an in-line fuse holder connected to a set of test leads. It should have a five ampere fuse. Never connect a jumper wire across a short circuit. The direct battery short will blow the fuse. Short Finder (Short Circuit Locator) Short finders are available to locate shorts to ground. The short finder creates a pulsing magnetic field in the shorted circuit which you can follow to the location of the short. To order any test equipment shown above, contact your local tool supplier. For a list of suppliers and tool numbers, refer to Honda Required Special Tools and Equipment Service Bulletin. Page 5613 Steering Transfer Gear: Service and Repair REMOVAL 1. Remove universal joint bolt (steering shaft side). 2. Remove universal joint bolt (steering unit side). 3. Loosen fixing bolt and nut and remove transfer gear assembly with shim. INSPECTION AND REPAIR The transfer gear assembly cannot be disassembled. If damage or abnormal condition are found, replace with a new one. INSTALLATION 1. Install transfer gear assembly with shim and tighten bolt and nut to the specified torque. Torque to 54 Nm (40 ft. lbs.). 2. Connect universal joint (both side) and tighten the bolt to the specified torque. Torque to 31 Nm (23 ft. lbs.). Page 727 Throttle Position Sensor: Description and Operation Throttle Position (TP) Sensor The throttle position (TP) sensor is a potentiometer connected to the throttle shaft on the throttle body. The PCM monitors the voltage on the signal line and calculates throttle position. As the throttle valve angle is changed (accelerator pedal moved), the TP sensor signal also changes. At a closed throttle position, the output of the TP1 sensor is low. As the throttle valve opens, the output increases so that at wide open throttle (WOT), the output voltage should be above 92 % (Tech 2 Display). The PCM calculates fuel delivery based on throttle valve angle (driver demand). A broken or loose TP sensor may cause intermittent bursts of fuel from an injector and unstable idle because the PCM thinks the throttle is moving. Page 1530 Note: Take care not to confuse the alignment mark (2) and the size mark (1) during the installation procedure. Reassembly 1. Install connecting rod 2. Install piston 3. Install piston pin - Apply a thin coat of engine oil to the piston pin. Try to insert the piston pin into the piston pin hole with normal finger pressure. Note: When changing piston/connecting rod combinations, do not change the piston/piston pin combination and do not reuse the old piston pin. - Attach the piston to the connecting rod with the piston front mark and the connecting rod front mark on the same side. Page 126 Wire Color Abbreviations The following abbreviations are used to identify wire colors in the circuit schematics: WHT................................... White YEL................................... Yellow BLK................................... Black BLU................................... Blue GRN................................... Green RED................................... Red ORN................................... Orange PNK................................... Pink BRN................................... Brown GRY................................... Gray PUR................................... Purple LT BLU................................... Light Blue LT GRN................................... Light Green Page 1794 6. Lock the camshaft gear to its subgear with a 5 x 0.5 mm bolt through either side of the hole in the gears. This holds the spring-loaded subgear in place so you can remove the camshaft. Do this for each camshaft you need to remove. 7. Remove the camshaft bearing caps, noting the location and direction of each cap. 8. Remove the camshaft(s). 9. For each valve needing adjustment, do steps 10 thru 13. 10. Insert a pick or a small screwdriver into the tappet notch, and pry out the shim. 11. Wipe oft the shim, then write its number on the Valve Inspection Chart for that valve and cylinder. If there is no number on the shim, measure its thickness with a micrometer, and write down the measurement on the Valve Inspection Chart. 12. Follow the directions on the Valve Shim Replacement Chart to select the correct shim. 13. Insert the correct shim, number side down, into the tappet. Make sure the shim is fully seated. 14. Install the camshafts (see steps 2 thru 9 of CAMSHAFT SUBGEAR PRELOADING, GEAR TIMING, AND CAMSHAFT INSTALLATION). 15. Rotate the camshaft pulleys a few turns to ensure the new shims are fully seated. 16. Recheck the clearances of the valves you adjusted with the Go/No-Go method (see step 3). If any clearances are incorrect, readjust them. Removal and Installation Brake Caliper: Service and Repair Removal and Installation REMOVAL 1. Raise the vehicle and support with suitable safety stands. 2. Remove wheel and tire assembly. 3. Remove the bolt and gaskets, then disconnect the flexible hose from the caliper and after disconnecting the flexible hose (1), cap or tape the openings to prevent entry of foreign material. 4. Since the brake fluid flows out from the connecting coupler, place a drain pan under the vehicle. 5. Remove lock bolt (3). Locations Electronic Brake Control Module: Locations Right Rear Corner Of Engine Compartment Page 3729 If there is no photo number below or beside a component name or a connector, ground, or terminal number, look up that name or number in the appropriate Connector Identification Chart. The chart lists how many cavities a connector has, where it's located, and what it connects to. The related illustration shows the connector's location on the harness, and the harness routing. NOTE: Photos listed by number are located at Locations / Components / Photograohs. See: Locations/Component Locations/Photographs Circuit Schematics Page 5864 Tires: Testing and Inspection Diagnosis List If the following conditions are noted, rotation is required. 1. Front tire wear is different from rear. 2. Uneven wear exists across the tread of any tire. 3. Left and right front tire wear is unequal. 4. Left and right rear tire wear is unequal. If the following conditions are noted, check the wheel alignment. 1. Left and right front tire wear is unequal. 2. Uneven wear exists across the tread of any tire. 3. Front tire treads have scuffed appearance with "feather" edges on one side of tread ribs or blocks. 4. There is cupping, flat spotting etc. Higher than recommended pressure can cause: 1. Hard ride. 2. Poor steering stability. 3. Rapid and uneven wear at center of the tread. Lower than recommended pressure can cause: 1. Tire squeal on turns. 2. Hard steering. 3. Rapid and uneven wear on the edges of the tread. 4. Tire rim bruises and rupture. 5. Tire cord breakage. 6. High tire temperatures. 7. Reduced handling. 8. Reduced fuel economy. Unequal pressure on same axle can cause: 1. Uneven braking. 2. Steering lead. 3. Reduced handling. 4. Swerve on acceleration. Testing and Inspection Mechanical Diagnosis Page 55 Each schematic represents one circuit. A circuit's wires and components are arranged to show current flow, from power at the top of the page, to ground, at the bottom. Shared Circuits Other circuits may share power or ground terminals or wiring with the circuit shown. A wire that connects one circuit to another, for example, is cut short and has an arrowhead at the end of it pointing in the direction of current flow. Next to the arrowhead is the name of the circuit or component which shares that wiring. To quickly check shared wiring, check the operation of a component it serves. If that component works, you know the shared wiring is OK. Connectors All in-line and junction connectors are numbered (C725, C416, etc.). Component connectors are not numbered but are identified either by the name of Page 2827 7. Modify the original APPS by cutting the connector housing off of the sensor. 8. Connect the 10P connector to the modified APPS connector housing. 9. Using a DVOM, check the voltage between the reference voltage pin for each sensor and ground. ^ If the sensor circuits all read 5.0 volts, go to step 11. ^ If any sensor circuit is above or below 5.0 volts, go to step 10. 10. Troubleshoot for an internal short in another sensor or a PCM malfunction. ^ To find the sensor with an internal short, monitor the incorrect reference voltage, and disconnect each sensor (FTPS, EGR, MAP, TPS, CKP, and CMP) one at a time until the reference voltage reads 5.0 volts. Replace that sensor, and repeat step 3. ^ To find a malfunctioning PCM, replace it with a known-good PCM. If all three sensors (APP Sensor 1, APP Sensor 2, and APP Sensor 3) are within range, the original PCM is faulty; replace it and repeat step 3. Page 8163 3. Remove the hatchgate ball stud (LH and RH). - Remove gas stay fixing screw and pull up the gas stay assembly (3) from the ball stud by spreading the retainer (2) holding the ball stud at the end of the gas stay with screwdriver (1), etc. 4. Remove the hatchgate hinge nuts from body side. 5. Remove the hatchgate glass. - When pulling down the hatchgate glass, exercise special care so as not to damage it. Hatchgate glass assembly is heavy and removal operation requires two people. 6. Remove the two screws to remove hatchgate striker and fastener. 7. Remove the outside handle. 8. Remove the hinges. 9. Remove the high mount stoplight. 10. Remove the hatchgate finisher. Installation To install, follow the removal steps in the reverse order, noting the following points. 1. Attach the upper seal (1) to the hatchgate glass (2) indicated portion (3) so that the end of the glass contacts the bottom of the upper seal. Page 497 Wires Wire insulation can be one color, or one color with another color stripe. (The second color is the stripe.) This circuit continues on another image. (The arrow shows direction of current flow.) To follow the RED/BLK wire in this example, you would turn to "Fuel and Emissions" and look for the "A" arrow. Front Wheel Speed Sensor: Service and Repair Front REMOVAL 1. Remove speed sensor connector. 2. Remove sensor cable fixing bolt (Upper side). 3. Remove sensor cable! fixing bolt (Lower side). 4. Remove the speed sensor cable fixing bolt. 5. Remove speed sensor. INSTALLATION 1. Install speed sensor and take care not to hit the speed sensor pole piece during installation. 2. Install speed sensor fixing bolt and tighten the fixing bolt to the specified torque. Torque: 11 Nm (95 inch lbs.) 3. Install speed sensor cable fixing bolt (Lower side) and tighten the fixing bolt to the specified torque. Torque: 24 Nm (18 ft. lbs.) 4. Install speed sensor cable fixing bolt (Upper side) and tighten the fixing bolt to the specified torque. Torque: 6 Nm (52 ft. lbs.) Page 8070 If there is no photo number below or beside a component name or a connector, ground, or terminal number, look up that name or number in the appropriate Connector Identification Chart. The chart lists how many cavities a connector has, where it's located, and what it connects to. The related illustration shows the connector's location on the harness, and the harness routing. NOTE: Photos listed by number are located at Locations / Components / Photograohs. See: Locations/Component Locations/Photographs Circuit Schematics Page 4226 Test Equipment CAUTION: Most circuits include solid-state devices. Test the voltages in these circuits only with a 10-megaohm or higher impedance digital multimeter. Never use a test light or analog meter on circuits that contain solid-state devices. Damage to the devices may result. Test Light and DVOM On circuits without solid-state devices, use a test light to check for voltage. A test light is made up of a 12 volt bulb with a pair of leads attached. After grounding one lead, touch the other lead to various points along the circuit where voltage should be present. The bulb will go on if there is voltage at the point being tested. If you need to know how much voltage is present, use a digital volt/ohmmeter (DVOM). Self-Powered Test Light and DVOM Use a self-powered test light to check for continuity. This tool is made up of a light bulb, battery, and two leads. To test it, touch the leads together: the light should go on. Use a self-powered test light only on an unpowered circuit. First, disconnect the battery, or remove the fuse that feeds the circuit you are working on. Select two points in the circuit between which you want to check continuity. Connect one lead of the self-powered test light to each point. If there is continuity, the test light's circuit will be completed, and the light will go on. If, in addition, you need to know exactly how much resistance there is between two points, use a digital volt/ohmmeter (DVOM). In the "OHMS" range, the DVOM will measure resistance between two points along a circuit. Low resistance means good continuity. Diodes and solid-state devices in a circuit can make a DVOM give a false reading. To check a reading, reverse the leads, and take a second reading. If the readings differ, the component is affecting the measurement. Jumper Wire Use a jumper wire to bypass an open circuit. A jumper wire is made up of an in-line fuse holder connected to a set of test leads. It should have a five ampere fuse. Never connect a jumper wire across a short circuit. The direct battery short will blow the fuse. Short Finder (Short Circuit Locator) Short finders are available to locate shorts to ground. The short finder creates a pulsing magnetic field in the shorted circuit which you can follow to the location of the short. To order any test equipment shown above, contact your local tool supplier. For a list of suppliers and tool numbers, refer to Honda Required Special Tools and Equipment Service Bulletin. Page 292 and the fuses. From Fuses to Relays and Components The second half of Power Distribution shows the wiring "From Fuses to Relays and Components." This can speed your troubleshooting by showing which circuits share fuses. If Power Distribution shows that an inoperative circuit and another circuit share a fuse, check a component in the other circuit. If it works, you know the fuse is good and power is available to the inoperative circuit. Ground Distribution Schematics Page 1685 10. Use the PGM Tester to check the broadcast code. Make sure the broadcast code matches the one you selected from the CD-ROM. WARRANTY CLAIM INFORMATION In warranty: The normal warranty applies. Failed Part: P/N 8-17087-655-0 H/C 4375820 Defect Code: 064 Contention Code: C01 Skill Level: Repair Technician Out of warranty: Any repair performed after warranty expiration may be eligible for goodwill consideration by the District Service Manager or your Zone Office. You must request consideration, and get a decision, before starting work. REPAIR PROCEDURE - ENGINE/BODY GROUND 1. Use the ETM for the appropriate year to locate these ground connectors: G101, G104, G105, G106 and G160. 2. Inspect each connector for corrosion or looseness. 3. Remove the bolt from any connector that is corroded or loose. Clean the terminal connector with a wire brush. File flat any solder bumps on the connector. 4. Clean the contact surface on the engine or body with a wire brush. 5. Replace the bolt if it is heavily corroded. Otherwise, clean it with a wire brush. 6. Apply lithium dielectric grease to both sides of the terminal connector. 7. Reinstall the bolt, torque it to 14 N.m (10 lb-ft). 8. Use the Smart Cable to reprogram the PCM with the latest software from the June 2001 or later HONDANET CD-ROM. Refer to Service Bulletin 99-005, Updating the Passport PCM, filed under Tools. 9. Use the PGM Tester to clear any DTCs. 10. Use the PGM Tester to check the broadcast code. Make sure the broadcast code matches the one you selected from the CD-ROM. WARRANTY CLAIM INFORMATION In warranty: The normal warranty applies. Failed Part: P/N 8-97086-823-0 Page 1153 Hose/Line HVAC: Service and Repair Repair Of Refrigerant Leaks Repair Of Refrigerant Leaks Install new O-ring, if required. When disconnecting or connecting lines, use two wrenches to prevent the connecting portion from twisting or becoming damaged. When connecting the refrigerant line at a block joint, securely insert the projecting portion of the joint portion into the connecting hole on the unit side and secure with a bolt. Apply the specified compressor oil to the O-ring prior to connecting. CAUTION: Compressor (PAG) oil to be used varies according to the compressor model. Be sure to apply oil specified for the model of compressor. Page 1742 Fuel Pressure: Testing and Inspection Fuel System Pressure Test A fuel system pressure test is part of several of the diagnostic charts and symptom checks. To perform this test, refer to Fuel Systems Diagnosis. Page 7890 Testing For A Short With A Self-Powered Test Light or DVOM 1. Remove the blown fuse and disconnect the battery and load. 2. Connect one lead of a self-powered test light or digital volt/ohmmeter (DVOM) (switched to the lowest "OHMS" range) to the fuse terminal on the load side. 3. Connect the other lead to a known good ground. 4. Beginning near the fuse box, wiggle the harness. Continue this at convenient points about six inches apart while watching the test light or DVOM. 5. If the self-powered test light goes on or the DVOM displays a low reading or no reading (zero), there is a short to ground in the wiring near that point. Testing for a Short with a Test Light or DVOM 1. Remove the blown fuse and disconnect the load. 2. Connect a test light or digital volt/ohmmeter (DVOM), switched to the appropriate DC volts range, across the fuse terminals to make sure voltage is present. You might have to turn the ignition switch to ON; check the schematic to see. 3. Beginning near the fuse box, wiggle the harness. Continue this at convenient points about six inches apart while watching the test light or DVOM. 4. Where the test light goes , or the DVOM voltage drops to zero, there is a short to ground in the wiring near that point. NOTE: Always use a DVOM on high impedance circuits. A test light may not glow (even with battery voltage present). Testing For A Short With A Short Circuit Locator (Short Finder) 1. Remove the blown fuse. Leave the battery connected. Page 4725 4WD Control Unit: Diagnostic Aids Before Troubleshooting Before Troubleshooting See: Service Precautions/Vehicle Damage Warnings/Tips and Precautions 1. Check applicable fuses in the appropriate fuse/relay box. 2. Check the battery for damage, state of charge, and clean and tight connections. CAUTION: Do not quick-charge a battery unless the battery ground cable has been disconnected, otherwise you will damage the alternator diodes. - Do not attempt to crank the engine with the battery ground cable loosely connected or you will severely damage the wiring. While You're Working 1. Make sure connectors are clean, and have no loose terminals or receptacles. 2. Make sure that connectors without wire seals are packed with dielectric (silicone) grease. Part Number: 08798-9001. 3. When connecting a connector, push it until it "clicks" into place. CAUTION: Do not pull on the wires when disconnecting a connector. Pull only on the connector housings. - Most circuits include solid-state devices. Test the voltages in these circuits only with a 10-megaohm or higher impedance digital multi meter. Never use a test light or analog meter on circuits that contain solid-state devices. Damage to the devices may result. Five-Step Troubleshooting 1. Verify The Complaint Turn on all the components in the problem circuit to check the accuracy of the customer complaint. Note the symptoms. Do not begin disassembly or testing until you have narrowed down the problem area. 2. Analyze The Schematic Look up the schematic for the problem circuit. Determine how the circuit is supposed to work by tracing the current paths from the power source through the circuit components to ground. Also, trace circuits that share wiring with the problem circuit. The names of circuits that share the same fuse, ground, or switch, and so on, are referred to in each circuit schematic. Try to operate any shared circuits you didn't check in step 1. If the shared circuits work, the shared wiring is OK, and the cause must be in the wiring used only by the problem circuit. If several circuits fail at the same time, the fuse or ground is a likely cause. Based on the symptoms and your understanding of the circuit's operation, identify one or more possible causes. 3. Isolate The Problem By Testing The Circuit Make circuit tests to check the diagnosis you made in step 2. Keep in mind that a logical, simple procedure is the key to efficient troubleshooting. Test for the most likely cause of failure first. Try to make tests at points that are easily accessible. 4. Fix The Problem Once the specific problem is identified, make the repair. Be sure to use proper tools and safe procedures. 5. Make Sure The Circuit Works Turn on all components in the repaired circuit in all modes to make sure you've fixed the entire problem. If the problem was a blown fuse, be sure to test all of the circuits on that fuse. Make sure no new problems turn up and the original problem does not recur. Page 7627 it is located, and what it connects to. Use the Connector Views to help locate the proper cavity when you need to probe a connector. It can be especially helpful if the connector has more than one wire of the same color. A dash symbol (-) indicates that the cavity is empty. Connector views can also be used to help diagnose multiple symptoms in separate circuits which could be caused by a single problem in a connector shared by those circuits. Here's an example: 1. Pick one of the multiple symptoms and look up the schematic for that circuit. 2. Make a list of all the in-line and fuse box connectors in that schematic , 3. Then, in the Connector Views, look up each connector on your list to see if circuits related to the other symptoms run through one of them. If they do, inspect that connector for the problem. Example: The blower, rear window defogger, and the windshield wiper don't work. List all in-line and fuse box connectors in the blower controls circuit and then check the Connector View (see the sample). You find that C324 is common to the blower controls, rear window defogger, and wiper/washer, so you inspect C324 and find the problem, bent terminals. Finding Component/Connector Locations Finding Component/Connector Locations To see where a component or connector is located on the car, look up its photo number in the "Component Location". The photo will also tell you the color of the connector, and how many cavities it has. Page 5810 Wheel Bearing: Service and Repair DISASSEMBLED VIEW DISASSEMBLY 1. Before disassembly, select the 2WD position with the 4WD switch. 2. Jack up the front of vehicle and support frame with jack stands. 3. Remove the disc brake caliper assembly and hang it on the frame with wires. 4. Remove bolt. 5. Remove cap. 6. Remove snap ring and shim. 7. Remove hub flange. 8. Remove lock washer and lock screw. Page 5580 The name of the component appears next to it followed by notes about its function along with any photo and connector view references. Connector "C" How to Identify Connector Terminals Cavity Numbering System The cavities (and wire terminals) in each connector are numbered starting from the upper left, looking at the male terminals from the terminal side (or looking at the female terminals from the wire side. Both views are in the same direction so the numbers are the same.) All actual cavities are numbered, even if they have no wire terminals in them. NOTE: Data Link Connector (DLC) terminals are numbered according to SAE standard J1962, not the Honda standard. The numbers of the four end terminals are molded into the corners of the connector face. Capacity Specifications Refrigerant: Capacity Specifications HVAC SYSTEM HVAC SYSTEM ITEM SPECIFICATION Refrigerant Type HFC - 134a (R-134a) Capacity of Systems 700 g (1.54 lbs) Page 5723 Page 6688 The wire insulation has one color or one color with another color stripe. The second color is the stripe. Page 2010 The connector cavity number is listed next to each terminal on the circuit schematic. The cavity / terminal shown is # 6. Diodes A rectifier diode works like a one way valve. It allows current to flow only in the direction of the arrow. A Zener diode blocks reverse current at normal voltages just like a rectifier diode. At high voltages, however, a Zener diode allows current to flow in reverse. Fuses Page 220 Ion Sensing Module: Description and Operation ION Sensing Module ION Sensing Module This module has the function to energize and de-energize the primary ignition coil in response to signals from the PCM. Page 7438 Ground - "G" Shielding Sheilding This represents RFI (Radio Frequency Interference) shielding around a wire. The shielding is always connected to ground. Splices Locations Gear Sensor/Switch: Locations Top Right Side Of Transfer Case Page 617 Air Flow Meter/Sensor: Service and Repair Mass Air Flow (MAF) Sensor REMOVAL PROCEDURE 1. Disconnect the negative battery cable. 2. Disconnect the electrical connector from the MAF sensor. 3. Loosen the clamps which secure the intake air duct and the air cleaner to the MAF sensor. 4. Remove the intake air duct from the MAF sensor. 5. Remove the MAF sensor from the air cleaner. INSTALLATION PROCEDURE Page 6158 2. Connect one lead of a self-powered test light or DVOM to one end of the part of the circuit you want to test. 3. Connect the other lead to the other end. 4. If the self-powered test light glows, there is continuity. If you're using a DVOM, a low reading or no reading (zero), means good continuity. Testing For Voltage When testing for voltage at a connector without wire seals, you do not have to separate the two halves of the connector. Instead, probe the connector from the back. Always check both sides of the connector because dirty, corroded, and bent terminals can cause problems (no electrical contact = an open). 1. Connect one lead of the lest light to a known good ground, or, if you're using a digital volt ohmmeter (DVOM), place it in the appropriate DC volts range, and connect its negative lead to ground. 2. Connect the other lead of the test light or DVOM to the point you want to check. 3. If the test light glows, there is voltage present. If you're using a DVOM, note the voltage reading. It should be within one volt of measured battery voltage. A loss of more than one volt indicates a problem. NOTE: Always use a DVOM on high impedance circuits. A test light may not glow (even with battery voltage present). Testing For Voltage Drop Wires, connectors, and switches are designed to conduct current with a minimum loss of voltage. A voltage drop of more than one volt indicates a problem. 1. Place the digital volt/ohmmeter (DVOM) in the appropriate DC volts range. Connect the positive lead to the end of the wire (or to the connector or switch) closest to the battery. 2. Connect the negative lead to the other end of the wire (or the other side of the connector or switch). 3. Turn on the components in the circuit. 4. The DVOM will show the difference in voltage between the two points. A difference, or drop, of more than one volt indicates a problem. Check the circuit for loose, dirty, or bent terminals. Page 488 Each schematic represents one circuit. A circuit's wires and components are arranged to show current flow, from power at the top of the page, to ground, at the bottom. Shared Circuits Other circuits may share power or ground terminals or wiring with the circuit shown. A wire that connects one circuit to another, for example, is cut short and has an arrowhead at the end of it pointing in the direction of current flow. Next to the arrowhead is the name of the circuit or component which shares that wiring. To quickly check shared wiring, check the operation of a component it serves. If that component works, you know the shared wiring is OK. Connectors All in-line and junction connectors are numbered (C725, C416, etc.). Component connectors are not numbered but are identified either by the name of Page 2039 it is located, and what it connects to. Use the Connector Views to help locate the proper cavity when you need to probe a connector. It can be especially helpful if the connector has more than one wire of the same color. A dash symbol (-) indicates that the cavity is empty. Connector views can also be used to help diagnose multiple symptoms in separate circuits which could be caused by a single problem in a connector shared by those circuits. Here's an example: 1. Pick one of the multiple symptoms and look up the schematic for that circuit. 2. Make a list of all the in-line and fuse box connectors in that schematic , 3. Then, in the Connector Views, look up each connector on your list to see if circuits related to the other symptoms run through one of them. If they do, inspect that connector for the problem. Example: The blower, rear window defogger, and the windshield wiper don't work. List all in-line and fuse box connectors in the blower controls circuit and then check the Connector View (see the sample). You find that C324 is common to the blower controls, rear window defogger, and wiper/washer, so you inspect C324 and find the problem, bent terminals. Finding Component/Connector Locations Finding Component/Connector Locations To see where a component or connector is located on the car, look up its photo number in the "Component Location". The photo will also tell you the color of the connector, and how many cavities it has. Locations Page 1803 Water Pump: Service and Repair Water Pump Removal 1. Disconnect battery ground cable. 2. Drain coolant. 3. Radiator hose (on inlet pipe side). 4. Remove timing belt. 5. Remove Idle pulley. 6. Remove water pump assembly. 7. Remove gasket. Inspection Make necessary repair and parts replacement if extreme wear or damage is found during inspection. Should any of the following problems occur, the entire water pump assembly must be replaced. Crack in the water pump body - EC leakage from the seal unit - Play or abnormal noise in the bearing - Cracks or corrosion in the impeller Installation 1. Install gasket, clean the mating surface of gasket before installation. Page 1480 Crankshaft: Service and Repair Page 2740 6. Place the end of the return hose in a container. Have someone start the engine, then pour ATF into the reservoir while you watch the fluid coming out of the return hose. When the fluid coming out is the same color as the new fluid, turn off the engine. 7. Reconnect the return hose to the reservoir. 8. Start the engine. Fill the power steering reservoir to the proper level with ATF then turn off the engine. 9. Use the Smart Cable to reprogram the PCM with the latest software from the June 2001 or later HONDANET CD-ROM. Refer to Service Bulletin 99-005, Updating the Passport PCM, filed under Tools. 10. Use the PGM Tester to clear any DTCs. 11. Use the PGM Tester to check the broadcast code. Make sure the broadcast code matches the one you selected from the CD-ROM. WARRANTY CLAIM INFORMATION In warranty: The normal warranty applies. Failed Part: P/N 8-97181-590-0 H/C 5698030 Defect Code: 064 Contention Code: C01 Skill Level: Repair Technician Out of warranty: Any repair performed after warranty expiration may be eligible for goodwill consideration by the District Service Manager or your Zone Office. You must request consideration, and get a decision, before starting work. REPAIR PROCEDURE - APPS GROUND 1. Unclamp the air cleaner housing cover, and move it to the side for access to connector C123 (16P BLK). Page 6846 2. Remove the regulator handle(1). - Pull the hook(2) out and remove the regulator handle. 3. Remove the one screw from the pullcase. 4. Remove the inside handle fixing screw. CAUTION: Do not apply excessive force on the inside handle link or damage may occur, which could make the inside handle difficult to operate. 5. Remove the rear door comer garnish. - Pull the garnish to disconnect the retaining clip. Page 5534 2. Unfasten C123 from the side of the engine compartment using a 90-degree pick. 3. Disconnect C123, and clean the terminals on both sides of the connector with contact cleaner. Shake the residue out of the connector. Allow the contact cleaner to evaporate for at least 3 minutes, then reconnect C123. 4. Fasten C123 to the left side of the engine compartment, and reinstall the air cleaner housing cover. 5. Remove the connector position assurance (CPA) clip from the APPS connector. 6. Disconnect the lop connector from the APPS. 7. Clean the terminals of the 10P APPS connector (harness side) with contact cleaner. Shake out residue from the connector, and allow the contact cleaner to evaporate for at least 3 minutes, then reconnect it. 8. Use the Smart Cable to reprogram the PCM with the latest software from the June 2001 or later HONDANET CD-ROM. Refer to Service Bulletin 99-005, Updating the Passport PCM, filed under Tools. 9. Use the PGM Tester to clear any DTCs. Page 1006 6. Test-drive the vehicle to make sure it no longer pulls. If the steering wheel is now off-center by more than 2 mm, go to REPAIR PROCEDURE C. 7. Use your diagnosis worksheet to fill in the following table and build your 15-digit DTC. NOTE: Enter each reading in decimal degrees. Example 30' = 0.50. REPAIR PROCEDURE C 1. Make sure the steering wheel is centered. ^ Turn the steering wheel all the way to the right until it stops. ^ Turn the steering wheel all the way to the left, and count the number of revolutions until it stops. ^ Divide the number of revolutions in half, and turn the steering wheel until it is centered. For example, if it takes four revolutions of the steering wheel to go from lock to lock, then two turns is centered. ^ If the steering wheel is off-center by a large amount (20 mm or more), it may not be centered on the steering column shaft. Reinstall the steering wheel before going to step 2. 2. Place the vehicle on a lift, turn the steering wheel until it is centered, and then raise the vehicle. 3. Adjust the tie-rods. Use your measurements from question 13 of the test-drive to make your adjustment. Page 3288 it is located, and what it connects to. Use the Connector Views to help locate the proper cavity when you need to probe a connector. It can be especially helpful if the connector has more than one wire of the same color. A dash symbol (-) indicates that the cavity is empty. Connector views can also be used to help diagnose multiple symptoms in separate circuits which could be caused by a single problem in a connector shared by those circuits. Here's an example: 1. Pick one of the multiple symptoms and look up the schematic for that circuit. 2. Make a list of all the in-line and fuse box connectors in that schematic , 3. Then, in the Connector Views, look up each connector on your list to see if circuits related to the other symptoms run through one of them. If they do, inspect that connector for the problem. Example: The blower, rear window defogger, and the windshield wiper don't work. List all in-line and fuse box connectors in the blower controls circuit and then check the Connector View (see the sample). You find that C324 is common to the blower controls, rear window defogger, and wiper/washer, so you inspect C324 and find the problem, bent terminals. Finding Component/Connector Locations Finding Component/Connector Locations To see where a component or connector is located on the car, look up its photo number in the "Component Location". The photo will also tell you the color of the connector, and how many cavities it has. Locations 4WD Control Unit: Locations Under Center Console Page 2228 Splices Splices are shown as a dot. Their location and the number of wires may vary depending on the harness manufacturer. Switches Switches These switches move together; the broken straight line between them means they are mechanically connected. Other types of switches are controlled by a coil or a solid state circuit. Unless otherwise noted, all switches are shown in their normal (rest) position, with power off. Terminal "T" Page 7789 Terminals - "T" Each "T" terminal (ring type) is numbered for reference and location. A "T" terminal is secured with a screw or bolt. Wires Page 8165 Liftgate Window Glass: Service and Repair Tailgate Glass (Resin Top) Tailgate Glass (Resin Top) Removal 1. Disconnect the battery ground cable. 2. Remove the spare tire. 3. Remove the rear wiper. 4. Disconnect the rear defogger connectors (LH & RH). 5. Remove the tailgate glass stays. - Remove the two seats of two tailgate trim cover fixing bolts. 6. Remove the tailgate glass assembly. - Remove the two caps each on the left and right sides, then remove the screws. - Remove the two clips from the two ends of the tailgate moulding, then lift the glass assembly up and out. - Removing and installing the glass assembly require two persons. 7. Remove the tailgate seal. Installation To install, follow the removal steps in the reverse order, noting the following points. 1. Tighten the tailgate glass stay fixing bolts to the specified torque. Torque:19 Nm (14 lb.ft) 2. Make sure the lip is properly oriented when installing the tailgate seal. Page 4879 3. Install support bracket and tighten the bolt (7) to the specified torque. Torque: 103 Nm (76 ft. lbs.) 4. Install caliper assembly. 5. Install lock bolt and guide bolt (8) and tighten the bolt to the specified torque. Torque: 44 Nm (32 ft. lbs.) 6. Install brake flexible hose, always use new gaskets and be sure to put the hooked edge of the flexible hose end into the anti-rotation cavity then tighten the eye-bolt (9) to the specified torque. Torque: 35 Nm (26 ft. lbs.) 7. Install the wheel and tire assembly. 8. Bleed brakes. Moonroof - Visor Sags in The Middle Sunroof / Moonroof Weatherstrip: All Technical Service Bulletins Moonroof - Visor Sags in The Middle 00-061 August 22, 2000 Applies To: 1998-00 Passport - ALL Accessory Moonroof Visor Appearance PROBLEM The rear edge of the moonroof visor sags in the middle, and/or the roof seal is distorted. CORRECTIVE ACTION Replace the moonroof visor and the roof seal with a new assembly. PARTS INFORMATION Accessory Moonroof Visor Kit: P/N 08R01-ED1101, H/C 6483838 WARRANTY CLAIM INFORMATION In warranty: The normal warranty applies. Out of warranty: Any repair performed after warranty expiration may be eligible for goodwill consideration by the District Service Manager or your Zone Office. You must request consideration, and get a decision, before starting work. REPAIR PROCEDURE 1. Remove the moonroof visor, the roof seal, and all related hardware. 2. Install the new moonroof visor kit. Refer to the Accessory Installation Instructions binder for the installation instructions. Disclaimer Page 5581 The connector cavity number is listed next to each terminal on the circuit schematic. The cavity / terminal shown is # 6. Diodes A rectifier diode works like a one way valve. It allows current to flow only in the direction of the arrow. A Zener diode blocks reverse current at normal voltages just like a rectifier diode. At high voltages, however, a Zener diode allows current to flow in reverse. Fuses Page 6847 6. Remove the door trim panel. - Pull out the eight clip positions from the door panel. - Disconnect the power window switch connector to lift the trim panel and unlock the engagement of the waist seal section, then pass the inside lever through the mounting hole of the trim panel, and detach the trim panel. 7. Remove the inside handle. 8. Remove the power window switch and pull case. - Remove the fixing screws from back side of the rear door trim. Installation To install, follow the removal steps in the reverse order. Page 4905 Brake Rotor/Disc: Specifications Disc Type Ventilated Disc Thickness 18 mm Disc Effective Diameter 269.2 mm Page 2928 2. Unfasten C123 from the side of the engine compartment using a 90-degree pick. 3. Disconnect C123, and clean the terminals on both sides of the connector with contact cleaner. Shake the residue out of the connector. Allow the contact cleaner to evaporate for at least 3 minutes, then reconnect C123. 4. Fasten C123 to the left side of the engine compartment, and reinstall the air cleaner housing cover. 5. Remove the connector position assurance (CPA) clip from the APPS connector. 6. Disconnect the lop connector from the APPS. 7. Clean the terminals of the 10P APPS connector (harness side) with contact cleaner. Shake out residue from the connector, and allow the contact cleaner to evaporate for at least 3 minutes, then reconnect it. 8. Use the Smart Cable to reprogram the PCM with the latest software from the June 2001 or later HONDANET CD-ROM. Refer to Service Bulletin 99-005, Updating the Passport PCM, filed under Tools. 9. Use the PGM Tester to clear any DTCs. Page 5391 ^ Loosen the front subframe bolts. See the applicable service manual for more information. NOTE: The front wheels are being viewed from the rear of the vehicle. ^ Depending which way you need to shift the subframe, insert a pry bar between the subframe and body at both the front and rear positions of the subframe. NOTE: Be careful not to damage the vehicle. You could bend and damage the frame and/or body if you apply too much pressure. ^ Press on both pry bars to shift the subframe. It will move only a few millimeters. This should adjust the camber about 0.2-0.5°. ^ While holding the subframe in place, have an assistant torque the subframe bolts to their proper torque. Front Camber Adjustment, Strut Suspension ^ Raise the vehicle, and remove the front tires. ^ Loosen the damper pinch bolts and the flange nuts. ^ Adjust the camber by moving the bottom of the damper within the range of the damper pinch bolt free play. NOTE: Some vehicles have special pinch bolts that allow more adjustment. For more information, refer to the parts catalog. ^ Tighten the damper pinch bolts to the specified torque. ^ Reinstall the front wheels and lower the vehicle. Bounce the front of the vehicle several times to stabilize the suspension. Starting System - Unable To Key In Ignition Switch Key: Technical Service Bulletins Starting System - Unable To Key In Ignition Switch Can't Turn Ignition Switch? Check for Locked Steering Got a service customer complaining he or she can't turn the ignition switch to start the engine? The reason could just be the steering column lock pin is engaged with the front wheels turned. Here's what typically happens: Some folks use the steering wheel to help support themselves while climbing in or out of the vehicle. This is very common among elderly or disabled drivers. Doing this turns the front wheels, which twists the tires against the ground. The twisted tires apply torque to the steering column. With the ignition switch in LOCK (0), the steering column lock pin is engaged. But the applied torque on the steering column binds the lock pin, making it tough to turn the ignition switch. The ignition switch won't turn to ON (II) if the lock pin isn't disengaged from the steering column. Tell your customer there's nothing wrong with the ignition switch itself. All he or she needs to do is turn the steering wheel from side to side while turning the switch. This usually releases the lock pin so the engine can be started. In some cases, though, your customer may need to give a good tug on the wheel. This could easily happen when parking on a hill and the wheels are turned sharply before the engine is shut off. Diagram Information and Instructions 4WD Control Unit: Diagram Information and Instructions How to Identify Wiring Color-Coded Insulation Wire Color Wire Color Coding Page 5637 Ball Joint: Service and Repair Lower REMOVAL 1. Raise the vehicle and support the frame with suitable safety stands. 2. Remove wheel and tire assembly. 3. Remove the tie-rod end from the knuckle. 4. Remove the retaining ring from the front axle driving shaft to release the shaft from hub. 5. Support lower control arm with a jack. 6. Remove lower ball joint nut and cotter pin, then use remover J-29107 to remove the lower ball joint from the knuckle. CAUTION: Be careful not to damage the ball joint boot. 7. Remove nut. 8. Remove bolt. 9. Remove lower ball joint. INSPECTION AND REPAIR Recall 10V436000: Rear Lower Control Arm Bracket Control Arm: All Technical Service Bulletins Recall 10V436000: Rear Lower Control Arm Bracket VEHICLE MAKE/MODEL: MODEL YEAR(S): Honda/Passport 1998-2002 Isuzu/Axiom 2002 Isuzu/Rodeo 1998-2002 MANUFACTURER: Isuzu Manufacturing Services of America MFR'S REPORT DATE: September 22, 2010 NHTSA CAMPAIGN ID NUMBER: 10V436000 NHTSA ACTION NUMBER: 2 Investigations found COMPONENT: Suspension: Rear POTENTIAL NUMBER OF UNITS AFFECTED: ? SUMMARY: Isuzu is recalling certain model year 1998-2002 Isuzu Rodeo and model year 2002 Isuzu Axiom vehicles, and Honda is recalling certain 1998-2002 Honda Passport vehicles, that were originally sold, or are currently registered, in the states of Maine, New Hampshire, Vermont, Massachusetts, Rhode Island, Connecticut, New York, New Jersey, Pennsylvania, Delaware, Maryland, The District of Columbia, West Virginia, Ohio, Indiana, Michigan, Illinois, Wisconsin, Minnesota, Iowa, Missouri, and Kentucky. Vehicles that have experienced sustained exposure to highly corrosive materials used in some jurisdictions for road deicing purposes may experience excessive corrosion in the vicinity of the forward mounting point bracket for the left or right rear suspension lower link prior to the time that such corrosion would normally be expected. CONSEQUENCE: Excessive corrosion may result in the left or right rear suspension lower link bracket becoming detached from the frame, which can affect vehicle handling and potentially cause a crash. REMEDY: Dealers will inspect the rear suspension lower link bracket area. For vehicles in which little or no corrosion is found, the area will be treated with an anti-corrosive compound. For vehicles in which corrosion has damaged the rear suspension lower link bracket and affected its connection to the vehicle frame, a reinforcement bracket will be installed. In the rare event the corrosion is so severe that the reinforcement bracket remedy would not be appropriate, Isuzu and Honda will develop an appropriate remedy. All inspections and remedies will be provided free of charge for vehicles that are 10 years old or less. For vehicles older than 10 years, Isuzu will offer a free remedy, but only if the vehicle is presented to an Isuzu service facility, or Honda dealer (as applicable), dealer within 12 months of when owner notifications were issued. The manufacturer has not yet provided an owner notification schedule. Isuzu owners may contact Isuzu at 1-800-255-6727. Honda owners may contact Honda at 1-800-999-1009. NOTES: Owners may also contact The National Highway Traffic Safety Administration's Vehicle Safety Hotline at 1-888-327-4236 (TTY 1-800-424-9153), or go to http://www.safercar.gov. Page 3680 5. Remove the meter assembly. - Push the metal cover (6) with the screw driver (7). 6. Remove the meter rear cover. 7. Remove the meter circuit board. 8. Remove the A/T shift indicator bulb. Installation To install, follow the removal steps in the reverse order. Page 5060 Wheel Speed Sensor: Description and Operation It consists of a sensor and a rotor. The sensor is attached to the knuckle on the front wheels and to the rear axle case on the rear differential. The rotor is press-fit in the axle shaft. The flux generated from electrodes magnetized by a magnet in the sensor varies due to rotation of the rotor, and the electromagnetic induction generates alternating voltage in the coil. This voltage draws a "sine curve" with the frequency proportional to rotor speed and it allows detection of wheel speed. Service and Repair Shifter M/T: Service and Repair For further information regarding this component and the system that it is a part of, please refer to Manual Transmission/Transaxle; Service and Repair; Unit Overhaul Page 6548 4. Connect the appropriate pigtail adapter to the SRS deployment harness. 5. Remove the driver air bag assembly from vehicle. Refer to driver air bag assembly Removal. WARNING: WHEN STORING A LIVE AIR BAG ASSEMBLY OR WHEN LEAVING A LIVE AIR BAG ASSEMBLY UNATTENDED ON A BENCH OR OTHER SURFACE, ALWAYS FACE THE AIR BAG AND TRIM COVER UP AND AWAY FROM THE SURFACE. THIS IS NECESSARY SO THAT A FREE SPACE IS PROVIDED TO ALLOW THE AIR BAG TO EXPAND IN THE UNLIKELY EVENT OF ACCIDENTAL DEPLOYMENT. FAILURE TO FOLLOW PROCEDURES MAY RESULT IN PERSONAL INJURY. 6. Clear a space on the ground about 183 cm (8 feet) in clearance where the driver air bag assembly is to be deployed. A paved, outdoor location where there is no activity is preferred. If an outdoor location is not available, a space on the shop floor where there is no activity and sufficient ventilation is recommended. Ensure no loose or flammable objects are within the deployment area. 7. Place the J-41497 on the bench vice. This is necessary to provide sufficient stabilization of the fixture during deployment. 8. Attach the driver airbag assembly in the J-41497. Airbag assembly must be mounted facing upward on J-41497. SECURELY HAND-TIGHTEN ALL FASTENERS PRIOR TO DEPLOYMENT. 9. The double pole extension cord must be atleast 10 m (33 feet) away from the airbag assembly. Page 3129 Accelerator Pedal: Service and Repair Removal 1. Disconnect battery ground cable. 2. Disconnect Accelerator position (AP) sensor (1) connector from Accelerator pedal assembly. 3. Disconnect kick down switch (3) connector from Accelerator pedal assembly. 4. Remove Accelerator pedal assembly (2). Installation 1. Install Accelerator pedal assembly (2). 2. Connect AP sensor (1) harness and kick down switch (3) harness connector. 3. Connect battery ground cable. Page 6832 2. Remove the power window switch/regulator handle. - Pry out the power window switch and remove the connectors. - To remove the regulator handle (1), remove the clip (2) at the root of the handle by using wire with hook. 3. Remove the screw while pulling the inside lever toward you and then remove the inside handle. 4. Remove the speaker grille (3). - Pull out the front side of the grille. Page 4631 5. Install magnet, main case oil pan with new gasket, and sixteen 10 mm screws. Tighten the screws to the specified torque. Torque: 11 Nm (96 Inch lbs.) 6. Fill transmission through the overfill screw hole of oil pan, using ATF DEXRON-III. 7. Connect battery ground cable. Page 6888 Hood Sensor/Switch (For Alarm): Service and Repair Removal 1. Disconnect the battery ground cable. 2. Disconnect the connector. 3. Remove the engine hood switch (1). Installation To install, follow the removal steps in the reverse order. Page 903 6. Place the end of the return hose in a container. Have someone start the engine, then pour ATF into the reservoir while you watch the fluid coming out of the return hose. When the fluid coming out is the same color as the new fluid, turn off the engine. 7. Reconnect the return hose to the reservoir. 8. Start the engine. Fill the power steering reservoir to the proper level with ATF then turn off the engine. 9. Use the Smart Cable to reprogram the PCM with the latest software from the June 2001 or later HONDANET CD-ROM. Refer to Service Bulletin 99-005, Updating the Passport PCM, filed under Tools. 10. Use the PGM Tester to clear any DTCs. 11. Use the PGM Tester to check the broadcast code. Make sure the broadcast code matches the one you selected from the CD-ROM. WARRANTY CLAIM INFORMATION In warranty: The normal warranty applies. Failed Part: P/N 8-97181-590-0 H/C 5698030 Defect Code: 064 Contention Code: C01 Skill Level: Repair Technician Out of warranty: Any repair performed after warranty expiration may be eligible for goodwill consideration by the District Service Manager or your Zone Office. You must request consideration, and get a decision, before starting work. REPAIR PROCEDURE - APPS GROUND 1. Unclamp the air cleaner housing cover, and move it to the side for access to connector C123 (16P BLK). Page 1276 Brake Bleeding: Service and Repair Flushing Brake Hydraulic System FLUSHING BRAKE HYDRAULIC SYSTEM It is recommended that the entire hydraulic system be thoroughly flushed with clean brake fluid whenever new parts are installed in the hydraulic system. Approximately one quart of fluid is required to flush the hydraulic system. The system must be flushed if there is any doubt as to the grade of fluid in the system or if fluid has been used which contains the slightest trace of mineral oil. All rubber parts that have been subjected to a contaminated fluid must be replaced. Page 2843 7. Modify the original APPS by cutting the connector housing off of the sensor. 8. Connect the 10P connector to the modified APPS connector housing. 9. Using a DVOM, check the voltage between the reference voltage pin for each sensor and ground. ^ If the sensor circuits all read 5.0 volts, go to step 11. ^ If any sensor circuit is above or below 5.0 volts, go to step 10. 10. Troubleshoot for an internal short in another sensor or a PCM malfunction. ^ To find the sensor with an internal short, monitor the incorrect reference voltage, and disconnect each sensor (FTPS, EGR, MAP, TPS, CKP, and CMP) one at a time until the reference voltage reads 5.0 volts. Replace that sensor, and repeat step 3. ^ To find a malfunctioning PCM, replace it with a known-good PCM. If all three sensors (APP Sensor 1, APP Sensor 2, and APP Sensor 3) are within range, the original PCM is faulty; replace it and repeat step 3. Page 465 The wire insulation has one color or one color with another color stripe. The second color is the stripe. Diagrams Transmission Mode Switch: Diagrams Page 7531 Test Equipment CAUTION: Most circuits include solid-state devices. Test the voltages in these circuits only with a 10-megaohm or higher impedance digital multimeter. Never use a test light or analog meter on circuits that contain solid-state devices. Damage to the devices may result. Test Light and DVOM On circuits without solid-state devices, use a test light to check for voltage. A test light is made up of a 12 volt bulb with a pair of leads attached. After grounding one lead, touch the other lead to various points along the circuit where voltage should be present. The bulb will go on if there is voltage at the point being tested. If you need to know how much voltage is present, use a digital volt/ohmmeter (DVOM). Self-Powered Test Light and DVOM Use a self-powered test light to check for continuity. This tool is made up of a light bulb, battery, and two leads. To test it, touch the leads together: the light should go on. Use a self-powered test light only on an unpowered circuit. First, disconnect the battery, or remove the fuse that feeds the circuit you are working on. Select two points in the circuit between which you want to check continuity. Connect one lead of the self-powered test light to each point. If there is continuity, the test light's circuit will be completed, and the light will go on. If, in addition, you need to know exactly how much resistance there is between two points, use a digital volt/ohmmeter (DVOM). In the "OHMS" range, the DVOM will measure resistance between two points along a circuit. Low resistance means good continuity. Diodes and solid-state devices in a circuit can make a DVOM give a false reading. To check a reading, reverse the leads, and take a second reading. If the readings differ, the component is affecting the measurement. Jumper Wire Use a jumper wire to bypass an open circuit. A jumper wire is made up of an in-line fuse holder connected to a set of test leads. It should have a five ampere fuse. Never connect a jumper wire across a short circuit. The direct battery short will blow the fuse. Short Finder (Short Circuit Locator) Short finders are available to locate shorts to ground. The short finder creates a pulsing magnetic field in the shorted circuit which you can follow to the location of the short. To order any test equipment shown above, contact your local tool supplier. For a list of suppliers and tool numbers, refer to Honda Required Special Tools and Equipment Service Bulletin. Page 5602 Control Assembly / Control Cable HVAC Control Bezel: Service and Repair Control Assembly / Control Cable Removal 1. Disconnect the battery ground cable. 2. Remove instrument panel driver lower cover assembly. 3. Remove meter cluster assembly. 4. Remove glove box. 5. Remove the control lever attaching screws. Page 5388 DIAGNOSTIC WORKSHEET REPAIR PROCEDURE A Audio System - CD/DVD Precautions Compact Disc Player (CD): All Technical Service Bulletins Audio System - CD/DVD Precautions Adhesive Labels or Protective Disc Covers on CDs or DVDs: A Big Taboo NOTE: This article applies to all Honda models with a factory- or dealer-installed CD/DVD player or changer. We can't emphasize this enough: Never put adhesive labels or protective disc covers on recordable CDs or DVDs to be used in automotive CD/DVD players or changers. Here's why: ^ Recordable CDs and DVDs are actually thicker than their pre-recorded brethern. Automotive players and changers use rollers to draw the disc into the unit. The added thickness of an adhesive label or a protective disc cover can cause the disc to jam when it's loaded into or ejected from the unit. ^ CD/DVD players or changers are exposed to high temperatures inside the vehicle. High temperature can cause the label adhesive to soften. This can cause the label to curl on the edges and even form bubbles. Curled edges can catch on the rollers and bubbles add thickness to the disc. Either one can cause the disc to jam. To cut down on customer-caused damage, all '05 and later 0/Ms include this notice: Do not use CDs with adhesive labels. The label can curl up and cause the CD to jam in the unit. Anytime a service customer comes in with a loading or ejecting problem for a CD/DVD player or changer, ask if he or she used any discs with adhesive labels or protective disc covers. If the answer is yes, contact your DPSM for possible goodwill assistance. If the answer is no, then replace the audio unit under normal warranty. Page 7435 This sample Ground Distribution schematic shows all of the components that share two ground points. Components A solid border line means the entire component is shown. A broken border line indicates that only part of the component is shown. Page 3138 Disclaimer Repair Procedure 1. Unclamp the air cleaner housing cover, and move it to the side for access to connector C123 (16P BLK). 2. Unfasten C123 from the side of the engine compartment using a 90-degree pick. 3. Disconnect C123, and clean the terminals on both sides of the connector with contact cleaner. Shake the residue out of the connector. Allow the contact cleaner to evaporate for at least 3 minutes, then reconnect C123. 4. Fasten C123 to the left side of the engine compartment, then reinstall the air cleaner housing cover. 5. While supporting the accelerator pedal assembly, remove the two bolts that secure the assembly to the bulkhead. Carefully lower the assembly to gain access to the connector. Steering/Suspension - Vehicle Pulls Left/Right Alignment: All Technical Service Bulletins Steering/Suspension - Vehicle Pulls Left/Right 06-068 May 2, 2009 Applies To: ALL *Vehicle Pulls or Drifts, and/or Steering Wheel Is Off-Center (Supersedes 06-068, Vehicle Pulling or Drifting, dated October 4, 2007, to revise the information marked by asterisks) (Replaces 90-011, Steering Wheel Off-Center Adjustment at PDI)* *REVISION SUMMARY The title description was revised.* SYMPTOM While driving on a straight road, the vehicle pulls or drifts to the right or left. BACKGROUND New tools were developed to help you diagnose and correct a pulling and/or steering wheel off-center issue. There is a diagnosis worksheet included to take on your test-drive and record your findings. These values are used to build the 15-digit DTC (diagnostic trouble code) that is required for your warranty claim. The last step in each repair procedure helps you create the correct code. In the rare case that you have to repair a vehicle that pulls and has the steering wheel off-center, use REPAIR PROCEDURE B to file your warranty claim. For more information, refer to Training Module SSC 44 - Steering Drift or Pull Interactive Service Bulletin. PROBABLE CAUSES Several conditions can cause the vehicle to pull or drift: ^ Wheel alignment ^ Tires ^ Off-center steering wheel (no pulling or drifting, but a customer may believe this is the case) CORRECTIVE ACTION Diagnose the problem using the special tools and the worksheet on page 4 that guides you to one of four repair procedures. TOOL INFORMATION Centering Tape (enough to diagnose 240 vehicles): T/N O7AAJ-001A300 Steering Drift Set Level: T/N 07AAJ-00100 Steering Drift Set: T/N O7MJ-001A140 Replacement Weight for Steering Drift Set: T/N 07AAJ-001A400 WARRANTY CLAIM INFORMATION In warranty: The normal warranty applies. Failed Part: P/N 53560-SDA-AO1 H/C 7139652 Service and Repair Front Door Window Glass Weatherstrip: Service and Repair Front Window Regulator, Glass and Glass Run Front Window Regulator, Glass And Glass Run Removal 1. Disconnect the battery ground cable. Page 2169 Oxygen Sensor: Service and Repair HEATED OXYGEN SENSOR (HO2S) REMOVAL PROCEDURE 1. Disconnect the negative battery cable. 2. Locate the four oxygen sensors. - Bank 1 sensor 1 is mounted on the exhaust pipe ahead of the right-hand catalytic converter. - Bank 1 sensor 2 is mounted behind the right-hand catalytic converter. Service and Repair Shift Indicator: Service and Repair Removal 1. Disconnect the battery ground cable. 3. Remove the meter lens (3) from the meter visor (4). 4. Remove the meter visor from the meter case(5). Page 6431 2. Remove the air bag assembly (6) from steering wheel (7) by removing two bolts (8). Lift air bag assembly out of steering wheel. 3. Disconnect the 2 - pin yellow connector (2) and remove air bag assembly. 4. Disconnect horn lead connector (1). 5. Remove the steering wheel attachment nut (5). 6. Move the tires to the straight ahead position before removing the steering wheel and remove wheel with J-29752. 7. Apply a setting mark (4) across the steering wheel and shaft so parts can be reassembled in their original position. 8. Feed wiring though the wheel and remove wheel. CAUTION: Never apply force to the steering wheel in the direction of the shaft by using a hammer or other impact tools in an attempt to remove the steering wheel. The steering shaft is designed as an energy absorbing unit. 9. Remove the steering lower cover. 10. Remove the driver knee bolster assembly. 11. Remove the steering column cover (3). Page 5232 Fuse: Diagrams Instrument Panel Page 7450 Page 1496 4. Move serpentine belt tensioner to loose side using wrench then remove serpentine belt. 5. Remove cooling fan assembly four fixing nuts, then the cooling fan assembly. 6. Remove crankshaft pulley assembly using J-8614-01 crankshaft holder, hold crankshaft pulley then remove center bolt and pulley. Installation 1. Install crankshaft pulley using J-8614-01 crankshaft holder, hold the crankshaft pulley and tighten center bolt to the specified torque. Torque: 167 Nm (123 ft. lbs.) 2. Install cooling fan assembly and tighten bolts/nuts to the specified torque. Torque: 22 Nm (16 ft. lbs.) for fan pulley and fan bracket. Torque: 7.5 Nm (66.4 inch lbs.) for fan and clutch assembly. 3. Move serpentine belt tensioner to loose side using wrench, then install serpentine belt to normal position. 4. Install radiator upper fan shroud. 5. Install air cleaner assembly. Moonroof - Visor Sags in The Middle Sun Shade: Customer Interest Moonroof - Visor Sags in The Middle 00-061 August 22, 2000 Applies To: 1998-00 Passport - ALL Accessory Moonroof Visor Appearance PROBLEM The rear edge of the moonroof visor sags in the middle, and/or the roof seal is distorted. CORRECTIVE ACTION Replace the moonroof visor and the roof seal with a new assembly. PARTS INFORMATION Accessory Moonroof Visor Kit: P/N 08R01-ED1101, H/C 6483838 WARRANTY CLAIM INFORMATION In warranty: The normal warranty applies. Out of warranty: Any repair performed after warranty expiration may be eligible for goodwill consideration by the District Service Manager or your Zone Office. You must request consideration, and get a decision, before starting work. REPAIR PROCEDURE 1. Remove the moonroof visor, the roof seal, and all related hardware. 2. Install the new moonroof visor kit. Refer to the Accessory Installation Instructions binder for the installation instructions. Disclaimer Page 851 Ignition Switch Lock Cylinder: Testing and Inspection TESTING AND INSPECTION Turn the ignition switch to "ON" while watching warning light. The light should flash 7 times and then go off. Page 2490 5. Insert a thin stainless steel ruler or a "Slim Jim" under the magazine, about 1-1/2" from the right side of the opening. 6. Push the ruler in until it presses against the eject lever at the back of the unit. 7. Slowly remove the ruler and magazine at the same time. Two-piece door model: 1. Remove the changer from the vehicle. 2. Remove the top cover plate from the changer, and look for a jammed tray. 3. If a tray is stuck in the player, reinstall the cover and replace the changer. If all the trays are in the magazine, insert a thin stainless steel ruler or a "Slim Jim" under the magazine, about 1/2" from the right side of the opening. 4. Push the ruler in until it presses against the eject lever at the back of the unit. 5. Slowly remove the ruler and magazine at the same time. Page 3591 Terminals - "T" Each "T" terminal (ring type) is numbered for reference and location. A "T" terminal is secured with a screw or bolt. Wires Page 5825 Supportable Point: Front - Position the chassis stands at the bottom of the frame sidemember, behind the front wheel. Lifting Point: Rear - Position the floor jack at the center of the rear axle case when lifting the vehicle. Supportable Point: Rear - Position the chassis stands at the bottom of the frame sidemember, just behind the trailing link bracket. Page 2539 Camshaft Position Sensor: Description and Operation Camshaft Position (CMP) Sensor and Signal The camshaft position (CMP) sensor sends a CMP signal to the PCM. The PCM uses this signal as a "sync pulse" to trigger the injectors in the proper sequence. The PCM uses the CMP signal to indicate the position of the #1 piston during its power stroke. This allows the PCM to calculate true sequential fuel injection (SFI) mode of operation. If the PCM detects an incorrect CMP signal while the engine is running, DTC P0341 will set. If the CMP signal is lost while the engine is running, the fuel injection system will shift to a calculated sequential fuel injection mode based on the last fuel injection pulse, and the engine will continue to run. As long as the fault is present, the engine can be restarted. It will run in the calculated sequential mode with a 1-in-6 chance of the injector sequence being correct. Refer to DTC P0341 for further information. CMP Signal The PCM uses this signal to determine the position of the number 1 piston during its power stroke, allowing the PCM to calculate true sequential multiport fuel injection (SFI). Loss of this signal will set a DTC P0341. If the CMP signal is lost while the engine is running, the fuel injection system will shift to a calculated sequential fuel injection based on the last fuel injection pulse, and the engine will continue to run. The engine can be restarted and will run in the calculated sequential mode as long as the fault is present, with a 1-in-6 chance of being correct. Service and Repair Instrument Panel Bulb: Service and Repair Warning Light Bulbs and Indicator Light Bulbs Removal 1. Disconnect the battery ground cable. 2. Remove the meter assembly. 3. Remove the bulb. - Hold the bulb socket by hand, rotate it counterclockwise and pull it out. Installation To install, follow the removal steps in the reverse order. Page 7099 The wire insulation has one color or one color with another color stripe. The second color is the stripe. Page 6388 2. Connect one lead of a self-powered test light or DVOM to one end of the part of the circuit you want to test. 3. Connect the other lead to the other end. 4. If the self-powered test light glows, there is continuity. If you're using a DVOM, a low reading or no reading (zero), means good continuity. Testing For Voltage When testing for voltage at a connector without wire seals, you do not have to separate the two halves of the connector. Instead, probe the connector from the back. Always check both sides of the connector because dirty, corroded, and bent terminals can cause problems (no electrical contact = an open). 1. Connect one lead of the lest light to a known good ground, or, if you're using a digital volt ohmmeter (DVOM), place it in the appropriate DC volts range, and connect its negative lead to ground. 2. Connect the other lead of the test light or DVOM to the point you want to check. 3. If the test light glows, there is voltage present. If you're using a DVOM, note the voltage reading. It should be within one volt of measured battery voltage. A loss of more than one volt indicates a problem. NOTE: Always use a DVOM on high impedance circuits. A test light may not glow (even with battery voltage present). Testing For Voltage Drop Wires, connectors, and switches are designed to conduct current with a minimum loss of voltage. A voltage drop of more than one volt indicates a problem. 1. Place the digital volt/ohmmeter (DVOM) in the appropriate DC volts range. Connect the positive lead to the end of the wire (or to the connector or switch) closest to the battery. 2. Connect the negative lead to the other end of the wire (or the other side of the connector or switch). 3. Turn on the components in the circuit. 4. The DVOM will show the difference in voltage between the two points. A difference, or drop, of more than one volt indicates a problem. Check the circuit for loose, dirty, or bent terminals. Page 4338 Grease Amount - Hub: 35 g (1.23 oz.) - Outer bearing: 10 g (0.35 oz.) - Inner bearing: 15 g (0.53 oz.) 8. Install hub nut. Turn to the place where there is a chamfer in the tapped hole to the outer side, then attach the nut by using front hub nut wrench J-36827. PRELOAD ADJUSTMENT 1. Tighten the hub nut to 29 Nm (22 ft. lbs.), then fully loosen the nut. Page 1491 4. Tighten the bolts and nuts to the specified torque. Torque: 10 Nm (89 inch lbs.) 11. Install cylinder head assembly. Page 2108 1. Install the MAF sensor on the air cleaner with the clamp. 2. Install the intake air duct and the clamp on the MAF sensor. 3. Tighten the clamps to secure the MAF sensor to the intake air duct and the air cleaner. 4. Connect the MAF electrical connector. 5. Connect the negative battery cable. Locations Page 3361 and the fuses. From Fuses to Relays and Components The second half of Power Distribution shows the wiring "From Fuses to Relays and Components." This can speed your troubleshooting by showing which circuits share fuses. If Power Distribution shows that an inoperative circuit and another circuit share a fuse, check a component in the other circuit. If it works, you know the fuse is good and power is available to the inoperative circuit. Ground Distribution Schematics Page 7641 The wire insulation has one color or one color with another color stripe. The second color is the stripe. Page 7496 2. Connect one lead of a self-powered test light or DVOM to one end of the part of the circuit you want to test. 3. Connect the other lead to the other end. 4. If the self-powered test light glows, there is continuity. If you're using a DVOM, a low reading or no reading (zero), means good continuity. Testing For Voltage When testing for voltage at a connector without wire seals, you do not have to separate the two halves of the connector. Instead, probe the connector from the back. Always check both sides of the connector because dirty, corroded, and bent terminals can cause problems (no electrical contact = an open). 1. Connect one lead of the lest light to a known good ground, or, if you're using a digital volt ohmmeter (DVOM), place it in the appropriate DC volts range, and connect its negative lead to ground. 2. Connect the other lead of the test light or DVOM to the point you want to check. 3. If the test light glows, there is voltage present. If you're using a DVOM, note the voltage reading. It should be within one volt of measured battery voltage. A loss of more than one volt indicates a problem. NOTE: Always use a DVOM on high impedance circuits. A test light may not glow (even with battery voltage present). Testing For Voltage Drop Wires, connectors, and switches are designed to conduct current with a minimum loss of voltage. A voltage drop of more than one volt indicates a problem. 1. Place the digital volt/ohmmeter (DVOM) in the appropriate DC volts range. Connect the positive lead to the end of the wire (or to the connector or switch) closest to the battery. 2. Connect the negative lead to the other end of the wire (or the other side of the connector or switch). 3. Turn on the components in the circuit. 4. The DVOM will show the difference in voltage between the two points. A difference, or drop, of more than one volt indicates a problem. Check the circuit for loose, dirty, or bent terminals. Page 3564 Wire Color Abbreviations The following abbreviations are used to identify wire colors in the circuit schematics: WHT................................... White YEL................................... Yellow BLK................................... Black BLU................................... Blue GRN................................... Green RED................................... Red ORN................................... Orange PNK................................... Pink BRN................................... Brown GRY................................... Gray PUR................................... Purple LT BLU................................... Light Blue LT GRN................................... Light Green Page 7460 Air Bag(s) Arming and Disarming: Service Precautions Airbag Handling and Storage Airbag Handling and Storage Do not disassemble an airbag. It has no serviceable parts. Once an airbag has been deployed, it cannot be repaired or reused. For temporary storage of the airbag during service, please observe the following precautions. - Store the removed airbag with the pad surface up. Never put anything on the removed airbag. - Keep free from any oil, grease, detergent, or water to prevent damage to the airbag assembly. - Store the removed airbag on a secure, flat surface away from any high heat source (exceeding 200 °F/93 °C). - Never perform electrical inspections to the airbags, such as measuring resistance. - Do not position yourself in front of the airbag assembly during removal, inspection, or replacement. Page 567 2. Connect one lead of a self-powered test light or DVOM to one end of the part of the circuit you want to test. 3. Connect the other lead to the other end. 4. If the self-powered test light glows, there is continuity. If you're using a DVOM, a low reading or no reading (zero), means good continuity. Testing For Voltage When testing for voltage at a connector without wire seals, you do not have to separate the two halves of the connector. Instead, probe the connector from the back. Always check both sides of the connector because dirty, corroded, and bent terminals can cause problems (no electrical contact = an open). 1. Connect one lead of the lest light to a known good ground, or, if you're using a digital volt ohmmeter (DVOM), place it in the appropriate DC volts range, and connect its negative lead to ground. 2. Connect the other lead of the test light or DVOM to the point you want to check. 3. If the test light glows, there is voltage present. If you're using a DVOM, note the voltage reading. It should be within one volt of measured battery voltage. A loss of more than one volt indicates a problem. NOTE: Always use a DVOM on high impedance circuits. A test light may not glow (even with battery voltage present). Testing For Voltage Drop Wires, connectors, and switches are designed to conduct current with a minimum loss of voltage. A voltage drop of more than one volt indicates a problem. 1. Place the digital volt/ohmmeter (DVOM) in the appropriate DC volts range. Connect the positive lead to the end of the wire (or to the connector or switch) closest to the battery. 2. Connect the negative lead to the other end of the wire (or the other side of the connector or switch). 3. Turn on the components in the circuit. 4. The DVOM will show the difference in voltage between the two points. A difference, or drop, of more than one volt indicates a problem. Check the circuit for loose, dirty, or bent terminals. Page 3244 3. For removal of the return pipe (returning fuel to the tank), hold the pipe in one hand, and pull out the connector with the other hand while pressing the square relieve button of the retainer, as illustrated. NOTE: This work should be done by hands. Do not use any tools. Should the pipe can hardly be removed from the connector, use a lubricant (light oil) and/or push and pull the connector longitudinally until the pipe is removed. When reusing the delivery pipe retainer, reuse without removing the retainer from the pipe. If the retainer is damaged or deformed, however, replace with a new retainer. Cover the connectors removed with a plastic bag, etc. to prevent the entry of dust or rain water. Page 905 10. Use the PGM Tester to check the broadcast code. Make sure the broadcast code matches the one you selected from the CD-ROM. WARRANTY CLAIM INFORMATION In warranty: The normal warranty applies. Failed Part: P/N 8-17087-655-0 H/C 4375820 Defect Code: 064 Contention Code: C01 Skill Level: Repair Technician Out of warranty: Any repair performed after warranty expiration may be eligible for goodwill consideration by the District Service Manager or your Zone Office. You must request consideration, and get a decision, before starting work. REPAIR PROCEDURE - ENGINE/BODY GROUND 1. Use the ETM for the appropriate year to locate these ground connectors: G101, G104, G105, G106 and G160. 2. Inspect each connector for corrosion or looseness. 3. Remove the bolt from any connector that is corroded or loose. Clean the terminal connector with a wire brush. File flat any solder bumps on the connector. 4. Clean the contact surface on the engine or body with a wire brush. 5. Replace the bolt if it is heavily corroded. Otherwise, clean it with a wire brush. 6. Apply lithium dielectric grease to both sides of the terminal connector. 7. Reinstall the bolt, torque it to 14 N.m (10 lb-ft). 8. Use the Smart Cable to reprogram the PCM with the latest software from the June 2001 or later HONDANET CD-ROM. Refer to Service Bulletin 99-005, Updating the Passport PCM, filed under Tools. 9. Use the PGM Tester to clear any DTCs. 10. Use the PGM Tester to check the broadcast code. Make sure the broadcast code matches the one you selected from the CD-ROM. WARRANTY CLAIM INFORMATION In warranty: The normal warranty applies. Failed Part: P/N 8-97086-823-0 Page 3050 Catalytic Converter: Service and Repair Left Side Removal and Installation TWC LH and Forked Exhaust Pipe and Associated Parts REMOVAL 1. Disconnect battery ground cable. 2. Lift up the vehicle and support with suitable safety stands. 3. Disconnect O2 sensor harness connectors (8) (10). 4. Remove the forked exhaust pipe fixing bolts and nuts (1) (4) (6) and the exhaust silencer fixing nuts (5), then remove the forked exhaust pipe (3) and the mass damper (2). 5. Remove the three way catalytic converter fixing nuts (11) and the mounting rubber (7), then remove the three way catalytic converter (9). INSTALLATION 1. Install the three way catalytic converter (9) and the mounting rubber (7), and tighten the fixing nuts (11) to the specific torque. Torque Nuts: 67 Nm (49 ft. lbs.) 2. Install the forked exhaust pipe (3) and the mass damper (2), and tighten the fixing bolts (1) (6) and nuts (4) (5) to the specified torque. Torque Bolts & Nuts: 43 Nm (32 ft. lbs.) Nuts: 43 Nm (32 ft. lbs.) 3. Connect the O2 sensor connectors (8) (10). Page 6263 Refrigerant Pressure Sensor / Switch: Description and Operation A/C Dual Pressure Switch (M/T) To prevent compressor damage, the dual pressure switch will open if system pressure is too low or too high: below 176.5 ± 19.6 kPa (25.6 ± 2.8 psi) or above 2943 ± 196.2 kPa (426.7 ± 28.4 psi). A/C Triple Pressure Switch (A/T) Low and high switch operation is the same as the dual pressure switch. The medium pressure switch will close when system pressure exceeds 1471.5 ± 98.1 kPa (213.3 ± 14.2 psi), turning on the condenser fan. Page 1968 Powertrain Control Module: Diagnostic Aids Before Troubleshooting Before Troubleshooting See: Service Precautions/Vehicle Damage Warnings/Tips and Precautions 1. Check applicable fuses in the appropriate fuse/relay box. 2. Check the battery for damage, state of charge, and clean and tight connections. CAUTION: Do not quick-charge a battery unless the battery ground cable has been disconnected, otherwise you will damage the alternator diodes. - Do not attempt to crank the engine with the battery ground cable loosely connected or you will severely damage the wiring. While You're Working 1. Make sure connectors are clean, and have no loose terminals or receptacles. 2. Make sure that connectors without wire seals are packed with dielectric (silicone) grease. Part Number: 08798-9001. 3. When connecting a connector, push it until it "clicks" into place. CAUTION: Do not pull on the wires when disconnecting a connector. Pull only on the connector housings. - Most circuits include solid-state devices. Test the voltages in these circuits only with a 10-megaohm or higher impedance digital multi meter. Never use a test light or analog meter on circuits that contain solid-state devices. Damage to the devices may result. Five-Step Troubleshooting 1. Verify The Complaint Turn on all the components in the problem circuit to check the accuracy of the customer complaint. Note the symptoms. Do not begin disassembly or testing until you have narrowed down the problem area. 2. Analyze The Schematic Look up the schematic for the problem circuit. Determine how the circuit is supposed to work by tracing the current paths from the power source through the circuit components to ground. Also, trace circuits that share wiring with the problem circuit. The names of circuits that share the same fuse, ground, or switch, and so on, are referred to in each circuit schematic. Try to operate any shared circuits you didn't check in step 1. If the shared circuits work, the shared wiring is OK, and the cause must be in the wiring used only by the problem circuit. If several circuits fail at the same time, the fuse or ground is a likely cause. Based on the symptoms and your understanding of the circuit's operation, identify one or more possible causes. 3. Isolate The Problem By Testing The Circuit Make circuit tests to check the diagnosis you made in step 2. Keep in mind that a logical, simple procedure is the key to efficient troubleshooting. Test for the most likely cause of failure first. Try to make tests at points that are easily accessible. 4. Fix The Problem Once the specific problem is identified, make the repair. Be sure to use proper tools and safe procedures. 5. Make Sure The Circuit Works Turn on all components in the repaired circuit in all modes to make sure you've fixed the entire problem. If the problem was a blown fuse, be sure to test all of the circuits on that fuse. Make sure no new problems turn up and the original problem does not recur. Page 681 4. Remove the sensor from the exhaust pipe. Because of the expansion and contraction of the metal in the exhaust system over time, this may be difficult if the engine temperature is below 48 ° C (120 °F). INSTALLATION PROCEDURE IMPORTANT: - A special anti-seize compound on the HO2S threads. This compound consists of glass beads suspended in a liquid graphite solution. The graphite burns away with engine heat, but the glass beads will remain, making the sensor easier to remove. - New or service sensors will already have the compound applied to the threads. If a sensor is removed and is to be reinstalled for any reason, the threads must have anti-seize compound applied. 1. Apply anti-seize compound or the equivalent to the threads of the oxygen sensor, if necessary. 2. Install the oxygen sensor on the exhaust pipe in its original position. Tighten Tighten the oxygen sensor to 55 N.m (40 lb ft.). 3. Connect the pigtail to the wiring harness. 4. Connect the negative battery cable. Page 3157 20. Using a DVOM, check the voltage between the reference voltage pin for each sensor and ground. ^ If the sensor circuits all read 5.0 volts, go to step 22. ^ If any sensor circuit is above or below 5.0 volts, go to step 21. 21. Troubleshoot for an internal short in another sensor or a PCM malfunction. ^ To find the sensor with an internal short, monitor the reference voltage, and disconnect each sensor (FTPS, EGR, MAP TPS, CKP and CMP) one at a time until the reference voltage reads 5.0 volts. Replace that sensor, and repeat step 14. ^ To find a malfunctioning PCM, replace it with a known-good PCM. If all three sensors (APP Sensor 1, APP Sensor 2, and APP Sensor 3) are within range, the original PCM is faulty; replace it and repeat step 14. 22. Using a jumper wire, connect the reference voltage of each circuit to its signal input, and view the APP Sensor values in the Engine Data List. APP Sensor 1 should have a value of 99%, and APP Sensor 2 and APP Sensor 3 should each have a value of 0%. ^ If the values are not as specified, troubleshoot for high resistance on the signal input or a PCM malfunction. Repair the circuit or replace the PCM, then repeat step 14. ^ If the values are as specified, the problem may be intermittent. Disconnect the 10 P connector from the modified APPS, and connect it to the new APPS; then repeat step 14. Wiggle the APPS wires as you go through the adjustment procedure to find the intermittent problem. 23. Install the accelerator pedal assembly, and torque the bolts to 10 N.m (7 lb-ft). Page 469 2. Connect the short finder across the battery terminals and the load (component) side of the fuse terminal. 3. Close all switches in the circuit you're testing. 4. Turn on the short finder. This creates a pulsing magnetic field around the wiring between the fuse box and the short. 5. Beginning at the fuse box, slowly move the short finder along the circuit wiring. The meter will read current pulses through sheet metal and body trim. As long as the meter is between the fuse and the short, the needle will move with each current pulse. Once you move the meter past the point of the short, the needle will stop moving. Check the wiring and connectors in this area to locate the cause of the short. Testing For Continuity When testing for continuity at a connector without wire seals, you do not have to separate the two halves of the connector. Instead, probe the connector from the back. Always check both sides of the connector because dirty, corroded, and bent terminals can cause problems (no electrical contact = an open). 1. Disconnect the negative cable from the car battery. If you're using a DVOM, place it in the lowest "OHMS" range. Page 7293 3. Photocopy the template that is shown. Cut out the template. Page 3797 6. Place the end of the return hose in a container. Have someone start the engine, then pour ATF into the reservoir while you watch the fluid coming out of the return hose. When the fluid coming out is the same color as the new fluid, turn off the engine. 7. Reconnect the return hose to the reservoir. 8. Start the engine. Fill the power steering reservoir to the proper level with ATF then turn off the engine. 9. Use the Smart Cable to reprogram the PCM with the latest software from the June 2001 or later HONDANET CD-ROM. Refer to Service Bulletin 99-005, Updating the Passport PCM, filed under Tools. 10. Use the PGM Tester to clear any DTCs. 11. Use the PGM Tester to check the broadcast code. Make sure the broadcast code matches the one you selected from the CD-ROM. WARRANTY CLAIM INFORMATION In warranty: The normal warranty applies. Failed Part: P/N 8-97181-590-0 H/C 5698030 Defect Code: 064 Contention Code: C01 Skill Level: Repair Technician Out of warranty: Any repair performed after warranty expiration may be eligible for goodwill consideration by the District Service Manager or your Zone Office. You must request consideration, and get a decision, before starting work. REPAIR PROCEDURE - APPS GROUND 1. Unclamp the air cleaner housing cover, and move it to the side for access to connector C123 (16P BLK). Page 5582 Ground - "G" Shielding Sheilding This represents RFI (Radio Frequency Interference) shielding around a wire. The shielding is always connected to ground. Splices Page 964 Power Window Switch: Service and Repair Passenger's Window Switch Replacement Removal 1. Disconnect the battery ground cable. 2. Remove the switch (1). - Pull out the switch by pushing the spring with the tip of a screwdriver. - Disconnect the connector. Installation To install, follow the removal steps in the reverse order. Page 4141 1. Visually inspect the disassembled piston and piston cup for excessive wear and damage. Replace the inner parts with new parts if necessary. 2. Measure the clearance between slave cylinder wall and piston. If the measured value exceeds the specified limit, the slave cylinder assembly must be replaced. Standard: 0.07 mm (0.0028 inch) Limit: 0.15 mm (0.0059 inch) REASSEMBLY To reassemble, follow the disassembly steps in the reverse order, noting the following points: Piston Assembly 1. Before installing the parts, apply a thin coat of rubber grease. 2. Install cup in groove in piston with the lip turned to the front of cylinder. Use care so as not to scratch the cylinder. Page 2040 If there is no photo number below or beside a component name or a connector, ground, or terminal number, look up that name or number in the appropriate Connector Identification Chart. The chart lists how many cavities a connector has, where it's located, and what it connects to. The related illustration shows the connector's location on the harness, and the harness routing. NOTE: Photos listed by number are located at Locations / Components / Photograohs. See: Locations/Component Locations/Photographs Circuit Schematics Page 2857 Camshaft Position Sensor: Description and Operation Camshaft Position (CMP) Sensor and Signal The camshaft position (CMP) sensor sends a CMP signal to the PCM. The PCM uses this signal as a "sync pulse" to trigger the injectors in the proper sequence. The PCM uses the CMP signal to indicate the position of the #1 piston during its power stroke. This allows the PCM to calculate true sequential fuel injection (SFI) mode of operation. If the PCM detects an incorrect CMP signal while the engine is running, DTC P0341 will set. If the CMP signal is lost while the engine is running, the fuel injection system will shift to a calculated sequential fuel injection mode based on the last fuel injection pulse, and the engine will continue to run. As long as the fault is present, the engine can be restarted. It will run in the calculated sequential mode with a 1-in-6 chance of the injector sequence being correct. Refer to DTC P0341 for further information. CMP Signal The PCM uses this signal to determine the position of the number 1 piston during its power stroke, allowing the PCM to calculate true sequential multiport fuel injection (SFI). Loss of this signal will set a DTC P0341. If the CMP signal is lost while the engine is running, the fuel injection system will shift to a calculated sequential fuel injection based on the last fuel injection pulse, and the engine will continue to run. The engine can be restarted and will run in the calculated sequential mode as long as the fault is present, with a 1-in-6 chance of being correct. Service Precautions Suspension Control Module: Service Precautions The Intelligent Suspension System interfaces directly with the Control Unit which is a control computer that is similar in some regards to the Powertrain Control Module. These modules are designed to withstand normal current draws associated with vehicle operation. However, care must be taken to avoid overloading any of the Control Unit circuits. In testing for opens or shorts, do not ground or apply voltage to any of the circuits unless instructed to do so by the appropriate diagnostic procedure. These circuits should only be tested with a high impedance multimeter (J-39200) or special tools. Power should never be removed or applied to any control module with the ignition in the "ON" position. Before removing or connecting battery cables, fuses or connectors, always turn the ignition switch to the "OFF" position. Page 1244 4. Connect the high pressure charging hose of the manifold gauge to the high pressure side service valve of the vehicle. 5. Place the refrigerant container(3) up right on a weight scale(4). Note the total weight before charging the refrigerant. a. Open the refrigerant container valve. b. Open the low side vale on the manifold gauge set. Refer to the manufacturer's instructions for a weight scale charging station. 6. Perform a system leak test: - Charge the system with approximately 200 g (0.44 lbs) of HFC-134a. - Make sure the high pressure valve of the manifold gauge is closed. - Check to ensure that the degree of pressure does not change. - Check for refrigerant leaks by using a HFC-134a leak detector. - If a leak occurs, recover the refrigerant. Repair the leak and start all over again from the first step of evacuation. 7. If no leaks are found, continue charging refrigerant to the air conditioning system. Page 1733 8. Remove the bolts used to hold the preload of the camshaft subgears. 9. If not already done, inspect the camshaft thrust clearances. If any clearances are not within specification, replace the cylinder head(s). Page 7567 Each schematic represents one circuit. A circuit's wires and components are arranged to show current flow, from power at the top of the page, to ground, at the bottom. Shared Circuits Other circuits may share power or ground terminals or wiring with the circuit shown. A wire that connects one circuit to another, for example, is cut short and has an arrowhead at the end of it pointing in the direction of current flow. Next to the arrowhead is the name of the circuit or component which shares that wiring. To quickly check shared wiring, check the operation of a component it serves. If that component works, you know the shared wiring is OK. Connectors All in-line and junction connectors are numbered (C725, C416, etc.). Component connectors are not numbered but are identified either by the name of Page 6110 the component if the component only has one connector, or by a capital letter (A, B, C, etc.) if the component has more than one connector. Below most connector numbers and component names are PHOTO and VIEW numbers. The PHOTO number refers to a photo in the back of the book that shows the connector's location on the car. The VIEW number refers to an illustration in the back of the book that shows the connector face, wire colors, connector cavity numbers, and other details. The connector cavity numbering sequence begins at the top left corner of the connector. Disregard any numbers molded into the connector housing. Wires Wires are identified by the abbreviated names of their colors; the second color is the color of the stripe. Wires are also identified by their location in a connector. The number "2" next to the male and female wire terminals at C416, for example, means those terminals join in cavity 2 of connector C416. Symbols A complete description of schematic symbols is given under wire color abbreviation. Power Distribution Schematics Power Distribution schematics show how power is supplied from the positive battery terminal to various circuits in the car. Refer to the Power Distribution section to get a more detailed picture of how power is supplied to the circuit you're working on. From Battery to Ignition Switch, Fuses, and Relays Individual circuit schematics begin with a fuse. The first half of Power Distribution, however, shows the wiring "upstream" between the battery Page 4450 Splices Splices are shown as a dot. Their location and the number of wires may vary depending on the harness manufacturer. Switches Switches These switches move together; the broken straight line between them means they are mechanically connected. Other types of switches are controlled by a coil or a solid state circuit. Unless otherwise noted, all switches are shown in their normal (rest) position, with power off. Terminal "T" Page 7951 Terminals - "T" Each "T" terminal (ring type) is numbered for reference and location. A "T" terminal is secured with a screw or bolt. Wires Page 3032 Vehicle Speed Sensor: Testing and Inspection 1. Inspect the electrical connector for signs of corrosion or warping. Replace the VSS if the electrical connector is corroded or warped. 2. Inspect the VSS driven gear for chips, breaks, or worn condition. Replace the VSS if the driven gear is chipped, broken or worn. 3. Inspect the O-ring for wear, nicks, tears, or looseness. Replace the O-ring if necessary. Page 88 Page 551 the component if the component only has one connector, or by a capital letter (A, B, C, etc.) if the component has more than one connector. Below most connector numbers and component names are PHOTO and VIEW numbers. The PHOTO number refers to a photo in the back of the book that shows the connector's location on the car. The VIEW number refers to an illustration in the back of the book that shows the connector face, wire colors, connector cavity numbers, and other details. The connector cavity numbering sequence begins at the top left corner of the connector. Disregard any numbers molded into the connector housing. Wires Wires are identified by the abbreviated names of their colors; the second color is the color of the stripe. Wires are also identified by their location in a connector. The number "2" next to the male and female wire terminals at C416, for example, means those terminals join in cavity 2 of connector C416. Symbols A complete description of schematic symbols is given under wire color abbreviation. Power Distribution Schematics Power Distribution schematics show how power is supplied from the positive battery terminal to various circuits in the car. Refer to the Power Distribution section to get a more detailed picture of how power is supplied to the circuit you're working on. From Battery to Ignition Switch, Fuses, and Relays Individual circuit schematics begin with a fuse. The first half of Power Distribution, however, shows the wiring "upstream" between the battery Locations Rear Window Regulator, Glass And Glass Run Page 3710 The wire insulation has one color or one color with another color stripe. The second color is the stripe. Page 301 Wire Color Abbreviations The following abbreviations are used to identify wire colors in the circuit schematics: WHT................................... White YEL................................... Yellow BLK................................... Black BLU................................... Blue GRN................................... Green RED................................... Red ORN................................... Orange PNK................................... Pink BRN................................... Brown GRY................................... Gray PUR................................... Purple LT BLU................................... Light Blue LT GRN................................... Light Green Page 5718 RH and Legend For Both REMOVAL 1. Disconnect the battery ground cable. 2. Disconnect the connector (1) from the harness and remove the connector (1) from the bracket. 3. Remove the clip. 4. Remove the rear shock absorber. 5. Disconnect the connector (10) from the harness and remove the connector (10) from the gusset. 6. Remove the nut and washer. 7. Disconnect the G-sensor. INSPECTION AND REPAIR Make necessary correction or parts replacement if wear, damage, corrosion or any other abnormal condition are found through inspection. Check the following parts: Shock absorber - Rubber bushing INSTALLATION 1. Set the G-sensor on the gusset. 2. Install the washer and nut, then tighten it to the specified torque. Torque: 41 Nm (30 ft. lbs.) Page 4279 Wire Color Abbreviations The following abbreviations are used to identify wire colors in the circuit schematics: WHT................................... White YEL................................... Yellow BLK................................... Black BLU................................... Blue GRN................................... Green RED................................... Red ORN................................... Orange PNK................................... Pink BRN................................... Brown GRY................................... Gray PUR................................... Purple LT BLU................................... Light Blue LT GRN................................... Light Green Safety Stop Switch Sunroof/Moonroof Limit Switch: Service and Repair Safety Stop Switch Removal 1. Disconnect the battery ground cable. 2. Remove the sunroof drive unit assembly (1) to remove the safety stop switch (2). Installation To install, follow the removal steps in the reverse order Page 4862 Wires Wire insulation can be one color, or one color with another color stripe. (The second color is the stripe.) This circuit continues on another image. (The arrow shows direction of current flow.) To follow the RED/BLK wire in this example, you would turn to "Fuel and Emissions" and look for the "A" arrow. Page 6920 License Plate Frame: Service and Repair License Plate Garnish License Plate Garnish Removal 1. Disconnect the battery ground cable. 2. Remove the license plate light. - Remove the left and right license plate light fixing screws. Disconnect the harness connectors. 3. Remove the tailgate trim cover assembly (3). - Remove the two screws (2) holding the hatchgate lock assembly (1) first and the two screws fixing the trim cover assembly. Pull up the trim cover while detaching the clips from tailgate panel. Page 874 10. Move the front wheels to the straight ahead position, then use steering wheel remover J-29752 to remove the steering wheel CAUTION: Never apply force to the steering wheel in direction of the shaft by using a hammer or other impact tools in an attempt to remove the steering wheel. The steering shaft is designed as an energy absorbing unit. WARNING: THE INFLATOR MODULE SHOULD ALWAYS BE CARRIED WITH THE URETHANE COVER AWAY FROM YOUR BODY AND SHOULD ALWAYS BE LAID ON A FLAT SURFACE WITH THE URETHANE SIDE UP. THIS IS NECESSARY BECAUSE A FREE SPACE IS PROVIDED TO ALLOW THE AIR CUSHION TO EXPAND IN THE UNLIKELY EVENT OF ACCIDENTAL DEPLOYMENT. OTHERWISE. PERSONAL INJURY MAY RESULT. 11. .Remove steering column cover. 12. Disconnect the wiring harness connectors located under the steering column. 13. Remove the combination switch assembly with SRS coil. NOTE: The SRS coil is a part of the combination switch assembly, which can not be replaced separately. Therefore, be sure not to remove the SRS coil from the combination switch assembly. 14. Remove snap ring. 15. Remove cushion rubber. 16. Remove shift lock cable (for A/T). 17. Disconnect the starter switch harness connector located under the steering column, then remove lock cylinder assembly. Page 3015 This sample Ground Distribution schematic shows all of the components that share two ground points. Components A solid border line means the entire component is shown. A broken border line indicates that only part of the component is shown. Description and Operation Brake Pedal Assy: Description and Operation Brake Pedal Travel Vehicles equipped with the Anti-lock Brake System may be stopped by applying normal force to the brakes pedal. Although there is no need to push the pedal beyond the point where it stops or holds the vehicle, by applying more force the pedal will continue to travel toward the floor. This extra brake pedal travel is normal. Page 6608 NOTE: Once you submit your order, you can track it using the Warranty Audio VIN Inquiry screen on the iN. For details, go to WARRANTY AUDIO ORDER PROGRAM FREQUENTLY ASKED QUESTIONS in this service bulletin. 7. You will receive a remanufactured audio/navigation/RES unit packed in a reusable shipping box. Save this box and the packing materials. You must return the failed audio/navigation/RES unit core in this box. Otherwise your dealership risks being billed a core loss charge, ranging from $800 to $2,500, depending on the unit. 8. Remove the failed audio/navigation/RES unit: ^ Refer to the appropriate component section of the service manual or, ^ Online, enter a keyword: AUDIO, NAVIGATION, or RES. Select the appropriate removal procedure from the list. 9. Install the remanufactured audio/navigation/RES unit: ^ Refer to the appropriate component section of the service manual or ^ Online, enter a keyword: AUDIO, NAVIGATION, or RES. Select the appropriate installation procedure from the list. 10. If the remanufactured unit has a shipping cover and shipping screws, make sure you transfer them to the faulty unit being returned. Also be sure to transfer all of the mounting brackets to the replacement unit. Failure to do this may result in dash squeaks and rattles. NOTE: If the customer's media (CD, CD magazine, DVD, DVD-A, cassette tape, etc.) is stuck in the unit, leave it there for these reasons: ^ The manufacturer needs it for diagnosis and testing. ^ Any failed audio/navigation/RES unit core that is returned disassembled is considered an unusable core. Customer media (CDs, CD magazines, DVDs, DVD-As, cassette tapes, etc.) will be properly removed by the supplier at the point of tear down and inspection of the failed unit, and mailed to your dealer. Make sure the failed audio/navigation/RES unit core is not disassembled! If the core is disassembled, your dealership will be debited a core loss charge ranging from $800 to $2,500, depending on the unit. 11. Put the failed audio/navigation/RES unit core in the same box that the remanufactured unit came in. NOTE: If you do not return the failed audio/navigation/RES unit core in this same box, your warranty claim will be debited and the core will be sent back to your dealership. Parts Manager: 12. The Warranty Audio/Navigation/RES Unit Order form you submitted is kept on the iN for 60 days. Print out a copy to put in the box with your core return: ^ From the iN main menu, click on SERVICE. ^ Click on Transactions. ^ Click on Advanced Search, and enter a date range. ^ Click on Filtered by Service. ^ Under Transaction Description, click on Warranty Audio Order, then go back to the top of the page and click on Search. ^ Scroll down to the appropriate VIN, then select it to view the form. ^ Review the form, then print out a copy by clicking on the printer icon. 13. Print out a copy of the Core Return Update Acknowledgement to put in the box with your core return: ^ From the iN main menu, click on PARTS. Page 7489 This means the branch of the wire connects to another circuit. The arrow points to the name of the circuit branch where the wire continues. Page 31 Electronic Brake Control Module: Service Precautions CONTROL MODULE PRECAUTIONS The Anti-lock Brake System interfaces directly with the Electronic Hydraulic Control Unit (EHCU) which is a control computer that is similar in some regards to the Powertrain Control Module. These modules are designed to withstand normal current draws associated with vehicle operation. However, care must be taken to avoid overloading any of the EHCU circuits. In testing for opens or shorts, do not ground or apply voltage to any of the circuits unless instructed to do so by the appropriate diagnostic procedure. These circuits should only be tested with a high impedance multimeter (J-39200) or special tools. Power should never be removed or applied to any control module with the ignition in the "ON" position. Before removing or connecting battery cables, fuses or connectors, always turn the ignition switch to the "OFF" position. Page 7087 Each schematic represents one circuit. A circuit's wires and components are arranged to show current flow, from power at the top of the page, to ground, at the bottom. Shared Circuits Other circuits may share power or ground terminals or wiring with the circuit shown. A wire that connects one circuit to another, for example, is cut short and has an arrowhead at the end of it pointing in the direction of current flow. Next to the arrowhead is the name of the circuit or component which shares that wiring. To quickly check shared wiring, check the operation of a component it serves. If that component works, you know the shared wiring is OK. Connectors All in-line and junction connectors are numbered (C725, C416, etc.). Component connectors are not numbered but are identified either by the name of Page 7728 Transmission Shift Position Indicator Lamp: Description and Operation A/T Gear Position Indicator How the Circuit Works With the ignition switch in ON or START battery voltage is applied to the transmission range switch through fuse 14. The transmission range switch sends a signal to the PCM which communicates this information to the multiplex control unit which in turn controls the A/T gear position indicator corresponding to the gear selected. The multiplex control unit applies voltage to the appropriate A/T gear position indicator light in the gauge assembly, causing it to come on. Page 3737 Splices Splices are shown as a dot. Their location and the number of wires may vary depending on the harness manufacturer. Switches Switches These switches move together; the broken straight line between them means they are mechanically connected. Other types of switches are controlled by a coil or a solid state circuit. Unless otherwise noted, all switches are shown in their normal (rest) position, with power off. Terminal "T" Page 2730 2. Unfasten C123 from the side of the engine compartment using a 90-degree pick. 3. Disconnect C123, and clean the terminals on both sides of the connector with contact cleaner. Shake the residue out of the connector. Allow the contact cleaner to evaporate for at least 3 minutes, then reconnect C123. 4. Fasten C123 to the left side of the engine compartment, and reinstall the air cleaner housing cover. 5. Remove the connector position assurance (CPA) clip from the APPS connector. 6. Disconnect the lop connector from the APPS. 7. Clean the terminals of the 10P APPS connector (harness side) with contact cleaner. Shake out residue from the connector, and allow the contact cleaner to evaporate for at least 3 minutes, then reconnect it. 8. Use the Smart Cable to reprogram the PCM with the latest software from the June 2001 or later HONDANET CD-ROM. Refer to Service Bulletin 99-005, Updating the Passport PCM, filed under Tools. 9. Use the PGM Tester to clear any DTCs. Page 5275 V6 Engine Room Page 7682 Key Reminder Switch: Electrical Diagrams Seat Belt, Lights-ON and Ignition Key Reminders Part 1 Of 2 Page 3641 Spark Plug: Service and Repair Inspection and Repair Inspection and Repair The spark plug affects entire engine performance and therefore its inspection is very important. - Check electrode and insulator for presence of cracks, and replace if any. - Check electrode for wear, and replace if necessary.. - Check gasket for damage, and replace if necessary. - Measure insulation resistance with an ohmmeter, and replace if faulty. - Adjust spark plug gap to 1.0 mm (0.040 in) to 1.1 mm (0.043 in). - Check fuel and electrical systems if spark plug is extremely dirty. - Use spark plugs having low heat value (hot type plug) if fuel and electrical systems are normal. - Use spark plugs having high heat value (cold type plug) if insulator and electrode are extremely burned. Sooty Spark Plugs Much deposit of carbon or oil on the electrode and insulator of spark plug reduces the engine performance. Possible causes: - Too rich mixture - Presence of oil in combustion chamber - Incorrectly adjusted spark plug gap Burning Electrodes This fault is characterized by scorched or heavily oxidized electrode or blistered insulator nose. Possible causes: - Too lean mixture - Improper heat value Measuring Insulation Resistance - Measure insulation resistance using a 500 volt megaohm meter. - Replace spark plugs if measured value is out of standard. Insulation resistance: 50 Mohm or more. Page 8203 14. Remove the glass. - First, align the height of regulator to the access hole. Remove 2 screws attaching bottom channel and regulator, then remove the glass. - Remove the window glass by tilting it as necessary. 15. Remove the window regulator. - Remove the window regulator fixing bolts and pull the regulator out from the lower hole of the door panel. 16. Remove the glass run. - Pull the glass run out from the door frame. Installation Page 2238 2. Connect one lead of a self-powered test light or DVOM to one end of the part of the circuit you want to test. 3. Connect the other lead to the other end. 4. If the self-powered test light glows, there is continuity. If you're using a DVOM, a low reading or no reading (zero), means good continuity. Testing For Voltage When testing for voltage at a connector without wire seals, you do not have to separate the two halves of the connector. Instead, probe the connector from the back. Always check both sides of the connector because dirty, corroded, and bent terminals can cause problems (no electrical contact = an open). 1. Connect one lead of the lest light to a known good ground, or, if you're using a digital volt ohmmeter (DVOM), place it in the appropriate DC volts range, and connect its negative lead to ground. 2. Connect the other lead of the test light or DVOM to the point you want to check. 3. If the test light glows, there is voltage present. If you're using a DVOM, note the voltage reading. It should be within one volt of measured battery voltage. A loss of more than one volt indicates a problem. NOTE: Always use a DVOM on high impedance circuits. A test light may not glow (even with battery voltage present). Testing For Voltage Drop Wires, connectors, and switches are designed to conduct current with a minimum loss of voltage. A voltage drop of more than one volt indicates a problem. 1. Place the digital volt/ohmmeter (DVOM) in the appropriate DC volts range. Connect the positive lead to the end of the wire (or to the connector or switch) closest to the battery. 2. Connect the negative lead to the other end of the wire (or the other side of the connector or switch). 3. Turn on the components in the circuit. 4. The DVOM will show the difference in voltage between the two points. A difference, or drop, of more than one volt indicates a problem. Check the circuit for loose, dirty, or bent terminals. Page 394 INSTALLATION 1. Install speed sensor (3). 2. Tighten the sensor fixing bolt (2) to the specified torque. Torque: 11 Nm (95 inch lbs.) 3. Connect harness connector (1). Page 1124 - Set the camshaft marked "RE" and "LE into the exhaust side of the cylinder bank, with "RE" at the 12 o'clock position. Make sure the single timing dot on the camshaft gear aligns with the timing dot on the camshaft drive gear. 5. Install the left cylinder bank intake and exhaust camshafts: - Set the camshaft marked "LI" into the intake side of the head. Make sure the dual timing dots on the camshaft gear align with the timing dot on the camshaft drive gear. - Set the camshaft marked "LE" and "RE," into the exhaust side of the cylinder bank, with "LE" at the 12 o'clock position. Make sure the dual timing dots on the camshaft gear align with the timing dot on the camshaft drive gear. 6. Install the camshaft bearing caps in the same locations and directions they were before you removed them. NOTE: On the right cylinder bank, the directional arrows on the bearing caps should point towards the front of the engine. On the left bank, the arrows should point towards the rear of the engine. 7. Install the bearing cap bolts, then torque them to 10 N.m (7 lb-ft) in the sequence shown below. Page 5290 Distinct Of Circuit By Wire Base Color All wires have color-coded insulation. Wires belonging to a system's main harness will have a single color. Wires belonging to a system's sub-circuits will have a colored stripe. Striped wires use the codes found in the chart to show wire size and colors. Abbreviations are used to indicate wire color within a circuit diagram. How to Identify Connector Terminals How to Identify Connector Terminals Cavity Numbering System The cavities (and wire terminals) in each connector are numbered starting from the upper left, looking at the male terminals from the terminal side (or looking at the female terminals from the wire side. Both views are in the same direction so the numbers are the same.) All actual cavities are numbered, even if they have no wire terminals in them. NOTE: Data Link Connector (DLC) terminals are numbered according to SAE standard J1962, not the Honda standard. The numbers of the four end terminals are molded into the corners of the connector face. The connector cavity number is listed next to each terminal on the circuit schematic. The cavity / terminal shown is # 6. Using/Identifying Connector Terminal Views How to Use Connector Terminal Views To see the configuration of a connector's cavities, look up its view number in the Connector Views. Each view includes the color of the connector, where Forked Exhaust Pipe Exhaust Pipe: Service and Repair Forked Exhaust Pipe Forked Exhaust Pipe Removal 1. Disconnect battery ground cable. 2. Lift up the vehicle and support with suitable safety stands. 3. Remove the forked exhaust pipe fixing bolts & nuts (1) (3) (5) and the exhaust silencer fixing nuts (4), then remove the forked exhaust pipe (2). Installation 1. Install the forked exhaust pipe (2), and tighten the fixing bolts (1) (5) and the nuts (3) (4) to the specified torque. Torque Bolts & nuts: 43 Nm (32 ft. lbs.) Nuts: 43 Nm (32 ft. lbs.) Page 4860 Splices Splices are shown as a dot. Their location and the number of wires may vary depending on the harness manufacturer. Switches Switches These switches move together; the broken straight line between them means they are mechanically connected. Other types of switches are controlled by a coil or a solid state circuit. Unless otherwise noted, all switches are shown in their normal (rest) position, with power off. Terminal "T" Page 622 Camshaft Position Sensor: Description and Operation Camshaft Position (CMP) Sensor and Signal The camshaft position (CMP) sensor sends a CMP signal to the PCM. The PCM uses this signal as a "sync pulse" to trigger the injectors in the proper sequence. The PCM uses the CMP signal to indicate the position of the #1 piston during its power stroke. This allows the PCM to calculate true sequential fuel injection (SFI) mode of operation. If the PCM detects an incorrect CMP signal while the engine is running, DTC P0341 will set. If the CMP signal is lost while the engine is running, the fuel injection system will shift to a calculated sequential fuel injection mode based on the last fuel injection pulse, and the engine will continue to run. As long as the fault is present, the engine can be restarted. It will run in the calculated sequential mode with a 1-in-6 chance of the injector sequence being correct. Refer to DTC P0341 for further information. CMP Signal The PCM uses this signal to determine the position of the number 1 piston during its power stroke, allowing the PCM to calculate true sequential multiport fuel injection (SFI). Loss of this signal will set a DTC P0341. If the CMP signal is lost while the engine is running, the fuel injection system will shift to a calculated sequential fuel injection based on the last fuel injection pulse, and the engine will continue to run. The engine can be restarted and will run in the calculated sequential mode as long as the fault is present, with a 1-in-6 chance of being correct. Page 5186 Magnetic Switch Check for continuity of shunt coil between terminals S and M. Replace, if there is no continuity (i.e., coil is disconnected). Continuity of Series Coil Check for continuity between terminals S and M. Replace, if there is no continuity (i.e., coil is disconnected). Page 6375 The name of the component appears next to it followed by notes about its function along with any photo and connector view references. Connector "C" How to Identify Connector Terminals Cavity Numbering System The cavities (and wire terminals) in each connector are numbered starting from the upper left, looking at the male terminals from the terminal side (or looking at the female terminals from the wire side. Both views are in the same direction so the numbers are the same.) All actual cavities are numbered, even if they have no wire terminals in them. NOTE: Data Link Connector (DLC) terminals are numbered according to SAE standard J1962, not the Honda standard. The numbers of the four end terminals are molded into the corners of the connector face. Page 4971 Brake Hose/Line: Testing and Inspection Brake Hose Inspection The brake hose should be inspected at least twice a year. The brake hose assembly should be checked for road hazard, cracks and chafing of the outer cover, and for leaks and blisters. Inspect for proper routing and mounting of the hose. A brake hose that rubs on suspension components will wear and eventually fail. A light and mirror may be needed for an adequate inspection. If any of the above conditions are observed on the brake hose, adjust or replace the hose as necessary. CAUTION: Never allow brake components such as calipers to hang from the brake hoses, as damage to the hoses may occur. Page 6091 Page 7447 Testing For A Short With A Self-Powered Test Light or DVOM 1. Remove the blown fuse and disconnect the battery and load. 2. Connect one lead of a self-powered test light or digital volt/ohmmeter (DVOM) (switched to the lowest "OHMS" range) to the fuse terminal on the load side. 3. Connect the other lead to a known good ground. 4. Beginning near the fuse box, wiggle the harness. Continue this at convenient points about six inches apart while watching the test light or DVOM. 5. If the self-powered test light goes on or the DVOM displays a low reading or no reading (zero), there is a short to ground in the wiring near that point. Testing for a Short with a Test Light or DVOM 1. Remove the blown fuse and disconnect the load. 2. Connect a test light or digital volt/ohmmeter (DVOM), switched to the appropriate DC volts range, across the fuse terminals to make sure voltage is present. You might have to turn the ignition switch to ON; check the schematic to see. 3. Beginning near the fuse box, wiggle the harness. Continue this at convenient points about six inches apart while watching the test light or DVOM. 4. Where the test light goes , or the DVOM voltage drops to zero, there is a short to ground in the wiring near that point. NOTE: Always use a DVOM on high impedance circuits. A test light may not glow (even with battery voltage present). Testing For A Short With A Short Circuit Locator (Short Finder) 1. Remove the blown fuse. Leave the battery connected. Diagram Information and Instructions Fuel Pump Relay: Diagram Information and Instructions How to Identify Wiring Color-Coded Insulation Wire Color Wire Color Coding Page 5432 During the test-drive, attach the bracket and the weights to the steering wheel on the side opposite the pulling direction. For example, if the vehicle pulls to the right, attach the bracket and weights to the left side of the steering wheel. Start with the maximum amount of weight on the steering wheel, and remove the weights until the vehicle drives in a straight line. When recording the pull on the worksheet, write down the direction of the pull (lefi or right) and the number of weights required to balance the pull (one through six). For example, if you have the bracket and two weights on the steering wheel, then record this as three weights. NOTE: The bracket counts as one weight. The road crown gauge measures the amount of road crown. Almost all roads have a crown to help drain water during rainstorms. Use the suction cup to attach the road crown gauge bracket to the vehicle in a vertical position. If necessary, bend the bracket until the gauge is vertical. Once you attach and align the road crown gauge, calibrate the gauge to zero. There are two ways to calibrate the gauge: ^ Park the vehicle on a level surface, such as an alignment rack, and calibrate the gauge by moving the gauge until the ball is on the zero mark. ^ If you do not have a perfectly flat surface, park the vehicle on a reasonably flat surface and note the gauge reading. Turn the vehicle 1800 and, with the tires in the same spot, note the new gauge reading. Then move the gauge half of the difference. For example, if your first reading is +3 and, after moving the vehicle, the gauge reads -1, then the difference is 4 degrees. Position the gauge to read +1. Page 8169 Rear Quarter Glass (resin Top) Page 4797 Hydraulic Control Assembly - Antilock Brakes: Service and Repair Disassembly and Reassembly HYDRAULIC CONTROL UNIT DISASSEMBLY 1. Remove fixing bolts from EHCU. 2. Remove coil integrated module from hydraulic unit. REASSEMBLY To reassembly, follow the disassembly steps in the reverse order, noting the following points: Torque: Fixing bolts: 4.4 Nm (39 inch lbs.) Service and Repair Shift Indicator: Service and Repair Removal 1. Disconnect the battery ground cable. 3. Remove the meter lens (3) from the meter visor (4). 4. Remove the meter visor from the meter case(5). Page 1027 6. Test-drive the vehicle to make sure it no longer pulls. If the steering wheel is now off-center by more than 2 mm, go to REPAIR PROCEDURE C. 7. Use your diagnosis worksheet to fill in the following table and build your 15-digit DTC. NOTE: Enter each reading in decimal degrees. Example 30' = 0.50. REPAIR PROCEDURE C 1. Make sure the steering wheel is centered. ^ Turn the steering wheel all the way to the right until it stops. ^ Turn the steering wheel all the way to the left, and count the number of revolutions until it stops. ^ Divide the number of revolutions in half, and turn the steering wheel until it is centered. For example, if it takes four revolutions of the steering wheel to go from lock to lock, then two turns is centered. ^ If the steering wheel is off-center by a large amount (20 mm or more), it may not be centered on the steering column shaft. Reinstall the steering wheel before going to step 2. 2. Place the vehicle on a lift, turn the steering wheel until it is centered, and then raise the vehicle. 3. Adjust the tie-rods. Use your measurements from question 13 of the test-drive to make your adjustment. Page 7723 Testing For A Short With A Self-Powered Test Light or DVOM 1. Remove the blown fuse and disconnect the battery and load. 2. Connect one lead of a self-powered test light or digital volt/ohmmeter (DVOM) (switched to the lowest "OHMS" range) to the fuse terminal on the load side. 3. Connect the other lead to a known good ground. 4. Beginning near the fuse box, wiggle the harness. Continue this at convenient points about six inches apart while watching the test light or DVOM. 5. If the self-powered test light goes on or the DVOM displays a low reading or no reading (zero), there is a short to ground in the wiring near that point. Testing for a Short with a Test Light or DVOM 1. Remove the blown fuse and disconnect the load. 2. Connect a test light or digital volt/ohmmeter (DVOM), switched to the appropriate DC volts range, across the fuse terminals to make sure voltage is present. You might have to turn the ignition switch to ON; check the schematic to see. 3. Beginning near the fuse box, wiggle the harness. Continue this at convenient points about six inches apart while watching the test light or DVOM. 4. Where the test light goes , or the DVOM voltage drops to zero, there is a short to ground in the wiring near that point. NOTE: Always use a DVOM on high impedance circuits. A test light may not glow (even with battery voltage present). Testing For A Short With A Short Circuit Locator (Short Finder) 1. Remove the blown fuse. Leave the battery connected. Page 5658 6. Install the caster shims (2) between the chassis frame and fulcrum pin. 7. Install the camber shims (1) between the chassis frame and fulcrum pin. 8. Install nut assembly. 9. Install bolt and plate, then tighten the bolt to the specified torque. Torque to 152 Nm (112 ft. lbs.). 10. Install upper ball joint and tighten it to the specified torque. Torque to 57 Nm (42 ft. lbs.). 11. Install nut and cotter pin then tighten the nut to the specified torque, with just enough additional torque to align cotter pin holes. Install new cotter pin. Torque to 98 Nm (72 ft. lbs.). 12. Install speed sensor cable. Testing and Inspection Air Filter Element: Testing and Inspection Air Cleaner Element Check the air cleaner filter for damage or dust clogging. Replace if it is damaged, or clean if it is clogged. Page 4692 The wire insulation has one color or one color with another color stripe. The second color is the stripe. Specifications Differential Fluid - Transfer Case: Specifications Transfer FLUID Transfer (4WD) .................................................................................................................................... ............................................................ SAE 5W-30 Shift on the fly system ......................................................................................................................... ..................................................... GL-5 Gear Lube* *Use the axle chart above for Shift On The Fly System oil weight Page 5233 L4 Engine Room Page 3308 Fuel Pump Relay: Description and Operation In order to control the FPAS operation, the FPAS relay is provided. When the starter switch is turned to "ON" position, the FPAS relay operates the FPAS for 2 seconds. When it is turned to "START" position, the Engine Control Module receives the reference pulse from the Ignition Control Module and it operates the relay, again causing the FPAS to feed fuel. Locations Crankshaft Position Sensor: Locations CKP Sensor 36. Bottom Right Side of Engine Bottom Right Side of Engine Page 7962 Part 2 Of 2 Service and Repair Common Chamber: Service and Repair Common Chamber Removal 1. Disconnect battery ground cable. 2. Remove air cleaner duct assembly. 3. Disconnect accelerator pedal cable from throttle body and cable bracket. 4. Disconnect vacuum booster hose from common chamber. 5. Disconnect connector from manifold absolute pressure sensor, idle air control valve, throttle position sensor, solenoid valve, electric vacuum sensing valve, and EGR valve. 6. Disconnect vacuum hose on canister VSV and positive crankcase ventilation hose, fuel rail assembly with pressure control valve bracket. 7. Remove ventilation hose from throttle valve and intake duct and remove water hose. 8. Remove the four throttle body fixing bolts. 9. Remove exhaust gas recirculation valve assembly fixing bolt and nut on common chamber and remove EGR valve assembly. 10. Remove two bolts from common chamber rear side for remove fuel hose bracket. Page 2671 Each schematic represents one circuit. A circuit's wires and components are arranged to show current flow, from power at the top of the page, to ground, at the bottom. Shared Circuits Other circuits may share power or ground terminals or wiring with the circuit shown. A wire that connects one circuit to another, for example, is cut short and has an arrowhead at the end of it pointing in the direction of current flow. Next to the arrowhead is the name of the circuit or component which shares that wiring. To quickly check shared wiring, check the operation of a component it serves. If that component works, you know the shared wiring is OK. Connectors All in-line and junction connectors are numbered (C725, C416, etc.). Component connectors are not numbered but are identified either by the name of Page 5293 Each schematic represents one circuit. A circuit's wires and components are arranged to show current flow, from power at the top of the page, to ground, at the bottom. Shared Circuits Other circuits may share power or ground terminals or wiring with the circuit shown. A wire that connects one circuit to another, for example, is cut short and has an arrowhead at the end of it pointing in the direction of current flow. Next to the arrowhead is the name of the circuit or component which shares that wiring. To quickly check shared wiring, check the operation of a component it serves. If that component works, you know the shared wiring is OK. Connectors All in-line and junction connectors are numbered (C725, C416, etc.). Component connectors are not numbered but are identified either by the name of Service and Repair Sunroof / Moonroof Switch: Service and Repair Removal 1. Disconnect the battery ground cable. 2. Remove the sunroof switch (1). - Remove the switch by pushing the spring with the tip of a screwdriver. - Disconnect the switch connector. Installation To install, follow the removal steps in the reverse order. Page 2906 96. Rear of Right Catalytic Converter Rear of right catalytic converter 94. Rear of Left Catalytic Converter Rear of Left Catalytic Converter Page 3961 3. Start the engine, and let it warm up to normal operating temperature. 4. Move the selector lever through all shift positions, then apply the brakes, and move the lever to Park. 5. Check the drain plug and fill plug for signs of leakage. ^ If you see signs of leakage, turn off the engine. Remove and discard both plugs and gaskets. Let the oil pan drain completely, then install the new drain plug. Torque the drain plug to 38 N.m (28 lb-ft). Add DEXRON III ATF until it runs out the fill hole. Install the new fill plug hand tight. Go to step 6. ^ If you do not see signs of leakage, look for other possible causes of the leak. 6. Connect the PGM Tester to the 16P data link connector to measure ATF temperature. Start the engine. 7. Remove the fill plug, and add ATF until it runs out the fill hole. Reinstall the fill plug. 8. Move the selector lever through all shift positions, then apply the brakes, and move the lever to Park. 9. Remove the fill plug. 10. Let the engine idle until the ATF temperature is between 90° and 135° F (32° and 57° C). As the temperature increases, ATF drips out the fill hole until the correct fluid level is reached. 11. Reinstall the fill plug. Torque the fill plug to 38 N.m (28 lb-ft). 12. Turn off the engine, and disconnect the PGM Tester. Lower the vehicle. DISCLAIMER Page 1709 spring compressor and J42898 valve spring compressor adapter to install the split collars. 6. Install tappet with shim. 7. Install camshaft assembly. - Refer to installation procedure for Camshaft. Valve Clearance Adjustments Note: To adjust valve clearance, apply engine oil to the cam as well as to the adjusting shim (2) with the cylinder head built on the cylinder block, give a few turns to the camshaft by means of timing pulley tightening bolt, and measure valve clearance when the nose of cam is just opposite to maximum cam lift (1) as shown in illustration. Valve Clearance Standard Value (cold) Intake: 0.23 mm - 0.33 mm (0.0091 inch - 0.01 30 inch) Exhaust: 0.25 mm-0.35 mm (0.0098 in-0.0138 inch) Selection of Adjusting Shim Shim to be selected = (Thickness of removed shim) + (Valve clearance measurement - Standard value) Based on the above formula, the best suited shim should be selected from 41 sorts of shim (differently thick at 0.02 mm (0.0008 inch) intervals from 2.40 mm (0.0945 inch) through 3.2 mm (0.1260 inch) thick). Install the shim and check valve clearance. Replacement of Shim Page 6266 Refrigerant Pressure Sensor / Switch: Testing and Inspection Triple Pressure Switch 1. Disconnect the connector and check for continuity between pressure switch side connector terminals (1) and (2). 2. Reconnect the connector to activate the A/C switch and check to see if there is continuity between the chassis side connector terminals (3) and (4) and the fan operates. Page 8177 Quarter Window Glass: Service and Repair Rear Quarter Glass (Resin Top) Rear Quarter Glass (Resin Top) Rear Quarter Glass (Resin Top) Removal 1. Disconnect the battery ground cable. 2. Remove the rear quarter glass assembly. Installation 1. Use alcohol or the like to wipe clean the areas of the resin top and glass assembly that are to be affixed to each other. 2. Apply the primer (2) to the area of the resin top to which the glass is to be affixed. Service Precautions Fuel: Service Precautions CAUTION: Your vehicle must use unleaded fuel only. Using leaded fuel will damage the catalytic converter and affect the warranty coverage validity. Page 7626 Distinct Of Circuit By Wire Base Color All wires have color-coded insulation. Wires belonging to a system's main harness will have a single color. Wires belonging to a system's sub-circuits will have a colored stripe. Striped wires use the codes found in the chart to show wire size and colors. Abbreviations are used to indicate wire color within a circuit diagram. How to Identify Connector Terminals How to Identify Connector Terminals Cavity Numbering System The cavities (and wire terminals) in each connector are numbered starting from the upper left, looking at the male terminals from the terminal side (or looking at the female terminals from the wire side. Both views are in the same direction so the numbers are the same.) All actual cavities are numbered, even if they have no wire terminals in them. NOTE: Data Link Connector (DLC) terminals are numbered according to SAE standard J1962, not the Honda standard. The numbers of the four end terminals are molded into the corners of the connector face. The connector cavity number is listed next to each terminal on the circuit schematic. The cavity / terminal shown is # 6. Using/Identifying Connector Terminal Views How to Use Connector Terminal Views To see the configuration of a connector's cavities, look up its view number in the Connector Views. Each view includes the color of the connector, where Page 5208 Splices Splices are shown as a dot. Their location and the number of wires may vary depending on the harness manufacturer. Switches Switches These switches move together; the broken straight line between them means they are mechanically connected. Other types of switches are controlled by a coil or a solid state circuit. Unless otherwise noted, all switches are shown in their normal (rest) position, with power off. Terminal "T" Page 3358 If there is no photo number below or beside a component name or a connector, ground, or terminal number, look up that name or number in the appropriate Connector Identification Chart. The chart lists how many cavities a connector has, where it's located, and what it connects to. The related illustration shows the connector's location on the harness, and the harness routing. NOTE: Photos listed by number are located at Locations / Components / Photograohs. See: Locations/Component Locations/Photographs Circuit Schematics General Precautions Air Bag(s) Arming and Disarming: Service Precautions General Precautions General Precautions Please read the following precautions carefully before performing the airbag system service. Observe the instructions described or the airbags could accidentally deploy and cause damage or injuries. Except when performing electrical inspections, always turn the ignition switch OFF and disconnect the negative cable from the battery, and wait at least three minutes before beginning work. NOTE: The contents in the memory is not erased even if the ignition switch is turned OFF or the battery cables are disconnected from the battery. Use the replacement parts which are manufactured to the same standards as the original parts and quality. Do not install used SRS parts from another vehicle. Use only new parts when making SRS repairs. Carefully inspect any SRS part before you install it. Do not install any part that shows signs of being dropped or improperly handled, such as dents, cracks or deformation. Before removing any of the SRS parts (including the disconnection of the connectors), always disconnect the SRS connector. Use only a digital multimeter to check the system. If it is not a Honda multimeter, make sure its output is 10 mA (0.01 A) or less when switched to the lowest value in the ohmmeter range. A tester with a higher output could cause accidental deployment and possible injury. Do not put objects on the front passenger's airbag. The original radio has a coded theft protection circuit. Be sure to get the customer's radio code before disconnecting the battery cable. Page 4854 the component if the component only has one connector, or by a capital letter (A, B, C, etc.) if the component has more than one connector. Below most connector numbers and component names are PHOTO and VIEW numbers. The PHOTO number refers to a photo in the back of the book that shows the connector's location on the car. The VIEW number refers to an illustration in the back of the book that shows the connector face, wire colors, connector cavity numbers, and other details. The connector cavity numbering sequence begins at the top left corner of the connector. Disregard any numbers molded into the connector housing. Wires Wires are identified by the abbreviated names of their colors; the second color is the color of the stripe. Wires are also identified by their location in a connector. The number "2" next to the male and female wire terminals at C416, for example, means those terminals join in cavity 2 of connector C416. Symbols A complete description of schematic symbols is given under wire color abbreviation. Power Distribution Schematics Power Distribution schematics show how power is supplied from the positive battery terminal to various circuits in the car. Refer to the Power Distribution section to get a more detailed picture of how power is supplied to the circuit you're working on. From Battery to Ignition Switch, Fuses, and Relays Individual circuit schematics begin with a fuse. The first half of Power Distribution, however, shows the wiring "upstream" between the battery Page 1863 Page 8017 Ground - "G" Shielding Sheilding This represents RFI (Radio Frequency Interference) shielding around a wire. The shielding is always connected to ground. Splices Page 5567 Air Bag(s) Arming and Disarming: Service and Repair Connector Disconnection / Connection REMOVAL To remove the connector, hold the cover insulator(l) and pull it. The cover insulator slides and lock will be released. Do not hold the socket insulator(2). INSTALLATION Page 2632 Testing For A Short With A Self-Powered Test Light or DVOM 1. Remove the blown fuse and disconnect the battery and load. 2. Connect one lead of a self-powered test light or digital volt/ohmmeter (DVOM) (switched to the lowest "OHMS" range) to the fuse terminal on the load side. 3. Connect the other lead to a known good ground. 4. Beginning near the fuse box, wiggle the harness. Continue this at convenient points about six inches apart while watching the test light or DVOM. 5. If the self-powered test light goes on or the DVOM displays a low reading or no reading (zero), there is a short to ground in the wiring near that point. Testing for a Short with a Test Light or DVOM 1. Remove the blown fuse and disconnect the load. 2. Connect a test light or digital volt/ohmmeter (DVOM), switched to the appropriate DC volts range, across the fuse terminals to make sure voltage is present. You might have to turn the ignition switch to ON; check the schematic to see. 3. Beginning near the fuse box, wiggle the harness. Continue this at convenient points about six inches apart while watching the test light or DVOM. 4. Where the test light goes , or the DVOM voltage drops to zero, there is a short to ground in the wiring near that point. NOTE: Always use a DVOM on high impedance circuits. A test light may not glow (even with battery voltage present). Testing For A Short With A Short Circuit Locator (Short Finder) 1. Remove the blown fuse. Leave the battery connected. Locations Page 504 2. Connect the short finder across the battery terminals and the load (component) side of the fuse terminal. 3. Close all switches in the circuit you're testing. 4. Turn on the short finder. This creates a pulsing magnetic field around the wiring between the fuse box and the short. 5. Beginning at the fuse box, slowly move the short finder along the circuit wiring. The meter will read current pulses through sheet metal and body trim. As long as the meter is between the fuse and the short, the needle will move with each current pulse. Once you move the meter past the point of the short, the needle will stop moving. Check the wiring and connectors in this area to locate the cause of the short. Testing For Continuity When testing for continuity at a connector without wire seals, you do not have to separate the two halves of the connector. Instead, probe the connector from the back. Always check both sides of the connector because dirty, corroded, and bent terminals can cause problems (no electrical contact = an open). 1. Disconnect the negative cable from the car battery. If you're using a DVOM, place it in the lowest "OHMS" range. Page 6768 This sample Ground Distribution schematic shows all of the components that share two ground points. Components A solid border line means the entire component is shown. A broken border line indicates that only part of the component is shown. Page 4472 Distinct Of Circuit By Wire Base Color All wires have color-coded insulation. Wires belonging to a system's main harness will have a single color. Wires belonging to a system's sub-circuits will have a colored stripe. Striped wires use the codes found in the chart to show wire size and colors. Abbreviations are used to indicate wire color within a circuit diagram. How to Identify Connector Terminals How to Identify Connector Terminals Cavity Numbering System The cavities (and wire terminals) in each connector are numbered starting from the upper left, looking at the male terminals from the terminal side (or looking at the female terminals from the wire side. Both views are in the same direction so the numbers are the same.) All actual cavities are numbered, even if they have no wire terminals in them. NOTE: Data Link Connector (DLC) terminals are numbered according to SAE standard J1962, not the Honda standard. The numbers of the four end terminals are molded into the corners of the connector face. The connector cavity number is listed next to each terminal on the circuit schematic. The cavity / terminal shown is # 6. Using/Identifying Connector Terminal Views How to Use Connector Terminal Views To see the configuration of a connector's cavities, look up its view number in the Connector Views. Each view includes the color of the connector, where Locations Page 7423 Cigarette Lighter: Description and Operation Cigarette Lighter When the cigarette lighter is pushed in with the starter switch at either "ACC" or "ON" position, a circuit is formed in the cigarette lighter case to heat the lighter coil. The cigarette lighter springs back to its original position after the lighter coil is heated. Service and Repair Oil Filter: Service and Repair Oil Filter Removal 1. Disconnect battery ground cable. 2. Drain engine oil. 3. Remove oil filter using J-36390 filter wrench. Installation 1. Clean filter fitting surface and apply small amount of engine oil to sealing surface. 2. Install oil filter cartridge by hand until it comes in contact with sealing surface then rotate additional 2/3 turn to tighten using J-36390 filter wrench. 3. Fill engine oil until full level on dipstick. 4. Reconnect battery ground cable. Page 3551 it is located, and what it connects to. Use the Connector Views to help locate the proper cavity when you need to probe a connector. It can be especially helpful if the connector has more than one wire of the same color. A dash symbol (-) indicates that the cavity is empty. Connector views can also be used to help diagnose multiple symptoms in separate circuits which could be caused by a single problem in a connector shared by those circuits. Here's an example: 1. Pick one of the multiple symptoms and look up the schematic for that circuit. 2. Make a list of all the in-line and fuse box connectors in that schematic , 3. Then, in the Connector Views, look up each connector on your list to see if circuits related to the other symptoms run through one of them. If they do, inspect that connector for the problem. Example: The blower, rear window defogger, and the windshield wiper don't work. List all in-line and fuse box connectors in the blower controls circuit and then check the Connector View (see the sample). You find that C324 is common to the blower controls, rear window defogger, and wiper/washer, so you inspect C324 and find the problem, bent terminals. Finding Component/Connector Locations Finding Component/Connector Locations To see where a component or connector is located on the car, look up its photo number in the "Component Location". The photo will also tell you the color of the connector, and how many cavities it has. Locations Acceleration Sensor: Locations Below Left Side of Dash Page 311 Part 3 Of 3 Page 2969 This sample Ground Distribution schematic shows all of the components that share two ground points. Components A solid border line means the entire component is shown. A broken border line indicates that only part of the component is shown. Page 7380 This sample Ground Distribution schematic shows all of the components that share two ground points. Components A solid border line means the entire component is shown. A broken border line indicates that only part of the component is shown. Page 6751 Trailer Lighting Connector (Part 2 Of 3) Page 2234 Vehicle Speed Sensor: Diagnostic Aids Before Troubleshooting Before Troubleshooting See: Service Precautions/Vehicle Damage Warnings/Tips and Precautions 1. Check applicable fuses in the appropriate fuse/relay box. 2. Check the battery for damage, state of charge, and clean and tight connections. CAUTION: Do not quick-charge a battery unless the battery ground cable has been disconnected, otherwise you will damage the alternator diodes. - Do not attempt to crank the engine with the battery ground cable loosely connected or you will severely damage the wiring. While You're Working 1. Make sure connectors are clean, and have no loose terminals or receptacles. 2. Make sure that connectors without wire seals are packed with dielectric (silicone) grease. Part Number: 08798-9001. 3. When connecting a connector, push it until it "clicks" into place. CAUTION: Do not pull on the wires when disconnecting a connector. Pull only on the connector housings. - Most circuits include solid-state devices. Test the voltages in these circuits only with a 10-megaohm or higher impedance digital multi meter. Never use a test light or analog meter on circuits that contain solid-state devices. Damage to the devices may result. Five-Step Troubleshooting 1. Verify The Complaint Turn on all the components in the problem circuit to check the accuracy of the customer complaint. Note the symptoms. Do not begin disassembly or testing until you have narrowed down the problem area. 2. Analyze The Schematic Look up the schematic for the problem circuit. Determine how the circuit is supposed to work by tracing the current paths from the power source through the circuit components to ground. Also, trace circuits that share wiring with the problem circuit. The names of circuits that share the same fuse, ground, or switch, and so on, are referred to in each circuit schematic. Try to operate any shared circuits you didn't check in step 1. If the shared circuits work, the shared wiring is OK, and the cause must be in the wiring used only by the problem circuit. If several circuits fail at the same time, the fuse or ground is a likely cause. Based on the symptoms and your understanding of the circuit's operation, identify one or more possible causes. 3. Isolate The Problem By Testing The Circuit Make circuit tests to check the diagnosis you made in step 2. Keep in mind that a logical, simple procedure is the key to efficient troubleshooting. Test for the most likely cause of failure first. Try to make tests at points that are easily accessible. 4. Fix The Problem Once the specific problem is identified, make the repair. Be sure to use proper tools and safe procedures. 5. Make Sure The Circuit Works Turn on all components in the repaired circuit in all modes to make sure you've fixed the entire problem. If the problem was a blown fuse, be sure to test all of the circuits on that fuse. Make sure no new problems turn up and the original problem does not recur. Page 3642 Cleaning Spark Plugs - Clean spark plugs with a spark plug cleaner. - Raise the ground electrode to an position of 45 to 60 degrees. If electrode is wet, dry it before cleaning. - After spark plug is thoroughly cleaned, check insulator for presence of cracks. - Clean threads and metal body with a wire brush. - File the electrode tip if electrode is extremely worn. - Bend the ground electrode to adjust the spark plug gap. Page 4592 and the fuses. From Fuses to Relays and Components The second half of Power Distribution shows the wiring "From Fuses to Relays and Components." This can speed your troubleshooting by showing which circuits share fuses. If Power Distribution shows that an inoperative circuit and another circuit share a fuse, check a component in the other circuit. If it works, you know the fuse is good and power is available to the inoperative circuit. Ground Distribution Schematics Page 2055 Test Equipment CAUTION: Most circuits include solid-state devices. Test the voltages in these circuits only with a 10-megaohm or higher impedance digital multimeter. Never use a test light or analog meter on circuits that contain solid-state devices. Damage to the devices may result. Test Light and DVOM On circuits without solid-state devices, use a test light to check for voltage. A test light is made up of a 12 volt bulb with a pair of leads attached. After grounding one lead, touch the other lead to various points along the circuit where voltage should be present. The bulb will go on if there is voltage at the point being tested. If you need to know how much voltage is present, use a digital volt/ohmmeter (DVOM). Self-Powered Test Light and DVOM Use a self-powered test light to check for continuity. This tool is made up of a light bulb, battery, and two leads. To test it, touch the leads together: the light should go on. Use a self-powered test light only on an unpowered circuit. First, disconnect the battery, or remove the fuse that feeds the circuit you are working on. Select two points in the circuit between which you want to check continuity. Connect one lead of the self-powered test light to each point. If there is continuity, the test light's circuit will be completed, and the light will go on. If, in addition, you need to know exactly how much resistance there is between two points, use a digital volt/ohmmeter (DVOM). In the "OHMS" range, the DVOM will measure resistance between two points along a circuit. Low resistance means good continuity. Diodes and solid-state devices in a circuit can make a DVOM give a false reading. To check a reading, reverse the leads, and take a second reading. If the readings differ, the component is affecting the measurement. Jumper Wire Use a jumper wire to bypass an open circuit. A jumper wire is made up of an in-line fuse holder connected to a set of test leads. It should have a five ampere fuse. Never connect a jumper wire across a short circuit. The direct battery short will blow the fuse. Short Finder (Short Circuit Locator) Short finders are available to locate shorts to ground. The short finder creates a pulsing magnetic field in the shorted circuit which you can follow to the location of the short. To order any test equipment shown above, contact your local tool supplier. For a list of suppliers and tool numbers, refer to Honda Required Special Tools and Equipment Service Bulletin. Page 5470 2. Unfasten C123 from the side of the engine compartment using a 90-degree pick. 3. Disconnect C123, and clean the terminals on both sides of the connector with contact cleaner. Shake the residue out of the connector. Allow the contact cleaner to evaporate for at least 3 minutes, then reconnect C123. 4. Fasten C123 to the left side of the engine compartment, and reinstall the air cleaner housing cover. 5. Remove the connector position assurance (CPA) clip from the APPS connector. 6. Disconnect the lop connector from the APPS. 7. Clean the terminals of the 10P APPS connector (harness side) with contact cleaner. Shake out residue from the connector, and allow the contact cleaner to evaporate for at least 3 minutes, then reconnect it. 8. Use the Smart Cable to reprogram the PCM with the latest software from the June 2001 or later HONDANET CD-ROM. Refer to Service Bulletin 99-005, Updating the Passport PCM, filed under Tools. 9. Use the PGM Tester to clear any DTCs. Page 8113 Diagram Information and Instructions Ion Sensing Module: Diagram Information and Instructions How to Identify Wiring Color-Coded Insulation Wire Color Wire Color Coding Page 2760 2. Compare the retrieved code with the listed codes. ^ If the code is in the list, go to step 3. ^ If the code is not in the list, the PCM has already been updated. Troubleshoot other causes for the detonation. NOTE: Since the Smart Cable may need to be cleared from a previous PCM update or the Smart Cable firmware may need to be reprogrammed, always begin each PCM update at the iN workstation. 3. Update the PCM software with the Smart Cable. For instructions, refer to Service Bulletin 99-005. NOTE: Make sure you select the most recent broadcast code from the list on the iN screen that applies to the model year, transmission type, and emission level. This code is not necessarily at the top of the list since the most recent code is the last one in the alphabetical sequence, letter by letter. 4. Use the PGM Tester to clear any DTCs set during programming. 5. Retrieve the broadcast code. Make sure it does not match any of the codes in the list in step 2 (indicating the PCM has been updated) and that it applies to the model year, transmission type, and emission level for the vehicle. The broadcast code should match a code in the list below. Disclaimer Page 1795 Valve Shims (While 41 shims are available, the 10 sizes will cover most valve adjustments): Page 6368 Distinct Of Circuit By Wire Base Color All wires have color-coded insulation. Wires belonging to a system's main harness will have a single color. Wires belonging to a system's sub-circuits will have a colored stripe. Striped wires use the codes found in the chart to show wire size and colors. Abbreviations are used to indicate wire color within a circuit diagram. How to Identify Connector Terminals How to Identify Connector Terminals Cavity Numbering System The cavities (and wire terminals) in each connector are numbered starting from the upper left, looking at the male terminals from the terminal side (or looking at the female terminals from the wire side. Both views are in the same direction so the numbers are the same.) All actual cavities are numbered, even if they have no wire terminals in them. NOTE: Data Link Connector (DLC) terminals are numbered according to SAE standard J1962, not the Honda standard. The numbers of the four end terminals are molded into the corners of the connector face. The connector cavity number is listed next to each terminal on the circuit schematic. The cavity / terminal shown is # 6. Using/Identifying Connector Terminal Views How to Use Connector Terminal Views To see the configuration of a connector's cavities, look up its view number in the Connector Views. Each view includes the color of the connector, where Service and Repair Output Shaft: Service and Repair For further information regarding this component and the system that it is a part of, please refer to Manual Transmission/Transaxle; Service and Repair; Unit Overhaul Page 4220 Terminals - "T" Each "T" terminal (ring type) is numbered for reference and location. A "T" terminal is secured with a screw or bolt. Wires Page 6680 The name of the component appears next to it followed by notes about its function along with any photo and connector view references. Connector "C" How to Identify Connector Terminals Cavity Numbering System The cavities (and wire terminals) in each connector are numbered starting from the upper left, looking at the male terminals from the terminal side (or looking at the female terminals from the wire side. Both views are in the same direction so the numbers are the same.) All actual cavities are numbered, even if they have no wire terminals in them. NOTE: Data Link Connector (DLC) terminals are numbered according to SAE standard J1962, not the Honda standard. The numbers of the four end terminals are molded into the corners of the connector face. Page 1002 DIAGNOSTIC WORKSHEET REPAIR PROCEDURE A Page 7761 This means the branch of the wire connects to another circuit. The arrow points to the name of the circuit branch where the wire continues. Page 8079 Terminals - "T" Each "T" terminal (ring type) is numbered for reference and location. A "T" terminal is secured with a screw or bolt. Wires Page 3460 11. Using a jumper wire, connect the reference voltage of each circuit to its signal input and view the APP Sensor values in the Engine Data List. APP Sensor 1 should have a value of 99%, and APP Sensor 2 and APP Sensor 3 should each have a value of 0%. ^ If the values are not as specified, troubleshoot for high resistance on the signal input or a PCM malfunction. Repair the circuit or replace the PCM, then repeat step 3. ^ If the values are as specified, the problem may be intermittent. Disconnect the 10P connector from the modified APPS, and connect it to the new APPS; then repeat step 3. Wiggle the APPS wires as you go through the adjustment procedure to find the intermittent problem. 12. Turn off the ignition switch, and disconnect the PGM Tester.* DISCLAIMER Page 3063 The Number(s) below refer to the step number(s) on the Diagnostic Chart: 1. Check to see if the solenoid is open or closed. The solenoid is normally de-energized in this step, so it should be closed. 2. This step checks to determine if the solenoid was open due to an electrical circuit problem or a defective solenoid. 3. This should normally energize the solenoid, opening the valve and allowing the vacuum to drop (purge "ON"). Page 6951 1. Remove the storage cover. 2. Remove and discard the original lock knob. 3. Push the new lock knob into place, and turn the knob until the lock tabs secure it. Disclaimer Page 5661 - Lower control arm - Bushing INSTALLATION 1. Install rear bushing by using installer J-36834. 2. Install front bushing by using installer J-36833. 3. Install lower ball joint bolt. 4. Install torsion bar arm bolt. 5. Install lower control arm. 6. Install rear bolt. 7. Install front bolt. 8. Install lower ball joint and tighten it to the specified torque. Torque to 116 Nm (85 ft. lbs.). 9. Install shock absorber and tighten it to the specified torque. Torque to 93 Nm (69 ft. lbs.). 10. Install stabilizer link and tighten it to the specified torque. Torque to 50 Nm (37 ft. lbs.). 11. Install torsion bar arm bracket and tighten it to the specified torque. Torque to 116 Nm (85 ft. lbs.). 12. Install Torsion bar. 13. Install rear nut and tighten lower link nut finger-tight. NOTE: Torque lower control arm nut after adjusting buffer clearance. Buffer clearance: 22 mm (0.87 inch). Torque to 235 Nm (174 ft. lbs.). 14. Install front nut then tighten lower link nut finger-tight. Air Bag Disarming and Arming Air Bag(s) Arming and Disarming: Service and Repair Air Bag Disarming and Arming Disabling The SRS Removal Turn the ignition switch to "lock" and remove key. 1. Remove SRS fuse "METER" and "SRS", from left dash side lower fuse block or disconnect battery. 2. Disconnect yellow 2 - pin connector at the base of steering column. 3. Remove glove box assembly, Refer to "Passenger Air Bag Assembly Replacement". 4. Disconnect yellow 2 - pin connector behind the glove box assembly. CAUTION: With the "SRS" fuse removed and ignition switch "ON", "AIR BAG" warning lamp will be "ON". This is normal operation and does not indicate an SRS malfunction. Enabling The SRS Installation CAUTION: Never use the air bag assembly from another vehicle. Use only the air bag assembly. Turn ignition switch to "LOCK" and remove key. 1. Connect yellow 2 - pin connector passenger air bag assembly. 2. Install glove box assembly, refer to "Passenger Air Bag Assembly Replacement". 3. Connect yellow 2 - pin connector at the base of steering column. 4. Install "AIR BAG" fuse "METER" and "SRS" to left dash side lower fuse block or connect battery. Turn ignition switch to "ON" and verify that the "AIR BAG" warning lamp flashes seven times and then turns "OFF". If it does not operate as described, perform the "Supplemental Restraint System (SRS) Diagnostic System Check". Page 1819 Coolant Temperature Sensor/Switch (For Computer): Service and Repair ENGINE COOLANT TEMPERATURE (ECT) SENSOR REMOVAL PROCEDURE NOTE: Care must be taken when handling the engine coolant temperature (ECT) sensor. Damage to the ECT sensor will affect proper operation of the fuel injection system. 1. Disconnect the negative battery cable. 2. Drain the radiator coolant. Refer to Draining and Refilling Cooling System. 3. Disconnect the electrical connector. 4. Remove the ECT sensor from the coolant crossover. INSTALLATION PROCEDURE 1. Apply sealer or the equivalent to the threads of the ECT sensor. 2. Install the ECT sensor in the coolant crossover. Tighten Tighten the ECT sensor to 30 N.m (22 lb ft.). Page 8186 14. Remove the glass. - First, align the height of regulator to the access hole. Remove 2 screws attaching bottom channel and regulator, then remove the glass. - Remove the window glass by tilting it as necessary. 15. Remove the window regulator. - Remove the window regulator fixing bolts and pull the regulator out from the lower hole of the door panel. 16. Remove the glass run. - Pull the glass run out from the door frame. Installation Page 3156 14. While watching the APP Sensor values in the Engine Data List, adjust the APPS by turning it until the values are within the ranges shown at closed throttle and wide open throttle (accelerator pedal pushed all the way down), then tighten the mounting screws and recheck the values. ^ If all three sensors are within range, go to step 23. ^ If APP Sensor 1 APP Sensor 2, and/or APP Sensor 3 cannot be brought into range, go to step 15. 15. Troubleshoot for an open circuit or a PCM malfunction. ^ If APP Sensor 1 has a value of 0% or APP Sensor 2 and/or APP Sensor 3 have a value of 99%, an open circuit exists or the PCM is malfunctioning. Repair the circuit or replace the PCM, and repeat step 14. ^ If you don't find a problem, go to step 16. 16. Disconnect the 10 P connector from the APPS. 17. View the APP Sensor values in the Engine Data List. ^ If APP Sensor 1 has a value of 0% or APP Sensor 2 and/or APP Sensor 3 have a value of 99%, go to step 18. ^ If APP Sensor 1 has a value other than 0%, or APP Sensor 2 and/or APP Sensor 3 have a value other than 99%, a short circuit exists or the PCM is malfunctioning. Repair the circuit or replace the PCM, and repeat step 14. 18. Modify the original APPS by cutting the connector housing off of the sensor. 19. Connect the 10 P connector to the modified APPS connector housing. Page 5428 6. Test-drive the vehicle to make sure it no longer pulls. If the steering wheel is now off-center by more than 2 mm, go to REPAIR PROCEDURE C. 7. Use your diagnosis worksheet to fill in the following table and build your 15-digit DTC. NOTE: Enter each reading in decimal degrees. Example 30' = 0.50. REPAIR PROCEDURE C 1. Make sure the steering wheel is centered. ^ Turn the steering wheel all the way to the right until it stops. ^ Turn the steering wheel all the way to the left, and count the number of revolutions until it stops. ^ Divide the number of revolutions in half, and turn the steering wheel until it is centered. For example, if it takes four revolutions of the steering wheel to go from lock to lock, then two turns is centered. ^ If the steering wheel is off-center by a large amount (20 mm or more), it may not be centered on the steering column shaft. Reinstall the steering wheel before going to step 2. 2. Place the vehicle on a lift, turn the steering wheel until it is centered, and then raise the vehicle. 3. Adjust the tie-rods. Use your measurements from question 13 of the test-drive to make your adjustment. Page 7573 Ground - "G" Shielding Sheilding This represents RFI (Radio Frequency Interference) shielding around a wire. The shielding is always connected to ground. Splices Page 8225 5. Apply the primer to the windshield and body panel. - Apply the primer (3) (Sun star # 435 - 40 or equivalent) to the windshield side bonding surface as shown in the figure. - Apply the primer (Sun star # 435 - 95 or equivalent) to the body side bonding surface. NOTE: Apply an adhesive 3 minutes or more but within 24 hours after the application of primer. If more than 24 hours have passed, reapply primer. Primer should be handled as following: 1. Use the primer manufactured 3 months or less ago and having been kept in an refrigerator. 2. Wipe off primer-stains on positions other than requires application. 3. Stir the primer for a minute or more before use. 6. Apply the adhesive (1) to the windshield. - After drying primer completely, apply a sealing adhesive (Sun star # 555 or equivalent) along the edge of the glass so that the sealing adhesive Page 4486 Wire Color Abbreviations The following abbreviations are used to identify wire colors in the circuit schematics: WHT................................... White YEL................................... Yellow BLK................................... Black BLU................................... Blue GRN................................... Green RED................................... Red ORN................................... Orange PNK................................... Pink BRN................................... Brown GRY................................... Gray PUR................................... Purple LT BLU................................... Light Blue LT GRN................................... Light Green Page 3346 Fuel Tank Unit: Diagnostic Aids Before Troubleshooting Before Troubleshooting See: Service Precautions/Vehicle Damage Warnings/Tips and Precautions 1. Check applicable fuses in the appropriate fuse/relay box. 2. Check the battery for damage, state of charge, and clean and tight connections. CAUTION: Do not quick-charge a battery unless the battery ground cable has been disconnected, otherwise you will damage the alternator diodes. - Do not attempt to crank the engine with the battery ground cable loosely connected or you will severely damage the wiring. While You're Working 1. Make sure connectors are clean, and have no loose terminals or receptacles. 2. Make sure that connectors without wire seals are packed with dielectric (silicone) grease. Part Number: 08798-9001. 3. When connecting a connector, push it until it "clicks" into place. CAUTION: Do not pull on the wires when disconnecting a connector. Pull only on the connector housings. - Most circuits include solid-state devices. Test the voltages in these circuits only with a 10-megaohm or higher impedance digital multi meter. Never use a test light or analog meter on circuits that contain solid-state devices. Damage to the devices may result. Five-Step Troubleshooting 1. Verify The Complaint Turn on all the components in the problem circuit to check the accuracy of the customer complaint. Note the symptoms. Do not begin disassembly or testing until you have narrowed down the problem area. 2. Analyze The Schematic Look up the schematic for the problem circuit. Determine how the circuit is supposed to work by tracing the current paths from the power source through the circuit components to ground. Also, trace circuits that share wiring with the problem circuit. The names of circuits that share the same fuse, ground, or switch, and so on, are referred to in each circuit schematic. Try to operate any shared circuits you didn't check in step 1. If the shared circuits work, the shared wiring is OK, and the cause must be in the wiring used only by the problem circuit. If several circuits fail at the same time, the fuse or ground is a likely cause. Based on the symptoms and your understanding of the circuit's operation, identify one or more possible causes. 3. Isolate The Problem By Testing The Circuit Make circuit tests to check the diagnosis you made in step 2. Keep in mind that a logical, simple procedure is the key to efficient troubleshooting. Test for the most likely cause of failure first. Try to make tests at points that are easily accessible. 4. Fix The Problem Once the specific problem is identified, make the repair. Be sure to use proper tools and safe procedures. 5. Make Sure The Circuit Works Turn on all components in the repaired circuit in all modes to make sure you've fixed the entire problem. If the problem was a blown fuse, be sure to test all of the circuits on that fuse. Make sure no new problems turn up and the original problem does not recur. Locations Description and Operation EGR Valve Position Sensor: Description and Operation EGR Pintle Position Sensor The PCM monitors the EGR valve pintle position input to endure that the valve responds properly to commands from the PCM and to detect a fault if the pintle position sensor and control circuits are open or shorted. If the PCM detects a pintle position signal voltage outside the normal range of the pintle position sensor, or a signal voltage that is not within a tolerance considered acceptable for proper EGR system operation, the PCM will set DTC P1406. Page 6778 Trailer Connector: Diagnostic Aids Before Troubleshooting Before Troubleshooting See: Service Precautions/Vehicle Damage Warnings/Tips and Precautions 1. Check applicable fuses in the appropriate fuse/relay box. 2. Check the battery for damage, state of charge, and clean and tight connections. CAUTION: Do not quick-charge a battery unless the battery ground cable has been disconnected, otherwise you will damage the alternator diodes. - Do not attempt to crank the engine with the battery ground cable loosely connected or you will severely damage the wiring. While You're Working 1. Make sure connectors are clean, and have no loose terminals or receptacles. 2. Make sure that connectors without wire seals are packed with dielectric (silicone) grease. Part Number: 08798-9001. 3. When connecting a connector, push it until it "clicks" into place. CAUTION: Do not pull on the wires when disconnecting a connector. Pull only on the connector housings. - Most circuits include solid-state devices. Test the voltages in these circuits only with a 10-megaohm or higher impedance digital multi meter. Never use a test light or analog meter on circuits that contain solid-state devices. Damage to the devices may result. Five-Step Troubleshooting 1. Verify The Complaint Turn on all the components in the problem circuit to check the accuracy of the customer complaint. Note the symptoms. Do not begin disassembly or testing until you have narrowed down the problem area. 2. Analyze The Schematic Look up the schematic for the problem circuit. Determine how the circuit is supposed to work by tracing the current paths from the power source through the circuit components to ground. Also, trace circuits that share wiring with the problem circuit. The names of circuits that share the same fuse, ground, or switch, and so on, are referred to in each circuit schematic. Try to operate any shared circuits you didn't check in step 1. If the shared circuits work, the shared wiring is OK, and the cause must be in the wiring used only by the problem circuit. If several circuits fail at the same time, the fuse or ground is a likely cause. Based on the symptoms and your understanding of the circuit's operation, identify one or more possible causes. 3. Isolate The Problem By Testing The Circuit Make circuit tests to check the diagnosis you made in step 2. Keep in mind that a logical, simple procedure is the key to efficient troubleshooting. Test for the most likely cause of failure first. Try to make tests at points that are easily accessible. 4. Fix The Problem Once the specific problem is identified, make the repair. Be sure to use proper tools and safe procedures. 5. Make Sure The Circuit Works Turn on all components in the repaired circuit in all modes to make sure you've fixed the entire problem. If the problem was a blown fuse, be sure to test all of the circuits on that fuse. Make sure no new problems turn up and the original problem does not recur. Page 7518 the component if the component only has one connector, or by a capital letter (A, B, C, etc.) if the component has more than one connector. Below most connector numbers and component names are PHOTO and VIEW numbers. The PHOTO number refers to a photo in the back of the book that shows the connector's location on the car. The VIEW number refers to an illustration in the back of the book that shows the connector face, wire colors, connector cavity numbers, and other details. The connector cavity numbering sequence begins at the top left corner of the connector. Disregard any numbers molded into the connector housing. Wires Wires are identified by the abbreviated names of their colors; the second color is the color of the stripe. Wires are also identified by their location in a connector. The number "2" next to the male and female wire terminals at C416, for example, means those terminals join in cavity 2 of connector C416. Symbols A complete description of schematic symbols is given under wire color abbreviation. Power Distribution Schematics Power Distribution schematics show how power is supplied from the positive battery terminal to various circuits in the car. Refer to the Power Distribution section to get a more detailed picture of how power is supplied to the circuit you're working on. From Battery to Ignition Switch, Fuses, and Relays Individual circuit schematics begin with a fuse. The first half of Power Distribution, however, shows the wiring "upstream" between the battery Page 7264 Power Seat Switch Page 3330 Distinct Of Circuit By Wire Base Color All wires have color-coded insulation. Wires belonging to a system's main harness will have a single color. Wires belonging to a system's sub-circuits will have a colored stripe. Striped wires use the codes found in the chart to show wire size and colors. Abbreviations are used to indicate wire color within a circuit diagram. How to Identify Connector Terminals How to Identify Connector Terminals Cavity Numbering System The cavities (and wire terminals) in each connector are numbered starting from the upper left, looking at the male terminals from the terminal side (or looking at the female terminals from the wire side. Both views are in the same direction so the numbers are the same.) All actual cavities are numbered, even if they have no wire terminals in them. NOTE: Data Link Connector (DLC) terminals are numbered according to SAE standard J1962, not the Honda standard. The numbers of the four end terminals are molded into the corners of the connector face. The connector cavity number is listed next to each terminal on the circuit schematic. The cavity / terminal shown is # 6. Using/Identifying Connector Terminal Views How to Use Connector Terminal Views To see the configuration of a connector's cavities, look up its view number in the Connector Views. Each view includes the color of the connector, where Page 1108 Valve Inspection Chart Page 3925 5. Install magnet, main case oil pan with new gasket, and sixteen 10 mm screws. Tighten the screws to the specified torque. Torque: 11 Nm (96 Inch lbs.) 6. Fill transmission through the overfill screw hole of oil pan, using ATF DEXRON-III. 7. Connect battery ground cable. Locations Page 7954 Wire Color Abbreviations The following abbreviations are used to identify wire colors in the circuit schematics: WHT................................... White YEL................................... Yellow BLK................................... Black BLU................................... Blue GRN................................... Green RED................................... Red ORN................................... Orange PNK................................... Pink BRN................................... Brown GRY................................... Gray PUR................................... Purple LT BLU................................... Light Blue LT GRN................................... Light Green Page 7498 Part 2 Of 2 Page 3400 This sample Ground Distribution schematic shows all of the components that share two ground points. Components A solid border line means the entire component is shown. A broken border line indicates that only part of the component is shown. Page 3030 Page 5202 the component if the component only has one connector, or by a capital letter (A, B, C, etc.) if the component has more than one connector. Below most connector numbers and component names are PHOTO and VIEW numbers. The PHOTO number refers to a photo in the back of the book that shows the connector's location on the car. The VIEW number refers to an illustration in the back of the book that shows the connector face, wire colors, connector cavity numbers, and other details. The connector cavity numbering sequence begins at the top left corner of the connector. Disregard any numbers molded into the connector housing. Wires Wires are identified by the abbreviated names of their colors; the second color is the color of the stripe. Wires are also identified by their location in a connector. The number "2" next to the male and female wire terminals at C416, for example, means those terminals join in cavity 2 of connector C416. Symbols A complete description of schematic symbols is given under wire color abbreviation. Power Distribution Schematics Power Distribution schematics show how power is supplied from the positive battery terminal to various circuits in the car. Refer to the Power Distribution section to get a more detailed picture of how power is supplied to the circuit you're working on. From Battery to Ignition Switch, Fuses, and Relays Individual circuit schematics begin with a fuse. The first half of Power Distribution, however, shows the wiring "upstream" between the battery Page 3359 Each schematic represents one circuit. A circuit's wires and components are arranged to show current flow, from power at the top of the page, to ground, at the bottom. Shared Circuits Other circuits may share power or ground terminals or wiring with the circuit shown. A wire that connects one circuit to another, for example, is cut short and has an arrowhead at the end of it pointing in the direction of current flow. Next to the arrowhead is the name of the circuit or component which shares that wiring. To quickly check shared wiring, check the operation of a component it serves. If that component works, you know the shared wiring is OK. Connectors All in-line and junction connectors are numbered (C725, C416, etc.). Component connectors are not numbered but are identified either by the name of Page 3611 3. Connect the electrical connector to the CMP sensor. 4. Install the common chamber assembly. 5. Install the engine cover. 6. Connect the negative battery cable. Page 4684 The name of the component appears next to it followed by notes about its function along with any photo and connector view references. Connector "C" How to Identify Connector Terminals Cavity Numbering System The cavities (and wire terminals) in each connector are numbered starting from the upper left, looking at the male terminals from the terminal side (or looking at the female terminals from the wire side. Both views are in the same direction so the numbers are the same.) All actual cavities are numbered, even if they have no wire terminals in them. NOTE: Data Link Connector (DLC) terminals are numbered according to SAE standard J1962, not the Honda standard. The numbers of the four end terminals are molded into the corners of the connector face. PCM Service Precautions Powertrain Control Module: Service Precautions PCM Service Precautions PCM Service Precautions The PCM is designed to withstand normal current draws associated with vehicle operation. Avoid overloading any circuit. When testing for opens and shorts, do not ground or apply voltage to any of the PCM's circuits unless instructed to do so. These circuits should only be tested using digital voltmeter J 39200. The PCM should remain connected to the PCM or to a recommended breakout box. Page 7673 Wires Wire insulation can be one color, or one color with another color stripe. (The second color is the stripe.) This circuit continues on another image. (The arrow shows direction of current flow.) To follow the RED/BLK wire in this example, you would turn to "Fuel and Emissions" and look for the "A" arrow. Locations Crankshaft Position Sensor: Locations CKP Sensor 36. Bottom Right Side of Engine Bottom Right Side of Engine Page 7904 and the fuses. From Fuses to Relays and Components The second half of Power Distribution shows the wiring "From Fuses to Relays and Components." This can speed your troubleshooting by showing which circuits share fuses. If Power Distribution shows that an inoperative circuit and another circuit share a fuse, check a component in the other circuit. If it works, you know the fuse is good and power is available to the inoperative circuit. Ground Distribution Schematics Locations Electronic Brake Control Module: Locations Right Rear Corner Of Engine Compartment Locations Page 6928 8. Remove the front wheel arch moulding (If so equipped). Installation To install, follow the removal steps in the reverse order, noting the following points: 1. Tighten the front fender panel fixing bolts to the specified torque. Torque: 7 N.m (61 lb.in) 2. Check the fender and front door(1). Clearance: 5.0 mm (0.196 in) Height (step): Flush Page 2072 Disclaimer Repair Procedure 1. Unclamp the air cleaner housing cover, and move it to the side for access to connector C123 (16P BLK). 2. Unfasten C123 from the side of the engine compartment using a 90-degree pick. 3. Disconnect C123, and clean the terminals on both sides of the connector with contact cleaner. Shake the residue out of the connector. Allow the contact cleaner to evaporate for at least 3 minutes, then reconnect C123. 4. Fasten C123 to the left side of the engine compartment, then reinstall the air cleaner housing cover. 5. While supporting the accelerator pedal assembly, remove the two bolts that secure the assembly to the bulkhead. Carefully lower the assembly to gain access to the connector. Locations Data Link Connector: Locations 61 - Left Side Of Dash Left Side of Dash Page 7826 Wires Wire insulation can be one color, or one color with another color stripe. (The second color is the stripe.) This circuit continues on another image. (The arrow shows direction of current flow.) To follow the RED/BLK wire in this example, you would turn to "Fuel and Emissions" and look for the "A" arrow. Page 143 Powertrain Control Module: Description and Operation PCM Function PCM Function The PCM supplies either 5 or 12 volts to power various sensors or switches. The power is supplied through resistances in the PCM which are so high in value that a test light will not light when connected to the circuit. In some cases, even an ordinary shop voltmeter will not give an accurate reading because its resistance is too low. Therefore, a digital voltmeter with at least 10 megohms input impedance is required to ensure accurate voltage readings. Tool J 39200 meets this requirement. The PCM controls output circuits such as the injectors, fan relays, etc., by controlling the ground or the power feed circuit through transistors or through either of the following two devices: - Output Driver Module (0DM) - Quad Driver Module (QDM) Page 7458 Air Bag(s) Arming and Disarming: Service Precautions Precautions For Electrical Inspections Precautions For Electrical Inspections When using electrical test equipment, insert the probe of the tester into the wire side of the connector. Do not insert the probe of the tester into the terminal side of the connector, and do not tamper with the connector. Use a U-shaped probe. Do not insert the probe forcibly. Use specified service connectors in troubleshooting. Using improper tools could cause an error in inspection due to poor metal-to-metal contact. Page 4475 Each schematic represents one circuit. A circuit's wires and components are arranged to show current flow, from power at the top of the page, to ground, at the bottom. Shared Circuits Other circuits may share power or ground terminals or wiring with the circuit shown. A wire that connects one circuit to another, for example, is cut short and has an arrowhead at the end of it pointing in the direction of current flow. Next to the arrowhead is the name of the circuit or component which shares that wiring. To quickly check shared wiring, check the operation of a component it serves. If that component works, you know the shared wiring is OK. Connectors All in-line and junction connectors are numbered (C725, C416, etc.). Component connectors are not numbered but are identified either by the name of Service and Repair Transmission Temperature Sensor/Switch: Service and Repair REMOVAL 1. Raise the vehicle and support it on jack stands. 2. Disconnect battery ground cable. 3. Drain fluid. 4. Remove sixteen 10 mm adapter case oil pan fixing screws, adapter case oil pan, and gasket. 5. Disconnect wiring harness from shift solenoid, band apply solenoid, and 7 pin connector of main case. Pull only on connectors, not on wiring harness. 6. Remove wiring harness assembly with transmission oil temperature sensor. INSTALLATION 1. Install wiring harness from shift solenoid, band apply solenoid, and 7 pin connector of main case. 2. Install oil pan gasket, oil pan and sixteen 10 mm fixing screws. Tighten the screws to the specified torque. Torque: 11 Nm (96 Ft. lbs.) 3. Fill transmission through the overfill screw hole of oil pan, using ATF DEXRON III. 4. Connect battery ground cable. Page 2633 2. Connect the short finder across the battery terminals and the load (component) side of the fuse terminal. 3. Close all switches in the circuit you're testing. 4. Turn on the short finder. This creates a pulsing magnetic field around the wiring between the fuse box and the short. 5. Beginning at the fuse box, slowly move the short finder along the circuit wiring. The meter will read current pulses through sheet metal and body trim. As long as the meter is between the fuse and the short, the needle will move with each current pulse. Once you move the meter past the point of the short, the needle will stop moving. Check the wiring and connectors in this area to locate the cause of the short. Testing For Continuity When testing for continuity at a connector without wire seals, you do not have to separate the two halves of the connector. Instead, probe the connector from the back. Always check both sides of the connector because dirty, corroded, and bent terminals can cause problems (no electrical contact = an open). 1. Disconnect the negative cable from the car battery. If you're using a DVOM, place it in the lowest "OHMS" range. Page 1054 Fuel Pressure: Testing and Inspection Fuel System Pressure Test A fuel system pressure test is part of several of the diagnostic charts and symptom checks. To perform this test, refer to Fuel Systems Diagnosis. Page 4457 Test Equipment CAUTION: Most circuits include solid-state devices. Test the voltages in these circuits only with a 10-megaohm or higher impedance digital multimeter. Never use a test light or analog meter on circuits that contain solid-state devices. Damage to the devices may result. Test Light and DVOM On circuits without solid-state devices, use a test light to check for voltage. A test light is made up of a 12 volt bulb with a pair of leads attached. After grounding one lead, touch the other lead to various points along the circuit where voltage should be present. The bulb will go on if there is voltage at the point being tested. If you need to know how much voltage is present, use a digital volt/ohmmeter (DVOM). Self-Powered Test Light and DVOM Use a self-powered test light to check for continuity. This tool is made up of a light bulb, battery, and two leads. To test it, touch the leads together: the light should go on. Use a self-powered test light only on an unpowered circuit. First, disconnect the battery, or remove the fuse that feeds the circuit you are working on. Select two points in the circuit between which you want to check continuity. Connect one lead of the self-powered test light to each point. If there is continuity, the test light's circuit will be completed, and the light will go on. If, in addition, you need to know exactly how much resistance there is between two points, use a digital volt/ohmmeter (DVOM). In the "OHMS" range, the DVOM will measure resistance between two points along a circuit. Low resistance means good continuity. Diodes and solid-state devices in a circuit can make a DVOM give a false reading. To check a reading, reverse the leads, and take a second reading. If the readings differ, the component is affecting the measurement. Jumper Wire Use a jumper wire to bypass an open circuit. A jumper wire is made up of an in-line fuse holder connected to a set of test leads. It should have a five ampere fuse. Never connect a jumper wire across a short circuit. The direct battery short will blow the fuse. Short Finder (Short Circuit Locator) Short finders are available to locate shorts to ground. The short finder creates a pulsing magnetic field in the shorted circuit which you can follow to the location of the short. To order any test equipment shown above, contact your local tool supplier. For a list of suppliers and tool numbers, refer to Honda Required Special Tools and Equipment Service Bulletin. Page 2681 This means the branch of the wire connects to another circuit. The arrow points to the name of the circuit branch where the wire continues. Page 651 Fuel Tank Pressure Sensor: Testing and Inspection 1. Inspect the vapor pressure sensor for cracks in the housing and corrosion on the electrical terminals. 2. Inspect the rubber grommet for tears and signs of rot. Page 5761 35. Temporarily install both type B reinforcement brackets again, then make sure all of the bolts can be started in each pop nut. 36. Remove both type B reinforcement brackets. 37. Cover all 32 holes with the 3/4 in. round labels from the kit. This will prevent the Noxudol from contaminating the pop nut threads. 38. Use masking tape to cover the upper trailing link brackets. This will prevent the Noxudol from contaminating the bracket mounting surfaces. 39. Apply Noxudol 700 and Noxudol 300 anti-corrosion waxes (see steps 5 thru 19 of STAGE 2 REPAIR). 40. Remove the round labels and the masking tape. 41. Install the left and right type B reinforcement brackets using all of the hardware in the kit. Torque the bolts and nuts, in the order shown on the illustrations below: ^ Torque the bracket bolts to 35 Nm (25 Ib-ft). ^ Torque the body mount studs and nuts to 30 Nm (22 lb-ft). Locations Trim Panel: Locations Interior Trim Panels (LWB) And Associated Parts Page 1375 Tires: Service and Repair Tire Replacement TIRE REPLACEMENT When replacement is necessary, the original metric the size should be used. Most metric tire sizes do not have exact corresponding alphanumeric tire sizes. It is recommended that new tires be installed in pairs on the same axle. If necessary to replace only one tire, it should be paired with tire having the most tread, to equalize braking traction. CAUTION: Do not mix different types of tires such as radial, bias and bias-belted tires except in emergencies, because vehicle handling may be seriously affected and may result in loss of control. Tire Dismounting Remove valve cap on valve step and deflate the tire. Then use a tire changing machine to mount or dismount tires. Follow the equipment manufacturer's instruction. Do not use hand tools or tire lever alone to change tires as they may damage the tire beads or wheel rim. Tire Mounting Rim bead seats should be cleaned with a wire brush or coarse steel wool to remove lubricants, and light rust. Before mounting a tire, the bead area should be well lubricated with an approved tire lubricant. After mounting, inflate the tire to 196 kPa (28 psi) so that beads are completely seated. Inflate the air to specified pressure and install valve cap to the stem. WARNING: Never stand over tire when inflating. bead may break when bead snaps over rim's safety hump and cause serious personal injury. never exceed 240 kPa (35 psi) pressure when inflating. if 240 kPa (35 psi) pressure will not seat beads, deflate, re-lubricate and re-inflate. over inflation may cause the bead to break and cause serious personal injury. Tire Repair There are many different materials on the market used to repair tires. Manufacturers have published detailed instructions on how and when to repair tires. These instructions can be obtained from the tire manufacturer if they are not included with the repair kit. Wheel Inspection Damaged wheels and wheels with excessive run-out must be replaced. Wheel run out at rim (Base on hub Bore) is shown in provided table. Preliminary Checks Alignment: Service and Repair Preliminary Checks INSPECTION Before making any adjustments affecting caster, camber or toe-in, the following front end inspection should be made. 1. Inspect the tires for proper inflation pressure. 2. Make sure that the vehicle is unladen condition (With no passenger or loading). 3. Make sure that the spare tire is installed at the normal position. 4. Inspect the front wheel bearings for proper adjustment. 5. Inspect the ball joints and tie rod ends. If excessive looseness is noted, correct before adjusting. 6. Inspect the wheel and tires for run-out. 7. Inspect the trim height. If not within specifications, the correction must be made before adjusting caster. 8. Inspect the steering unit for looseness at the frame. 9. Inspect shock absorbers for leaks or any noticeable noise. 10. Inspect the control arms or stabilizer bar attachment for looseness. 11. Inspect the front end alignment using alignment equipment. Follow the manufacturer's instructions. 12. Park the vehicle on a level surface. Page 7464 Air Bag(s) Arming and Disarming: Description and Operation Definitions Air Bag An inflatable cloth cushion designed to deploy in certain frontal crashes. It supplements the protection offered by the seat belts by distributing the impact load more evenly over the vehicle occupant's head and torso. Asynchronous Performed in a nonperiodic fashion, (i.e., no defined time or interval). (B+) Battery voltage, (B+) The voltage available at the battery at the time of the indicated measurement. With the key "ON" and the engine not running, the system voltage will likely be between 12 and 12.5 volts. At idle the voltage may be 14 to 16 volts. The voltage could be as low as 10 volts during engine cranking. Bulb Check The SDM will cause the "AIR BAG" warning lamp to flash seven times and then go "OFF" whenever the ignition switch transitions to the ON position from any other ignition switch position and no malfunctions are detected. "CONTINUOUS MONITORING" Tests performed by the SDM on the SRS every 100 milliseconds while "Ignition 1" voltage is in the normal operating voltage range at the SDM. Data Link Connector (DLC) Formerly "DLC" a connector which allows communication with an external computer, such as a scan tool. Datum Line A base line parallel to the plane of the underbody or frame from which all vertical measurements originate. Deploy To inflate the air bag. Deployment Loops The circuits which supply current to the air bag assemblies to deploy the air bag. Diagnostic Trouble Code (DTC) Formerly "Code", a numerical designator used by the SDM to indicate specific SRS malfunctions. Driver Current Source An output of the SDM which applies current into the driver air bag assembly circuit during the "Initiator Assembly Resistance Test". Driver Air Bag Assembly An assembly located in the steering wheel hub consisting of an inflatable bag, an inflator and an initiator. EEPROM Electronically Erasable Programmable Read Only Memory. Memory which retains its contents when power is removed from the SDM. Ignition Cycle The voltage at the SDM "Ignition 1" inputs, with ignition switch "ON", is within the normal operating voltage range for at least ten seconds before turning ignition switch "OFF". Ignition 1 Page 5180 26. Remove pinion shaft. Reassembly To install, follow the removal steps in the reverse order, noting the following points: Grease application places - Bushing in rear cover and center bracket. - Gears in reduction gear. - Shift lever operating portion. - Sliding portion of pinion. - Plunger sliding portion of magnetic switch. Reassembling Yoke Assembly Before reassembly, make sure that no metallic parts attach to the yoke assembly. Because of strong magnetic force, hold the yoke assembly and insert it slowly into the armature. Torque Torque for each part (See Torque Specifications) Pinion Jump-out Dimension Connect the "+" cable of battery to terminal S and the "-" cable to terminal M. Turn the switch on, and measure pinion travel dimension in thrust Page 1629 Engine Oil Pressure: Testing and Inspection Engine Oil Pressure Check 1. Check for dirt, gasoline or water in the engine oil. a. Check the viscosity of the oil. b. Check the viscosity of the oil. c. Change the oil if the viscosity is outside the specified standard. 2. Check the engine oil level. The level should fall somewhere between the "ADD" and the "FULL" marks on the oil level dipstick. If the oil level does not reach the "ADD" mark on the oil level dipstick, engine oil must be added. 3. Remove the oil pressure unit. 4. Install an oil pressure gauge. 5. Start the engine and allow the engine to reach normal operating temperature (About 80°C). 6. Measure the oil pressure. Oil pressure should be: 392 - 550 kPa (56.9 - 80.4 psi) at 3000 rpm. 7. Stop the engine. 8. Remove the oil pressure gauge. 9. Install the oil pressure unit. 10. Start the engine and check for leaks. Page 2936 ^ If the idle speed ever exceeds 1,300 rpm 2. Remove the vacuum hose from the fuel pressure regulator, then start the engine. ^ If fuel comes out of the fuel pressure regulator vacuum hose connection, go to REPAIR PROCEDURE FUEL PRESSURE REGULATOR. ^ If no fuel comes out of the regulator, reconnect the vacuum hose and continue to step 3. 3. Connect the PGM Tester. Set it to Engine Data List. 4. Have an assistant drive the vehicle under the conditions described by the customer. 5. If the high or erratic idle condition occurs, note the values of the PSP Switch and APP Sensor 1 when it is occurring. ^ If the PSP Switch is HIGH, and you are not turning, go to REPAIR PROCEDURE POWER STEERING SWITCH. ^ If the APP Sensor 1 is greater than 15% and APP Sensor 2 and/or APP Sensor 3 are less than 85%, and the accelerator pedal is not depressed, go to REPAIR PROCEDURE APPS GROUND. ^ If the PSP Switch is reading LOW when not turning and HIGH when turning, and the APP Sensors are reading within the range shown, discontinue the test-drive and go to step 6. 6. Do these repairs: ^ REPAIR PROCEDURE APPS GROUND ^ REPAIR PROCEDURE ENGINE/BODY GROUND REPAIR PROCEDURE - FUEL PRESSURE REGULATOR 1. Relieve fuel system pressure: ^ Remove the fuel fill cap. ^ Remove the fuel pump relay. ^ Start the engine and run it until it stalls. ^ Crank the engine for 3 seconds. 2. Remove the vacuum hose from the fuel pressure regulator. 3. Remove the fuel pressure regulator shield from the common chamber (two bolts). Page 1005 ^ Loosen the front subframe bolts. See the applicable service manual for more information. NOTE: The front wheels are being viewed from the rear of the vehicle. ^ Depending which way you need to shift the subframe, insert a pry bar between the subframe and body at both the front and rear positions of the subframe. NOTE: Be careful not to damage the vehicle. You could bend and damage the frame and/or body if you apply too much pressure. ^ Press on both pry bars to shift the subframe. It will move only a few millimeters. This should adjust the camber about 0.2-0.5°. ^ While holding the subframe in place, have an assistant torque the subframe bolts to their proper torque. Front Camber Adjustment, Strut Suspension ^ Raise the vehicle, and remove the front tires. ^ Loosen the damper pinch bolts and the flange nuts. ^ Adjust the camber by moving the bottom of the damper within the range of the damper pinch bolt free play. NOTE: Some vehicles have special pinch bolts that allow more adjustment. For more information, refer to the parts catalog. ^ Tighten the damper pinch bolts to the specified torque. ^ Reinstall the front wheels and lower the vehicle. Bounce the front of the vehicle several times to stabilize the suspension. Service and Repair Fog/Driving Lamp Bulb: Service and Repair Removal 1. Disconnect the battery ground cable. 2. Remove the fog light bulb (2). e Disconnect the connector (5). - Remove the cap (4). - Loosen the retaining clip (1). - Pull out the bulb (2). - Disconnect the terminal (3). Installation To install, follow the removal steps in the reverse order. Page 1513 - With J-24086-C Piston pin service set and a press, press fit the piston pin. Note: Heat the connecting rod small end to a suitable temperature to ensure smooth installation. 4. Install piston ring with the piston ring expander. The compression ring must be set with the T mark (1) facing up. Marked T: No.1 Compression ring Marked T2: No.2 Compression ring Install piston rings in the following sequence. 1. Oil ring Expander ring Upper side rail Lower side rail 2. 2nd compression ring 3. 1st compression ring - The compression rings must be set with the T or T2 mark facing up. Marked T: No. 1 Compression ring Marked T2: No.2 Compression ring Page 7430 it is located, and what it connects to. Use the Connector Views to help locate the proper cavity when you need to probe a connector. It can be especially helpful if the connector has more than one wire of the same color. A dash symbol (-) indicates that the cavity is empty. Connector views can also be used to help diagnose multiple symptoms in separate circuits which could be caused by a single problem in a connector shared by those circuits. Here's an example: 1. Pick one of the multiple symptoms and look up the schematic for that circuit. 2. Make a list of all the in-line and fuse box connectors in that schematic , 3. Then, in the Connector Views, look up each connector on your list to see if circuits related to the other symptoms run through one of them. If they do, inspect that connector for the problem. Example: The blower, rear window defogger, and the windshield wiper don't work. List all in-line and fuse box connectors in the blower controls circuit and then check the Connector View (see the sample). You find that C324 is common to the blower controls, rear window defogger, and wiper/washer, so you inspect C324 and find the problem, bent terminals. Finding Component/Connector Locations Finding Component/Connector Locations To see where a component or connector is located on the car, look up its photo number in the "Component Location". The photo will also tell you the color of the connector, and how many cavities it has. Page 5390 1. Place the vehicle on a commercially available, computerized, four-wheel alignment rack, and record the following measurements. Follow the equipment manufacturer's instructions. NOTE: Enter each reading in decimal degrees. Example 30' = 0.50. 2. If any measurement is out of specification, inspect the front suspension for any damage. Repair any damaged parts before continuing your diagnosis. 3. Determine how the front wheel camber is affecting the pull. Pick the combination of left- and right-front camber that best matches the vehicle you are repairing, then note the camber thrust direction for that combination: NOTE: ^ If the camber of both front wheels is negative, but one wheel is grossly more negative than the other, the camber thrust direction will be opposite the wheel with more negative camber (for example, if the left-front wheel is more negative, the camber thrust direction is right). ^ If the camber of both front wheels is positive, but one wheel is grossly more positive than the other, the camber thrust direction will be the same as the wheel with more positive camber (for example, if the left-front wheel is more positive, the camber thrust direction is left). 4. Determine how the camber needs to be adjusted. 5. Adjust the camber as needed. Front Camber Adjustment, Double Wishbone Suspension Body - Unibody Repair Guidelines Unibody: Technical Service Bulletins Body - Unibody Repair Guidelines 07-008 February 2, 2007 Applies To: ALL Clarification of Honda Unibody Repair Policy BACKGROUND Honda automobiles and trucks are built to precise standards so that they can perform well under many situations. For example, they offer a firm responsive ride yet yield when necessary under the forces of a collision to help protect the vehicle occupants. HONDA REPAIR POLICY Sectioning Frame Components When body repairs are necessary, Honda recommends that any repairs be performed by an experienced professional, using the Honda body repair manual, and that component replacement be accomplished along factory seams. Failure to do so can result in a number of problems, including improperly fitting parts, noises, tire wear, and most importantly, changes in vehicle dynamics and occupant protection in a subsequent crash. In particular, Honda strongly recommends against the process of joining cut pieces from separate vehicle~commonly referred to as clipping. This is not an authorized Honda repair method. Any problem with other components resulting from such improper vehicle repairs is not covered under Honda's factory or extended warranties. Also, because what's in a part is as important as how it looks, Honda strongly recommends the use of Honda Genuine repair parts. The material used to create the part, such as high-strength steel, and the subtle shapes of the part, determine how it will perform in normal operation or in a subsequent collision. Using Honda Genuine repair parts helps return the vehicle to its pre-crash condition. ADHESIVES/WELDING Using adhesives in place of welding for component replacement is not an authorized Honda repair method. It is important to repair at factory seams using the same procedure as the factory assembly process except where specified otherwise in the Honda body repair manual. The door skin is welded at the top and is glued around the crimp. Each body repair manual states that if the reinforcement in the door is damaged, the complete door must be replaced. NOTE: Because they are made of high-strength steel, door and bumper reinforcements must not be repaired or straightened. INFORMATION RESOURCES Extensive research and development goes into every Honda to provide safety for those inside as well as outside the vehicle. Therefore, it is critical that collision repair facilities do not change a vehicle during collision repair. Please visit the following websites for further information about Honda safety: ^ world.honda.com/safety, and ^ world.honda.com/news/2003/4030904_2.html Body repair manuals are available for every new Honda model series that is sold in the U.S. Each manual provides instructions for proper repair procedures, and drawings that show where each factory seam and weld on the vehicle is located. In a few instances, the manual also indicates where it is acceptable to cut panels and sections other than at factory seams. Body repair manuals can be purchased from Helm, Inc. using one of these methods: ^ Call Helm Inc. at 1-800-782-4356 ^ Go online at www.helminc.com Collision repair facilities can also subscribe to all manuals at www. serviceexpress.honda.com. Dealers can log onto ISIS and view body repair manuals in the Search By Publication section. Page 2915 - Bank 2 sensor 1 is mounted on the exhaust pipe ahead of the left-hand catalytic converter. - Bank 2 sensor 2 is mounted behind the left-hand catalytic converter. 3. Disconnect the pigtail from the wiring harness. IMPORTANT: The pigtail is permanently attached to the sensor. Be careful not to pull the wires out. NOTE: Do not use a torch to remove an HO2S unless the sensor is being replaced. Using a torch could damage the sensor. Page 4360 DISASSEMBLY 1. Lay the shaft horizontally on a bench and secure. 2. Indicate the original assembled position (1) by marking the phasing of the shaft prior to disassembly. 3. Using the flat blade of a screwdriver, pry the loose end of the boot clamp upwards and away from the propeller shaft boot. Be careful not to damage the boot. 4. When boot clamps becomes loose, remove by hand. 5. Repeat for the other boot clamp. 6. Remove the slip yoke assembly from the driveshaft, by securing the boot with one hand and pulling on the slip yoke. 7. Remove the boot from the shaft assembly. Page 1359 Spare Tire Hanger - Parts Locations Description and Operation Tachometer: Description and Operation The tachometer displays engine speed in RPM. Voltage pulses are taken from the ignition system and sent to the tachometer which responds to the frequency of the pulses. Solid-state circuits process these pulses into a signal that causes the gauge needle to move. Page 1804 2. Install water pump assembly and tighten bolts to the specified torque in sequence (shown in image). Torque: 25 Nm (18 ft. lbs.) Note: To prevent the oil leakage, apply the LOCTITE 262 or an equivalent, to the arrow marked fixing bolt thread. 3. Idle pulley - Install idle pulley and tighten bolt to the specified torque. Torque: 52 Nm (38 ft. lbs.) 4. Timing belt - Install timing belt. 5. Connect radiator inlet hose and replenish engine coolant. 6. Connect battery ground cable. Page 210 Wires Wire insulation can be one color, or one color with another color stripe. (The second color is the stripe.) This circuit continues on another image. (The arrow shows direction of current flow.) To follow the RED/BLK wire in this example, you would turn to "Fuel and Emissions" and look for the "A" arrow. Page 4902 Finishing the Job Remove the vibration damper and the protective band (if used). Use a micrometer to measure the thickness of the brake disc. Make sure the thickness is within the service manual specifications. Clean the brake disc with soapy water or brake cleaner, then wipe it dry. Use a vacuum cleaner to remove any dust or chips, but do not use compressed air. Unplug the tool bed feed motor from the drive motor assembly, and remove the mounting yoke from the brake disc. Remove the speed mount from the steering knuckle. Apply a small amount of Molykote 77 grease to the brake pad shims. Reinstall the caliper assembly. (If you did not use the power drive system, use the brake pad spreader to push the pistons back into the caliper.) Torque the nuts and bolts to the required specification (see the appropriate service manual). Refinish the other front brake disc using the same guidelines. Check the brake fluid level, then test-drive the vehicle to make sure the brake pedal is firm and does not pulsate. Lightly apply the brakes about 20 times during the test-drive to seat the brake pads. REAR BRAKE DISCS It is possible to use an on-car lathe on some models if the rear caliper mounts are low enough to clear the vehicle body. A power driver is needed for front drive models. Refinish rear brake discs on bench-mounted equipment if necessary. Follow the same guidelines you used for refinishing front brake discs, noting these differences: ^ Mount the brake lathe to the rear knuckle with the Honda 2-Piece Adapter (P/N KWY-1 08102504). You can order the 2-piece adapter through the Honda Tool and Equipment Program (see ORDERING INFORMATION). Disclaimer Page 6133 HVAC Control Bezel: Service and Repair Control Panel Bulb Control Panel Illumination Bulb And Associated Parts Removal 1. Disconnect the battery ground cable. 2. Remove control lever assembly. 3. Pull out the bulb socket from the panel by turning it counterclockwise. 4. Pull the illumination bulb from the socket. Installation To install, follow the removal steps in the reverse order. Page 6684 Terminals - "T" Each "T" terminal (ring type) is numbered for reference and location. A "T" terminal is secured with a screw or bolt. Wires Page 6673 Distinct Of Circuit By Wire Base Color All wires have color-coded insulation. Wires belonging to a system's main harness will have a single color. Wires belonging to a system's sub-circuits will have a colored stripe. Striped wires use the codes found in the chart to show wire size and colors. Abbreviations are used to indicate wire color within a circuit diagram. How to Identify Connector Terminals How to Identify Connector Terminals Cavity Numbering System The cavities (and wire terminals) in each connector are numbered starting from the upper left, looking at the male terminals from the terminal side (or looking at the female terminals from the wire side. Both views are in the same direction so the numbers are the same.) All actual cavities are numbered, even if they have no wire terminals in them. NOTE: Data Link Connector (DLC) terminals are numbered according to SAE standard J1962, not the Honda standard. The numbers of the four end terminals are molded into the corners of the connector face. The connector cavity number is listed next to each terminal on the circuit schematic. The cavity / terminal shown is # 6. Using/Identifying Connector Terminal Views How to Use Connector Terminal Views To see the configuration of a connector's cavities, look up its view number in the Connector Views. Each view includes the color of the connector, where Service and Repair Transmission Temperature Sensor/Switch: Service and Repair REMOVAL 1. Raise the vehicle and support it on jack stands. 2. Disconnect battery ground cable. 3. Drain fluid. 4. Remove sixteen 10 mm adapter case oil pan fixing screws, adapter case oil pan, and gasket. 5. Disconnect wiring harness from shift solenoid, band apply solenoid, and 7 pin connector of main case. Pull only on connectors, not on wiring harness. 6. Remove wiring harness assembly with transmission oil temperature sensor. INSTALLATION 1. Install wiring harness from shift solenoid, band apply solenoid, and 7 pin connector of main case. 2. Install oil pan gasket, oil pan and sixteen 10 mm fixing screws. Tighten the screws to the specified torque. Torque: 11 Nm (96 Ft. lbs.) 3. Fill transmission through the overfill screw hole of oil pan, using ATF DEXRON III. 4. Connect battery ground cable. Page 3362 This sample Ground Distribution schematic shows all of the components that share two ground points. Components A solid border line means the entire component is shown. A broken border line indicates that only part of the component is shown. Page 4959 Brake Fluid: Vehicle Damage Warnings Deterioration of Brake Fluid Using any other brake fluid than specified or brake fluid with mineral oil or water mixed in will drop the boiling point of brake fluid. It may, in turn, result in vapor lock or deteriorated rubber parts of the hydraulic system. Be sure to change the brake fluid at specified intervals. If the rubber parts are deteriorated, remove all the system parts and clean them with alcohol. Prior to reassembly, dry the cleaned parts with air to remove the alcohol. Replace all the hoses and rubber parts of the system. Page 830 Throttle Position Sensor: Testing and Inspection Function Check Use a Tech 2 to check the TP sensor output voltage at closed throttle. - The voltage should be under 0.85 volt. - If the reading is greater than 0.85 volt, check the throttle shaft to see if it is binding. Page 5547 H/C 4408092 Defect Code: 017 Contention Code: C99 Skill Level: Repair Technician Out of warranty: Any repair performed after warranty expiration may be eligible for goodwill consideration by the District Service Manager or your Zone Office. You must request consideration, and get a decision, before starting work. DISCLAIMER Page 1393 13. Tighten the bolts to the specified torque. Torque: 59 Nm (43 ft. lbs.) Page 6397 produced as a by product of the deployment reaction. The sodium hydroxide then quickly reacts with atmospheric moisture and is converted to sodium carbonate and sodium bicarbonate (baking soda). Therefore, it is unlikely that sodium hydroxide will be present after deployment. WARNING: SAFETY PRECAUTIONS MUST BE OBSERVED WHEN HANDLING A DEPLOYED AIR BAG ASSEMBLY. AFTER DEPLOYMENT, THE METAL SURFACES OF THE AIR BAG ASSEMBLY WILL BE VERY HOT. ALLOW THE AIR BAG ASSEMBLY TO COOL BEFORE HANDLING ANY METAL PORTION OF IT. DO NOT PLACE THE HOT DEPLOYED AIR BAG ASSEMBLY NEAR ANY FLAMMABLE OBJECTS. FAILURE TO FOLLOW PROCEDURES COULD RESULT IN FIRE OR PERSONAL INJURY. After an air bag assembly has been deployed, the metal canister and surrounding areas of the air bag assembly will be very hot. Do not touch the metal areas of the air bag assembly for about 30 minutes after deployment. If the deployed air bag assembly must be moved before it is cool, wear gloves and handle by the air bag or trim cover. 31. Short the driver deployment harness wires by twisting together one end from each. Repeat this procedure for the passenger deployment harness. 32. Carefully remove drop cloth from vehicle and clean off any fragments or discard drop cloth entirely. 33. Disconnect driver deployment harness and passenger deployment harness from vehicle and discard. 34. In the unlikely event that either or both of the air bag assemblies did not deploy after following these procedures, proceed immediately with Steps 36 through 37. If the air bag assembly deployed, proceed to step 35. 35. With both air bags deployed, the vehicle may be scrapped in the same manner as a non - SRS equipped vehicle. NOTE: The remaining steps are to be followed in the unlikely event that the air bag assembly did not deploy after following these procedures. 36. Remove the undeployed air bag assembly (s) from the vehicle. For driver air bag assembly refer to in the "Passenger Air Bag Assembly Removal". WARNING: WHEN STORING A LIVE AIR BAG ASSEMBLY OR WHEN LEAVING A LIVE AIR BAG ASSEMBLY UNATTENDED ON A BENCH OR OTHER SURFACE, ALWAYS FACE THE BAG AND TRIM COVER UP, AWAY FROM THE SURFACE. THIS IS NECESSARY SO THAT A FREE SPACE IS PROVIDED TO ALLOW THE AIR BAG TO EXPAND IN THE UNLIKELY EVENT OF ACCIDENTAL DEPLOYMENT. FAILURE TO FOLLOW PROCEDURES COULD RESULT IN PERSONAL INJURY. 37. Temporarily store the air bag assembly with the air bag opening facing up, away from the surface upon which it rests. Deploying the Airbags/Tensioner (Outside Vehicle) Deployment of a live (undeployed) airbag assembly for disposal should not take place in the vehicle. This includes vehicles that needs replacement airbag assembly. Disposal of a malfunctioning air bag assembly is subjected to a retention period. Proper service procedures must be followed when performing live (undeployed) airbag deployment in the shop floor or open area live (undeployed) airbag deployment. Safety glasses and gloves must always be worn during live (undeployed) airbag deployment until the deployed airbag assembly has been properly disposed of or an undeployed airbag assembly is shipped. Before performing the procedures you should be familiar with servicing the SRS and with proper handling of the air bag assembly. Procedures should be read fully before they are performed. Page 2847 Accelerator Pedal Position Sensor: Service and Repair Accelerator Position Sensor Replacement CAUTION: Remove the Accelerator (A) pedal assembly as a unit to have it services. Do not remove the Accelerator Position (AP) sensor on the A pedal. If the AP sensor is removed for emergency cause, refer to following Items as necessary. Removal Procedure 1. Disconnect the negative battery cable. 2. Disconnect the electrical harness from the AP sensor. 3. Remove the AP sensor. Installation Procedure 1. Install the accelerator position (AP) sensor to bolts with accelerator (A) pedal. 2. Connect the connector to AP sensor. 3. Install the negative battery cable. Page 3266 ^ If the idle speed ever exceeds 1,300 rpm 2. Remove the vacuum hose from the fuel pressure regulator, then start the engine. ^ If fuel comes out of the fuel pressure regulator vacuum hose connection, go to REPAIR PROCEDURE FUEL PRESSURE REGULATOR. ^ If no fuel comes out of the regulator, reconnect the vacuum hose and continue to step 3. 3. Connect the PGM Tester. Set it to Engine Data List. 4. Have an assistant drive the vehicle under the conditions described by the customer. 5. If the high or erratic idle condition occurs, note the values of the PSP Switch and APP Sensor 1 when it is occurring. ^ If the PSP Switch is HIGH, and you are not turning, go to REPAIR PROCEDURE POWER STEERING SWITCH. ^ If the APP Sensor 1 is greater than 15% and APP Sensor 2 and/or APP Sensor 3 are less than 85%, and the accelerator pedal is not depressed, go to REPAIR PROCEDURE APPS GROUND. ^ If the PSP Switch is reading LOW when not turning and HIGH when turning, and the APP Sensors are reading within the range shown, discontinue the test-drive and go to step 6. 6. Do these repairs: ^ REPAIR PROCEDURE APPS GROUND ^ REPAIR PROCEDURE ENGINE/BODY GROUND REPAIR PROCEDURE - FUEL PRESSURE REGULATOR 1. Relieve fuel system pressure: ^ Remove the fuel fill cap. ^ Remove the fuel pump relay. ^ Start the engine and run it until it stalls. ^ Crank the engine for 3 seconds. 2. Remove the vacuum hose from the fuel pressure regulator. 3. Remove the fuel pressure regulator shield from the common chamber (two bolts). Page 4278 This means the branch of the wire connects to another circuit. The arrow points to the name of the circuit branch where the wire continues. Page 6296 Wires Wire insulation can be one color, or one color with another color stripe. (The second color is the stripe.) This circuit continues on another image. (The arrow shows direction of current flow.) To follow the RED/BLK wire in this example, you would turn to "Fuel and Emissions" and look for the "A" arrow. Page 4268 Each schematic represents one circuit. A circuit's wires and components are arranged to show current flow, from power at the top of the page, to ground, at the bottom. Shared Circuits Other circuits may share power or ground terminals or wiring with the circuit shown. A wire that connects one circuit to another, for example, is cut short and has an arrowhead at the end of it pointing in the direction of current flow. Next to the arrowhead is the name of the circuit or component which shares that wiring. To quickly check shared wiring, check the operation of a component it serves. If that component works, you know the shared wiring is OK. Connectors All in-line and junction connectors are numbered (C725, C416, etc.). Component connectors are not numbered but are identified either by the name of Exhaust System - Catalytic Converter Noise Catalytic Converter: Technical Service Bulletins Exhaust System - Catalytic Converter Noise SOURCE: Honda Service News TITLE: Catalytic Converter Noise? Check the Heat Shield APPLIES TO: All models SERVICE TIP: Got a vehicle in your shop that buzzes or rattles, and you suspect the catalytic converter is the culprit? Before you start replacing the converter, first check the heat shield area. If there any stones or debris trapped inside, they can cause buzzing or rattling. Page 6460 12. Remove the three SDM fixing bolts (4) and remove SDM (3). Installation 1. Install the SDM (1) on bracket and fixing bolts (4) and tighten the fixing bolts to the specified torque. Torque: 10 ± 3 N.m (1.0 ± 0.3 kg.m / 87 ± 26 lb.in) 2. Connect the SDM harness connector (3) and after that, put CPA into connector (2). 3. Install air conditioning duct for rear seat to normal position. 4. Return carpet normal position. 5. Install right side stay between instrument panel and floor, tighten to the specified torque. Torque: 10 ± 3 N.m (1.0 ± 0.3 kg.m / 87 ± 26 lb.in) 6. Install PCM with bracket and tighten to the specified torque. (Y22SE 2.2L Engine only) Torque: 10 ± 3 N.m (1.0 ± 0.3 kg.m / 87 ± 26 lb.in) Page 2626 Wires Wire insulation can be one color, or one color with another color stripe. (The second color is the stripe.) This circuit continues on another image. (The arrow shows direction of current flow.) To follow the RED/BLK wire in this example, you would turn to "Fuel and Emissions" and look for the "A" arrow. Locations Sunroof Deflector (SWB) Page 5798 42. Reinstall both lower trailing links with new front mounting nuts and bolts. Hand-tighten the nuts. 43. Remove the ratcheting straps. 44. Lower the vehicle to the ground. 45. Carefully raise the rear of the body off the frame using the method you chose earlier in the repair, then remove the wood blocks. 46. With the body still raised off the frame, reinstall the No. 5 body mounts, and torque the bolts to 50 Nm (37 Ib-ft). 47. Spray some Noxudol 300 around the No. 4 body mount locations. 48. Carefully lower the body onto the frame, then torque the body mount nuts and bolts to 50 Nm (37 Ib-ft). 49. Torque the lower trailing link front mounting bolts to 165-180 Nm (122-133 Ib-ft). 50. Raise the vehicle, then reattach the EVAP canister line to the bulkhead (three clips). 51. Loosen the bracket bolts and clip from both front fenderwells. Reattach the ABS speed sensor harness clips in the front fenderwells, then torque the ABS speed sensor harness bracket bolts to 11 Nm (8 Ib-ft). Reconnect the ABS speed sensor harnesses. 52. Reattach the brake lines to the passenger's side of the frame using the four new clips from the kit. 53. Reattach the wire harness along the driver's side of the frame using the six new clips from the kit. 54. Reinstall the parking brake cable mounting brackets on both sides of the frame using the four new bolts from the kit. Torque the bolts to 7 Nm (5 Ib-ft). 55. Reinstall the fuel tank assembly using the new mounting bolts, the nut, and the clips from the kit. Torque the mounting bolts and the nut to 68 Nm (50 Ib-ft). 56. Reinstall the exhaust silencer (muffler) with a new gasket and new nuts. Torque the silencer nuts to 43 Nm (32 Ib-ft). Torque the silencer bracket mounting nuts to 15 Nm (11 lb-ft). 57. Reinstall the rear bumper assembly. Torque the bumper mounting bolts to 147 Nm (108 Ib-ft) 58. Reinstall the linear EGR valve with a new gasket. Torque the bolts to 25 Nm (18 Ib-ft). 59. Reinstall the radiator grille. 60. If the side steps or the running boards were removed, reinstall them. 61. Fill out the information on a campaign completion label. Stick this label to the back edge of the driver's door, just below the door latch. *NOTE: Page 7649 Dimmer Switch: Service and Repair Removal 1. Disconnect the battery ground cable. 2. Remove the instrument panel driver lower cover assembly (3). 3. Remove the illumination controller (2). - Disconnect the controller connector. - Remove the controller knob (1). - Remove the nut. - Remove the controller from the back side of the instrument panel driver lower cover assembly. Installation To install, follow the removal steps in the reverse order. Audio Unit with CD Player/Changer - Error Codes Compact Disc Player (CD): All Technical Service Bulletins Audio Unit with CD Player/Changer Error Codes 00-015 March 14, 2000 Applies To: All with CD Player/Changer Audio Unit Error Codes (Replaces 91-007, dated October 6, 1997) *If the audio unit displays an error code, use the troubleshooting tables in this service bulletin to troubleshoot the problem. Refer to service bulletin 98-019 for CD Player/Changer exchange information.* Audio System - CD/DVD Precautions Accelerator Pedal Position Sensor: All Technical Service Bulletins Accelerator Pedal Assembly/Sensor - Adjustment Update 00-045 August 14, 2001 Applies To: 2000-02 Passport - ALL Service Manual Update: Accelerator Pedal Position Sensor (APPS) (Supersedes 00-045, dated May 23, 2000) Updated information is shown by asterisks and black bars. BACKGROUND When the accelerator pedal position sensor (APPS) or the accelerator pedal assembly is replaced for any reason, you must adjust the APPS. *This procedure is missing in the 2000 service manual and is wrong in the 2001 and 2002 service manuals. Make a note on page 6E2-539 of the 2000 Passport Fuel and Emissions manual, on page 6E2-553 of the 2001 Passport Fuel and Emissions manual, and on page 6E2-545 of the 2002 Passport Fuel and Emissions manual to refer to this bulletin.* ADJUSTMENT PROCEDURE 1. Replace the APPS or the accelerator pedal assembly, and leave the mounting screws for the APPS loose. 2. Connect the PGM Tester to the data link connector (DLC), and turn the ignition switch to ON (II). *3. While watching the APP Sensor values in the Engine Data List, adjust the APPS by turning it until the values are within the ranges shown at closed pushed all the way down), then tighten the throttle and wide open throttle (accelerator pedal mounting screws and recheck the values. ^ If all three sensors are within range, go to step 12. ^ If APP Sensor 1, APP Sensor 2, and/or APP Sensor 3 cannot be brought into range, go to step 4. 4. Troubleshoot for an open circuit or a PCM malfunction. ^ If APP Sensor 1 has a value of 0% or APP Sensor 2 and/or APP Sensor 3 have a value of 99%, an open circuit exists or the PCM is malfunctioning. Repair the circuit or replace the PCM, and repeat step 3. ^ If you don't find a problem, go to step 5. 5. Disconnect the 10P connector from the APPS. 6. View the APP Sensor values in the Engine Data List. ^ If APP Sensor 1 has a value of 0% or APP Sensor 2 and/or APP Sensor 3 have a value of 99%, go to step 7. ^ If APP Sensor 1 has a value other than 0%, or APP Sensor 2 and/or APP Sensor 3 have a value other than 99%, a short circuit exists or the PCM is malfunctioning. Repair the circuit or replace the PCM, and repeat step 3. Page 3709 Wire Color Abbreviations The following abbreviations are used to identify wire colors in the circuit schematics: WHT................................... White YEL................................... Yellow BLK................................... Black BLU................................... Blue GRN................................... Green RED................................... Red ORN................................... Orange PNK................................... Pink BRN................................... Brown GRY................................... Gray PUR................................... Purple LT BLU................................... Light Blue LT GRN................................... Light Green Page 6406 2. Remove air bag assembly from steering wheel by removing two bolts. Lift air bag assembly out of steering wheel. 3. Disconnect connector and remove air bag assembly. 4. Disconnect horn lead. Installation 1. Connect air bag to wiring harness connector. NOTE: Pass the lead wire through the tabs on the plastic cover (wire protector) of air bag to prevent lead wire from being pinched. 2. Correct horn lead. 3. Install air bag into steering wheel and tighten bolts to specified sequence as shown in figure. Torque: 8.8 N.m (0.9 kg.m / 78 lb.in) CAUTION: Never use the air bag assembly from another vehicle. Use only the air bag assembly for UE. 4. Enable the Supplemental Restraint System (SRS). Specifications Fuel Injector: Specifications Information not provided by the manufacturer. Page 6678 and the fuses. From Fuses to Relays and Components The second half of Power Distribution shows the wiring "From Fuses to Relays and Components." This can speed your troubleshooting by showing which circuits share fuses. If Power Distribution shows that an inoperative circuit and another circuit share a fuse, check a component in the other circuit. If it works, you know the fuse is good and power is available to the inoperative circuit. Ground Distribution Schematics Page 121 Ground - "G" Shielding Sheilding This represents RFI (Radio Frequency Interference) shielding around a wire. The shielding is always connected to ground. Splices Page 3790 2. Compare the retrieved code with the listed codes. ^ If the code is in the list, go to step 3. ^ If the code is not in the list, the PCM has already been updated. Troubleshoot other causes for the detonation. NOTE: Since the Smart Cable may need to be cleared from a previous PCM update or the Smart Cable firmware may need to be reprogrammed, always begin each PCM update at the iN workstation. 3. Update the PCM software with the Smart Cable. For instructions, refer to Service Bulletin 99-005. NOTE: Make sure you select the most recent broadcast code from the list on the iN screen that applies to the model year, transmission type, and emission level. This code is not necessarily at the top of the list since the most recent code is the last one in the alphabetical sequence, letter by letter. 4. Use the PGM Tester to clear any DTCs set during programming. 5. Retrieve the broadcast code. Make sure it does not match any of the codes in the list in step 2 (indicating the PCM has been updated) and that it applies to the model year, transmission type, and emission level for the vehicle. The broadcast code should match a code in the list below. Disclaimer Page 7088 the component if the component only has one connector, or by a capital letter (A, B, C, etc.) if the component has more than one connector. Below most connector numbers and component names are PHOTO and VIEW numbers. The PHOTO number refers to a photo in the back of the book that shows the connector's location on the car. The VIEW number refers to an illustration in the back of the book that shows the connector face, wire colors, connector cavity numbers, and other details. The connector cavity numbering sequence begins at the top left corner of the connector. Disregard any numbers molded into the connector housing. Wires Wires are identified by the abbreviated names of their colors; the second color is the color of the stripe. Wires are also identified by their location in a connector. The number "2" next to the male and female wire terminals at C416, for example, means those terminals join in cavity 2 of connector C416. Symbols A complete description of schematic symbols is given under wire color abbreviation. Power Distribution Schematics Power Distribution schematics show how power is supplied from the positive battery terminal to various circuits in the car. Refer to the Power Distribution section to get a more detailed picture of how power is supplied to the circuit you're working on. From Battery to Ignition Switch, Fuses, and Relays Individual circuit schematics begin with a fuse. The first half of Power Distribution, however, shows the wiring "upstream" between the battery Page 1088 Spark Plug: Application and ID Plug Types: K16PR-P11 RC10PYPP4 PK16PR11 Page 5932 2. Connect one lead of a self-powered test light or DVOM to one end of the part of the circuit you want to test. 3. Connect the other lead to the other end. 4. If the self-powered test light glows, there is continuity. If you're using a DVOM, a low reading or no reading (zero), means good continuity. Testing For Voltage When testing for voltage at a connector without wire seals, you do not have to separate the two halves of the connector. Instead, probe the connector from the back. Always check both sides of the connector because dirty, corroded, and bent terminals can cause problems (no electrical contact = an open). 1. Connect one lead of the lest light to a known good ground, or, if you're using a digital volt ohmmeter (DVOM), place it in the appropriate DC volts range, and connect its negative lead to ground. 2. Connect the other lead of the test light or DVOM to the point you want to check. 3. If the test light glows, there is voltage present. If you're using a DVOM, note the voltage reading. It should be within one volt of measured battery voltage. A loss of more than one volt indicates a problem. NOTE: Always use a DVOM on high impedance circuits. A test light may not glow (even with battery voltage present). Testing For Voltage Drop Wires, connectors, and switches are designed to conduct current with a minimum loss of voltage. A voltage drop of more than one volt indicates a problem. 1. Place the digital volt/ohmmeter (DVOM) in the appropriate DC volts range. Connect the positive lead to the end of the wire (or to the connector or switch) closest to the battery. 2. Connect the negative lead to the other end of the wire (or the other side of the connector or switch). 3. Turn on the components in the circuit. 4. The DVOM will show the difference in voltage between the two points. A difference, or drop, of more than one volt indicates a problem. Check the circuit for loose, dirty, or bent terminals. Page 1288 Air Bag(s) Arming and Disarming: Description and Operation Definitions Air Bag An inflatable cloth cushion designed to deploy in certain frontal crashes. It supplements the protection offered by the seat belts by distributing the impact load more evenly over the vehicle occupant's head and torso. Asynchronous Performed in a nonperiodic fashion, (i.e., no defined time or interval). (B+) Battery voltage, (B+) The voltage available at the battery at the time of the indicated measurement. With the key "ON" and the engine not running, the system voltage will likely be between 12 and 12.5 volts. At idle the voltage may be 14 to 16 volts. The voltage could be as low as 10 volts during engine cranking. Bulb Check The SDM will cause the "AIR BAG" warning lamp to flash seven times and then go "OFF" whenever the ignition switch transitions to the ON position from any other ignition switch position and no malfunctions are detected. "CONTINUOUS MONITORING" Tests performed by the SDM on the SRS every 100 milliseconds while "Ignition 1" voltage is in the normal operating voltage range at the SDM. Data Link Connector (DLC) Formerly "DLC" a connector which allows communication with an external computer, such as a scan tool. Datum Line A base line parallel to the plane of the underbody or frame from which all vertical measurements originate. Deploy To inflate the air bag. Deployment Loops The circuits which supply current to the air bag assemblies to deploy the air bag. Diagnostic Trouble Code (DTC) Formerly "Code", a numerical designator used by the SDM to indicate specific SRS malfunctions. Driver Current Source An output of the SDM which applies current into the driver air bag assembly circuit during the "Initiator Assembly Resistance Test". Driver Air Bag Assembly An assembly located in the steering wheel hub consisting of an inflatable bag, an inflator and an initiator. EEPROM Electronically Erasable Programmable Read Only Memory. Memory which retains its contents when power is removed from the SDM. Ignition Cycle The voltage at the SDM "Ignition 1" inputs, with ignition switch "ON", is within the normal operating voltage range for at least ten seconds before turning ignition switch "OFF". Ignition 1 Page 1726 Timing Belt: Service and Repair Timing Belt Installation THIS ARTICLE HAS BEEN UPDATED BY TSB 02-047 NOTE: - Do not install the timing belt until you are sure the camshafts, camshaft pulleys, and crankshaft timing pulley are in their correct "timed" positions. - Left and right engine callouts are from the driver's seat. 1. With the green direction arrows on the timing belt pointing clockwise, slip the belt over the right camshaft pulley so its solid white line (the line closest to the direction arrows) aligns with the mark on the pulley. Secure the belt to the pulley with a large binder clip. 2. Wrap the timing belt around the bottom of the water pump pulley, and draw it tight. 3. Slip the timing belt over the left camshaft pulley so its other solid white line (the one farthest from the direction arrows) aligns with the mark on the pulley. Secure the belt to the pulley with a large binder clip. 4. Wrap the timing belt around the inner side of the idler pulley, then slip the belt over the crankshaft timing pulley with its dotted white line aligned to the green mark on the crankshaft timing pulley. NOTE: For correct belt stretch, the doffed line must meet the green mark on the crankshaft timing pulley at the 9 o'clock position. If there isn't enough slack to slip the belt over the pulley in the correct position, turn the crankshaft a few degrees counterclockwise, install the belt, then turn the crankshaft back to the 9 o'clock position. Front Hub and Disc Front Hub And Disc (4WD) Page 5787 Install the lower trailing link front mounting nut and bolt hand-tight, then torque the remaining bolts and nuts, in the order shown on the illustration below: ^ Torque the bracket bolts to 35 Nm (25 Ib-ft). ^ Torque the body mount studs and nut to 30 Nm (22 Ib-ft). Page 4691 Wire Color Abbreviations The following abbreviations are used to identify wire colors in the circuit schematics: WHT................................... White YEL................................... Yellow BLK................................... Black BLU................................... Blue GRN................................... Green RED................................... Red ORN................................... Orange PNK................................... Pink BRN................................... Brown GRY................................... Gray PUR................................... Purple LT BLU................................... Light Blue LT GRN................................... Light Green Locations Page 450 Distinct Of Circuit By Wire Base Color All wires have color-coded insulation. Wires belonging to a system's main harness will have a single color. Wires belonging to a system's sub-circuits will have a colored stripe. Striped wires use the codes found in the chart to show wire size and colors. Abbreviations are used to indicate wire color within a circuit diagram. How to Identify Connector Terminals How to Identify Connector Terminals Cavity Numbering System The cavities (and wire terminals) in each connector are numbered starting from the upper left, looking at the male terminals from the terminal side (or looking at the female terminals from the wire side. Both views are in the same direction so the numbers are the same.) All actual cavities are numbered, even if they have no wire terminals in them. NOTE: Data Link Connector (DLC) terminals are numbered according to SAE standard J1962, not the Honda standard. The numbers of the four end terminals are molded into the corners of the connector face. The connector cavity number is listed next to each terminal on the circuit schematic. The cavity / terminal shown is # 6. Using/Identifying Connector Terminal Views How to Use Connector Terminal Views To see the configuration of a connector's cavities, look up its view number in the Connector Views. Each view includes the color of the connector, where Page 1576 Valve Guide Replacement 1. Using Valve guide replacer: J-42899, drive out the valve guide from the combustion chamber side. 2. Apply engine oil to the outside of the valve guide. Using valve guide replacer J-42899, drive in a new valve guide from the camshaft side, and check the valve guide height. Valve guide upper end height: 13.0 mm (0.5118 inch) (Measured from the cylinder head upper face) 3. Check the clearance. If the clearance is less than the specified value, ream the inside diameter of valve guide. Using a sharp 6 mm reamer, ream the valve guide to obtain the specified clearance. Valve Seat 1. Measure the protrusion of the valve stem when a new valve is installed in the cylinder head. If the protrusion of the valve stem exceeds the limit, replace the valve seat insert or the cylinder head assembly. Protrusion of valve stem Intake Standard: 39.32 mm (1.5480 inch) Page 2002 Distinct Of Circuit By Wire Base Color All wires have color-coded insulation. Wires belonging to a system's main harness will have a single color. Wires belonging to a system's sub-circuits will have a colored stripe. Striped wires use the codes found in the chart to show wire size and colors. Abbreviations are used to indicate wire color within a circuit diagram. How to Identify Connector Terminals How to Identify Connector Terminals Cavity Numbering System The cavities (and wire terminals) in each connector are numbered starting from the upper left, looking at the male terminals from the terminal side (or looking at the female terminals from the wire side. Both views are in the same direction so the numbers are the same.) All actual cavities are numbered, even if they have no wire terminals in them. NOTE: Data Link Connector (DLC) terminals are numbered according to SAE standard J1962, not the Honda standard. The numbers of the four end terminals are molded into the corners of the connector face. The connector cavity number is listed next to each terminal on the circuit schematic. The cavity / terminal shown is # 6. Using/Identifying Connector Terminal Views How to Use Connector Terminal Views To see the configuration of a connector's cavities, look up its view number in the Connector Views. Each view includes the color of the connector, where Page 2687 2. Connect the short finder across the battery terminals and the load (component) side of the fuse terminal. 3. Close all switches in the circuit you're testing. 4. Turn on the short finder. This creates a pulsing magnetic field around the wiring between the fuse box and the short. 5. Beginning at the fuse box, slowly move the short finder along the circuit wiring. The meter will read current pulses through sheet metal and body trim. As long as the meter is between the fuse and the short, the needle will move with each current pulse. Once you move the meter past the point of the short, the needle will stop moving. Check the wiring and connectors in this area to locate the cause of the short. Testing For Continuity When testing for continuity at a connector without wire seals, you do not have to separate the two halves of the connector. Instead, probe the connector from the back. Always check both sides of the connector because dirty, corroded, and bent terminals can cause problems (no electrical contact = an open). 1. Disconnect the negative cable from the car battery. If you're using a DVOM, place it in the lowest "OHMS" range. Page 4218 Ground - "G" Shielding Sheilding This represents RFI (Radio Frequency Interference) shielding around a wire. The shielding is always connected to ground. Splices Page 1282 Air Bag(s) Arming and Disarming: Service Precautions Precautions For Electrical Inspections Precautions For Electrical Inspections When using electrical test equipment, insert the probe of the tester into the wire side of the connector. Do not insert the probe of the tester into the terminal side of the connector, and do not tamper with the connector. Use a U-shaped probe. Do not insert the probe forcibly. Use specified service connectors in troubleshooting. Using improper tools could cause an error in inspection due to poor metal-to-metal contact. Page 5620 5. Install air bag into steering wheel and tighten bolts (7) to specified sequence as show in figure. Torque: 8.8 N.m (78 lb in) CAUTION: Never use the air bag assembly from another vehicle and difference model year air bag assembly. The air bag assembly has identification colors on the bar code label from '00 model as follows. Light blue color for driver air bag assembly. Light blue color for passenger air bag assembly. Use only the air bag assembly for Rodeo or Amigo. 6. Enable the SRS. Locations 105. Left Side of Driver's Seat Locations 46 - Top Front Of 3.2L Engine (Intake Duct Removed) Page 2828 11. Using a jumper wire, connect the reference voltage of each circuit to its signal input and view the APP Sensor values in the Engine Data List. APP Sensor 1 should have a value of 99%, and APP Sensor 2 and APP Sensor 3 should each have a value of 0%. ^ If the values are not as specified, troubleshoot for high resistance on the signal input or a PCM malfunction. Repair the circuit or replace the PCM, then repeat step 3. ^ If the values are as specified, the problem may be intermittent. Disconnect the 10P connector from the modified APPS, and connect it to the new APPS; then repeat step 3. Wiggle the APPS wires as you go through the adjustment procedure to find the intermittent problem. 12. Turn off the ignition switch, and disconnect the PGM Tester.* DISCLAIMER Page 181 2. Connect the short finder across the battery terminals and the load (component) side of the fuse terminal. 3. Close all switches in the circuit you're testing. 4. Turn on the short finder. This creates a pulsing magnetic field around the wiring between the fuse box and the short. 5. Beginning at the fuse box, slowly move the short finder along the circuit wiring. The meter will read current pulses through sheet metal and body trim. As long as the meter is between the fuse and the short, the needle will move with each current pulse. Once you move the meter past the point of the short, the needle will stop moving. Check the wiring and connectors in this area to locate the cause of the short. Testing For Continuity When testing for continuity at a connector without wire seals, you do not have to separate the two halves of the connector. Instead, probe the connector from the back. Always check both sides of the connector because dirty, corroded, and bent terminals can cause problems (no electrical contact = an open). 1. Disconnect the negative cable from the car battery. If you're using a DVOM, place it in the lowest "OHMS" range. Component Locations 54. Below Center of Dash (Console Removed) Page 148 Powertrain Control Module: Component Tests and General Diagnostics Powertrain Control Module (PCM) Diagnosis To read and clear diagnostic trouble codes, use a Tech 2. IMPORTANT: Use of a Tech 2 is recommended to clear diagnostic trouble codes from the PCM memory. Diagnostic trouble codes can also be cleared by turning the ignition "OFF" and disconnecting the battery power from the PCM for 30 seconds. Turning off the ignition and disconnecting the battery power from the PCM will cause all diagnostic information in the PCM memory to be cleared. Therefore, all the diagnostic tests will have to be re-run. Since the PCM can have a failure which may affect only one circuit, following the diagnostic procedures will determine which circuit has a problem and where it is. If a diagnostic chart indicates that the PCM connections or the PCM is the cause of a problem, and the PCM is replaced, but this does not correct the problem, one of the following may be the reason: - There is a problem with the PCM terminal connections. The terminals may have to be removed from the connector in order to check them properly. - EEPROM program is not correct for the application. Incorrect components or reprogramming the PCM with the wrong EEPROM program may cause a malfunction and may or may not set a DTC. - The problem is intermittent. This means that the problem is not present at the time the system is being checked. In this case, refer to Symptom Diagnosis and make a careful physical inspection of all component and wiring associated with the affected system. - There is a shorted solenoid, relay coil, or harness. Solenoids and relays are turned "ON" and "OFF" by the PCM using internal electronic switches called drivers. A shorted solenoid, relay coil, or harness will not damage the PCM but will cause the solenoid or relay to be inoperative. Page 5772 REQUIRED MATERIALS TOOL INFORMATION Page 5698 LH Page 401 Coolant Temperature Sensor/Switch (For Computer): Service and Repair ENGINE COOLANT TEMPERATURE (ECT) SENSOR REMOVAL PROCEDURE NOTE: Care must be taken when handling the engine coolant temperature (ECT) sensor. Damage to the ECT sensor will affect proper operation of the fuel injection system. 1. Disconnect the negative battery cable. 2. Drain the radiator coolant. Refer to Draining and Refilling Cooling System. 3. Disconnect the electrical connector. 4. Remove the ECT sensor from the coolant crossover. INSTALLATION PROCEDURE 1. Apply sealer or the equivalent to the threads of the ECT sensor. 2. Install the ECT sensor in the coolant crossover. Tighten Tighten the ECT sensor to 30 N.m (22 lb ft.). Page 2572 Wires Wire insulation can be one color, or one color with another color stripe. (The second color is the stripe.) This circuit continues on another image. (The arrow shows direction of current flow.) To follow the RED/BLK wire in this example, you would turn to "Fuel and Emissions" and look for the "A" arrow. Page 1090 may be due to improper gap adjustment or to excessive wear of the electrode during use. A check of the gap size and comparison to the gap specified for the vehicle in Maintenance and Lubrication will tell if the gap is too wide. A spark plug gap that is too small may cause an unstable idle condition. Excessive gap wear can be an indication of continuous operation at high speeds or with engine loads, causing the spark to run too hot. Another possible cause is an excessively lean fuel mixture. Low or high spark plug installation torque or improper seating can result in the spark plug running too hot and can cause excessive center electrode wear. The plug and the cylinder head seats must be in good contact for proper heat transfer and spark plug cooling. Dirty or damaged threads in the head or on the spark plug can keep it from seating even though the proper torque is applied. Once spark plugs are properly seated, tighten them to the torque shown in the Specifications Table. Low torque may result in poor contact of the seats due to a loose spark plug. Overtightening may cause the spark plug shell to be stretched and will result in poor contact between the seats. In extreme cases, exhaust blow-by and damage beyond simple gap wear may occur. Cracked or broken insulators may be the result of improper installation, damage during spark plug re-gapping, or heat shock to the insulator material. Upper insulators can be broken when a poorly fitting tool is used during installation or removal, when the spark plug is hit from the outside, or is dropped on a hard surface. Cracks in the upper insulator may be inside the shell and not visible. Also, the breakage may not cause problems until oil or moisture penetrates the crack later. A broken or cracked lower insulator tip (around the center electrode) may result from damage during re-gapping or from "heat shock" (spark plug suddenly operating too hot). - Damage during re-gapping can happen if the gapping tool is pushed against the center electrode or the insulator around it, causing the insulator to crack. When re-gapping a spark plug, make the adjustment by bending only the ground side terminal, keeping the tool clear of other parts. - "Heat shock" breakage in the lower insulator tip generally occurs during several engine operating conditions (high speeds or heavy loading) and may be caused by over-advanced timing or low grade fuels. Heat shock refers to a rapid increase in the tip temperature that causes the insulator material to crack. Spark plugs with less than the recommended amount of service can sometimes be cleaned and re-gapped then returned to service. However, if there is any doubt about the serviceability of a spark plug, replace it. Spark plugs with cracked or broken insulators should always be replaced. Service and Repair Heated Glass Element Switch: Service and Repair Removal 1. Disconnect the battery ground cable. 2. Remove the meter cluster assembly (1). 3. Remove the rear defogger switch (2). - Disconnect the switch connector. - To remove the switch, push the lock from the back side of the meter cluster assembly. Installation To install, follow the removal steps in the reverse order. Page 7762 Wire Color Abbreviations The following abbreviations are used to identify wire colors in the circuit schematics: WHT................................... White YEL................................... Yellow BLK................................... Black BLU................................... Blue GRN................................... Green RED................................... Red ORN................................... Orange PNK................................... Pink BRN................................... Brown GRY................................... Gray PUR................................... Purple LT BLU................................... Light Blue LT GRN................................... Light Green Page 3148 7. Modify the original APPS by cutting the connector housing off of the sensor. 8. Connect the 10P connector to the modified APPS connector housing. 9. Using a DVOM, check the voltage between the reference voltage pin for each sensor and ground. ^ If the sensor circuits all read 5.0 volts, go to step 11. ^ If any sensor circuit is above or below 5.0 volts, go to step 10. 10. Troubleshoot for an internal short in another sensor or a PCM malfunction. ^ To find the sensor with an internal short, monitor the incorrect reference voltage, and disconnect each sensor (FTPS, EGR, MAP, TPS, CKP, and CMP) one at a time until the reference voltage reads 5.0 volts. Replace that sensor, and repeat step 3. ^ To find a malfunctioning PCM, replace it with a known-good PCM. If all three sensors (APP Sensor 1, APP Sensor 2, and APP Sensor 3) are within range, the original PCM is faulty; replace it and repeat step 3. Page 1507 10. Remove the piston pin (9) using J-24086-C piston pin service set and piston support with a press. Note: Keep the parts removed from each cylinder separate. All parts must be reinstalled in their original positions. Heating the connecting rod will permit easy removal of the piston pin. 11. Piston (10) 12. Connecting rod (11) Inspection and Repair Pistons (10) Carefully clean away all the carbon adhering to the piston head and the piston ring grooves. Note: Never use a wire brush to clean the pistons. Damage will result Visually check each piston for cracking, scoring, and other signs of excessive wear. If any of the above conditions are found, the piston must be replaced. Piston Diameter 1. Measure the piston outside diameter with micrometer at the piston grading position and a right angle to the piston pin. Piston grading position (from piston head) Piston grading position: 43.0 mm (1.6929 inch) Removal/Installation Brake Master Cylinder: Service and Repair Removal/Installation REMOVAL CAUTION: When removing the master cylinder from the vacuum booster, be sure to get rid of the internal negative pressure of the vacuum booster (by, for instance, disconnecting the vacuum hose) in advance. If any negative pressure remains in the vacuum booster, the piston may possibly come out when the master cylinder is being removed, letting the brake fluid run out. While removing the master cylinder, further, do not hold the piston as it can be easily pulled out. Outside surface of the piston is the surface on which seals are to slide. Care should be taken to keep the surface free of cuts and dents. 1. Disconnect electrical connector. 2. Remove brake pipes and after disconnecting the brake pipe, cap or tape the openings of the brake pipe to prevent the entry of foreign matter. 3. Remove 2 attaching nuts. 4. Remove P&B; valve and bracket 5. Remove master cylinder. 6. Remove spacer and the 2 gaskets. INSPECTION AND REPAIR Master Cylinder The master cylinder is not repairable and must be replaced as a complete assembly if found defective. Inspection Excessive brake pedal travel, malfunction or dragging brake suggests that the master cylinder is defective. In such cases perform the following visual check: Visual Check Page 5181 direction from the jump-out position. In measuring the dimension, pull the pinion out a little in the arrow direction. Dimension(L): 0.05 mm to 1.5 mm (0.002 in to 0.06 in) If the measured value is out of standard, insert dust cover, or disassemble and adjust. Characteristic Test For easily confirming the characteristics, conduct the no load test as follows: Rating as short as 30 seconds requires rapid testing. Fix the starter on the test bench, and wire as shown in illustration. When the switch is closed, the current flows and the starter runs under no load. At this time, measure current, voltage and speed to check if they satisfy the standard Page 7027 12. Remove the tonneau cover assembly (1). 13. Remove the lower anchor bolt cover (6) and the lower anchor bolt (5) from the rear seat belt. 14. Remove the lower quarter trim cover (1). - Remove the tool box lid (3) and fixing screw (4). Pry the five (RH) or six (LH) clip positions (2) free from the body panel. - Disconnect the accessory socket connector (LH side). 15. Remove the upper quarter trim cover (1). - Pry the twelve clip positions (2) free from the body panel. Page 3337 The name of the component appears next to it followed by notes about its function along with any photo and connector view references. Connector "C" How to Identify Connector Terminals Cavity Numbering System The cavities (and wire terminals) in each connector are numbered starting from the upper left, looking at the male terminals from the terminal side (or looking at the female terminals from the wire side. Both views are in the same direction so the numbers are the same.) All actual cavities are numbered, even if they have no wire terminals in them. NOTE: Data Link Connector (DLC) terminals are numbered according to SAE standard J1962, not the Honda standard. The numbers of the four end terminals are molded into the corners of the connector face. Page 1441 Page 7024 Trim Panel: Service and Repair Rear Door Trim Panel Removal 1. Disconnect the battery ground cable. 2. Remove the regulator handle(1). - Pull the hook(2) out and remove the regulator handle. 3. Remove the one screw from the pullcase. Page 3451 14. While watching the APP Sensor values in the Engine Data List, adjust the APPS by turning it until the values are within the ranges shown at closed throttle and wide open throttle (accelerator pedal pushed all the way down), then tighten the mounting screws and recheck the values. ^ If all three sensors are within range, go to step 23. ^ If APP Sensor 1 APP Sensor 2, and/or APP Sensor 3 cannot be brought into range, go to step 15. 15. Troubleshoot for an open circuit or a PCM malfunction. ^ If APP Sensor 1 has a value of 0% or APP Sensor 2 and/or APP Sensor 3 have a value of 99%, an open circuit exists or the PCM is malfunctioning. Repair the circuit or replace the PCM, and repeat step 14. ^ If you don't find a problem, go to step 16. 16. Disconnect the 10 P connector from the APPS. 17. View the APP Sensor values in the Engine Data List. ^ If APP Sensor 1 has a value of 0% or APP Sensor 2 and/or APP Sensor 3 have a value of 99%, go to step 18. ^ If APP Sensor 1 has a value other than 0%, or APP Sensor 2 and/or APP Sensor 3 have a value other than 99%, a short circuit exists or the PCM is malfunctioning. Repair the circuit or replace the PCM, and repeat step 14. 18. Modify the original APPS by cutting the connector housing off of the sensor. 19. Connect the 10 P connector to the modified APPS connector housing. Page 2441 14. While watching the APP Sensor values in the Engine Data List, adjust the APPS by turning it until the values are within the ranges shown at closed throttle and wide open throttle (accelerator pedal pushed all the way down), then tighten the mounting screws and recheck the values. ^ If all three sensors are within range, go to step 23. ^ If APP Sensor 1 APP Sensor 2, and/or APP Sensor 3 cannot be brought into range, go to step 15. 15. Troubleshoot for an open circuit or a PCM malfunction. ^ If APP Sensor 1 has a value of 0% or APP Sensor 2 and/or APP Sensor 3 have a value of 99%, an open circuit exists or the PCM is malfunctioning. Repair the circuit or replace the PCM, and repeat step 14. ^ If you don't find a problem, go to step 16. 16. Disconnect the 10 P connector from the APPS. 17. View the APP Sensor values in the Engine Data List. ^ If APP Sensor 1 has a value of 0% or APP Sensor 2 and/or APP Sensor 3 have a value of 99%, go to step 18. ^ If APP Sensor 1 has a value other than 0%, or APP Sensor 2 and/or APP Sensor 3 have a value other than 99%, a short circuit exists or the PCM is malfunctioning. Repair the circuit or replace the PCM, and repeat step 14. 18. Modify the original APPS by cutting the connector housing off of the sensor. 19. Connect the 10 P connector to the modified APPS connector housing. Page 2194 2. Unfasten C123 from the side of the engine compartment using a 90-degree pick. 3. Disconnect C123, and clean the terminals on both sides of the connector with contact cleaner. Shake the residue out of the connector. Allow the contact cleaner to evaporate for at least 3 minutes, then reconnect C123. 4. Fasten C123 to the left side of the engine compartment, and reinstall the air cleaner housing cover. 5. Remove the connector position assurance (CPA) clip from the APPS connector. 6. Disconnect the lop connector from the APPS. 7. Clean the terminals of the 10P APPS connector (harness side) with contact cleaner. Shake out residue from the connector, and allow the contact cleaner to evaporate for at least 3 minutes, then reconnect it. 8. Use the Smart Cable to reprogram the PCM with the latest software from the June 2001 or later HONDANET CD-ROM. Refer to Service Bulletin 99-005, Updating the Passport PCM, filed under Tools. 9. Use the PGM Tester to clear any DTCs. Page 6345 Air Bag(s) Arming and Disarming: Service Precautions Precautions For Electrical Inspections Precautions For Electrical Inspections When using electrical test equipment, insert the probe of the tester into the wire side of the connector. Do not insert the probe of the tester into the terminal side of the connector, and do not tamper with the connector. Use a U-shaped probe. Do not insert the probe forcibly. Use specified service connectors in troubleshooting. Using improper tools could cause an error in inspection due to poor metal-to-metal contact. Diagrams Power Window Switch: Diagrams Page 5131 1. Measure the resistance between each diode terminal and aluminum diode fin in forward and reverse directions with the connection of the tester leads switched. The diodes are normal if resistance is nearly zero ohms in one direction and is infinitely high in the other direction. 2. If a diode has no resistance or equal resistance in both directions, it is defective and should be replaced together with the holder. IC Regulator Assembly Connect a variable resistor, two 12V batteries, a fixed resistor, and a voltmeter to the IC regulator as shown in illustration. a. Measuring equipment specifications 1. Fixed resistor (R1) :10 Ohms /3 W 2. Variable resistor (Rv) : 0 - 300 Ohms/12 W 3. Batteries (BAT1 BAT2) :12 V (2 Batteries) 4. DC voltmeter: 0 - 50 V/0.5 steps (4 Check points) b. Measuring procedure 1. Measure the voltage "V1" across the first battery (BAT1). If the reading is between 10 and 13 volts, the battery is normal. 2. Measure the voltage "V3" across both the batteries (BAT1, BAT2). If the reading is between 20 and 26 bolts, the batteries are normal. 3. Gradually increase the resistance of the variable resistor from zero. Measure the voltage "V2" (the voltage across the F and E terminals). Check to see that the voltage across "Vi" changes at this time. If there is no change, the voltage regulator is faulty and must be replaced. 4. Measure the voltage at "V4" (the voltage across the variable resistor center tap and terminal E with the variable resistor resistance held constant). The measure voltage should be within the specified (14.4 ± 0.3 volts) limits. If it is not, the regulator must be replaced. Diagram Information and Instructions Powertrain Control Module: Diagram Information and Instructions How to Identify Wiring Color-Coded Insulation Wire Color Wire Color Coding Page 268 This means the branch of the wire connects to another circuit. The arrow points to the name of the circuit branch where the wire continues. Page 8146 Power Window Switch: Service and Repair Rear Passengers Window Switches Removal 1. Disconnect the battery ground cable. 2. Remove the rear door trim pad (2). - Disconnect the rear power window switch (1) connector. 3. Remove the rear power window switch (1). - Remove the switch fixing screw from the back side of the rear door trim (2). Installation To install, follow the removal steps in the reverse order. Page 108 2. Compare the retrieved code with the listed codes. ^ If the code is in the list, go to step 3. ^ If the code is not in the list, the PCM has already been updated. Troubleshoot other causes for the detonation. NOTE: Since the Smart Cable may need to be cleared from a previous PCM update or the Smart Cable firmware may need to be reprogrammed, always begin each PCM update at the iN workstation. 3. Update the PCM software with the Smart Cable. For instructions, refer to Service Bulletin 99-005. NOTE: Make sure you select the most recent broadcast code from the list on the iN screen that applies to the model year, transmission type, and emission level. This code is not necessarily at the top of the list since the most recent code is the last one in the alphabetical sequence, letter by letter. 4. Use the PGM Tester to clear any DTCs set during programming. 5. Retrieve the broadcast code. Make sure it does not match any of the codes in the list in step 2 (indicating the PCM has been updated) and that it applies to the model year, transmission type, and emission level for the vehicle. The broadcast code should match a code in the list below. Disclaimer Locations Page 4454 Wire Color Abbreviations The following abbreviations are used to identify wire colors in the circuit schematics: WHT................................... White YEL................................... Yellow BLK................................... Black BLU................................... Blue GRN................................... Green RED................................... Red ORN................................... Orange PNK................................... Pink BRN................................... Brown GRY................................... Gray PUR................................... Purple LT BLU................................... Light Blue LT GRN................................... Light Green Page 7209 Sunroof / Moonroof Module: Service and Repair Removal 1. Disconnect the battery ground cable. 2. Remove the headlining (2). 3. Remove the sunroof control unit (1). - Disconnect two connectors. - Remove two screws. Installation To install, follow the removal steps in the reverse order. Page 2940 10. Use the PGM Tester to check the broadcast code. Make sure the broadcast code matches the one you selected from the CD-ROM. WARRANTY CLAIM INFORMATION In warranty: The normal warranty applies. Failed Part: P/N 8-17087-655-0 H/C 4375820 Defect Code: 064 Contention Code: C01 Skill Level: Repair Technician Out of warranty: Any repair performed after warranty expiration may be eligible for goodwill consideration by the District Service Manager or your Zone Office. You must request consideration, and get a decision, before starting work. REPAIR PROCEDURE - ENGINE/BODY GROUND 1. Use the ETM for the appropriate year to locate these ground connectors: G101, G104, G105, G106 and G160. 2. Inspect each connector for corrosion or looseness. 3. Remove the bolt from any connector that is corroded or loose. Clean the terminal connector with a wire brush. File flat any solder bumps on the connector. 4. Clean the contact surface on the engine or body with a wire brush. 5. Replace the bolt if it is heavily corroded. Otherwise, clean it with a wire brush. 6. Apply lithium dielectric grease to both sides of the terminal connector. 7. Reinstall the bolt, torque it to 14 N.m (10 lb-ft). 8. Use the Smart Cable to reprogram the PCM with the latest software from the June 2001 or later HONDANET CD-ROM. Refer to Service Bulletin 99-005, Updating the Passport PCM, filed under Tools. 9. Use the PGM Tester to clear any DTCs. 10. Use the PGM Tester to check the broadcast code. Make sure the broadcast code matches the one you selected from the CD-ROM. WARRANTY CLAIM INFORMATION In warranty: The normal warranty applies. Failed Part: P/N 8-97086-823-0 Page 8193 2. Remove the power window switch/regulator handle. - Pry out the power window switch and remove the connectors. - To remove the regulator handle (1), remove the clip (2) at the root of the handle by using wire with hook. 3. Remove the screw while pulling the inside lever toward you and then remove the inside handle. 4. Remove the speaker grille (3). - Pull out the front side of the grille. Page 339 Power Door Lock Switch: Service and Repair Door Switch Removal 1. Disconnect the battery ground cable. 2. Remove the door switch (2). - Remove the screw (1). - Disconnect the connector (3). Installation To install, follow the removal steps in the reverse order. Page 7606 The wire insulation has one color or one color with another color stripe. The second color is the stripe. Page 6765 Each schematic represents one circuit. A circuit's wires and components are arranged to show current flow, from power at the top of the page, to ground, at the bottom. Shared Circuits Other circuits may share power or ground terminals or wiring with the circuit shown. A wire that connects one circuit to another, for example, is cut short and has an arrowhead at the end of it pointing in the direction of current flow. Next to the arrowhead is the name of the circuit or component which shares that wiring. To quickly check shared wiring, check the operation of a component it serves. If that component works, you know the shared wiring is OK. Connectors All in-line and junction connectors are numbered (C725, C416, etc.). Component connectors are not numbered but are identified either by the name of Page 5709 1. Install coil spring and make sure that the coil spring is installed in the proper position. Paint mark (1) should be downward. 2. Fit the end of the coil spring to the coil spring seat and mount the coil spring on the rear axle case. 3. Install the insulator on the coil spring. Jack up the axle case gently with the top of the coil spring set to the spring seat on the frame side. 4. Install shock absorber and tighten the nut lightly, then retighten it to the specified torque after the vehicle is at curb height. NOTE: When mounting shock absorber, be sure not to use grease on bushings or any other nearby part. Torque to 78 Nm (58 ft. lbs.). 5. Install stabilizer bar. Torque to 31 Nm (23 ft. lbs.). 6. Install upper link with rubber plate and tighten fixing bolt. Torque to 137 Nm (101 ft. lbs.). 7. Install breather hose. 8. Connect brake hose and bleed the brake system. Page 1708 6. Insert the press-fit into the valve seat horizontally. 7. Standard fitting interference: 0.14 mm 0.09 mm (0.0055 inch - 0.0035 inch) 8. After insertion, use a seat grinder to grind finish the seating face. Carefully note the seating angle, the contact width, and the depression. 9. Lap the valve and the seat. Reassembly 1. Install valve guide (1) to cylinder head. Apply engine oil to the outside of the valve guide. Using valve guide replacer J-42899, drive in a new valve guide from the camshaft side. 2. Install oil controller (3) and spring lower seat (2). Using oil controller replacer J-37281, drive in a new oil controller. 3. Install valve to valve guide. Before install valve guide apply engine oil to the outside of the valve stem. 4. Install valve spring to cylinder head. Attach the valve spring to the lower spring seat. The painted area of the valve spring should be facing downward. 5. Install lower valve spring seat, valve spring and upper valve spring seat then put split collars on the upper spring seat, using the J-8062 valve Page 1453 Connecting Rod: Specifications Torque Specifications - The bearing cap number must be the same as connecting rod number. - Apply engine oil to the thread and seating surface of each nut. - Tighten nuts to the specified torque. Torque: 54 Nm (40 ft. lbs.) - After tightening the nuts, make sure that the crankshaft rotates smoothly. Page 2654 Powertrain Control Module: Service and Repair Reprogramming the PCM Electrically Erasable Programmable Read Only Memory (EEPROM) The electrically erasable programmable read only memory (EEPROM) is a permanent memory chip that is physically soldered within the PCM. The EEPROM contains the program and the calibration information that the PCM needs to control powertrain operation. Unlike the PROM used in past applications, the EEPROM is not replaceable. If the PCM is replaced, the new PCM will need to be programmed. Equipment containing the correct program and calibration for the vehicle is required to program the PCM. EEPROM Programming 1. Set-up - Ensure that the following conditions have been met: - The battery is fully charged. - The ignition is "ON." - The Vehicle Interface Module cable connection at the DLC is secure. 2. Program the PCM using the latest software matching the vehicle. Refer to up-to-date Techline equipment user's instructions. 3. If the PCM fails to program, proceed as follows: - Ensure that all PCM connections are OK. - Check the Techline equipment for the latest software version. - Attempt to program the PCM. If the PCM still cannot be programmed properly, replace the PCM. The replacement PCM must be programmed. Functional Check 1. Perform the On-Board Diagnostic System Check. 2. Start the engine and run for least one minute. 3. Check for DTCs using Scan Tool. 4. If the PCM fails to program, proceed as follow: - Ensure that all PCM connections are OK. - Check the ITCS for latest version software. - Attempt to program PCM again. If PCM still cannot be programmed properly, replace PCM. The replacement PCM must be programmed. Page 2050 Wires Wire insulation can be one color, or one color with another color stripe. (The second color is the stripe.) This circuit continues on another image. (The arrow shows direction of current flow.) To follow the RED/BLK wire in this example, you would turn to "Fuel and Emissions" and look for the "A" arrow. Page 7833 2. Connect the short finder across the battery terminals and the load (component) side of the fuse terminal. 3. Close all switches in the circuit you're testing. 4. Turn on the short finder. This creates a pulsing magnetic field around the wiring between the fuse box and the short. 5. Beginning at the fuse box, slowly move the short finder along the circuit wiring. The meter will read current pulses through sheet metal and body trim. As long as the meter is between the fuse and the short, the needle will move with each current pulse. Once you move the meter past the point of the short, the needle will stop moving. Check the wiring and connectors in this area to locate the cause of the short. Testing For Continuity When testing for continuity at a connector without wire seals, you do not have to separate the two halves of the connector. Instead, probe the connector from the back. Always check both sides of the connector because dirty, corroded, and bent terminals can cause problems (no electrical contact = an open). 1. Disconnect the negative cable from the car battery. If you're using a DVOM, place it in the lowest "OHMS" range. Page 2196 H/C 4408092 Defect Code: 017 Contention Code: C99 Skill Level: Repair Technician Out of warranty: Any repair performed after warranty expiration may be eligible for goodwill consideration by the District Service Manager or your Zone Office. You must request consideration, and get a decision, before starting work. DISCLAIMER Page 2267 7. Modify the original APPS by cutting the connector housing off of the sensor. 8. Connect the 10P connector to the modified APPS connector housing. 9. Using a DVOM, check the voltage between the reference voltage pin for each sensor and ground. ^ If the sensor circuits all read 5.0 volts, go to step 11. ^ If any sensor circuit is above or below 5.0 volts, go to step 10. 10. Troubleshoot for an internal short in another sensor or a PCM malfunction. ^ To find the sensor with an internal short, monitor the incorrect reference voltage, and disconnect each sensor (FTPS, EGR, MAP, TPS, CKP, and CMP) one at a time until the reference voltage reads 5.0 volts. Replace that sensor, and repeat step 3. ^ To find a malfunctioning PCM, replace it with a known-good PCM. If all three sensors (APP Sensor 1, APP Sensor 2, and APP Sensor 3) are within range, the original PCM is faulty; replace it and repeat step 3. Page 3560 Splices Splices are shown as a dot. Their location and the number of wires may vary depending on the harness manufacturer. Switches Switches These switches move together; the broken straight line between them means they are mechanically connected. Other types of switches are controlled by a coil or a solid state circuit. Unless otherwise noted, all switches are shown in their normal (rest) position, with power off. Terminal "T" Service and Repair Band Control Solenoid Valve: Service and Repair REMOVAL 1. Raise the vehicle and support it on jack stands. 2. Disconnect battery ground cable. 3. Drain fluid. 4. Remove sixteen 10 mm screws, main case oil pan, magnet, and gasket. 5. Remove three 13 mm screws, oil filter. 6. Disconnect wiring harness from band control solenoid and shift solenoids. Pull only on connectors, not on wiring harness. 7. Remove spring pin for shift solenoid A, shift solenoid B, and band control solenoid respectively, using suitable pliers taking care not to damage solenoids. 8. Remove shift solenoid A, shift solenoid B, band control solenoid, and gaskets from main case valve body. Do not pull on wiring harness. Remove solenoids by grasping the metal tip. INSTALLATION 1. Install shift solenoid A, shift solenoid B, band control solenoid with new gaskets to main case valve body respectively. 2. Carefully install spring pin with hammer to avoid damage to valve body, etc. 3. Connect wiring harness to solenoids. 4. Install oil filter with a new gasket and the three 13 mm screws, tighten to the specified torque. Torque: 20 Nm (15 Ft. lbs.) Page 6241 Refrigerant: Description and Operation Air conditioning systems contain HFC-134a. This is a chemical mixture which requires special handling procedures to avoid personal injury. Diagram Information and Instructions Dimmer Switch: Diagram Information and Instructions How to Identify Wiring Color-Coded Insulation Wire Color Wire Color Coding Page 6784 Trailer Connector: Electrical Diagrams Trailer Lighting Connector (Part 1 Of 3) Page 6116 Splices Splices are shown as a dot. Their location and the number of wires may vary depending on the harness manufacturer. Switches Switches These switches move together; the broken straight line between them means they are mechanically connected. Other types of switches are controlled by a coil or a solid state circuit. Unless otherwise noted, all switches are shown in their normal (rest) position, with power off. Terminal "T" Page 3076 Evaporative Emissions Hose: Application and ID Emissions Control Information Label The engine compartment "Vehicle Emissions Control Information Label" contains important emission specifications and setting procedures. In the upper left corner is exhaust emission information. This identifies the emission standard (Federal, California, or Canada) of the engine, the displacement of the engine in liters, the class of the vehicle, and the type of fuel metering system. There is also an illustrated emission components and vacuum hose schematic. This label is located in the engine compartment of every vehicle. If the label has been removed it should be replaced, it can be ordered from Isuzu Dealership. Recall 10V436000: Rear Lower Control Arm Bracket Control Arm: Recalls Recall 10V436000: Rear Lower Control Arm Bracket VEHICLE MAKE/MODEL: MODEL YEAR(S): Honda/Passport 1998-2002 Isuzu/Axiom 2002 Isuzu/Rodeo 1998-2002 MANUFACTURER: Isuzu Manufacturing Services of America MFR'S REPORT DATE: September 22, 2010 NHTSA CAMPAIGN ID NUMBER: 10V436000 NHTSA ACTION NUMBER: 2 Investigations found COMPONENT: Suspension: Rear POTENTIAL NUMBER OF UNITS AFFECTED: ? SUMMARY: Isuzu is recalling certain model year 1998-2002 Isuzu Rodeo and model year 2002 Isuzu Axiom vehicles, and Honda is recalling certain 1998-2002 Honda Passport vehicles, that were originally sold, or are currently registered, in the states of Maine, New Hampshire, Vermont, Massachusetts, Rhode Island, Connecticut, New York, New Jersey, Pennsylvania, Delaware, Maryland, The District of Columbia, West Virginia, Ohio, Indiana, Michigan, Illinois, Wisconsin, Minnesota, Iowa, Missouri, and Kentucky. Vehicles that have experienced sustained exposure to highly corrosive materials used in some jurisdictions for road deicing purposes may experience excessive corrosion in the vicinity of the forward mounting point bracket for the left or right rear suspension lower link prior to the time that such corrosion would normally be expected. CONSEQUENCE: Excessive corrosion may result in the left or right rear suspension lower link bracket becoming detached from the frame, which can affect vehicle handling and potentially cause a crash. REMEDY: Dealers will inspect the rear suspension lower link bracket area. For vehicles in which little or no corrosion is found, the area will be treated with an anti-corrosive compound. For vehicles in which corrosion has damaged the rear suspension lower link bracket and affected its connection to the vehicle frame, a reinforcement bracket will be installed. In the rare event the corrosion is so severe that the reinforcement bracket remedy would not be appropriate, Isuzu and Honda will develop an appropriate remedy. All inspections and remedies will be provided free of charge for vehicles that are 10 years old or less. For vehicles older than 10 years, Isuzu will offer a free remedy, but only if the vehicle is presented to an Isuzu service facility, or Honda dealer (as applicable), dealer within 12 months of when owner notifications were issued. The manufacturer has not yet provided an owner notification schedule. Isuzu owners may contact Isuzu at 1-800-255-6727. Honda owners may contact Honda at 1-800-999-1009. NOTES: Owners may also contact The National Highway Traffic Safety Administration's Vehicle Safety Hotline at 1-888-327-4236 (TTY 1-800-424-9153), or go to http://www.safercar.gov. Page 3345 The wire insulation has one color or one color with another color stripe. The second color is the stripe. Adjustments Valve Clearance: Adjustments THIS ARTICLE HAS BEEN UPDATED BY TSB 02-047 NOTE: - Valve adjustment can be done either on-vehicle or off-vehicle. - To measure exhaust valves, you need a 0.25 mm and a 0.35 mm feeler gauge. - To measure intake valves, you need a 0.23 mm and a 0.33 mm feeler gauge. Since these are odd sizes, you may need to stack two gauges (for example, 0.11 mm and 0.12 mm to make 0.23 mm). If you do this, make sure the gauges are clean and in good condition. If you're not sure the gauge stack is correct, measure it with a micrometer. On-Vehicle Valve Adjustment 1. Make a copy of the Valve Inspection Chart. 2. Make a copy of the Valve Shim Replacement Chart, then tape the pages together, side-by-side. 3. Remove the cylinder head covers. 4. Measure the valve clearances using the Go/No-Go method (see the note below). The clearances must be - Intake valves: 0.25 mm +/- 0.05 mm - Exhaust valves: 0.30 mm +/- 0.05 mm NOTE: - To measure with the Go/No-Go method, use two feeler gauges, one to measure the smallest allowable clearance, and the other to measure the largest. - If the small gauge fits and the large gauge doesn't, the valve adjustment is OK. - If the small gauge doesn't fit, or if the large gauge slides easily, the valve needs adjustment. - The feeler gauges slide through the clearance gap at a slight angle, making the drag a little more than it would be on other engines. 5. For valves with the correct clearance, draw an "X" in the appropriate circle on the Valve Inspection Chart. For valves with incorrect clearances, write down the clearance you measured in the circle. 6. If you need to replace a valve shim, turn the crankshaft (or camshaft) until the cam lobe for the valve points away from the valve. Page 2240 Vehicle Speed Sensor: Description and Operation Vehicle Speed Sensor (VSS) The PCM determines the speed of the vehicle by converting a plusing voltage signal from the vehicle speed sensor (VSS) into miles per hour. The PCM uses this signal to operate the cruise control, speedometer, and the TCC and shift solenoids in the transmission. For more information on the TCC and shift solenoids, refer to 4L30-E Automatic Transmission (Transmission Control System Diagnosis). How the Circuit Works The VSS generates a signal for the speedometer. The speedometer consists of its own speed sensor, an ammeter (to move the needle), stepper motor (to turn the odometer), and a driving circuit (printed circuit board). The VSS is mounted to the transmission. The transmission pinion shaft generates four pulses per one rotation. The rate at which the pulses are generated indicates the vehicle speed. The speed sensor in the speedometer uses the pulses to control how far and fast the needle moves and to send vehicle speed information (4096 pulses per mile) to the ECM or PCM. Page 4048 16. Tear off a corner from a business card or some other suitable material. Insert the card piece between the cable slider and the interlock pin. 17. Pry out the adjuster clip, then snap it back into place. Remove the card piece. Make sure the ignition switch turns to LOCK, then press firmly on the shift lever pushbutton, and pull down on the shift lever to make sure the lever is locked in R. 18. Plug in the connectors for the accessory power outlet, then reinstall the front console. 19. On 4WD models, reinstall the knob on the transfer control lever. 20. Plug in the connectors for the POWER and WINTER switches, then reinstall the rear console. 21. Move the shift lever to L. Plug in the connectors for the cigarette lighter, then reinstall the lower cluster assembly. 22. Reinstall the upper steering column cover. 23. Reinstall the driver's dashboard lower cover. 24. Reinstall the driver's kick panel. 25. Make sure the hood is fully closed. Page 7471 To install the connector, hold the socket insulator(l) and insert it. The cover insulator slides and connector will be locked. Do not hold the cover insulator(2). Removal and Installation Powertrain Control Module: Service and Repair Removal and Installation REMOVAL 1. Disconnect the negative battery cable. 2. Remove the two screws from the PCM electrical connectors. 3. Disconnect the PCM electrical connectors. 4. After removing the clip which fixes the PCM to the bracket, remove PCM. INSTALLATION 1. Install the PCM to bracket and fix with the clip. Accelerator Pedal Position Sensor - MIL ON/DTC's Set Technical Service Bulletin # 01-047 Date: 010814 Accelerator Pedal Position Sensor - MIL ON/DTC's Set 01-047 August 14, 2001 Applies To: 2000-01 Passport - ALL MIL Comes On With Accelerator Pedal Position Sensor DTC(s) P1271, P1273, P1275, P1280, and/or P1285 SYMPTOM The MIL is on with DTC P1271, P1273, P1275, P1280, or P1285 (various accelerator pedal position sensor problems) stored. The REDUCED POWER indicator may also be on; and the engine may occasionally idle too high, or the idle may fluctuate. PROBABLE CAUSE Contaminated grease on the potentiometer circuit board of the accelerator pedal position sensor (APPS) causes high resistance in the APPS circuit. CORRECTIVE ACTION Replace and adjust the APPS, remove all grease from the accelerator link, and clean the APPS harness connector and connector C123. PARTS INFORMATION Accelerator Pedal Position Sensor: P/N 8-97193-713-0, H/C 6198311 REQUIRED MATERIALS CAIG DeoxIT D5-S6 Contact Cleaner: P/N 341-200 (available from www.partsexpress.com) or Permatex Electrical Contact Cleaner: Permatex P/N 24379 WARRANTY CLAIM INFORMATION In warranty: The normal warranty applies. Operation Number: 122114 Flat Rate Time: 0.5 hour Failed Part: P/N 8-97220-540-0 H/C 6202436 Defect Code: 091 Contention Code: C99 Template ID: 01-047A Skill Level: Repair Technician Out of warranty: Any repair performed after warranty expiration may be eligible for goodwill consideration by the District Service Manager or your Zone Office. You must request consideration, and get a decision, before starting work. Page 1022 The steering wheel offset gauge is a sticker that attaches to the steering wheel and the steering column cover. Place the sticker on the steering wheel when the steering wheel is straight. When you test-drive the vehicle, you can read how many millimeters the steering wheel is off-center. NOTE: If the vehicle is pulling, repairing the pull may correct the steering wheel offset. Front Drive Shaft Drive/Propeller Shaft: Service and Repair Front Drive Shaft FRONT PROPELLER SHAFT AND ASSOCIATED PARTS REMOVAL 1. Raise the vehicle on a hoist. NOTE: Apply alignment marks on the flange at the front propeller shaft both front and rear side. 2. Remove bolt, nut and washer (Front axle side). 3. Remove bolt, nut and washer (Transfer side). 4. Remove front propeller shaft. INSTALLATION NOTE: Never install the shaft assembly backwards. Never insert bar between yoke lugs when tightening or removing bolts. Completely remove the black paint from the connecting surface of flange coupling on each end of propeller shaft. Clean so that no foreign matter will be caught in between. 1. Align the mark which is applied at removal. Install front propeller shaft and tighten the bolts to the specified torque. Torque: 63 Nm (46 Ft. lbs.) Page 3290 Each schematic represents one circuit. A circuit's wires and components are arranged to show current flow, from power at the top of the page, to ground, at the bottom. Shared Circuits Other circuits may share power or ground terminals or wiring with the circuit shown. A wire that connects one circuit to another, for example, is cut short and has an arrowhead at the end of it pointing in the direction of current flow. Next to the arrowhead is the name of the circuit or component which shares that wiring. To quickly check shared wiring, check the operation of a component it serves. If that component works, you know the shared wiring is OK. Connectors All in-line and junction connectors are numbered (C725, C416, etc.). Component connectors are not numbered but are identified either by the name of Page 4597 Splices Splices are shown as a dot. Their location and the number of wires may vary depending on the harness manufacturer. Switches Switches These switches move together; the broken straight line between them means they are mechanically connected. Other types of switches are controlled by a coil or a solid state circuit. Unless otherwise noted, all switches are shown in their normal (rest) position, with power off. Terminal "T" Technician Safety Information Accelerator Pedal: Technician Safety Information WARNING: THIS VEHICLE HAS A SUPPLEMENTAL RESTRAINT SYSTEM. REFER TO RESTRAINT SYSTEMS IN ORDER TO DETERMINE WHETHER YOU ARE PERFORMING SERVICE ON OR NEAR THE RESTRAINT SYSTEM COMPONENTS OR WIRING. WHEN YOU ARE PERFORMING SERVICE ON OR NEAR THE RESTRAINT SYSTEM COMPONENTS OR WIRING, REFER TO THE RESTRAINT SYSTEM SERVICE INFORMATION. FAILURE TO FOLLOW WARNINGS COULD RESULT IN POSSIBLE AIR BAG DEPLOYMENT, PERSONAL INJURY, OR OTHERWISE UNNEEDED SYSTEM REPAIRS. Page 2227 Ground - "G" Shielding Sheilding This represents RFI (Radio Frequency Interference) shielding around a wire. The shielding is always connected to ground. Splices Locations Shift Interlock Relay: Locations Under Center Console Page 3111 Fuel Pressure: Testing and Inspection Fuel System Pressure Test A fuel system pressure test is part of several of the diagnostic charts and symptom checks. To perform this test, refer to Fuel Systems Diagnosis. Page 629 Coolant Temperature Sensor/Switch (For Computer): Description and Operation Engine Coolant Temperature (ECT) Sensor The engine coolant temperature (ECT) sensor is a thermistor (a resistor which changes value based on temperature) mounted in the engine coolant stream. Low coolant temperature produces a high resistance of 100,000 ohms at -40 °C (-40 °F). High temperature causes a low resistance of 70 ohms at 130 °C (266 °F). The PCM supplies a 5-volt signal to the ECT sensor through resistors in the PCM and measures the voltage. The signal voltage will be high when the engine is cold and low when the engine is hot. By measuring the voltage, the PCM calculates the engine coolant temperature. Engine coolant temperature affects most of the systems that the PCM controls. The Tech 2 displays engine coolant temperature in degrees. After engine start-up, the temperature should rise steadily to about 85 °C (185 °F). It then stabilizes when the thermostat opens. If the engine has not been run for several hours (overnight), the engine coolant temperature and intake air temperature displays should be close to each other. A hard fault in the engine coolant sensor circuit will set DTC P0177 or DTC P0118. An intermittent fault will set a DTC P1114 or P1115. Page 3175 Air Filter Element: Service and Repair Cleaning Method Air Cleaner Element Tap the air cleaner filter gently so as not to damage the paper filter, or clean the element by blowing with compressed air of about 490 kPa (71 psi) from the clean side if it is extremely dirty. Page 6140 If there is no photo number below or beside a component name or a connector, ground, or terminal number, look up that name or number in the appropriate Connector Identification Chart. The chart lists how many cavities a connector has, where it's located, and what it connects to. The related illustration shows the connector's location on the harness, and the harness routing. NOTE: Photos listed by number are located at Locations / Components / Photograohs. See: Locations/Component Locations/Photographs Circuit Schematics Front Speaker Speaker: Service and Repair Front Speaker Removal 1. Disconnect the battery ground cable. 2. Pull the grille (1) to release the locks and then remove it. 3. Remove four screws and disconnect the connector (3) to remove the speaker (2). Installation To install, follow the removal steps in the reverse order, noting the following point: Page 5814 Grease Amount - Hub: 35 g (1.23 oz.) - Outer bearing: 10 g (0.35 oz.) - Inner bearing: 15 g (0.53 oz.) 8. Install hub nut. Turn to the place where there is a chamfer in the tapped hole to the outer side, then attach the nut by using front hub nut wrench J-36827. PRELOAD ADJUSTMENT 1. Tighten the hub nut to 29 Nm (22 ft. lbs.), then fully loosen the nut. Page 6295 Terminals - "T" Each "T" terminal (ring type) is numbered for reference and location. A "T" terminal is secured with a screw or bolt. Wires Locations 46 - Top Front Of 3.2L Engine (Intake Duct Removed) Page 3569 2. Connect the short finder across the battery terminals and the load (component) side of the fuse terminal. 3. Close all switches in the circuit you're testing. 4. Turn on the short finder. This creates a pulsing magnetic field around the wiring between the fuse box and the short. 5. Beginning at the fuse box, slowly move the short finder along the circuit wiring. The meter will read current pulses through sheet metal and body trim. As long as the meter is between the fuse and the short, the needle will move with each current pulse. Once you move the meter past the point of the short, the needle will stop moving. Check the wiring and connectors in this area to locate the cause of the short. Testing For Continuity When testing for continuity at a connector without wire seals, you do not have to separate the two halves of the connector. Instead, probe the connector from the back. Always check both sides of the connector because dirty, corroded, and bent terminals can cause problems (no electrical contact = an open). 1. Disconnect the negative cable from the car battery. If you're using a DVOM, place it in the lowest "OHMS" range. Page 854 10. Move the front wheels to the straight ahead position, then use steering wheel remover J-29752 to remove the steering wheel CAUTION: Never apply force to the steering wheel in direction of the shaft by using a hammer or other impact tools in an attempt to remove the steering wheel. The steering shaft is designed as an energy absorbing unit. WARNING: THE INFLATOR MODULE SHOULD ALWAYS BE CARRIED WITH THE URETHANE COVER AWAY FROM YOUR BODY AND SHOULD ALWAYS BE LAID ON A FLAT SURFACE WITH THE URETHANE SIDE UP. THIS IS NECESSARY BECAUSE A FREE SPACE IS PROVIDED TO ALLOW THE AIR CUSHION TO EXPAND IN THE UNLIKELY EVENT OF ACCIDENTAL DEPLOYMENT. OTHERWISE. PERSONAL INJURY MAY RESULT. 11. .Remove steering column cover. 12. Disconnect the wiring harness connectors located under the steering column. 13. Remove the combination switch assembly with SRS coil. NOTE: The SRS coil is a part of the combination switch assembly, which can not be replaced separately. Therefore, be sure not to remove the SRS coil from the combination switch assembly. 14. Remove snap ring. 15. Remove cushion rubber. 16. Remove shift lock cable (for A/T). 17. Disconnect the starter switch harness connector located under the steering column, then remove lock cylinder assembly. Blower (Heater) Motor Gets Hot and Blows A Fuse Blower Motor: All Technical Service Bulletins Blower (Heater) Motor Gets Hot and Blows A Fuse SOURCE: Honda Service News November 2003 TITLE: Heater Blower Motor Gets Hot or Blows a Fuse APPLIES TO: 1990-04 Accords, 1992-04 Civics, 1997-04 CR-Vs, 2003 Elements, 2000-04 Insights, 1995-04 Odysseys, 1996-02 Passports, 2003-04 Pilots, 1997-01 Preludes, and 2000-04 S2000s SERVICE TIP: A blocked cooling hose for the heater blower motor can cause the motor to overheat, draw more current, blow a fuse, or even melt its plastic impeller. Before you order a replacement blower motor, make sure the cooling hose isn't blocked. On some models, you'll find the cooling hose molded into the blower motor housing; on other models, it's a separate piece. Check the S/M for the vehicle you're working on to determine the actual location of the cooling hose. Page 228 SRS Unit Page 1972 2. Connect one lead of a self-powered test light or DVOM to one end of the part of the circuit you want to test. 3. Connect the other lead to the other end. 4. If the self-powered test light glows, there is continuity. If you're using a DVOM, a low reading or no reading (zero), means good continuity. Testing For Voltage When testing for voltage at a connector without wire seals, you do not have to separate the two halves of the connector. Instead, probe the connector from the back. Always check both sides of the connector because dirty, corroded, and bent terminals can cause problems (no electrical contact = an open). 1. Connect one lead of the lest light to a known good ground, or, if you're using a digital volt ohmmeter (DVOM), place it in the appropriate DC volts range, and connect its negative lead to ground. 2. Connect the other lead of the test light or DVOM to the point you want to check. 3. If the test light glows, there is voltage present. If you're using a DVOM, note the voltage reading. It should be within one volt of measured battery voltage. A loss of more than one volt indicates a problem. NOTE: Always use a DVOM on high impedance circuits. A test light may not glow (even with battery voltage present). Testing For Voltage Drop Wires, connectors, and switches are designed to conduct current with a minimum loss of voltage. A voltage drop of more than one volt indicates a problem. 1. Place the digital volt/ohmmeter (DVOM) in the appropriate DC volts range. Connect the positive lead to the end of the wire (or to the connector or switch) closest to the battery. 2. Connect the negative lead to the other end of the wire (or the other side of the connector or switch). 3. Turn on the components in the circuit. 4. The DVOM will show the difference in voltage between the two points. A difference, or drop, of more than one volt indicates a problem. Check the circuit for loose, dirty, or bent terminals. Page 2570 Splices Splices are shown as a dot. Their location and the number of wires may vary depending on the harness manufacturer. Switches Switches These switches move together; the broken straight line between them means they are mechanically connected. Other types of switches are controlled by a coil or a solid state circuit. Unless otherwise noted, all switches are shown in their normal (rest) position, with power off. Terminal "T" Page 4088 3. Connect the appropriate fittings to the ATF cooler inlet and outlet lines. Connect the red hose to the cooler outlet line (the line going to the external filter). Connect the blue hose to the cooler inlet line. 4. Connect a shop air hose to the air purge valve. NOTICE The quick connect fitting has a one-way check valve to keep ATF from entering your shop's air system. Do not remove or replace the fitting. Attach the coupler provided with the cooler cleaner to your shop air line if your coupler is not compatible. 5. Flip the MOTOR toggle switch to ON, and let the pump run for 5 minutes. While the pump is running, open and close the air purge valve periodically to cause agitation and improve the cleaning process. 6. Flip the MOTOR toggle switch to OFF with the air purge valve open. Leave the air purge valve open for at least 15 seconds to purge the lines of residual ATF. 7. Disconnect the red and blue hoses from the ATF cooler, then connect the red hose to the cooler inlet line. 8. Connect the blue hose to the cooler outlet line. 9. Flip the MOTOR toggle switch to ON, and let the pump run for 5 minutes. While the pump is running, open and close the air purge valve periodically. 10. Flip the MOTOR toggle switch to OFF with the air purge valve open. Leave the air purge valve open for at least 15 seconds to purge the lines of residual ATF. 11. Disconnect the red and blue hoses from the ATF cooler lines. Connect the red and blue hoses to each other. 12. Disconnect the shop air from the air purge valve. Disconnect and stow the coupler if used. 13. Disconnect and stow the fittings from the ATF cooler inlet and outlet lines. 14. Unplug the cooler cleaner from the 110 V outlet. TOOL MAINTENANCE Follow these instructions to keep the ATF cooler cleaner working properly: *^ Replace the two magnetic nonbypass spin-on filters every 20 hours, based on hour meter reading. For more information on filter replacement, see the January 2008 Honda ServiceNews article, Hour Meter Tells You When to Replace ATF Cooler Cleaner Filters.* ^ Fill the tank so the ATF is 4.5 inches from the top of the filler hole; do not overfill. NOTE: If the fluid level is low, the red indicator above the HEAT toggle switch comes on and the tank heater will not work. ^ Replace the ATF in the tank when it looks dark or dirty. Page 1021 The road crown gauge measures the amount of road crown. Almost all roads have a crown to help drain water during rainstorms. Use the suction cup to attach the road crown gauge bracket to the vehicle in a vertical position. If necessary, bend the bracket until the gauge is vertical. Once you attach and align the road crown gauge, calibrate the gauge to zero. There are two ways to calibrate the gauge: ^ Park the vehicle on a level surface, such as an alignment rack, and calibrate the gauge by moving the gauge until the ball is on the zero mark. ^ If you do not have a perfectly flat surface, park the vehicle on a reasonably flat surface and note the gauge reading. Turn the vehicle 1800 and, with the tires in the same spot, note the new gauge reading. Then move the gauge half of the difference. For example, if your first reading is +3 and, after moving the vehicle, the gauge reads -1, then the difference is 4 degrees. Position the gauge to read +1. NOTE: You must calibrate the gauge with the same weight in the vehicle that you will use for the test-drive. If you plan to have an assistant help you during the test-drive, calibrate the gauge while both of you are sitting in the vehicle. Page 1337 4. Align the template on the mud flap. Mark the area on the mud flap that needs to be cut away with a pencil or scribe. 5. Use a utility knife to remove the marked area. 6. Repeat steps 4 and 5 on the other mud flap. 7. Reinstall the mud flaps on the vehicle. DISCLAIMER Page 1454 Connecting Rod: Diagrams Piston, Connecting Rod and Associate Parts Page 8089 Page 3733 This sample Ground Distribution schematic shows all of the components that share two ground points. Components A solid border line means the entire component is shown. A broken border line indicates that only part of the component is shown. Page 434 Evaporator Temperature Sensor / Switch: Service and Repair Electronic Thermostat, Evaporator Core and/or Expansion Valve Electronic Thermostat, Evaporator Core And/Or Expansion Valve - Disassembled View Removal 1. Disconnect the battery ground cable. 2. Discharge and recover refrigerant. 3. Remove evaporator assembly. 4. Remove the electronic thermostat sensor fixing clip. Pull the sensor from the evaporator assembly. 5. Remove clip. 6. Remove attaching screw. 7. Remove upper case. Page 1032 NOTE: You must calibrate the gauge with the same weight in the vehicle that you will use for the test-drive. If you plan to have an assistant help you during the test-drive, calibrate the gauge while both of you are sitting in the vehicle. The steering wheel offset gauge is a sticker that attaches to the steering wheel and the steering column cover. Place the sticker on the steering wheel when the steering wheel is straight. When you test-drive the vehicle, you can read how many millimeters the steering wheel is off-center. NOTE: If the vehicle is pulling, repairing the pull may correct the steering wheel offset. Page 7421 2. Connect one lead of a self-powered test light or DVOM to one end of the part of the circuit you want to test. 3. Connect the other lead to the other end. 4. If the self-powered test light glows, there is continuity. If you're using a DVOM, a low reading or no reading (zero), means good continuity. Testing For Voltage When testing for voltage at a connector without wire seals, you do not have to separate the two halves of the connector. Instead, probe the connector from the back. Always check both sides of the connector because dirty, corroded, and bent terminals can cause problems (no electrical contact = an open). 1. Connect one lead of the lest light to a known good ground, or, if you're using a digital volt ohmmeter (DVOM), place it in the appropriate DC volts range, and connect its negative lead to ground. 2. Connect the other lead of the test light or DVOM to the point you want to check. 3. If the test light glows, there is voltage present. If you're using a DVOM, note the voltage reading. It should be within one volt of measured battery voltage. A loss of more than one volt indicates a problem. NOTE: Always use a DVOM on high impedance circuits. A test light may not glow (even with battery voltage present). Testing For Voltage Drop Wires, connectors, and switches are designed to conduct current with a minimum loss of voltage. A voltage drop of more than one volt indicates a problem. 1. Place the digital volt/ohmmeter (DVOM) in the appropriate DC volts range. Connect the positive lead to the end of the wire (or to the connector or switch) closest to the battery. 2. Connect the negative lead to the other end of the wire (or the other side of the connector or switch). 3. Turn on the components in the circuit. 4. The DVOM will show the difference in voltage between the two points. A difference, or drop, of more than one volt indicates a problem. Check the circuit for loose, dirty, or bent terminals. Page 7819 and the fuses. From Fuses to Relays and Components The second half of Power Distribution shows the wiring "From Fuses to Relays and Components." This can speed your troubleshooting by showing which circuits share fuses. If Power Distribution shows that an inoperative circuit and another circuit share a fuse, check a component in the other circuit. If it works, you know the fuse is good and power is available to the inoperative circuit. Ground Distribution Schematics Driver's Air Bag - Replace Torx Bolts Properly Air Bag: Technical Service Bulletins Driver's Air Bag - Replace Torx Bolts Properly SOURCE: Honda Service News September 2004 TITLE: Replace Drivers Air Bag Torx Bolts Properly APPLIES TO: All Models SERVICE TIP: When replacing a drivers's side air bag, make sure you replace the torx bolts properly. When removing the bolts, use a high-quality bit, making sure the bit is aligned. DON'T USE AIR TOOLS. When installing bolts, always start the bolts by hand to avoid cross-treading, and torque the bolts to the value listed in the service manual. Page 6525 Rear Seat Belt And Associated Parts REMOVAL 1. Disconnect the battery ground cable. 2. Remove the luggage side lid (2). 3. Remove the luggage side front cover (4). 4. Remove the luggage side upper cover (3). 5. Remove the canopy cover (1) (Resin top model). - Remove two fixing clips. Page 453 Each schematic represents one circuit. A circuit's wires and components are arranged to show current flow, from power at the top of the page, to ground, at the bottom. Shared Circuits Other circuits may share power or ground terminals or wiring with the circuit shown. A wire that connects one circuit to another, for example, is cut short and has an arrowhead at the end of it pointing in the direction of current flow. Next to the arrowhead is the name of the circuit or component which shares that wiring. To quickly check shared wiring, check the operation of a component it serves. If that component works, you know the shared wiring is OK. Connectors All in-line and junction connectors are numbered (C725, C416, etc.). Component connectors are not numbered but are identified either by the name of Description and Operation Temperature Gauge: Description and Operation The engine coolant temperature gauge consists of two intersecting coils wound around a permanent magnet rotor. When voltage from fuse 11 is applied to the coils, a magnetic field is generated. This causes the rotor to rotate and the gauge needle to move. The magnetic field is controlled by the sender. As the resistance in the sender varies, current through the gauge coils changes. The gauge needle moves according to the changing magnetic field. Page 7186 Sunroof/Moonroof Limit Switch: Service and Repair Limit Switch Removal 1. Disconnect the battery ground cable. 2. Remove the sunroof drive unit assembly (1) to remove the limit switch (2). Installation To install, follow the removal steps in the reverse order. Page 4221 Wires Wire insulation can be one color, or one color with another color stripe. (The second color is the stripe.) This circuit continues on another image. (The arrow shows direction of current flow.) To follow the RED/BLK wire in this example, you would turn to "Fuel and Emissions" and look for the "A" arrow. Page 3876 3. Connect the terminals as shown in figure. Shift rod of the motor actuator moves and stops at 2WD position. 4. If 2) and 3) fail, replace with a new motor actuator. Page 5918 This sample Ground Distribution schematic shows all of the components that share two ground points. Components A solid border line means the entire component is shown. A broken border line indicates that only part of the component is shown. Page 6392 Air Bag: Description and Operation Air Bag Assemblies The air bag assembly consist of an inflatable air bag assembly and an inflator (a canister of gas generating material and an initiating device). When the vehicle is in a frontal crash of sufficient force. The SDM causes current flow through the deployment loops. Current passing through the inflator ignites the material in the air bag assembly. The gas produced from this reaction rapidly inflates the air bag assembly. There is a shorting clip on the driver air bag assembly connector which connects the SRS coil assembly. The shorting clip shorts across the driver air bag assembly circuits when driver air bag assembly connector is disconnected. The circuit to the driver air bag assembly is shorted in this way to help prevent unwanted deployment of the air bag when servicing the driver air bag assembly, the steering column or other Supplemental Restraint System (SRS) components. There is a shorting clip on the passenger air bag assembly connector which connects to the SRS harness. The shorting clip shorts across the passenger air bag assembly circuit when the passenger air bag assembly connector is disconnected. The circuit to the passenger air bag assembly is shorted in this way to help prevent unwanted deployment of the air bag when servicing the passenger air bag assembly, the instrument panel or other SRS components. Page 609 11. Using a jumper wire, connect the reference voltage of each circuit to its signal input and view the APP Sensor values in the Engine Data List. APP Sensor 1 should have a value of 99%, and APP Sensor 2 and APP Sensor 3 should each have a value of 0%. ^ If the values are not as specified, troubleshoot for high resistance on the signal input or a PCM malfunction. Repair the circuit or replace the PCM, then repeat step 3. ^ If the values are as specified, the problem may be intermittent. Disconnect the 10P connector from the modified APPS, and connect it to the new APPS; then repeat step 3. Wiggle the APPS wires as you go through the adjustment procedure to find the intermittent problem. 12. Turn off the ignition switch, and disconnect the PGM Tester.* DISCLAIMER Page 4790 Hydraulic Control Assembly - Antilock Brakes: Testing and Inspection B-11 FL Isolation Solenoid Valve Failure (DTC 41/C0245, C0247) Chart B-11 FL Isolation Solenoid Coil Failure (DTC 41 (Flash Out) / C0245, C0247 (Serial Communications)) Part 1 of 2 Page 6733 and the fuses. From Fuses to Relays and Components The second half of Power Distribution shows the wiring "From Fuses to Relays and Components." This can speed your troubleshooting by showing which circuits share fuses. If Power Distribution shows that an inoperative circuit and another circuit share a fuse, check a component in the other circuit. If it works, you know the fuse is good and power is available to the inoperative circuit. Ground Distribution Schematics Page 5998 Wire Color Abbreviations The following abbreviations are used to identify wire colors in the circuit schematics: WHT................................... White YEL................................... Yellow BLK................................... Black BLU................................... Blue GRN................................... Green RED................................... Red ORN................................... Orange PNK................................... Pink BRN................................... Brown GRY................................... Gray PUR................................... Purple LT BLU................................... Light Blue LT GRN................................... Light Green Page 6409 6. Remove passenger air bag assembly from glove box opening of instrument panel. Installation 1. Install passenger air bag assembly from glove box opening of instrument panel. 2. Install reinforcement from glove box opening of instrument panel. 3. Install air bag assembly fixing nuts and bolts. And tighten to specified torque. Torque: 7.8 N.m (69 lb.in) 4. Connect air bag assembly harness connector. 5. Install glove box assembly. 6. Enable the SRS Page 3339 Ground - "G" Shielding Sheilding This represents RFI (Radio Frequency Interference) shielding around a wire. The shielding is always connected to ground. Splices Page 5343 4. Remove the fuel pressure regulator from the fuel rail. 5. Remove the fuel return line from the regulator. 6. Install the new fuel pressure regulator in the reverse order of removal. 7. Use the Smart Cable to reprogram the PCM with the latest software from the June 2001 or later HONDANET CD-ROM. Refer to Service Bulletin 99-005, Updating the Passport PCM, filed under Tools. 8. Use the PGM Tester to clear any DTCs. 9. Use the PGM Tester to check the broadcast code. Make sure the broadcast code matches the one you selected from the CD-ROM. WARRANTY CLAIM INFORMATION In warranty: The normal warranty applies. Failed Part: P/N 8-17113-398-0 H/C 5504386 Defect Code: 092 Contention Code: C99 Skill Level: Repair Technician Out of warranty: Any repair performed after warranty expiration may be eligible for goodwill consideration by the District Service Manager or your Zone Office. You must request consideration, and get a decision, before starting work. REPAIR PROCEDURE - POWER STEERING SWITCH 1. Drain the power steering fluid out of the system. 2. Remove the power steering fluid reservoir. Clean the reservoir with solvent, then with soap and water. Rinse and dry it thoroughly. 3. Reinstall the reservoir. Do not connect the return hose. 4. Remove the power steering pressure switch, then clean it with brake cleaner and a scraper. Reinstall the switch, and torque it to 20 N.m (14 lb-ft). 5. Cover the unconnected end of the reservoir with your finger, then fill the reservoir with Dexron III ATF Page 3298 Terminals - "T" Each "T" terminal (ring type) is numbered for reference and location. A "T" terminal is secured with a screw or bolt. Wires Page 277 Part 3 Of 3 Page 7571 The name of the component appears next to it followed by notes about its function along with any photo and connector view references. Connector "C" How to Identify Connector Terminals Cavity Numbering System The cavities (and wire terminals) in each connector are numbered starting from the upper left, looking at the male terminals from the terminal side (or looking at the female terminals from the wire side. Both views are in the same direction so the numbers are the same.) All actual cavities are numbered, even if they have no wire terminals in them. NOTE: Data Link Connector (DLC) terminals are numbered according to SAE standard J1962, not the Honda standard. The numbers of the four end terminals are molded into the corners of the connector face. Engine Controls - Engine Spark Knock Or Pinging Powertrain Control Module: Customer Interest Engine Controls - Engine Spark Knock Or Pinging 01-084 June 19, 2009 Applies To: 2000-02 Passport - ALL Engine Spark Knock (Pinging) (Supersedes 01-084, dated March 18, 2003, to revise the information marked by asterisks) *REVISION SUMMARY Under WARRANTY CLAIM INFORMATION, the failed part number, the Honda code, the defect code, and the symptom code have been updated.* SYMPTOM An engine spark knock (pinging). PROBABLE CAUSE The programmed ignition timing does not correct quickly enough in some climates. CORRECTIVE ACTION Update the PCM software with the Smart Cable. TOOL INFORMATION PGM Tester with software update release SN200P (9/1/01) or later. For the other tools and equipment you need to update the PCM software, refer to Service Bulletin 99-005, Updathg the Passport POM, filed under Tools. WARRANTY CLAIM INFORMATION In warranty: The normal warranty applies. Operation Number: 125517 Flat Rate Time: 0.3 hour *Failed Part: P/N 8-12212-079-0 H/C 6974992 Defect Code: 03214 Symptom Code: 09117* Template ID: 01-084A Skill Level: Repair Technician Out of warranty: Any repair performed after warranty expiration may be eligible for goodwill consideration by the District Parts and Service Manager or your Zone Office. You must request consideration, and get a decision, before starting work. REPAIR PROCEDURE 1. Retrieve the PCM broadcast code with the PGM Tester or the Smart Cable (refer to Service Bulletin 99-005, Updathg the Passport PCM). Page 7763 The wire insulation has one color or one color with another color stripe. The second color is the stripe. Page 2209 c. Remove mode switch connector with bracket from the transmission case. d. Connect multimeter (resistance mode) to terminals 1(E) and 4(H) on mode switch connector. e. Loosen two mounting screws. f. Rotate mode switch slightly in both directions to determine the range (approx. 5 degrees) of electrical contact. g. Position mode switch in middle of contact range. h. Tighten two mounting screws. i. Remove multimeter and install mode switch harness connector with bracket to the transmission case. j. Connect transmission harness connector to mode switch connector. Diagram Information and Instructions 4WD Control Unit: Diagram Information and Instructions How to Identify Wiring Color-Coded Insulation Wire Color Wire Color Coding Page 1835 To install, follow the removal steps in the reverse order, noting the following point: 1. Check that each mode door operates properly. Page 2388 6. Lock the camshaft gear to its subgear with a 5 x 0.5 mm bolt through either side of the hole in the gears. This holds the spring-loaded subgear in place so you can remove the camshaft. Do this for each camshaft you need to remove. 7. Remove the camshaft bearing caps, noting the location and direction of each cap. 8. Remove the camshaft(s). 9. For each valve needing adjustment, do steps 10 thru 13. 10. Insert a pick or a small screwdriver into the tappet notch, and pry out the shim. 11. Wipe oft the shim, then write its number on the Valve Inspection Chart for that valve and cylinder. If there is no number on the shim, measure its thickness with a micrometer, and write down the measurement on the Valve Inspection Chart. 12. Follow the directions on the Valve Shim Replacement Chart to select the correct shim. 13. Insert the correct shim, number side down, into the tappet. Make sure the shim is fully seated. 14. Install the camshafts (see steps 2 thru 9 of CAMSHAFT SUBGEAR PRELOADING, GEAR TIMING, AND CAMSHAFT INSTALLATION). 15. Rotate the camshaft pulleys a few turns to ensure the new shims are fully seated. 16. Recheck the clearances of the valves you adjusted with the Go/No-Go method (see step 3). If any clearances are incorrect, readjust them. Page 1007 ^ If the wheels are pointed to the right, shorten the driver's side tie-rod, and lengthen the passenger's side. ^ If the wheels are pointed to the left, shorten the passenger's side tie-rod, and lengthen the driver's side. ^ Each 360° turn of the tie-rod equals about 8 mm of steering wheel adjustment. For example, a steering wheel is off-center by 4 mm with the front wheels pointed right (when the steering wheel is centered). To correct the off-center, shorten the driver's side tie-rod by a half-turn, and lengthen the passenger's side tie-rod by a half-turn. 4. Use your diagnosis worksheet to fill in the following table and build your 15-digit DTC. Page 6861 Rear Door Window Motor: Service and Repair Removal 1. Disconnect the battery ground cable. 2. Remove the rear window regulator assembly (2). 3. Remove the power window motor (1). - Remove three screws. Installation To install, follow the removal steps in the reverse order. Page 7885 This means the branch of the wire connects to another circuit. The arrow points to the name of the circuit branch where the wire continues. Page 1579 6. Insert the press-fit into the valve seat horizontally. 7. Standard fitting interference: 0.14 mm 0.09 mm (0.0055 inch - 0.0035 inch) 8. After insertion, use a seat grinder to grind finish the seating face. Carefully note the seating angle, the contact width, and the depression. 9. Lap the valve and the seat. Reassembly 1. Install valve guide (1) to cylinder head. Apply engine oil to the outside of the valve guide. Using valve guide replacer J-42899, drive in a new valve guide from the camshaft side. 2. Install oil controller (3) and spring lower seat (2). Using oil controller replacer J-37281, drive in a new oil controller. 3. Install valve to valve guide. Before install valve guide apply engine oil to the outside of the valve stem. 4. Install valve spring to cylinder head. Attach the valve spring to the lower spring seat. The painted area of the valve spring should be facing downward. 5. Install lower valve spring seat, valve spring and upper valve spring seat then put split collars on the upper spring seat, using the J-8062 valve Page 471 Dimmer Switch: Electrical Diagrams Part 1 Of 2 Page 1233 3. Connect the universal connect set and the Tracer- Stick dye capsule: (a) Be sure the quick coupler and control valves on the set are closed. (b) Remove the low-side service port sealing cap, and connect the set to the low-side service port using the quick coupler. (c) Hold a new dye capsule so that the embossed arrow is pointing up. Remove the black end cap, and carefully attach the capsule to the control valve fitting. NOTE: The capsule must be held with the embossed arrow pointing up or the dye will leak out of the capsule. (d) Turn the capsule so the embossed arrow is pointing down. Remove the orange end cap, and carefully attach the service valve fitting provided in the kit (finger tight). NOTE: The capsule must be held with the embossed arrow pointing down or the dye will leak out. 4. Connect the NC service equipment: With the universal connect set and dye capsule attached to the vehicle's low-side service port, connect the A/C refrigerant recovery and charging station's low-side hose quick coupler to the service valve fitting. Open the blue hand-wheel valves on both quick couplers. Leave the control valve (black knob) on the universal connect set closed. NOTE: * ^ If you have recovered refrigerant to weigh it as part of your diagnostics, or if there is a low charge, it is more efficient to recharge the system using normal procedures before installing the universal connect set. Dye can then be added using approximately 0.05 lb (0.02 kg) of refrigerant.* ^ You do not need to connect the service equipment's high-side hose to the vehicle to install the dye. If the high-side hose is connected, make sure its coupler valve is closed before proceeding. ^ Do not use the A/C recovery and charging station to recover or evacuate the A/C system when a full dye capsule is attached. The dye will be drawn into the service equipment instead of being added to the vehicle's A/C system. 5. Inspect the A/C system for leaks: (a) Run the A/C system for at least 15 minutes to circulate the dye through the system. Large leaks will be seen immediately as a fluorescent yellow glow. Smaller leaks may require at least 24 hours of vehicle operation before they become visible. Operate the A/C system as much as possible during this time to keep the dye circulating. (b) Stop the vehicle's engine and inspect the system for leaks using the ultraviolet (UV) lamp and fluorescence-enhancing glasses from the kit. Locations Electrical - Battery Replacement Precautions Battery Cable: Technical Service Bulletins Electrical - Battery Replacement Precautions Replacing a Battery? Don't Disconnect the Cables With the Engine Running When replacing a battery, many service techs disconnect the battery cables with the engine running to keep the data alive in volatile memory. This practice worked fine back in the day when vehicles were pretty much a box on wheels, but with so many of today's vehicles sporting a impressive array of cool, high tech hardware, it's not recommended. Here's why: ^ The battery works as a capacitor to prevent sudden swings in voltage. With the battery cables disconnected, the alternator voltage regulator tries to stabilize the system voltage, but it can only do so by turning the alternator on and off. ^ When solenoids or relays are turned on and of{ they produce a very high voltage spike that travels through the 12-volt system. This voltage spike can fry sensitive solid state components or corrupt the data that's stored in volatile memory for such components as the gauge control module, the radio, and the various control units. The best way to keep data alive in volatile memory when replacing a battery is to hook up a Honda Computer Memory Saver to the 16P data link connector (DLC). This portable tool works as a secondary 12-volt source. It saves you the hassle of writing down your customer's audio presets, resetting the clock, or even doing the idle learn procedure. Locations Evaporator Temperature Sensor / Switch: Locations Electronic Thermostat, Evaporator Core And/Or Expansion Valve - Disassembled View Removal and Installation Powertrain Control Module: Service and Repair Removal and Installation REMOVAL 1. Disconnect the negative battery cable. 2. Remove the two screws from the PCM electrical connectors. 3. Disconnect the PCM electrical connectors. 4. After removing the clip which fixes the PCM to the bracket, remove PCM. INSTALLATION 1. Install the PCM to bracket and fix with the clip. Page 5880 Front Tires - Rub On Mud Flap On Sharp Turns Tires: Customer Interest Front Tires - Rub On Mud Flap On Sharp Turns 01-088 September 11, 2001 Applies To: 1998-01 Passport - ALL Front Tire Rubs Against the Mud Flap PROBLEM The front tire rubs against the mud flap when the wheel is turned to full lock. CORRECTIVE ACTION Trim away part of the mud flap. WARRANTY CLAIM INFORMATION In warranty: The normal warranty applies. Operation Number: 031005 Flat Rate Time: 0.3 hour Failed Part: P/N 8-97261-990-0 H/C 6633416 Defect Code: 042 Contention Code: B07 Template ID: 01-088A Skill Level: Repair Technician Out of warranty: Any repair performed after warranty expiration may be eligible for goodwill consideration by the District Service Manager or your Zone Office. You must request consideration, and get a decision, before starting work. REPAIR PROCEDURE 1. Remove the mud flaps from the front fenders (four screws each). 2. Wipe off the mud flaps. Page 5423 The steering wheel offset gauge is a sticker that attaches to the steering wheel and the steering column cover. Place the sticker on the steering wheel when the steering wheel is straight. When you test-drive the vehicle, you can read how many millimeters the steering wheel is off-center. NOTE: If the vehicle is pulling, repairing the pull may correct the steering wheel offset. Diagram Information and Instructions Key Reminder Switch: Diagram Information and Instructions How to Identify Wiring Color-Coded Insulation Wire Color Wire Color Coding Page 7892 2. Connect one lead of a self-powered test light or DVOM to one end of the part of the circuit you want to test. 3. Connect the other lead to the other end. 4. If the self-powered test light glows, there is continuity. If you're using a DVOM, a low reading or no reading (zero), means good continuity. Testing For Voltage When testing for voltage at a connector without wire seals, you do not have to separate the two halves of the connector. Instead, probe the connector from the back. Always check both sides of the connector because dirty, corroded, and bent terminals can cause problems (no electrical contact = an open). 1. Connect one lead of the lest light to a known good ground, or, if you're using a digital volt ohmmeter (DVOM), place it in the appropriate DC volts range, and connect its negative lead to ground. 2. Connect the other lead of the test light or DVOM to the point you want to check. 3. If the test light glows, there is voltage present. If you're using a DVOM, note the voltage reading. It should be within one volt of measured battery voltage. A loss of more than one volt indicates a problem. NOTE: Always use a DVOM on high impedance circuits. A test light may not glow (even with battery voltage present). Testing For Voltage Drop Wires, connectors, and switches are designed to conduct current with a minimum loss of voltage. A voltage drop of more than one volt indicates a problem. 1. Place the digital volt/ohmmeter (DVOM) in the appropriate DC volts range. Connect the positive lead to the end of the wire (or to the connector or switch) closest to the battery. 2. Connect the negative lead to the other end of the wire (or the other side of the connector or switch). 3. Turn on the components in the circuit. 4. The DVOM will show the difference in voltage between the two points. A difference, or drop, of more than one volt indicates a problem. Check the circuit for loose, dirty, or bent terminals. Page 3268 6. Place the end of the return hose in a container. Have someone start the engine, then pour ATF into the reservoir while you watch the fluid coming out of the return hose. When the fluid coming out is the same color as the new fluid, turn off the engine. 7. Reconnect the return hose to the reservoir. 8. Start the engine. Fill the power steering reservoir to the proper level with ATF then turn off the engine. 9. Use the Smart Cable to reprogram the PCM with the latest software from the June 2001 or later HONDANET CD-ROM. Refer to Service Bulletin 99-005, Updating the Passport PCM, filed under Tools. 10. Use the PGM Tester to clear any DTCs. 11. Use the PGM Tester to check the broadcast code. Make sure the broadcast code matches the one you selected from the CD-ROM. WARRANTY CLAIM INFORMATION In warranty: The normal warranty applies. Failed Part: P/N 8-97181-590-0 H/C 5698030 Defect Code: 064 Contention Code: C01 Skill Level: Repair Technician Out of warranty: Any repair performed after warranty expiration may be eligible for goodwill consideration by the District Service Manager or your Zone Office. You must request consideration, and get a decision, before starting work. REPAIR PROCEDURE - APPS GROUND 1. Unclamp the air cleaner housing cover, and move it to the side for access to connector C123 (16P BLK). Page 4267 If there is no photo number below or beside a component name or a connector, ground, or terminal number, look up that name or number in the appropriate Connector Identification Chart. The chart lists how many cavities a connector has, where it's located, and what it connects to. The related illustration shows the connector's location on the harness, and the harness routing. NOTE: Photos listed by number are located at Locations / Components / Photograohs. See: Locations/Component Locations/Photographs Circuit Schematics Page 2421 5. Insert a thin stainless steel ruler or a "Slim Jim" under the magazine, about 1-1/2" from the right side of the opening. 6. Push the ruler in until it presses against the eject lever at the back of the unit. 7. Slowly remove the ruler and magazine at the same time. Two-piece door model: 1. Remove the changer from the vehicle. 2. Remove the top cover plate from the changer, and look for a jammed tray. 3. If a tray is stuck in the player, reinstall the cover and replace the changer. If all the trays are in the magazine, insert a thin stainless steel ruler or a "Slim Jim" under the magazine, about 1/2" from the right side of the opening. 4. Push the ruler in until it presses against the eject lever at the back of the unit. 5. Slowly remove the ruler and magazine at the same time. Page 6564 Alarm Horn: Service and Repair Removal 1. Disconnect the battery ground cable. 2. Remove the anti-theft horn (1). Disconnect the connector. - Remove a fixing bolt. Installation To install, follow the removal steps in the reverse order. Page 486 it is located, and what it connects to. Use the Connector Views to help locate the proper cavity when you need to probe a connector. It can be especially helpful if the connector has more than one wire of the same color. A dash symbol (-) indicates that the cavity is empty. Connector views can also be used to help diagnose multiple symptoms in separate circuits which could be caused by a single problem in a connector shared by those circuits. Here's an example: 1. Pick one of the multiple symptoms and look up the schematic for that circuit. 2. Make a list of all the in-line and fuse box connectors in that schematic , 3. Then, in the Connector Views, look up each connector on your list to see if circuits related to the other symptoms run through one of them. If they do, inspect that connector for the problem. Example: The blower, rear window defogger, and the windshield wiper don't work. List all in-line and fuse box connectors in the blower controls circuit and then check the Connector View (see the sample). You find that C324 is common to the blower controls, rear window defogger, and wiper/washer, so you inspect C324 and find the problem, bent terminals. Finding Component/Connector Locations Finding Component/Connector Locations To see where a component or connector is located on the car, look up its photo number in the "Component Location". The photo will also tell you the color of the connector, and how many cavities it has. Page 2646 Powertrain Control Module: Description and Operation Circuit Operation The engine or powertrain control module (ECM or PCM) receives inputs from the engine sensors and switches, controlling the functions of the engine. It also turns on the malfunction indicator "check engine" light whenever a malfunction or abnormal engine performance is detected, and allows for diagnostic testing through the data link connector (DLC). Electrically Erasable Programmable Read Only Memory (EEPROM) Electrically Erasable Programmable Read Only Memory (EEPROM) The electrically erasable programmable read only memory (EEPROM) is a permanent memory chip that is physically soldered within the PCM. The EEPROM contains the program and the calibration information that the PCM needs to control powertrain operation. Unlike the PROM used in past applications, the EEPROM is not replaceable. If the PCM is replaced, the new PCM will need to be programmed. Equipment containing the correct program and calibration for the vehicle is required to program the PCM. PCM Components PCM Components The PCM is designed to maintain exhaust emission levels to government mandated standards while providing excellent driveability and fuel efficiency. The PCM monitors numerous engine and vehicle functions via electronic sensors such as the throttle position (TP) sensor, heated oxygen sensor (HO2S), and vehicle speed sensor (VSS). The PCM also controls certain engine operations through the following: - Fuel injector control - Ignition control module - ION sensing module - Automatic transmission shift functions - Cruise control - Evaporative emission (EVAP) purge - A/C clutch control PCM Function PCM Function The PCM supplies either 5 or 12 volts to power various sensors or switches. The power is supplied through resistances in the PCM which are so high in value that a test light will not light when connected to the circuit. In some cases, even an ordinary shop voltmeter will not give an accurate reading because its resistance is too low. Therefore, a digital voltmeter with at least 10 megohms input impedance is required to ensure accurate voltage readings. Tool J 39200 meets this requirement. The PCM controls output circuits such as the injectors, fan relays, etc., by controlling the ground or the power feed circuit through transistors or through either of the following two devices: - Output Driver Module (0DM) - Quad Driver Module (QDM) PCM Input/Outputs PCM Input/Outputs Inputs - Operating Conditions Read - Air Conditioning "ON" or "OFF" Technician Safety Information Fuel Line Coupler: Technician Safety Information FUEL TUBE/QUICK - CONNECTOR FITTINGS Lighting of Fires Prohibited. Keep flames away from your work area to prevent the inflammable from catching fire. Disconnect the battery negative cable to prevent shorting during work. When welding or conducting other heat-generating work on other parts, be sure to provide pretreatment to protect the piping system from thermal damage or spattering. Rear Hatchgate Liftgate Window Glass: Service and Repair Rear Hatchgate Rear Hatchgate Rear Hatchgate (LWB) Removal 1. Disconnect the battery ground cable. 2. Disconnect the high mount stoplight and rear defogger harness connectors. Page 1959 The name of the component appears next to it followed by notes about its function along with any photo and connector view references. Connector "C" How to Identify Connector Terminals Cavity Numbering System The cavities (and wire terminals) in each connector are numbered starting from the upper left, looking at the male terminals from the terminal side (or looking at the female terminals from the wire side. Both views are in the same direction so the numbers are the same.) All actual cavities are numbered, even if they have no wire terminals in them. NOTE: Data Link Connector (DLC) terminals are numbered according to SAE standard J1962, not the Honda standard. The numbers of the four end terminals are molded into the corners of the connector face. Page 4308 2. Install retainer. Note direction - do not install backwards. 3. Install oil seal. Note direction. 4. Install bearing assembly, using installer and press. NOTE: Install bearing with cup towards inboard side. Page 6827 Front Door Window Motor: Service and Repair Removal 1. Disconnect the battery ground cable. 2. Remove the window regulator assembly (2). 3. Remove the power window motor (1). - Remove three screws. Installation To install, follow the removal steps in the reverse order. Page 7827 This means the branch of the wire connects to another circuit. The arrow points to the name of the circuit branch where the wire continues. Page 2858 Camshaft Position Sensor: Testing and Inspection 1. Inspect the sensor O-ring for cracks or leaks. 2. Replace the O-ring if it is worn or damaged. 3. Lubricate the new O-ring with engine oil. 4. Install the lubricated O-ring. Page 5792 11. Remove the body mount mounting nuts (mounts No. 1, 2, 3, and 5) and bolt (mount No. 4). 12. Using two ratcheting straps, lash up both sides of the rear axle to support it during the following steps: ^ Attach one end of the strap above the axle at the driver's side inside frame rail. ^ Route the other end of the strap down, underneath the rear axle, and then back up above the outside of the driver's side frame rail. ^ Connect both ends of the strap together and remove any slack. ^ Attach the other ratcheting strap to the passenger's side the same way as the driver's side. 13. Lower the vehicle to the ground. 14. Carefully raise the rear of the body about 10 inches off the frame, and temporarily support it. The equipment/method used to raise the body off the frame include, but are not limited to, one of these options: ^ Raise the body at the rear wheelwells using a vehicle hoist with padded swing arms. ^ Raise the body at the bottom of the rear swing out door using a 4x4 in. piece of wood (running the width of the body) and a forklift. To prevent injury or vehicle damage, be sure to chose the safest possible method for your particular situation. 15. Remove the mounting bolts for the left and right side No.5 body mounts, then remove the mounts. Refer to step 11. Blower Motor - Will Not Run In One Or More Settings Blower Motor Resistor: Customer Interest Blower Motor - Will Not Run In One Or More Settings 01-007 October 16, 2001 Applies To: 1998-01 Passport - ALL Blower Does Not Run in One or More Settings (Supersedes 01-007, dated July 3, 2001) SYMPTOM The blower does not run in one or more fan control lever positions. PROBABLE CAUSE A high current draw on the blower resistor causes it overheat and to become electrically "open." This high current draw is usually caused by high friction in the blower motor bearings and/or debris in the blower assembly housing, which jams or slows the blower motor and damages its commutator. CORRECTIVE ACTION Replace the blower resistor and the blower motor assembly. Clean out all debris from inside the blower assembly housing. PARTS INFORMATION Blower Resistor (1998-99 models): P/N 8-97078-452-1, H/C 4906202 Blower Resistor (2000-01 models): P/N 8-97260-283-0, H/C 6633390 Blower Motor Assembly (1998-99 models): P/N 8-97231-642-0, H/C 6447544 Blower Motor Assembly (2000-01 models): P/N 8-97229-613-1, H/C 6262083 WARRANTY CLAIM INFORMATION In warranty: The normal warranty applies. Operation Number: 612109 Flat Rate Time: 0.4 hour Failed Part: P/N 8-97046-497-0 H/C 4402186 Defect Code: 032 Contention Code: B01 Template ID: 01-007A (1998-99 models) 01-007B (2000-01 models) Skill Level: Repair Technician Out of warranty: Any repair performed after warranty expiration may be eligible for goodwill consideration by the District Service Manager or your Zone Office. You must request consideration, and get a decision, before starting work. REPAIR PROCEDURE Page 6762 Distinct Of Circuit By Wire Base Color All wires have color-coded insulation. Wires belonging to a system's main harness will have a single color. Wires belonging to a system's sub-circuits will have a colored stripe. Striped wires use the codes found in the chart to show wire size and colors. Abbreviations are used to indicate wire color within a circuit diagram. How to Identify Connector Terminals How to Identify Connector Terminals Cavity Numbering System The cavities (and wire terminals) in each connector are numbered starting from the upper left, looking at the male terminals from the terminal side (or looking at the female terminals from the wire side. Both views are in the same direction so the numbers are the same.) All actual cavities are numbered, even if they have no wire terminals in them. NOTE: Data Link Connector (DLC) terminals are numbered according to SAE standard J1962, not the Honda standard. The numbers of the four end terminals are molded into the corners of the connector face. The connector cavity number is listed next to each terminal on the circuit schematic. The cavity / terminal shown is # 6. Using/Identifying Connector Terminal Views How to Use Connector Terminal Views To see the configuration of a connector's cavities, look up its view number in the Connector Views. Each view includes the color of the connector, where Page 5207 Ground - "G" Shielding Sheilding This represents RFI (Radio Frequency Interference) shielding around a wire. The shielding is always connected to ground. Splices Page 6275 Compressor Clutch Relay: Testing and Inspection 1. Disconnect relays and check for continuity and resistance between relay terminals. - For handling of these relays, refer to Heater Relay. Page 2346 Air Filter Element: Service and Repair Cleaning Method Air Cleaner Element Tap the air cleaner filter gently so as not to damage the paper filter, or clean the element by blowing with compressed air of about 490 kPa (71 psi) from the clean side if it is extremely dirty. Page 5657 parts: - Upper control arm - Bushing - Fulcrum pin INSTALLATION 1. Install fulcrum pin. 2. Install bushing by using installer J-29755 and J-39376. 3. Install plate. 4. Install nut and tighten fulcrum pin nut finger-tight. NOTE: Torque fulcrum pin nut after adjusting buffer clearance. Buffer clearance: 22 mm (0.87 inch). 5. Install upper control arm assembly with the fulcrum pin projections turned inward. Page 5797 35. Temporarily install both type B reinforcement brackets again, then make sure all of the bolts can be started in each pop nut. 36. Remove both type B reinforcement brackets. 37. Cover all 32 holes with the 3/4 in. round labels from the kit. This will prevent the Noxudol from contaminating the pop nut threads. 38. Use masking tape to cover the upper trailing link brackets. This will prevent the Noxudol from contaminating the bracket mounting surfaces. 39. Apply Noxudol 700 and Noxudol 300 anti-corrosion waxes (see steps 5 thru 19 of STAGE 2 REPAIR). 40. Remove the round labels and the masking tape. 41. Install the left and right type B reinforcement brackets using all of the hardware in the kit. Torque the bolts and nuts, in the order shown on the illustrations below: ^ Torque the bracket bolts to 35 Nm (25 Ib-ft). ^ Torque the body mount studs and nuts to 30 Nm (22 lb-ft). Page 4132 REMOVAL 1. Disconnect the ground battery cable. 2. Remove the instrument panel lower cover (7) and driver knee bolster panel assembly (8). 3. Remove pin and jaw joint pin (1). 4. Remove pedal assembly and switch (2). 5. Remove oil line pipe (3). 6. Remove slave cylinder assembly (4). X22SE / MUA 7. Remove master cylinder assembly (5). 8. Remove oil line hose (6). INSPECTION AND REPAIR Make necessary adjustments, repairs, and part replacements if wear, damage or other problems are discovered during inspection. INSTALLATION Clutch Pedal Adjustment Page 1442 8. Align timing mark on intake camshaft (one dot for right bank, two dot for left bank) and exhaust camshaft (one dot for right bank, two dots for left bank) to timing mark on camshaft drive gear (one dot). 9. Tighten twenty bolts on numerical order an one side bank as shown in the illustration. Torque: 10 Nm (89 inch lbs.) 10. Install cylinder head cover RH. 11. Install cylinder head cover LH. 12. Install timing belt. 13. Install crankshaft pulley. 14. Install Accelerator pedal cable. Page 6692 2. Connect the short finder across the battery terminals and the load (component) side of the fuse terminal. 3. Close all switches in the circuit you're testing. 4. Turn on the short finder. This creates a pulsing magnetic field around the wiring between the fuse box and the short. 5. Beginning at the fuse box, slowly move the short finder along the circuit wiring. The meter will read current pulses through sheet metal and body trim. As long as the meter is between the fuse and the short, the needle will move with each current pulse. Once you move the meter past the point of the short, the needle will stop moving. Check the wiring and connectors in this area to locate the cause of the short. Testing For Continuity When testing for continuity at a connector without wire seals, you do not have to separate the two halves of the connector. Instead, probe the connector from the back. Always check both sides of the connector because dirty, corroded, and bent terminals can cause problems (no electrical contact = an open). 1. Disconnect the negative cable from the car battery. If you're using a DVOM, place it in the lowest "OHMS" range. Page 4337 4. Use installer J-36828 and grip J-8092 then install the outer bearing by driving it into the hub. 5. Apply grease (NLG1 No.2 or equivalent) to the lip portion, then install oil seal by using installer J-36830 and grip J-8092. 6. Install ABS sensor ring, then tighten the bolts to the specified torque. Torque: 18 Nm (13 ft. lbs.) 7. Install hub and disc assembly. - Apply grease in the hub. - Apply wheel bearing type grease NLGI No. 2 or equivalent to the outer and inner bearing. Component Locations 4WD Motor Actuator: Component Locations Beneath Center of Vehicle, on Transfer Case (A/T) Page 3204 Each schematic represents one circuit. A circuit's wires and components are arranged to show current flow, from power at the top of the page, to ground, at the bottom. Shared Circuits Other circuits may share power or ground terminals or wiring with the circuit shown. A wire that connects one circuit to another, for example, is cut short and has an arrowhead at the end of it pointing in the direction of current flow. Next to the arrowhead is the name of the circuit or component which shares that wiring. To quickly check shared wiring, check the operation of a component it serves. If that component works, you know the shared wiring is OK. Connectors All in-line and junction connectors are numbered (C725, C416, etc.). Component connectors are not numbered but are identified either by the name of Locations Starter Motor: Locations General Precautions Air Bag(s) Arming and Disarming: Service Precautions General Precautions General Precautions Please read the following precautions carefully before performing the airbag system service. Observe the instructions described or the airbags could accidentally deploy and cause damage or injuries. Except when performing electrical inspections, always turn the ignition switch OFF and disconnect the negative cable from the battery, and wait at least three minutes before beginning work. NOTE: The contents in the memory is not erased even if the ignition switch is turned OFF or the battery cables are disconnected from the battery. Use the replacement parts which are manufactured to the same standards as the original parts and quality. Do not install used SRS parts from another vehicle. Use only new parts when making SRS repairs. Carefully inspect any SRS part before you install it. Do not install any part that shows signs of being dropped or improperly handled, such as dents, cracks or deformation. Before removing any of the SRS parts (including the disconnection of the connectors), always disconnect the SRS connector. Use only a digital multimeter to check the system. If it is not a Honda multimeter, make sure its output is 10 mA (0.01 A) or less when switched to the lowest value in the ohmmeter range. A tester with a higher output could cause accidental deployment and possible injury. Do not put objects on the front passenger's airbag. The original radio has a coded theft protection circuit. Be sure to get the customer's radio code before disconnecting the battery cable. Page 7146 Soft Top Assembly And Associated Parts Locations Camshaft Position Sensor Page 2561 it is located, and what it connects to. Use the Connector Views to help locate the proper cavity when you need to probe a connector. It can be especially helpful if the connector has more than one wire of the same color. A dash symbol (-) indicates that the cavity is empty. Connector views can also be used to help diagnose multiple symptoms in separate circuits which could be caused by a single problem in a connector shared by those circuits. Here's an example: 1. Pick one of the multiple symptoms and look up the schematic for that circuit. 2. Make a list of all the in-line and fuse box connectors in that schematic , 3. Then, in the Connector Views, look up each connector on your list to see if circuits related to the other symptoms run through one of them. If they do, inspect that connector for the problem. Example: The blower, rear window defogger, and the windshield wiper don't work. List all in-line and fuse box connectors in the blower controls circuit and then check the Connector View (see the sample). You find that C324 is common to the blower controls, rear window defogger, and wiper/washer, so you inspect C324 and find the problem, bent terminals. Finding Component/Connector Locations Finding Component/Connector Locations To see where a component or connector is located on the car, look up its photo number in the "Component Location". The photo will also tell you the color of the connector, and how many cavities it has. Locations Vapor Pressure Sensor / Fuel Gauge And Fuel Pump Connector Page 6632 Locations Brake Fluid Level Sensor/Switch: Locations Left Side Of Engine Compartment Page 296 Ground - "G" Shielding Sheilding This represents RFI (Radio Frequency Interference) shielding around a wire. The shielding is always connected to ground. Splices Page 6599 Make sure the "Compilations" setting is switched off in the settings menu on the customer's iPod: - Go to the Main Menu. - Select Settings. - See Compilation. Is the "Compilations" setting switched off? Yes - There is a TTS software program error. Tell the customer to rerun the TTS software. No - Change the "Compilations" setting on the customer's iPod to off. Song/Artist is not categorized in the correct grouping when using Disc 1-4 search functions. Remind the customer that the TTS software must be run after any songs are changed on the iPod, and advise them to run the TTS software and retest the iPod search functions. Explain to the customer that once the TTS software has run: ^ If the iPod functions properly, there was an intermittent TTS software program error. ^ If the iPod does not function properly, direct the customer to contact Customer Service for assistance with TTS software loading problems. CUSTOMER INFORMATION NEEDED BEFORE CALLING HONDA'S CUSTOMER SERVICE DEPARTMENT Print this page, and give it to the customer if they are experiencing a ITS software-related issue. Direct them to answer the questions, then contact American Honda's Automobile Customer Service Department at (800) 999-1009. Customer Information Before calling customer service, go to http//musiclink.honda.com/Tech_Faq.html and view the technical FAQs and troubleshooting. Also, go to www.apple.com, select support, and view the technical FAQs and troubleshooting. Please have the following information ready when contacting customer service: ^ What is the main issue? ^ What type of iPod do you have? Refer to www.apple.com. ^ What version iPod firmware (unit software) is loaded? To find out what firmware (unit software) is loaded on the iPod: - Go to the Main Menu. - Select Settings. - Select About. ^ What version iTunes are you using on your home computer? ^ When you connect your iPod to the vehicle's Music Link connector, is the check mark displayed on your iPod display screen? ^ What type of computer do you have (Mac or PC)? ^ What operating system are you using? ^ Have you loaded the ITS software on your home computer? ^ Do you run the ITS software every time you connect your iPod to your home computer? Rough Idle And/Or Diagnostic Trouble Code (DTC) stored Intake Manifold Gasket: Customer Interest Rough Idle And/Or Diagnostic Trouble Code (DTC) stored 00-010 February 1, 2000 Applies To: 1998-99 Passport-ALL 2000 Passport-From VIN 4S6..58W..Y4400001 Thru VIN 456..58W..Y4407271 Rough Idle and/or DTCs P0171, P0174, or P1171 SYMPTOM Intermittent rough idle and/or the MIL is on with DTC P0171 (Fuel Trim System Lean Bank 1), P0174 (Fuel Trim System Lean Bank 2), or P1171 (Fuel Trim System Lean During Acceleration), and normal troubleshooting procedures have not resolved the problem. PROBABLE CAUSE Cracked intake manifold gasket(s). CORRECTIVE ACTION Replace both intake manifold gaskets. PARTS INFORMATION Intake Manifold Gasket (2 required): P/N 8-97237-538-0, H/C 6312086 EGR Valve Gasket: P/N 8-97104-317-1, H/C 4909776 Throttle Body Gasket, 1998-99 models: P/N 8-94389-939-0, H/C 4389037 Throttle Body Gasket, 2000 models: P/N 8-97193-729-1, H/C 6198329 WARRANTY CLAIM INFORMATION In warranty: The normal warranty applies. Operation Number: 111115 Flat Rate Time: 1.1 hour Failed Part: P/N 8-97131-894-2 H/C 5510771 Defect Code: 017 Contention Code: C99 Template ID: 00-010 A (1998-99 Models) 00-010 B (2000 Models) Skill Level: Repair Technician Out of warranty: Any repair performed after warranty expiration may be eligible for goodwill consideration by the District Service Manager or your Zone Office. You must request consideration, and get a decision, before starting work. REPAIR PROCEDURE Refer to page 6A-22 of the 1998,1999, or 2000 Passport Service Manual. 1. Remove the intake manifold from the cylinder heads. Separating the upper and lower intake manifold sections is not necessary. 2. Remove both old intake manifold gaskets. Be sure to carefully remove all of the old gasket material. Page 4240 17. Support the differential case by the jack. 18. Remove the front axle mounting bolts and nuts, lower the jack slowly. Remove the left side drive shaft end from the knuckle, then lower the axle assembly from the vehicle. CAUTION: 1. During the work, be sure that the axle assembly is supported securely. 2. Be careful not to damage the bellows of the power steering unit by interference. 3. Be careful not to damage the hose bracket of the shift on the fly interference. INSTALLATION 1. Support the differential case by the jack. 2. Jack up the front drive axle assembly, install the left side drive shaft to the knuckle, then install the mount bolts and nuts. CAUTION: 1. Be careful not to damage the bellows of the power steering unit by interference. 2. Be careful not to damage the hose bracket of the shift on the fly interference. 3. When installing the drive shaft to the knuckle, be careful not to damage the oil seal inside of the knuckle. 3. Tighten the mounting bolts and nuts to the specified torque. Torque: 168 Nm (124 ft. lbs.) 4. Install the right side knuckle with lower control arm to the upper control arm. CAUTION: When insert the drive shaft to the knuckle, be careful not to damage the oil seal inside of the knuckle. 5. Align the bolt hole of the lower control arm, install the bolts and nuts. NOTE: Adjust the buffer clearance before tighten the bolts and nuts of the lower control arm. Page 5860 Tires: Description and Operation GENERAL DESCRIPTION Replacement wheels or tires must be equivalent to the originals in load capacity, specified dimension and mounting configuration. Improper size or type may affect bearing life, brake performance, speedometer/odometer calibration, vehicle ground clearance and tire clearance to the body and chassis. All model are equipped with metric sized tubeless steel belted radial tires. Correct tire pressures and driving habits have an important influence on tire life. Heavy cornering, excessively rapid acceleration and unnecessary sharp braking increase premature and uneven wear. TREAD WEAR INDICATORS The original equipment tires have built-in tread wear indicators (1) to show when tires need replacement. These indicators may appear as wide bands. When the indicators appear in two or more grooves at three locations, tire replacement is recommended. Page 183 Fuel Pump Relay: Description and Operation In order to control the FPAS operation, the FPAS relay is provided. When the starter switch is turned to "ON" position, the FPAS relay operates the FPAS for 2 seconds. When it is turned to "START" position, the Engine Control Module receives the reference pulse from the Ignition Control Module and it operates the relay, again causing the FPAS to feed fuel. Page 6352 A battery voltage (B+) circuit which is only powered with the ignition switch in the ON, or START positions. Initiator The electrical component inside the air bag assembly which, when sufficient current flows, sets off the chemical reaction that inflates the air bag. "Initiator Assembly Resistance Test" Tests performed once each ignition cycle when no malfunctions are detected during "Turn-ON" or "Continuous Monitoring." This test checks for the correct SDM configuration for the vehicle, shorts to "Ignition 1 in the deployment loops, high resistance or opens in the "Driver Side High", "Driver Side Low", "Passenger Side High" and "Passenger Side Low" circuits and measures the resistance of the inflator assembly consisting of: 1. Initiators. 2. SRS coil assembly (driver side only). 3. Connectors and associated wiring. Normal Operating Voltage Range The voltage measured between the SDM "Ignition 1" terminals and "Ground" terminals is between 9 and 16 volts. Passenger Current Source An output of the SDM which applies current into the passenger air bag assembly circuit during the "Initiator Assembly Resistance Test". Passenger Air Bag Assembly An assembly located in the right side of the instrument panel consisting of an inflatable bag, an inflator and an initiator. Scan Tool An external computer used to read diagnostic information from on-board computers via the data link connector. SDM Sensing and Diagnostic Module which provides reserve energy to the deployment loops, deploys the air bags when required and performs diagnostic monitoring of all SRS components. Serial Data Information representing the status of the SRS. SRS Supplemental Restraint System. SRS Coil Assembly An assembly of two current-carrying coils in the driver deployment loop that allows the rotation of the steering wheel while maintaining the continuous contact of the driver deployment loop to the driver air bag assembly. SRS Wiring Harness The wires and connectors that electrically connect the components in the SRS. "Turn-ON" Test which the SDM performs on the SRS once during each ignition cycle immediately after "Ignition 1" voltage is applied to the SDM and before "Continuous Monitoring". Page 6461 7. Reconnect three connector to Powertrain Control Module (PCM). (Y22SE 2.2L Engine only) 8. Install the center console. 9. Install the transfer shift lever knob. 10. Install the dressing panel around the radio and reconnect cigar lighter harness. 11. Enable the SRS. Page 43 Compressor Clutch Relay: Testing and Inspection 1. Disconnect relays and check for continuity and resistance between relay terminals. - For handling of these relays, refer to Heater Relay. Electronic Hydraulic Control Unit and Associated Parts Audio System - CD/DVD Precautions Compact Disc Player (CD): All Technical Service Bulletins Audio System - CD/DVD Precautions Adhesive Labels or Protective Disc Covers on CDs or DVDs: A Big Taboo NOTE: This article applies to all Honda models with a factory- or dealer-installed CD/DVD player or changer. We can't emphasize this enough: Never put adhesive labels or protective disc covers on recordable CDs or DVDs to be used in automotive CD/DVD players or changers. Here's why: ^ Recordable CDs and DVDs are actually thicker than their pre-recorded brethern. Automotive players and changers use rollers to draw the disc into the unit. The added thickness of an adhesive label or a protective disc cover can cause the disc to jam when it's loaded into or ejected from the unit. ^ CD/DVD players or changers are exposed to high temperatures inside the vehicle. High temperature can cause the label adhesive to soften. This can cause the label to curl on the edges and even form bubbles. Curled edges can catch on the rollers and bubbles add thickness to the disc. Either one can cause the disc to jam. To cut down on customer-caused damage, all '05 and later 0/Ms include this notice: Do not use CDs with adhesive labels. The label can curl up and cause the CD to jam in the unit. Anytime a service customer comes in with a loading or ejecting problem for a CD/DVD player or changer, ask if he or she used any discs with adhesive labels or protective disc covers. If the answer is yes, contact your DPSM for possible goodwill assistance. If the answer is no, then replace the audio unit under normal warranty. Page 211 This means the branch of the wire connects to another circuit. The arrow points to the name of the circuit branch where the wire continues. Page 494 Ground - "G" Shielding Sheilding This represents RFI (Radio Frequency Interference) shielding around a wire. The shielding is always connected to ground. Splices Page 6785 Trailer Lighting Connector (Part 2 Of 3) Page 5002 Make parts replacement as required if wear, distortion, nicks, cuts, corrosion, or other abnormal conditions are found through the following parts inspection: - Master cylinder body - Fluid reservoir - O-ring Functional Inspection of Master Cylinder Piston Push the primary piston (1) with your fingers to check that it travels smoothly. If the motion is questionable, replace the master cylinder as a complete assembly. Functional Inspection of Master Cylinder Inspect the master cylinder for function as follows. If any abnormal function is found, replace with a new one. Install the primary piston holder (3) J-39242 (including the master cylinder attachment (5) and master cylinder plug (7)) onto the master cylinder (4). Make sure the spacer (2)(2 bolts) with its adjusting bolt is screwed in up to the "0" line. Connect the master cylinder attachment (5) J-39242 with the end of the radiator cap tester (6) J-24460-01, and apply air pressure with the cap tester. Make sure there is no rise in pressure and that with the adjusting bolt further screwed in 5 mm (align the adjusting bolt to the "5" line). There should be a pressure increase of 0.5 kg or more. NOTE: When checking the front (or primary) side, be sure to mount the master cylinder plug in the rear (or secondary) port. Apply air pressure to the front and rear ports "0" Line - No pressure rise. "5" Line - Pressure increase of 0.5 kg or more Remarks Page 491 This sample Ground Distribution schematic shows all of the components that share two ground points. Components A solid border line means the entire component is shown. A broken border line indicates that only part of the component is shown. Page 2761 Powertrain Control Module: Locations 30. Left Side of Engine Compartment Left Side Of Engine Compartment Page 8019 Terminals - "T" Each "T" terminal (ring type) is numbered for reference and location. A "T" terminal is secured with a screw or bolt. Wires Page 3720 Axle Disconnect Control Control Unit: Service and Repair SHIFT ON THE FLY CONTROLLER AND ASSOCIATED PARTS REMOVAL 1. Disconnect the battery ground cable. 2. Remove the front console assembly. 3. Disconnect the connector from the controller. 4. Remove the nut. 5. Remove the controller. INSTALLATION 1. To install, follow the removal steps in the reverse order, noting the following points. Torque: Nut (1) 8 Nm (69 inch lbs.) Page 8179 Quarter Window Glass: Service and Repair Side Window Glass Side Window Glass (SWB) Removal 1. Remove the quarter trim cover. 2. Remove the side window garnish assembly. - Pull out the three clips to disengage them. 3. Remove the side window molding. 4. Remove the side window glass. Installation 1. Install the side window glass. - Clean the areas of the glass and body panel that are to be affixed to each other. - Apply the primer to the specified areas of the glass and body panel. - Stick the spacer and fastener tape in place in the specified locations. - Apply the adhesive to the entire circumference of the glass, as shown in the figure. - Insert the glass clips into the panel and then push the glass against the panel to affix it in place. - Wipe away any adhesive that oozes out around the edges. 2. Install the side window garnish assembly. - Install it securely so that it does not come loose in places. 3. Install the side window molding. - insert it securely so that it does not come loose in places. - Make sure that there is no water leakage from the side window glass. 4. Install the quarter trim cover. Specifications Piston: Specifications Outside Diameter Size Mark A 93.360 - 93.370 mm Size Mark B 93.371 - 93.380 mm Size mark C 93.381 - 93.390 mm Piston Grading Position 43.0 mm Total Piston Displacement 31.65 cc Locations Transmission Position Switch/Sensor: Locations Left Side Of Automatic Transmission Locations ECT Sensor Page 6469 Air Bag(s) Arming and Disarming: Service Precautions Wiring Precautions Wiring Precautions SRS wiring can be identified by special yellow outer covering (except the SRS indicator light circuit). Never attempt to modify, splice, or repair SRS wiring. If there is an open or damage in SRS wiring, replace the harness. Be sure to install the harness wires so that they are not pinched, or interfere with other parts. Make sure all SRS ground locations are clean, and grounds are securely fastened for optimum metal-to-metal contact. Poor grounding can cause intermittent problems that are difficult to diagnose. Page 1833 Heater Core: Service and Repair Removal 1. Disconnect the battery ground cable. 2. Drain the engine coolant. 3. Discharge and recover refrigerant (with air conditioning). 4. Remove heater unit. 5. Remove duct. 6. Remove case (Mode control) and do not remove link unit at this step. Page 5068 Part 1 of 2 Page 5255 H/C 4408092 Defect Code: 017 Contention Code: C99 Skill Level: Repair Technician Out of warranty: Any repair performed after warranty expiration may be eligible for goodwill consideration by the District Service Manager or your Zone Office. You must request consideration, and get a decision, before starting work. DISCLAIMER Page 4949 6. Remove guide bolt (2). 7. Remove caliper assembly. 8. Remove support bracket with pad assembly and take care not to damage the flexible brake hose when removing the support bracket. 9. Remove pad assembly with shim and mark the lining locations if they are to be reinstalled. 10. Remove clip. INSTALLATION 1. Install clip (4). 2. Apply special grease (approximately 0.2 g) to both contacting surfaces of the inner shims (5). Wipe off extruded grease after installing. Install pad assembly with shim. Page 2058 2. Connect one lead of a self-powered test light or DVOM to one end of the part of the circuit you want to test. 3. Connect the other lead to the other end. 4. If the self-powered test light glows, there is continuity. If you're using a DVOM, a low reading or no reading (zero), means good continuity. Testing For Voltage When testing for voltage at a connector without wire seals, you do not have to separate the two halves of the connector. Instead, probe the connector from the back. Always check both sides of the connector because dirty, corroded, and bent terminals can cause problems (no electrical contact = an open). 1. Connect one lead of the lest light to a known good ground, or, if you're using a digital volt ohmmeter (DVOM), place it in the appropriate DC volts range, and connect its negative lead to ground. 2. Connect the other lead of the test light or DVOM to the point you want to check. 3. If the test light glows, there is voltage present. If you're using a DVOM, note the voltage reading. It should be within one volt of measured battery voltage. A loss of more than one volt indicates a problem. NOTE: Always use a DVOM on high impedance circuits. A test light may not glow (even with battery voltage present). Testing For Voltage Drop Wires, connectors, and switches are designed to conduct current with a minimum loss of voltage. A voltage drop of more than one volt indicates a problem. 1. Place the digital volt/ohmmeter (DVOM) in the appropriate DC volts range. Connect the positive lead to the end of the wire (or to the connector or switch) closest to the battery. 2. Connect the negative lead to the other end of the wire (or the other side of the connector or switch). 3. Turn on the components in the circuit. 4. The DVOM will show the difference in voltage between the two points. A difference, or drop, of more than one volt indicates a problem. Check the circuit for loose, dirty, or bent terminals. Page 746 If there is no photo number below or beside a component name or a connector, ground, or terminal number, look up that name or number in the appropriate Connector Identification Chart. The chart lists how many cavities a connector has, where it's located, and what it connects to. The related illustration shows the connector's location on the harness, and the harness routing. NOTE: Photos listed by number are located at Locations / Components / Photograohs. See: Locations/Component Locations/Photographs Circuit Schematics Page 4734 4WD Control Unit: Service and Repair 4WD CONTROL UNIT ASSOCIATED PARTS REMOVAL 1. Remove center console assembly. 2. Remove two screws and harness connector (1) from 4WD control unit. INSTALLATION 1. Connect harness connector, then install 4WD control unit. 2. Install center console assembly. Page 2291 Air Flow Meter/Sensor: Description and Operation Mass Air Flow (MAF) Sensor The mass air flow (MAF) sensor measures the difference between the volume and the quantity of air that enters the engine. "Volume" means the size of the space to be filled. "Quantity" means the number of air molecules that will fit into the space. This information is important to the PCM because heavier, denser air will hold more fuel than lighter, thinner air. The PCM adjusts the air/fuel ratio as needed depending on the MAF value. The Tech 2 reads the MAF value and displays it in terms of grams per second (g/sec). At idle, the Tech 2 should read between 4 - 7 g/sec on a fully warmed up engine. Values should change quickly on acceleration. Values should remain stable at any given RPM. A failure in the MAF sensor or circuit will set DTC P0101, DTC P0102, or DTC P0103. Removal and Installation Camshaft: Service and Repair Removal and Installation REMOVAL 1. Disconnect battery ground cable. 2. Remove crankshaft pulley. Refer to removal procedure for Crankshaft Pulley. 3. Remove timing belt. Refer to removal procedure for Timing Belt. 4. Remove cylinder head cover LH. Refer to removal procedure for Cylinder Head Cover LH. 5. Remove cylinder head cover RH. Refer to removal procedure for Cylinder Head Cover RH. 6. Remove twenty fixing bolts from inlet and exhaust camshaft bracket on one side bank, then camshaft brackets. 7. Remove camshaft assembly. 8. Remove fixing bolt for camshaft drive gear pulley. 9. Remove three fixing bolts from camshaft drive gear retainer, then camshaft drive gear assembly. INSTALLATION 1. Install camshaft drive gear assembly and tighten three bolts to the specified torque. Torque: 10 Nm (89 inch lbs.) 2. Tighten bolt for camshaft drive gear assembly pulley to the specified torque. Torque: 98 Nm (72 ft. lbs.) Page 6780 Testing For A Short With A Self-Powered Test Light or DVOM 1. Remove the blown fuse and disconnect the battery and load. 2. Connect one lead of a self-powered test light or digital volt/ohmmeter (DVOM) (switched to the lowest "OHMS" range) to the fuse terminal on the load side. 3. Connect the other lead to a known good ground. 4. Beginning near the fuse box, wiggle the harness. Continue this at convenient points about six inches apart while watching the test light or DVOM. 5. If the self-powered test light goes on or the DVOM displays a low reading or no reading (zero), there is a short to ground in the wiring near that point. Testing for a Short with a Test Light or DVOM 1. Remove the blown fuse and disconnect the load. 2. Connect a test light or digital volt/ohmmeter (DVOM), switched to the appropriate DC volts range, across the fuse terminals to make sure voltage is present. You might have to turn the ignition switch to ON; check the schematic to see. 3. Beginning near the fuse box, wiggle the harness. Continue this at convenient points about six inches apart while watching the test light or DVOM. 4. Where the test light goes , or the DVOM voltage drops to zero, there is a short to ground in the wiring near that point. NOTE: Always use a DVOM on high impedance circuits. A test light may not glow (even with battery voltage present). Testing For A Short With A Short Circuit Locator (Short Finder) 1. Remove the blown fuse. Leave the battery connected. Page 4729 2. Connect one lead of a self-powered test light or DVOM to one end of the part of the circuit you want to test. 3. Connect the other lead to the other end. 4. If the self-powered test light glows, there is continuity. If you're using a DVOM, a low reading or no reading (zero), means good continuity. Testing For Voltage When testing for voltage at a connector without wire seals, you do not have to separate the two halves of the connector. Instead, probe the connector from the back. Always check both sides of the connector because dirty, corroded, and bent terminals can cause problems (no electrical contact = an open). 1. Connect one lead of the lest light to a known good ground, or, if you're using a digital volt ohmmeter (DVOM), place it in the appropriate DC volts range, and connect its negative lead to ground. 2. Connect the other lead of the test light or DVOM to the point you want to check. 3. If the test light glows, there is voltage present. If you're using a DVOM, note the voltage reading. It should be within one volt of measured battery voltage. A loss of more than one volt indicates a problem. NOTE: Always use a DVOM on high impedance circuits. A test light may not glow (even with battery voltage present). Testing For Voltage Drop Wires, connectors, and switches are designed to conduct current with a minimum loss of voltage. A voltage drop of more than one volt indicates a problem. 1. Place the digital volt/ohmmeter (DVOM) in the appropriate DC volts range. Connect the positive lead to the end of the wire (or to the connector or switch) closest to the battery. 2. Connect the negative lead to the other end of the wire (or the other side of the connector or switch). 3. Turn on the components in the circuit. 4. The DVOM will show the difference in voltage between the two points. A difference, or drop, of more than one volt indicates a problem. Check the circuit for loose, dirty, or bent terminals. Removal and Installation Ignition Coil: Service and Repair Removal and Installation Removal 1. Disconnect battery ground cable. 2. Ignition coil connector and ignition coil. - Disconnect three connector from ignition coil. - Remove harness bracket bolt on cylinder head cover. - Remove fixing bolts on ignition coil. Installation 1. Install the ignition coil assembly (3). Connect ignition coil connector (1) and ignition coil (3), then tighten bolt (2) to the specified torque. Torque: 4 Nm (35.4 lb in) CAUTION: Ignition coil assembly # 6 is different from ignition coil assembly from # 1 to # 5. Ignition coil assembly # 6 is short type. So, note it when installing ignition coil assembly of # 6. Adjustments Brake Switch (Cruise Control): Adjustments 1. Check that the brake pedal (3) is fully returned by pedal return spring. 2. Disconnect the switch connector. 3. Loosen the lock nut (2). 4. Rotate the brake switch (1) by hand until push rod disappears from brake switch tip (4). 5. Return the brake switch by a half turn. 6. Tighten the lock nut. 7. Connect the switch connector. Page 2044 This sample Ground Distribution schematic shows all of the components that share two ground points. Components A solid border line means the entire component is shown. A broken border line indicates that only part of the component is shown. Page 5912 Distinct Of Circuit By Wire Base Color All wires have color-coded insulation. Wires belonging to a system's main harness will have a single color. Wires belonging to a system's sub-circuits will have a colored stripe. Striped wires use the codes found in the chart to show wire size and colors. Abbreviations are used to indicate wire color within a circuit diagram. How to Identify Connector Terminals How to Identify Connector Terminals Cavity Numbering System The cavities (and wire terminals) in each connector are numbered starting from the upper left, looking at the male terminals from the terminal side (or looking at the female terminals from the wire side. Both views are in the same direction so the numbers are the same.) All actual cavities are numbered, even if they have no wire terminals in them. NOTE: Data Link Connector (DLC) terminals are numbered according to SAE standard J1962, not the Honda standard. The numbers of the four end terminals are molded into the corners of the connector face. The connector cavity number is listed next to each terminal on the circuit schematic. The cavity / terminal shown is # 6. Using/Identifying Connector Terminal Views How to Use Connector Terminal Views To see the configuration of a connector's cavities, look up its view number in the Connector Views. Each view includes the color of the connector, where Page 5746 9. Using a 3/8 in. drill motor, a 1/4 in. drill guide, and a 1/4 in. bit, drill three pilot holes per side into the bottom of the frame rail, through each hole in the type A reinforcement bracket. NOTE: On some 2000 models and all 2001-02 models, the driver's side requires only two holes due to the welded nut inside the frame, at the front bracket hole. Do not drill a hole in this location. Page 2622 The connector cavity number is listed next to each terminal on the circuit schematic. The cavity / terminal shown is # 6. Diodes A rectifier diode works like a one way valve. It allows current to flow only in the direction of the arrow. A Zener diode blocks reverse current at normal voltages just like a rectifier diode. At high voltages, however, a Zener diode allows current to flow in reverse. Fuses Page 6287 Each schematic represents one circuit. A circuit's wires and components are arranged to show current flow, from power at the top of the page, to ground, at the bottom. Shared Circuits Other circuits may share power or ground terminals or wiring with the circuit shown. A wire that connects one circuit to another, for example, is cut short and has an arrowhead at the end of it pointing in the direction of current flow. Next to the arrowhead is the name of the circuit or component which shares that wiring. To quickly check shared wiring, check the operation of a component it serves. If that component works, you know the shared wiring is OK. Connectors All in-line and junction connectors are numbered (C725, C416, etc.). Component connectors are not numbered but are identified either by the name of Page 3370 Wire Color Abbreviations The following abbreviations are used to identify wire colors in the circuit schematics: WHT................................... White YEL................................... Yellow BLK................................... Black BLU................................... Blue GRN................................... Green RED................................... Red ORN................................... Orange PNK................................... Pink BRN................................... Brown GRY................................... Gray PUR................................... Purple LT BLU................................... Light Blue LT GRN................................... Light Green Page 5585 Wires Wire insulation can be one color, or one color with another color stripe. (The second color is the stripe.) This circuit continues on another image. (The arrow shows direction of current flow.) To follow the RED/BLK wire in this example, you would turn to "Fuel and Emissions" and look for the "A" arrow. Page 4352 Drive/Propeller Shaft: Specifications Rear Propeller Shaft REAR PROPELLER SHAFT General Specifications Torque Specifications Page 7556 To install the connector, hold the socket insulator(l) and insert it. The cover insulator slides and connector will be locked. Do not hold the cover insulator(2). Page 6153 The wire insulation has one color or one color with another color stripe. The second color is the stripe. Locations Diagram Information and Instructions Key Reminder Switch: Diagram Information and Instructions How to Identify Wiring Color-Coded Insulation Wire Color Wire Color Coding Vibration When Idling Engine Mount: All Technical Service Bulletins Vibration When Idling 00-040 April 11, 2000 Applies To: 1998-99 Passport - ALL 2000 Passport-From VIN 4S6..58W.Y4400001 thru 4S6..58W.Y4400051 Vibration When Idling SYMPTOM Harsh vibration comes from the body, the steering wheel, the seats, or the floor when the transmission is in Drive with the engine idling. The vibration is worse when the engine is cold. Sometimes, you can hear banging while starting the engine. PROBABLE CAUSE The right engine mount cover hits the chassis side of the engine mount. CORRECTIVE ACTION Shift the engine assembly slightly forward using REPAIR PROCEDURE A. If the vibration is still there, replace the right engine mount cover using REPAIR PROCEDURE B. PARTS INFORMATION Engine Mount Cover: P/N 8-97241-056-0, H/C 6362701 WARRANTY CLAIM INFORMATION In warranty: The normal warranty applies. REPAIR PROCEDURE A Operation Number: 112010 Flat Rate Time: 0.2 hour Failed Part: P/N 8-97125-561-7 H/C 6360812 Detect Code: 045 Contention Code: B99 Template ID: 00-040A Skill Level: Repair Technician REPAIR PROCEDURE B Operation Number: 112125 Flat Rate Time: 1.5 hours Failed Part: P/N 8-97125-306-0 H/C 5508981 Defect Code: 045 Contention Code: B99 Template ID: 00-040B Skill Level: Repair Technician Out of warranty: Any repair performed after warranty expiration may be eligible for goodwill consideration by the District Service Manager or your Zone Office. You must request consideration, and get a decision, before starting work. REPAIR PROCEDURE A 1. Raise the vehicle on a lift. Page 4944 Brake Bleeding: Service and Repair Flushing Brake Hydraulic System FLUSHING BRAKE HYDRAULIC SYSTEM It is recommended that the entire hydraulic system be thoroughly flushed with clean brake fluid whenever new parts are installed in the hydraulic system. Approximately one quart of fluid is required to flush the hydraulic system. The system must be flushed if there is any doubt as to the grade of fluid in the system or if fluid has been used which contains the slightest trace of mineral oil. All rubber parts that have been subjected to a contaminated fluid must be replaced. Page 5758 21. Remove and discard the frame rail side hole plug from both frame rails. 22. Using a hammer, knock on the outside of both frame rails to loosen any rust on the inside of the frame. 23. Using a wire brush and a scraper, remove any loose frame coating and rust from the outside frame rail. Clean 10 inches (250 mm) forward and rearward of the bracket area. 24. Use a dry rag to remove any remaining dust or debris. 25. Temporarily install both type B reinforcement brackets using new body mount studs and nuts, and C-clamps: ^ Secure the bracket to the frame using the new body mount stud and nut at the upper link bracket. ^ Firmly push the bracket up against the frame, and clamp it into place with a C-clamp. Make sure the C-clamp compresses the bracket against the frame so there is no possibility of bracket movement when drilling pilot holes into the frame. Page 4898 Raise the vehicle on a lift. Check for loose wheel bearings. You must replace loose wheel bearings before you refinish the brake discs. If you do not, the brake lathe will not correct for brake disc runout, resulting in an uneven finish and brake pulsation. Remove the front wheels, then reinstall the wheel nuts with flat washers to compensate for the removed wheel. Torque the wheel nuts to the required specification (see the appropriate service manual). Remove the caliper assembly. Use a wire or a S-hook to hold the caliper to the spring or damper tower. Do not kink the brake hose or use it to support the caliper. If you are not using the power drive system and the vehicle has ICS or VSA, make sure you install a brake pad spreader between the pads on the hanging caliper. Also, make sure the ICS or VSA is turned off anytime the engine is started. If the system is not turned off, the brakes could activate, causing the brake pads on the hanging caliper to hit each other or the caliper pistons to fall out. Install the vibration damper on the brake disc. If you are not using the power drive system, make sure you install the protective band around the wheel nuts. If you are not using the power drive system, use a fabric tie-down strap to secure the brake disc that is opposite to the one you are refinishing. If you are working on a Prelude with ATTS, do not use a tie-down strap; let both wheels turn freely. Mounting the Brake Lathe Remove the tool bed from the brake lathe, then mount the brake lathe to the steering knuckle with a Honda 1-piece speed mount. These mounts provide quicker, more accurate mounting, and can be ordered through the Honda Tool and Equipment Program (see ORDERING INFORMATION). Page 440 Refrigerant Pressure Sensor / Switch: Description and Operation A/C Dual Pressure Switch (M/T) To prevent compressor damage, the dual pressure switch will open if system pressure is too low or too high: below 176.5 ± 19.6 kPa (25.6 ± 2.8 psi) or above 2943 ± 196.2 kPa (426.7 ± 28.4 psi). A/C Triple Pressure Switch (A/T) Low and high switch operation is the same as the dual pressure switch. The medium pressure switch will close when system pressure exceeds 1471.5 ± 98.1 kPa (213.3 ± 14.2 psi), turning on the condenser fan. Page 6395 10. Bend twisted connection made in the previous step flat and wrap tightly with electrical tape to insulate and secure. 11. Twist together bend and tape the remaining connector wire lead to the remaining deployment wire. 12. Connect the deployment harness to the driver air bag assembly, yellow 2 - pin connector at the base of the steering column. Route deployment harness out the driver side of the vehicle. WARNING: DEPLOYMENT WIRES SHALL REMAIN SHORTED AND NOT BE CONNECTED TO A POWER SOURCE UNTIL THE AIR BAG IS TO BE DEPLOYED. THE AIR BAG ASSEMBLY WILL IMMEDIATELY DEPLOY THE AIR BAG WHEN A POWER SOURCE IS CONNECTED TO IT. CONNECTING THE DEPLOYMENT WIRES TO THE POWER SOURCE SHOULD ALWAYS BE THE FINAL STEP IN THE AIR BAG ASSEMBLY DEPLOYMENT PROCEDURE. FAILURE TO FOLLOW PROCEDURES IN THE ORDER LISTED COULD RESULT IN PERSONAL INJURY. 13. Disconnect passenger air bag assembly. Yellow 2 - pin connector located behind glove box assembly. 14. Cut the passenger sir bag assembly harness connector from the vehicle leaving at least 16 cm (six inches) of wire at the connector. 15. Strip 13 mm (1/2 inch) of insulation from yellow - green and yellow - red wire lead of the connector. 16. Cut two 900 cm (30 feet) deployment wires from 0.8 sq.mm (18 gauge) or thicker multi-strand wire. These wires will be used to fabricate the passenger deployment harness. 17. Strip 13 mm (1/2 inch) of insulation from both ends of the wires cut in the previous step. 18. Short the wires by twisting together one end from each. Deployment wires shall remain shorted and not be connected to a power source until the air bag is to be deployed. WARNING: FAILURE TO FOLLOW PROCEDURES IN THE ORDER LISTED COULD RESULT IN PERSONAL INJURY. NEVER CONNECT DEPLOYMENT WIRES TO ANY POWER SOURCE BEFORE CONNECTING DEPLOYMENT WIRES TO THE AIR BAG ASSEMBLY LEADS. DEPLOYMENT WIRES SHALL REMAIN SHORTED AND DISCONNECTED FROM ANY POWER SOURCE UNTIL THE AIRBAG IS TO BE DEPLOYED OR ACCIDENTAL AIRBAG DEPLOYMENT WILL IMMEDIATELY OCCUR. THIS MAY CAUSE PERSONAL INJURY. ALWAYS WEAR SAFETY GLASSES DURING AIRBAG DEPLOYMENT AND DISPOSAL. 19. Twist together one connector wire lead to one deployment wire. The connection should be mechanically secure. Page 5568 To install the connector, hold the socket insulator(l) and insert it. The cover insulator slides and connector will be locked. Do not hold the cover insulator(2). Diagrams Service and Repair Sunroof / Moonroof Switch: Service and Repair Removal 1. Disconnect the battery ground cable. 2. Remove the sunroof switch (1). - Remove the switch by pushing the spring with the tip of a screwdriver. - Disconnect the switch connector. Installation To install, follow the removal steps in the reverse order. SRS Operation Air Bag(s) Arming and Disarming: Description and Operation SRS Operation The SRS is a safety device which, when used in conjunction with the seat belt, is designed to help protect the driver (and front passenger) in a frontal impact exceeding a certain set limit. The system consists of the SRS unit (including safing sensor and impact sensor), the cable reel, the driver's airbag (and front passenger's airbag). Operation The main circuit in the SRS unit senses and judges the force of impact and, if necessary, ignites the inflator charge(s). If battery voltage is too low or power is disconnected due to the impact, the voltage regulator and the back-up power circuit respectively will keep voltage at a constant level. For the SRS to operate: 1. The impact sensor must activate, and send electric signals to the microprocessor. 2. The microprocessor must compute the signals, and must send signals to the airbag inflator(s). 3. The inflator(s) must ignite and deploy the airbag(s). Self-diagnosis System A self-diagnosis circuit is built into the SRS unit; when the ignition switch is turned ON (II), the SRS indicator light comes on and goes off after about six seconds if the system is operating normally. If the light does not come on, or does not go off after six seconds, or if it comes on while driving, it indicates an abnormality in the system. The system must be inspected and repaired as soon as possible. For better serviceability, the memory will store the cause of the malfunction, and the data link circuit passes on the information from the memory to the data link connector (DLC). This information can be read with the Honda PGM Tester connected to the DLC (16P). Page 4594 The name of the component appears next to it followed by notes about its function along with any photo and connector view references. Connector "C" How to Identify Connector Terminals Cavity Numbering System The cavities (and wire terminals) in each connector are numbered starting from the upper left, looking at the male terminals from the terminal side (or looking at the female terminals from the wire side. Both views are in the same direction so the numbers are the same.) All actual cavities are numbered, even if they have no wire terminals in them. NOTE: Data Link Connector (DLC) terminals are numbered according to SAE standard J1962, not the Honda standard. The numbers of the four end terminals are molded into the corners of the connector face. Locations Page 7612 Page 5805 Trailing Arm: Service and Repair Trailing Arm REMOVAL 1. Remove the parking brake cable from the trailing link. 2. Remove the trailing link fixing bolt, nut and protector. 3. Remove trailing link. INSPECTION AND REPAIR Make necessary correction or parts replacement if wear, damage, corrosion or any other abnormal condition are found through inspection. 1. Trailing link 2. Rubber bushing - Remove the rubber bushing by using remover J-39214. Page 1590 2. Measure the valve spring squareness with a steel square and replace the valve springs if the measured value exceeds the specified limit. Limit: 2 mm (0.079 inch) 3. Using a spring tester to compress the springs to the installed height, measure the compressed spring tension, and replace the springs if the measured tension is below the specified limit. At installed height: 35.0 mm (1.38 inch) Standard: 196 N (44 lbs.) Limit: Less than 181 N (41 lbs.) Valve Guide Caution: Take care not to damage the valve seat contact surface, when removing carbon adhering to the valve head. Carefully inspect the valve stem for scratches or abnormal wear. If these conditions are present, the valve and the valve guide must be replaced as a set 1. Measure the valve stem diameter with a micrometer. If the valve stem diameter is less than the specified limit, the valve and the valve guide must be replaced as a set. Diameter of Valve Stem Intake Standard: 5.977 mm - 5.959 mm (0.2353 in 0.2346 inch) Limit: 5.90 mm (0.2323 inch) Exhaust Standard: 5.952 mm - 5.970 mm (0.2343 in 0.2350 inch) Limit: 5.90 mm (0.2323 inch) 2. Measure the inside diameter of the valve guide with a micrometer. Subtract the measured outer diameter of the valve stem from the measured inner diameter of the valve guide. If the value exceeds the specified limit, the valve and the valve guide must be replaced as a set. Inside Diameter of the Valve Guide Inlet clearance Standard: 0.023 mm - 0.056 mm (0.0009 in - 0.0002 inch) Limit: 0.20 mm (0.00787 inch) Exhaust clearance Standard: 0.030 mm - 0.063 mm (0.0012 in - 0.0025 inch) Limit: 0.20 mm (0.00787 inch) Service and Repair Sunroof / Moonroof Switch: Service and Repair Removal 1. Disconnect the battery ground cable. 2. Remove the sunroof switch (1). - Remove the switch by pushing the spring with the tip of a screwdriver. - Disconnect the switch connector. Installation To install, follow the removal steps in the reverse order. Page 3334 the component if the component only has one connector, or by a capital letter (A, B, C, etc.) if the component has more than one connector. Below most connector numbers and component names are PHOTO and VIEW numbers. The PHOTO number refers to a photo in the back of the book that shows the connector's location on the car. The VIEW number refers to an illustration in the back of the book that shows the connector face, wire colors, connector cavity numbers, and other details. The connector cavity numbering sequence begins at the top left corner of the connector. Disregard any numbers molded into the connector housing. Wires Wires are identified by the abbreviated names of their colors; the second color is the color of the stripe. Wires are also identified by their location in a connector. The number "2" next to the male and female wire terminals at C416, for example, means those terminals join in cavity 2 of connector C416. Symbols A complete description of schematic symbols is given under wire color abbreviation. Power Distribution Schematics Power Distribution schematics show how power is supplied from the positive battery terminal to various circuits in the car. Refer to the Power Distribution section to get a more detailed picture of how power is supplied to the circuit you're working on. From Battery to Ignition Switch, Fuses, and Relays Individual circuit schematics begin with a fuse. The first half of Power Distribution, however, shows the wiring "upstream" between the battery Accelerator Pedal Assembly/Sensor - Adjustment Update Accelerator Pedal Position Sensor: All Technical Service Bulletins Accelerator Pedal Assembly/Sensor - Adjustment Update 00-045 August 14, 2001 Applies To: 2000-02 Passport - ALL Service Manual Update: Accelerator Pedal Position Sensor (APPS) (Supersedes 00-045, dated May 23, 2000) Updated information is shown by asterisks and black bars. BACKGROUND When the accelerator pedal position sensor (APPS) or the accelerator pedal assembly is replaced for any reason, you must adjust the APPS. *This procedure is missing in the 2000 service manual and is wrong in the 2001 and 2002 service manuals. Make a note on page 6E2-539 of the 2000 Passport Fuel and Emissions manual, on page 6E2-553 of the 2001 Passport Fuel and Emissions manual, and on page 6E2-545 of the 2002 Passport Fuel and Emissions manual to refer to this bulletin.* ADJUSTMENT PROCEDURE 1. Replace the APPS or the accelerator pedal assembly, and leave the mounting screws for the APPS loose. 2. Connect the PGM Tester to the data link connector (DLC), and turn the ignition switch to ON (II). *3. While watching the APP Sensor values in the Engine Data List, adjust the APPS by turning it until the values are within the ranges shown at closed pushed all the way down), then tighten the throttle and wide open throttle (accelerator pedal mounting screws and recheck the values. ^ If all three sensors are within range, go to step 12. ^ If APP Sensor 1, APP Sensor 2, and/or APP Sensor 3 cannot be brought into range, go to step 4. 4. Troubleshoot for an open circuit or a PCM malfunction. ^ If APP Sensor 1 has a value of 0% or APP Sensor 2 and/or APP Sensor 3 have a value of 99%, an open circuit exists or the PCM is malfunctioning. Repair the circuit or replace the PCM, and repeat step 3. ^ If you don't find a problem, go to step 5. 5. Disconnect the 10P connector from the APPS. 6. View the APP Sensor values in the Engine Data List. ^ If APP Sensor 1 has a value of 0% or APP Sensor 2 and/or APP Sensor 3 have a value of 99%, go to step 7. ^ If APP Sensor 1 has a value other than 0%, or APP Sensor 2 and/or APP Sensor 3 have a value other than 99%, a short circuit exists or the PCM is malfunctioning. Repair the circuit or replace the PCM, and repeat step 3. Page 817 Air Flow Meter/Sensor: Description and Operation Mass Air Flow (MAF) Sensor The mass air flow (MAF) sensor measures the difference between the volume and the quantity of air that enters the engine. "Volume" means the size of the space to be filled. "Quantity" means the number of air molecules that will fit into the space. This information is important to the PCM because heavier, denser air will hold more fuel than lighter, thinner air. The PCM adjusts the air/fuel ratio as needed depending on the MAF value. The Tech 2 reads the MAF value and displays it in terms of grams per second (g/sec). At idle, the Tech 2 should read between 4 - 7 g/sec on a fully warmed up engine. Values should change quickly on acceleration. Values should remain stable at any given RPM. A failure in the MAF sensor or circuit will set DTC P0101, DTC P0102, or DTC P0103. Page 2006 the component if the component only has one connector, or by a capital letter (A, B, C, etc.) if the component has more than one connector. Below most connector numbers and component names are PHOTO and VIEW numbers. The PHOTO number refers to a photo in the back of the book that shows the connector's location on the car. The VIEW number refers to an illustration in the back of the book that shows the connector face, wire colors, connector cavity numbers, and other details. The connector cavity numbering sequence begins at the top left corner of the connector. Disregard any numbers molded into the connector housing. Wires Wires are identified by the abbreviated names of their colors; the second color is the color of the stripe. Wires are also identified by their location in a connector. The number "2" next to the male and female wire terminals at C416, for example, means those terminals join in cavity 2 of connector C416. Symbols A complete description of schematic symbols is given under wire color abbreviation. Power Distribution Schematics Power Distribution schematics show how power is supplied from the positive battery terminal to various circuits in the car. Refer to the Power Distribution section to get a more detailed picture of how power is supplied to the circuit you're working on. From Battery to Ignition Switch, Fuses, and Relays Individual circuit schematics begin with a fuse. The first half of Power Distribution, however, shows the wiring "upstream" between the battery Page 1574 5. Use the J-8062 valve spring compressor and J-42898 valve spring compressor adapter to remove split collar. 6. Remove valve spring. 7. Remove valve. 8. Remove oil controller and spring lower seat. 9. Remove the valve guide using the J-42899 valve guide replacer. Inspection and Repair Valve Spring Caution: Visually inspect the valve springs and replace them if damage or abnormal wear is evident. 1. Measure the free height of the springs. The springs must be replaced if the free height is below the specified limit. Standard: 44.6 mm (1.756 inch) Limit: 43.6 mm (1.717 inch) Page 6081 Terminals - "T" Each "T" terminal (ring type) is numbered for reference and location. A "T" terminal is secured with a screw or bolt. Wires Diagram Information and Instructions Parking Lamp: Diagram Information and Instructions How to Identify Wiring Color-Coded Insulation Wire Color Wire Color Coding Page 6219 Housing Assembly HVAC: Service and Repair Heater Core and/or Mode Door Removal 1. Disconnect the battery ground cable. 2. Drain the engine coolant. 3. Discharge and recover refrigerant (with air conditioning). 4. Remove heater unit. 5. Remove duct. 6. Remove case (Mode control) and do not remove link unit at this step. Page 5399 Defect Code: 07406 Symptom Code: 03602 Skill Level: Repair Technician Diagnostic Trouble Code: To create the 15-digit DTC, see the applicable repair procedure. Out of warranty: Any repair performed after warranty expiration may be eligible for goodwill consideration by the District Parts and Service Manager or your Zone Office. You must request consideration, and get a decision, before starting work. TOOL DESCRIPTIONS The holding force gauge measures the amount of pull on the vehicle. It is a bracket that counts as one weight, plus five removable weights. During the test-drive, attach the bracket and the weights to the steering wheel on the side opposite the pulling direction. For example, if the vehicle pulls to the right, attach the bracket and weights to the left side of the steering wheel. Start with the maximum amount of weight on the steering wheel, and remove the weights until the vehicle drives in a straight line. When recording the pull on the worksheet, write down the direction of the pull (lefi or right) and the number of weights required to balance the pull (one through six). For example, if you have the bracket and two weights on the steering wheel, then record this as three weights. NOTE: The bracket counts as one weight. Description and Operation Transmission Mode Indicator - A/T: Description and Operation With the ignition switch in ON or START battery voltage is applied to the A/T gear position switch through fuse 14. The A/T gear position switch sends a signal to the PCM which communicates this information to the multiplex control unit which in turn controls the A/T gear position indicator corresponding to the gear selected. The multiplex control unit applies voltage to the appropriate A/T gear position indicator light in the meter assembly, causing it to come on. Page 4491 2. Connect the short finder across the battery terminals and the load (component) side of the fuse terminal. 3. Close all switches in the circuit you're testing. 4. Turn on the short finder. This creates a pulsing magnetic field around the wiring between the fuse box and the short. 5. Beginning at the fuse box, slowly move the short finder along the circuit wiring. The meter will read current pulses through sheet metal and body trim. As long as the meter is between the fuse and the short, the needle will move with each current pulse. Once you move the meter past the point of the short, the needle will stop moving. Check the wiring and connectors in this area to locate the cause of the short. Testing For Continuity When testing for continuity at a connector without wire seals, you do not have to separate the two halves of the connector. Instead, probe the connector from the back. Always check both sides of the connector because dirty, corroded, and bent terminals can cause problems (no electrical contact = an open). 1. Disconnect the negative cable from the car battery. If you're using a DVOM, place it in the lowest "OHMS" range. Page 1916 11. Working through the right front wheelwell, remove the two flange bolts holding the engine mount to the chassis. Repeat this on the left side. 12. Working from under the vehicle, remove the two lower flange bolts holding the right engine bracket to the engine. 13. Use the powertrain lift to raise the engine until both engine mounts clear the chassis. Locations Fuel Pump Relay: Locations Fuse/Relay Box (Cover Removed) Power Window Switch Driver Seat Side Power Window Switch: Service and Repair Power Window Switch Driver Seat Side Power Window Switch Driver Seat Side Removal 1. Disconnect the battery ground cable. 2. Remove the switch (1). - Pull out the switch by pushing the spring with the tip of a screwdriver. - Disconnect the connector. Installation To install, follow the removal steps in the reverse order. Front Passenger Seat Side Removal 1. Disconnect the battery ground cable. 2. Remove the switch (1). - Pull out the switch by pushing the spring with the tip of a screwdriver. - Disconnect the connector. Installation Page 6628 ^ ALO/BOA - Your order has been allocated, but not released for shipment. ^ REL/BOR - Your order has been picked, packed, and shipped. ^ INV - Your order has been invoiced to your dealer parts account. CORE RETURN INFORMATION Service Technician: 1. If the customer's media (CD, CD magazine, DVD, DVD-A, or cassette tape) is stuck inside the faulty unit, fill out a Customer Media Return Label (reorder number Y0325), and attach it to the unit. The manufacturer will remove the media, and mail it back to your dealership. 2. Use the pre paid shipping label. Each audio supplier provides a prepaid shipping label with the remanufactured audio unit. Return the core using this label to ensure it is received at the appropriate location for credit. Use the pre paid shipping labels to return audio cores to authorized locations only; do not use them for any other purpose. If you need additional prepaid shipping labels, contact Remanufactured Parts Operations. ^ Complete the shipping label with your dealership information. ^ Pack one audio unit per box, and use a separate shipping label for each one. ^ On the line requesting Your Internal Reference Information, enter YOUR DEALER NUMBER and the WARRANTY CLAIM NUMBER. 3. On the repair order, write down the warranty claim number, the original part number, the serial numbers from both the faulty and remanufactured units, and the return tracking number. 4. Ship the faulty unit in the same box the remanufactured unit came in. Make sure you include this required paperwork: ^ A copy of the Core Return Update Acknowledgement from the iN. ^ A copy of the warranty audio order. NOTE: When the Remanufacturing Center gets the faulty unit, your warranty audio order will be updated to indicate that the core was received. If the core is received 31-60 days from the order date, and you have been debited a core loss charge, your dealership will be credited back, less a $250 late fee. OUT-OF-WARRANTY REPAIR (AUDIO, NAVIGATION, AND RES UNITS PRODUCED IN 1998 OR LATER) NOTE: If you are making a repair or exchange because of a service bulletin or service campaign, do not use OUT-OF-WARRANTY procedures. Refer to IN-WARRANTY EXCHANGE for more information. Service Advisor: 1. Give your customer an estimate for repairing the unit (see step 6), plus the labor cost to replace it. For an Alpine unit, your customer has the option of contacting Alpine Electronics directly. Alpine's customer service number is 800-421-2284, Ext. 860304. Service Technician: 2. Remove the failed unit: ^ Refer to the appropriate component section of the service manual or, Page 6405 To install the connector, hold the socket insulator(l) and insert it. The cover insulator slides and connector will be locked. Do not hold the cover insulator(2). Removal and Installation WARNING: SAFETY PRECAUTIONS MUST BE FOLLOWED WHEN HANDLING A DEPLOYED AIR BAG ASSEMBLY. AFTER DEPLOYMENT, THE AIR BAG ASSEMBLY SURFACE MAY CONTAIN A SMALL AMOUNT OF SODIUM HYDROXIDE, A BY - PRODUCT OF THE DEPLOYMENT REACTION, THAT IS IRRITATING TO THE SKIN AND EYES. MOST OF THE POWDER ON THE AIR BAG ASSEMBLY IS HARMLESS. AS A PRECAUTION, WEAR GLOVES AND SAFETY GLASSES WHEN HANDLING A DEPLOYED AIR BAG ASSEMBLY, AND WASH YOUR HANDS WITH MILD SOAP AND WATER AFTERWARDS. WARNING: WHEN CARRYING A LIVE AIR BAG ASSEMBLY, MAKE SURE THE BAG AND TRIM COVER ARE POINTED AWAY FROM YOU. NEVER CARRY AIR BAG ASSEMBLY BY THE WIRES OR CONNECTOR ON THE UNDERSIDE OF MODULE. IN THE CASE OF AN ACCIDENTAL DEPLOYMENT; THE BAG WILL THEN DEPLOY WITH MINIMAL CHANCE OF INJURY. WHEN PLACING A LIVE AIR BAG ASSEMBLY ON A BENCH OR OTHER SURFACE, ALWAYS FACE BAG AND TRIM COVER UP AWAY FROM THE SURFACE. NEVER REST A STEERING COLUMN ASSEMBLY ON THE STEERING WHEEL WITH THE AIR BAG ASSEMBLY FACE DOWN AND COLUMN VERTICAL. THIS IS NECESSARY SO THAT A FREE SPACE IS PROVIDED TO ALLOW THE AIR BAG ASSEMBLY TO EXPAND IN THE UNLIKELY EVENT OF ACCIDENTAL DEPLOYMENT. OTHERWISE, PERSONAL INJURY COULD RESULT. NOTE: In the event deployment has occurred, inspect coil assembly wire for any signs of scorching, melting or any other damage due to excessive heat. If the coil has been damaged, replace it. Removal 1. Disable the Supplemental Restraint System (SRS). (Refer to "Disabling the SRS".) Page 4837 Brake Bleeding: Service and Repair Flushing Brake Hydraulic System FLUSHING BRAKE HYDRAULIC SYSTEM It is recommended that the entire hydraulic system be thoroughly flushed with clean brake fluid whenever new parts are installed in the hydraulic system. Approximately one quart of fluid is required to flush the hydraulic system. The system must be flushed if there is any doubt as to the grade of fluid in the system or if fluid has been used which contains the slightest trace of mineral oil. All rubber parts that have been subjected to a contaminated fluid must be replaced. Page 2985 Vehicle Speed Sensor: Description and Operation Vehicle Speed Sensor (VSS) The PCM determines the speed of the vehicle by converting a plusing voltage signal from the vehicle speed sensor (VSS) into miles per hour. The PCM uses this signal to operate the cruise control, speedometer, and the TCC and shift solenoids in the transmission. For more information on the TCC and shift solenoids, refer to 4L30-E Automatic Transmission (Transmission Control System Diagnosis). How the Circuit Works The VSS generates a signal for the speedometer. The speedometer consists of its own speed sensor, an ammeter (to move the needle), stepper motor (to turn the odometer), and a driving circuit (printed circuit board). The VSS is mounted to the transmission. The transmission pinion shaft generates four pulses per one rotation. The rate at which the pulses are generated indicates the vehicle speed. The speed sensor in the speedometer uses the pulses to control how far and fast the needle moves and to send vehicle speed information (4096 pulses per mile) to the ECM or PCM. Description and Operation Ignition Cable: Description and Operation Spark Plug Cables Spark Plug Cables The cable contains a synthetic conductor which is easily damaged. Never stretch or kink the cable. Disconnect the cable from spark plug and the ignition coil. The original equipment cables and the ignition coil are marked to show correct location of the cables. If spark plug cables or the ignition coil are replaced previously, before cables are removed from the ignition coil, mark the cables and the coil so they can be reconnected in the same position. Page 7415 Wire Color Abbreviations The following abbreviations are used to identify wire colors in the circuit schematics: WHT................................... White YEL................................... Yellow BLK................................... Black BLU................................... Blue GRN................................... Green RED................................... Red ORN................................... Orange PNK................................... Pink BRN................................... Brown GRY................................... Gray PUR................................... Purple LT BLU................................... Light Blue LT GRN................................... Light Green Page 7097 This means the branch of the wire connects to another circuit. The arrow points to the name of the circuit branch where the wire continues. Page 1488 If the seal was removed from retainer for replacement, apply engine oil to the oil seal lip and install the oil seal using J-39201 oil seal installer. 3. Flywheel (9) 1. Thoroughly clean and remove the oil from the threads of crankshaft. 2. Remove the oil from the crankshaft and flywheel mounting faces. 3. Mount the flywheel on the crankshaft and then install the washer. 4. Hold the crankshaft to prevent from rotating then install the bolts in the order shown to the specified torque. Torque: 54 Nm (40 ft. lbs.) Note: Do not reuse the bolt and do not apply oil or thread lock to the bolt. Page 498 This means the branch of the wire connects to another circuit. The arrow points to the name of the circuit branch where the wire continues. Page 7719 Wire Color Abbreviations The following abbreviations are used to identify wire colors in the circuit schematics: WHT................................... White YEL................................... Yellow BLK................................... Black BLU................................... Blue GRN................................... Green RED................................... Red ORN................................... Orange PNK................................... Pink BRN................................... Brown GRY................................... Gray PUR................................... Purple LT BLU................................... Light Blue LT GRN................................... Light Green Page 6728 Distinct Of Circuit By Wire Base Color All wires have color-coded insulation. Wires belonging to a system's main harness will have a single color. Wires belonging to a system's sub-circuits will have a colored stripe. Striped wires use the codes found in the chart to show wire size and colors. Abbreviations are used to indicate wire color within a circuit diagram. How to Identify Connector Terminals How to Identify Connector Terminals Cavity Numbering System The cavities (and wire terminals) in each connector are numbered starting from the upper left, looking at the male terminals from the terminal side (or looking at the female terminals from the wire side. Both views are in the same direction so the numbers are the same.) All actual cavities are numbered, even if they have no wire terminals in them. NOTE: Data Link Connector (DLC) terminals are numbered according to SAE standard J1962, not the Honda standard. The numbers of the four end terminals are molded into the corners of the connector face. The connector cavity number is listed next to each terminal on the circuit schematic. The cavity / terminal shown is # 6. Using/Identifying Connector Terminal Views How to Use Connector Terminal Views To see the configuration of a connector's cavities, look up its view number in the Connector Views. Each view includes the color of the connector, where Engine Controls - High/Erratic Engine Idle Fuel Pressure Regulator: Customer Interest Engine Controls - High/Erratic Engine Idle 01-080 August 14, 2001 Applies To: 2000-02 Passport - ALL 2000-02 Passport: High or Erratic Idle SYMPTOM The engine occasionally idles at too high a speed, or the idle speed fluctuates. PROBABLE CAUSES The symptom could be the result of any of these conditions: ^ Loose or corroded engine or body ground ^ High resistance in the APPS ground circuit ^ PSP (power steering pressure) switch is internally shorted to ground ^ Fuel pressure regulator is leaking fuel into the intake manifold CORRECTIVE ACTION Diagnose the cause of the idle condition, and select the proper REPAIR PROCEDURE. PARTS INFORMATION REQUIRED MATERIALS REQUIRED SOFTWARE Each REPAIR PROCEDURE requires you to use the Smart Cable to reprogram the PCM with the latest software. To select the latest software from the CDROM, enter the year, model, engine, transmission, and emissions type (49-state or California). This gives you a list of broadcast codes. Select the broadcast code at the top of the list. WARRANTY CLAIM INFORMATION Refer to the Warranty Claim Information for each Repair Procedure. DIAGNOSIS 1. Find out from the customer when the high or erratic idle condition occurs and what the RPM range is: ^ Within 20 minutes of a cold start ^ After braking to a stop ^ All the time ^ Intermittently, with no set pattern Page 5981 Page 769 2. Secure the VSS in place with the clamp and the bolt. 3. Tighten the bolt to 27 Nm (20 lb ft.). 4. Connect the VSS electrical connector. 5. Check the transfer case oil level. Add fluid if necessary. 6. Connect the negative battery cable. Page 176 Wire Color Abbreviations The following abbreviations are used to identify wire colors in the circuit schematics: WHT................................... White YEL................................... Yellow BLK................................... Black BLU................................... Blue GRN................................... Green RED................................... Red ORN................................... Orange PNK................................... Pink BRN................................... Brown GRY................................... Gray PUR................................... Purple LT BLU................................... Light Blue LT GRN................................... Light Green Page 2475 CD Player/Changer Troubleshooting (Passport only) Manually Removing a Jammed Magazine (All except Passport) One-piece door model: 1. Remove the changer from the vehicle. 2. Remove the rear cover plate from the changer, and look for a jammed disc. 3. If a disc is jammed between the player and the magazine, turn the loading gear until the disc returns to the player mechanism. Do not attempt to reload the disc back into the magazine. 4. After the disc is loaded into the player mechanism, turn the changer so that the front is facing you. Locations Page 4462 Part 3 Of 3 Service and Repair Map Light Bulb: Service and Repair Removal 1. Disconnect the battery ground cable. 2. Remove the lens (2). 3. Remove the bulb (1). - Pull out the bulb. Installation To install, follow the removal steps in the reverse order. Page 3990 5. Remove the meter assembly. - Push the metal cover (6) with the screw driver (7). 6. Remove the meter rear cover. 7. Remove the meter circuit board. 8. Remove the A/T shift indicator bulb. Installation To install, follow the removal steps in the reverse order. Page 7910 Terminals - "T" Each "T" terminal (ring type) is numbered for reference and location. A "T" terminal is secured with a screw or bolt. Wires Diagram Information and Instructions Powertrain Control Module: Diagram Information and Instructions How to Identify Wiring Color-Coded Insulation Wire Color Wire Color Coding Locations Safing Sensor: Locations The safing sensor is located inside the SRS Unit, refer to SRS Unit / Service and Repair. Page 7596 and the fuses. From Fuses to Relays and Components The second half of Power Distribution shows the wiring "From Fuses to Relays and Components." This can speed your troubleshooting by showing which circuits share fuses. If Power Distribution shows that an inoperative circuit and another circuit share a fuse, check a component in the other circuit. If it works, you know the fuse is good and power is available to the inoperative circuit. Ground Distribution Schematics Page 6683 Splices Splices are shown as a dot. Their location and the number of wires may vary depending on the harness manufacturer. Switches Switches These switches move together; the broken straight line between them means they are mechanically connected. Other types of switches are controlled by a coil or a solid state circuit. Unless otherwise noted, all switches are shown in their normal (rest) position, with power off. Terminal "T" Page 6120 Wire Color Abbreviations The following abbreviations are used to identify wire colors in the circuit schematics: WHT................................... White YEL................................... Yellow BLK................................... Black BLU................................... Blue GRN................................... Green RED................................... Red ORN................................... Orange PNK................................... Pink BRN................................... Brown GRY................................... Gray PUR................................... Purple LT BLU................................... Light Blue LT GRN................................... Light Green Locations Parking Brake Warning Switch: Locations Under Center Console Page 4919 11. Snap Ring and Shim. Adjust the clearance between the hub body and the snap ring. Clearance 0-0.3 mm (0-0.012 inch) Shims Available 0.2, 0.3, 0.5, 1.0 mm (0.008, 0.012, 0.020, 0.039 inch) 12. Hub cap. 13. Bolt. Tighten the bolts to the specified torque. - Torque 59 Nm (43 ft. lbs.). Page 3349 2. Connect the short finder across the battery terminals and the load (component) side of the fuse terminal. 3. Close all switches in the circuit you're testing. 4. Turn on the short finder. This creates a pulsing magnetic field around the wiring between the fuse box and the short. 5. Beginning at the fuse box, slowly move the short finder along the circuit wiring. The meter will read current pulses through sheet metal and body trim. As long as the meter is between the fuse and the short, the needle will move with each current pulse. Once you move the meter past the point of the short, the needle will stop moving. Check the wiring and connectors in this area to locate the cause of the short. Testing For Continuity When testing for continuity at a connector without wire seals, you do not have to separate the two halves of the connector. Instead, probe the connector from the back. Always check both sides of the connector because dirty, corroded, and bent terminals can cause problems (no electrical contact = an open). 1. Disconnect the negative cable from the car battery. If you're using a DVOM, place it in the lowest "OHMS" range. Page 7544 Air Bag(s) Arming and Disarming: Service Precautions Wiring Precautions Wiring Precautions SRS wiring can be identified by special yellow outer covering (except the SRS indicator light circuit). Never attempt to modify, splice, or repair SRS wiring. If there is an open or damage in SRS wiring, replace the harness. Be sure to install the harness wires so that they are not pinched, or interfere with other parts. Make sure all SRS ground locations are clean, and grounds are securely fastened for optimum metal-to-metal contact. Poor grounding can cause intermittent problems that are difficult to diagnose. Page 3208 The name of the component appears next to it followed by notes about its function along with any photo and connector view references. Connector "C" How to Identify Connector Terminals Cavity Numbering System The cavities (and wire terminals) in each connector are numbered starting from the upper left, looking at the male terminals from the terminal side (or looking at the female terminals from the wire side. Both views are in the same direction so the numbers are the same.) All actual cavities are numbered, even if they have no wire terminals in them. NOTE: Data Link Connector (DLC) terminals are numbered according to SAE standard J1962, not the Honda standard. The numbers of the four end terminals are molded into the corners of the connector face. Page 203 and the fuses. From Fuses to Relays and Components The second half of Power Distribution shows the wiring "From Fuses to Relays and Components." This can speed your troubleshooting by showing which circuits share fuses. If Power Distribution shows that an inoperative circuit and another circuit share a fuse, check a component in the other circuit. If it works, you know the fuse is good and power is available to the inoperative circuit. Ground Distribution Schematics Page 2017 The wire insulation has one color or one color with another color stripe. The second color is the stripe. Locations Page 6598 NOTE: Known-good test iPods are available from Tech Line. No - Repair the faulty connection at the audio unit. Music Link has no sound, the disc number and track number flashes on the audio display. Disconnect and reconnect the iPod, then retest. Does Music Link operate normally? Yes - The iPod connector pins are loose. Replace the cable if the connector is damaged. No - There is a firmware error. Advise the customer to install the latest iPod firmware (unit software). Check mark is shown on iPod display screen, radio does not switch to CD-C or CD-4 mode. 1. Make sure the audio unit works in all other modes. Does the audio unit work in all other modes? Yes - Go to step 2. No - Do a vehicle battery cable reset, then retest: ^ Remove the negative and positive battery cables. Use a jumper wire to short the two cables together, then turn the ignition switch to ON (II) and wait 15 minutes. ^ Turn the ignition switch to LOCK (0), and remove the jumper wire. Reconnect the positive battery cable first, then reconnect the negative cable. 2. Remove the Music Link interface unit, and verify the software version on the unit label is SW 1.06 or higher. Is the software version SW 1.06 or higher? Yes - Do the "Check mark is not shown on iPod display screen, radio will not switch to CD-C or CD-4 mode" troubleshooting. No - Replace the Music Link interface unit and iPod cable. iPod music and XM radio music play at the same time (Pilot). There is a software compatibility issue in the XM receiver unit. Refer to S/B 06-061, XM(R) Satellite Radio and Audio Accessories Play at the Same Time for repair information. Music Link will not do Disc 1-4 search functions. NOTE: TTS software must be loaded on the customer's home computer before Disc 1-4 search functions work. 1. Use a known-good iPod to verify that the search functions (Disc 1-4) work. NOTE: Known-good test iPods are available from Tech Line. Does the known-good iPod do search functions (Disc 1-4)? Yes - Verify with the customer if the TTS software is loaded. If the customer needs assistance, refer the customer to American Honda's Automobile Customer Service Department for assistance with TTS software loading problems (see page 6 of this bulletin). No - Do the battery cable reset, then retest: ^ Remove the negative and positive battery cables. Use a jumper wire to short the two cables together, then turn the ignition switch to ON (II), and wait 15 minutes. ^ Turn the ignition switch to LOCK (0), and remove the jumper wire. Reconnect the positive battery cable first, then reconnect the negative cable. 2. If the problem does not go away, do "Check mark is not shown on iPod display screen, radio will not switch to CD-C or CD-4 mode" troubleshooting. Artist is not categorized in the correct grouping when using (Disc 2) search function. Page 7086 If there is no photo number below or beside a component name or a connector, ground, or terminal number, look up that name or number in the appropriate Connector Identification Chart. The chart lists how many cavities a connector has, where it's located, and what it connects to. The related illustration shows the connector's location on the harness, and the harness routing. NOTE: Photos listed by number are located at Locations / Components / Photograohs. See: Locations/Component Locations/Photographs Circuit Schematics Page 5905 Air Conditioning Switch: Testing and Inspection 1. Check for continuity between the fan switch and the A/C switch side connector terminals. Page 693 2. Unfasten C123 from the side of the engine compartment using a 90-degree pick. 3. Disconnect C123, and clean the terminals on both sides of the connector with contact cleaner. Shake the residue out of the connector. Allow the contact cleaner to evaporate for at least 3 minutes, then reconnect C123. 4. Fasten C123 to the left side of the engine compartment, and reinstall the air cleaner housing cover. 5. Remove the connector position assurance (CPA) clip from the APPS connector. 6. Disconnect the lop connector from the APPS. 7. Clean the terminals of the 10P APPS connector (harness side) with contact cleaner. Shake out residue from the connector, and allow the contact cleaner to evaporate for at least 3 minutes, then reconnect it. 8. Use the Smart Cable to reprogram the PCM with the latest software from the June 2001 or later HONDANET CD-ROM. Refer to Service Bulletin 99-005, Updating the Passport PCM, filed under Tools. 9. Use the PGM Tester to clear any DTCs. Specifications Differential Fluid - Transfer Case: Specifications Transfer FLUID Transfer (4WD) .................................................................................................................................... ............................................................ SAE 5W-30 Shift on the fly system ......................................................................................................................... ..................................................... GL-5 Gear Lube* *Use the axle chart above for Shift On The Fly System oil weight Page 975 Wiper Switch: Service and Repair Rear Wiper and Washer Switch Removal 1. Disconnect the battery ground cable. 2. Remove the dash side trim panel (1). 3. Remove the lower cover assembly (2). 4. Remove the meter cluster assembly (4). 5. Remove the rear wiper & washer switch (5). - Disconnect the connector. - Push the lock from the back side of the meter cluster assembly. Installation To install, follow the removal steps in the reverse order, noting the following point: 1. Push the switch with your fingers until it locks securely. Page 7671 Splices Splices are shown as a dot. Their location and the number of wires may vary depending on the harness manufacturer. Switches Switches These switches move together; the broken straight line between them means they are mechanically connected. Other types of switches are controlled by a coil or a solid state circuit. Unless otherwise noted, all switches are shown in their normal (rest) position, with power off. Terminal "T" Locations Oil Pressure Switch (For Fuel Pump): Locations Bottom Center Front of Engine Page 5216 Testing For A Short With A Self-Powered Test Light or DVOM 1. Remove the blown fuse and disconnect the battery and load. 2. Connect one lead of a self-powered test light or digital volt/ohmmeter (DVOM) (switched to the lowest "OHMS" range) to the fuse terminal on the load side. 3. Connect the other lead to a known good ground. 4. Beginning near the fuse box, wiggle the harness. Continue this at convenient points about six inches apart while watching the test light or DVOM. 5. If the self-powered test light goes on or the DVOM displays a low reading or no reading (zero), there is a short to ground in the wiring near that point. Testing for a Short with a Test Light or DVOM 1. Remove the blown fuse and disconnect the load. 2. Connect a test light or digital volt/ohmmeter (DVOM), switched to the appropriate DC volts range, across the fuse terminals to make sure voltage is present. You might have to turn the ignition switch to ON; check the schematic to see. 3. Beginning near the fuse box, wiggle the harness. Continue this at convenient points about six inches apart while watching the test light or DVOM. 4. Where the test light goes , or the DVOM voltage drops to zero, there is a short to ground in the wiring near that point. NOTE: Always use a DVOM on high impedance circuits. A test light may not glow (even with battery voltage present). Testing For A Short With A Short Circuit Locator (Short Finder) 1. Remove the blown fuse. Leave the battery connected. Page 3381 10. Install air cleaner duct assembly. Page 6627 Question: Who do I call if I need help diagnosing the problem or if I have technical questions about the unit? Answer: If you cannot find the answers in the appropriate service manual, service bulletins, or ServiceNews articles on iN, create a Tech Line access code, then call Tech Line: 1. From the iN main menu, select SERVICE. 2. Select Tech Line. A dropdown menu appears, then select Tech Line. The ISIS main screen appears. 3. Select SEARCH BY VEHICLE, and enter any vehicle with any keyword like NAVI, AUDIO, or RES. 4. At the top of the screen you will see this statement: If you cannot resolve the problem with the information below, then click Tech Line. Select Tech Line. 5. The Tech Line access code screen appears. Fill in all the required fields, then select SUBMIT. 6. Have the access number ready when you call Tech Line. Question: Do I need a Tech Line reference number to order a remanufactured audio/navigation/RES unit? Answer: No. Question: What year and model audio/navigation/RES unit can I order through the warranty audio order program? Answer: Most current models are available through the vehicle's standard warranty period. If your application is not available, you will receive a message instructing you to call the Re manufactured Parts Dealer Service Group at 888-997-7278. Question: How can I track my order once I submit it? Answer: To track your order, go the Warranty Audio Order VIN Inquiry screen on the iN. 1. From the iN main menu, click on PARTS. 2. Click on Parts Ordering. 3. Click on Audio VIN Inquiry. 4. Enter a date in the All Orders Accepted Since box, then click on Submit. The AUDIO VIN INQUIRY ACKNOWLEDGEMENT screen appears, listing orders by VIN, ORD REF (Order Reference), STAT (Status), SHIP DATE, SHIPPER, and PART NUMBER. The status of your order is displayed by one of these codes: Codes generated by RPO Tech Line: ^ PEND - Your order is waiting to be processed by RPO Tech Line. ^ HOLD - Your order is waiting for additional dealer diagnosis. ^ ERR - Your order caused an error; call. ^ DENY - RPO Tech Line denied your order; call. ^ APPR - RPO Tech Line approved your order and forwarded it to AHM Parts. Codes generated by AHM Parts Division: ^ BO/TOS - Your order is on back order or is temporarily out of stock. ^ CAN/BOC - Your order has been cancelled contact your assigned parts center. Page 7792 Wire Color Abbreviations The following abbreviations are used to identify wire colors in the circuit schematics: WHT................................... White YEL................................... Yellow BLK................................... Black BLU................................... Blue GRN................................... Green RED................................... Red ORN................................... Orange PNK................................... Pink BRN................................... Brown GRY................................... Gray PUR................................... Purple LT BLU................................... Light Blue LT GRN................................... Light Green Page 1224 Power Steering Fluid: Fluid Type Specifications Power Steering Fluid ........................................................................................................................... ................................................................. Dexron III Page 4989 Part 2 of 2 Front Stabilizer Bar: Service and Repair Front REMOVAL 1. Raise the vehicle and support the frame with suitable safety stands. 2. Remove the stone guard. 3. Remove wheel and tire assembly. 4. Remove nut. CAUTION: Be careful not to break the ball joint boot. 5. Remove link. 6. Remove bracket. 7. Remove stabilizer bar. 8. Remove rubber bushing. INSPECTION AND REPAIR Make necessary correction or parts replacement if wear, damage, corrosion or any other abnormal condition are found through inspection. Check the following parts: Stabilizer bar - Rubber bushing - Link ball joint INSTALLATION 1. Install rubber bushing. 2. Install stabilizer bar. 3. Install bracket, then tighten it to the specified torque. Torque to 25 Nm (18 ft. lbs.). 4. Install link. 5. Install nut, then tighten it to the specified torque. Torque to 50 Nm (37 ft. lbs.). Locations Transmission Position Switch/Sensor: Locations Left Side Of Automatic Transmission Page 5717 Suspension Strut / Shock Absorber: Service and Repair Rear With Intelligent Suspension System REAR SHOCK ABSORBER AND ASSOCIATED PARTS LH Page 4090 Transmission Cooler: Technical Service Bulletins A/T - Avoiding Fluid Contamination SOURCE: Honda Service News TITLE: Avoiding Comebacks From A/T Contamination APPLIES TO: All models SERVICE TIP: Installing a reman A/T? Here are some important tips to keep in mind to ensure a first-time fix and to avoid any come-backs: - If the vehicle has an ATF cooler, make sure you clean the cooler with the ATF Cooler Cleaner (P/N GHTTTCF6H). See S/B 89-022, ATF Cooler Cleaner, for details. - If the reman A/T kit includes an in-line filter, don't forget to install it. If the vehicle already has an in-line filter from an earlier A/T replacement, then remove the existing filter, and install the new one. - Spray the driveshaft splines with solvent and compressed air before installing them in the reman A/T. If the failed A/T had a speed sensor, make sure it's clean before you install it. Debris from the failed A/T can catch in the driveshaft splines or on the speed sensor and contaminate the reman A/T. - If the reman A/T comes with a heater/cooler, make sure you install the reman A/T with that heater/cooler. Never install the heater/cooler from the failed A/T; you could contaminate the reman A/T. Page 4683 This sample Ground Distribution schematic shows all of the components that share two ground points. Components A solid border line means the entire component is shown. A broken border line indicates that only part of the component is shown. Page 3708 This means the branch of the wire connects to another circuit. The arrow points to the name of the circuit branch where the wire continues. Page 3027 Testing For A Short With A Self-Powered Test Light or DVOM 1. Remove the blown fuse and disconnect the battery and load. 2. Connect one lead of a self-powered test light or digital volt/ohmmeter (DVOM) (switched to the lowest "OHMS" range) to the fuse terminal on the load side. 3. Connect the other lead to a known good ground. 4. Beginning near the fuse box, wiggle the harness. Continue this at convenient points about six inches apart while watching the test light or DVOM. 5. If the self-powered test light goes on or the DVOM displays a low reading or no reading (zero), there is a short to ground in the wiring near that point. Testing for a Short with a Test Light or DVOM 1. Remove the blown fuse and disconnect the load. 2. Connect a test light or digital volt/ohmmeter (DVOM), switched to the appropriate DC volts range, across the fuse terminals to make sure voltage is present. You might have to turn the ignition switch to ON; check the schematic to see. 3. Beginning near the fuse box, wiggle the harness. Continue this at convenient points about six inches apart while watching the test light or DVOM. 4. Where the test light goes , or the DVOM voltage drops to zero, there is a short to ground in the wiring near that point. NOTE: Always use a DVOM on high impedance circuits. A test light may not glow (even with battery voltage present). Testing For A Short With A Short Circuit Locator (Short Finder) 1. Remove the blown fuse. Leave the battery connected. Starting System - Unable To Key In Ignition Switch Ignition Switch Lock Cylinder: Technical Service Bulletins Starting System - Unable To Key In Ignition Switch Can't Turn Ignition Switch? Check for Locked Steering Got a service customer complaining he or she can't turn the ignition switch to start the engine? The reason could just be the steering column lock pin is engaged with the front wheels turned. Here's what typically happens: Some folks use the steering wheel to help support themselves while climbing in or out of the vehicle. This is very common among elderly or disabled drivers. Doing this turns the front wheels, which twists the tires against the ground. The twisted tires apply torque to the steering column. With the ignition switch in LOCK (0), the steering column lock pin is engaged. But the applied torque on the steering column binds the lock pin, making it tough to turn the ignition switch. The ignition switch won't turn to ON (II) if the lock pin isn't disengaged from the steering column. Tell your customer there's nothing wrong with the ignition switch itself. All he or she needs to do is turn the steering wheel from side to side while turning the switch. This usually releases the lock pin so the engine can be started. In some cases, though, your customer may need to give a good tug on the wheel. This could easily happen when parking on a hill and the wheels are turned sharply before the engine is shut off. Page 4724 The wire insulation has one color or one color with another color stripe. The second color is the stripe. Service and Repair Courtesy Lamp Bulb: Service and Repair Removal 1. Disconnect the battery ground cable. 2. Remove the lens (2). 3. Remove the bulb (1). - Pull out the bulb. Installation To install, follow the removal steps in the reverse order. Page 3736 Ground - "G" Shielding Sheilding This represents RFI (Radio Frequency Interference) shielding around a wire. The shielding is always connected to ground. Splices Page 7785 The name of the component appears next to it followed by notes about its function along with any photo and connector view references. Connector "C" How to Identify Connector Terminals Cavity Numbering System The cavities (and wire terminals) in each connector are numbered starting from the upper left, looking at the male terminals from the terminal side (or looking at the female terminals from the wire side. Both views are in the same direction so the numbers are the same.) All actual cavities are numbered, even if they have no wire terminals in them. NOTE: Data Link Connector (DLC) terminals are numbered according to SAE standard J1962, not the Honda standard. The numbers of the four end terminals are molded into the corners of the connector face. Locations Electronic Thermostat, Evaporator Core And/Or Expansion Valve - Disassembled View Page 7603 Wires Wire insulation can be one color, or one color with another color stripe. (The second color is the stripe.) This circuit continues on another image. (The arrow shows direction of current flow.) To follow the RED/BLK wire in this example, you would turn to "Fuel and Emissions" and look for the "A" arrow. Page 30 Page 5250 ^ If the idle speed ever exceeds 1,300 rpm 2. Remove the vacuum hose from the fuel pressure regulator, then start the engine. ^ If fuel comes out of the fuel pressure regulator vacuum hose connection, go to REPAIR PROCEDURE FUEL PRESSURE REGULATOR. ^ If no fuel comes out of the regulator, reconnect the vacuum hose and continue to step 3. 3. Connect the PGM Tester. Set it to Engine Data List. 4. Have an assistant drive the vehicle under the conditions described by the customer. 5. If the high or erratic idle condition occurs, note the values of the PSP Switch and APP Sensor 1 when it is occurring. ^ If the PSP Switch is HIGH, and you are not turning, go to REPAIR PROCEDURE POWER STEERING SWITCH. ^ If the APP Sensor 1 is greater than 15% and APP Sensor 2 and/or APP Sensor 3 are less than 85%, and the accelerator pedal is not depressed, go to REPAIR PROCEDURE APPS GROUND. ^ If the PSP Switch is reading LOW when not turning and HIGH when turning, and the APP Sensors are reading within the range shown, discontinue the test-drive and go to step 6. 6. Do these repairs: ^ REPAIR PROCEDURE APPS GROUND ^ REPAIR PROCEDURE ENGINE/BODY GROUND REPAIR PROCEDURE - FUEL PRESSURE REGULATOR 1. Relieve fuel system pressure: ^ Remove the fuel fill cap. ^ Remove the fuel pump relay. ^ Start the engine and run it until it stalls. ^ Crank the engine for 3 seconds. 2. Remove the vacuum hose from the fuel pressure regulator. 3. Remove the fuel pressure regulator shield from the common chamber (two bolts). Page 1562 Valve Guide Replacement 1. Using Valve guide replacer: J-42899, drive out the valve guide from the combustion chamber side. 2. Apply engine oil to the outside of the valve guide. Using valve guide replacer J-42899, drive in a new valve guide from the camshaft side, and check the valve guide height. Valve guide upper end height: 13.0 mm (0.5118 inch) (Measured from the cylinder head upper face) 3. Check the clearance. If the clearance is less than the specified value, ream the inside diameter of valve guide. Using a sharp 6 mm reamer, ream the valve guide to obtain the specified clearance. Valve Seat 1. Measure the protrusion of the valve stem when a new valve is installed in the cylinder head. If the protrusion of the valve stem exceeds the limit, replace the valve seat insert or the cylinder head assembly. Protrusion of valve stem Intake Standard: 39.32 mm (1.5480 inch) Page 4744 Transmission Position Switch/Sensor: Service and Repair REMOVAL 1. Place selector lever in neutral. 2. Disconnect battery ground cable. 3. Remove mode switch cover (1). 4. Disconnect selector lever (2) from the mode switch. 5. Remove bracket with cable (3). 6. Disconnect transmission harness from the mode switch connector (4). 7. Remove bracket with mode switch connector from the transmission case. 8. Remove mode switch connector (4) from the bracket (5). 9. Remove two mode switch bolts and nut then remove mode switch (6). INSTALLATION To install, follow the removal steps in the reverse order, noting the following points; 1. Torque Mode switch bolt: 13 Nm (113 inch lbs.) Selector lever nut: 23 Nm (17 ft. lbs.) 2. Mode switch setting procedure. Perform either of the following adjustment procedures: Procedure 1 a. Place selector lever in neutral. b. Remove selector lever from the mode switch. c. Remove the mode switch cover. d. Loosen the two 10 mm screws. e. Rotate the mode switch until the slot in the mode switch housing aligns with the selector shaft bushing, and insert a 3/32 inch (2.4 mm) drill bit or punch (1) into the slot. f. Tighten the screws to 13 Nm (113 inch lbs.). g. After completing adjustment, snap the mode switch cover into place. h. Reinstall the selector lever. Procedure 2 a. Place selector lever in neutral. b. Disconnect transmission harness connector from mode switch connector. Front Accessory Power Socket Auxiliary Power Outlet: Service and Repair Front Accessory Power Socket Removal 1. Disconnect the battery ground cable. 2. Remove the front console assembly. 3. Remove the front accessory socket (2). - Disconnect the connectors (1). - Pull out the front accessory socket from the socket cover (3). Installation To install, follow the removal steps in the reverse order, noting the following point: Page 7978 Page 1596 Let the cam push down the edge of tappet by using J-42689 valve clearance adjusting tool and push out the shim with a flat blade screw driver as shown in illustrations. Page 7639 This means the branch of the wire connects to another circuit. The arrow points to the name of the circuit branch where the wire continues. Diagrams Transmission Mode Switch: Diagrams Page 5291 it is located, and what it connects to. Use the Connector Views to help locate the proper cavity when you need to probe a connector. It can be especially helpful if the connector has more than one wire of the same color. A dash symbol (-) indicates that the cavity is empty. Connector views can also be used to help diagnose multiple symptoms in separate circuits which could be caused by a single problem in a connector shared by those circuits. Here's an example: 1. Pick one of the multiple symptoms and look up the schematic for that circuit. 2. Make a list of all the in-line and fuse box connectors in that schematic , 3. Then, in the Connector Views, look up each connector on your list to see if circuits related to the other symptoms run through one of them. If they do, inspect that connector for the problem. Example: The blower, rear window defogger, and the windshield wiper don't work. List all in-line and fuse box connectors in the blower controls circuit and then check the Connector View (see the sample). You find that C324 is common to the blower controls, rear window defogger, and wiper/washer, so you inspect C324 and find the problem, bent terminals. Finding Component/Connector Locations Finding Component/Connector Locations To see where a component or connector is located on the car, look up its photo number in the "Component Location". The photo will also tell you the color of the connector, and how many cavities it has. Locations Tailgate Glass (Resin Top) Locations Vapor Pressure Sensor / Fuel Gauge And Fuel Pump Connector Page 4855 and the fuses. From Fuses to Relays and Components The second half of Power Distribution shows the wiring "From Fuses to Relays and Components." This can speed your troubleshooting by showing which circuits share fuses. If Power Distribution shows that an inoperative circuit and another circuit share a fuse, check a component in the other circuit. If it works, you know the fuse is good and power is available to the inoperative circuit. Ground Distribution Schematics Page 2193 6. Place the end of the return hose in a container. Have someone start the engine, then pour ATF into the reservoir while you watch the fluid coming out of the return hose. When the fluid coming out is the same color as the new fluid, turn off the engine. 7. Reconnect the return hose to the reservoir. 8. Start the engine. Fill the power steering reservoir to the proper level with ATF then turn off the engine. 9. Use the Smart Cable to reprogram the PCM with the latest software from the June 2001 or later HONDANET CD-ROM. Refer to Service Bulletin 99-005, Updating the Passport PCM, filed under Tools. 10. Use the PGM Tester to clear any DTCs. 11. Use the PGM Tester to check the broadcast code. Make sure the broadcast code matches the one you selected from the CD-ROM. WARRANTY CLAIM INFORMATION In warranty: The normal warranty applies. Failed Part: P/N 8-97181-590-0 H/C 5698030 Defect Code: 064 Contention Code: C01 Skill Level: Repair Technician Out of warranty: Any repair performed after warranty expiration may be eligible for goodwill consideration by the District Service Manager or your Zone Office. You must request consideration, and get a decision, before starting work. REPAIR PROCEDURE - APPS GROUND 1. Unclamp the air cleaner housing cover, and move it to the side for access to connector C123 (16P BLK). Page 1585 Valve: Diagrams Valve Spring, Oil Controller, Valve, Valve Guide and Associated Parts Page 3588 The connector cavity number is listed next to each terminal on the circuit schematic. The cavity / terminal shown is # 6. Diodes A rectifier diode works like a one way valve. It allows current to flow only in the direction of the arrow. A Zener diode blocks reverse current at normal voltages just like a rectifier diode. At high voltages, however, a Zener diode allows current to flow in reverse. Fuses Page 3596 Ion Sensing Module: Diagnostic Aids Before Troubleshooting Before Troubleshooting See: Service Precautions/Vehicle Damage Warnings/Tips and Precautions 1. Check applicable fuses in the appropriate fuse/relay box. 2. Check the battery for damage, state of charge, and clean and tight connections. CAUTION: Do not quick-charge a battery unless the battery ground cable has been disconnected, otherwise you will damage the alternator diodes. - Do not attempt to crank the engine with the battery ground cable loosely connected or you will severely damage the wiring. While You're Working 1. Make sure connectors are clean, and have no loose terminals or receptacles. 2. Make sure that connectors without wire seals are packed with dielectric (silicone) grease. Part Number: 08798-9001. 3. When connecting a connector, push it until it "clicks" into place. CAUTION: Do not pull on the wires when disconnecting a connector. Pull only on the connector housings. - Most circuits include solid-state devices. Test the voltages in these circuits only with a 10-megaohm or higher impedance digital multi meter. Never use a test light or analog meter on circuits that contain solid-state devices. Damage to the devices may result. Five-Step Troubleshooting 1. Verify The Complaint Turn on all the components in the problem circuit to check the accuracy of the customer complaint. Note the symptoms. Do not begin disassembly or testing until you have narrowed down the problem area. 2. Analyze The Schematic Look up the schematic for the problem circuit. Determine how the circuit is supposed to work by tracing the current paths from the power source through the circuit components to ground. Also, trace circuits that share wiring with the problem circuit. The names of circuits that share the same fuse, ground, or switch, and so on, are referred to in each circuit schematic. Try to operate any shared circuits you didn't check in step 1. If the shared circuits work, the shared wiring is OK, and the cause must be in the wiring used only by the problem circuit. If several circuits fail at the same time, the fuse or ground is a likely cause. Based on the symptoms and your understanding of the circuit's operation, identify one or more possible causes. 3. Isolate The Problem By Testing The Circuit Make circuit tests to check the diagnosis you made in step 2. Keep in mind that a logical, simple procedure is the key to efficient troubleshooting. Test for the most likely cause of failure first. Try to make tests at points that are easily accessible. 4. Fix The Problem Once the specific problem is identified, make the repair. Be sure to use proper tools and safe procedures. 5. Make Sure The Circuit Works Turn on all components in the repaired circuit in all modes to make sure you've fixed the entire problem. If the problem was a blown fuse, be sure to test all of the circuits on that fuse. Make sure no new problems turn up and the original problem does not recur. Page 1028 ^ If the wheels are pointed to the right, shorten the driver's side tie-rod, and lengthen the passenger's side. ^ If the wheels are pointed to the left, shorten the passenger's side tie-rod, and lengthen the driver's side. ^ Each 360° turn of the tie-rod equals about 8 mm of steering wheel adjustment. For example, a steering wheel is off-center by 4 mm with the front wheels pointed right (when the steering wheel is centered). To correct the off-center, shorten the driver's side tie-rod by a half-turn, and lengthen the passenger's side tie-rod by a half-turn. 4. Use your diagnosis worksheet to fill in the following table and build your 15-digit DTC. Technical Service Bulletin # SN030915 Date: 030901 Suspension - Drifting & Pulling At Highway Speeds SOURCE: Honda Service News September 2003 TITLE: Drifting and Pulling at Highway Speeds APPLIES TO: All Models SERVICE TIP: Got a customer complaining that the vehicle drifts or pulls when driving at highway speeds? Use this handy procedure to diagnose and repair the problem. NOTE: Before doing the procedure in this article, check ISIS for related S/Bs and other S/N articles for the model you're working on. 1. Check if your customer has original equipment wheels and tires and that the ride height hasn't been modified. - If the wheels, tires, and ride height are OK, go to step 2. - If the wheels or tires aren't original equipment or the ride height was modified, stop here. Aftermarket wheels or tires or a ride height that's been modified pose challenges that this article doesn't cover. Resolve these issues with your customer before going further. 2. Set the tire pressures to the recommended cold inflation values listed on the doorjamb sticker. 3. Find a straight stretch of 4-lane road where you can safely (and legally) go 60 mph for several minutes. Ideally, you want a road that's perfectly flat, but most roads have a crown that¡C■s anywhere from 1.5° to 1.75° so they can drain. Flat Road - While driving at 60 mph, use a stopwatch to time how long it takes to drift one full lane from center to center. Record the time. Repeat this, driving in the opposite direction to cancel the effects of wind, then average the two times you recorded. If the vehicle drifts one full lane from center to center in less than 6 seconds, go to step 4. If not, return the vehicle to your customer. Crowned Road - While driving at 60 mph, check if the vehicle climbs the crown. Do this for both a left- and right-crowned road. A drift to the right on a right-crowned road and a drift to the left on left-crowned road are considered normal. If the vehicle climbs the crown or it drifts to the right on a left crowned road, go to step 4. 4. Record the original toe, camber, and caster readings. On Passports, set the ride height to spec if needed. Refer to Ride Height Adjustment in S/B 99-043, Steering Wheel Shimmy or Chassis Vibration. 5. Loosen the subframe mounting bolts, and move the rear beam (it¡C■s the entire front subframe on some models) to get the maximum amount of caster and equal side-to-side camber. (As little as 0.4° of camber stagger can cause the vehicle to pull.) 6. Make sure the steering wheel is centered, then set the front and rear toe to the maximum toe-in spec. (Toe-in improves vehicle stability and reduces the tendency to drift or pull.) 7. Test-drive the vehicle on the same road you used earlier. - If the drift is now within spec, return the vehicle to your customer. - If the drift is still out of spec, go to step 8. 8. Swap the front and rear tires on each side of the vehicle, then adjust the tire pressures to the recommended cold inflation values listed on the doorjamb sticker. Page 184 Fuel Pump Relay: Testing and Inspection Relays Test This test is conducted to check Fuel Pump Relay and A/C Clutch for proper operation. Tech 2 must be used for this test. Test Procedure: 1. Connect Tech 2 to the vehicle DLC. 2. Ignition SW is "On". 3. Select F3 : Miscellaneous Test in the Application Menu. 4. Select F1 : Relay Test in the Miscellaneous Test. Page 5298 The connector cavity number is listed next to each terminal on the circuit schematic. The cavity / terminal shown is # 6. Diodes A rectifier diode works like a one way valve. It allows current to flow only in the direction of the arrow. A Zener diode blocks reverse current at normal voltages just like a rectifier diode. At high voltages, however, a Zener diode allows current to flow in reverse. Fuses Specifications Evaporator Case: Specifications Main Data And Specifications Main Data And Specifications EVAPORATOR ASSEMBLY Capacity 4.8 kw (4100 Kcal./hr.) Air flow 430 cu.m/hr Page 1239 Refrigerant: Description and Operation Air conditioning systems contain HFC-134a. This is a chemical mixture which requires special handling procedures to avoid personal injury. Page 2836 20. Using a DVOM, check the voltage between the reference voltage pin for each sensor and ground. ^ If the sensor circuits all read 5.0 volts, go to step 22. ^ If any sensor circuit is above or below 5.0 volts, go to step 21. 21. Troubleshoot for an internal short in another sensor or a PCM malfunction. ^ To find the sensor with an internal short, monitor the reference voltage, and disconnect each sensor (FTPS, EGR, MAP TPS, CKP and CMP) one at a time until the reference voltage reads 5.0 volts. Replace that sensor, and repeat step 14. ^ To find a malfunctioning PCM, replace it with a known-good PCM. If all three sensors (APP Sensor 1, APP Sensor 2, and APP Sensor 3) are within range, the original PCM is faulty; replace it and repeat step 14. 22. Using a jumper wire, connect the reference voltage of each circuit to its signal input, and view the APP Sensor values in the Engine Data List. APP Sensor 1 should have a value of 99%, and APP Sensor 2 and APP Sensor 3 should each have a value of 0%. ^ If the values are not as specified, troubleshoot for high resistance on the signal input or a PCM malfunction. Repair the circuit or replace the PCM, then repeat step 14. ^ If the values are as specified, the problem may be intermittent. Disconnect the 10 P connector from the modified APPS, and connect it to the new APPS; then repeat step 14. Wiggle the APPS wires as you go through the adjustment procedure to find the intermittent problem. 23. Install the accelerator pedal assembly, and torque the bolts to 10 N.m (7 lb-ft). Page 7878 This sample Ground Distribution schematic shows all of the components that share two ground points. Components A solid border line means the entire component is shown. A broken border line indicates that only part of the component is shown. Page 1539 6. Lock the camshaft gear to its subgear with a 5 x 0.5 mm bolt through either side of the hole in the gears. This holds the spring-loaded subgear in place so you can remove the camshaft. Do this for each camshaft you need to remove. 7. Remove the camshaft bearing caps, noting the location and direction of each cap. 8. Remove the camshaft(s). 9. For each valve needing adjustment, do steps 10 thru 13. 10. Insert a pick or a small screwdriver into the tappet notch, and pry out the shim. 11. Wipe oft the shim, then write its number on the Valve Inspection Chart for that valve and cylinder. If there is no number on the shim, measure its thickness with a micrometer, and write down the measurement on the Valve Inspection Chart. 12. Follow the directions on the Valve Shim Replacement Chart to select the correct shim. 13. Insert the correct shim, number side down, into the tappet. Make sure the shim is fully seated. 14. Install the camshafts (see steps 2 thru 9 of CAMSHAFT SUBGEAR PRELOADING, GEAR TIMING, AND CAMSHAFT INSTALLATION). 15. Rotate the camshaft pulleys a few turns to ensure the new shims are fully seated. 16. Recheck the clearances of the valves you adjusted with the Go/No-Go method (see step 3). If any clearances are incorrect, readjust them. Locations Acceleration Sensor: Locations Below Left Side of Dash Locations Page 309 4WD Control Unit: Electrical Diagrams Part 1 Of 3 Page 1105 17. Recheck the valve clearance using the Go/No-Go method (see step 4). - If the clearance is OK, repeat steps 6 thru 17 for the other valves needing adjustment. - If the clearance is still incorrect, repeat steps 6 through 17 until it is correct, then adjust the remaining valves. 18. Turn the camshaft pulleys until the single timing dot (right cylinder bank) and dual timing dots (left cylinder bank) align with the single timing dots on the camshaft drive gears. 19. Install the cylinder head covers with new gaskets. Torque the cover bolts to 9 N.m (6.5 lb-ft). Off-Vehicle Valve Adjustment 1. Make a copy of the Valve Inspection Chart. 2. Make a copy of the Valve Shim Replacement Chart, then tape the pages together, side-by-side. 3. Measure the valve clearances using the Go/No-Go method (see the note below). The clearances must be - Intake valves: 0.25 mm +0.05 mm - Exhaust valves: 0.30 mm +0.05 mm NOTE: - To measure with the Go/No-Go method, use two feeler gauges, one to measure the smallest allowable clearance, and the other to measure the largest. - If the small gauge fits and the large gauge doesn't, the valve adjustment is OK. - If the small gauge doesn't fit, or if the large gauge slides easily, the valve needs adjustment. - The feeler gauges slide through the clearance gap at a slight angle, making the drag a little more than it would be on other engines. 4. For valves with the correct clearance, draw an "X" in the appropriate circle on the Valve Inspection Chart. For valves with incorrect clearances, write down the clearance you measured in the circle. 5. Rotate the camshaft pulley until the dual timing dots (exhaust camshaft) and single timing dot (intake camshaft) align with the timing dots on the camshaft drive gear. Page 2219 it is located, and what it connects to. Use the Connector Views to help locate the proper cavity when you need to probe a connector. It can be especially helpful if the connector has more than one wire of the same color. A dash symbol (-) indicates that the cavity is empty. Connector views can also be used to help diagnose multiple symptoms in separate circuits which could be caused by a single problem in a connector shared by those circuits. Here's an example: 1. Pick one of the multiple symptoms and look up the schematic for that circuit. 2. Make a list of all the in-line and fuse box connectors in that schematic , 3. Then, in the Connector Views, look up each connector on your list to see if circuits related to the other symptoms run through one of them. If they do, inspect that connector for the problem. Example: The blower, rear window defogger, and the windshield wiper don't work. List all in-line and fuse box connectors in the blower controls circuit and then check the Connector View (see the sample). You find that C324 is common to the blower controls, rear window defogger, and wiper/washer, so you inspect C324 and find the problem, bent terminals. Finding Component/Connector Locations Finding Component/Connector Locations To see where a component or connector is located on the car, look up its photo number in the "Component Location". The photo will also tell you the color of the connector, and how many cavities it has. Page 379 Wheel Speed Sensor: Description and Operation It consists of a sensor and a rotor. The sensor is attached to the knuckle on the front wheels and to the rear axle case on the rear differential. The rotor is press-fit in the axle shaft. The flux generated from electrodes magnetized by a magnet in the sensor varies due to rotation of the rotor, and the electromagnetic induction generates alternating voltage in the coil. This voltage draws a "sine curve" with the frequency proportional to rotor speed and it allows detection of wheel speed. Page 4617 Seals and Gaskets: Service and Repair Rear Oil Seal TRANSFER REAR OIL SEAL AND ASSOCIATED PARTS REMOVAL 1. Disconnect the rear propeller shaft (1) from the transfer case side. 2. Remove end nut and rear companion flange (2), using the companion flange holder J-8614-11. 3. Use the universal puller to remove the rear companion flange and O-ring. 4. Remove the oil seal from the transfer case. INSTALLATION 1. Install oil seal and apply engine oil to the oil seal outer surfaces. 2. Apply the recommended grease (BESCO L2) or equivalent to the oil seal lip. Page 6518 Front Seat Belt And Associated Parts REMOVAL 1. Disconnect the battery ground cable. 2. Remove the sill plate (Front & Rear). 3. Remove the anchor cover and seat belt lower anchor bolt. 4. Remove the lower center pillar trim cover. 5. Remove the door seal finisher (Front & Rear). 6. Remove the upper center pillar trim cover. 7. Remove the seat belt upper anchor bolt. 8. Remove the retractor fixing bolt. 9. Remove the seat belt assembly. 10. Remove the adjustable shoulder anchor assembly. - Remove the two fixing bolts. INSTALLATION To install, follow the removal steps in the reverse order, noting the following points. CAUTION: When replacing the front seat belt, always replace the seat belt with the same parts/part number. 1. Tighten the adjustable shoulder anchor assembly fixing bolts to the specified torque. Torque: 39 N.m (29 lb.ft) 2. Tighten the seat belt anchor bolts (Upper & Lower) and the retractor fixing bolts to the specified torque. Torque: 39 N.m (29 lb.ft) Removable Top Engine Controls - CHECK TRANS/CRUISE SET Lamps Flashing PROM - Programmable Read Only Memory: All Technical Service Bulletins Engine Controls CHECK TRANS/CRUISE SET Lamps Flashing 01-044 May 8, 2001 Applies To: 2000 Passport - ALL 2001 Passport - From VIN 4S6..58W.14400001 thru 4S6..58W.14409430 CHECK TRANS and CRUISE SET Indicators Are Flashing SYMPTOM The CHECK TRANS and CRUISE SET indicators on the instrument panel flash when the ignition switch is turned to ON (II). PROBABLE CAUSE Using a brand of spark plugs other than Denso can cause the PCM to detect an additional crank sensor pulse. If this happens, the PCM resets itself and turns on the CHECK TRANS and CRUISE SET indicators. CORRECTIVE ACTION Update the PCM software with the Smart Cable. TOOL INFORMATION PGM Tester loaded with SN131 (04/16/01) or later software. For other tools and equipment needed to update the PCM software, refer to Service Bulletin 99-005, Updating the Passport PCM, filed under Tools. WARRANTY CLAIM INFORMATION In warranty: The normal warranty applies. Operation Number: 122305 Flat Rate Time: 0.3 hour Failed Part: P/N 8-09392-189-0 H/C 6392971 Defect Code: 093 Contention Code: C05 Template ID: 01-044A Skill Level: Repair Technician Out of warranty: Any repair performed after warranty expiration may be eligible for goodwill consideration by the District Service Manager or your Zone Office. You must request consideration, and get a decision, before starting work. REPAIR PROCEDURE 1. Retrieve the PCM broadcast code with the PGM Tester. (From the MISC. TESTS menu, select BROADCAST CODE). Page 5004 Brake Master Cylinder: Service and Repair Brake Fluid Reservoir, Removal / Installation REMOVAL NOTE: Before removing the fluid reservoir, remove the brake fluid from the fluid reservoir. 1. Disconnect electrical connector. 2. Remove retainer (1). 3. Remove fluid reservoir and the fluid level sensor built into the fluid reservoir. The fluid level sensor cannot be removed for servicing. 4. Remove O-ring. INSTALLATION To install, follow the removal steps in the reverse order, noting the following points: Page 6679 This sample Ground Distribution schematic shows all of the components that share two ground points. Components A solid border line means the entire component is shown. A broken border line indicates that only part of the component is shown. Page 3697 If there is no photo number below or beside a component name or a connector, ground, or terminal number, look up that name or number in the appropriate Connector Identification Chart. The chart lists how many cavities a connector has, where it's located, and what it connects to. The related illustration shows the connector's location on the harness, and the harness routing. NOTE: Photos listed by number are located at Locations / Components / Photograohs. See: Locations/Component Locations/Photographs Circuit Schematics Page 2610 2. Compare the retrieved code with the listed codes. ^ If the code is in the list, go to step 3. ^ If the code is not in the list, the PCM has already been updated. Troubleshoot other causes for the detonation. NOTE: Since the Smart Cable may need to be cleared from a previous PCM update or the Smart Cable firmware may need to be reprogrammed, always begin each PCM update at the iN workstation. 3. Update the PCM software with the Smart Cable. For instructions, refer to Service Bulletin 99-005. NOTE: Make sure you select the most recent broadcast code from the list on the iN screen that applies to the model year, transmission type, and emission level. This code is not necessarily at the top of the list since the most recent code is the last one in the alphabetical sequence, letter by letter. 4. Use the PGM Tester to clear any DTCs set during programming. 5. Retrieve the broadcast code. Make sure it does not match any of the codes in the list in step 2 (indicating the PCM has been updated) and that it applies to the model year, transmission type, and emission level for the vehicle. The broadcast code should match a code in the list below. Disclaimer Page 3897 Shift Solenoid: Service and Repair REMOVAL 1. Raise the vehicle and support it on jack stands. 2. Disconnect battery ground cable. 3. Drain fluid. 4. Remove sixteen 10 mm screws, main case oil pan, magnet, and gasket. 5. Remove three 13 mm screws, oil filter. 6. Disconnect wiring harness from band control solenoid and shift solenoids. Pull only on connectors, not on wiring harness. 7. Remove spring pin for shift solenoid A, shift solenoid B, and band control solenoid respectively, using suitable pliers taking care not to damage solenoids. 8. Remove shift solenoid A, shift solenoid B, band control solenoid, and gaskets from main case valve body. Do not pull on wiring harness. Remove solenoids by grasping the metal tip. INSTALLATION 1. Install shift solenoid A, shift solenoid B, band control solenoid with new gaskets to main case valve body respectively. 2. Carefully install spring pin with hammer to avoid damage to valve body, etc. 3. Connect wiring harness to solenoids. 4. Install oil filter with a new gasket and the three 13 mm screws, tighten to the specified torque. Torque: 20 Nm (15 Ft. lbs.) Engine Controls - High/Erratic Engine Idle Power Steering Pressure Switch: All Technical Service Bulletins Engine Controls - High/Erratic Engine Idle 01-080 August 14, 2001 Applies To: 2000-02 Passport - ALL 2000-02 Passport: High or Erratic Idle SYMPTOM The engine occasionally idles at too high a speed, or the idle speed fluctuates. PROBABLE CAUSES The symptom could be the result of any of these conditions: ^ Loose or corroded engine or body ground ^ High resistance in the APPS ground circuit ^ PSP (power steering pressure) switch is internally shorted to ground ^ Fuel pressure regulator is leaking fuel into the intake manifold CORRECTIVE ACTION Diagnose the cause of the idle condition, and select the proper REPAIR PROCEDURE. PARTS INFORMATION REQUIRED MATERIALS REQUIRED SOFTWARE Each REPAIR PROCEDURE requires you to use the Smart Cable to reprogram the PCM with the latest software. To select the latest software from the CDROM, enter the year, model, engine, transmission, and emissions type (49-state or California). This gives you a list of broadcast codes. Select the broadcast code at the top of the list. WARRANTY CLAIM INFORMATION Refer to the Warranty Claim Information for each Repair Procedure. DIAGNOSIS 1. Find out from the customer when the high or erratic idle condition occurs and what the RPM range is: ^ Within 20 minutes of a cold start ^ After braking to a stop ^ All the time ^ Intermittently, with no set pattern Page 2977 Wire Color Abbreviations The following abbreviations are used to identify wire colors in the circuit schematics: WHT................................... White YEL................................... Yellow BLK................................... Black BLU................................... Blue GRN................................... Green RED................................... Red ORN................................... Orange PNK................................... Pink BRN................................... Brown GRY................................... Gray PUR................................... Purple LT BLU................................... Light Blue LT GRN................................... Light Green Diagrams Page 3229 Step 9 Locations A/T Main Case Oil Plug - Fluid Leaks Drain Plug: All Technical Service Bulletins A/T Main Case Oil Plug - Fluid Leaks 01-078 October 16, 2001 Applies To: 1996-00 Passport - ALL with A/T A/T Main Case Oil Pan Plug Leaks SYMPTOM The main case oil pan appears to leak ATF at the drain plug, the fill plug, or both. PROBABLE CAUSE An irregular surface finish on the main case oil pan damages the 0-rings on the plugs. CORRECTIVE ACTION Check the drain plug and fill plug on the main case oil pan for signs of leakage. If either plug leaks, replace both plugs and gaskets with captive 0-ring plugs. PARTS INFORMATION WARRANTY CLAIM INFORMATION In warranty: The normal warranty applies. Operation Number: 218159 Flat Rate Time: 0.3 hour Failed Part: P/N 8-96015-481-0 H/C 5043229 Defect Code: 051 Contention Code: B06 Template ID: 01-078A Skill Level: Repair Technician Out of warranty: Any repair performed after warranty expiration may be eligible for goodwill consideration by the District Service Manager or your Zone Office. You must request consideration, and get a decision, before starting work. REPAIR PROCEDURE 1. Raise the vehicle on a lift, making sure the vehicle is level. 2. Clean the area around the drain plug and fill plug on the A/T main case oil pan. Page 8280 Wiper Motor: Service and Repair Rear Window Wiper Motor Replacement Removal 1. Disconnect the battery ground cable. 2. Remove the tailgate trim pad. 3. Remove the wiper arm/blade. Refer to Rear Wiper Arm/Blade. 4. Remove the rear wiper motor (1). - Disconnect the connector. - Remove the rear wiper motor fixing screws. Installation To install, follow the removal steps in the reverse order, noting the following points: 1. Before installing the wiper arm/blade to the motor shaft, confirm that the motor stops at the autostop position. 2. Install the wiper arm/blade so that the wiper arm (2) contact with the stopper portion (3) on the hatch gate cover (1) as shown in the figure. Page 602 24. Verify APP Sensor 1 is between 11 and 15 percent, and APP Sensor 2 and APP Sensor 3 are between 89 and 85 percent with the pedal up (closed throttle). If not, loosen the mounting screws on the APPS sensor, and go to step 14. 25. Clear all DTCs with the PGM Tester. 26. Turn off the ignition switch, and disconnect the PGM Tester. Page 4966 Brake Fluid Level Sensor/Switch: Description and Operation The brake system warning light goes on to alert the driver that the parking brake is applied or that the brake fluid is low. It also lights as a bulb test when the engine is cranked. With the ignition switch in ON or START, battery voltage is applied to fuse 11 and to the brake system warning light. If the brake fluid is low, the brake fluid level switch closes and provides a ground for the light. The brake system warning light comes on to warn the driver of low brake fluid level in the brake master cylinder. (Note: Check brake pad wear before adding fluid). Page 1289 A battery voltage (B+) circuit which is only powered with the ignition switch in the ON, or START positions. Initiator The electrical component inside the air bag assembly which, when sufficient current flows, sets off the chemical reaction that inflates the air bag. "Initiator Assembly Resistance Test" Tests performed once each ignition cycle when no malfunctions are detected during "Turn-ON" or "Continuous Monitoring." This test checks for the correct SDM configuration for the vehicle, shorts to "Ignition 1 in the deployment loops, high resistance or opens in the "Driver Side High", "Driver Side Low", "Passenger Side High" and "Passenger Side Low" circuits and measures the resistance of the inflator assembly consisting of: 1. Initiators. 2. SRS coil assembly (driver side only). 3. Connectors and associated wiring. Normal Operating Voltage Range The voltage measured between the SDM "Ignition 1" terminals and "Ground" terminals is between 9 and 16 volts. Passenger Current Source An output of the SDM which applies current into the passenger air bag assembly circuit during the "Initiator Assembly Resistance Test". Passenger Air Bag Assembly An assembly located in the right side of the instrument panel consisting of an inflatable bag, an inflator and an initiator. Scan Tool An external computer used to read diagnostic information from on-board computers via the data link connector. SDM Sensing and Diagnostic Module which provides reserve energy to the deployment loops, deploys the air bags when required and performs diagnostic monitoring of all SRS components. Serial Data Information representing the status of the SRS. SRS Supplemental Restraint System. SRS Coil Assembly An assembly of two current-carrying coils in the driver deployment loop that allows the rotation of the steering wheel while maintaining the continuous contact of the driver deployment loop to the driver air bag assembly. SRS Wiring Harness The wires and connectors that electrically connect the components in the SRS. "Turn-ON" Test which the SDM performs on the SRS once during each ignition cycle immediately after "Ignition 1" voltage is applied to the SDM and before "Continuous Monitoring". Page 3695 Distinct Of Circuit By Wire Base Color All wires have color-coded insulation. Wires belonging to a system's main harness will have a single color. Wires belonging to a system's sub-circuits will have a colored stripe. Striped wires use the codes found in the chart to show wire size and colors. Abbreviations are used to indicate wire color within a circuit diagram. How to Identify Connector Terminals How to Identify Connector Terminals Cavity Numbering System The cavities (and wire terminals) in each connector are numbered starting from the upper left, looking at the male terminals from the terminal side (or looking at the female terminals from the wire side. Both views are in the same direction so the numbers are the same.) All actual cavities are numbered, even if they have no wire terminals in them. NOTE: Data Link Connector (DLC) terminals are numbered according to SAE standard J1962, not the Honda standard. The numbers of the four end terminals are molded into the corners of the connector face. The connector cavity number is listed next to each terminal on the circuit schematic. The cavity / terminal shown is # 6. Using/Identifying Connector Terminal Views How to Use Connector Terminal Views To see the configuration of a connector's cavities, look up its view number in the Connector Views. Each view includes the color of the connector, where Page 5705 View A REMOVAL 1. Disconnect the battery ground cable. 2. Remove the front console assembly. 3. Disconnect the connector from the control unit. 4. Remove 4 nuts. 5. Disconnect the control unit with brackets. 6. Remove 4 screws. 7. Disconnect the control unit from brackets. INSTALLATION To install, follow the removal steps in the reverse order, noting the following points. Torque: Nut (1) 8 Nm (69 inch lbs.) Front Wipers (In Combination Switch) Page 1575 2. Measure the valve spring squareness with a steel square and replace the valve springs if the measured value exceeds the specified limit. Limit: 2 mm (0.079 inch) 3. Using a spring tester to compress the springs to the installed height, measure the compressed spring tension, and replace the springs if the measured tension is below the specified limit. At installed height: 35.0 mm (1.38 inch) Standard: 196 N (44 lbs.) Limit: Less than 181 N (41 lbs.) Valve Guide Caution: Take care not to damage the valve seat contact surface, when removing carbon adhering to the valve head. Carefully inspect the valve stem for scratches or abnormal wear. If these conditions are present, the valve and the valve guide must be replaced as a set 1. Measure the valve stem diameter with a micrometer. If the valve stem diameter is less than the specified limit, the valve and the valve guide must be replaced as a set. Diameter of Valve Stem Intake Standard: 5.977 mm - 5.959 mm (0.2353 in 0.2346 inch) Limit: 5.90 mm (0.2323 inch) Exhaust Standard: 5.952 mm - 5.970 mm (0.2343 in 0.2350 inch) Limit: 5.90 mm (0.2323 inch) 2. Measure the inside diameter of the valve guide with a micrometer. Subtract the measured outer diameter of the valve stem from the measured inner diameter of the valve guide. If the value exceeds the specified limit, the valve and the valve guide must be replaced as a set. Inside Diameter of the Valve Guide Inlet clearance Standard: 0.023 mm - 0.056 mm (0.0009 in - 0.0002 inch) Limit: 0.20 mm (0.00787 inch) Exhaust clearance Standard: 0.030 mm - 0.063 mm (0.0012 in - 0.0025 inch) Limit: 0.20 mm (0.00787 inch) Service and Repair Slip Yoke: Service and Repair For further information regarding this component and the system that it is a part of, please refer to Drive/Propeller Shaft; Service and Repair; Front Drive Shaft. Suspension - Drifting & Pulling At Highway Speeds Alignment: All Technical Service Bulletins Suspension - Drifting & Pulling At Highway Speeds SOURCE: Honda Service News September 2003 TITLE: Drifting and Pulling at Highway Speeds APPLIES TO: All Models SERVICE TIP: Got a customer complaining that the vehicle drifts or pulls when driving at highway speeds? Use this handy procedure to diagnose and repair the problem. NOTE: Before doing the procedure in this article, check ISIS for related S/Bs and other S/N articles for the model you're working on. 1. Check if your customer has original equipment wheels and tires and that the ride height hasn't been modified. - If the wheels, tires, and ride height are OK, go to step 2. - If the wheels or tires aren't original equipment or the ride height was modified, stop here. Aftermarket wheels or tires or a ride height that's been modified pose challenges that this article doesn't cover. Resolve these issues with your customer before going further. 2. Set the tire pressures to the recommended cold inflation values listed on the doorjamb sticker. 3. Find a straight stretch of 4-lane road where you can safely (and legally) go 60 mph for several minutes. Ideally, you want a road that's perfectly flat, but most roads have a crown that¡C■s anywhere from 1.5° to 1.75° so they can drain. Flat Road - While driving at 60 mph, use a stopwatch to time how long it takes to drift one full lane from center to center. Record the time. Repeat this, driving in the opposite direction to cancel the effects of wind, then average the two times you recorded. If the vehicle drifts one full lane from center to center in less than 6 seconds, go to step 4. If not, return the vehicle to your customer. Crowned Road - While driving at 60 mph, check if the vehicle climbs the crown. Do this for both a left- and right-crowned road. A drift to the right on a right-crowned road and a drift to the left on left-crowned road are considered normal. If the vehicle climbs the crown or it drifts to the right on a left crowned road, go to step 4. 4. Record the original toe, camber, and caster readings. On Passports, set the ride height to spec if needed. Refer to Ride Height Adjustment in S/B 99-043, Steering Wheel Shimmy or Chassis Vibration. 5. Loosen the subframe mounting bolts, and move the rear beam (it¡C■s the entire front subframe on some models) to get the maximum amount of caster and equal side-to-side camber. (As little as 0.4° of camber stagger can cause the vehicle to pull.) 6. Make sure the steering wheel is centered, then set the front and rear toe to the maximum toe-in spec. (Toe-in improves vehicle stability and reduces the tendency to drift or pull.) 7. Test-drive the vehicle on the same road you used earlier. - If the drift is now within spec, return the vehicle to your customer. - If the drift is still out of spec, go to step 8. 8. Swap the front and rear tires on each side of the vehicle, then adjust the tire pressures to the recommended cold inflation values listed on the doorjamb sticker. 9. Test-drive the vehicle on the same road you used earlier. - If the drift is now within spec, swap each rear tire back to the front, one at a time, and test-drive the vehicle on the same road you used earlier. Replace the bad tire, then return the vehicle to your customer. - If the drift is still out of spec after swapping the front and rear tires, go to step 10. 10. Test-drive a known-good donor vehicle on the same road you used earlier, and check its pull. 11. Swap all four tires from the donor vehicle with the tires on your customer¡C■s vehicle. Locations Page 1023 DIAGNOSTIC WORKSHEET REPAIR PROCEDURE A Page 2277 24. Verify APP Sensor 1 is between 11 and 15 percent, and APP Sensor 2 and APP Sensor 3 are between 89 and 85 percent with the pedal up (closed throttle). If not, loosen the mounting screws on the APPS sensor, and go to step 14. 25. Clear all DTCs with the PGM Tester. 26. Turn off the ignition switch, and disconnect the PGM Tester. Page 4722 This means the branch of the wire connects to another circuit. The arrow points to the name of the circuit branch where the wire continues. Page 4544 it is located, and what it connects to. Use the Connector Views to help locate the proper cavity when you need to probe a connector. It can be especially helpful if the connector has more than one wire of the same color. A dash symbol (-) indicates that the cavity is empty. Connector views can also be used to help diagnose multiple symptoms in separate circuits which could be caused by a single problem in a connector shared by those circuits. Here's an example: 1. Pick one of the multiple symptoms and look up the schematic for that circuit. 2. Make a list of all the in-line and fuse box connectors in that schematic , 3. Then, in the Connector Views, look up each connector on your list to see if circuits related to the other symptoms run through one of them. If they do, inspect that connector for the problem. Example: The blower, rear window defogger, and the windshield wiper don't work. List all in-line and fuse box connectors in the blower controls circuit and then check the Connector View (see the sample). You find that C324 is common to the blower controls, rear window defogger, and wiper/washer, so you inspect C324 and find the problem, bent terminals. Finding Component/Connector Locations Finding Component/Connector Locations To see where a component or connector is located on the car, look up its photo number in the "Component Location". The photo will also tell you the color of the connector, and how many cavities it has. Page 5988 the component if the component only has one connector, or by a capital letter (A, B, C, etc.) if the component has more than one connector. Below most connector numbers and component names are PHOTO and VIEW numbers. The PHOTO number refers to a photo in the back of the book that shows the connector's location on the car. The VIEW number refers to an illustration in the back of the book that shows the connector face, wire colors, connector cavity numbers, and other details. The connector cavity numbering sequence begins at the top left corner of the connector. Disregard any numbers molded into the connector housing. Wires Wires are identified by the abbreviated names of their colors; the second color is the color of the stripe. Wires are also identified by their location in a connector. The number "2" next to the male and female wire terminals at C416, for example, means those terminals join in cavity 2 of connector C416. Symbols A complete description of schematic symbols is given under wire color abbreviation. Power Distribution Schematics Power Distribution schematics show how power is supplied from the positive battery terminal to various circuits in the car. Refer to the Power Distribution section to get a more detailed picture of how power is supplied to the circuit you're working on. From Battery to Ignition Switch, Fuses, and Relays Individual circuit schematics begin with a fuse. The first half of Power Distribution, however, shows the wiring "upstream" between the battery Page 8152 2. Remove the power window switch/regulator handle. - Pry out the power window switch and remove the connectors. - To remove the regulator handle (1), remove the clip (2) at the root of the handle by using wire with hook. 3. Remove the screw while pulling the inside lever toward you and then remove the inside handle. 4. Remove the speaker grille (3). - Pull out the front side of the grille. Page 560 This means the branch of the wire connects to another circuit. The arrow points to the name of the circuit branch where the wire continues. Page 4648 Actuator: Testing and Inspection MOTOR ACTUATOR ASSEMBLY Inspect the function of the motor actuator assembly as follows: 1. Disassemble the motor actuator from transfer rear case. 2. Connect the terminals as shown in figure. Shift rod of the motor actuator moves and stops at 4WD position. Page 2276 20. Using a DVOM, check the voltage between the reference voltage pin for each sensor and ground. ^ If the sensor circuits all read 5.0 volts, go to step 22. ^ If any sensor circuit is above or below 5.0 volts, go to step 21. 21. Troubleshoot for an internal short in another sensor or a PCM malfunction. ^ To find the sensor with an internal short, monitor the reference voltage, and disconnect each sensor (FTPS, EGR, MAP TPS, CKP and CMP) one at a time until the reference voltage reads 5.0 volts. Replace that sensor, and repeat step 14. ^ To find a malfunctioning PCM, replace it with a known-good PCM. If all three sensors (APP Sensor 1, APP Sensor 2, and APP Sensor 3) are within range, the original PCM is faulty; replace it and repeat step 14. 22. Using a jumper wire, connect the reference voltage of each circuit to its signal input, and view the APP Sensor values in the Engine Data List. APP Sensor 1 should have a value of 99%, and APP Sensor 2 and APP Sensor 3 should each have a value of 0%. ^ If the values are not as specified, troubleshoot for high resistance on the signal input or a PCM malfunction. Repair the circuit or replace the PCM, then repeat step 14. ^ If the values are as specified, the problem may be intermittent. Disconnect the 10 P connector from the modified APPS, and connect it to the new APPS; then repeat step 14. Wiggle the APPS wires as you go through the adjustment procedure to find the intermittent problem. 23. Install the accelerator pedal assembly, and torque the bolts to 10 N.m (7 lb-ft). Diagrams Page 4866 Brake Warning Indicator: Diagnostic Aids Before Troubleshooting Before Troubleshooting See: Service Precautions/Vehicle Damage Warnings/Tips and Precautions 1. Check applicable fuses in the appropriate fuse/relay box. 2. Check the battery for damage, state of charge, and clean and tight connections. CAUTION: Do not quick-charge a battery unless the battery ground cable has been disconnected, otherwise you will damage the alternator diodes. - Do not attempt to crank the engine with the battery ground cable loosely connected or you will severely damage the wiring. While You're Working 1. Make sure connectors are clean, and have no loose terminals or receptacles. 2. Make sure that connectors without wire seals are packed with dielectric (silicone) grease. Part Number: 08798-9001. 3. When connecting a connector, push it until it "clicks" into place. CAUTION: Do not pull on the wires when disconnecting a connector. Pull only on the connector housings. - Most circuits include solid-state devices. Test the voltages in these circuits only with a 10-megaohm or higher impedance digital multi meter. Never use a test light or analog meter on circuits that contain solid-state devices. Damage to the devices may result. Five-Step Troubleshooting 1. Verify The Complaint Turn on all the components in the problem circuit to check the accuracy of the customer complaint. Note the symptoms. Do not begin disassembly or testing until you have narrowed down the problem area. 2. Analyze The Schematic Look up the schematic for the problem circuit. Determine how the circuit is supposed to work by tracing the current paths from the power source through the circuit components to ground. Also, trace circuits that share wiring with the problem circuit. The names of circuits that share the same fuse, ground, or switch, and so on, are referred to in each circuit schematic. Try to operate any shared circuits you didn't check in step 1. If the shared circuits work, the shared wiring is OK, and the cause must be in the wiring used only by the problem circuit. If several circuits fail at the same time, the fuse or ground is a likely cause. Based on the symptoms and your understanding of the circuit's operation, identify one or more possible causes. 3. Isolate The Problem By Testing The Circuit Make circuit tests to check the diagnosis you made in step 2. Keep in mind that a logical, simple procedure is the key to efficient troubleshooting. Test for the most likely cause of failure first. Try to make tests at points that are easily accessible. 4. Fix The Problem Once the specific problem is identified, make the repair. Be sure to use proper tools and safe procedures. 5. Make Sure The Circuit Works Turn on all components in the repaired circuit in all modes to make sure you've fixed the entire problem. If the problem was a blown fuse, be sure to test all of the circuits on that fuse. Make sure no new problems turn up and the original problem does not recur. Page 1376 Tires: Service and Repair General Balance Procedure Deposits of mud, etc. must be cleaned from the inside of the rim. The tire should be inspected for the following: match mount paint marks, bent rims, bulges, irregular tire wear, proper wheel size and inflation pressure. Then balance according to the equipment manufacturer's recommendations. There are two types of wheel and tire balance. Static balance is the equal distribution of weight around the wheel. Assemblies that are statically unbalanced cause a bouncing action called tramp. This condition will eventually cause uneven tire wear. Dynamic balance is the equal distribution of weight on each side of the wheel center-line so that when the tire spins there is no tendency for the assembly to move from side to side. Assemblies that are dynamically unbalanced may cause shimmy. WARNING: Stones should be removed from the tread to avoid operator injury during spin balancing and to obtain a good balance. Diagram Information and Instructions Cargo Lamp: Diagram Information and Instructions How to Identify Wiring Color-Coded Insulation Wire Color Wire Color Coding Page 7493 Test Equipment CAUTION: Most circuits include solid-state devices. Test the voltages in these circuits only with a 10-megaohm or higher impedance digital multimeter. Never use a test light or analog meter on circuits that contain solid-state devices. Damage to the devices may result. Test Light and DVOM On circuits without solid-state devices, use a test light to check for voltage. A test light is made up of a 12 volt bulb with a pair of leads attached. After grounding one lead, touch the other lead to various points along the circuit where voltage should be present. The bulb will go on if there is voltage at the point being tested. If you need to know how much voltage is present, use a digital volt/ohmmeter (DVOM). Self-Powered Test Light and DVOM Use a self-powered test light to check for continuity. This tool is made up of a light bulb, battery, and two leads. To test it, touch the leads together: the light should go on. Use a self-powered test light only on an unpowered circuit. First, disconnect the battery, or remove the fuse that feeds the circuit you are working on. Select two points in the circuit between which you want to check continuity. Connect one lead of the self-powered test light to each point. If there is continuity, the test light's circuit will be completed, and the light will go on. If, in addition, you need to know exactly how much resistance there is between two points, use a digital volt/ohmmeter (DVOM). In the "OHMS" range, the DVOM will measure resistance between two points along a circuit. Low resistance means good continuity. Diodes and solid-state devices in a circuit can make a DVOM give a false reading. To check a reading, reverse the leads, and take a second reading. If the readings differ, the component is affecting the measurement. Jumper Wire Use a jumper wire to bypass an open circuit. A jumper wire is made up of an in-line fuse holder connected to a set of test leads. It should have a five ampere fuse. Never connect a jumper wire across a short circuit. The direct battery short will blow the fuse. Short Finder (Short Circuit Locator) Short finders are available to locate shorts to ground. The short finder creates a pulsing magnetic field in the shorted circuit which you can follow to the location of the short. To order any test equipment shown above, contact your local tool supplier. For a list of suppliers and tool numbers, refer to Honda Required Special Tools and Equipment Service Bulletin. A/T - Avoiding Fluid Contamination Fluid - A/T: Technical Service Bulletins A/T - Avoiding Fluid Contamination SOURCE: Honda Service News TITLE: Avoiding Comebacks From A/T Contamination APPLIES TO: All models SERVICE TIP: Installing a reman A/T? Here are some important tips to keep in mind to ensure a first-time fix and to avoid any come-backs: - If the vehicle has an ATF cooler, make sure you clean the cooler with the ATF Cooler Cleaner (P/N GHTTTCF6H). See S/B 89-022, ATF Cooler Cleaner, for details. - If the reman A/T kit includes an in-line filter, don't forget to install it. If the vehicle already has an in-line filter from an earlier A/T replacement, then remove the existing filter, and install the new one. - Spray the driveshaft splines with solvent and compressed air before installing them in the reman A/T. If the failed A/T had a speed sensor, make sure it's clean before you install it. Debris from the failed A/T can catch in the driveshaft splines or on the speed sensor and contaminate the reman A/T. - If the reman A/T comes with a heater/cooler, make sure you install the reman A/T with that heater/cooler. Never install the heater/cooler from the failed A/T; you could contaminate the reman A/T. Page 1019 Alignment: By Symptom Technical Service Bulletin # 06-068 Date: 090502 Steering/Suspension - Vehicle Pulls Left/Right 06-068 May 2, 2009 Applies To: ALL *Vehicle Pulls or Drifts, and/or Steering Wheel Is Off-Center (Supersedes 06-068, Vehicle Pulling or Drifting, dated October 4, 2007, to revise the information marked by asterisks) (Replaces 90-011, Steering Wheel Off-Center Adjustment at PDI)* *REVISION SUMMARY The title description was revised.* SYMPTOM While driving on a straight road, the vehicle pulls or drifts to the right or left. BACKGROUND New tools were developed to help you diagnose and correct a pulling and/or steering wheel off-center issue. There is a diagnosis worksheet included to take on your test-drive and record your findings. These values are used to build the 15-digit DTC (diagnostic trouble code) that is required for your warranty claim. The last step in each repair procedure helps you create the correct code. In the rare case that you have to repair a vehicle that pulls and has the steering wheel off-center, use REPAIR PROCEDURE B to file your warranty claim. For more information, refer to Training Module SSC 44 - Steering Drift or Pull Interactive Service Bulletin. PROBABLE CAUSES Several conditions can cause the vehicle to pull or drift: ^ Wheel alignment ^ Tires ^ Off-center steering wheel (no pulling or drifting, but a customer may believe this is the case) CORRECTIVE ACTION Diagnose the problem using the special tools and the worksheet on page 4 that guides you to one of four repair procedures. TOOL INFORMATION Centering Tape (enough to diagnose 240 vehicles): T/N O7AAJ-001A300 Steering Drift Set Level: T/N 07AAJ-00100 Steering Drift Set: T/N O7MJ-001A140 Replacement Weight for Steering Drift Set: T/N 07AAJ-001A400 WARRANTY CLAIM INFORMATION In warranty: The normal warranty applies. Page 385 Part 1 of 2 Part 2 of 2 B-22 Rear Speed Sensor Missing (DTC 63/C0237) Chart B-22 Rear Speed Sensor Missing (DTC 63 (Flash Out) / C0236, C0237 (Serial Communications)) Page 3437 24. Verify APP Sensor 1 is between 11 and 15 percent, and APP Sensor 2 and APP Sensor 3 are between 89 and 85 percent with the pedal up (closed throttle). If not, loosen the mounting screws on the APPS sensor, and go to step 14. 25. Clear all DTCs with the PGM Tester. 26. Turn off the ignition switch, and disconnect the PGM Tester. Page 4361 UNIVERSAL JOINT DISASSEMBLY 1. Using a soft drift, tap the outside of the bearing cup assembly to loosen snap ring. Tap bearing only hard enough to break assembly away from snap ring. Remove snap ring from yoke. Turn joint over, tap bearing away from snap ring, then remove opposite snap ring. Apply alignment marks (1) on the yokes of the universal joint, then remove snap ring. Page 4513 Transmission Speed Sensor: Locations Top Of Transfer Case Page 5621 Steering Wheel: Service and Repair Steering Wheel REMOVAL 1. Turn the steering wheel so that the vehicle's wheels are pointing straight ahead. 2. Turn the ignition switch to "LOCK". 3. Disconnect the battery "-" terminal cable, and wait at least 5 minutes. 4. Disconnect the yellow 2-way SRS connector located under the steering column. 5. Loosen the inflator module fixing bolt from behind the steering wheel assembly using a TORX (R) driver or equivalent until the inflator module can be released from steering assembly. Page 8016 The connector cavity number is listed next to each terminal on the circuit schematic. The cavity / terminal shown is # 6. Diodes A rectifier diode works like a one way valve. It allows current to flow only in the direction of the arrow. A Zener diode blocks reverse current at normal voltages just like a rectifier diode. At high voltages, however, a Zener diode allows current to flow in reverse. Fuses Page 7945 and the fuses. From Fuses to Relays and Components The second half of Power Distribution shows the wiring "From Fuses to Relays and Components." This can speed your troubleshooting by showing which circuits share fuses. If Power Distribution shows that an inoperative circuit and another circuit share a fuse, check a component in the other circuit. If it works, you know the fuse is good and power is available to the inoperative circuit. Ground Distribution Schematics Page 7953 This means the branch of the wire connects to another circuit. The arrow points to the name of the circuit branch where the wire continues. Page 3570 2. Connect one lead of a self-powered test light or DVOM to one end of the part of the circuit you want to test. 3. Connect the other lead to the other end. 4. If the self-powered test light glows, there is continuity. If you're using a DVOM, a low reading or no reading (zero), means good continuity. Testing For Voltage When testing for voltage at a connector without wire seals, you do not have to separate the two halves of the connector. Instead, probe the connector from the back. Always check both sides of the connector because dirty, corroded, and bent terminals can cause problems (no electrical contact = an open). 1. Connect one lead of the lest light to a known good ground, or, if you're using a digital volt ohmmeter (DVOM), place it in the appropriate DC volts range, and connect its negative lead to ground. 2. Connect the other lead of the test light or DVOM to the point you want to check. 3. If the test light glows, there is voltage present. If you're using a DVOM, note the voltage reading. It should be within one volt of measured battery voltage. A loss of more than one volt indicates a problem. NOTE: Always use a DVOM on high impedance circuits. A test light may not glow (even with battery voltage present). Testing For Voltage Drop Wires, connectors, and switches are designed to conduct current with a minimum loss of voltage. A voltage drop of more than one volt indicates a problem. 1. Place the digital volt/ohmmeter (DVOM) in the appropriate DC volts range. Connect the positive lead to the end of the wire (or to the connector or switch) closest to the battery. 2. Connect the negative lead to the other end of the wire (or the other side of the connector or switch). 3. Turn on the components in the circuit. 4. The DVOM will show the difference in voltage between the two points. A difference, or drop, of more than one volt indicates a problem. Check the circuit for loose, dirty, or bent terminals. Page 751 The name of the component appears next to it followed by notes about its function along with any photo and connector view references. Connector "C" How to Identify Connector Terminals Cavity Numbering System The cavities (and wire terminals) in each connector are numbered starting from the upper left, looking at the male terminals from the terminal side (or looking at the female terminals from the wire side. Both views are in the same direction so the numbers are the same.) All actual cavities are numbered, even if they have no wire terminals in them. NOTE: Data Link Connector (DLC) terminals are numbered according to SAE standard J1962, not the Honda standard. The numbers of the four end terminals are molded into the corners of the connector face. Page 4480 The connector cavity number is listed next to each terminal on the circuit schematic. The cavity / terminal shown is # 6. Diodes A rectifier diode works like a one way valve. It allows current to flow only in the direction of the arrow. A Zener diode blocks reverse current at normal voltages just like a rectifier diode. At high voltages, however, a Zener diode allows current to flow in reverse. Fuses Engine Controls - High/Erratic Engine Idle PROM - Programmable Read Only Memory: All Technical Service Bulletins Engine Controls High/Erratic Engine Idle 01-080 August 14, 2001 Applies To: 2000-02 Passport - ALL 2000-02 Passport: High or Erratic Idle SYMPTOM The engine occasionally idles at too high a speed, or the idle speed fluctuates. PROBABLE CAUSES The symptom could be the result of any of these conditions: ^ Loose or corroded engine or body ground ^ High resistance in the APPS ground circuit ^ PSP (power steering pressure) switch is internally shorted to ground ^ Fuel pressure regulator is leaking fuel into the intake manifold CORRECTIVE ACTION Diagnose the cause of the idle condition, and select the proper REPAIR PROCEDURE. PARTS INFORMATION REQUIRED MATERIALS REQUIRED SOFTWARE Each REPAIR PROCEDURE requires you to use the Smart Cable to reprogram the PCM with the latest software. To select the latest software from the CDROM, enter the year, model, engine, transmission, and emissions type (49-state or California). This gives you a list of broadcast codes. Select the broadcast code at the top of the list. WARRANTY CLAIM INFORMATION Refer to the Warranty Claim Information for each Repair Procedure. DIAGNOSIS 1. Find out from the customer when the high or erratic idle condition occurs and what the RPM range is: ^ Within 20 minutes of a cold start ^ After braking to a stop ^ All the time ^ Intermittently, with no set pattern Locations Page 261 This sample Ground Distribution schematic shows all of the components that share two ground points. Components A solid border line means the entire component is shown. A broken border line indicates that only part of the component is shown. Page 6773 Terminals - "T" Each "T" terminal (ring type) is numbered for reference and location. A "T" terminal is secured with a screw or bolt. Wires Page 3149 11. Using a jumper wire, connect the reference voltage of each circuit to its signal input and view the APP Sensor values in the Engine Data List. APP Sensor 1 should have a value of 99%, and APP Sensor 2 and APP Sensor 3 should each have a value of 0%. ^ If the values are not as specified, troubleshoot for high resistance on the signal input or a PCM malfunction. Repair the circuit or replace the PCM, then repeat step 3. ^ If the values are as specified, the problem may be intermittent. Disconnect the 10P connector from the modified APPS, and connect it to the new APPS; then repeat step 3. Wiggle the APPS wires as you go through the adjustment procedure to find the intermittent problem. 12. Turn off the ignition switch, and disconnect the PGM Tester.* DISCLAIMER Page 4281 Axle Disconnect Control Control Unit: Diagnostic Aids Before Troubleshooting Before Troubleshooting See: Service Precautions/Vehicle Damage Warnings/Tips and Precautions 1. Check applicable fuses in the appropriate fuse/relay box. 2. Check the battery for damage, state of charge, and clean and tight connections. CAUTION: Do not quick-charge a battery unless the battery ground cable has been disconnected, otherwise you will damage the alternator diodes. - Do not attempt to crank the engine with the battery ground cable loosely connected or you will severely damage the wiring. While You're Working 1. Make sure connectors are clean, and have no loose terminals or receptacles. 2. Make sure that connectors without wire seals are packed with dielectric (silicone) grease. Part Number: 08798-9001. 3. When connecting a connector, push it until it "clicks" into place. CAUTION: Do not pull on the wires when disconnecting a connector. Pull only on the connector housings. - Most circuits include solid-state devices. Test the voltages in these circuits only with a 10-megaohm or higher impedance digital multi meter. Never use a test light or analog meter on circuits that contain solid-state devices. Damage to the devices may result. Five-Step Troubleshooting 1. Verify The Complaint Turn on all the components in the problem circuit to check the accuracy of the customer complaint. Note the symptoms. Do not begin disassembly or testing until you have narrowed down the problem area. 2. Analyze The Schematic Look up the schematic for the problem circuit. Determine how the circuit is supposed to work by tracing the current paths from the power source through the circuit components to ground. Also, trace circuits that share wiring with the problem circuit. The names of circuits that share the same fuse, ground, or switch, and so on, are referred to in each circuit schematic. Try to operate any shared circuits you didn't check in step 1. If the shared circuits work, the shared wiring is OK, and the cause must be in the wiring used only by the problem circuit. If several circuits fail at the same time, the fuse or ground is a likely cause. Based on the symptoms and your understanding of the circuit's operation, identify one or more possible causes. 3. Isolate The Problem By Testing The Circuit Make circuit tests to check the diagnosis you made in step 2. Keep in mind that a logical, simple procedure is the key to efficient troubleshooting. Test for the most likely cause of failure first. Try to make tests at points that are easily accessible. 4. Fix The Problem Once the specific problem is identified, make the repair. Be sure to use proper tools and safe procedures. 5. Make Sure The Circuit Works Turn on all components in the repaired circuit in all modes to make sure you've fixed the entire problem. If the problem was a blown fuse, be sure to test all of the circuits on that fuse. Make sure no new problems turn up and the original problem does not recur. Locations Windshield Wipers - Blade Care & Replacement Wiper Blade: Technical Service Bulletins Windshield Wipers - Blade Care & Replacement SOURCE: Honda Service News TITLE: Windshield Wiper Blade Care and Replacement APPLIES TO: All models SERVICE TIP: A buildup of road film, oil, or grease on the windshield or the wiper blades can cause the wiper blades to smear, streak, or chatter when being used. If your customers complain of this problem, and their wiper blades are less than 6 months old, try doing this before you replace the blades: - Use Glass Cleaner or equivalent, to thoroughly clean the windshield. Make sure you clean it well enough so that water slides off of it, not just beads up. - Use Windshield Washer Concentrate Cleaner & Antifreeze straight from the bottle on a soft cloth to clean the wiper blades. This stuff contains a wetting agent that conditions the blade rubber. If the wiper blades still smear, streak, or chatter after you've cleaned the windshield and the blades, then blade replacement is in order. When you remove the old blade from its holder, make sure you grab the locking end of the blade on its top and bottom (use your thumb and index finger for this). Tug on the blade until it releases, then slide it off the holder. Don't grab the locking end from the sides. The metal rails could come loose and you could also wind up with a nasty cut. If the new blades don't have rails, make sure you install the rails from the old blades on the new blades like this: If the old rails are curved: - Install them on the new driver's-side wiper blade with the ends bowing away from the windshield. This makes the blade press harder against the middle of the windshield, providing a clear center of vision for the driver. - Install them on the new passenger's side wiper blade with the ends bowing toward the windshield. This makes the blade press harder against the edges of the windshield to clear off any water at the upper and lower ends of each wiper pass. If the old rails lie flat: Install them on either new wiper blade. If one of the new blades is shorter than the other (this is common on many vehicles), just install the shorter blade on the driver's side. Page 6292 The connector cavity number is listed next to each terminal on the circuit schematic. The cavity / terminal shown is # 6. Diodes A rectifier diode works like a one way valve. It allows current to flow only in the direction of the arrow. A Zener diode blocks reverse current at normal voltages just like a rectifier diode. At high voltages, however, a Zener diode allows current to flow in reverse. Fuses Locations Crankshaft Position Sensor: Locations CKP Sensor 36. Bottom Right Side of Engine Bottom Right Side of Engine Component Tests and General Diagnostics Electronic Brake Control Module: Component Tests and General Diagnostics Page 1696 10. Use the PGM Tester to check the broadcast code. Make sure the broadcast code matches the one you selected from the CD-ROM. WARRANTY CLAIM INFORMATION In warranty: The normal warranty applies. Failed Part: P/N 8-17087-655-0 H/C 4375820 Defect Code: 064 Contention Code: C01 Skill Level: Repair Technician Out of warranty: Any repair performed after warranty expiration may be eligible for goodwill consideration by the District Service Manager or your Zone Office. You must request consideration, and get a decision, before starting work. REPAIR PROCEDURE - ENGINE/BODY GROUND 1. Use the ETM for the appropriate year to locate these ground connectors: G101, G104, G105, G106 and G160. 2. Inspect each connector for corrosion or looseness. 3. Remove the bolt from any connector that is corroded or loose. Clean the terminal connector with a wire brush. File flat any solder bumps on the connector. 4. Clean the contact surface on the engine or body with a wire brush. 5. Replace the bolt if it is heavily corroded. Otherwise, clean it with a wire brush. 6. Apply lithium dielectric grease to both sides of the terminal connector. 7. Reinstall the bolt, torque it to 14 N.m (10 lb-ft). 8. Use the Smart Cable to reprogram the PCM with the latest software from the June 2001 or later HONDANET CD-ROM. Refer to Service Bulletin 99-005, Updating the Passport PCM, filed under Tools. 9. Use the PGM Tester to clear any DTCs. 10. Use the PGM Tester to check the broadcast code. Make sure the broadcast code matches the one you selected from the CD-ROM. WARRANTY CLAIM INFORMATION In warranty: The normal warranty applies. Failed Part: P/N 8-97086-823-0 Page 2967 the component if the component only has one connector, or by a capital letter (A, B, C, etc.) if the component has more than one connector. Below most connector numbers and component names are PHOTO and VIEW numbers. The PHOTO number refers to a photo in the back of the book that shows the connector's location on the car. The VIEW number refers to an illustration in the back of the book that shows the connector face, wire colors, connector cavity numbers, and other details. The connector cavity numbering sequence begins at the top left corner of the connector. Disregard any numbers molded into the connector housing. Wires Wires are identified by the abbreviated names of their colors; the second color is the color of the stripe. Wires are also identified by their location in a connector. The number "2" next to the male and female wire terminals at C416, for example, means those terminals join in cavity 2 of connector C416. Symbols A complete description of schematic symbols is given under wire color abbreviation. Power Distribution Schematics Power Distribution schematics show how power is supplied from the positive battery terminal to various circuits in the car. Refer to the Power Distribution section to get a more detailed picture of how power is supplied to the circuit you're working on. From Battery to Ignition Switch, Fuses, and Relays Individual circuit schematics begin with a fuse. The first half of Power Distribution, however, shows the wiring "upstream" between the battery Page 6737 Ground - "G" Shielding Sheilding This represents RFI (Radio Frequency Interference) shielding around a wire. The shielding is always connected to ground. Splices Description and Operation Fuel Level Sensor: Description and Operation Fuel Level Sensor The fuel level sensor is an important input to the PCM for the enhanced EVAP system diagnostic. The PCM needs fuel level information to know the volume of fuel in the tank. The fuel level affects the rate of change of air pressure in the EVAP system. Several of the enhanced EVAP system diagnostic sub-tests are dependent upon correct fuel level information. The diagnostic will not run when the tank is less than 15 % or more than 85 % full. Be sure to diagnose any Fuel Level Sensor DTCs first, as they can cause other DTCs to set. Page 2286 Accelerator Pedal Position Sensor: Adjustments Accelerator Position Sensor Adjustment AP sensor is controlled three multiple control system, and adjust the idle position and WOT position are between A and B for AP sensor 1, AP sensor 2, and AP sensor 3. Refer to "How to adjust for AP sensor". How To Adjust For AP Sensor 1. Connect the Tech 2 to DLC on vehicle. 2. Ignition "ON," engine "OFF". 3. Display the APS date list. Check the following item for AP position (%). 4. If the problem was found, adjust as necessary. Page 6422 12. Remove the three SDM fixing bolts (4) and remove SDM (3). Installation 1. Install the SDM (1) on bracket and fixing bolts (4) and tighten the fixing bolts to the specified torque. Torque: 10 ± 3 N.m (1.0 ± 0.3 kg.m / 87 ± 26 lb.in) 2. Connect the SDM harness connector (3) and after that, put CPA into connector (2). 3. Install air conditioning duct for rear seat to normal position. 4. Return carpet normal position. 5. Install right side stay between instrument panel and floor, tighten to the specified torque. Torque: 10 ± 3 N.m (1.0 ± 0.3 kg.m / 87 ± 26 lb.in) 6. Install PCM with bracket and tighten to the specified torque. (Y22SE 2.2L Engine only) Torque: 10 ± 3 N.m (1.0 ± 0.3 kg.m / 87 ± 26 lb.in) Page 7408 The name of the component appears next to it followed by notes about its function along with any photo and connector view references. Connector "C" How to Identify Connector Terminals Cavity Numbering System The cavities (and wire terminals) in each connector are numbered starting from the upper left, looking at the male terminals from the terminal side (or looking at the female terminals from the wire side. Both views are in the same direction so the numbers are the same.) All actual cavities are numbered, even if they have no wire terminals in them. NOTE: Data Link Connector (DLC) terminals are numbered according to SAE standard J1962, not the Honda standard. The numbers of the four end terminals are molded into the corners of the connector face. Removal and Installation Valve Spring: Service and Repair Removal and Installation Valve Stem Oil Controller, Valve Spring and Valve Guide Removal 1. Disconnect battery ground cable. 2. Drain engine oil. - Drain engine coolant. 3. Remove cylinder head assembly. Refer to removal procedure for Cylinder Head. 4. Remove camshaft. Refer to removal procedure for Camshaft. 5. Remove tappets with shim. Note: Do not damage shim surface. 6. Remove valve springs using J-8062 valve spring compressor and J-42898 valve spring compressor adapter then remove upper valve spring seat and lower seat. 7. Remove oil controller using J-37281 oil controller remover, remove each valve stem oil controller. 8. Remove valve guide using J-37985 valve guide replacer. Installation 1. Install valve guide using J-42899 valve guide installer. 2. Install oil controller using J-38537 oil controller installer. 3. Install lower valve spring seat, valve spring and upper valve spring seat then put split collars on the upper spring seat, using J-8062 valve spring compressor and J-42898 valve spring compressor adapter to install the split collars. 4. Install tappet with shim. 5. Install camshaft assembly. Refer to installation procedure for Camshaft. 6. Install cylinder head assembly. Refer to installation procedure for Cylinder Head. 7. Fill engine oil until full level. 8. Fill engine coolant. Page 2201 Throttle Position Sensor: Description and Operation Throttle Position (TP) Sensor The throttle position (TP) sensor is a potentiometer connected to the throttle shaft on the throttle body. The PCM monitors the voltage on the signal line and calculates throttle position. As the throttle valve angle is changed (accelerator pedal moved), the TP sensor signal also changes. At a closed throttle position, the output of the TP1 sensor is low. As the throttle valve opens, the output increases so that at wide open throttle (WOT), the output voltage should be above 92 % (Tech 2 Display). The PCM calculates fuel delivery based on throttle valve angle (driver demand). A broken or loose TP sensor may cause intermittent bursts of fuel from an injector and unstable idle because the PCM thinks the throttle is moving. Page 2167 amount of oxygen present in the exhaust gas entering the three-way catalytic converter. The Bank 1 HO2S 2 and the Bank 2 HO2S 2 sensors produce an output signal which indicates the oxygen storage capacity of the catalyst. This indicates the catalyst's ability to efficiently convert exhaust gases. If the catalyst is operating efficiently, the Bank 1 HO2S 1 and the Bank 2 HO2S 1 signals will be more active than the signals produced by the Bank 1 HO2S 2 and the Bank 2 HO2S 2 sensors. The catalyst monitor sensors operate the same as the fuel control sensors. The Bank 1 HO2S 2 and the Bank 2 HO2S 2 sensors" main function is catalyst monitoring, but they also have a limited role in fuel control. If a sensor output indicates a voltage either above or below the 450 mV bias voltage for an extended period of time, the PCM will make a slight adjustment to fuel trim to ensure that fuel delivery is correct for catalyst monitoring. A problem with the Bank 1 HO2S 2 signal circuit will set DTC P0137, P0138, or P0140, depending on the specific condition. A problem with the Bank 2 HO2S 2 signal circuit will set DTC P0157, P0158, or P0160, depending on the specific condition. A fault in the heated oxygen sensor heater element or its ignition feed or ground will result in lower sensor response. This may cause incorrect catalyst monitor diagnostic results. Page 4257 Pinion Gear: Specifications Pinion Gear Clearance --Gear Ratio 6VD1 With A/T 4.100 : 1 6VD1 With M/T 4.300 : 1 X22SE With M/T 4.777 : 1 Page 7375 it is located, and what it connects to. Use the Connector Views to help locate the proper cavity when you need to probe a connector. It can be especially helpful if the connector has more than one wire of the same color. A dash symbol (-) indicates that the cavity is empty. Connector views can also be used to help diagnose multiple symptoms in separate circuits which could be caused by a single problem in a connector shared by those circuits. Here's an example: 1. Pick one of the multiple symptoms and look up the schematic for that circuit. 2. Make a list of all the in-line and fuse box connectors in that schematic , 3. Then, in the Connector Views, look up each connector on your list to see if circuits related to the other symptoms run through one of them. If they do, inspect that connector for the problem. Example: The blower, rear window defogger, and the windshield wiper don't work. List all in-line and fuse box connectors in the blower controls circuit and then check the Connector View (see the sample). You find that C324 is common to the blower controls, rear window defogger, and wiper/washer, so you inspect C324 and find the problem, bent terminals. Finding Component/Connector Locations Finding Component/Connector Locations To see where a component or connector is located on the car, look up its photo number in the "Component Location". The photo will also tell you the color of the connector, and how many cavities it has. Page 8076 The connector cavity number is listed next to each terminal on the circuit schematic. The cavity / terminal shown is # 6. Diodes A rectifier diode works like a one way valve. It allows current to flow only in the direction of the arrow. A Zener diode blocks reverse current at normal voltages just like a rectifier diode. At high voltages, however, a Zener diode allows current to flow in reverse. Fuses Page 4118 Clutch Disc: Description and Operation DRIVEN PLATE ASSEMBLY X22SE Engine, MUA Transmissions 6VD1 Engine, MUA Transmission The driven plate assembly consists of the plate and the facing. The plate consists of the clutch center, the cushioning plate, and the torsion springs. The facing is riveted to both sides of the cushioning plate. The cushioning plate provides a longer service life by minimizing wear and vibration at the clutch contact surfaces. Page 6224 Housing Assembly HVAC: Service and Repair Heater Temperature Control Link Unit Heater Temperature Control Link Unit Removal 1. Disconnect the battery ground cable. 2. Drain engine coolant. 3. Discharge and recover refrigerant (with air conditioning). 4. Remove heater unit. 5. Remove the case (Temperature control) from the heater unit. 6. Remove rod. 7. Remove sub-lever. 8. Pull out the door lever while raising up the catch of the door lever. 9. Remove clip. Installation To install, follow the removal steps in the reverse order, noting the following points: 1. Apply grease to the sub-lever and to the abrasive surface of the heater unit. 2. After installing the link unit, check to see if the link unit operates correctly. Page 2223 and the fuses. From Fuses to Relays and Components The second half of Power Distribution shows the wiring "From Fuses to Relays and Components." This can speed your troubleshooting by showing which circuits share fuses. If Power Distribution shows that an inoperative circuit and another circuit share a fuse, check a component in the other circuit. If it works, you know the fuse is good and power is available to the inoperative circuit. Ground Distribution Schematics Page 4078 Torque Converter: Service and Repair For further information regarding this component and the system that it is a part of, please refer to Automatic Transmission/Transaxle; Service and Repair; Unit Overhaul Page 308 Page 6193 Service Precautions Clockspring Assembly / Spiral Cable: Service Precautions Steering-related Precautions Cable Reel Alignment Misalignment of the cable reel could cause an open in the wiring, making the SRS system and the horns inoperative. Center the cable reel whenever the following is performed. * Installation of the steering wheel * Installation of the cable reel * Installation of the steering column * Other steering-related adjustment or installation Do not disassemble the cable reel. Do not apply grease to the cable reel. If the cable reel shows any signs of damage, replace it with a new one. For example, it does not rotate smoothly. Page 1024 NOTE: Do this repair procedure if, after doing step 10 of the test-drive, the vehicle pulled in the opposite direction after you swapped the front tires. 1. Swap wheels 2 and 4 on the passenger's side of the vehicle, and test-drive again. ^ If the pull goes away, replace the tire on wheel 2, then go to step 3. ^ If the pull does not go away, put wheels 2 and 4 back to their original positions, and go to step 2. 2. Swap wheels 1 and 3 on the driver's side of the vehicle, and test-drive again. ^ If the pull goes away, replace the tire on wheel 1, then go to step 3. ^ If the pull does not go away, use a known-good tire in position 1 and continue diagnosis. 3. Use your diagnosis worksheet to fill in the following table and build your 15-digit DTC. REPAIR PROCEDURE B Page 2075 20. Using a DVOM, check the voltage between the reference voltage pin for each sensor and ground. ^ If the sensor circuits all read 5.0 volts, go to step 22. ^ If any sensor circuit is above or below 5.0 volts, go to step 21. 21. Troubleshoot for an internal short in another sensor or a PCM malfunction. ^ To find the sensor with an internal short, monitor the reference voltage, and disconnect each sensor (FTPS, EGR, MAP TPS, CKP and CMP) one at a time until the reference voltage reads 5.0 volts. Replace that sensor, and repeat step 14. ^ To find a malfunctioning PCM, replace it with a known-good PCM. If all three sensors (APP Sensor 1, APP Sensor 2, and APP Sensor 3) are within range, the original PCM is faulty; replace it and repeat step 14. 22. Using a jumper wire, connect the reference voltage of each circuit to its signal input, and view the APP Sensor values in the Engine Data List. APP Sensor 1 should have a value of 99%, and APP Sensor 2 and APP Sensor 3 should each have a value of 0%. ^ If the values are not as specified, troubleshoot for high resistance on the signal input or a PCM malfunction. Repair the circuit or replace the PCM, then repeat step 14. ^ If the values are as specified, the problem may be intermittent. Disconnect the 10 P connector from the modified APPS, and connect it to the new APPS; then repeat step 14. Wiggle the APPS wires as you go through the adjustment procedure to find the intermittent problem. 23. Install the accelerator pedal assembly, and torque the bolts to 10 N.m (7 lb-ft). Page 3198 Fuel Injector: Connector Locations 26. Left Front of Engine Left Front Of Engine Page 6415 SRS Unit Page 2233 The wire insulation has one color or one color with another color stripe. The second color is the stripe. Page 3123 11. Using a jumper wire, connect the reference voltage of each circuit to its signal input and view the APP Sensor values in the Engine Data List. APP Sensor 1 should have a value of 99%, and APP Sensor 2 and APP Sensor 3 should each have a value of 0%. ^ If the values are not as specified, troubleshoot for high resistance on the signal input or a PCM malfunction. Repair the circuit or replace the PCM, then repeat step 3. ^ If the values are as specified, the problem may be intermittent. Disconnect the 10P connector from the modified APPS, and connect it to the new APPS; then repeat step 3. Wiggle the APPS wires as you go through the adjustment procedure to find the intermittent problem. 12. Turn off the ignition switch, and disconnect the PGM Tester.* DISCLAIMER Page 2908 96. Rear of Right Catalytic Converter Rear of right catalytic converter 94. Rear of Left Catalytic Converter Rear of Left Catalytic Converter Page 4604 Test Equipment CAUTION: Most circuits include solid-state devices. Test the voltages in these circuits only with a 10-megaohm or higher impedance digital multimeter. Never use a test light or analog meter on circuits that contain solid-state devices. Damage to the devices may result. Test Light and DVOM On circuits without solid-state devices, use a test light to check for voltage. A test light is made up of a 12 volt bulb with a pair of leads attached. After grounding one lead, touch the other lead to various points along the circuit where voltage should be present. The bulb will go on if there is voltage at the point being tested. If you need to know how much voltage is present, use a digital volt/ohmmeter (DVOM). Self-Powered Test Light and DVOM Use a self-powered test light to check for continuity. This tool is made up of a light bulb, battery, and two leads. To test it, touch the leads together: the light should go on. Use a self-powered test light only on an unpowered circuit. First, disconnect the battery, or remove the fuse that feeds the circuit you are working on. Select two points in the circuit between which you want to check continuity. Connect one lead of the self-powered test light to each point. If there is continuity, the test light's circuit will be completed, and the light will go on. If, in addition, you need to know exactly how much resistance there is between two points, use a digital volt/ohmmeter (DVOM). In the "OHMS" range, the DVOM will measure resistance between two points along a circuit. Low resistance means good continuity. Diodes and solid-state devices in a circuit can make a DVOM give a false reading. To check a reading, reverse the leads, and take a second reading. If the readings differ, the component is affecting the measurement. Jumper Wire Use a jumper wire to bypass an open circuit. A jumper wire is made up of an in-line fuse holder connected to a set of test leads. It should have a five ampere fuse. Never connect a jumper wire across a short circuit. The direct battery short will blow the fuse. Short Finder (Short Circuit Locator) Short finders are available to locate shorts to ground. The short finder creates a pulsing magnetic field in the shorted circuit which you can follow to the location of the short. To order any test equipment shown above, contact your local tool supplier. For a list of suppliers and tool numbers, refer to Honda Required Special Tools and Equipment Service Bulletin. Page 3741 Wire Color Abbreviations The following abbreviations are used to identify wire colors in the circuit schematics: WHT................................... White YEL................................... Yellow BLK................................... Black BLU................................... Blue GRN................................... Green RED................................... Red ORN................................... Orange PNK................................... Pink BRN................................... Brown GRY................................... Gray PUR................................... Purple LT BLU................................... Light Blue LT GRN................................... Light Green Page 2727 ^ If the idle speed ever exceeds 1,300 rpm 2. Remove the vacuum hose from the fuel pressure regulator, then start the engine. ^ If fuel comes out of the fuel pressure regulator vacuum hose connection, go to REPAIR PROCEDURE FUEL PRESSURE REGULATOR. ^ If no fuel comes out of the regulator, reconnect the vacuum hose and continue to step 3. 3. Connect the PGM Tester. Set it to Engine Data List. 4. Have an assistant drive the vehicle under the conditions described by the customer. 5. If the high or erratic idle condition occurs, note the values of the PSP Switch and APP Sensor 1 when it is occurring. ^ If the PSP Switch is HIGH, and you are not turning, go to REPAIR PROCEDURE POWER STEERING SWITCH. ^ If the APP Sensor 1 is greater than 15% and APP Sensor 2 and/or APP Sensor 3 are less than 85%, and the accelerator pedal is not depressed, go to REPAIR PROCEDURE APPS GROUND. ^ If the PSP Switch is reading LOW when not turning and HIGH when turning, and the APP Sensors are reading within the range shown, discontinue the test-drive and go to step 6. 6. Do these repairs: ^ REPAIR PROCEDURE APPS GROUND ^ REPAIR PROCEDURE ENGINE/BODY GROUND REPAIR PROCEDURE - FUEL PRESSURE REGULATOR 1. Relieve fuel system pressure: ^ Remove the fuel fill cap. ^ Remove the fuel pump relay. ^ Start the engine and run it until it stalls. ^ Crank the engine for 3 seconds. 2. Remove the vacuum hose from the fuel pressure regulator. 3. Remove the fuel pressure regulator shield from the common chamber (two bolts). Locations Behind Glove Box Page 7388 Wire Color Abbreviations The following abbreviations are used to identify wire colors in the circuit schematics: WHT................................... White YEL................................... Yellow BLK................................... Black BLU................................... Blue GRN................................... Green RED................................... Red ORN................................... Orange PNK................................... Pink BRN................................... Brown GRY................................... Gray PUR................................... Purple LT BLU................................... Light Blue LT GRN................................... Light Green Locations Page 5455 Suspension Control Module: Service and Repair Page 5948 Air Duct: Service and Repair Rear Heater Duct, Defroster Nozzle and Ventilation Duct Removal 1. Disconnect the battery ground cable. 2. Remove instrument panel assembly. 3. Remove center ventilation duct and side defroster duct. - Remove 5 screws. 4. Remove instrument panel brackets. 5. Remove cross beam assembly. 6. Remove ventilation lower duct. 7. Remove rear heater duct. - Remove foot rest carpet and 3 clips. 8. Remove defroster nozzle. Installation To install, follow the removal steps in the reverse order, noting the following point: 1. Connect each duct and nozzle securely leaving no clearance between them and making no improper matching. Page 4878 6. Remove guide bolt (2). 7. Remove caliper assembly. 8. Remove support bracket with pad assembly and take care not to damage the flexible brake hose when removing the support bracket. 9. Remove pad assembly with shim and mark the lining locations if they are to be reinstalled. 10. Remove clip. INSTALLATION 1. Install clip (4). 2. Apply special grease (approximately 0.2 g) to both contacting surfaces of the inner shims (5). Wipe off extruded grease after installing. Install pad assembly with shim. Page 547 Distinct Of Circuit By Wire Base Color All wires have color-coded insulation. Wires belonging to a system's main harness will have a single color. Wires belonging to a system's sub-circuits will have a colored stripe. Striped wires use the codes found in the chart to show wire size and colors. Abbreviations are used to indicate wire color within a circuit diagram. How to Identify Connector Terminals How to Identify Connector Terminals Cavity Numbering System The cavities (and wire terminals) in each connector are numbered starting from the upper left, looking at the male terminals from the terminal side (or looking at the female terminals from the wire side. Both views are in the same direction so the numbers are the same.) All actual cavities are numbered, even if they have no wire terminals in them. NOTE: Data Link Connector (DLC) terminals are numbered according to SAE standard J1962, not the Honda standard. The numbers of the four end terminals are molded into the corners of the connector face. The connector cavity number is listed next to each terminal on the circuit schematic. The cavity / terminal shown is # 6. Using/Identifying Connector Terminal Views How to Use Connector Terminal Views To see the configuration of a connector's cavities, look up its view number in the Connector Views. Each view includes the color of the connector, where Page 1692 ^ If the idle speed ever exceeds 1,300 rpm 2. Remove the vacuum hose from the fuel pressure regulator, then start the engine. ^ If fuel comes out of the fuel pressure regulator vacuum hose connection, go to REPAIR PROCEDURE FUEL PRESSURE REGULATOR. ^ If no fuel comes out of the regulator, reconnect the vacuum hose and continue to step 3. 3. Connect the PGM Tester. Set it to Engine Data List. 4. Have an assistant drive the vehicle under the conditions described by the customer. 5. If the high or erratic idle condition occurs, note the values of the PSP Switch and APP Sensor 1 when it is occurring. ^ If the PSP Switch is HIGH, and you are not turning, go to REPAIR PROCEDURE POWER STEERING SWITCH. ^ If the APP Sensor 1 is greater than 15% and APP Sensor 2 and/or APP Sensor 3 are less than 85%, and the accelerator pedal is not depressed, go to REPAIR PROCEDURE APPS GROUND. ^ If the PSP Switch is reading LOW when not turning and HIGH when turning, and the APP Sensors are reading within the range shown, discontinue the test-drive and go to step 6. 6. Do these repairs: ^ REPAIR PROCEDURE APPS GROUND ^ REPAIR PROCEDURE ENGINE/BODY GROUND REPAIR PROCEDURE - FUEL PRESSURE REGULATOR 1. Relieve fuel system pressure: ^ Remove the fuel fill cap. ^ Remove the fuel pump relay. ^ Start the engine and run it until it stalls. ^ Crank the engine for 3 seconds. 2. Remove the vacuum hose from the fuel pressure regulator. 3. Remove the fuel pressure regulator shield from the common chamber (two bolts). Page 5262 4. Remove the fuel pressure regulator from the fuel rail. 5. Remove the fuel return line from the regulator. 6. Install the new fuel pressure regulator in the reverse order of removal. 7. Use the Smart Cable to reprogram the PCM with the latest software from the June 2001 or later HONDANET CD-ROM. Refer to Service Bulletin 99-005, Updating the Passport PCM, filed under Tools. 8. Use the PGM Tester to clear any DTCs. 9. Use the PGM Tester to check the broadcast code. Make sure the broadcast code matches the one you selected from the CD-ROM. WARRANTY CLAIM INFORMATION In warranty: The normal warranty applies. Failed Part: P/N 8-17113-398-0 H/C 5504386 Defect Code: 092 Contention Code: C99 Skill Level: Repair Technician Out of warranty: Any repair performed after warranty expiration may be eligible for goodwill consideration by the District Service Manager or your Zone Office. You must request consideration, and get a decision, before starting work. REPAIR PROCEDURE - POWER STEERING SWITCH 1. Drain the power steering fluid out of the system. 2. Remove the power steering fluid reservoir. Clean the reservoir with solvent, then with soap and water. Rinse and dry it thoroughly. 3. Reinstall the reservoir. Do not connect the return hose. 4. Remove the power steering pressure switch, then clean it with brake cleaner and a scraper. Reinstall the switch, and torque it to 20 N.m (14 lb-ft). 5. Cover the unconnected end of the reservoir with your finger, then fill the reservoir with Dexron III ATF Page 1982 Powertrain Control Module: Description and Operation PCM Components PCM Components The PCM is designed to maintain exhaust emission levels to government mandated standards while providing excellent driveability and fuel efficiency. The PCM monitors numerous engine and vehicle functions via electronic sensors such as the throttle position (TP) sensor, heated oxygen sensor (HO2S), and vehicle speed sensor (VSS). The PCM also controls certain engine operations through the following: - Fuel injector control - Ignition control module - ION sensing module - Automatic transmission shift functions - Cruise control - Evaporative emission (EVAP) purge - A/C clutch control Page 7441 Wires Wire insulation can be one color, or one color with another color stripe. (The second color is the stripe.) This circuit continues on another image. (The arrow shows direction of current flow.) To follow the RED/BLK wire in this example, you would turn to "Fuel and Emissions" and look for the "A" arrow. Page 676 Oxygen Sensor: Description and Operation Catalyst Monitor Heated Oxygen Sensors Catalyst Monitor Heated Oxygen Sensors Three-way catalytic converters are used to control emissions of hydrocarbons (HC), carbon monoxide (CO), and oxides of nitrogen (NOx). The catalyst within the converters promotes a chemical reaction. This reaction oxidizes the HC and CO present in the exhaust gas and converts them into harmless water vapor and carbon dioxide. The catalyst also reduces NOx by converting it to nitrogen. The PCM can monitor this process using the Bank 1 HO2S 2 and the Bank 2 HO2S 2 heated oxygen sensors. The Bank 1 HO2S 1 and the Bank 2 HO2S 1 sensors produce an output signal which indicates the Technician Safety Information Air Bag Control Module: Technician Safety Information Service Precautions WARNING: DURING SERVICE PROCEDURES, BE VERY CAREFUL WHEN HANDLING SDM. NEVER STRIKE OR JAR SDM. UNDER SOME CIRCUMSTANCES, IT COULD CAUSE DEPLOYMENT AND RESULT IN PERSONAL INJURY OR IMPROPER OPERATION OF THE SUPPLEMENTAL RESTRAINT SYSTEM (SRS). SDM MOUNTING BRACKET BOLTS MUST BE CAREFULLY TORQUED TO ASSURE PROPER OPERATION. THE SRS SHOULD ONLY BE CONNECTED TO A POWER SOURCE WHEN IT IS INSTALLED SECURELY IN THE VEHICLE. THE SDM MAY SUDDENLY DEPLOY THE AIRBAGS CAUSING PERSONAL INJURY WARNING: PROPER OPERATION OF THE SENSING AND DIAGNOSTIC MODULE (SDM) REQUIRES THE SDM TO BE SECURELY INSTALLED ON THE VEHICLE AND THE ARROW ON THE SENSOR MUST BE POINTING TOWARD THE FRONT OF THE VEHICLE. SDM is specifically calibrated and is keyed to the SDM location SRS wiring harness. Caution should be used to ensure proper location of the SDM. The keying of the SDM to its location and wiring harness connectors should never be modified in the field. Be careful not to bump or impact the SRS unit or the side impact sensors whenever the ignition switch is ON (II), or at least for three minutes after the ignition switch is turned OFF. During installation or replacement, be careful not to bump (by impact wrench, hammer, etc.) the area around the SRS unit and the side impact sensor. The airbags could accidentally deploy and cause damage or injury. After a collision in which the airbags were deployed, replace the SRS unit. After a collision in which the side airbag was deployed, replace the side impact sensor on the side where the side airbag deployed and the SRS unit. After a collision in which the airbags or the side airbags did not deploy, inspect for any damage or any deformation on the SRS unit and the side impact sensors. If there is any damage, replace the SRS unit and/or the side impact sensors. Do not disassemble the SRS unit or the side impact sensors. Turn the ignition switch OFF, disconnect the battery negative cable and wait at least three minutes before beginning installation or replacement of the SRS unit, and disconnect the connectors from the SRS unit. Be sure the SRS unit and side impact sensors are installed securely with the mounting bolts torqued to 9.8 Nm (1.0 kg.m, 7.2 lb.ft) Do not spill water or oil on the SRS unit or the side impact sensors and keep them away from dust. Store the SRS unit and the side impact sensors in a cool (less than 104°F / 40°C) and dry (less than 80% relative humidity, no moisture) area. Page 5719 3. Connect the connector (10) to the harness and insert the connector (10) to the gusset. 4. Install the rear shock absorber. 5. Connect the connector (1) to the harness and insert the connector (1) to the bracket. 6. Insert the clip to the bracket. 7. Connect the battery ground cable. Without Intelligent Suspension System REMOVAL 1. Remove shock absorber fixing nut, bush and washer (upper side). 2. Remove shock absorber fixing nut and washer (lower side). 3. Remove shock absorber. INSPECTION AND REPAIR Make necessary correction or parts replacement if wear, damage, corrosion or any other abnormal condition are found through inspection. Check the following parts: Shock absorber - Rubber bushing NOTE: When mounting rubber bushings, be sure not to use grease on bushings or any other nearby part. INSTALLATION 1. Install shock absorber. When mounting shock absorber, be sure not to use grease on bushings or any other nearby part. 2. Install nut and washer (lower side), then tighten the nut lightly. Retighten to the bolt and nut specified torque after the vehicle is at curb height. Torque to 78 Nm (58 ft. lbs.). 3. Install nut, bush and washer (upper side), then tighten the nut lightly. Retighten to the nut specified torque after the vehicle is at curb height. Torque to 20 Nm (14 ft. lbs.). Page 4119 Clutch Disc: Service and Repair For further information regarding this component and the system that it is a part of, please refer to Clutch; Service and Repair; Unit Overhaul Page 705 10. Use the PGM Tester to check the broadcast code. Make sure the broadcast code matches the one you selected from the CD-ROM. WARRANTY CLAIM INFORMATION In warranty: The normal warranty applies. Failed Part: P/N 8-17087-655-0 H/C 4375820 Defect Code: 064 Contention Code: C01 Skill Level: Repair Technician Out of warranty: Any repair performed after warranty expiration may be eligible for goodwill consideration by the District Service Manager or your Zone Office. You must request consideration, and get a decision, before starting work. REPAIR PROCEDURE - ENGINE/BODY GROUND 1. Use the ETM for the appropriate year to locate these ground connectors: G101, G104, G105, G106 and G160. 2. Inspect each connector for corrosion or looseness. 3. Remove the bolt from any connector that is corroded or loose. Clean the terminal connector with a wire brush. File flat any solder bumps on the connector. 4. Clean the contact surface on the engine or body with a wire brush. 5. Replace the bolt if it is heavily corroded. Otherwise, clean it with a wire brush. 6. Apply lithium dielectric grease to both sides of the terminal connector. 7. Reinstall the bolt, torque it to 14 N.m (10 lb-ft). 8. Use the Smart Cable to reprogram the PCM with the latest software from the June 2001 or later HONDANET CD-ROM. Refer to Service Bulletin 99-005, Updating the Passport PCM, filed under Tools. 9. Use the PGM Tester to clear any DTCs. 10. Use the PGM Tester to check the broadcast code. Make sure the broadcast code matches the one you selected from the CD-ROM. WARRANTY CLAIM INFORMATION In warranty: The normal warranty applies. Failed Part: P/N 8-97086-823-0 Page 3018 Ground - "G" Shielding Sheilding This represents RFI (Radio Frequency Interference) shielding around a wire. The shielding is always connected to ground. Splices Page 4732 Part 2 Of 3 Accelerator Pedal Position Sensor - MIL ON/DTC's Set Technical Service Bulletin # 01-047 Date: 010814 Accelerator Pedal Position Sensor - MIL ON/DTC's Set 01-047 August 14, 2001 Applies To: 2000-01 Passport - ALL MIL Comes On With Accelerator Pedal Position Sensor DTC(s) P1271, P1273, P1275, P1280, and/or P1285 SYMPTOM The MIL is on with DTC P1271, P1273, P1275, P1280, or P1285 (various accelerator pedal position sensor problems) stored. The REDUCED POWER indicator may also be on; and the engine may occasionally idle too high, or the idle may fluctuate. PROBABLE CAUSE Contaminated grease on the potentiometer circuit board of the accelerator pedal position sensor (APPS) causes high resistance in the APPS circuit. CORRECTIVE ACTION Replace and adjust the APPS, remove all grease from the accelerator link, and clean the APPS harness connector and connector C123. PARTS INFORMATION Accelerator Pedal Position Sensor: P/N 8-97193-713-0, H/C 6198311 REQUIRED MATERIALS CAIG DeoxIT D5-S6 Contact Cleaner: P/N 341-200 (available from www.partsexpress.com) or Permatex Electrical Contact Cleaner: Permatex P/N 24379 WARRANTY CLAIM INFORMATION In warranty: The normal warranty applies. Operation Number: 122114 Flat Rate Time: 0.5 hour Failed Part: P/N 8-97220-540-0 H/C 6202436 Defect Code: 091 Contention Code: C99 Template ID: 01-047A Skill Level: Repair Technician Out of warranty: Any repair performed after warranty expiration may be eligible for goodwill consideration by the District Service Manager or your Zone Office. You must request consideration, and get a decision, before starting work. Page 7089 and the fuses. From Fuses to Relays and Components The second half of Power Distribution shows the wiring "From Fuses to Relays and Components." This can speed your troubleshooting by showing which circuits share fuses. If Power Distribution shows that an inoperative circuit and another circuit share a fuse, check a component in the other circuit. If it works, you know the fuse is good and power is available to the inoperative circuit. Ground Distribution Schematics Page 843 Crankshaft Position Sensor: Description and Operation Crankshaft Position (CKP) Sensor The crankshaft position (CKP) sensor provides a signal used by the powertrain control module (PCM) to calculate the ignition sequence. The CKP sensor initiates the 58X reference pulses which the PCM uses to calculate RPM and crankshaft position. Page 4490 Testing For A Short With A Self-Powered Test Light or DVOM 1. Remove the blown fuse and disconnect the battery and load. 2. Connect one lead of a self-powered test light or digital volt/ohmmeter (DVOM) (switched to the lowest "OHMS" range) to the fuse terminal on the load side. 3. Connect the other lead to a known good ground. 4. Beginning near the fuse box, wiggle the harness. Continue this at convenient points about six inches apart while watching the test light or DVOM. 5. If the self-powered test light goes on or the DVOM displays a low reading or no reading (zero), there is a short to ground in the wiring near that point. Testing for a Short with a Test Light or DVOM 1. Remove the blown fuse and disconnect the load. 2. Connect a test light or digital volt/ohmmeter (DVOM), switched to the appropriate DC volts range, across the fuse terminals to make sure voltage is present. You might have to turn the ignition switch to ON; check the schematic to see. 3. Beginning near the fuse box, wiggle the harness. Continue this at convenient points about six inches apart while watching the test light or DVOM. 4. Where the test light goes , or the DVOM voltage drops to zero, there is a short to ground in the wiring near that point. NOTE: Always use a DVOM on high impedance circuits. A test light may not glow (even with battery voltage present). Testing For A Short With A Short Circuit Locator (Short Finder) 1. Remove the blown fuse. Leave the battery connected. Page 4037 ^ If you cannot turn the switch to LOCK and the cable slider is clear of the white plastic interlock pin, troubleshoot the lock cylinder assembly. 13. Move the cable slider so it clears the interlock pin, then turn the ignition switch to LOCK. 14. Pry out the shift lock cable adjuster clip, then snap it back into place. Make sure the raised "T" on the side of the clip faces up. 15. Turn the ignition switch to ACC. Push the cable slider toward the cable until it stops. Turn the ignition switch to LOCK. ^ If you can turn the switch to LOCK, the shift lock cable is properly adjusted. Press firmly on the shift lever pushbutton, and pull down on the shift lever to make sure the lever is locked in P. Go to step 18. ^ If you cannot turn the switch to LOCK or it still feels notchy when you turn it, more adjusting is needed. Go to step 16. Page 4640 5. Install magnet, main case oil pan with new gasket, and sixteen 10 mm screws. Tighten the screws to the specified torque. Torque: 11 Nm (96 Inch lbs.) 6. Fill transmission through the overfill screw hole of oil pan, using ATF DEXRON-III. 7. Connect battery ground cable. Page 7872 Distinct Of Circuit By Wire Base Color All wires have color-coded insulation. Wires belonging to a system's main harness will have a single color. Wires belonging to a system's sub-circuits will have a colored stripe. Striped wires use the codes found in the chart to show wire size and colors. Abbreviations are used to indicate wire color within a circuit diagram. How to Identify Connector Terminals How to Identify Connector Terminals Cavity Numbering System The cavities (and wire terminals) in each connector are numbered starting from the upper left, looking at the male terminals from the terminal side (or looking at the female terminals from the wire side. Both views are in the same direction so the numbers are the same.) All actual cavities are numbered, even if they have no wire terminals in them. NOTE: Data Link Connector (DLC) terminals are numbered according to SAE standard J1962, not the Honda standard. The numbers of the four end terminals are molded into the corners of the connector face. The connector cavity number is listed next to each terminal on the circuit schematic. The cavity / terminal shown is # 6. Using/Identifying Connector Terminal Views How to Use Connector Terminal Views To see the configuration of a connector's cavities, look up its view number in the Connector Views. Each view includes the color of the connector, where Diagrams Transmission Mode Switch: Diagrams Page 558 Terminals - "T" Each "T" terminal (ring type) is numbered for reference and location. A "T" terminal is secured with a screw or bolt. Wires Technician Safety Information Brake Fluid: Technician Safety Information SAFETY PRECAUTIONS WARNING: Brake fluid may be irritating to the skin or eyes. In case of contact, take the following actions: * Eye Contact - rinse eyes thoroughly with water. * Skin Contact - wash skin with soap and water. Page 8143 To install, follow the removal steps in the reverse order. Rear-Left and Right Sides Removal 1. Disconnect the battery ground cable. 2. Remove the rear door trim pad (2). - Disconnect the rear power window switch (1) connector. 3. Remove the rear power window switch (1). - Remove the switch fixing screw from the back side of the rear door trim (2). Installation To install, follow the removal steps in the reverse order. Page 1355 ^ Reversible drill motor (800 RPM MAX) ^ Tire spreader ^ Inspection lamp * For repairable injuries that exceed 25 degrees TIRE REPAIR GUIDELINES Never repair tires worn below 2/32 inch of tread. Never repair a tire without removing the tire from the wheel for internal inspection. Never repair a tire with a tread injury larger than 1/4 inch (6 mm). Never use only a plug (stem) or a patch only to repair a tire injury. NOTE: If the angle of the tire injury exceeds 25 degrees, you must use the two-piece repair system as recommended by the RMA. MICHELIN PAX SYSTEM SUPPORT RING INSPECTION PAX System support rings are not repairable, under any circumstances, but they can be reused if no damage is found during a thorough inspection. If a PAX System tire ran flat or underinflated, dismount the tire from the wheel and inspect the wheel, tire, and support ring for damage. Refer to the Michelin PAX Support Rings Technical Bulletin in ISIS. Enter SEARCH BY PUBLICATION, select Job Aids, then select Michelin PAX Support Rings Technical Bulletin from the list. Disclaimer Specifications Firing Order: Specifications Firing Order Firing Order Firing Order 1-2-3-4-5-6 Page 7327 - Remove the fixing screws from back side of the rear door trim panel. 8. Remove the bracket. 9. Disconnect the speaker harness connector. 10. Remove the speaker with the speaker harness connector from the door inner panel. 11. Remove the waterproof sheet (1). - Taking notice of the door harness, peel the waterproof sheet off the door panel carefully. 12. Remove the speaker bracket. - Remove the six fixing screws. 13. Remove the fixing glass. - Remove one bolt and screw as shown in the figure, then pull it upward. Page 557 Splices Splices are shown as a dot. Their location and the number of wires may vary depending on the harness manufacturer. Switches Switches These switches move together; the broken straight line between them means they are mechanically connected. Other types of switches are controlled by a coil or a solid state circuit. Unless otherwise noted, all switches are shown in their normal (rest) position, with power off. Terminal "T" Page 7123 Passport Paint Supplier Phone Number Dupont Color/Technical Hotline: 800-3 DUPONT PPG Color Library: 440-572-6100 Technical Service: 440-572-6111 BASF Call Center: 800-825-3000 Sherwin Williams Customer Assistance: 800-798-5872 Martin Senour Customer Assistance: 800-526-6704 Sikkens Color Helpline: 800-618-1010 Spies-Hecker Color Questions: 800-447-7437 Other Questions: 516-777-7100 Standox North America Toll-free Color Questions:800-551-9296 Other Questions: 734-454-4556 ICI Autocolor 800-647-6050 American Honda does not make any special endorsements to any paint company or type of paint; this information is provided for reference only. Disclaimer Page 1524 2. Remove cylinder head gasket (2). 3. Remove crankcase with oil pan (3). 4. Remove oil pipe and O-ring (4). 5. Remove oil strainer and O-ring (5). 6. Remove oil gallery (6). 7. Remove connecting rod cap with connecting rod lower bearing (12). 8. Remove piston and connecting rod assembly (7). Note: Before removing piston and connecting rod assembly, measure thrust clearance. - Remove any ridge or carbon build up from the top end of the cylinder. 9. Remove the piston rings (8) with a piston ring expander. Arrange the removed piston rings in the cylinder number order. Page 6223 9. Pull out the door lever while raising up the catch of the door lever. 10. Remove clip. Installation To install, follow the remove steps in the reverse order, noting the following points: 1. Apply grease to the mode sub-lever and to the abrasive surface of the heater unit. 2. After installing the link unit, check to see if the link unit operates correctly. Adjustments Valve Clearance: Adjustments THIS ARTICLE HAS BEEN UPDATED BY TSB 02-047 NOTE: - Valve adjustment can be done either on-vehicle or off-vehicle. - To measure exhaust valves, you need a 0.25 mm and a 0.35 mm feeler gauge. - To measure intake valves, you need a 0.23 mm and a 0.33 mm feeler gauge. Since these are odd sizes, you may need to stack two gauges (for example, 0.11 mm and 0.12 mm to make 0.23 mm). If you do this, make sure the gauges are clean and in good condition. If you're not sure the gauge stack is correct, measure it with a micrometer. On-Vehicle Valve Adjustment 1. Make a copy of the Valve Inspection Chart. 2. Make a copy of the Valve Shim Replacement Chart, then tape the pages together, side-by-side. 3. Remove the cylinder head covers. 4. Measure the valve clearances using the Go/No-Go method (see the note below). The clearances must be - Intake valves: 0.25 mm +/- 0.05 mm - Exhaust valves: 0.30 mm +/- 0.05 mm NOTE: - To measure with the Go/No-Go method, use two feeler gauges, one to measure the smallest allowable clearance, and the other to measure the largest. - If the small gauge fits and the large gauge doesn't, the valve adjustment is OK. - If the small gauge doesn't fit, or if the large gauge slides easily, the valve needs adjustment. - The feeler gauges slide through the clearance gap at a slight angle, making the drag a little more than it would be on other engines. 5. For valves with the correct clearance, draw an "X" in the appropriate circle on the Valve Inspection Chart. For valves with incorrect clearances, write down the clearance you measured in the circle. 6. If you need to replace a valve shim, turn the crankshaft (or camshaft) until the cam lobe for the valve points away from the valve. Page 7479 Each schematic represents one circuit. A circuit's wires and components are arranged to show current flow, from power at the top of the page, to ground, at the bottom. Shared Circuits Other circuits may share power or ground terminals or wiring with the circuit shown. A wire that connects one circuit to another, for example, is cut short and has an arrowhead at the end of it pointing in the direction of current flow. Next to the arrowhead is the name of the circuit or component which shares that wiring. To quickly check shared wiring, check the operation of a component it serves. If that component works, you know the shared wiring is OK. Connectors All in-line and junction connectors are numbered (C725, C416, etc.). Component connectors are not numbered but are identified either by the name of Locations Fuel Pump Relay: Locations Fuse/Relay Box (Cover Removed) Page 152 Powertrain Control Module: Service and Repair Reprogramming the PCM Electrically Erasable Programmable Read Only Memory (EEPROM) The electrically erasable programmable read only memory (EEPROM) is a permanent memory chip that is physically soldered within the PCM. The EEPROM contains the program and the calibration information that the PCM needs to control powertrain operation. Unlike the PROM used in past applications, the EEPROM is not replaceable. If the PCM is replaced, the new PCM will need to be programmed. Equipment containing the correct program and calibration for the vehicle is required to program the PCM. EEPROM Programming 1. Set-up - Ensure that the following conditions have been met: - The battery is fully charged. - The ignition is "ON." - The Vehicle Interface Module cable connection at the DLC is secure. 2. Program the PCM using the latest software matching the vehicle. Refer to up-to-date Techline equipment user's instructions. 3. If the PCM fails to program, proceed as follows: - Ensure that all PCM connections are OK. - Check the Techline equipment for the latest software version. - Attempt to program the PCM. If the PCM still cannot be programmed properly, replace the PCM. The replacement PCM must be programmed. Functional Check 1. Perform the On-Board Diagnostic System Check. 2. Start the engine and run for least one minute. 3. Check for DTCs using Scan Tool. 4. If the PCM fails to program, proceed as follow: - Ensure that all PCM connections are OK. - Check the ITCS for latest version software. - Attempt to program PCM again. If PCM still cannot be programmed properly, replace PCM. The replacement PCM must be programmed. Page 1043 TOE-IN: This illustration shows view from the top of the vehicle. Toe-in is the measured amount the front wheels are turn in. The actual amount of toe-in is normally a fraction of a degree. Toe-in is measured from the center of the tire treads or from the inside of the tires. The purpose of toe-in is to insure parallel rolling of the front wheels and to offset any small deflections of the wheel support system which occurs when the vehicle is rolling forward. Incorrect toe-in results in excessive toe-in and unstable steering. Toe-in is the last alignment to be set in the front end alignment procedure. Page 5515 Power Steering Pump: Description and Operation GENERAL DESCRIPTION The hydraulic pump is vane-type design. The submerged pump has housing and internal parts that are inside the reservoir and operate submerged in oil. There are two bore openings at the rear of the pump housing. The larger opening contains the cam ring, pressure plate, thrust plate, rotor and vane assembly, and end plate. The smaller opening contains the pressure line union, flow control valve and spring. The flow control orifice is part of the pressure line union. The pressure relief valve inside the flow control valve limits the Pump Pressure. Page 3214 This means the branch of the wire connects to another circuit. The arrow points to the name of the circuit branch where the wire continues. Page 5092 7. When installing the steering column cover, be sure to wire (through each harness) as illustrated so that the harnesses starter switch, combination switch and SRS coil may not catch wiring. 8. Install steering wheel by aligning the setting marks made during removal. CAUTION: Never apply force to the steering wheel in direction of the shaft by using a hammer or other impact tools in an attempt to remove the steering wheel. The steering shaft is designed as an energy absorbing unit. 9. Tighten the steering wheel fixing nut to the specified torque. Torque: 34 Nm (25 ft. lbs.) 10. Support inflator module and carefully connect the SRS connector and horn lead, then install inflator module. NOTE: Pass the lead wire through the tabs on the plastic cover (wire protector) of inflator to prevent lead wire from being pinched. 11. Tighten fixing bolts to specified torque. Torque: 9 Nm (78 inch lbs.) 12. Install driver knee bolster (reinforcement). 13. Install instrument panel lower cover, then install the engine hood opening lever. 14. Connect the yellow 2-way SRS connector located under the steering column. 15. Connect the battery "-" terminal cable. Engine Controls - High/Erratic Engine Idle Power Steering Pressure Switch: Customer Interest Engine Controls - High/Erratic Engine Idle 01-080 August 14, 2001 Applies To: 2000-02 Passport - ALL 2000-02 Passport: High or Erratic Idle SYMPTOM The engine occasionally idles at too high a speed, or the idle speed fluctuates. PROBABLE CAUSES The symptom could be the result of any of these conditions: ^ Loose or corroded engine or body ground ^ High resistance in the APPS ground circuit ^ PSP (power steering pressure) switch is internally shorted to ground ^ Fuel pressure regulator is leaking fuel into the intake manifold CORRECTIVE ACTION Diagnose the cause of the idle condition, and select the proper REPAIR PROCEDURE. PARTS INFORMATION REQUIRED MATERIALS REQUIRED SOFTWARE Each REPAIR PROCEDURE requires you to use the Smart Cable to reprogram the PCM with the latest software. To select the latest software from the CDROM, enter the year, model, engine, transmission, and emissions type (49-state or California). This gives you a list of broadcast codes. Select the broadcast code at the top of the list. WARRANTY CLAIM INFORMATION Refer to the Warranty Claim Information for each Repair Procedure. DIAGNOSIS 1. Find out from the customer when the high or erratic idle condition occurs and what the RPM range is: ^ Within 20 minutes of a cold start ^ After braking to a stop ^ All the time ^ Intermittently, with no set pattern Locations Air Flow Meter/Sensor: Locations 28. Left Side of Engine Compartment Left Side Of Engine Compartment Page 2147 Intake Air Temperature Sensor: Service and Repair INTAKE AIR TEMPERATURE (IAT) SENSOR REMOVAL PROCEDURE 1. Disconnect the negative battery cable. 2. Remove the engine cover 3. The IAT sensor is located in the intake air duct, behind the throttle body. 4. Disconnect the electrical connector from the IAT sensor. 5. Remove the IAT sensor from the intake air duct by using a rocking motion while pulling the sensor. INSTALLATION PROCEDURE 1. Install the IAT sensor into the grommet in the intake air duct. 2. Correct the IAT electrical connector. 3. Install the engine cover. 4. Connect the negative battery cable. Page 5930 Testing For A Short With A Self-Powered Test Light or DVOM 1. Remove the blown fuse and disconnect the battery and load. 2. Connect one lead of a self-powered test light or digital volt/ohmmeter (DVOM) (switched to the lowest "OHMS" range) to the fuse terminal on the load side. 3. Connect the other lead to a known good ground. 4. Beginning near the fuse box, wiggle the harness. Continue this at convenient points about six inches apart while watching the test light or DVOM. 5. If the self-powered test light goes on or the DVOM displays a low reading or no reading (zero), there is a short to ground in the wiring near that point. Testing for a Short with a Test Light or DVOM 1. Remove the blown fuse and disconnect the load. 2. Connect a test light or digital volt/ohmmeter (DVOM), switched to the appropriate DC volts range, across the fuse terminals to make sure voltage is present. You might have to turn the ignition switch to ON; check the schematic to see. 3. Beginning near the fuse box, wiggle the harness. Continue this at convenient points about six inches apart while watching the test light or DVOM. 4. Where the test light goes , or the DVOM voltage drops to zero, there is a short to ground in the wiring near that point. NOTE: Always use a DVOM on high impedance circuits. A test light may not glow (even with battery voltage present). Testing For A Short With A Short Circuit Locator (Short Finder) 1. Remove the blown fuse. Leave the battery connected. Page 3101 Positive Crankcase Ventilation Valve: Service and Repair REMOVAL PROCEDURE 1. Remove the vacuum hose at the PCV valve. 2. Slide the clamp back to release the hose. 3. Pull the PCV valve from the rubber grommet in the right valve cover. INSTALLATION PROCEDURE 1. Push the PCV valve into the rubber grommet in the left valve cover. 2. Install the vacuum hose on the PCV valve and secure the vacuum hose with the clamp. Page 5121 Alternator: Testing and Inspection Bench Test Conduct a bench test of the generator. Preparation Remove generator from the vehicle. 1. Secure generator to the bench test equipment and connect wires. Terminal "IG" for energization Terminal "L" for neutral (warning lamp) Terminal "B" for output 2. Conduct the generator characteristic test. Characteristics of generator are shown in illustration. Repair or replace the generator if its outputs are abnormal. Description and Operation Electric Load Sensor: Description and Operation Electrical Load Detector (ELD) Since the early ’90s, Honda vehicles have come with an electrical load detector (ELD) unit in the under-hood fuse/relay box. This unit allows the ECM/PCM to regulate the alternator (switch it between high output and low output) to provide the best combination of fuel economy and electrical system operation. The ELD sends a signal to the ECM/PCM that is proportional to the electrical demand. The ECM/PCM switches the alternator between high output and low output depending on several factors, which include electrical demand, battery charge level, and the driving cycle. When the alternator is in low output, the engine load is reduced and fuel economy improves. Page 2004 If there is no photo number below or beside a component name or a connector, ground, or terminal number, look up that name or number in the appropriate Connector Identification Chart. The chart lists how many cavities a connector has, where it's located, and what it connects to. The related illustration shows the connector's location on the harness, and the harness routing. NOTE: Photos listed by number are located at Locations / Components / Photograohs. See: Locations/Component Locations/Photographs Circuit Schematics Page 4217 The connector cavity number is listed next to each terminal on the circuit schematic. The cavity / terminal shown is # 6. Diodes A rectifier diode works like a one way valve. It allows current to flow only in the direction of the arrow. A Zener diode blocks reverse current at normal voltages just like a rectifier diode. At high voltages, however, a Zener diode allows current to flow in reverse. Fuses Page 8133 Rear Door Window Motor: Service and Repair Removal 1. Disconnect the battery ground cable. 2. Remove the rear window regulator assembly (2). 3. Remove the power window motor (1). - Remove three screws. Installation To install, follow the removal steps in the reverse order. Page 4718 Ground - "G" Shielding Sheilding This represents RFI (Radio Frequency Interference) shielding around a wire. The shielding is always connected to ground. Splices Page 2510 The connector cavity number is listed next to each terminal on the circuit schematic. The cavity / terminal shown is # 6. Diodes A rectifier diode works like a one way valve. It allows current to flow only in the direction of the arrow. A Zener diode blocks reverse current at normal voltages just like a rectifier diode. At high voltages, however, a Zener diode allows current to flow in reverse. Fuses Page 7095 Terminals - "T" Each "T" terminal (ring type) is numbered for reference and location. A "T" terminal is secured with a screw or bolt. Wires Page 1830 Page 219 Page 2769 and the fuses. From Fuses to Relays and Components The second half of Power Distribution shows the wiring "From Fuses to Relays and Components." This can speed your troubleshooting by showing which circuits share fuses. If Power Distribution shows that an inoperative circuit and another circuit share a fuse, check a component in the other circuit. If it works, you know the fuse is good and power is available to the inoperative circuit. Ground Distribution Schematics Page 7908 Ground - "G" Shielding Sheilding This represents RFI (Radio Frequency Interference) shielding around a wire. The shielding is always connected to ground. Splices Front Tires - Rub On Mud Flap On Sharp Turns Mud Flap: All Technical Service Bulletins Front Tires - Rub On Mud Flap On Sharp Turns 01-088 September 11, 2001 Applies To: 1998-01 Passport - ALL Front Tire Rubs Against the Mud Flap PROBLEM The front tire rubs against the mud flap when the wheel is turned to full lock. CORRECTIVE ACTION Trim away part of the mud flap. WARRANTY CLAIM INFORMATION In warranty: The normal warranty applies. Operation Number: 031005 Flat Rate Time: 0.3 hour Failed Part: P/N 8-97261-990-0 H/C 6633416 Defect Code: 042 Contention Code: B07 Template ID: 01-088A Skill Level: Repair Technician Out of warranty: Any repair performed after warranty expiration may be eligible for goodwill consideration by the District Service Manager or your Zone Office. You must request consideration, and get a decision, before starting work. REPAIR PROCEDURE 1. Remove the mud flaps from the front fenders (four screws each). 2. Wipe off the mud flaps. Page 305 Testing For A Short With A Self-Powered Test Light or DVOM 1. Remove the blown fuse and disconnect the battery and load. 2. Connect one lead of a self-powered test light or digital volt/ohmmeter (DVOM) (switched to the lowest "OHMS" range) to the fuse terminal on the load side. 3. Connect the other lead to a known good ground. 4. Beginning near the fuse box, wiggle the harness. Continue this at convenient points about six inches apart while watching the test light or DVOM. 5. If the self-powered test light goes on or the DVOM displays a low reading or no reading (zero), there is a short to ground in the wiring near that point. Testing for a Short with a Test Light or DVOM 1. Remove the blown fuse and disconnect the load. 2. Connect a test light or digital volt/ohmmeter (DVOM), switched to the appropriate DC volts range, across the fuse terminals to make sure voltage is present. You might have to turn the ignition switch to ON; check the schematic to see. 3. Beginning near the fuse box, wiggle the harness. Continue this at convenient points about six inches apart while watching the test light or DVOM. 4. Where the test light goes , or the DVOM voltage drops to zero, there is a short to ground in the wiring near that point. NOTE: Always use a DVOM on high impedance circuits. A test light may not glow (even with battery voltage present). Testing For A Short With A Short Circuit Locator (Short Finder) 1. Remove the blown fuse. Leave the battery connected. Page 6119 This means the branch of the wire connects to another circuit. The arrow points to the name of the circuit branch where the wire continues. Page 199 it is located, and what it connects to. Use the Connector Views to help locate the proper cavity when you need to probe a connector. It can be especially helpful if the connector has more than one wire of the same color. A dash symbol (-) indicates that the cavity is empty. Connector views can also be used to help diagnose multiple symptoms in separate circuits which could be caused by a single problem in a connector shared by those circuits. Here's an example: 1. Pick one of the multiple symptoms and look up the schematic for that circuit. 2. Make a list of all the in-line and fuse box connectors in that schematic , 3. Then, in the Connector Views, look up each connector on your list to see if circuits related to the other symptoms run through one of them. If they do, inspect that connector for the problem. Example: The blower, rear window defogger, and the windshield wiper don't work. List all in-line and fuse box connectors in the blower controls circuit and then check the Connector View (see the sample). You find that C324 is common to the blower controls, rear window defogger, and wiper/washer, so you inspect C324 and find the problem, bent terminals. Finding Component/Connector Locations Finding Component/Connector Locations To see where a component or connector is located on the car, look up its photo number in the "Component Location". The photo will also tell you the color of the connector, and how many cavities it has. Page 6213 Blower Link Unit and/or Mode Door Page 763 2. Connect the short finder across the battery terminals and the load (component) side of the fuse terminal. 3. Close all switches in the circuit you're testing. 4. Turn on the short finder. This creates a pulsing magnetic field around the wiring between the fuse box and the short. 5. Beginning at the fuse box, slowly move the short finder along the circuit wiring. The meter will read current pulses through sheet metal and body trim. As long as the meter is between the fuse and the short, the needle will move with each current pulse. Once you move the meter past the point of the short, the needle will stop moving. Check the wiring and connectors in this area to locate the cause of the short. Testing For Continuity When testing for continuity at a connector without wire seals, you do not have to separate the two halves of the connector. Instead, probe the connector from the back. Always check both sides of the connector because dirty, corroded, and bent terminals can cause problems (no electrical contact = an open). 1. Disconnect the negative cable from the car battery. If you're using a DVOM, place it in the lowest "OHMS" range. Engine Controls - High/Erratic Engine Idle Fuel Pressure Regulator: All Technical Service Bulletins Engine Controls - High/Erratic Engine Idle 01-080 August 14, 2001 Applies To: 2000-02 Passport - ALL 2000-02 Passport: High or Erratic Idle SYMPTOM The engine occasionally idles at too high a speed, or the idle speed fluctuates. PROBABLE CAUSES The symptom could be the result of any of these conditions: ^ Loose or corroded engine or body ground ^ High resistance in the APPS ground circuit ^ PSP (power steering pressure) switch is internally shorted to ground ^ Fuel pressure regulator is leaking fuel into the intake manifold CORRECTIVE ACTION Diagnose the cause of the idle condition, and select the proper REPAIR PROCEDURE. PARTS INFORMATION REQUIRED MATERIALS REQUIRED SOFTWARE Each REPAIR PROCEDURE requires you to use the Smart Cable to reprogram the PCM with the latest software. To select the latest software from the CDROM, enter the year, model, engine, transmission, and emissions type (49-state or California). This gives you a list of broadcast codes. Select the broadcast code at the top of the list. WARRANTY CLAIM INFORMATION Refer to the Warranty Claim Information for each Repair Procedure. DIAGNOSIS 1. Find out from the customer when the high or erratic idle condition occurs and what the RPM range is: ^ Within 20 minutes of a cold start ^ After braking to a stop ^ All the time ^ Intermittently, with no set pattern Page 612 Accelerator Pedal Position Sensor: Service and Repair Accelerator Position Sensor Replacement CAUTION: Remove the Accelerator (A) pedal assembly as a unit to have it services. Do not remove the Accelerator Position (AP) sensor on the A pedal. If the AP sensor is removed for emergency cause, refer to following Items as necessary. Removal Procedure 1. Disconnect the negative battery cable. 2. Disconnect the electrical harness from the AP sensor. 3. Remove the AP sensor. Installation Procedure 1. Install the accelerator position (AP) sensor to bolts with accelerator (A) pedal. 2. Connect the connector to AP sensor. 3. Install the negative battery cable. Removal and Installation Compressor Clutch: Service and Repair Removal and Installation Magnetic Clutch Assembly (DKV-14G Type) Magnetic Clutch Assembly (DKV-14G Type) 1. Using drive plate holder J-33939 (1) to prevent the drive plate from rotating, then remove the drive plate bolt. Unit Overhaul Clutch Master Cylinder: Service and Repair Unit Overhaul Master Cylinder NOTE: Disassembling and assembling the master cylinder is not approved. Page 749 and the fuses. From Fuses to Relays and Components The second half of Power Distribution shows the wiring "From Fuses to Relays and Components." This can speed your troubleshooting by showing which circuits share fuses. If Power Distribution shows that an inoperative circuit and another circuit share a fuse, check a component in the other circuit. If it works, you know the fuse is good and power is available to the inoperative circuit. Ground Distribution Schematics Page 3571 Page 7759 Terminals - "T" Each "T" terminal (ring type) is numbered for reference and location. A "T" terminal is secured with a screw or bolt. Wires Locations Main Relay (Computer/Fuel System): Locations 9. Fuse/Relay Box (Cover Removed) Fuse/Relay Box (Cover Removed) Page 3911 6. Screw the accumulator cover removal tool clockwise into the accumulator cover. 7. Using a 22 mm wrench, continue turning the tool clockwise until the accumulator cover turns in the housing. 8. Position a drain pan under the transmission. 9. Using the 22 mm wrench as a lever and the transmission case as the fulcrum, pry the accumulator cover out of the housing. NOTE: For maximum leverage, do not fully seat the 22 mm wrench against the removal tool. Line up the end of the wrench with the center of the tool. 10. Clean the accumulator housing. 11. Lubricate the accumulator housing and the accumulator cover with clean ATF. NOTE: The accumulator cover is rubber coated and does not require an 0-ring or sealant. Page 172 Splices Splices are shown as a dot. Their location and the number of wires may vary depending on the harness manufacturer. Switches Switches These switches move together; the broken straight line between them means they are mechanically connected. Other types of switches are controlled by a coil or a solid state circuit. Unless otherwise noted, all switches are shown in their normal (rest) position, with power off. Terminal "T" Page 2515 This means the branch of the wire connects to another circuit. The arrow points to the name of the circuit branch where the wire continues. Testing and Inspection Wheel Bearing: Testing and Inspection FRONT HUB BEARING PRELOAD CHECK Check the hub bearing preload at the wheel pin. New bearing and New oil seal: 19.6 - 24.5 N (4.4 - 5.5 lbs.) Used bearing and New oil seal: 11.8 17.7 N (2.6 - 4.0 lbs.) Page 2274 6. Remove the connector position assurance (CPA) clip from the APPS connector. 7. Disconnect the 10 P connector from the APPS. 8. Remove the bolts, the APPS, the spacer, and the accelerator link from the accelerator pedal assembly. 9. Separate the spacer from the APPS. Clean the grease off the spacer and the accelerator link with a clean shop towel. 10. Clean the terminals of the 10 P APPS connector (harness side) with contact cleaner. Shake the residue out of the connector, and allow the contact cleaner to evaporate for at least 3 minutes before reconnecting the connector. 11. Install a new APPS, the spacer, and the accelerator link onto the accelerator pedal assembly. Leave the mounting screws loose so the sensor can be adjusted. 12. Connect the 10 P connector to the new APPS, and lock the connector in place with the CPA. 13. Connect the PGM Tester to the data link connector (DLC), and turn the ignition switch to ON (II). Page 5211 This means the branch of the wire connects to another circuit. The arrow points to the name of the circuit branch where the wire continues. Page 729 Throttle Position Sensor: Service and Repair REMOVAL PROCEDURE 1. Disconnect the negative battery cable. 2. Disconnect the TPS electrical connector. 3. Remove the bolts and the TP sensor from the throttle body. NOTE: Do not clean the TP sensor by soaking it in solvent. The sensor will be damaged as a result. INSTALLATION PROCEDURE 1. Install the TP sensor on the throttle body with the bolts. 2. Connect the TP electrical connector. 3. Install the negative battery cable. Page 3493 Throttle Position Sensor: Description and Operation Throttle Position (TP) Sensor The throttle position (TP) sensor is a potentiometer connected to the throttle shaft on the throttle body. The PCM monitors the voltage on the signal line and calculates throttle position. As the throttle valve angle is changed (accelerator pedal moved), the TP sensor signal also changes. At a closed throttle position, the output of the TP1 sensor is low. As the throttle valve opens, the output increases so that at wide open throttle (WOT), the output voltage should be above 92 % (Tech 2 Display). The PCM calculates fuel delivery based on throttle valve angle (driver demand). A broken or loose TP sensor may cause intermittent bursts of fuel from an injector and unstable idle because the PCM thinks the throttle is moving. Page 5407 ^ If the wheels are pointed to the right, shorten the driver's side tie-rod, and lengthen the passenger's side. ^ If the wheels are pointed to the left, shorten the passenger's side tie-rod, and lengthen the driver's side. ^ Each 360° turn of the tie-rod equals about 8 mm of steering wheel adjustment. For example, a steering wheel is off-center by 4 mm with the front wheels pointed right (when the steering wheel is centered). To correct the off-center, shorten the driver's side tie-rod by a half-turn, and lengthen the passenger's side tie-rod by a half-turn. 4. Use your diagnosis worksheet to fill in the following table and build your 15-digit DTC. Removal and Installation Hose/Line HVAC: Service and Repair Removal and Installation Removal 1. Disconnect the battery ground cable. 2. Discharge and recover refrigerant. 3. Remove radiator grille. 4. Remove clip and clamp. 5. Disconnect liquid line (High-pressure pipe). 6. Disconnect suction line (Low-pressure pipe) using a back-up wrench. 7. Disconnect suction line (Low-pressure hose) using a back-up wrench. 8. Disconnect discharge line (High-pressure hose) using a back-up wrench. - Use a backup wrench when disconnecting and reconnecting the refrigerant lines. - When removing the refrigerant line connecting part, the connecting part should immediately be plugged or capped to prevent foreign matter from being mixed into the line. Installation To install, follow the removal steps in the reverse order, noting the following point: 1. O-rings cannot be reused. Always replace with new ones. 2. Be sure to apply new compressor oil to the O-ring when connecting lines. 3. Tighten the refrigerant line to the specified torque. Refer to Main Data and Specifications for Torque Specifications. Page 1783 Spark Plug: Service and Repair Inspection and Repair Inspection and Repair The spark plug affects entire engine performance and therefore its inspection is very important. - Check electrode and insulator for presence of cracks, and replace if any. - Check electrode for wear, and replace if necessary.. - Check gasket for damage, and replace if necessary. - Measure insulation resistance with an ohmmeter, and replace if faulty. - Adjust spark plug gap to 1.0 mm (0.040 in) to 1.1 mm (0.043 in). - Check fuel and electrical systems if spark plug is extremely dirty. - Use spark plugs having low heat value (hot type plug) if fuel and electrical systems are normal. - Use spark plugs having high heat value (cold type plug) if insulator and electrode are extremely burned. Sooty Spark Plugs Much deposit of carbon or oil on the electrode and insulator of spark plug reduces the engine performance. Possible causes: - Too rich mixture - Presence of oil in combustion chamber - Incorrectly adjusted spark plug gap Burning Electrodes This fault is characterized by scorched or heavily oxidized electrode or blistered insulator nose. Possible causes: - Too lean mixture - Improper heat value Measuring Insulation Resistance - Measure insulation resistance using a 500 volt megaohm meter. - Replace spark plugs if measured value is out of standard. Insulation resistance: 50 Mohm or more. Page 2506 the component if the component only has one connector, or by a capital letter (A, B, C, etc.) if the component has more than one connector. Below most connector numbers and component names are PHOTO and VIEW numbers. The PHOTO number refers to a photo in the back of the book that shows the connector's location on the car. The VIEW number refers to an illustration in the back of the book that shows the connector face, wire colors, connector cavity numbers, and other details. The connector cavity numbering sequence begins at the top left corner of the connector. Disregard any numbers molded into the connector housing. Wires Wires are identified by the abbreviated names of their colors; the second color is the color of the stripe. Wires are also identified by their location in a connector. The number "2" next to the male and female wire terminals at C416, for example, means those terminals join in cavity 2 of connector C416. Symbols A complete description of schematic symbols is given under wire color abbreviation. Power Distribution Schematics Power Distribution schematics show how power is supplied from the positive battery terminal to various circuits in the car. Refer to the Power Distribution section to get a more detailed picture of how power is supplied to the circuit you're working on. From Battery to Ignition Switch, Fuses, and Relays Individual circuit schematics begin with a fuse. The first half of Power Distribution, however, shows the wiring "upstream" between the battery Page 7958 Testing For A Short With A Self-Powered Test Light or DVOM 1. Remove the blown fuse and disconnect the battery and load. 2. Connect one lead of a self-powered test light or digital volt/ohmmeter (DVOM) (switched to the lowest "OHMS" range) to the fuse terminal on the load side. 3. Connect the other lead to a known good ground. 4. Beginning near the fuse box, wiggle the harness. Continue this at convenient points about six inches apart while watching the test light or DVOM. 5. If the self-powered test light goes on or the DVOM displays a low reading or no reading (zero), there is a short to ground in the wiring near that point. Testing for a Short with a Test Light or DVOM 1. Remove the blown fuse and disconnect the load. 2. Connect a test light or digital volt/ohmmeter (DVOM), switched to the appropriate DC volts range, across the fuse terminals to make sure voltage is present. You might have to turn the ignition switch to ON; check the schematic to see. 3. Beginning near the fuse box, wiggle the harness. Continue this at convenient points about six inches apart while watching the test light or DVOM. 4. Where the test light goes , or the DVOM voltage drops to zero, there is a short to ground in the wiring near that point. NOTE: Always use a DVOM on high impedance circuits. A test light may not glow (even with battery voltage present). Testing For A Short With A Short Circuit Locator (Short Finder) 1. Remove the blown fuse. Leave the battery connected. Page 3713 Testing For A Short With A Self-Powered Test Light or DVOM 1. Remove the blown fuse and disconnect the battery and load. 2. Connect one lead of a self-powered test light or digital volt/ohmmeter (DVOM) (switched to the lowest "OHMS" range) to the fuse terminal on the load side. 3. Connect the other lead to a known good ground. 4. Beginning near the fuse box, wiggle the harness. Continue this at convenient points about six inches apart while watching the test light or DVOM. 5. If the self-powered test light goes on or the DVOM displays a low reading or no reading (zero), there is a short to ground in the wiring near that point. Testing for a Short with a Test Light or DVOM 1. Remove the blown fuse and disconnect the load. 2. Connect a test light or digital volt/ohmmeter (DVOM), switched to the appropriate DC volts range, across the fuse terminals to make sure voltage is present. You might have to turn the ignition switch to ON; check the schematic to see. 3. Beginning near the fuse box, wiggle the harness. Continue this at convenient points about six inches apart while watching the test light or DVOM. 4. Where the test light goes , or the DVOM voltage drops to zero, there is a short to ground in the wiring near that point. NOTE: Always use a DVOM on high impedance circuits. A test light may not glow (even with battery voltage present). Testing For A Short With A Short Circuit Locator (Short Finder) 1. Remove the blown fuse. Leave the battery connected. Page 3734 The name of the component appears next to it followed by notes about its function along with any photo and connector view references. Connector "C" How to Identify Connector Terminals Cavity Numbering System The cavities (and wire terminals) in each connector are numbered starting from the upper left, looking at the male terminals from the terminal side (or looking at the female terminals from the wire side. Both views are in the same direction so the numbers are the same.) All actual cavities are numbered, even if they have no wire terminals in them. NOTE: Data Link Connector (DLC) terminals are numbered according to SAE standard J1962, not the Honda standard. The numbers of the four end terminals are molded into the corners of the connector face. Diagram Information and Instructions Axle Disconnect Control Control Unit: Diagram Information and Instructions How to Identify Wiring Color-Coded Insulation Wire Color Wire Color Coding Diagram Information and Instructions 4WD Control Unit: Diagram Information and Instructions How to Identify Wiring Color-Coded Insulation Wire Color Wire Color Coding Page 7635 Ground - "G" Shielding Sheilding This represents RFI (Radio Frequency Interference) shielding around a wire. The shielding is always connected to ground. Splices Locations Camshaft Position Sensor Front Wipers (In Combination Switch) Locations EGR Valve: Locations Right Side of Engine Cylinder Head Cover LH Valve Cover: Service and Repair Cylinder Head Cover LH Cylinder Head Cover LH Removal 1. Disconnect battery ground cable. 2. Remove air cleaner duct assembly. 3. Disconnect positive crankcase ventilation hose. 4. Remove camshaft angle sensor connector. 5. Remove ground cable fixing bolt on cylinder head cover. 6. Ignition coil connector and ignition coil. - Disconnect the three connectors from the ignition coils. - Remove harness bracket bolt on cylinder head cover. - Remove fixing bolts on ignition coils. Page 2287 Accelerator Pedal Position Sensor: Service and Repair Accelerator Position Sensor Replacement CAUTION: Remove the Accelerator (A) pedal assembly as a unit to have it services. Do not remove the Accelerator Position (AP) sensor on the A pedal. If the AP sensor is removed for emergency cause, refer to following Items as necessary. Removal Procedure 1. Disconnect the negative battery cable. 2. Disconnect the electrical harness from the AP sensor. 3. Remove the AP sensor. Installation Procedure 1. Install the accelerator position (AP) sensor to bolts with accelerator (A) pedal. 2. Connect the connector to AP sensor. 3. Install the negative battery cable. Service and Repair Axle Shaft: Service and Repair AXLE SHAFT, OIL SEAL AND BEARING AXLE SHAFT AND ASSOCIATED PARTS Disc Brake Model Drum Brake Model REMOVAL 1. Raise the vehicle. 2. Remove rear wheels and brake calipers or drums. Do not let calipers hang from the vehicle by the brake line or hose. Wire them to frame of vehicle to prevent damage. 3. Remove four nuts and lockwashers. 4. Remove shaft assembly from the axle housing. 5. Remove snap ring and bearing cup. Page 2466 24. Verify APP Sensor 1 is between 11 and 15 percent, and APP Sensor 2 and APP Sensor 3 are between 89 and 85 percent with the pedal up (closed throttle). If not, loosen the mounting screws on the APPS sensor, and go to step 14. 25. Clear all DTCs with the PGM Tester. 26. Turn off the ignition switch, and disconnect the PGM Tester. Page 1725 NOTE: You may need to rotate the camshaft pulley up to four complete turns before its green mark aligns directly with the bolt hole. 4. Rotate the left cylinder bank's camshaft pulley clockwise another 1/4 turn to align its green mark with the valve cover timing mark. Page 5252 6. Place the end of the return hose in a container. Have someone start the engine, then pour ATF into the reservoir while you watch the fluid coming out of the return hose. When the fluid coming out is the same color as the new fluid, turn off the engine. 7. Reconnect the return hose to the reservoir. 8. Start the engine. Fill the power steering reservoir to the proper level with ATF then turn off the engine. 9. Use the Smart Cable to reprogram the PCM with the latest software from the June 2001 or later HONDANET CD-ROM. Refer to Service Bulletin 99-005, Updating the Passport PCM, filed under Tools. 10. Use the PGM Tester to clear any DTCs. 11. Use the PGM Tester to check the broadcast code. Make sure the broadcast code matches the one you selected from the CD-ROM. WARRANTY CLAIM INFORMATION In warranty: The normal warranty applies. Failed Part: P/N 8-97181-590-0 H/C 5698030 Defect Code: 064 Contention Code: C01 Skill Level: Repair Technician Out of warranty: Any repair performed after warranty expiration may be eligible for goodwill consideration by the District Service Manager or your Zone Office. You must request consideration, and get a decision, before starting work. REPAIR PROCEDURE - APPS GROUND 1. Unclamp the air cleaner housing cover, and move it to the side for access to connector C123 (16P BLK). Page 7920 Page 7722 Test Equipment CAUTION: Most circuits include solid-state devices. Test the voltages in these circuits only with a 10-megaohm or higher impedance digital multimeter. Never use a test light or analog meter on circuits that contain solid-state devices. Damage to the devices may result. Test Light and DVOM On circuits without solid-state devices, use a test light to check for voltage. A test light is made up of a 12 volt bulb with a pair of leads attached. After grounding one lead, touch the other lead to various points along the circuit where voltage should be present. The bulb will go on if there is voltage at the point being tested. If you need to know how much voltage is present, use a digital volt/ohmmeter (DVOM). Self-Powered Test Light and DVOM Use a self-powered test light to check for continuity. This tool is made up of a light bulb, battery, and two leads. To test it, touch the leads together: the light should go on. Use a self-powered test light only on an unpowered circuit. First, disconnect the battery, or remove the fuse that feeds the circuit you are working on. Select two points in the circuit between which you want to check continuity. Connect one lead of the self-powered test light to each point. If there is continuity, the test light's circuit will be completed, and the light will go on. If, in addition, you need to know exactly how much resistance there is between two points, use a digital volt/ohmmeter (DVOM). In the "OHMS" range, the DVOM will measure resistance between two points along a circuit. Low resistance means good continuity. Diodes and solid-state devices in a circuit can make a DVOM give a false reading. To check a reading, reverse the leads, and take a second reading. If the readings differ, the component is affecting the measurement. Jumper Wire Use a jumper wire to bypass an open circuit. A jumper wire is made up of an in-line fuse holder connected to a set of test leads. It should have a five ampere fuse. Never connect a jumper wire across a short circuit. The direct battery short will blow the fuse. Short Finder (Short Circuit Locator) Short finders are available to locate shorts to ground. The short finder creates a pulsing magnetic field in the shorted circuit which you can follow to the location of the short. To order any test equipment shown above, contact your local tool supplier. For a list of suppliers and tool numbers, refer to Honda Required Special Tools and Equipment Service Bulletin. Locations Brake Fluid Level Sensor/Switch: Locations Left Side Of Engine Compartment Specifications Crankshaft Main Bearing: Specifications Main Bearing Cap Bolts 39 Nm Oil Gallery Fixing Bolts 29 Nm Crank Case Side Bolts 39 Nm Locations Evaporative Emission Vent Canister Cut Valve: Locations Rear Underside of Vehicle Moonroof - Visor Sags in The Middle Sunroof / Moonroof Weatherstrip: All Technical Service Bulletins Moonroof - Visor Sags in The Middle 00-061 August 22, 2000 Applies To: 1998-00 Passport - ALL Accessory Moonroof Visor Appearance PROBLEM The rear edge of the moonroof visor sags in the middle, and/or the roof seal is distorted. CORRECTIVE ACTION Replace the moonroof visor and the roof seal with a new assembly. PARTS INFORMATION Accessory Moonroof Visor Kit: P/N 08R01-ED1101, H/C 6483838 WARRANTY CLAIM INFORMATION In warranty: The normal warranty applies. Out of warranty: Any repair performed after warranty expiration may be eligible for goodwill consideration by the District Service Manager or your Zone Office. You must request consideration, and get a decision, before starting work. REPAIR PROCEDURE 1. Remove the moonroof visor, the roof seal, and all related hardware. 2. Install the new moonroof visor kit. Refer to the Accessory Installation Instructions binder for the installation instructions. Disclaimer Page 2389 Valve Shims (While 41 shims are available, the 10 sizes will cover most valve adjustments): Page 2710 96. Rear of Right Catalytic Converter Rear of right catalytic converter 94. Rear of Left Catalytic Converter Rear of Left Catalytic Converter Locations Page 6002 Testing For A Short With A Self-Powered Test Light or DVOM 1. Remove the blown fuse and disconnect the battery and load. 2. Connect one lead of a self-powered test light or digital volt/ohmmeter (DVOM) (switched to the lowest "OHMS" range) to the fuse terminal on the load side. 3. Connect the other lead to a known good ground. 4. Beginning near the fuse box, wiggle the harness. Continue this at convenient points about six inches apart while watching the test light or DVOM. 5. If the self-powered test light goes on or the DVOM displays a low reading or no reading (zero), there is a short to ground in the wiring near that point. Testing for a Short with a Test Light or DVOM 1. Remove the blown fuse and disconnect the load. 2. Connect a test light or digital volt/ohmmeter (DVOM), switched to the appropriate DC volts range, across the fuse terminals to make sure voltage is present. You might have to turn the ignition switch to ON; check the schematic to see. 3. Beginning near the fuse box, wiggle the harness. Continue this at convenient points about six inches apart while watching the test light or DVOM. 4. Where the test light goes , or the DVOM voltage drops to zero, there is a short to ground in the wiring near that point. NOTE: Always use a DVOM on high impedance circuits. A test light may not glow (even with battery voltage present). Testing For A Short With A Short Circuit Locator (Short Finder) 1. Remove the blown fuse. Leave the battery connected. Page 5726 2. Apply grease to the portion that fits into the bracket then install height control arm and align the setting marks (2). 3. Apply grease to the bolt portion of the end piece (4) Apply grease to the portion of the seat (5) that fits into the bracket. 4. Apply grease to the serrated portions. 5. Install adjust bolt and seat, then turn the adjust bolt to the setting mark (1) applied during disassembly. NOTE: Adjust the trim height. Page 57 and the fuses. From Fuses to Relays and Components The second half of Power Distribution shows the wiring "From Fuses to Relays and Components." This can speed your troubleshooting by showing which circuits share fuses. If Power Distribution shows that an inoperative circuit and another circuit share a fuse, check a component in the other circuit. If it works, you know the fuse is good and power is available to the inoperative circuit. Ground Distribution Schematics Page 7483 The name of the component appears next to it followed by notes about its function along with any photo and connector view references. Connector "C" How to Identify Connector Terminals Cavity Numbering System The cavities (and wire terminals) in each connector are numbered starting from the upper left, looking at the male terminals from the terminal side (or looking at the female terminals from the wire side. Both views are in the same direction so the numbers are the same.) All actual cavities are numbered, even if they have no wire terminals in them. NOTE: Data Link Connector (DLC) terminals are numbered according to SAE standard J1962, not the Honda standard. The numbers of the four end terminals are molded into the corners of the connector face. Bleeding Brake Hydraulic System Brake Bleeding: Service and Repair Bleeding Brake Hydraulic System This procedure has been updated by TSB Manual Update # 01-016 dated January 30, 2001. BRAKE SYSTEM BLEEDING A bleeding operation is necessary to remove air from the hydraulic brake system whenever air is introduced into the hydraulic system. It may be necessary to bleed the hydraulic system at all four brakes if air has been introduced through a low fluid level or by disconnecting brake pipes at the master cylinder. If a brake pipe is disconnected at one wheel, only that wheel cylinder/caliper needs to be bled. If the pipes are disconnected at any fitting located between the master cylinder and brakes, then the brake system served by the disconnected pipe must be bled. 1. For 4-Wheel Antilock Brake System (ABS) equipped vehicle, be sure to remove the ABS main fuse 60A located at the relay and fuse box before bleeding air. If you attempt to bleed air without removing the main fuse, air cannot be let out thoroughly, and this may cause damage to the hydraulic unit. After bleeding air, be sure to replace the ABS main fuse back to its original position. 2. Set the parking brake completely, then start the engine. NOTE: The vacuum booster will be damaged if the bleeding operation is performed with the engine off. NOTE: To avoid trapping air bubbles in the ABS hydraulic unit while bleeding the brakes, the hydraulic unit must be tilted forward at a 15-degree angle or greater. Before bleeding, check the angle of the ABS hydraulic unit with an angle locator level. If needed, raise the rear of the vehicle to get the proper angle. The angle locator level (P/N SUN-YA328A) is available through the Honda Tool and Equipment Program. 3. Remove the master cylinder reservoir cap. 4. Fill the master cylinder reservoir with brake fluid. Keep the reservoir at least half full during the air bleeding operation 5. Always use new brake fluid for replenishment. 6. In replenishing brake fluid, take care that air bubbles do not enter the brake fluid. When the master cylinder is replaced or overhauled, first bleed the air from the master cylinder, then from each wheel cylinder and caliper following the procedures. BLEEDING THE MASTER CYLINDER 7. Disconnect the rear wheel brake pipe (1) from the master cylinder. Page 7906 The name of the component appears next to it followed by notes about its function along with any photo and connector view references. Connector "C" How to Identify Connector Terminals Cavity Numbering System The cavities (and wire terminals) in each connector are numbered starting from the upper left, looking at the male terminals from the terminal side (or looking at the female terminals from the wire side. Both views are in the same direction so the numbers are the same.) All actual cavities are numbered, even if they have no wire terminals in them. NOTE: Data Link Connector (DLC) terminals are numbered according to SAE standard J1962, not the Honda standard. The numbers of the four end terminals are molded into the corners of the connector face. Capacity Specifications Fluid - Differential: Capacity Specifications Differential Oil Capacity ............................................................................................................................................... ...................................................................... 1.87 Qt Page 8217 13. Remove the window regulator. - Remove the window regulator fixing bolts and pull the regulator out from the lower hole of the door panel. 14. Remove the glass run. - Pull the glass run out from the door frame. Installation To install, follow the removal steps in the reverse order, noting the following points: 1. Install the regulator handle as shown in the illustration, if equipped without power windows. 2. Check to see that the window regulator operates smoothly and the glass opens and closes properly. Install the waterproof sheet with no clearance between the door panel and the waterproof sheet. Page 2573 This means the branch of the wire connects to another circuit. The arrow points to the name of the circuit branch where the wire continues. Page 6246 4. Connect the high pressure charging hose of the manifold gauge to the high pressure side service valve of the vehicle. 5. Place the refrigerant container(3) up right on a weight scale(4). Note the total weight before charging the refrigerant. a. Open the refrigerant container valve. b. Open the low side vale on the manifold gauge set. Refer to the manufacturer's instructions for a weight scale charging station. 6. Perform a system leak test: - Charge the system with approximately 200 g (0.44 lbs) of HFC-134a. - Make sure the high pressure valve of the manifold gauge is closed. - Check to ensure that the degree of pressure does not change. - Check for refrigerant leaks by using a HFC-134a leak detector. - If a leak occurs, recover the refrigerant. Repair the leak and start all over again from the first step of evacuation. 7. If no leaks are found, continue charging refrigerant to the air conditioning system. Locations Gear Sensor/Switch: Locations Top Right Side Of Transfer Case Page 5480 6. Place the end of the return hose in a container. Have someone start the engine, then pour ATF into the reservoir while you watch the fluid coming out of the return hose. When the fluid coming out is the same color as the new fluid, turn off the engine. 7. Reconnect the return hose to the reservoir. 8. Start the engine. Fill the power steering reservoir to the proper level with ATF then turn off the engine. 9. Use the Smart Cable to reprogram the PCM with the latest software from the June 2001 or later HONDANET CD-ROM. Refer to Service Bulletin 99-005, Updating the Passport PCM, filed under Tools. 10. Use the PGM Tester to clear any DTCs. 11. Use the PGM Tester to check the broadcast code. Make sure the broadcast code matches the one you selected from the CD-ROM. WARRANTY CLAIM INFORMATION In warranty: The normal warranty applies. Failed Part: P/N 8-97181-590-0 H/C 5698030 Defect Code: 064 Contention Code: C01 Skill Level: Repair Technician Out of warranty: Any repair performed after warranty expiration may be eligible for goodwill consideration by the District Service Manager or your Zone Office. You must request consideration, and get a decision, before starting work. REPAIR PROCEDURE - APPS GROUND 1. Unclamp the air cleaner housing cover, and move it to the side for access to connector C123 (16P BLK). Page 6867 - Remove the fixing screws from back side of the rear door trim panel. 8. Remove the bracket. 9. Disconnect the speaker harness connector. 10. Remove the speaker with the speaker harness connector from the door inner panel. 11. Remove the waterproof sheet (1). - Taking notice of the door harness, peel the waterproof sheet off the door panel carefully. 12. Remove the speaker bracket. - Remove the six fixing screws. 13. Remove the fixing glass. - Remove one bolt and screw as shown in the figure, then pull it upward. Page 4453 This means the branch of the wire connects to another circuit. The arrow points to the name of the circuit branch where the wire continues. Page 5372 Locations Headliner: Locations LWB Page 2577 Test Equipment CAUTION: Most circuits include solid-state devices. Test the voltages in these circuits only with a 10-megaohm or higher impedance digital multimeter. Never use a test light or analog meter on circuits that contain solid-state devices. Damage to the devices may result. Test Light and DVOM On circuits without solid-state devices, use a test light to check for voltage. A test light is made up of a 12 volt bulb with a pair of leads attached. After grounding one lead, touch the other lead to various points along the circuit where voltage should be present. The bulb will go on if there is voltage at the point being tested. If you need to know how much voltage is present, use a digital volt/ohmmeter (DVOM). Self-Powered Test Light and DVOM Use a self-powered test light to check for continuity. This tool is made up of a light bulb, battery, and two leads. To test it, touch the leads together: the light should go on. Use a self-powered test light only on an unpowered circuit. First, disconnect the battery, or remove the fuse that feeds the circuit you are working on. Select two points in the circuit between which you want to check continuity. Connect one lead of the self-powered test light to each point. If there is continuity, the test light's circuit will be completed, and the light will go on. If, in addition, you need to know exactly how much resistance there is between two points, use a digital volt/ohmmeter (DVOM). In the "OHMS" range, the DVOM will measure resistance between two points along a circuit. Low resistance means good continuity. Diodes and solid-state devices in a circuit can make a DVOM give a false reading. To check a reading, reverse the leads, and take a second reading. If the readings differ, the component is affecting the measurement. Jumper Wire Use a jumper wire to bypass an open circuit. A jumper wire is made up of an in-line fuse holder connected to a set of test leads. It should have a five ampere fuse. Never connect a jumper wire across a short circuit. The direct battery short will blow the fuse. Short Finder (Short Circuit Locator) Short finders are available to locate shorts to ground. The short finder creates a pulsing magnetic field in the shorted circuit which you can follow to the location of the short. To order any test equipment shown above, contact your local tool supplier. For a list of suppliers and tool numbers, refer to Honda Required Special Tools and Equipment Service Bulletin. Page 5373 Relay Box: Diagrams Instrument Panel Page 276 Page 7610 2. Connect the short finder across the battery terminals and the load (component) side of the fuse terminal. 3. Close all switches in the circuit you're testing. 4. Turn on the short finder. This creates a pulsing magnetic field around the wiring between the fuse box and the short. 5. Beginning at the fuse box, slowly move the short finder along the circuit wiring. The meter will read current pulses through sheet metal and body trim. As long as the meter is between the fuse and the short, the needle will move with each current pulse. Once you move the meter past the point of the short, the needle will stop moving. Check the wiring and connectors in this area to locate the cause of the short. Testing For Continuity When testing for continuity at a connector without wire seals, you do not have to separate the two halves of the connector. Instead, probe the connector from the back. Always check both sides of the connector because dirty, corroded, and bent terminals can cause problems (no electrical contact = an open). 1. Disconnect the negative cable from the car battery. If you're using a DVOM, place it in the lowest "OHMS" range. Page 5367 V6 Engine Room Page 6514 If any of the following abnormalities is found, replace on an assembly basis. - Deformed and malfunctioning adjustable shoulder anchor (1). - Uneven movement of upper/lower anchors (2) in the circumferential direction. - Damaged and/or deformed through ring (3). - Damaged and/or deformed tongue (4). - Damaged and/or frayed webbing (5). - Deformed retractor bracket (6). - Seat belt does not retract (7). - Resistance or abnormal sound when seat belt is pulled out or retracted (7). - Retractor (7) abnormality. Page 7534 2. Connect one lead of a self-powered test light or DVOM to one end of the part of the circuit you want to test. 3. Connect the other lead to the other end. 4. If the self-powered test light glows, there is continuity. If you're using a DVOM, a low reading or no reading (zero), means good continuity. Testing For Voltage When testing for voltage at a connector without wire seals, you do not have to separate the two halves of the connector. Instead, probe the connector from the back. Always check both sides of the connector because dirty, corroded, and bent terminals can cause problems (no electrical contact = an open). 1. Connect one lead of the lest light to a known good ground, or, if you're using a digital volt ohmmeter (DVOM), place it in the appropriate DC volts range, and connect its negative lead to ground. 2. Connect the other lead of the test light or DVOM to the point you want to check. 3. If the test light glows, there is voltage present. If you're using a DVOM, note the voltage reading. It should be within one volt of measured battery voltage. A loss of more than one volt indicates a problem. NOTE: Always use a DVOM on high impedance circuits. A test light may not glow (even with battery voltage present). Testing For Voltage Drop Wires, connectors, and switches are designed to conduct current with a minimum loss of voltage. A voltage drop of more than one volt indicates a problem. 1. Place the digital volt/ohmmeter (DVOM) in the appropriate DC volts range. Connect the positive lead to the end of the wire (or to the connector or switch) closest to the battery. 2. Connect the negative lead to the other end of the wire (or the other side of the connector or switch). 3. Turn on the components in the circuit. 4. The DVOM will show the difference in voltage between the two points. A difference, or drop, of more than one volt indicates a problem. Check the circuit for loose, dirty, or bent terminals. Page 7960 2. Connect one lead of a self-powered test light or DVOM to one end of the part of the circuit you want to test. 3. Connect the other lead to the other end. 4. If the self-powered test light glows, there is continuity. If you're using a DVOM, a low reading or no reading (zero), means good continuity. Testing For Voltage When testing for voltage at a connector without wire seals, you do not have to separate the two halves of the connector. Instead, probe the connector from the back. Always check both sides of the connector because dirty, corroded, and bent terminals can cause problems (no electrical contact = an open). 1. Connect one lead of the lest light to a known good ground, or, if you're using a digital volt ohmmeter (DVOM), place it in the appropriate DC volts range, and connect its negative lead to ground. 2. Connect the other lead of the test light or DVOM to the point you want to check. 3. If the test light glows, there is voltage present. If you're using a DVOM, note the voltage reading. It should be within one volt of measured battery voltage. A loss of more than one volt indicates a problem. NOTE: Always use a DVOM on high impedance circuits. A test light may not glow (even with battery voltage present). Testing For Voltage Drop Wires, connectors, and switches are designed to conduct current with a minimum loss of voltage. A voltage drop of more than one volt indicates a problem. 1. Place the digital volt/ohmmeter (DVOM) in the appropriate DC volts range. Connect the positive lead to the end of the wire (or to the connector or switch) closest to the battery. 2. Connect the negative lead to the other end of the wire (or the other side of the connector or switch). 3. Turn on the components in the circuit. 4. The DVOM will show the difference in voltage between the two points. A difference, or drop, of more than one volt indicates a problem. Check the circuit for loose, dirty, or bent terminals. Page 3742 The wire insulation has one color or one color with another color stripe. The second color is the stripe. Page 3529 Crankshaft Position Sensor: Testing and Inspection 1. Inspect the sensor O-ring for cracks or leaks. 2. Replace the O-ring if it is worn or damaged. 3. Lubricate the new O-ring with engine oil. 4. Install the lubricated O-ring. Page 3270 10. Use the PGM Tester to check the broadcast code. Make sure the broadcast code matches the one you selected from the CD-ROM. WARRANTY CLAIM INFORMATION In warranty: The normal warranty applies. Failed Part: P/N 8-17087-655-0 H/C 4375820 Defect Code: 064 Contention Code: C01 Skill Level: Repair Technician Out of warranty: Any repair performed after warranty expiration may be eligible for goodwill consideration by the District Service Manager or your Zone Office. You must request consideration, and get a decision, before starting work. REPAIR PROCEDURE - ENGINE/BODY GROUND 1. Use the ETM for the appropriate year to locate these ground connectors: G101, G104, G105, G106 and G160. 2. Inspect each connector for corrosion or looseness. 3. Remove the bolt from any connector that is corroded or loose. Clean the terminal connector with a wire brush. File flat any solder bumps on the connector. 4. Clean the contact surface on the engine or body with a wire brush. 5. Replace the bolt if it is heavily corroded. Otherwise, clean it with a wire brush. 6. Apply lithium dielectric grease to both sides of the terminal connector. 7. Reinstall the bolt, torque it to 14 N.m (10 lb-ft). 8. Use the Smart Cable to reprogram the PCM with the latest software from the June 2001 or later HONDANET CD-ROM. Refer to Service Bulletin 99-005, Updating the Passport PCM, filed under Tools. 9. Use the PGM Tester to clear any DTCs. 10. Use the PGM Tester to check the broadcast code. Make sure the broadcast code matches the one you selected from the CD-ROM. WARRANTY CLAIM INFORMATION In warranty: The normal warranty applies. Failed Part: P/N 8-97086-823-0 Page 2713 Oxygen Sensor: Description and Operation Catalyst Monitor Heated Oxygen Sensors Catalyst Monitor Heated Oxygen Sensors Three-way catalytic converters are used to control emissions of hydrocarbons (HC), carbon monoxide (CO), and oxides of nitrogen (NOx). The catalyst within the converters promotes a chemical reaction. This reaction oxidizes the HC and CO present in the exhaust gas and converts them into harmless water vapor and carbon dioxide. The catalyst also reduces NOx by converting it to nitrogen. The PCM can monitor this process using the Bank 1 HO2S 2 and the Bank 2 HO2S 2 heated oxygen sensors. The Bank 1 HO2S 1 and the Bank 2 HO2S 1 sensors produce an output signal which indicates the Page 8088 2. Connect one lead of a self-powered test light or DVOM to one end of the part of the circuit you want to test. 3. Connect the other lead to the other end. 4. If the self-powered test light glows, there is continuity. If you're using a DVOM, a low reading or no reading (zero), means good continuity. Testing For Voltage When testing for voltage at a connector without wire seals, you do not have to separate the two halves of the connector. Instead, probe the connector from the back. Always check both sides of the connector because dirty, corroded, and bent terminals can cause problems (no electrical contact = an open). 1. Connect one lead of the lest light to a known good ground, or, if you're using a digital volt ohmmeter (DVOM), place it in the appropriate DC volts range, and connect its negative lead to ground. 2. Connect the other lead of the test light or DVOM to the point you want to check. 3. If the test light glows, there is voltage present. If you're using a DVOM, note the voltage reading. It should be within one volt of measured battery voltage. A loss of more than one volt indicates a problem. NOTE: Always use a DVOM on high impedance circuits. A test light may not glow (even with battery voltage present). Testing For Voltage Drop Wires, connectors, and switches are designed to conduct current with a minimum loss of voltage. A voltage drop of more than one volt indicates a problem. 1. Place the digital volt/ohmmeter (DVOM) in the appropriate DC volts range. Connect the positive lead to the end of the wire (or to the connector or switch) closest to the battery. 2. Connect the negative lead to the other end of the wire (or the other side of the connector or switch). 3. Turn on the components in the circuit. 4. The DVOM will show the difference in voltage between the two points. A difference, or drop, of more than one volt indicates a problem. Check the circuit for loose, dirty, or bent terminals. Page 3166 129 - Below Left Side Of I/P Service and Repair Seat Back: Service and Repair Rear Seat Back Assembly And Associated Parts LWB) Removal 1. Pull the release knob and pull the seat back assembly forward. 2. Remove the luggage floor carpets. - Pull the nine carpet fixing clips from the backside of the seat back assembly. 3. Remove the seat back assembly. - Remove the four fixing bolts at each seat back. 4. Remove the seat lock covers. 5. Remove the headrests. 6. Remove the release knobs. - Turn the knob counterclockwise to remove it. 7. Remove the trim covers. 8. Remove the guide holders. 9. Remove the side hinges. - Remove the one fixing nut at each side hinge. 10. Remove the center hinge. - Remove the two fixing belts. Installation To install, follow the removal steps in the reverse order noting the following points: 1. Tighten the center hinge fixing bolts to the specified torque. Page 8228 4. Remove the rear view mirror. - Remove the clip (1) and disconnect the connector (2). - Turn the channel mount (3) 90 ° clockwise and pull down. 5. Remove the windshield wiper arm. 6. Remove the windshield side molding. - Pull the molding out from drip rail. 7. Remove the front cowl cover. 8. Remove the windshield support. 9. Remove the upper moulding. 10. Remove the windshield. - Use a knife to cut through part of the adhesive caulking material. - Secure one end of a piece of steel piano wire (0.02 inches in diameter) to a piece of wood that can serve as a handle. - Use a pair of needle nose pliers to insert the other end of the piano wire through the adhesive caulking material at the edge of the windshield glass. - Secure the other end of the piano wire to another piece of wood. - With the aid of an assistant, carefully move the piano wire with a sawing motion to cut through the adhesive caulking material around the entire circumference of the windshield glass - Attach some cloth tape (1) on the body for protecting the painting surface. - Clean the remaining adhesive caulking material from the area of the body which holds the windshield. Installation To install, follow the removal steps in the reverse order, noting the following points. 1. Clean the bonding surfaces of both the windshield and body panel with a soft rag and white gasoline. Page 2382 Compression Check: Testing and Inspection Engine Compression Test Procedure 1. Start and run the engine until the engine reaches normal operating temperature. 2. Turn the engine off. 3. Remove all the spark plugs. 4. Remove ignition coil fuse (15A) and disable the ignition system. 5. Remove the fuel pump relay from the relay and fuse box. 6. Engage the starter and check that the cranking speed is approximately 300 rpm. 7. Install cylinder compression gauge into spark plug hole. 8. With the throttle valve opened fully, keep the starter engaged until the compression gage needle reaches the maximum level. Note the reading. 9. Repeat the test with each cylinder. If the compression pressure obtained falls below the limit, engine overhaul is necessary. Limit: 1000 kPa (145 psi) Page 3259 10. Use the PGM Tester to check the broadcast code. Make sure the broadcast code matches the one you selected from the CD-ROM. WARRANTY CLAIM INFORMATION In warranty: The normal warranty applies. Failed Part: P/N 8-17087-655-0 H/C 4375820 Defect Code: 064 Contention Code: C01 Skill Level: Repair Technician Out of warranty: Any repair performed after warranty expiration may be eligible for goodwill consideration by the District Service Manager or your Zone Office. You must request consideration, and get a decision, before starting work. REPAIR PROCEDURE - ENGINE/BODY GROUND 1. Use the ETM for the appropriate year to locate these ground connectors: G101, G104, G105, G106 and G160. 2. Inspect each connector for corrosion or looseness. 3. Remove the bolt from any connector that is corroded or loose. Clean the terminal connector with a wire brush. File flat any solder bumps on the connector. 4. Clean the contact surface on the engine or body with a wire brush. 5. Replace the bolt if it is heavily corroded. Otherwise, clean it with a wire brush. 6. Apply lithium dielectric grease to both sides of the terminal connector. 7. Reinstall the bolt, torque it to 14 N.m (10 lb-ft). 8. Use the Smart Cable to reprogram the PCM with the latest software from the June 2001 or later HONDANET CD-ROM. Refer to Service Bulletin 99-005, Updating the Passport PCM, filed under Tools. 9. Use the PGM Tester to clear any DTCs. 10. Use the PGM Tester to check the broadcast code. Make sure the broadcast code matches the one you selected from the CD-ROM. WARRANTY CLAIM INFORMATION In warranty: The normal warranty applies. Failed Part: P/N 8-97086-823-0 Page 202 the component if the component only has one connector, or by a capital letter (A, B, C, etc.) if the component has more than one connector. Below most connector numbers and component names are PHOTO and VIEW numbers. The PHOTO number refers to a photo in the back of the book that shows the connector's location on the car. The VIEW number refers to an illustration in the back of the book that shows the connector face, wire colors, connector cavity numbers, and other details. The connector cavity numbering sequence begins at the top left corner of the connector. Disregard any numbers molded into the connector housing. Wires Wires are identified by the abbreviated names of their colors; the second color is the color of the stripe. Wires are also identified by their location in a connector. The number "2" next to the male and female wire terminals at C416, for example, means those terminals join in cavity 2 of connector C416. Symbols A complete description of schematic symbols is given under wire color abbreviation. Power Distribution Schematics Power Distribution schematics show how power is supplied from the positive battery terminal to various circuits in the car. Refer to the Power Distribution section to get a more detailed picture of how power is supplied to the circuit you're working on. From Battery to Ignition Switch, Fuses, and Relays Individual circuit schematics begin with a fuse. The first half of Power Distribution, however, shows the wiring "upstream" between the battery Page 4728 2. Connect the short finder across the battery terminals and the load (component) side of the fuse terminal. 3. Close all switches in the circuit you're testing. 4. Turn on the short finder. This creates a pulsing magnetic field around the wiring between the fuse box and the short. 5. Beginning at the fuse box, slowly move the short finder along the circuit wiring. The meter will read current pulses through sheet metal and body trim. As long as the meter is between the fuse and the short, the needle will move with each current pulse. Once you move the meter past the point of the short, the needle will stop moving. Check the wiring and connectors in this area to locate the cause of the short. Testing For Continuity When testing for continuity at a connector without wire seals, you do not have to separate the two halves of the connector. Instead, probe the connector from the back. Always check both sides of the connector because dirty, corroded, and bent terminals can cause problems (no electrical contact = an open). 1. Disconnect the negative cable from the car battery. If you're using a DVOM, place it in the lowest "OHMS" range. Page 4720 Terminals - "T" Each "T" terminal (ring type) is numbered for reference and location. A "T" terminal is secured with a screw or bolt. Wires Page 5332 Service and Repair Torque Converter Clutch Solenoid: Service and Repair REMOVAL 1. Raise the vehicle and support it on jack stands. 2. Disconnect battery ground cable. 3. Drain fluid. 4. Remove twelve 10 mm adapter case oil pan fixing screws, adapter case oil pan, and gasket. NOTE: Oil pan still contains transmission fluid. Place a large drain container under the oil pan. Drain the fluid carefully. 5. Disconnect wiring harness from force motor solenoid and converter clutch solenoid. Pull only on connectors, not on wiring harness. 6. Remove seven 13 mm screws from adapter case valve body assembly, then remove transfer plate, two gaskets, and adapter case valve body. INSTALLATION 1. Inspect electrical 4 pin connector and seal of adapter case. Replace if necessary. 2. Install gasket, transfer plate, and gasket. 3. Install adapter case valve body and seven 13 mm screws. Tighten the screws to the specified torque. Torque: 20 Nm (15 Ft. lbs.) 4. Connect wiring harness assembly to converter clutch solenoid and force motor. 5. Install oil pan gasket, oil pan, and twelve 10 mm screws. Tighten the screws to the specified torque. Torque: 11 Nm (96 Ft. lbs.) 6. Fill transmission through the overfill screw hole of oil pan, using ATF DEXRON III. 7. Connect battery ground cable. A/T - Fluid Leak From the Accumulator Cover Accumulator: All Technical Service Bulletins A/T - Fluid Leak From the Accumulator Cover 02-038 November 5, 2002 Applies To: 1998-02 Passport With A/T - ALL ATF Leaks From the Accumulator Cover (Supersedes 02-038, dated August 20, 2002) Updated information is shown by black bars and asterisks. SYMPTOM ATF leaks from the right side of the transmission. PROBABLE CAUSE The accumulator cover is cracked. CORRECTIVE ACTION Replace the accumulator cover. TOOL INFORMATION * Accumulator Cover Installation and Removal Tool Kit: T/N O7ZAF-IZAA12O, H/C 7259625 * NOTE: The accumulator cover installation and removal tool kit is available through the Honda Special Tool Loan Program. PARTS INFORMATION Accumulator Cover: P/N 5-96017-093-0, H/C 4555513 WARRANTY CLAIM INFORMATION In warranty: The normal warranty applies. Failed Part: P/N 5-96017-093-0 H/C 4555513 Defect Code: 051 Contention Code: B06 Skill Level: Repair Technician Out of warranty: Any repair performed after warranty expiration may be eligible for goodwill consideration by the District Parts and Service Manager or your Zone Office. You must request consideration, and get a decision, before starting work. Page 5889 4. Use installer J-36828 and grip J-8092 then install the outer bearing by driving it into the hub. 5. Apply grease (NLG1 No.2 or equivalent) to the lip portion, then install oil seal by using installer J-36830 and grip J-8092. 6. Install ABS sensor ring, then tighten the bolts to the specified torque. Torque: 18 Nm (13 ft. lbs.) 7. Install hub and disc assembly. - Apply grease in the hub. - Apply wheel bearing type grease NLGI No. 2 or equivalent to the outer and inner bearing. Page 8025 Test Equipment CAUTION: Most circuits include solid-state devices. Test the voltages in these circuits only with a 10-megaohm or higher impedance digital multimeter. Never use a test light or analog meter on circuits that contain solid-state devices. Damage to the devices may result. Test Light and DVOM On circuits without solid-state devices, use a test light to check for voltage. A test light is made up of a 12 volt bulb with a pair of leads attached. After grounding one lead, touch the other lead to various points along the circuit where voltage should be present. The bulb will go on if there is voltage at the point being tested. If you need to know how much voltage is present, use a digital volt/ohmmeter (DVOM). Self-Powered Test Light and DVOM Use a self-powered test light to check for continuity. This tool is made up of a light bulb, battery, and two leads. To test it, touch the leads together: the light should go on. Use a self-powered test light only on an unpowered circuit. First, disconnect the battery, or remove the fuse that feeds the circuit you are working on. Select two points in the circuit between which you want to check continuity. Connect one lead of the self-powered test light to each point. If there is continuity, the test light's circuit will be completed, and the light will go on. If, in addition, you need to know exactly how much resistance there is between two points, use a digital volt/ohmmeter (DVOM). In the "OHMS" range, the DVOM will measure resistance between two points along a circuit. Low resistance means good continuity. Diodes and solid-state devices in a circuit can make a DVOM give a false reading. To check a reading, reverse the leads, and take a second reading. If the readings differ, the component is affecting the measurement. Jumper Wire Use a jumper wire to bypass an open circuit. A jumper wire is made up of an in-line fuse holder connected to a set of test leads. It should have a five ampere fuse. Never connect a jumper wire across a short circuit. The direct battery short will blow the fuse. Short Finder (Short Circuit Locator) Short finders are available to locate shorts to ground. The short finder creates a pulsing magnetic field in the shorted circuit which you can follow to the location of the short. To order any test equipment shown above, contact your local tool supplier. For a list of suppliers and tool numbers, refer to Honda Required Special Tools and Equipment Service Bulletin. Page 4364 Preload should be 0 to 24.9 kg (O to 11.3 lbs.). Joints should rotate smoothly and freely and should exhibit no rough or ratchety movement. UNIVERSAL JOINT REASSEMBLY 1. Install spider to flange yoke. Be sure to install the spider by aligning the setting marks made during disassembly. 2. Pack the four grease cavities of the spider with a high quality, extreme pressure N.L.G.I. Grade 2 grease. Do not add additional grease to the bearing cup assembly. 3. Move one end of the spider to cause a trunnion to project through the spider hole beyond the outer machined face of the yoke lug. Place a bearing over the trunnion diameter and align it to the spider hole. Using an arbor press, hold the trunnion in alignment with the spider hole and place a solid plug on the upper bearing. Press the bearing into the spider hole enough to install a snap ring. 4. Install a snap ring. Be sure the snap rings are properly seated in the grooves. 5. Repeat steps 3 and 4 to install the opposite bearing. If the joint is stiff, strike the yoke ears with a soft hammer to seat needle bearings. 6. Align setting marks (1) and join the yokes. 7. Install snap ring. Page 2005 Each schematic represents one circuit. A circuit's wires and components are arranged to show current flow, from power at the top of the page, to ground, at the bottom. Shared Circuits Other circuits may share power or ground terminals or wiring with the circuit shown. A wire that connects one circuit to another, for example, is cut short and has an arrowhead at the end of it pointing in the direction of current flow. Next to the arrowhead is the name of the circuit or component which shares that wiring. To quickly check shared wiring, check the operation of a component it serves. If that component works, you know the shared wiring is OK. Connectors All in-line and junction connectors are numbered (C725, C416, etc.). Component connectors are not numbered but are identified either by the name of Page 1802 Page 221 Ion Sensing Module: Service and Repair ION Sensing Module REMOVAL PROCEDURE 1. Disconnect the negative battery cable. 2. Disconnect the ION sensing module connector. 3. Remove the bolts and the ION sensing module from the common chamber. INSTALLATION PROCEDURE 1. Install the ION sensing module on the common chamber with the bolts. Tighten Tighten the ION sensing module to 4 N.m (35 lb in.). 2. Connect the ION sensing module connectors as shown in the illustration. Page 4147 Clutch Pedal Assembly: Service and Repair For further information regarding this component and the system that it is a part of, please refer to Clutch Master Cylinder; Service and Repair; Clutch Control. Page 8271 - Check if the convex part (3) of wiper blade is installed in the groove of the wiper rubber. EVAP Canister Purge Valve Solenoid Check Canister Purge Solenoid: Testing and Inspection EVAP Canister Purge Valve Solenoid Check Circuit Description Canister purge is controlled by a solenoid valve that allows manifold vacuum to purge the canister. The powertrain control module (PCM) supplies a ground to energize the solenoid valve (purge "ON"). The EVAP purge solenoid control is turned "ON" and "OFF" several times a second. The duty cycle (pulse width or "ON" time) is determined by engine operating conditions including load, throttle position, coolant temperature and ambient temperature. The duty cycle is calculated by the PCM and the purge solenoid is enabled when the appropriate conditions have been met: The engine run time after start is more than 60 seconds. - The engine coolant temperature is above 30 °C (86 °F). - The fuel control system is operating in the closed-loop mode. Diagnostic Aids - Make a visual check of vacuum hoses. - Check the throttle body for possible cracked. Check the malfunction indicator lamp for a possible mechanical problem. Steps 1 - 2 Locations Trunk / Liftgate Lock Cylinder: Locations Tailgate Lock, Hatchgate (LWB) Lock And Associated Parts Locations Page 3898 5. Install magnet, main case oil pan with new gasket, and sixteen 10 mm screws. Tighten the screws to the specified torque. Torque: 11 Nm (96 Inch lbs.) 6. Fill transmission through the overfill screw hole of oil pan, using ATF DEXRON-III. 7. Connect battery ground cable. Page 1523 Piston Ring: Service and Repair Disassembly, Inspection and Assembly Piston and Connecting Rod Disassembly 1. Remove cylinder head assembly (1). Page 7232 Power Seat Switch Page 784 6. Remove the connector position assurance (CPA) clip from the APPS connector. 7. Disconnect the 10 P connector from the APPS. 8. Remove the bolts, the APPS, the spacer, and the accelerator link from the accelerator pedal assembly. 9. Separate the spacer from the APPS. Clean the grease off the spacer and the accelerator link with a clean shop towel. 10. Clean the terminals of the 10 P APPS connector (harness side) with contact cleaner. Shake the residue out of the connector, and allow the contact cleaner to evaporate for at least 3 minutes before reconnecting the connector. 11. Install a new APPS, the spacer, and the accelerator link onto the accelerator pedal assembly. Leave the mounting screws loose so the sensor can be adjusted. 12. Connect the 10 P connector to the new APPS, and lock the connector in place with the CPA. 13. Connect the PGM Tester to the data link connector (DLC), and turn the ignition switch to ON (II). Page 461 Terminals - "T" Each "T" terminal (ring type) is numbered for reference and location. A "T" terminal is secured with a screw or bolt. Wires Locations Page 3711 Axle Disconnect Control Control Unit: Diagnostic Aids Before Troubleshooting Before Troubleshooting See: Service Precautions/Vehicle Damage Warnings/Tips and Precautions 1. Check applicable fuses in the appropriate fuse/relay box. 2. Check the battery for damage, state of charge, and clean and tight connections. CAUTION: Do not quick-charge a battery unless the battery ground cable has been disconnected, otherwise you will damage the alternator diodes. - Do not attempt to crank the engine with the battery ground cable loosely connected or you will severely damage the wiring. While You're Working 1. Make sure connectors are clean, and have no loose terminals or receptacles. 2. Make sure that connectors without wire seals are packed with dielectric (silicone) grease. Part Number: 08798-9001. 3. When connecting a connector, push it until it "clicks" into place. CAUTION: Do not pull on the wires when disconnecting a connector. Pull only on the connector housings. - Most circuits include solid-state devices. Test the voltages in these circuits only with a 10-megaohm or higher impedance digital multi meter. Never use a test light or analog meter on circuits that contain solid-state devices. Damage to the devices may result. Five-Step Troubleshooting 1. Verify The Complaint Turn on all the components in the problem circuit to check the accuracy of the customer complaint. Note the symptoms. Do not begin disassembly or testing until you have narrowed down the problem area. 2. Analyze The Schematic Look up the schematic for the problem circuit. Determine how the circuit is supposed to work by tracing the current paths from the power source through the circuit components to ground. Also, trace circuits that share wiring with the problem circuit. The names of circuits that share the same fuse, ground, or switch, and so on, are referred to in each circuit schematic. Try to operate any shared circuits you didn't check in step 1. If the shared circuits work, the shared wiring is OK, and the cause must be in the wiring used only by the problem circuit. If several circuits fail at the same time, the fuse or ground is a likely cause. Based on the symptoms and your understanding of the circuit's operation, identify one or more possible causes. 3. Isolate The Problem By Testing The Circuit Make circuit tests to check the diagnosis you made in step 2. Keep in mind that a logical, simple procedure is the key to efficient troubleshooting. Test for the most likely cause of failure first. Try to make tests at points that are easily accessible. 4. Fix The Problem Once the specific problem is identified, make the repair. Be sure to use proper tools and safe procedures. 5. Make Sure The Circuit Works Turn on all components in the repaired circuit in all modes to make sure you've fixed the entire problem. If the problem was a blown fuse, be sure to test all of the circuits on that fuse. Make sure no new problems turn up and the original problem does not recur. Page 2980 Test Equipment CAUTION: Most circuits include solid-state devices. Test the voltages in these circuits only with a 10-megaohm or higher impedance digital multimeter. Never use a test light or analog meter on circuits that contain solid-state devices. Damage to the devices may result. Test Light and DVOM On circuits without solid-state devices, use a test light to check for voltage. A test light is made up of a 12 volt bulb with a pair of leads attached. After grounding one lead, touch the other lead to various points along the circuit where voltage should be present. The bulb will go on if there is voltage at the point being tested. If you need to know how much voltage is present, use a digital volt/ohmmeter (DVOM). Self-Powered Test Light and DVOM Use a self-powered test light to check for continuity. This tool is made up of a light bulb, battery, and two leads. To test it, touch the leads together: the light should go on. Use a self-powered test light only on an unpowered circuit. First, disconnect the battery, or remove the fuse that feeds the circuit you are working on. Select two points in the circuit between which you want to check continuity. Connect one lead of the self-powered test light to each point. If there is continuity, the test light's circuit will be completed, and the light will go on. If, in addition, you need to know exactly how much resistance there is between two points, use a digital volt/ohmmeter (DVOM). In the "OHMS" range, the DVOM will measure resistance between two points along a circuit. Low resistance means good continuity. Diodes and solid-state devices in a circuit can make a DVOM give a false reading. To check a reading, reverse the leads, and take a second reading. If the readings differ, the component is affecting the measurement. Jumper Wire Use a jumper wire to bypass an open circuit. A jumper wire is made up of an in-line fuse holder connected to a set of test leads. It should have a five ampere fuse. Never connect a jumper wire across a short circuit. The direct battery short will blow the fuse. Short Finder (Short Circuit Locator) Short finders are available to locate shorts to ground. The short finder creates a pulsing magnetic field in the shorted circuit which you can follow to the location of the short. To order any test equipment shown above, contact your local tool supplier. For a list of suppliers and tool numbers, refer to Honda Required Special Tools and Equipment Service Bulletin. Page 6377 Ground - "G" Shielding Sheilding This represents RFI (Radio Frequency Interference) shielding around a wire. The shielding is always connected to ground. Splices Page 3158 24. Verify APP Sensor 1 is between 11 and 15 percent, and APP Sensor 2 and APP Sensor 3 are between 89 and 85 percent with the pedal up (closed throttle). If not, loosen the mounting screws on the APPS sensor, and go to step 14. 25. Clear all DTCs with the PGM Tester. 26. Turn off the ignition switch, and disconnect the PGM Tester. Page 4302 NOTE: Do not drive in, but just temporarily set in the outer bearing by hand, which should be indirectly pressed in finally by tightening the flange nut. 3. By using the seal installer J-37263, install a new oil seal (1) that has grease on seal lip. 4. Install flange. 5. The pinion washer and a new nut while holding the pinion flange with J-8614-01. - Tighten the nut until the pinion end play is just taken up. Rotate the pinion while tightening the nut to seat the bearings. Once there is not end play in the pinion, the preload torque should be checked. - Remove J-8614-01. Using an inch-pound torque wrench, check to make sure the pinion preload is equal to or slightly over the reading recorded during removal. 6. Install propeller shaft to the flange. 7. Install bolt and nut. Tighten the bolt and nut to the specified torque. Torque: 63 Nm (46 ft. lbs.) Page 2503 it is located, and what it connects to. Use the Connector Views to help locate the proper cavity when you need to probe a connector. It can be especially helpful if the connector has more than one wire of the same color. A dash symbol (-) indicates that the cavity is empty. Connector views can also be used to help diagnose multiple symptoms in separate circuits which could be caused by a single problem in a connector shared by those circuits. Here's an example: 1. Pick one of the multiple symptoms and look up the schematic for that circuit. 2. Make a list of all the in-line and fuse box connectors in that schematic , 3. Then, in the Connector Views, look up each connector on your list to see if circuits related to the other symptoms run through one of them. If they do, inspect that connector for the problem. Example: The blower, rear window defogger, and the windshield wiper don't work. List all in-line and fuse box connectors in the blower controls circuit and then check the Connector View (see the sample). You find that C324 is common to the blower controls, rear window defogger, and wiper/washer, so you inspect C324 and find the problem, bent terminals. Finding Component/Connector Locations Finding Component/Connector Locations To see where a component or connector is located on the car, look up its photo number in the "Component Location". The photo will also tell you the color of the connector, and how many cavities it has. Page 3842 identify it.) 3. Connect the PC adapter end of the PC interface kit to the 9P serial port on the DCS workstation. NOTES: It the workstation you're using isn't the same one used for updating PGM Tester program cards, you'll need to disconnect the interface kit from one workstation, and then connect it to the 9P serial port on the other workstation. To avoid this extra step, get a PC interface kit for each workstation. 4. Connect the 110 VAC/12 VAC power supply to the Smart Cable box and to 110 VAC power. 5. Log in to HONDANET 2000. 6. At the top of the HONDANET 2000 screen, click on Service Bay, then click on Smart Cable from the drop-down menu. This brings up the Smart Cable Welcome screen. 7. Retrieve the PCM broadcast code with the Smart Cable or the PGM Tester. ^ To retrieve the code with the Smart Cable, go to step 8. ^ To retrieve the code with the PGM Tester, go to step 14. 8. From the Smart Cable Welcome screen, click on Get ID. When the "Smart Cable is programmed to Get ID" message appears, disconnect the cable from the workstation.* 9. *Disconnect the Smart Cable from the DCS workstation, then take it to the vehicle. Turn the ignition switch ON (II), and connect the Smart Cable to the vehicle's DLC. 10. When the green and yellow lights on the Smart Cable glow steadily, disconnect it from the DLC. 11. Reconnect the Smart Cable to the DCS workstation (steps 2 thru 4 above). 12. From the Smart Cable Welcome screen, click on View ID. The broadcast code needed by the PCM will be highlighted. 13. Click on the highlighted broadcast code, and follow the instructions to reprogram the Smart Cable with the broadcast code needed for the PCM update. When the Smart Cable has been reprogrammed, go to step 21. 14. Connect the Tester to the vehicle's DLC, then turn the ignition switch ON (II). 15. From the System Select menu, press 1: ENGINE 16. From the Test Mode menu, press 6: MISC TEST 17. From the MISC TEST menu, press 6: BROADCAST CODE 18. Write down the 4-digit broadcast code; you'll need it to reprogram the Smart Cable. 19. Write down the 4-digit broadcast code; you'll need it to reprogram the Smart Cable. 20. Go back to the DOS workstation. From the Smart Cable Welcome menu, click on Select. 21. Follow the instructions to reprogram the Smart Cable with the broadcast code needed for the PCM update. 22. Now that the Smart Cable is programmed to update the PCM, go to USING A PROGRAMMED SMART CABLE.* Page 7131 Keyless Entry Module: Service and Repair Anti-Theft & Keyless Entry Controller Removal 1. Disconnect the battery ground cable. 2. Remove the glove box from the instrument panel assembly (1). - Refer to the Instrument Panel Assembly in Body Structure section. 3. Remove the anti-theft & keyless entry controller (2). - Disconnect the connector. Remove two fixing screws. Installation To install, follow the removal steps in the reverse order. Page 680 - Bank 2 sensor 1 is mounted on the exhaust pipe ahead of the left-hand catalytic converter. - Bank 2 sensor 2 is mounted behind the left-hand catalytic converter. 3. Disconnect the pigtail from the wiring harness. IMPORTANT: The pigtail is permanently attached to the sensor. Be careful not to pull the wires out. NOTE: Do not use a torch to remove an HO2S unless the sensor is being replaced. Using a torch could damage the sensor. Specifications Power Steering Line/Hose: Specifications Power Steering Unit Lines 13 Nm Locations Air Bag Disarming and Arming Air Bag(s) Arming and Disarming: Service and Repair Air Bag Disarming and Arming Disabling The SRS Removal Turn the ignition switch to "lock" and remove key. 1. Remove SRS fuse "METER" and "SRS", from left dash side lower fuse block or disconnect battery. 2. Disconnect yellow 2 - pin connector at the base of steering column. 3. Remove glove box assembly, Refer to "Passenger Air Bag Assembly Replacement". 4. Disconnect yellow 2 - pin connector behind the glove box assembly. CAUTION: With the "SRS" fuse removed and ignition switch "ON", "AIR BAG" warning lamp will be "ON". This is normal operation and does not indicate an SRS malfunction. Enabling The SRS Installation CAUTION: Never use the air bag assembly from another vehicle. Use only the air bag assembly. Turn ignition switch to "LOCK" and remove key. 1. Connect yellow 2 - pin connector passenger air bag assembly. 2. Install glove box assembly, refer to "Passenger Air Bag Assembly Replacement". 3. Connect yellow 2 - pin connector at the base of steering column. 4. Install "AIR BAG" fuse "METER" and "SRS" to left dash side lower fuse block or connect battery. Turn ignition switch to "ON" and verify that the "AIR BAG" warning lamp flashes seven times and then turns "OFF". If it does not operate as described, perform the "Supplemental Restraint System (SRS) Diagnostic System Check". Page 8269 Wiper Blade: Service and Repair Rear Window Rear Wiper Arm/Blade Removal 1. Remove the arm nut (2). 2. Remove the wiper arm/blade (1). Installation To install, follow the removal steps in the reverse order, noting the following points: 1. Before installing the wiper arm/blade to the motor shaft, confirm that the motor stops at the autostop position. 2. Install the wiper arm/blade so that the wiper arm (2) contact with the stopper portion (3) on the hatch gate cover (1) as shown in the figure. 3. Tighten the motor shaft nut to the specified torque. Page 4719 Splices Splices are shown as a dot. Their location and the number of wires may vary depending on the harness manufacturer. Switches Switches These switches move together; the broken straight line between them means they are mechanically connected. Other types of switches are controlled by a coil or a solid state circuit. Unless otherwise noted, all switches are shown in their normal (rest) position, with power off. Terminal "T" Page 6267 Refrigerant Pressure Sensor / Switch: Service and Repair Removal 1. Disconnect the battery ground cable. 2. Discharge and recover refrigerant. 3. Remove radiator grille. 4. Disconnect pressure switch connector. 5. Disconnect pressure switch. - When removing the switch connected part, the connecting part should immediately be plugged or capped to prevent foreign matter from being mixed into the line. Installation To install, follow the removal steps in the reverse order, noting the following point: 1. O-ring cannot be reused. Always replace with a new one. 2. Be sure to apply new compressor oil to the O-ring when connecting pressure switch. 3. Tighten the pressure switch to the specified torque. Torque: 13 Nm (113 lb in) Page 2327 7. Loosen the inflator module fixing bolt from behind the steering wheel assembly using a TORE driver or equivalent until the inflator module can be released from steering assembly. 8. Disconnect the yellow 2-way SRS connector and horn lead located behind the inflator module. 9. Apply a setting mark (1) across the steering wheel and shaft so parts can be reassembled in their original position. Page 521 Backup Lamp Switch: Service and Repair Removal 1. Disconnect the battery ground cable. 2. Remove the backup light switch (1). - Disconnect the connector (2). Installation To install, follow the removal steps in the reverse order, noting the following point. 1. Apply liquid gasket to the screw portion of the switch to prevent oil leak. Specifications Brake Drum: Specifications Drum Inside Diameter 210 mm Page 7011 1. In case of installing sunroof finisher (1), fit the lip (2) to the headlining surely. Specifications Firing Order: Specifications Firing Order Firing Order Firing Order 1-2-3-4-5-6 Page 1831 Page 2523 Part 1 Of 3 Page 7665 the component if the component only has one connector, or by a capital letter (A, B, C, etc.) if the component has more than one connector. Below most connector numbers and component names are PHOTO and VIEW numbers. The PHOTO number refers to a photo in the back of the book that shows the connector's location on the car. The VIEW number refers to an illustration in the back of the book that shows the connector face, wire colors, connector cavity numbers, and other details. The connector cavity numbering sequence begins at the top left corner of the connector. Disregard any numbers molded into the connector housing. Wires Wires are identified by the abbreviated names of their colors; the second color is the color of the stripe. Wires are also identified by their location in a connector. The number "2" next to the male and female wire terminals at C416, for example, means those terminals join in cavity 2 of connector C416. Symbols A complete description of schematic symbols is given under wire color abbreviation. Power Distribution Schematics Power Distribution schematics show how power is supplied from the positive battery terminal to various circuits in the car. Refer to the Power Distribution section to get a more detailed picture of how power is supplied to the circuit you're working on. From Battery to Ignition Switch, Fuses, and Relays Individual circuit schematics begin with a fuse. The first half of Power Distribution, however, shows the wiring "upstream" between the battery Page 4788 Hydraulic Control Assembly - Antilock Brakes: Testing and Inspection B-11 FL Isolation Solenoid Valve Failure (DTC 41/C0245, C0247) Chart B-11 FL Isolation Solenoid Coil Failure (DTC 41 (Flash Out) / C0245, C0247 (Serial Communications)) Part 1 of 2 Part 2 of 2 Diagram Information and Instructions Vehicle Speed Sensor: Diagram Information and Instructions How to Identify Wiring Color-Coded Insulation Wire Color Wire Color Coding Page 4713 the component if the component only has one connector, or by a capital letter (A, B, C, etc.) if the component has more than one connector. Below most connector numbers and component names are PHOTO and VIEW numbers. The PHOTO number refers to a photo in the back of the book that shows the connector's location on the car. The VIEW number refers to an illustration in the back of the book that shows the connector face, wire colors, connector cavity numbers, and other details. The connector cavity numbering sequence begins at the top left corner of the connector. Disregard any numbers molded into the connector housing. Wires Wires are identified by the abbreviated names of their colors; the second color is the color of the stripe. Wires are also identified by their location in a connector. The number "2" next to the male and female wire terminals at C416, for example, means those terminals join in cavity 2 of connector C416. Symbols A complete description of schematic symbols is given under wire color abbreviation. Power Distribution Schematics Power Distribution schematics show how power is supplied from the positive battery terminal to various circuits in the car. Refer to the Power Distribution section to get a more detailed picture of how power is supplied to the circuit you're working on. From Battery to Ignition Switch, Fuses, and Relays Individual circuit schematics begin with a fuse. The first half of Power Distribution, however, shows the wiring "upstream" between the battery Page 2859 Camshaft Position Sensor: Service and Repair REMOVAL PROCEDURE 1. Disconnect the negative battery cable. 2. Remove the engine cover. 3. Remove the common chamber assembly. 4. Disconnect the electrical connector to the CMP sensor. 5. Remove the CMP retaining bolt from the side of left cylinder head. 6. Remove the CMP sensor from the cylinder head. INSTALLATION PROCEDURE 1. Install the CMP sensor in the cylinder head. 2. Install the CMP sensor retaining bolt. Tighten Tighten the retaining screw to 9 N.m (78 lb in.). Page 7523 Ground - "G" Shielding Sheilding This represents RFI (Radio Frequency Interference) shielding around a wire. The shielding is always connected to ground. Splices Service Precautions Seat Belt Tensioner: Service Precautions Airbag / Seat Belt Tensioner Handling and Storage Do not try to disassemble an airbag or a seat belt tensioner. They have no serviceable parts. Once an airbag or a seat belt tensioner have been deployed, they cannot be repaired or reused. For temporary storage of an airbag or a seat belt tensioner during service, please observe the following precautions: * Store the removed airbag with the pad surface up. The driver's/front passenger's airbag connectors and seat belt tensioner connectors have a built-in short contact. WARNING: If the airbag is improperly stored face down, accidental deployment could propel the unit with enough force to cause serious injury. * Store the removed airbag on a secure flat surface away from any high heat source (exceeding 212 °F/100 °C) and free of any oil, grease, detergent or water. * Improper handling or storage can internally damage the airbag and seat belt tensioner, making them inoperative. If you suspect the airbag and seat belt tensioner have been damaged, install new units and refer to the Deployment/Disposal Procedures for disposing of the damaged units. See: Air Bag Systems/Air Bag/Service and Repair Page 6659 CD Player/Changer Troubleshooting (Passport only) Manually Removing a Jammed Magazine (All except Passport) One-piece door model: 1. Remove the changer from the vehicle. 2. Remove the rear cover plate from the changer, and look for a jammed disc. 3. If a disc is jammed between the player and the magazine, turn the loading gear until the disc returns to the player mechanism. Do not attempt to reload the disc back into the magazine. 4. After the disc is loaded into the player mechanism, turn the changer so that the front is facing you. Page 5751 Install the lower trailing link front mounting nut and bolt hand-tight, then torque the remaining bolts and nuts, in the order shown on the illustration below: ^ Torque the bracket bolts to 35 Nm (25 Ib-ft). ^ Torque the body mount studs and nut to 30 Nm (22 Ib-ft). Locations Service and Repair Rear Door Window Glass Weatherstrip: Service and Repair Rear Window Regulator, Glass and Glass Run Rear Window Regulator, Glass and Glass Run Removal 1. Disconnect the battery ground cable. 2. Remove the rear corner garnish. - Pull the garnish to disconnect the retaining clip. Page 6163 Evaporator Case: Service and Repair Evaporator Assembly Removal 1. Disconnect the battery ground cable. 2. Discharge and recover refrigerant. 3. Remove glove box. 4. Disconnect resistor (2) and electronic thermostat connector (1). 5. Disconnect drain hose. 6. Disconnect refrigerant line. Page 6522 Seat Belt: Service and Repair Rear Rear Center Seat Belt and Rear Buckles Rear Center Seat Belt and Rear Bu Rear Center Seat Belt / Buckle Assembly And Associated Parts REMOVAL 1. Remove the seat lock cover (SWB). 2. Remove the rear cushion frame assembly (LWB). - Refer to Rear Seat Assembly in Seats. 3. Remove the rear seat lock assembly and rear seat belt buckle assembly. INSTALLATION To install, follow the removal steps in the reverse order, noting the following point. Tighten the rear seat lock assembly and rear seat belt buckle assembly fixing bolts to the specified torque. Torque: 39 N.m (29 lb.ft) NOTE: Removal and installation procedure of rear center seat belt assembly same as rear seat belt buckle assembly procedures. Hard Top Diagram Information and Instructions Control Module HVAC: Diagram Information and Instructions How to Identify Wiring Color-Coded Insulation Wire Color Wire Color Coding Capacity Specifications Engine Oil: Capacity Specifications Engine Oil For oil change, including filter .............................................................................................................. ....................................................................... 5.0 Qt For oil change, without filter ................................................................................................................. ....................................................................... 4.2 Qt NOTE: Listed capacities are approximate. Check fluid level after filling. Page 6403 Do not position yourself in front of the airbag assembly during removal, inspection, or replacement. Refer to the scrapping procedures for disposal of the damaged airbag. Page 3624 Ignition Switch Lock Cylinder: Service and Repair REMOVAL 1. Turn the steering wheel so that the vehicle's wheels are pointing straight ahead. 2. Turn the ignition switch to "LOCK". 3. Disconnect the battery "-" terminal cable, and wait at least 5 minutes. 4. Disconnect the yellow 2-way SRS connector located under the steering column. CAUTION: The wheels of the vehicle must be straight ahead and the steering column in the "LOCK" position before disconnecting the steering wheel. Failure to do so will cause the coil assembly to become uncentered which will cause damage to the coil assembly. 5. Remove the engine hood opening lever and steering lower cover. 6. Remove knee bolster (reinforcement). Page 7434 and the fuses. From Fuses to Relays and Components The second half of Power Distribution shows the wiring "From Fuses to Relays and Components." This can speed your troubleshooting by showing which circuits share fuses. If Power Distribution shows that an inoperative circuit and another circuit share a fuse, check a component in the other circuit. If it works, you know the fuse is good and power is available to the inoperative circuit. Ground Distribution Schematics Service and Repair Fuel Pressure Release: Service and Repair CAUTION: To reduce the risk of fire and personal injury, there are necessary to relieve the fuel system pressure filler and gauge unit before servicing the fuel system components. CAUTION: After relieving the system pressure, a small amount of fuel may be released when servicing fuel lines or connections. Reduce the chance of personal injury by covering the fuel line fittings with a shop towel before you disconnect the fittings. The towels will absorb any fuel that may leak out. When the disconnection is completed, place the towel in an approved container. 1. Remove the fuel cap. 2. Remove the fuel pump relay from the underhood relay box. 3. Start the engine and allow it to stall. 4. Crank the engine for 30 seconds. 5. Disconnect the negative battery cable. Page 7546 - Refer to the scrapping procedures for disposal of the damaged airbag. Capacity Specifications Fluid - A/T: Capacity Specifications A/T Fluid Capacity ............................................................................................................................................... ........................................................................... 8.6L Page 175 This means the branch of the wire connects to another circuit. The arrow points to the name of the circuit branch where the wire continues. Page 455 and the fuses. From Fuses to Relays and Components The second half of Power Distribution shows the wiring "From Fuses to Relays and Components." This can speed your troubleshooting by showing which circuits share fuses. If Power Distribution shows that an inoperative circuit and another circuit share a fuse, check a component in the other circuit. If it works, you know the fuse is good and power is available to the inoperative circuit. Ground Distribution Schematics Page 8230 primer. Primer should be handled as following: 1. Use the primer manufactured 3 months or less ago and having been kept in an refrigerator. 2. Wipe off primer-stains on positions other than requires application. 3. Stir the primer for a minute or more before use. 6. Apply the adhesive (1) to the windshield. - After drying primer completely, apply a sealing adhesive (Sun star # 555 or equivalent) along the edge of the glass so that the sealing adhesive has a 20 mm (0.79 in)junction at middle of the base of the glass. NOTE: Apply an adhesive 3 minutes or more but within 24 hours after the application of primer. If more than 24 hours have passed, reapply primer. Adhesive should be handled as follows: 1. Use the adhesive manufactured 3 months or less ago. 2. Wipe off adhesive-stains on positions other than requires application. 7. Install the windshield. - Set the windshield with sealing adhesive applied to entire circumference in the body panel. Specifically, adjust windshield support with the upper molding making contact with the body panel, press the glass, and tighten the windshield support. NOTE: Affix the glass within 5 minutes of application. 8. Install the front cowl cover. Engine Controls - Engine Spark Knock Or Pinging Powertrain Control Module: Customer Interest Engine Controls - Engine Spark Knock Or Pinging 01-084 June 19, 2009 Applies To: 2000-02 Passport - ALL Engine Spark Knock (Pinging) (Supersedes 01-084, dated March 18, 2003, to revise the information marked by asterisks) *REVISION SUMMARY Under WARRANTY CLAIM INFORMATION, the failed part number, the Honda code, the defect code, and the symptom code have been updated.* SYMPTOM An engine spark knock (pinging). PROBABLE CAUSE The programmed ignition timing does not correct quickly enough in some climates. CORRECTIVE ACTION Update the PCM software with the Smart Cable. TOOL INFORMATION PGM Tester with software update release SN200P (9/1/01) or later. For the other tools and equipment you need to update the PCM software, refer to Service Bulletin 99-005, Updathg the Passport POM, filed under Tools. WARRANTY CLAIM INFORMATION In warranty: The normal warranty applies. Operation Number: 125517 Flat Rate Time: 0.3 hour *Failed Part: P/N 8-12212-079-0 H/C 6974992 Defect Code: 03214 Symptom Code: 09117* Template ID: 01-084A Skill Level: Repair Technician Out of warranty: Any repair performed after warranty expiration may be eligible for goodwill consideration by the District Parts and Service Manager or your Zone Office. You must request consideration, and get a decision, before starting work. REPAIR PROCEDURE 1. Retrieve the PCM broadcast code with the PGM Tester or the Smart Cable (refer to Service Bulletin 99-005, Updathg the Passport PCM). Page 5218 2. Connect one lead of a self-powered test light or DVOM to one end of the part of the circuit you want to test. 3. Connect the other lead to the other end. 4. If the self-powered test light glows, there is continuity. If you're using a DVOM, a low reading or no reading (zero), means good continuity. Testing For Voltage When testing for voltage at a connector without wire seals, you do not have to separate the two halves of the connector. Instead, probe the connector from the back. Always check both sides of the connector because dirty, corroded, and bent terminals can cause problems (no electrical contact = an open). 1. Connect one lead of the lest light to a known good ground, or, if you're using a digital volt ohmmeter (DVOM), place it in the appropriate DC volts range, and connect its negative lead to ground. 2. Connect the other lead of the test light or DVOM to the point you want to check. 3. If the test light glows, there is voltage present. If you're using a DVOM, note the voltage reading. It should be within one volt of measured battery voltage. A loss of more than one volt indicates a problem. NOTE: Always use a DVOM on high impedance circuits. A test light may not glow (even with battery voltage present). Testing For Voltage Drop Wires, connectors, and switches are designed to conduct current with a minimum loss of voltage. A voltage drop of more than one volt indicates a problem. 1. Place the digital volt/ohmmeter (DVOM) in the appropriate DC volts range. Connect the positive lead to the end of the wire (or to the connector or switch) closest to the battery. 2. Connect the negative lead to the other end of the wire (or the other side of the connector or switch). 3. Turn on the components in the circuit. 4. The DVOM will show the difference in voltage between the two points. A difference, or drop, of more than one volt indicates a problem. Check the circuit for loose, dirty, or bent terminals. Page 2003 it is located, and what it connects to. Use the Connector Views to help locate the proper cavity when you need to probe a connector. It can be especially helpful if the connector has more than one wire of the same color. A dash symbol (-) indicates that the cavity is empty. Connector views can also be used to help diagnose multiple symptoms in separate circuits which could be caused by a single problem in a connector shared by those circuits. Here's an example: 1. Pick one of the multiple symptoms and look up the schematic for that circuit. 2. Make a list of all the in-line and fuse box connectors in that schematic , 3. Then, in the Connector Views, look up each connector on your list to see if circuits related to the other symptoms run through one of them. If they do, inspect that connector for the problem. Example: The blower, rear window defogger, and the windshield wiper don't work. List all in-line and fuse box connectors in the blower controls circuit and then check the Connector View (see the sample). You find that C324 is common to the blower controls, rear window defogger, and wiper/washer, so you inspect C324 and find the problem, bent terminals. Finding Component/Connector Locations Finding Component/Connector Locations To see where a component or connector is located on the car, look up its photo number in the "Component Location". The photo will also tell you the color of the connector, and how many cavities it has. Page 6865 Rear Door Window Regulator: Service and Repair Rear Window Regulator, Glass and Glass Run Rear Window Regulator, Glass and Glass Run Removal 1. Disconnect the battery ground cable. 2. Remove the rear corner garnish. - Pull the garnish to disconnect the retaining clip. Page 72 2. Connect one lead of a self-powered test light or DVOM to one end of the part of the circuit you want to test. 3. Connect the other lead to the other end. 4. If the self-powered test light glows, there is continuity. If you're using a DVOM, a low reading or no reading (zero), means good continuity. Testing For Voltage When testing for voltage at a connector without wire seals, you do not have to separate the two halves of the connector. Instead, probe the connector from the back. Always check both sides of the connector because dirty, corroded, and bent terminals can cause problems (no electrical contact = an open). 1. Connect one lead of the lest light to a known good ground, or, if you're using a digital volt ohmmeter (DVOM), place it in the appropriate DC volts range, and connect its negative lead to ground. 2. Connect the other lead of the test light or DVOM to the point you want to check. 3. If the test light glows, there is voltage present. If you're using a DVOM, note the voltage reading. It should be within one volt of measured battery voltage. A loss of more than one volt indicates a problem. NOTE: Always use a DVOM on high impedance circuits. A test light may not glow (even with battery voltage present). Testing For Voltage Drop Wires, connectors, and switches are designed to conduct current with a minimum loss of voltage. A voltage drop of more than one volt indicates a problem. 1. Place the digital volt/ohmmeter (DVOM) in the appropriate DC volts range. Connect the positive lead to the end of the wire (or to the connector or switch) closest to the battery. 2. Connect the negative lead to the other end of the wire (or the other side of the connector or switch). 3. Turn on the components in the circuit. 4. The DVOM will show the difference in voltage between the two points. A difference, or drop, of more than one volt indicates a problem. Check the circuit for loose, dirty, or bent terminals. Page 7952 Wires Wire insulation can be one color, or one color with another color stripe. (The second color is the stripe.) This circuit continues on another image. (The arrow shows direction of current flow.) To follow the RED/BLK wire in this example, you would turn to "Fuel and Emissions" and look for the "A" arrow. Page 3955 3. Start the engine, and let it warm up to normal operating temperature. 4. Move the selector lever through all shift positions, then apply the brakes, and move the lever to Park. 5. Check the drain plug and fill plug for signs of leakage. ^ If you see signs of leakage, turn off the engine. Remove and discard both plugs and gaskets. Let the oil pan drain completely, then install the new drain plug. Torque the drain plug to 38 N.m (28 lb-ft). Add DEXRON III ATF until it runs out the fill hole. Install the new fill plug hand tight. Go to step 6. ^ If you do not see signs of leakage, look for other possible causes of the leak. 6. Connect the PGM Tester to the 16P data link connector to measure ATF temperature. Start the engine. 7. Remove the fill plug, and add ATF until it runs out the fill hole. Reinstall the fill plug. 8. Move the selector lever through all shift positions, then apply the brakes, and move the lever to Park. 9. Remove the fill plug. 10. Let the engine idle until the ATF temperature is between 90° and 135° F (32° and 57° C). As the temperature increases, ATF drips out the fill hole until the correct fluid level is reached. 11. Reinstall the fill plug. Torque the fill plug to 38 N.m (28 lb-ft). 12. Turn off the engine, and disconnect the PGM Tester. Lower the vehicle. DISCLAIMER Page 7383 Ground - "G" Shielding Sheilding This represents RFI (Radio Frequency Interference) shielding around a wire. The shielding is always connected to ground. Splices Page 1652 Engine Oil Pressure: Testing and Inspection Engine Oil Pressure Check 1. Check for dirt, gasoline or water in the engine oil. a. Check the viscosity of the oil. b. Check the viscosity of the oil. c. Change the oil if the viscosity is outside the specified standard. 2. Check the engine oil level. The level should fall somewhere between the "ADD" and the "FULL" marks on the oil level dipstick. If the oil level does not reach the "ADD" mark on the oil level dipstick, engine oil must be added. 3. Remove the oil pressure unit. 4. Install an oil pressure gauge. 5. Start the engine and allow the engine to reach normal operating temperature (About 80°C). 6. Measure the oil pressure. Oil pressure should be: 392 - 550 kPa (56.9 - 80.4 psi) at 3000 rpm. 7. Stop the engine. 8. Remove the oil pressure gauge. 9. Install the oil pressure unit. 10. Start the engine and check for leaks. Page 290 Each schematic represents one circuit. A circuit's wires and components are arranged to show current flow, from power at the top of the page, to ground, at the bottom. Shared Circuits Other circuits may share power or ground terminals or wiring with the circuit shown. A wire that connects one circuit to another, for example, is cut short and has an arrowhead at the end of it pointing in the direction of current flow. Next to the arrowhead is the name of the circuit or component which shares that wiring. To quickly check shared wiring, check the operation of a component it serves. If that component works, you know the shared wiring is OK. Connectors All in-line and junction connectors are numbered (C725, C416, etc.). Component connectors are not numbered but are identified either by the name of Page 4133 1. With clutch switch. 1. Disconnect clutch switch connector. 2. Loosen lock nut, then turn switch out until there is a gap between the switch plunger and clutch pedal. 2. Loosen clutch master cylinder push rod lock nut. Turn push rod by hand to set clutch pedal height to within specification. Tighten push rod lock nut. Clutch Pedal Height: 178 - 188 mm (7.01 - 7.40 inch) Page 5669 Lateral Stabilizer Rod: Service and Repair REMOVAL 1. Remove nut and washer. 2. Remove bolt and nut. 3. Remove lateral rod. INSPECTION AND REPAIR Make necessary correction or parts replacement if wear, damage, corrosion or any other abnormal condition are found through inspection. 1. Lateral rod 2. Rubber bushing (Frame side) - Remove the rubber bushing (Frame side) by using remover J-39214. Page 6977 Air Bag(s) Arming and Disarming: Description and Operation Definitions Air Bag An inflatable cloth cushion designed to deploy in certain frontal crashes. It supplements the protection offered by the seat belts by distributing the impact load more evenly over the vehicle occupant's head and torso. Asynchronous Performed in a nonperiodic fashion, (i.e., no defined time or interval). (B+) Battery voltage, (B+) The voltage available at the battery at the time of the indicated measurement. With the key "ON" and the engine not running, the system voltage will likely be between 12 and 12.5 volts. At idle the voltage may be 14 to 16 volts. The voltage could be as low as 10 volts during engine cranking. Bulb Check The SDM will cause the "AIR BAG" warning lamp to flash seven times and then go "OFF" whenever the ignition switch transitions to the ON position from any other ignition switch position and no malfunctions are detected. "CONTINUOUS MONITORING" Tests performed by the SDM on the SRS every 100 milliseconds while "Ignition 1" voltage is in the normal operating voltage range at the SDM. Data Link Connector (DLC) Formerly "DLC" a connector which allows communication with an external computer, such as a scan tool. Datum Line A base line parallel to the plane of the underbody or frame from which all vertical measurements originate. Deploy To inflate the air bag. Deployment Loops The circuits which supply current to the air bag assemblies to deploy the air bag. Diagnostic Trouble Code (DTC) Formerly "Code", a numerical designator used by the SDM to indicate specific SRS malfunctions. Driver Current Source An output of the SDM which applies current into the driver air bag assembly circuit during the "Initiator Assembly Resistance Test". Driver Air Bag Assembly An assembly located in the steering wheel hub consisting of an inflatable bag, an inflator and an initiator. EEPROM Electronically Erasable Programmable Read Only Memory. Memory which retains its contents when power is removed from the SDM. Ignition Cycle The voltage at the SDM "Ignition 1" inputs, with ignition switch "ON", is within the normal operating voltage range for at least ten seconds before turning ignition switch "OFF". Ignition 1 Specifications Fuel Pressure: Specifications PRESSURE PRESSURE With Regulator Vacuume Hose Disconnected 42-55 Psi. Page 4679 If there is no photo number below or beside a component name or a connector, ground, or terminal number, look up that name or number in the appropriate Connector Identification Chart. The chart lists how many cavities a connector has, where it's located, and what it connects to. The related illustration shows the connector's location on the harness, and the harness routing. NOTE: Photos listed by number are located at Locations / Components / Photograohs. See: Locations/Component Locations/Photographs Circuit Schematics Page 3637 Spark Plug: Testing and Inspection Inspection and Repair The spark plug affects entire engine performance and therefore its inspection is very important. - Check electrode and insulator for presence of cracks, and replace if any. - Check electrode for wear, and replace if necessary.. - Check gasket for damage, and replace if necessary. - Measure insulation resistance with an ohmmeter, and replace if faulty. - Adjust spark plug gap to 1.0 mm (0.040 in) to 1.1 mm (0.043 in). - Check fuel and electrical systems if spark plug is extremely dirty. - Use spark plugs having low heat value (hot type plug) if fuel and electrical systems are normal. - Use spark plugs having high heat value (cold type plug) if insulator and electrode are extremely burned. Sooty Spark Plugs Much deposit of carbon or oil on the electrode and insulator of spark plug reduces the engine performance. Possible causes: - Too rich mixture - Presence of oil in combustion chamber - Incorrectly adjusted spark plug gap Burning Electrodes This fault is characterized by scorched or heavily oxidized electrode or blistered insulator nose. Possible causes: - Too lean mixture - Improper heat value Measuring Insulation Resistance - Measure insulation resistance using a 500 volt megaohm meter. - Replace spark plugs if measured value is out of standard. Insulation resistance: 50 Mohm or more. Page 2215 Vehicle Speed Sensor: Locations 92. Beneath Center of Vehicle, on Transfer Case (A/T) Beneath Center of Vehicle, on Transfer Case (A/T) Page 6323 - Tear off the insulator carefully. - Remove the sensor fixing clip. - Use a back-up wrench when disconnecting all refrigerant pipes. Installation To install, follow the removal steps in the reverse order, noting the following points: 1. The sensor is installed on the core with the clip. 2. The sensor must not interfere with the evaporator core. 3. When installing the new evaporator core, install the duct sensor (2) to the evaporator core (1) specified position with the clip in the illustration. 4. O-rings cannot be reused. Always replace with new ones. 5. Be sure to apply new compressor oil to the O-ring when connecting lines. 6. Be sure to install the sensor and the insulator on the place where they were before. 7. To install a new evaporator core, add 50cc (1.7 fl.oz.) of new compressor oil to the new core. 8. Tighten the refrigerant lines to the specified torque. Refer to Main Data and Specifications for Torque Specifications. 9. Apply an adhesive to the parting face of the lining when assembling the evaporator assembly. Page 7121 Paint: Technical Service Bulletins Paint Codes 00-032 March 7, 2000 Applies To: 2000 Models - ALL 2000 Honda Paint Codes Paint formulations are determined by each paint company. For questions about formulas or color matching, call your paint supplier or one of the companies listed in this bulletin. Component Tests Wheel Speed Sensor: Testing and Inspection Component Tests Front INSPECTION AND REPAIR 1. Check the speed sensor pole piece for presence of foreign materials; remove any dirt, etc. 2. Check the pole piece for damage; replace speed sensor if necessary. 3. Check the speed sensor cable for short or open circuit, and replace with a new one if necessary. To check for cable short or open, bend or stretch the cable while checking for continuity. 4. Check the sensor ring for damage including tooth chipping, and if damaged, replace the sensor ring assembly. Rear INSPECTION AND REPAIR 1. Check speed sensor pole piece for presence of foreign materials; remove any dirt, etc. 2. Check the pole piece for damage, and replace speed sensor if necessary. 3. Check speed sensor cable for short or open, and replace with a new one if necessary. To check for cable short or open, bend or stretch the cable while checking for continuity. 4. Check the sensor ring for damage including tooth chipping, and if damaged, replace the axle shaft assembly. Page 6072 If there is no photo number below or beside a component name or a connector, ground, or terminal number, look up that name or number in the appropriate Connector Identification Chart. The chart lists how many cavities a connector has, where it's located, and what it connects to. The related illustration shows the connector's location on the harness, and the harness routing. NOTE: Photos listed by number are located at Locations / Components / Photograohs. See: Locations/Component Locations/Photographs Circuit Schematics Accelerator Pedal Position Sensor - MIL ON/DTC's Set Technical Service Bulletin # 01-047 Date: 010814 Accelerator Pedal Position Sensor - MIL ON/DTC's Set 01-047 August 14, 2001 Applies To: 2000-01 Passport - ALL MIL Comes On With Accelerator Pedal Position Sensor DTC(s) P1271, P1273, P1275, P1280, and/or P1285 SYMPTOM The MIL is on with DTC P1271, P1273, P1275, P1280, or P1285 (various accelerator pedal position sensor problems) stored. The REDUCED POWER indicator may also be on; and the engine may occasionally idle too high, or the idle may fluctuate. PROBABLE CAUSE Contaminated grease on the potentiometer circuit board of the accelerator pedal position sensor (APPS) causes high resistance in the APPS circuit. CORRECTIVE ACTION Replace and adjust the APPS, remove all grease from the accelerator link, and clean the APPS harness connector and connector C123. PARTS INFORMATION Accelerator Pedal Position Sensor: P/N 8-97193-713-0, H/C 6198311 REQUIRED MATERIALS CAIG DeoxIT D5-S6 Contact Cleaner: P/N 341-200 (available from www.partsexpress.com) or Permatex Electrical Contact Cleaner: Permatex P/N 24379 WARRANTY CLAIM INFORMATION In warranty: The normal warranty applies. Operation Number: 122114 Flat Rate Time: 0.5 hour Failed Part: P/N 8-97220-540-0 H/C 6202436 Defect Code: 091 Contention Code: C99 Template ID: 01-047A Skill Level: Repair Technician Out of warranty: Any repair performed after warranty expiration may be eligible for goodwill consideration by the District Service Manager or your Zone Office. You must request consideration, and get a decision, before starting work. Locations Door Switch: Locations Page 7492 Dimmer Switch: Diagnostic Aids Before Troubleshooting Before Troubleshooting See: Service Precautions/Vehicle Damage Warnings/Tips and Precautions 1. Check applicable fuses in the appropriate fuse/relay box. 2. Check the battery for damage, state of charge, and clean and tight connections. CAUTION: Do not quick-charge a battery unless the battery ground cable has been disconnected, otherwise you will damage the alternator diodes. - Do not attempt to crank the engine with the battery ground cable loosely connected or you will severely damage the wiring. While You're Working 1. Make sure connectors are clean, and have no loose terminals or receptacles. 2. Make sure that connectors without wire seals are packed with dielectric (silicone) grease. Part Number: 08798-9001. 3. When connecting a connector, push it until it "clicks" into place. CAUTION: Do not pull on the wires when disconnecting a connector. Pull only on the connector housings. - Most circuits include solid-state devices. Test the voltages in these circuits only with a 10-megaohm or higher impedance digital multi meter. Never use a test light or analog meter on circuits that contain solid-state devices. Damage to the devices may result. Five-Step Troubleshooting 1. Verify The Complaint Turn on all the components in the problem circuit to check the accuracy of the customer complaint. Note the symptoms. Do not begin disassembly or testing until you have narrowed down the problem area. 2. Analyze The Schematic Look up the schematic for the problem circuit. Determine how the circuit is supposed to work by tracing the current paths from the power source through the circuit components to ground. Also, trace circuits that share wiring with the problem circuit. The names of circuits that share the same fuse, ground, or switch, and so on, are referred to in each circuit schematic. Try to operate any shared circuits you didn't check in step 1. If the shared circuits work, the shared wiring is OK, and the cause must be in the wiring used only by the problem circuit. If several circuits fail at the same time, the fuse or ground is a likely cause. Based on the symptoms and your understanding of the circuit's operation, identify one or more possible causes. 3. Isolate The Problem By Testing The Circuit Make circuit tests to check the diagnosis you made in step 2. Keep in mind that a logical, simple procedure is the key to efficient troubleshooting. Test for the most likely cause of failure first. Try to make tests at points that are easily accessible. 4. Fix The Problem Once the specific problem is identified, make the repair. Be sure to use proper tools and safe procedures. 5. Make Sure The Circuit Works Turn on all components in the repaired circuit in all modes to make sure you've fixed the entire problem. If the problem was a blown fuse, be sure to test all of the circuits on that fuse. Make sure no new problems turn up and the original problem does not recur. Page 6546 reaction, Potassium Chloride and copper metal dust. Compounds of Potassium Borate, Strontium Chloride, Copper Chloride, and Ammonium Chloride may be found in amounts of about 1% (each) of the total particulate. (Passenger air bag assembly) Put on a pair of shop gloves and safety glasses to protect your hands and eyes from possible irritation and heat when handling the deployed air bag assembly. After the air bag assembly has been deployed, the surface of the air bag may contain a powdery residue. This powder consists primarily of cornstarch (used to lubricate the bag as it inflates) and by products of the chemical reaction. Sodium hydroxide dust (similar to lye soap) is produced as a by product of the deployment reaction. The sodium hydroxide then quickly reacts with atmospheric moisture and is converted to sodium carbonate and sodium bicarbonate (baking soda). Therefore, it is unlikely that sodium hydroxide will be present after deployment. WARNING: SAFETY PRECAUTIONS MUST BE OBSERVED WHEN HANDLING A DEPLOYED AIR BAG ASSEMBLY. AFTER DEPLOYMENT, THE METAL SURFACES OF THE AIR BAG ASSEMBLY WILL BE VERY HOT. ALLOW THE AIR BAG ASSEMBLY TO COOL BEFORE HANDLING ANY METAL PORTION OF IT. DO NOT PLACE THE HOT DEPLOYED AIR BAG ASSEMBLY NEAR ANY FLAMMABLE OBJECTS. FAILURE TO FOLLOW PROCEDURES COULD RESULT IN FIRE OR PERSONAL INJURY. After an air bag assembly has been deployed, the metal canister and surrounding areas of the air bag assembly will be very hot. Do not touch the metal areas of the air bag assembly for about 30 minutes after deployment. If the deployed air bag assembly must be moved before it is cool, wear gloves and handle by the air bag or trim cover. 31. Short the driver deployment harness wires by twisting together one end from each. Repeat this procedure for the passenger deployment harness. 32. Carefully remove drop cloth from vehicle and clean off any fragments or discard drop cloth entirely. 33. Disconnect driver deployment harness and passenger deployment harness from vehicle and discard. 34. In the unlikely event that either or both of the air bag assemblies did not deploy after following these procedures, proceed immediately with Steps 36 through 37. If the air bag assembly deployed, proceed to step 35. 35. With both air bags deployed, the vehicle may be scrapped in the same manner as a non - SRS equipped vehicle. NOTE: The remaining steps are to be followed in the unlikely event that the air bag assembly did not deploy after following these procedures. 36. Remove the undeployed air bag assembly (s) from the vehicle. For driver air bag assembly refer to in the "Passenger Air Bag Assembly Removal". WARNING: WHEN STORING A LIVE AIR BAG ASSEMBLY OR WHEN LEAVING A LIVE AIR BAG ASSEMBLY UNATTENDED ON A BENCH OR OTHER SURFACE, ALWAYS FACE THE BAG AND TRIM COVER UP, AWAY FROM THE SURFACE. THIS IS NECESSARY SO THAT A FREE SPACE IS PROVIDED TO ALLOW THE AIR BAG TO EXPAND IN THE UNLIKELY EVENT OF ACCIDENTAL DEPLOYMENT. FAILURE TO FOLLOW PROCEDURES COULD RESULT IN PERSONAL INJURY. 37. Temporarily store the air bag assembly with the air bag opening facing up, away from the surface upon which it rests. Deploying Airbags/Tensioner (Outside Vehicle) Deployment of a live (undeployed) airbag assembly for disposal should not take place in the vehicle. This includes vehicles that needs replacement airbag assembly. Disposal of a malfunctioning air bag assembly is subjected to a retention period. Proper service procedures must be followed when performing live (undeployed) airbag deployment in the shop floor or open area live (undeployed) airbag deployment. Safety glasses and gloves must always be worn during live (undeployed) airbag deployment until the deployed airbag assembly has been properly disposed of or an undeployed airbag assembly is shipped. Before performing the procedures you should be familiar with servicing the SRS and with proper handling of the air bag assembly. Procedures should be read fully before they are performed. Page 2386 7. Turn the valve tappet with a pick or a small screwdriver until the tappet notch is within the indentation in the head. 8. Turn the crankshaft (or camshaft) pulley clockwise until the cam lobe presses the valve fully open. 9. On the tappet side closest to the bearing cap, insert the valve adjuster holder (T/N J-42659-AH) between the camshaft and the tappet. The tool should rest on the edge of the tappet without touching the shim. 10. Slowly turn the crankshaft (or camshaft) pulley counterclockwise so that when the valve closes, the tool catches between the camshaft and the tappet, holding the valve slightly open. NOTE: Do not turn the crankshaft (or camshaft) pulley too far or in the wrong direction. If you do, you might break the tool, or worse yet, damage the cylinder head. 11. Insert a pick or a small screwdriver into the tappet notch, and pry out the shim. 12. Wipe off the shim, then write its number on the Valve Inspection Chart for that valve and cylinder. If there is no number on the shim, measure its thickness with a micrometer, and write down the measurement on the Valve Inspection Chart. 13. Follow the directions on the Valve Shim Replacement Chart to select the correct shim. 14. Insert the correct shim, number side down, into the tappet. Make sure the shim is fully seated. 15. Release and remove the tool by turning the crankshaft (or camshaft) pulley clockwise. 16. Turn the crankshaft (or camshaft) pulley clockwise until the cam lobe again points away from the valve. Page 7705 Distinct Of Circuit By Wire Base Color All wires have color-coded insulation. Wires belonging to a system's main harness will have a single color. Wires belonging to a system's sub-circuits will have a colored stripe. Striped wires use the codes found in the chart to show wire size and colors. Abbreviations are used to indicate wire color within a circuit diagram. How to Identify Connector Terminals How to Identify Connector Terminals Cavity Numbering System The cavities (and wire terminals) in each connector are numbered starting from the upper left, looking at the male terminals from the terminal side (or looking at the female terminals from the wire side. Both views are in the same direction so the numbers are the same.) All actual cavities are numbered, even if they have no wire terminals in them. NOTE: Data Link Connector (DLC) terminals are numbered according to SAE standard J1962, not the Honda standard. The numbers of the four end terminals are molded into the corners of the connector face. The connector cavity number is listed next to each terminal on the circuit schematic. The cavity / terminal shown is # 6. Using/Identifying Connector Terminal Views How to Use Connector Terminal Views To see the configuration of a connector's cavities, look up its view number in the Connector Views. Each view includes the color of the connector, where Page 275 2. Connect one lead of a self-powered test light or DVOM to one end of the part of the circuit you want to test. 3. Connect the other lead to the other end. 4. If the self-powered test light glows, there is continuity. If you're using a DVOM, a low reading or no reading (zero), means good continuity. Testing For Voltage When testing for voltage at a connector without wire seals, you do not have to separate the two halves of the connector. Instead, probe the connector from the back. Always check both sides of the connector because dirty, corroded, and bent terminals can cause problems (no electrical contact = an open). 1. Connect one lead of the lest light to a known good ground, or, if you're using a digital volt ohmmeter (DVOM), place it in the appropriate DC volts range, and connect its negative lead to ground. 2. Connect the other lead of the test light or DVOM to the point you want to check. 3. If the test light glows, there is voltage present. If you're using a DVOM, note the voltage reading. It should be within one volt of measured battery voltage. A loss of more than one volt indicates a problem. NOTE: Always use a DVOM on high impedance circuits. A test light may not glow (even with battery voltage present). Testing For Voltage Drop Wires, connectors, and switches are designed to conduct current with a minimum loss of voltage. A voltage drop of more than one volt indicates a problem. 1. Place the digital volt/ohmmeter (DVOM) in the appropriate DC volts range. Connect the positive lead to the end of the wire (or to the connector or switch) closest to the battery. 2. Connect the negative lead to the other end of the wire (or the other side of the connector or switch). 3. Turn on the components in the circuit. 4. The DVOM will show the difference in voltage between the two points. A difference, or drop, of more than one volt indicates a problem. Check the circuit for loose, dirty, or bent terminals. Refrigerant Recovery Refrigerant: Service and Repair Refrigerant Recovery Air conditioning systems contain HFC-134a. This is a chemical mixture which requires special handling procedures to avoid personal injury. - Always wear safety goggles and protective gloves. - Always work in a well-ventilated area. Do not weld or steam clean on or near any vehicle-installed air conditioning lines or components. - If HFC-134a should come in contact with any part of the body, flush the exposed area with cold water and immediately seek medical help. - If it is necessary to transport or carry any container of HFC-134a in a vehicle, do not carry it in the passenger compartment. - If it is necessary to fill a small HFC-134a container from a large one, never fill the container completely. Space should always be allowed above the liquid for expansion. - HFC-134a and R-12 should never be mixed as their compositions are not the same. - HFC-134a PAG oil tends to absorb moisture more quickly than R-12 mineral oil and, therefore, should be handled more carefully. - Keep HFC-134a containers stored below 40 °C (100 °F). WARNING: - SHOULD HFC-134A CONTACT YOUR EYE(S), CONSULT A DOCTOR IMMEDIATELY. - DO NOT RUB THE AFFECTED EYE(S). INSTEAD, SPLASH QUANTITIES OF FRESH COLD WATER OVER THE AFFECTED AREA TO GRADUALLY RAISE THE TEMPERATURE OF THE REFRIGERANT ABOVE THE FREEZING POINT. - OBTAIN PROPER MEDICAL TREATMENT AS SOON AS POSSIBLE. SHOULD THE HFC-134A TOUCH THE SKIN, THE INJURY MUST BE TREATED THE SAME AS SKIN WHICH HAS BEEN FROSTBITTEN OR FROZEN. Refrigerant Recovery The refrigerant must be discharged and recovered by using the J-39500 (ACR4:HFC-134a Refrigerant Recovery/Recycling/Recharging/System) or equivalent before removing or mounting air conditioning parts. 1. Connect the high and low charging hoses of the ACR4 (or equivalent). 2. Recover the refrigerant by following the Manufacturer's Instructions. 3. When a part is removed, put a cap or a plug on the connecting portion so that dust, dirt or moisture cannot get into it. Refrigerant Recycling Recycle the refrigerant recovered by J-39500 (ACR4:HFC-134a Refrigerant Recovery/Recycling/Recharging/System) or equivalent. For the details of the actual operation, follow the steps in the ACR4 (or equivalent) Manufacturer's Instructions. Page 3704 Ground - "G" Shielding Sheilding This represents RFI (Radio Frequency Interference) shielding around a wire. The shielding is always connected to ground. Splices Page 4730 Page 4881 5. Insert a block of wood into the caliper and force out the piston by blowing compressed air into the caliper at the flexible hose attachment. This procedure must be done prior to removal of the dust boot. Remove piston. WARNING: Do not place your fingers in front of the piston in an attempt to catch or protect it when applying compressed air. this could result in personal injury. CAUTION: Use just enough air to ease the piston out of the bore. If the piston is blown out, it may be damaged. 6. Remove dust boot: piston. 7. Remove piston seal. 8. Remove bleeder with cap. 9. Remove caliper body. INSPECTION AND REPAIR Make necessary parts replacement, if wear, damage, corrosion or any other abnormal conditions are found through inspection. Check the following parts: Rotor - Cylinder body - Cylinder bore - Piston - Guide bolt, lock bolt - Support bracket NOTE: The piston dust seal and dust boot are to be replaced each time the caliper is overhauled. Discard these used rubber parts and replace with new ones. REASSEMBLY 1. Install caliper body. 2. Install bleeder with cap and tighten the cap to the specified torque. Torque: 8 Nm (69 ft. lbs.) 3. Install piston seal and apply special rubber grease to the piston seal and cylinder wall, then insert the piston seal into the cylinder. The special rubber grease is included in the repair kit. Page 4807 Part 1 of 2 Part 2 of 2 B-20 FL Speed Sensor Missing (DTC 61/C0226, C0227) Chart B-20 FL Speed Sensor Missing (DTC 61 (Flash Out) / C0226, C0227 (Serial Communications)) Page 8221 Windshield Page 1000 The road crown gauge measures the amount of road crown. Almost all roads have a crown to help drain water during rainstorms. Use the suction cup to attach the road crown gauge bracket to the vehicle in a vertical position. If necessary, bend the bracket until the gauge is vertical. Once you attach and align the road crown gauge, calibrate the gauge to zero. There are two ways to calibrate the gauge: ^ Park the vehicle on a level surface, such as an alignment rack, and calibrate the gauge by moving the gauge until the ball is on the zero mark. ^ If you do not have a perfectly flat surface, park the vehicle on a reasonably flat surface and note the gauge reading. Turn the vehicle 1800 and, with the tires in the same spot, note the new gauge reading. Then move the gauge half of the difference. For example, if your first reading is +3 and, after moving the vehicle, the gauge reads -1, then the difference is 4 degrees. Position the gauge to read +1. NOTE: You must calibrate the gauge with the same weight in the vehicle that you will use for the test-drive. If you plan to have an assistant help you during the test-drive, calibrate the gauge while both of you are sitting in the vehicle. Locations Gear Sensor/Switch: Locations Top Right Side Of Transfer Case Page 1900 Page 5749 16. Cover all six holes with the 3/4 in. round labels from the kit. This will prevent the Noxudol anti-corrosion wax from contaminating the pop nut threads and the weld nut threads (if applicable). Also, use masking tape to cover the other areas shown below. This will prevent the Noxudol from contaminating the bracket mounting surfaces. 17. Apply Noxudol 700 and Noxudol 300 anti-corrosion waxes (see steps 5 thru 13 of STAGE 2 REPAIR). 18. Remove the round labels and the masking tape. 19. Remove the passenger's side lower trailing link front mounting bolt. NOTE: On 2000-02 Passports, interference from the exhaust silencer (muffler) prevents removal of the front mounting bolt. On these vehicles, use a reciprocating saw to cut off the bolt head, then slide the rest of the bolt through the other side of the mount. Page 2027 Fuel Pump Relay: Service and Repair REMOVAL PROCEDURE 1. Remove the fuse and relay box cover from under the hood. 2. Consult the diagram on the cover to determine which is the correct relay. 3. Insert a small screwdriver into the catch slot on the forward side of the fuel pump relay. 4. The screwdriver blade will release the catch inside. 5. Pull the relay straight up and out of the fuse and relay box. INSTALLATION PROCEDURE 1. Insert the relay into the correct place in the fuse and relay box with the catch slot facing forward. 2. Press down until the catch engages. - An audible "click" will be heard. Page 3179 Air Flow Meter/Sensor: Description and Operation Mass Air Flow (MAF) Sensor The mass air flow (MAF) sensor measures the difference between the volume and the quantity of air that enters the engine. "Volume" means the size of the space to be filled. "Quantity" means the number of air molecules that will fit into the space. This information is important to the PCM because heavier, denser air will hold more fuel than lighter, thinner air. The PCM adjusts the air/fuel ratio as needed depending on the MAF value. The Tech 2 reads the MAF value and displays it in terms of grams per second (g/sec). At idle, the Tech 2 should read between 4 - 7 g/sec on a fully warmed up engine. Values should change quickly on acceleration. Values should remain stable at any given RPM. A failure in the MAF sensor or circuit will set DTC P0101, DTC P0102, or DTC P0103. Page 507 Seat Belt, Lights-ON and Ignition Key Reminders Part 2 Of 2 Page 3823 6. Place the end of the return hose in a container. Have someone start the engine, then pour ATF into the reservoir while you watch the fluid coming out of the return hose. When the fluid coming out is the same color as the new fluid, turn off the engine. 7. Reconnect the return hose to the reservoir. 8. Start the engine. Fill the power steering reservoir to the proper level with ATF then turn off the engine. 9. Use the Smart Cable to reprogram the PCM with the latest software from the June 2001 or later HONDANET CD-ROM. Refer to Service Bulletin 99-005, Updating the Passport PCM, filed under Tools. 10. Use the PGM Tester to clear any DTCs. 11. Use the PGM Tester to check the broadcast code. Make sure the broadcast code matches the one you selected from the CD-ROM. WARRANTY CLAIM INFORMATION In warranty: The normal warranty applies. Failed Part: P/N 8-97181-590-0 H/C 5698030 Defect Code: 064 Contention Code: C01 Skill Level: Repair Technician Out of warranty: Any repair performed after warranty expiration may be eligible for goodwill consideration by the District Service Manager or your Zone Office. You must request consideration, and get a decision, before starting work. REPAIR PROCEDURE - APPS GROUND 1. Unclamp the air cleaner housing cover, and move it to the side for access to connector C123 (16P BLK). Page 5344 6. Place the end of the return hose in a container. Have someone start the engine, then pour ATF into the reservoir while you watch the fluid coming out of the return hose. When the fluid coming out is the same color as the new fluid, turn off the engine. 7. Reconnect the return hose to the reservoir. 8. Start the engine. Fill the power steering reservoir to the proper level with ATF then turn off the engine. 9. Use the Smart Cable to reprogram the PCM with the latest software from the June 2001 or later HONDANET CD-ROM. Refer to Service Bulletin 99-005, Updating the Passport PCM, filed under Tools. 10. Use the PGM Tester to clear any DTCs. 11. Use the PGM Tester to check the broadcast code. Make sure the broadcast code matches the one you selected from the CD-ROM. WARRANTY CLAIM INFORMATION In warranty: The normal warranty applies. Failed Part: P/N 8-97181-590-0 H/C 5698030 Defect Code: 064 Contention Code: C01 Skill Level: Repair Technician Out of warranty: Any repair performed after warranty expiration may be eligible for goodwill consideration by the District Service Manager or your Zone Office. You must request consideration, and get a decision, before starting work. REPAIR PROCEDURE - APPS GROUND 1. Unclamp the air cleaner housing cover, and move it to the side for access to connector C123 (16P BLK). Page 5111 General Specifications Page 4940 angle. The angle locator level (P/N SUN-YA328A) is available through the Honda Tool and Equipment Program. To order one, call 888-424-6857. DISCLAIMER Page 7607 Low Fuel Lamp/Indicator: Diagnostic Aids Before Troubleshooting Before Troubleshooting See: Service Precautions/Vehicle Damage Warnings/Tips and Precautions 1. Check applicable fuses in the appropriate fuse/relay box. 2. Check the battery for damage, state of charge, and clean and tight connections. CAUTION: Do not quick-charge a battery unless the battery ground cable has been disconnected, otherwise you will damage the alternator diodes. - Do not attempt to crank the engine with the battery ground cable loosely connected or you will severely damage the wiring. While You're Working 1. Make sure connectors are clean, and have no loose terminals or receptacles. 2. Make sure that connectors without wire seals are packed with dielectric (silicone) grease. Part Number: 08798-9001. 3. When connecting a connector, push it until it "clicks" into place. CAUTION: Do not pull on the wires when disconnecting a connector. Pull only on the connector housings. - Most circuits include solid-state devices. Test the voltages in these circuits only with a 10-megaohm or higher impedance digital multi meter. Never use a test light or analog meter on circuits that contain solid-state devices. Damage to the devices may result. Five-Step Troubleshooting 1. Verify The Complaint Turn on all the components in the problem circuit to check the accuracy of the customer complaint. Note the symptoms. Do not begin disassembly or testing until you have narrowed down the problem area. 2. Analyze The Schematic Look up the schematic for the problem circuit. Determine how the circuit is supposed to work by tracing the current paths from the power source through the circuit components to ground. Also, trace circuits that share wiring with the problem circuit. The names of circuits that share the same fuse, ground, or switch, and so on, are referred to in each circuit schematic. Try to operate any shared circuits you didn't check in step 1. If the shared circuits work, the shared wiring is OK, and the cause must be in the wiring used only by the problem circuit. If several circuits fail at the same time, the fuse or ground is a likely cause. Based on the symptoms and your understanding of the circuit's operation, identify one or more possible causes. 3. Isolate The Problem By Testing The Circuit Make circuit tests to check the diagnosis you made in step 2. Keep in mind that a logical, simple procedure is the key to efficient troubleshooting. Test for the most likely cause of failure first. Try to make tests at points that are easily accessible. 4. Fix The Problem Once the specific problem is identified, make the repair. Be sure to use proper tools and safe procedures. 5. Make Sure The Circuit Works Turn on all components in the repaired circuit in all modes to make sure you've fixed the entire problem. If the problem was a blown fuse, be sure to test all of the circuits on that fuse. Make sure no new problems turn up and the original problem does not recur. Page 7713 The connector cavity number is listed next to each terminal on the circuit schematic. The cavity / terminal shown is # 6. Diodes A rectifier diode works like a one way valve. It allows current to flow only in the direction of the arrow. A Zener diode blocks reverse current at normal voltages just like a rectifier diode. At high voltages, however, a Zener diode allows current to flow in reverse. Fuses Page 4314 6. Break retainer ring with hammer and chisel. 7. Break bearing cage with hammer and chisel. 8. Remove oil seal, retainer, and emergency brake assembly. 9. Remove inner race from shaft with OTC-1126 bearing splitter and press. INSPECTION - Shaft for spalling or grooves from seal wear. - Retainer - bent or damaged. - Replace items if required. INSTALLATION 1. Emergency brake assembly. Page 6549 10. Place a power source near the shorted end of the SRS deployment harness. Recommended application: 12 volts minimum, 2 amps minimum. A vehicle battery is suggested. 11. Connect the driver air bag assembly to the pigtail adapter on the Supplemental Restraint System (SRS) deployment harness. Deployment harness shall remain shorted and not be connected to a power source until the air bag is to be deployed. The driver air bag assembly will immediately deploy the air bag when a power source is connected to it. NOTE: Ensure that the pigtail adapter is firmly seated into the driver air bag assembly connector. Failure to fully seat the connectors may leave the shorting bar located in the driver air bag assembly connector functioning (shorted) and may result in non deployment of the driver air bag assembly. 12. Verify that the area around the driver air bag assembly is clear of all people and loose or flammable objects. 13. Verify that the driver air bag assembly is firmly and properly in J-41434. 14. Notify all people in the immediate area that you intend to deploy the driver air bag. The deployment will be accompanied by a substantial noise which may startle the uninformed. 15. Separate the two banana plugs on the SRS deployment harness. NOTE: When the air bag deploys, the rapid gas expansion will create a substantial noise. Notify all people in the immediate area that you intend to deploy the driver air bag. WARNING: DEPLOYMENT HARNESS SHALL REMAIN SHORTED AND NOT BE CONNECTED TO A POWER SOURCE UNTIL THE AIR BAG IS TO BE DEPLOYED. THE AIR BAG ASSEMBLY WILL IMMEDIATELY DEPLOY THE AIR BAG WHEN A POWER SOURCE IS CONNECTED TO IT. CONNECTING THE DEPLOYMENT HARNESS TO THE POWER SOURCE SHOULD ALWAYS BE THE LAST STEP IN THE AIR BAG ASSEMBLY DEPLOYMENT PROCEDURE. FAILURE TO FOLLOW PROCEDURES IN THE ORDER LISTED MAY RESULT IN PERSONAL INJURY. 16. Connect the Supplemental Restraint System (SRS) deployment harness wires to the power source to immediately deploy the driver air bag. Recommended application: 12 volts minimum, 2 amps minimum. A vehicle battery is suggested. 17. Disconnect the SRS deployment harness from the power source. 18. Short the two SRS deployment harness leads together by fully seating one banana plug into the other. 19. In the unlikely event that the driver air bag assembly did not deploy after following these procedures, proceed immediately with Steps 24 through 26. If the driver air bag assembly did deploy, proceed with Steps 20 through 23. 20. Put on a pair of shop gloves and safety glasses to protect your hands and eyes from possible irritation and heat when handling the deployed driver air bag assembly. After the air bag assembly has been deployed, the surface of the air bag may contain solid particulate. This solid particulate consists primarily of by products of the chemical reaction, Potassium Chloride and copper metal dust. Compounds of Potassium Borate, Strontium Chloride, Copper Chloride, and Ammonium Chloride may be found in amounts of about 1 % (each) of the total particulate. WARNING: SAFETY PRECAUTIONS MUST BE OBSERVED WHEN HANDING A DEPLOYED AIR BAG ASSEMBLY. AFTER DEPLOYMENT, THE METAL SURFACES OF THE AIR BAG ASSEMBLY WILL BE VERY HOT. ALLOW THE INFLATOR MODULE TO COOL BEFORE HANDLING ANY METAL PORTION OF IT. DO NOT PLACE THE DEPLOYED AIR BAG ASSEMBLY NEAR ANY FLAMMABLE OBJECTS. FAILURE TO FOLLOW PROCEDURES MAY RESULT IN FIRE OR PERSONAL INJURY. AFTER A DRIVER AIR BAG ASSEMBLY HAS BEEN DEPLOYED, THE METAL CANISTER AND Page 7141 10. Remove the right luggage side trim cover. - Remove the jack & tool lid and take out the tools. Then remove the fixing screw and pull the clips out from the body panel. - To remove the left luggage side trim cover, disconnect the accessory socket connector. 11. Remove the rear seat belt assembly. 12. Remove the seat belt cross bar assembly. - Remove the two sets of seven fixing bolts on the left and right sides. Note that on the soft top model, two sets of the fixing bolts are also used to secure the tarpaulin frame assembly in place, and that on the resin top model, one set of the fixing bolts are also used to secure the resin top in place. Installation To install, follow the removal steps in the reverse order, noting the following points. 1. Tighten the rear seat belt anchor bolts to the specified torque. Torque: 39 Nm (29 lb.ft) 2. Tighten the seat belt cross bar assembly fixing bolts to the specified torque. Torque: 19 Nm (14 lb.ft) Page 2966 Each schematic represents one circuit. A circuit's wires and components are arranged to show current flow, from power at the top of the page, to ground, at the bottom. Shared Circuits Other circuits may share power or ground terminals or wiring with the circuit shown. A wire that connects one circuit to another, for example, is cut short and has an arrowhead at the end of it pointing in the direction of current flow. Next to the arrowhead is the name of the circuit or component which shares that wiring. To quickly check shared wiring, check the operation of a component it serves. If that component works, you know the shared wiring is OK. Connectors All in-line and junction connectors are numbered (C725, C416, etc.). Component connectors are not numbered but are identified either by the name of Page 8024 Headlamp Switch: Diagnostic Aids Before Troubleshooting Before Troubleshooting See: Service Precautions/Vehicle Damage Warnings/Tips and Precautions 1. Check applicable fuses in the appropriate fuse/relay box. 2. Check the battery for damage, state of charge, and clean and tight connections. CAUTION: Do not quick-charge a battery unless the battery ground cable has been disconnected, otherwise you will damage the alternator diodes. - Do not attempt to crank the engine with the battery ground cable loosely connected or you will severely damage the wiring. While You're Working 1. Make sure connectors are clean, and have no loose terminals or receptacles. 2. Make sure that connectors without wire seals are packed with dielectric (silicone) grease. Part Number: 08798-9001. 3. When connecting a connector, push it until it "clicks" into place. CAUTION: Do not pull on the wires when disconnecting a connector. Pull only on the connector housings. - Most circuits include solid-state devices. Test the voltages in these circuits only with a 10-megaohm or higher impedance digital multi meter. Never use a test light or analog meter on circuits that contain solid-state devices. Damage to the devices may result. Five-Step Troubleshooting 1. Verify The Complaint Turn on all the components in the problem circuit to check the accuracy of the customer complaint. Note the symptoms. Do not begin disassembly or testing until you have narrowed down the problem area. 2. Analyze The Schematic Look up the schematic for the problem circuit. Determine how the circuit is supposed to work by tracing the current paths from the power source through the circuit components to ground. Also, trace circuits that share wiring with the problem circuit. The names of circuits that share the same fuse, ground, or switch, and so on, are referred to in each circuit schematic. Try to operate any shared circuits you didn't check in step 1. If the shared circuits work, the shared wiring is OK, and the cause must be in the wiring used only by the problem circuit. If several circuits fail at the same time, the fuse or ground is a likely cause. Based on the symptoms and your understanding of the circuit's operation, identify one or more possible causes. 3. Isolate The Problem By Testing The Circuit Make circuit tests to check the diagnosis you made in step 2. Keep in mind that a logical, simple procedure is the key to efficient troubleshooting. Test for the most likely cause of failure first. Try to make tests at points that are easily accessible. 4. Fix The Problem Once the specific problem is identified, make the repair. Be sure to use proper tools and safe procedures. 5. Make Sure The Circuit Works Turn on all components in the repaired circuit in all modes to make sure you've fixed the entire problem. If the problem was a blown fuse, be sure to test all of the circuits on that fuse. Make sure no new problems turn up and the original problem does not recur. Page 3825 10. Use the PGM Tester to check the broadcast code. Make sure the broadcast code matches the one you selected from the CD-ROM. WARRANTY CLAIM INFORMATION In warranty: The normal warranty applies. Failed Part: P/N 8-17087-655-0 H/C 4375820 Defect Code: 064 Contention Code: C01 Skill Level: Repair Technician Out of warranty: Any repair performed after warranty expiration may be eligible for goodwill consideration by the District Service Manager or your Zone Office. You must request consideration, and get a decision, before starting work. REPAIR PROCEDURE - ENGINE/BODY GROUND 1. Use the ETM for the appropriate year to locate these ground connectors: G101, G104, G105, G106 and G160. 2. Inspect each connector for corrosion or looseness. 3. Remove the bolt from any connector that is corroded or loose. Clean the terminal connector with a wire brush. File flat any solder bumps on the connector. 4. Clean the contact surface on the engine or body with a wire brush. 5. Replace the bolt if it is heavily corroded. Otherwise, clean it with a wire brush. 6. Apply lithium dielectric grease to both sides of the terminal connector. 7. Reinstall the bolt, torque it to 14 N.m (10 lb-ft). 8. Use the Smart Cable to reprogram the PCM with the latest software from the June 2001 or later HONDANET CD-ROM. Refer to Service Bulletin 99-005, Updating the Passport PCM, filed under Tools. 9. Use the PGM Tester to clear any DTCs. 10. Use the PGM Tester to check the broadcast code. Make sure the broadcast code matches the one you selected from the CD-ROM. WARRANTY CLAIM INFORMATION In warranty: The normal warranty applies. Failed Part: P/N 8-97086-823-0 Page 1601 Drive Belt: Service and Repair Drive Belt and Cooling Fan The drive belt adjustment is not required as automatic drive belt tensioner is equipped. Inspection Check drive belt for wear or damage, and replace with a new one as necessary. Installation 1. Install cooling fan assembly and tighten bolts/nuts to the specified torque. Torque: 22 Nm (16 ft. lbs.) for fan pulley and fan bracket. Torque: 7.5 Nm (66.4 inch lbs.) for fan and clutch assembly. Note: Fan belts for 6VD1 Gasoline Engine mounted on 98-> Passport have been brought into one. As a result, the rotating direction of a fan belt is opposite to the direction of cooling fan for <-97 Passport 3.2 with no interchangeability. Therefore, incorrect installation of a fan may cause the air for cooling to now in the opposite direction, this resulting in the poor performance of the air-conditioner and a rise temperature in engine cooling water. Page 713 6. Screw the accumulator cover removal tool clockwise into the accumulator cover. 7. Using a 22 mm wrench, continue turning the tool clockwise until the accumulator cover turns in the housing. 8. Position a drain pan under the transmission. 9. Using the 22 mm wrench as a lever and the transmission case as the fulcrum, pry the accumulator cover out of the housing. NOTE: For maximum leverage, do not fully seat the 22 mm wrench against the removal tool. Line up the end of the wrench with the center of the tool. 10. Clean the accumulator housing. 11. Lubricate the accumulator housing and the accumulator cover with clean ATF. NOTE: The accumulator cover is rubber coated and does not require an 0-ring or sealant. Page 5754 ^ Disconnect the fuel tank at locations 2, 3, and 4. shown below. 6. Loosen the parking brake cable mounting brackets on both sides of the frame (four places). 7. On the driver's side of the frame, loosen the six wire harness clips. Locations Service and Repair Shift Indicator: Service and Repair Removal 1. Disconnect the battery ground cable. 3. Remove the meter lens (3) from the meter visor (4). 4. Remove the meter visor from the meter case(5). Page 7581 Test Equipment CAUTION: Most circuits include solid-state devices. Test the voltages in these circuits only with a 10-megaohm or higher impedance digital multimeter. Never use a test light or analog meter on circuits that contain solid-state devices. Damage to the devices may result. Test Light and DVOM On circuits without solid-state devices, use a test light to check for voltage. A test light is made up of a 12 volt bulb with a pair of leads attached. After grounding one lead, touch the other lead to various points along the circuit where voltage should be present. The bulb will go on if there is voltage at the point being tested. If you need to know how much voltage is present, use a digital volt/ohmmeter (DVOM). Self-Powered Test Light and DVOM Use a self-powered test light to check for continuity. This tool is made up of a light bulb, battery, and two leads. To test it, touch the leads together: the light should go on. Use a self-powered test light only on an unpowered circuit. First, disconnect the battery, or remove the fuse that feeds the circuit you are working on. Select two points in the circuit between which you want to check continuity. Connect one lead of the self-powered test light to each point. If there is continuity, the test light's circuit will be completed, and the light will go on. If, in addition, you need to know exactly how much resistance there is between two points, use a digital volt/ohmmeter (DVOM). In the "OHMS" range, the DVOM will measure resistance between two points along a circuit. Low resistance means good continuity. Diodes and solid-state devices in a circuit can make a DVOM give a false reading. To check a reading, reverse the leads, and take a second reading. If the readings differ, the component is affecting the measurement. Jumper Wire Use a jumper wire to bypass an open circuit. A jumper wire is made up of an in-line fuse holder connected to a set of test leads. It should have a five ampere fuse. Never connect a jumper wire across a short circuit. The direct battery short will blow the fuse. Short Finder (Short Circuit Locator) Short finders are available to locate shorts to ground. The short finder creates a pulsing magnetic field in the shorted circuit which you can follow to the location of the short. To order any test equipment shown above, contact your local tool supplier. For a list of suppliers and tool numbers, refer to Honda Required Special Tools and Equipment Service Bulletin. Page 3272 Fuel Pressure Regulator: Description and Operation Fuel Pressure Regulator The fuel pressure regulator is a diaphragm-operated relief valve mounted on the fuel rail with fuel pump pressure on one side and manifold pressure on the other side. The fuel pressure regulator maintains the fuel pressure available to the injector at three times barometric pressure adjusted for engine load. It may be serviced separate. If the pressure is too low, poor performance and a DTC P0131, DTC P0151, DTC P0171 or DTC P1171 will be the result. If the pressure is too high, excessive odor and/or a DTC P0132, DTC P0152, DTC P0172 will be the result. Refer to Fuel System Diagnosis for information on diagnosing fuel pressure conditions. See: Computers and Control Systems/Testing and Inspection/Component Tests and General Diagnostics/Fuel System Page 6290 This sample Ground Distribution schematic shows all of the components that share two ground points. Components A solid border line means the entire component is shown. A broken border line indicates that only part of the component is shown. Page 6595 - Select Settings. - Select About. ^ iPod reset procedure: http://docs.info.apple.com/ article.html?artnum=61705 Resources for Installation Instructions Online, enter the model and year, enter the keyword MUSIC LINK, and select the appropriate installation instructions. Music Link First-Use Information After installing the Music Link kit, switch the audio unit to AUX (auxiliary) mode and verify the audio unit displays CDC EJECT or CD4 EJECT. Connect the iPod to the Music Link connector. Make sure the check mark is displayed on the iPod display screen and that you hear music. ^ The Music Link disc supplied in the kit contains the TTS software and the User's Guide. It is for home computer use only. ^ The customer needs to load the TTS software/User's Guide on his/her home computer in order for all of the search functions (Disc 1-4) to operate. ^ Only the shuffle functions (Disc 5-6) will operate without the TTS software installed (see the Quick Reference Guide). ^ For the search functions (Disc 1-4) to operate properly, TTS software must be run after any songs are changed (added or removed) on the iPod. ^ You can change the Disc position on most audio units by using the Disc - (preset number 5) and Disc + (preset number 6). Always refer to the User's Guide for proper operation. iPod Reset Procedure Information The iPod reset procedure applies to these Apple iPod models: ^ Fifth-generation or later iPod (also known as iPod with video) ^ iPod nano(R) ^ iPod with color display (iPod photo) ^ iPod mini(R) NOTE: To view this information online, log on to http//docs.info.apple.com/article.html?artnum=6 1705 To reset the customer's iPod: 1. Cycle the Hold switch on and off (slide it to Hold, then turn it off again). 2. Press and hold the Menu and Select buttons for 6-10 seconds until the Apple logo appears. NOTE: If you are having difficulty resetting the iPod, set it on a flat surface. As you press the Select button, make sure your finger does not touch any part of the click wheel. Also make sure that you press the Menu button toward the outside of the click wheel and not near the center. 3. If the above steps do not work, try connecting the iPod to a power adapter and plug the power adapter into an electrical outlet, or connect the iPod to your computer. Make sure the computer is on and isn't set to sleep mode. BEFORE TROUBLESHOOTING ^ Before troubleshooting, ask the customer these questions: - What is the main issue? - What model and generation iPod do you have? Refer to www.apple.com. - What version iPod firmware (unit software) is loaded? ^ Go to the Main Menu. ^ Select Settings. Page 4143 Clutch Slave Cylinder: Service and Repair Clutch Control For further information regarding this component and the system that it is a part of, please refer to Clutch Master Cylinder; Service and Repair; Clutch Control. Page 902 4. Remove the fuel pressure regulator from the fuel rail. 5. Remove the fuel return line from the regulator. 6. Install the new fuel pressure regulator in the reverse order of removal. 7. Use the Smart Cable to reprogram the PCM with the latest software from the June 2001 or later HONDANET CD-ROM. Refer to Service Bulletin 99-005, Updating the Passport PCM, filed under Tools. 8. Use the PGM Tester to clear any DTCs. 9. Use the PGM Tester to check the broadcast code. Make sure the broadcast code matches the one you selected from the CD-ROM. WARRANTY CLAIM INFORMATION In warranty: The normal warranty applies. Failed Part: P/N 8-17113-398-0 H/C 5504386 Defect Code: 092 Contention Code: C99 Skill Level: Repair Technician Out of warranty: Any repair performed after warranty expiration may be eligible for goodwill consideration by the District Service Manager or your Zone Office. You must request consideration, and get a decision, before starting work. REPAIR PROCEDURE - POWER STEERING SWITCH 1. Drain the power steering fluid out of the system. 2. Remove the power steering fluid reservoir. Clean the reservoir with solvent, then with soap and water. Rinse and dry it thoroughly. 3. Reinstall the reservoir. Do not connect the return hose. 4. Remove the power steering pressure switch, then clean it with brake cleaner and a scraper. Reinstall the switch, and torque it to 20 N.m (14 lb-ft). 5. Cover the unconnected end of the reservoir with your finger, then fill the reservoir with Dexron III ATF Page 5609 Page 7675 Wire Color Abbreviations The following abbreviations are used to identify wire colors in the circuit schematics: WHT................................... White YEL................................... Yellow BLK................................... Black BLU................................... Blue GRN................................... Green RED................................... Red ORN................................... Orange PNK................................... Pink BRN................................... Brown GRY................................... Gray PUR................................... Purple LT BLU................................... Light Blue LT GRN................................... Light Green Windshield Wiper Motor Replacement Wiper Motor: Service and Repair Windshield Wiper Motor Replacement Removal 1. Disconnect the battery ground cable. 2. Disconnect the connector(2). 3. Remove 4 mounting bolts. 4. Remove the nut of the wiper motor shaft, and disconnect the linkage. 5. Remove the windshield wiper motor(1). CAUTION: To facilitate the removal of the nuts, be sure to put out the tip portion of the linkage sufficiently through the mounting hole of the motor by sliding the wiper blade slowly. Installation To install, follow the removal steps in the reverse order, noting the following points: 1. Tighten the wiper motor shaft nut to the specified torque. Torque: 14 Nm (122 lb in) 2. Remove the wiper arms on both sides, and rotate the wiper motor until it gets to the autostop position to reinstall the wiper blade. Page 5239 Removal and Installation Spark Plug: Service and Repair Removal and Installation Removal 1. Remove spark plugs. Installation 1. Spark plugs - Tighten spark plugs to the specified torque. Torque: 18 Nm (13 lb.ft) Service and Repair Fluid Pump: Service and Repair For further information regarding this component and the system that it is a part of, please refer to Automatic Transmission/Transaxle; Service and Repair; Unit Overhaul Page 5927 The wire insulation has one color or one color with another color stripe. The second color is the stripe. Locations Consoles And Associated Parts Page 118 This sample Ground Distribution schematic shows all of the components that share two ground points. Components A solid border line means the entire component is shown. A broken border line indicates that only part of the component is shown. Engine Controls - CHECK TRANS/CRUISE SET Lamps Flashing PROM - Programmable Read Only Memory: Customer Interest Engine Controls - CHECK TRANS/CRUISE SET Lamps Flashing 01-044 May 8, 2001 Applies To: 2000 Passport - ALL 2001 Passport - From VIN 4S6..58W.14400001 thru 4S6..58W.14409430 CHECK TRANS and CRUISE SET Indicators Are Flashing SYMPTOM The CHECK TRANS and CRUISE SET indicators on the instrument panel flash when the ignition switch is turned to ON (II). PROBABLE CAUSE Using a brand of spark plugs other than Denso can cause the PCM to detect an additional crank sensor pulse. If this happens, the PCM resets itself and turns on the CHECK TRANS and CRUISE SET indicators. CORRECTIVE ACTION Update the PCM software with the Smart Cable. TOOL INFORMATION PGM Tester loaded with SN131 (04/16/01) or later software. For other tools and equipment needed to update the PCM software, refer to Service Bulletin 99-005, Updating the Passport PCM, filed under Tools. WARRANTY CLAIM INFORMATION In warranty: The normal warranty applies. Operation Number: 122305 Flat Rate Time: 0.3 hour Failed Part: P/N 8-09392-189-0 H/C 6392971 Defect Code: 093 Contention Code: C05 Template ID: 01-044A Skill Level: Repair Technician Out of warranty: Any repair performed after warranty expiration may be eligible for goodwill consideration by the District Service Manager or your Zone Office. You must request consideration, and get a decision, before starting work. REPAIR PROCEDURE 1. Retrieve the PCM broadcast code with the PGM Tester. (From the MISC. TESTS menu, select BROADCAST CODE). Page 5874 Tires: Service and Repair Tire Replacement TIRE REPLACEMENT When replacement is necessary, the original metric the size should be used. Most metric tire sizes do not have exact corresponding alphanumeric tire sizes. It is recommended that new tires be installed in pairs on the same axle. If necessary to replace only one tire, it should be paired with tire having the most tread, to equalize braking traction. CAUTION: Do not mix different types of tires such as radial, bias and bias-belted tires except in emergencies, because vehicle handling may be seriously affected and may result in loss of control. Tire Dismounting Remove valve cap on valve step and deflate the tire. Then use a tire changing machine to mount or dismount tires. Follow the equipment manufacturer's instruction. Do not use hand tools or tire lever alone to change tires as they may damage the tire beads or wheel rim. Tire Mounting Rim bead seats should be cleaned with a wire brush or coarse steel wool to remove lubricants, and light rust. Before mounting a tire, the bead area should be well lubricated with an approved tire lubricant. After mounting, inflate the tire to 196 kPa (28 psi) so that beads are completely seated. Inflate the air to specified pressure and install valve cap to the stem. WARNING: Never stand over tire when inflating. bead may break when bead snaps over rim's safety hump and cause serious personal injury. never exceed 240 kPa (35 psi) pressure when inflating. if 240 kPa (35 psi) pressure will not seat beads, deflate, re-lubricate and re-inflate. over inflation may cause the bead to break and cause serious personal injury. Tire Repair There are many different materials on the market used to repair tires. Manufacturers have published detailed instructions on how and when to repair tires. These instructions can be obtained from the tire manufacturer if they are not included with the repair kit. Wheel Inspection Damaged wheels and wheels with excessive run-out must be replaced. Wheel run out at rim (Base on hub Bore) is shown in provided table. Page 8212 8. Remove the 5 screws (1), (3) and pull out the trim panel at the 6 clip positions (2). 9. Remove the waterproof sheet. 10. Remove the 2 screws through the access hole and pull out the glass upward. 11. Remove the window regulator. - Disconnect the window regulator motor harness connector, if equipped with power windows. 12. Remove the glass run. Page 1479 Crankshaft and Associated Parts Page 7748 Distinct Of Circuit By Wire Base Color All wires have color-coded insulation. Wires belonging to a system's main harness will have a single color. Wires belonging to a system's sub-circuits will have a colored stripe. Striped wires use the codes found in the chart to show wire size and colors. Abbreviations are used to indicate wire color within a circuit diagram. How to Identify Connector Terminals How to Identify Connector Terminals Cavity Numbering System The cavities (and wire terminals) in each connector are numbered starting from the upper left, looking at the male terminals from the terminal side (or looking at the female terminals from the wire side. Both views are in the same direction so the numbers are the same.) All actual cavities are numbered, even if they have no wire terminals in them. NOTE: Data Link Connector (DLC) terminals are numbered according to SAE standard J1962, not the Honda standard. The numbers of the four end terminals are molded into the corners of the connector face. The connector cavity number is listed next to each terminal on the circuit schematic. The cavity / terminal shown is # 6. Using/Identifying Connector Terminal Views How to Use Connector Terminal Views To see the configuration of a connector's cavities, look up its view number in the Connector Views. Each view includes the color of the connector, where Page 2621 The name of the component appears next to it followed by notes about its function along with any photo and connector view references. Connector "C" How to Identify Connector Terminals Cavity Numbering System The cavities (and wire terminals) in each connector are numbered starting from the upper left, looking at the male terminals from the terminal side (or looking at the female terminals from the wire side. Both views are in the same direction so the numbers are the same.) All actual cavities are numbered, even if they have no wire terminals in them. NOTE: Data Link Connector (DLC) terminals are numbered according to SAE standard J1962, not the Honda standard. The numbers of the four end terminals are molded into the corners of the connector face. Locations Oil Pressure Switch (For Fuel Pump): Locations Bottom Center Front of Engine Page 4853 Each schematic represents one circuit. A circuit's wires and components are arranged to show current flow, from power at the top of the page, to ground, at the bottom. Shared Circuits Other circuits may share power or ground terminals or wiring with the circuit shown. A wire that connects one circuit to another, for example, is cut short and has an arrowhead at the end of it pointing in the direction of current flow. Next to the arrowhead is the name of the circuit or component which shares that wiring. To quickly check shared wiring, check the operation of a component it serves. If that component works, you know the shared wiring is OK. Connectors All in-line and junction connectors are numbered (C725, C416, etc.). Component connectors are not numbered but are identified either by the name of Page 3559 Ground - "G" Shielding Sheilding This represents RFI (Radio Frequency Interference) shielding around a wire. The shielding is always connected to ground. Splices Page 5400 The road crown gauge measures the amount of road crown. Almost all roads have a crown to help drain water during rainstorms. Use the suction cup to attach the road crown gauge bracket to the vehicle in a vertical position. If necessary, bend the bracket until the gauge is vertical. Once you attach and align the road crown gauge, calibrate the gauge to zero. There are two ways to calibrate the gauge: ^ Park the vehicle on a level surface, such as an alignment rack, and calibrate the gauge by moving the gauge until the ball is on the zero mark. ^ If you do not have a perfectly flat surface, park the vehicle on a reasonably flat surface and note the gauge reading. Turn the vehicle 1800 and, with the tires in the same spot, note the new gauge reading. Then move the gauge half of the difference. For example, if your first reading is +3 and, after moving the vehicle, the gauge reads -1, then the difference is 4 degrees. Position the gauge to read +1. NOTE: You must calibrate the gauge with the same weight in the vehicle that you will use for the test-drive. If you plan to have an assistant help you during the test-drive, calibrate the gauge while both of you are sitting in the vehicle. Page 177 The wire insulation has one color or one color with another color stripe. The second color is the stripe. Locations Page 2564 the component if the component only has one connector, or by a capital letter (A, B, C, etc.) if the component has more than one connector. Below most connector numbers and component names are PHOTO and VIEW numbers. The PHOTO number refers to a photo in the back of the book that shows the connector's location on the car. The VIEW number refers to an illustration in the back of the book that shows the connector face, wire colors, connector cavity numbers, and other details. The connector cavity numbering sequence begins at the top left corner of the connector. Disregard any numbers molded into the connector housing. Wires Wires are identified by the abbreviated names of their colors; the second color is the color of the stripe. Wires are also identified by their location in a connector. The number "2" next to the male and female wire terminals at C416, for example, means those terminals join in cavity 2 of connector C416. Symbols A complete description of schematic symbols is given under wire color abbreviation. Power Distribution Schematics Power Distribution schematics show how power is supplied from the positive battery terminal to various circuits in the car. Refer to the Power Distribution section to get a more detailed picture of how power is supplied to the circuit you're working on. From Battery to Ignition Switch, Fuses, and Relays Individual circuit schematics begin with a fuse. The first half of Power Distribution, however, shows the wiring "upstream" between the battery Locations Fuel Pressure Sensor/Switch: Locations Top Rear of Fuel Tank Page 413 Cruise Control Switch: Service and Repair Removal 1. Disconnect the battery ground cable. 2. Remove the meter cluster assembly (1). 3. Remove the rear defogger switch (2). - Disconnect the switch connector. - To remove the switch, push the lock from the back side of the instrument panel cluster assembly. Installation To install, follow the removal steps in the reverse order. Page 6845 Rear Door Panel: Service and Repair Rear Door Trim Panel and Associated Parts Rear Door Trim Panel Removal 1. Disconnect the battery ground cable. Page 2007 and the fuses. From Fuses to Relays and Components The second half of Power Distribution shows the wiring "From Fuses to Relays and Components." This can speed your troubleshooting by showing which circuits share fuses. If Power Distribution shows that an inoperative circuit and another circuit share a fuse, check a component in the other circuit. If it works, you know the fuse is good and power is available to the inoperative circuit. Ground Distribution Schematics Page 2336 Fuel Pressure: Testing and Inspection Fuel System Pressure Test A fuel system pressure test is part of several of the diagnostic charts and symptom checks. To perform this test, refer to Fuel Systems Diagnosis. Page 4008 the torque converter housing; you must install the seal dry. 5. Slide the tool over the mainshaft as far as it will go. 6. With a soft-face hammer, lightly tap the driver until the seal is fully seated in the torque converter housing. 7. Reinstall the transmission. Disclaimer Page 1467 - With J-24086-C Piston pin service set and a press, press fit the piston pin. Note: Heat the connecting rod small end to a suitable temperature to ensure smooth installation. 4. Install piston ring with the piston ring expander. The compression ring must be set with the T mark (1) facing up. Marked T: No.1 Compression ring Marked T2: No.2 Compression ring Install piston rings in the following sequence. 1. Oil ring Expander ring Upper side rail Lower side rail 2. 2nd compression ring 3. 1st compression ring - The compression rings must be set with the T or T2 mark facing up. Marked T: No. 1 Compression ring Marked T2: No.2 Compression ring Page 2975 Wires Wire insulation can be one color, or one color with another color stripe. (The second color is the stripe.) This circuit continues on another image. (The arrow shows direction of current flow.) To follow the RED/BLK wire in this example, you would turn to "Fuel and Emissions" and look for the "A" arrow. Page 5326 V6 Engine Room Page 5031 4. Measure dimension (4). Dimension (4) (Standard): -0.1 - 0.1 mm (-0.0039 - 0.0039 inch) 5. If dimension (4) is out of the standard range, adjust push rod using the Push Rod Support J-39241. 6. Mount plate and seal assembly in vacuum booster front shell. Then install the retainer. 7. Install vacuum booster fixing nut and tighten the specified torque. Torque: 15 Nm (11 ft. lbs.) 8. Install yoke clevis. 9. Connect vacuum hose and make sure that the arrow on the hose points in the direction of the engine. 10. Install master cylinder. Page 6610 Question: Who do I call if I need help diagnosing the problem or if I have technical questions about the unit? Answer: If you cannot find the answers in the appropriate service manual, service bulletins, or ServiceNews articles on iN, create a Tech Line access code, then call Tech Line: 1. From the iN main menu, select SERVICE. 2. Select Tech Line. A dropdown menu appears, then select Tech Line. The ISIS main screen appears. 3. Select SEARCH BY VEHICLE, and enter any vehicle with any keyword like NAVI, AUDIO, or RES. 4. At the top of the screen you will see this statement: If you cannot resolve the problem with the information below, then click Tech Line. Select Tech Line. 5. The Tech Line access code screen appears. Fill in all the required fields, then select SUBMIT. 6. Have the access number ready when you call Tech Line. Question: Do I need a Tech Line reference number to order a remanufactured audio/navigation/RES unit? Answer: No. Question: What year and model audio/navigation/RES unit can I order through the warranty audio order program? Answer: Most current models are available through the vehicle's standard warranty period. If your application is not available, you will receive a message instructing you to call the Re manufactured Parts Dealer Service Group at 888-997-7278. Question: How can I track my order once I submit it? Answer: To track your order, go the Warranty Audio Order VIN Inquiry screen on the iN. 1. From the iN main menu, click on PARTS. 2. Click on Parts Ordering. 3. Click on Audio VIN Inquiry. 4. Enter a date in the All Orders Accepted Since box, then click on Submit. The AUDIO VIN INQUIRY ACKNOWLEDGEMENT screen appears, listing orders by VIN, ORD REF (Order Reference), STAT (Status), SHIP DATE, SHIPPER, and PART NUMBER. The status of your order is displayed by one of these codes: Codes generated by RPO Tech Line: ^ PEND - Your order is waiting to be processed by RPO Tech Line. ^ HOLD - Your order is waiting for additional dealer diagnosis. ^ ERR - Your order caused an error; call. ^ DENY - RPO Tech Line denied your order; call. ^ APPR - RPO Tech Line approved your order and forwarded it to AHM Parts. Codes generated by AHM Parts Division: ^ BO/TOS - Your order is on back order or is temporarily out of stock. ^ CAN/BOC - Your order has been cancelled contact your assigned parts center. Front Brake Pad: Specifications Pad Dimension 55 cm2 Diagrams Bumper Type License Plate Bulb: Service and Repair Bumper Type Removal 1. Disconnect the battery ground cable. 2. Remove the lens cover (3). - Remove two screws. 3. Remove the lens (2). 4. Remove the bulb (1). - Pull out the bulb from the socket. Installation To install, follow the removal steps in the reverse order. Description and Operation Ignition Cable: Description and Operation Spark Plug Cables Spark Plug Cables The cable contains a synthetic conductor which is easily damaged. Never stretch or kink the cable. Disconnect the cable from spark plug and the ignition coil. The original equipment cables and the ignition coil are marked to show correct location of the cables. If spark plug cables or the ignition coil are replaced previously, before cables are removed from the ignition coil, mark the cables and the coil so they can be reconnected in the same position. Page 5801 Locations Rear Window Regulator, Glass And Glass Run Page 3735 The connector cavity number is listed next to each terminal on the circuit schematic. The cavity / terminal shown is # 6. Diodes A rectifier diode works like a one way valve. It allows current to flow only in the direction of the arrow. A Zener diode blocks reverse current at normal voltages just like a rectifier diode. At high voltages, however, a Zener diode allows current to flow in reverse. Fuses PCM- Smart Cable Programming Procedures PROM - Programmable Read Only Memory: All Technical Service Bulletins PCM- Smart Cable Programming Procedures 99-005 May 11, 1999 *Applies To: 1996 and Later Passports* Updating the Passport PCM *(Supersedes 99-005 dated February 2, 1999, which was sent only to dealers who participated in the Smart Cable pilot test programs.)* The procedures in this service bulletin will be used end referenced in other service bulletins. PCMs (powertrain control modules) in 1996 and later Passports are programmable. The tool used to reprogram (update) Passport PCMs is a portable programming device called the Smart Cable. *When correctly programmed, the Smart Cable can read a Passport's current PCM broadcast code, decide if the code is correct, and if needed, update the PCM with another code. If the PCM broadcast code stored in the Smart Cable is different than the code needed by the PCM, you can reprogram the Smart Cable using your DCS workstation. This bulletin describes: ^ Updating a PCM with a programmed Smart Cable ^ Reprogramming a Smart Cable if its broadcast code is different than the one needed by the PCM ^ Smart Cable diagnosis ^ Who to contact for questions or problems when using the Smart Cable* WARRANTY CLAIM INFORMATION Refer to the bulletin for the symptom you are repairing. Skill level: Repair Technician REQUIRED TOOLS AND EQUIPMENT ^ Smart Cable Kit: P/N PTS-B001 *Includes cable, box, a copy of this bulletin (99-005), and a sheet on interpreting Smart Cable LED patterns.* ^ *PC Interface Kit: P/N VET01002582* This is the same kit used to connect the PGM Tester to the DCS computer when you update the Tester's program card. The kit includes a cable with an attached adapter. ^ *110 VAC/12 VDC Power Supply: P/N VET02001723* Page 3453 24. Verify APP Sensor 1 is between 11 and 15 percent, and APP Sensor 2 and APP Sensor 3 are between 89 and 85 percent with the pedal up (closed throttle). If not, loosen the mounting screws on the APPS sensor, and go to step 14. 25. Clear all DTCs with the PGM Tester. 26. Turn off the ignition switch, and disconnect the PGM Tester. Page 6721 Hood Sensor/Switch (For Alarm): Service and Repair Removal 1. Disconnect the battery ground cable. 2. Disconnect the connector. 3. Remove the engine hood switch (1). Installation To install, follow the removal steps in the reverse order. Page 7314 Disclaimer Page 1887 Catalytic Converter: Service and Repair Left Side Removal and Installation TWC LH and Forked Exhaust Pipe and Associated Parts REMOVAL 1. Disconnect battery ground cable. 2. Lift up the vehicle and support with suitable safety stands. 3. Disconnect O2 sensor harness connectors (8) (10). 4. Remove the forked exhaust pipe fixing bolts and nuts (1) (4) (6) and the exhaust silencer fixing nuts (5), then remove the forked exhaust pipe (3) and the mass damper (2). 5. Remove the three way catalytic converter fixing nuts (11) and the mounting rubber (7), then remove the three way catalytic converter (9). INSTALLATION 1. Install the three way catalytic converter (9) and the mounting rubber (7), and tighten the fixing nuts (11) to the specific torque. Torque Nuts: 67 Nm (49 ft. lbs.) 2. Install the forked exhaust pipe (3) and the mass damper (2), and tighten the fixing bolts (1) (6) and nuts (4) (5) to the specified torque. Torque Bolts & Nuts: 43 Nm (32 ft. lbs.) Nuts: 43 Nm (32 ft. lbs.) 3. Connect the O2 sensor connectors (8) (10). Page 1620 2. Loosen the two flange nuts holding the transmission mount to the third crossmember. 3. Use a pry bar to shift the engine assembly all the way forward. 4. Hold the prybar in place, and torque the flange nuts to 50 N.m (37 lb-ft). 5. Lower the vehicle. 6. Start the engine, and check for vibration. Make sure the chassis is not touching the lift during this check. ^ If the vibration is gone, no further action is required. ^ If the vibration is still there, go to REPAIR PROCEDURE B. REPAIR PROCEDURE B 1. Write down your customer's radio station presets and mode settings. 2. Disconnect the negative cable from the battery. 3. Raise the vehicle on a lift. 4. Remove both front wheels. 5. Models With 4WD: Remove the front skid plate (four bolts, four lock washers, four washers). Page 7414 This means the branch of the wire connects to another circuit. The arrow points to the name of the circuit branch where the wire continues. Page 3295 The connector cavity number is listed next to each terminal on the circuit schematic. The cavity / terminal shown is # 6. Diodes A rectifier diode works like a one way valve. It allows current to flow only in the direction of the arrow. A Zener diode blocks reverse current at normal voltages just like a rectifier diode. At high voltages, however, a Zener diode allows current to flow in reverse. Fuses Brake Pipes and Hoses Brake Hose/Line: Testing and Inspection Brake Pipes and Hoses The hydraulic brake system components are interconnected by special steel piping and flexible hoses. Flexible hoses are used between the frame and the front calipers, the frame and rear axle case and the rear axle and the rear calipers. When the hydraulic pipes have been disconnected for any reason, the brake system must be bled after reconnecting the pipe. Page 1928 18. Reinstall the bracket on the engine. Torque the flange bolts to 50 N.m (37 lb-ft). Be careful not to pinch the crankshaft position sensor harness, and on A/T models, the ATF cooler lines. 19. Lower the engine into position. Do it slowly to avoid wedging it between the mounts; if you lower it too fast, you will compress the mounts. If you compress the mounts, they will not be able to isolate noise and absorb vibration. 20. Reinstall the engine mounts on the chassis. Torque the flange bolts to 41 N.m (30 lb-ft). 21. Reinstall the crankshaft position sensor. Torque the bolt to 9 N.m (7 lb-ft). 22. Plug the 3P connector into the crankshaft position sensor. 23. Reinstall the crankshaft position sensor harness clamp. 24. Models With A/T: Reinstall the front and rear clamps for the A/T cooler lines. 25. Models With 4WD: Reinstall the front skid plate. 26. Reinstall the front wheels. Torque the lug nuts to 118 N.m (87 lb-ft). 27. Lower the vehicle. 28. Reconnect the negative cable to the battery. 29. Enter your customer's radio station presets and mode settings. Set the clock. Disclaimer Adjustments Brake Switch (Cruise Control): Adjustments 1. Check that the brake pedal (3) is fully returned by pedal return spring. 2. Disconnect the switch connector. 3. Loosen the lock nut (2). 4. Rotate the brake switch (1) by hand until push rod disappears from brake switch tip (4). 5. Return the brake switch by a half turn. 6. Tighten the lock nut. 7. Connect the switch connector. Page 4827 angle. The angle locator level (P/N SUN-YA328A) is available through the Honda Tool and Equipment Program. To order one, call 888-424-6857. DISCLAIMER Page 5542 ^ If the idle speed ever exceeds 1,300 rpm 2. Remove the vacuum hose from the fuel pressure regulator, then start the engine. ^ If fuel comes out of the fuel pressure regulator vacuum hose connection, go to REPAIR PROCEDURE FUEL PRESSURE REGULATOR. ^ If no fuel comes out of the regulator, reconnect the vacuum hose and continue to step 3. 3. Connect the PGM Tester. Set it to Engine Data List. 4. Have an assistant drive the vehicle under the conditions described by the customer. 5. If the high or erratic idle condition occurs, note the values of the PSP Switch and APP Sensor 1 when it is occurring. ^ If the PSP Switch is HIGH, and you are not turning, go to REPAIR PROCEDURE POWER STEERING SWITCH. ^ If the APP Sensor 1 is greater than 15% and APP Sensor 2 and/or APP Sensor 3 are less than 85%, and the accelerator pedal is not depressed, go to REPAIR PROCEDURE APPS GROUND. ^ If the PSP Switch is reading LOW when not turning and HIGH when turning, and the APP Sensors are reading within the range shown, discontinue the test-drive and go to step 6. 6. Do these repairs: ^ REPAIR PROCEDURE APPS GROUND ^ REPAIR PROCEDURE ENGINE/BODY GROUND REPAIR PROCEDURE - FUEL PRESSURE REGULATOR 1. Relieve fuel system pressure: ^ Remove the fuel fill cap. ^ Remove the fuel pump relay. ^ Start the engine and run it until it stalls. ^ Crank the engine for 3 seconds. 2. Remove the vacuum hose from the fuel pressure regulator. 3. Remove the fuel pressure regulator shield from the common chamber (two bolts). Page 2743 H/C 4408092 Defect Code: 017 Contention Code: C99 Skill Level: Repair Technician Out of warranty: Any repair performed after warranty expiration may be eligible for goodwill consideration by the District Service Manager or your Zone Office. You must request consideration, and get a decision, before starting work. DISCLAIMER Page 562 The wire insulation has one color or one color with another color stripe. The second color is the stripe. Page 5054 Parking Brake Warning Switch: Description and Operation The brake system warning light goes on to alert the driver that the parking brake is applied or that the brake fluid is low. It also lights as a bulb test when the engine is cranked. With the ignition switch in ON or START, battery voltage is applied through fuse 11 to the brake system warning light. When the parking brake is applied, the parking brake switch closes and provides a ground for the light. The brake system warning light goes on to remind the driver that the parking brake is applied. Page 4479 The name of the component appears next to it followed by notes about its function along with any photo and connector view references. Connector "C" How to Identify Connector Terminals Cavity Numbering System The cavities (and wire terminals) in each connector are numbered starting from the upper left, looking at the male terminals from the terminal side (or looking at the female terminals from the wire side. Both views are in the same direction so the numbers are the same.) All actual cavities are numbered, even if they have no wire terminals in them. NOTE: Data Link Connector (DLC) terminals are numbered according to SAE standard J1962, not the Honda standard. The numbers of the four end terminals are molded into the corners of the connector face. Page 748 the component if the component only has one connector, or by a capital letter (A, B, C, etc.) if the component has more than one connector. Below most connector numbers and component names are PHOTO and VIEW numbers. The PHOTO number refers to a photo in the back of the book that shows the connector's location on the car. The VIEW number refers to an illustration in the back of the book that shows the connector face, wire colors, connector cavity numbers, and other details. The connector cavity numbering sequence begins at the top left corner of the connector. Disregard any numbers molded into the connector housing. Wires Wires are identified by the abbreviated names of their colors; the second color is the color of the stripe. Wires are also identified by their location in a connector. The number "2" next to the male and female wire terminals at C416, for example, means those terminals join in cavity 2 of connector C416. Symbols A complete description of schematic symbols is given under wire color abbreviation. Power Distribution Schematics Power Distribution schematics show how power is supplied from the positive battery terminal to various circuits in the car. Refer to the Power Distribution section to get a more detailed picture of how power is supplied to the circuit you're working on. From Battery to Ignition Switch, Fuses, and Relays Individual circuit schematics begin with a fuse. The first half of Power Distribution, however, shows the wiring "upstream" between the battery Page 1970 Testing For A Short With A Self-Powered Test Light or DVOM 1. Remove the blown fuse and disconnect the battery and load. 2. Connect one lead of a self-powered test light or digital volt/ohmmeter (DVOM) (switched to the lowest "OHMS" range) to the fuse terminal on the load side. 3. Connect the other lead to a known good ground. 4. Beginning near the fuse box, wiggle the harness. Continue this at convenient points about six inches apart while watching the test light or DVOM. 5. If the self-powered test light goes on or the DVOM displays a low reading or no reading (zero), there is a short to ground in the wiring near that point. Testing for a Short with a Test Light or DVOM 1. Remove the blown fuse and disconnect the load. 2. Connect a test light or digital volt/ohmmeter (DVOM), switched to the appropriate DC volts range, across the fuse terminals to make sure voltage is present. You might have to turn the ignition switch to ON; check the schematic to see. 3. Beginning near the fuse box, wiggle the harness. Continue this at convenient points about six inches apart while watching the test light or DVOM. 4. Where the test light goes , or the DVOM voltage drops to zero, there is a short to ground in the wiring near that point. NOTE: Always use a DVOM on high impedance circuits. A test light may not glow (even with battery voltage present). Testing For A Short With A Short Circuit Locator (Short Finder) 1. Remove the blown fuse. Leave the battery connected. Page 3638 Cleaning Spark Plugs - Clean spark plugs with a spark plug cleaner. - Raise the ground electrode to an position of 45 to 60 degrees. If electrode is wet, dry it before cleaning. - After spark plug is thoroughly cleaned, check insulator for presence of cracks. - Clean threads and metal body with a wire brush. - File the electrode tip if electrode is extremely worn. - Bend the ground electrode to adjust the spark plug gap. Page 5888 - Disc - Caliper - Shift on the fly system parts (Cap, Hub flange, Shim, Snap ring) - ABS sensor ring For inspection and servicing of disc caliper and related parts, refer to Brakes and Traction Control; Brakes; Disc Brake System. REASSEMBLY 1. Install wheel pin. - Place the hub on a wood workbench or a block of wood approx. 6" by 6" to protect the wheel stud ends and threads. - Insert a wheel stud using a hammer. Be sure the wheel stud is started squarely and seats completely. 2. Align scribe marks (1) and attach the hub to the disc, then tighten the bolts to the specified torque. Torque: 103 Nm (76 ft. lbs.) 3. Use installer J-36829 and grip J-8092, then install the inner bearing by driving it into the hub. Service and Repair Shift Indicator: Service and Repair Removal 1. Disconnect the battery ground cable. 3. Remove the meter lens (3) from the meter visor (4). 4. Remove the meter visor from the meter case(5). Page 393 Wheel Speed Sensor: Service and Repair Rear REMOVAL 1. Disconnect harness connector (1). 2. Remove sensor fixing bolt (2). 3. Remove speed sensor (3). Page 52 Distinct Of Circuit By Wire Base Color All wires have color-coded insulation. Wires belonging to a system's main harness will have a single color. Wires belonging to a system's sub-circuits will have a colored stripe. Striped wires use the codes found in the chart to show wire size and colors. Abbreviations are used to indicate wire color within a circuit diagram. How to Identify Connector Terminals How to Identify Connector Terminals Cavity Numbering System The cavities (and wire terminals) in each connector are numbered starting from the upper left, looking at the male terminals from the terminal side (or looking at the female terminals from the wire side. Both views are in the same direction so the numbers are the same.) All actual cavities are numbered, even if they have no wire terminals in them. NOTE: Data Link Connector (DLC) terminals are numbered according to SAE standard J1962, not the Honda standard. The numbers of the four end terminals are molded into the corners of the connector face. The connector cavity number is listed next to each terminal on the circuit schematic. The cavity / terminal shown is # 6. Using/Identifying Connector Terminal Views How to Use Connector Terminal Views To see the configuration of a connector's cavities, look up its view number in the Connector Views. Each view includes the color of the connector, where Page 6414 Driver's Inflator Module Connector Testing and Inspection Blower Motor Relay: Testing and Inspection 1. Disconnect the heater relay (X-1). - When removing the connector for relay unfasten the tank lock of the connector by using a screwdriver, then pull the relay (1) out. 2. Check for continuity between the heater relay (X-1) terminals. Page 2016 Wire Color Abbreviations The following abbreviations are used to identify wire colors in the circuit schematics: WHT................................... White YEL................................... Yellow BLK................................... Black BLU................................... Blue GRN................................... Green RED................................... Red ORN................................... Orange PNK................................... Pink BRN................................... Brown GRY................................... Gray PUR................................... Purple LT BLU................................... Light Blue LT GRN................................... Light Green Accelerator Pedal Position Sensor - MIL ON/DTC's Set Technical Service Bulletin # 01-047 Date: 010814 Accelerator Pedal Position Sensor - MIL ON/DTC's Set 01-047 August 14, 2001 Applies To: 2000-01 Passport - ALL MIL Comes On With Accelerator Pedal Position Sensor DTC(s) P1271, P1273, P1275, P1280, and/or P1285 SYMPTOM The MIL is on with DTC P1271, P1273, P1275, P1280, or P1285 (various accelerator pedal position sensor problems) stored. The REDUCED POWER indicator may also be on; and the engine may occasionally idle too high, or the idle may fluctuate. PROBABLE CAUSE Contaminated grease on the potentiometer circuit board of the accelerator pedal position sensor (APPS) causes high resistance in the APPS circuit. CORRECTIVE ACTION Replace and adjust the APPS, remove all grease from the accelerator link, and clean the APPS harness connector and connector C123. PARTS INFORMATION Accelerator Pedal Position Sensor: P/N 8-97193-713-0, H/C 6198311 REQUIRED MATERIALS CAIG DeoxIT D5-S6 Contact Cleaner: P/N 341-200 (available from www.partsexpress.com) or Permatex Electrical Contact Cleaner: Permatex P/N 24379 WARRANTY CLAIM INFORMATION In warranty: The normal warranty applies. Operation Number: 122114 Flat Rate Time: 0.5 hour Failed Part: P/N 8-97220-540-0 H/C 6202436 Defect Code: 091 Contention Code: C99 Template ID: 01-047A Skill Level: Repair Technician Out of warranty: Any repair performed after warranty expiration may be eligible for goodwill consideration by the District Service Manager or your Zone Office. You must request consideration, and get a decision, before starting work. Page 7653 Door Switch: Service and Repair Removal 1. Disconnect the battery ground cable. 2. Remove the door switch (2). - Remove the screw (1). - Disconnect the connector (3). Installation To install, follow the removal steps in the reverse order. Page 5505 Power Steering Fluid: Testing and Inspection LEVEL CHECK 1. Run the engine until the power steering fluid reaches normal operating temperature, about 55°C (130°F) then shut the engine off. 2. Check the level of fluid in the reservoir. 3. If the fluid level is low, add power steering fluid to the proper level and install the receiver cap. 4. When checking the fluid level after the steering system has been serviced, air must be bled from the system. Page 3255 ^ If the idle speed ever exceeds 1,300 rpm 2. Remove the vacuum hose from the fuel pressure regulator, then start the engine. ^ If fuel comes out of the fuel pressure regulator vacuum hose connection, go to REPAIR PROCEDURE FUEL PRESSURE REGULATOR. ^ If no fuel comes out of the regulator, reconnect the vacuum hose and continue to step 3. 3. Connect the PGM Tester. Set it to Engine Data List. 4. Have an assistant drive the vehicle under the conditions described by the customer. 5. If the high or erratic idle condition occurs, note the values of the PSP Switch and APP Sensor 1 when it is occurring. ^ If the PSP Switch is HIGH, and you are not turning, go to REPAIR PROCEDURE POWER STEERING SWITCH. ^ If the APP Sensor 1 is greater than 15% and APP Sensor 2 and/or APP Sensor 3 are less than 85%, and the accelerator pedal is not depressed, go to REPAIR PROCEDURE APPS GROUND. ^ If the PSP Switch is reading LOW when not turning and HIGH when turning, and the APP Sensors are reading within the range shown, discontinue the test-drive and go to step 6. 6. Do these repairs: ^ REPAIR PROCEDURE APPS GROUND ^ REPAIR PROCEDURE ENGINE/BODY GROUND REPAIR PROCEDURE - FUEL PRESSURE REGULATOR 1. Relieve fuel system pressure: ^ Remove the fuel fill cap. ^ Remove the fuel pump relay. ^ Start the engine and run it until it stalls. ^ Crank the engine for 3 seconds. 2. Remove the vacuum hose from the fuel pressure regulator. 3. Remove the fuel pressure regulator shield from the common chamber (two bolts). Page 2222 the component if the component only has one connector, or by a capital letter (A, B, C, etc.) if the component has more than one connector. Below most connector numbers and component names are PHOTO and VIEW numbers. The PHOTO number refers to a photo in the back of the book that shows the connector's location on the car. The VIEW number refers to an illustration in the back of the book that shows the connector face, wire colors, connector cavity numbers, and other details. The connector cavity numbering sequence begins at the top left corner of the connector. Disregard any numbers molded into the connector housing. Wires Wires are identified by the abbreviated names of their colors; the second color is the color of the stripe. Wires are also identified by their location in a connector. The number "2" next to the male and female wire terminals at C416, for example, means those terminals join in cavity 2 of connector C416. Symbols A complete description of schematic symbols is given under wire color abbreviation. Power Distribution Schematics Power Distribution schematics show how power is supplied from the positive battery terminal to various circuits in the car. Refer to the Power Distribution section to get a more detailed picture of how power is supplied to the circuit you're working on. From Battery to Ignition Switch, Fuses, and Relays Individual circuit schematics begin with a fuse. The first half of Power Distribution, however, shows the wiring "upstream" between the battery Page 1846 4. Install lower fan guide (3). 5. Connect radiator inlet hose and outlet hose to the engine. 6. Connect oil cooler hose (1) to automatic transmission. 7. Connect battery ground cable. 8. Pour engine coolant up to filler neck of radiator, and up to MAX mark of reserve tank. Important operation (in case of 100% engine coolant change) procedure for filling with engine coolant. Engine Coolant Filling Up Procedure 1. Make sure that the engine is cool. WARNING: WHEN THE COOLANT IS HEATED TO A HIGH TEMPERATURE, BE SURE NOT TO LOOSEN OR REMOVE THE RADIATOR CAP. OTHERWISE YOU MIGHT GET SCALDED BY HOT VAPOR OR BOILING WATER. TO OPEN THE RADIATOR CAP, PUT A PIECE OF THICK CLOTH ON THE CAP AND LOOSEN THE CAP SLOWLY TO REDUCE THE PRESSURE WHEN THE COOLANT HAS BECOME COOLER. 2. Open radiator cap pour coolant up to filler neck. 3. Pour coolant into reservoir tank up to "MAX" line. 4. Tighten radiator cap and start the engine. After idling for 2 to 3 minutes, stop the engine and reopen radiator cap. If the water level is lower, replenish. 5. After replenish the coolant, tighten the radiator cap, warm up the engine at about 2000 rpm. Set heater adjustment to the highest temperature position, and let the coolant circulate also into heater water system. 6. Check to see the thermometer, continuously idling 5 minutes and stop the engine. 7. When the engine has been cooled, check filler neck for water level and replenish if required. Should extreme shortage of coolant is found, check the coolant system and reservoir tank hose for leakage. 8. Pour coolant into the reservoir tank up to "MAX" line. Page 7780 If there is no photo number below or beside a component name or a connector, ground, or terminal number, look up that name or number in the appropriate Connector Identification Chart. The chart lists how many cavities a connector has, where it's located, and what it connects to. The related illustration shows the connector's location on the harness, and the harness routing. NOTE: Photos listed by number are located at Locations / Components / Photograohs. See: Locations/Component Locations/Photographs Circuit Schematics Page 87 Page 3716 Locations ECT Sensor Page 2817 Disclaimer Repair Procedure 1. Unclamp the air cleaner housing cover, and move it to the side for access to connector C123 (16P BLK). 2. Unfasten C123 from the side of the engine compartment using a 90-degree pick. 3. Disconnect C123, and clean the terminals on both sides of the connector with contact cleaner. Shake the residue out of the connector. Allow the contact cleaner to evaporate for at least 3 minutes, then reconnect C123. 4. Fasten C123 to the left side of the engine compartment, then reinstall the air cleaner housing cover. 5. While supporting the accelerator pedal assembly, remove the two bolts that secure the assembly to the bulkhead. Carefully lower the assembly to gain access to the connector. Page 5973 6. Use a clean shop towel or a shop vacuum to remove any debris from the inside of the blower assembly housing. 7. Install the new blower resistor. 8. Install the new blower motor assembly and gasket, and plug in the 2P connector. 9. Plug the 6P connector into the new blower resistor. 10. 2000-01 Models: Reinstall the intake actuator relay. 11. Lift up the glove box, and push it back into the stops. Return the contents to the glove box. 12. Start the engine, and run the blower to make sure it works properly. Disclaimer Page 60 The connector cavity number is listed next to each terminal on the circuit schematic. The cavity / terminal shown is # 6. Diodes A rectifier diode works like a one way valve. It allows current to flow only in the direction of the arrow. A Zener diode blocks reverse current at normal voltages just like a rectifier diode. At high voltages, however, a Zener diode allows current to flow in reverse. Fuses Page 174 Wires Wire insulation can be one color, or one color with another color stripe. (The second color is the stripe.) This circuit continues on another image. (The arrow shows direction of current flow.) To follow the RED/BLK wire in this example, you would turn to "Fuel and Emissions" and look for the "A" arrow. Page 1047 The caster angle can be adjusted by means of the caster shims (1) installed between the chassis frame (2) and fulcrum pins. Caster angle: 2°30' ± 1° CAUTION: Left and right side must be equal within 30'. NOTE: Difference of the caster shim front/rear thickness should be 3.6 mm (0.142 inch) or less. Overall thickness of caster shim and camber shim should be 10.3 mm (0.425 inch) or less. Tighten the fulcrum pin bolt to the specified torque. Torque to 152 Nm (112 ft. lbs.) CAMBER The camber angle can be adjusted by means of the camber shims (2) installed in position between the chassis frame (1) and fulcrum pins. Camber angle: 0° ± 30'. King pin inclination: 12°30' ± 30'. Page 3256 4. Remove the fuel pressure regulator from the fuel rail. 5. Remove the fuel return line from the regulator. 6. Install the new fuel pressure regulator in the reverse order of removal. 7. Use the Smart Cable to reprogram the PCM with the latest software from the June 2001 or later HONDANET CD-ROM. Refer to Service Bulletin 99-005, Updating the Passport PCM, filed under Tools. 8. Use the PGM Tester to clear any DTCs. 9. Use the PGM Tester to check the broadcast code. Make sure the broadcast code matches the one you selected from the CD-ROM. WARRANTY CLAIM INFORMATION In warranty: The normal warranty applies. Failed Part: P/N 8-17113-398-0 H/C 5504386 Defect Code: 092 Contention Code: C99 Skill Level: Repair Technician Out of warranty: Any repair performed after warranty expiration may be eligible for goodwill consideration by the District Service Manager or your Zone Office. You must request consideration, and get a decision, before starting work. REPAIR PROCEDURE - POWER STEERING SWITCH 1. Drain the power steering fluid out of the system. 2. Remove the power steering fluid reservoir. Clean the reservoir with solvent, then with soap and water. Rinse and dry it thoroughly. 3. Reinstall the reservoir. Do not connect the return hose. 4. Remove the power steering pressure switch, then clean it with brake cleaner and a scraper. Reinstall the switch, and torque it to 20 N.m (14 lb-ft). 5. Cover the unconnected end of the reservoir with your finger, then fill the reservoir with Dexron III ATF Page 2576 Data Link Connector: Diagnostic Aids Before Troubleshooting Before Troubleshooting See: Service Precautions/Vehicle Damage Warnings/Tips and Precautions 1. Check applicable fuses in the appropriate fuse/relay box. 2. Check the battery for damage, state of charge, and clean and tight connections. CAUTION: Do not quick-charge a battery unless the battery ground cable has been disconnected, otherwise you will damage the alternator diodes. - Do not attempt to crank the engine with the battery ground cable loosely connected or you will severely damage the wiring. While You're Working 1. Make sure connectors are clean, and have no loose terminals or receptacles. 2. Make sure that connectors without wire seals are packed with dielectric (silicone) grease. Part Number: 08798-9001. 3. When connecting a connector, push it until it "clicks" into place. CAUTION: Do not pull on the wires when disconnecting a connector. Pull only on the connector housings. - Most circuits include solid-state devices. Test the voltages in these circuits only with a 10-megaohm or higher impedance digital multi meter. Never use a test light or analog meter on circuits that contain solid-state devices. Damage to the devices may result. Five-Step Troubleshooting 1. Verify The Complaint Turn on all the components in the problem circuit to check the accuracy of the customer complaint. Note the symptoms. Do not begin disassembly or testing until you have narrowed down the problem area. 2. Analyze The Schematic Look up the schematic for the problem circuit. Determine how the circuit is supposed to work by tracing the current paths from the power source through the circuit components to ground. Also, trace circuits that share wiring with the problem circuit. The names of circuits that share the same fuse, ground, or switch, and so on, are referred to in each circuit schematic. Try to operate any shared circuits you didn't check in step 1. If the shared circuits work, the shared wiring is OK, and the cause must be in the wiring used only by the problem circuit. If several circuits fail at the same time, the fuse or ground is a likely cause. Based on the symptoms and your understanding of the circuit's operation, identify one or more possible causes. 3. Isolate The Problem By Testing The Circuit Make circuit tests to check the diagnosis you made in step 2. Keep in mind that a logical, simple procedure is the key to efficient troubleshooting. Test for the most likely cause of failure first. Try to make tests at points that are easily accessible. 4. Fix The Problem Once the specific problem is identified, make the repair. Be sure to use proper tools and safe procedures. 5. Make Sure The Circuit Works Turn on all components in the repaired circuit in all modes to make sure you've fixed the entire problem. If the problem was a blown fuse, be sure to test all of the circuits on that fuse. Make sure no new problems turn up and the original problem does not recur. Page 2232 Wire Color Abbreviations The following abbreviations are used to identify wire colors in the circuit schematics: WHT................................... White YEL................................... Yellow BLK................................... Black BLU................................... Blue GRN................................... Green RED................................... Red ORN................................... Orange PNK................................... Pink BRN................................... Brown GRY................................... Gray PUR................................... Purple LT BLU................................... Light Blue LT GRN................................... Light Green Diagrams Page 2636 Locations Tailgate Glass (Resin Top) Page 456 This sample Ground Distribution schematic shows all of the components that share two ground points. Components A solid border line means the entire component is shown. A broken border line indicates that only part of the component is shown. Page 386 Part 1 of 2 Part 2 of 2 B-23 Simultaneous Drop-Out of FT Spd Sensor Sig. (DTC 64/C0229) Chart B-23 Simultaneous Drop-Out Of Front Speed Sensor Signal (DTC 64 (Flash Out) / C0229 (Serial Communications)) Page 1903 Exhaust Pipe: Service and Repair Rear Exhaust Pipe Rear Exhaust Pipe Removal 1. Disconnect battery ground cable. 2. Lift up the vehicle and support with suitable safety stands. 3. Remove the rear exhaust fixing nuts (2) and the mounting rubbers (1) (3), then remove the rear exhaust pipe (4). Installation 1. Install the rear exhaust pipe (4) and the mounting rubbers (1) (3), then tighten the fixing nuts (2) to the specified torque. Torque Nuts: 43 Nm (32 ft. lbs.) Fuel Control Heated Oxygen Sensors Oxygen Sensor: Description and Operation Fuel Control Heated Oxygen Sensors Fuel Control Heated Oxygen Sensors The fuel control heated oxygen sensors (Bank 1 HO2S 1 and Bank 2 HO2S 1) are mounted in the exhaust stream where they can monitor the oxygen content of the exhaust gas. The oxygen present in the exhaust gas reacts with the sensor to produce a voltage output. This voltage should constantly fluctuate from approximately 100 mV to 900 mV. The heated oxygen sensor voltage can be monitored with a Tech 2. By monitoring the voltage output of the oxygen sensor, the PCM calculates the pulse width command for the injectors to produce the proper combustion chamber mixture. - Low HO2S voltage is a lean mixture which will result in a rich command to compensate. - High HO2S voltage is a rich mixture which will result in a lean command to compensate. An open Bank 1 HO2S 1 signal circuit will set a DTC P0134 and the Tech 2 will display a constant voltage between 400 - 500 mV. A constant voltage below 300 mV in the sensor circuit (circuit grounded) will set DTC P0131. A constant voltage above 800 mV in the circuit will set DTC P0132. Faults in the Bank 2 HO2S 1 signal circuit will cause DTC 0154 (open circuit), DTC P0151 (grounded circuit), or DTC P0152 (signal voltage high) to set. A Fault in the Bank 1 HO2S 1 heater circuit will cause DTC P0135 to set. A fault in the Bank 2 HO2S 1 heater circuit will cause DTC P0155 to set. The PCM can also detect HO2S response problems. If the response time of an HO2S is determined to be too slow, the PCM will store a DTC that indicates degraded HO2S performance. Page 4599 Wires Wire insulation can be one color, or one color with another color stripe. (The second color is the stripe.) This circuit continues on another image. (The arrow shows direction of current flow.) To follow the RED/BLK wire in this example, you would turn to "Fuel and Emissions" and look for the "A" arrow. Page 7465 A battery voltage (B+) circuit which is only powered with the ignition switch in the ON, or START positions. Initiator The electrical component inside the air bag assembly which, when sufficient current flows, sets off the chemical reaction that inflates the air bag. "Initiator Assembly Resistance Test" Tests performed once each ignition cycle when no malfunctions are detected during "Turn-ON" or "Continuous Monitoring." This test checks for the correct SDM configuration for the vehicle, shorts to "Ignition 1 in the deployment loops, high resistance or opens in the "Driver Side High", "Driver Side Low", "Passenger Side High" and "Passenger Side Low" circuits and measures the resistance of the inflator assembly consisting of: 1. Initiators. 2. SRS coil assembly (driver side only). 3. Connectors and associated wiring. Normal Operating Voltage Range The voltage measured between the SDM "Ignition 1" terminals and "Ground" terminals is between 9 and 16 volts. Passenger Current Source An output of the SDM which applies current into the passenger air bag assembly circuit during the "Initiator Assembly Resistance Test". Passenger Air Bag Assembly An assembly located in the right side of the instrument panel consisting of an inflatable bag, an inflator and an initiator. Scan Tool An external computer used to read diagnostic information from on-board computers via the data link connector. SDM Sensing and Diagnostic Module which provides reserve energy to the deployment loops, deploys the air bags when required and performs diagnostic monitoring of all SRS components. Serial Data Information representing the status of the SRS. SRS Supplemental Restraint System. SRS Coil Assembly An assembly of two current-carrying coils in the driver deployment loop that allows the rotation of the steering wheel while maintaining the continuous contact of the driver deployment loop to the driver air bag assembly. SRS Wiring Harness The wires and connectors that electrically connect the components in the SRS. "Turn-ON" Test which the SDM performs on the SRS once during each ignition cycle immediately after "Ignition 1" voltage is applied to the SDM and before "Continuous Monitoring". Page 5579 This sample Ground Distribution schematic shows all of the components that share two ground points. Components A solid border line means the entire component is shown. A broken border line indicates that only part of the component is shown. Page 7600 Ground - "G" Shielding Sheilding This represents RFI (Radio Frequency Interference) shielding around a wire. The shielding is always connected to ground. Splices Page 3332 If there is no photo number below or beside a component name or a connector, ground, or terminal number, look up that name or number in the appropriate Connector Identification Chart. The chart lists how many cavities a connector has, where it's located, and what it connects to. The related illustration shows the connector's location on the harness, and the harness routing. NOTE: Photos listed by number are located at Locations / Components / Photograohs. See: Locations/Component Locations/Photographs Circuit Schematics Front Differential Pinion Gear: Specifications Pinion Gear Clearance --Gear Ratio 6VD1 With A/T 4.100 : 1 6VD1 With M/T 4.300 : 1 Page 2184 10. Use the PGM Tester to check the broadcast code. Make sure the broadcast code matches the one you selected from the CD-ROM. WARRANTY CLAIM INFORMATION In warranty: The normal warranty applies. Failed Part: P/N 8-17087-655-0 H/C 4375820 Defect Code: 064 Contention Code: C01 Skill Level: Repair Technician Out of warranty: Any repair performed after warranty expiration may be eligible for goodwill consideration by the District Service Manager or your Zone Office. You must request consideration, and get a decision, before starting work. REPAIR PROCEDURE - ENGINE/BODY GROUND 1. Use the ETM for the appropriate year to locate these ground connectors: G101, G104, G105, G106 and G160. 2. Inspect each connector for corrosion or looseness. 3. Remove the bolt from any connector that is corroded or loose. Clean the terminal connector with a wire brush. File flat any solder bumps on the connector. 4. Clean the contact surface on the engine or body with a wire brush. 5. Replace the bolt if it is heavily corroded. Otherwise, clean it with a wire brush. 6. Apply lithium dielectric grease to both sides of the terminal connector. 7. Reinstall the bolt, torque it to 14 N.m (10 lb-ft). 8. Use the Smart Cable to reprogram the PCM with the latest software from the June 2001 or later HONDANET CD-ROM. Refer to Service Bulletin 99-005, Updating the Passport PCM, filed under Tools. 9. Use the PGM Tester to clear any DTCs. 10. Use the PGM Tester to check the broadcast code. Make sure the broadcast code matches the one you selected from the CD-ROM. WARRANTY CLAIM INFORMATION In warranty: The normal warranty applies. Failed Part: P/N 8-97086-823-0 Page 2154 3. Check the vacuum hose to the sensor for leaking or restriction, Be sure that no other vacuum devices are connected to the MAP hose. IMPORTANT: Make sure the electrical connector remains securely fastened. 4. Disconnect the sensor from the bracket. Twist the sensor with your hand to check for an intermittent connection. Output changes greater than 0.10 volt indicate a bad sensor. Parallelism Brake Rotor/Disc: Description and Operation Parallelism Parallelism is the measurement of thickness of the rotor at four or more points around the circumference of the rotor. All measurement must be made at 22 mm (0.87 inch) from the edge of the rotor. The rotor thickness must not vary more than 0.010 mm (0.0004 inch) from point to point. Maximum parallelism: 0.010 mm (0.0004 inch) Page 5940 6. Pull the control lever assembly out and disconnect the fan switch and air conditioning switch connectors. 7. Remove control level assembly. 8. Disconnect control cables at each unit side. Installation To install, follow the removal steps in the reverse order, noting the following points: Page 5136 Clutch Switch: Adjustments 1. Turn the clutch switch (1) until the switch plunger is fully retracted against the clutch pedal arm. 2. Adjust clutch switch by backing it out half a turn and measure the clearance (4) between the clutch pedal arm (3) and the clutch switch. 3. Lock the lock nut (2). 4. Connect clutch switch connector. Clutch Switch (bolt) and Clutch Pedal Clearance 0.5 - 1.5 mm (0.020 - 0.059 in) Page 4324 16. Install bellows. Adjust the air pressure within the bellows by inserting a screwdriver or equivalent, so that it equals atmospheric pressure. 17. Install band. After installation, check that the bellows is free from distortion. Page 5191 4. Install heat protector(3). 5. Install exhaust front left pipe and tighten bolts and nuts to specified torque(2). Stud Nuts Torque: 67 Nm (49 lb.ft) Nuts Torque: 43 Nm (32 lb.ft) 6. Connect Heated O2 Sensor connector (1). 7. Reconnect the battery ground cable. Page 7376 If there is no photo number below or beside a component name or a connector, ground, or terminal number, look up that name or number in the appropriate Connector Identification Chart. The chart lists how many cavities a connector has, where it's located, and what it connects to. The related illustration shows the connector's location on the harness, and the harness routing. NOTE: Photos listed by number are located at Locations / Components / Photograohs. See: Locations/Component Locations/Photographs Circuit Schematics Page 4493 Page 8229 2. Install the spacer. - Attach spacers in ten locations as shown in the figure. - Always use new spacer. 3. Install the windshield upper molding. - Peel off the tear-away paper from the windshield upper molding, and start applying it with one end of the glass and cut away the surplus at the other end of the glass for length adjustment. - Always use new upper molding. 4. Temporary install the windshield support. 5. Apply the primer to the windshield and body panel. - Apply the primer (3) (Sun star # 435-40 or equivalent) to the windshield side bonding surface as shown in the figure. - Apply the primer (Sun star # 435-95 or equivalent) to the body side bonding surface. NOTE: Apply an adhesive 3 minutes or more but within 24 hours after the application of primer. If more than 24 hours have passed, reapply Locations Transmission Position Switch/Sensor: Locations Left Side Of Automatic Transmission Electrode Gap Spark Plug: Specifications Plug Gap Standard Service Limit 0.039-0.043 in (1.0-1.1 mm) 0.050 in (1.3 mm) Page 3364 The connector cavity number is listed next to each terminal on the circuit schematic. The cavity / terminal shown is # 6. Diodes A rectifier diode works like a one way valve. It allows current to flow only in the direction of the arrow. A Zener diode blocks reverse current at normal voltages just like a rectifier diode. At high voltages, however, a Zener diode allows current to flow in reverse. Fuses Page 3269 2. Unfasten C123 from the side of the engine compartment using a 90-degree pick. 3. Disconnect C123, and clean the terminals on both sides of the connector with contact cleaner. Shake the residue out of the connector. Allow the contact cleaner to evaporate for at least 3 minutes, then reconnect C123. 4. Fasten C123 to the left side of the engine compartment, and reinstall the air cleaner housing cover. 5. Remove the connector position assurance (CPA) clip from the APPS connector. 6. Disconnect the lop connector from the APPS. 7. Clean the terminals of the 10P APPS connector (harness side) with contact cleaner. Shake out residue from the connector, and allow the contact cleaner to evaporate for at least 3 minutes, then reconnect it. 8. Use the Smart Cable to reprogram the PCM with the latest software from the June 2001 or later HONDANET CD-ROM. Refer to Service Bulletin 99-005, Updating the Passport PCM, filed under Tools. 9. Use the PGM Tester to clear any DTCs. Page 2074 14. While watching the APP Sensor values in the Engine Data List, adjust the APPS by turning it until the values are within the ranges shown at closed throttle and wide open throttle (accelerator pedal pushed all the way down), then tighten the mounting screws and recheck the values. ^ If all three sensors are within range, go to step 23. ^ If APP Sensor 1 APP Sensor 2, and/or APP Sensor 3 cannot be brought into range, go to step 15. 15. Troubleshoot for an open circuit or a PCM malfunction. ^ If APP Sensor 1 has a value of 0% or APP Sensor 2 and/or APP Sensor 3 have a value of 99%, an open circuit exists or the PCM is malfunctioning. Repair the circuit or replace the PCM, and repeat step 14. ^ If you don't find a problem, go to step 16. 16. Disconnect the 10 P connector from the APPS. 17. View the APP Sensor values in the Engine Data List. ^ If APP Sensor 1 has a value of 0% or APP Sensor 2 and/or APP Sensor 3 have a value of 99%, go to step 18. ^ If APP Sensor 1 has a value other than 0%, or APP Sensor 2 and/or APP Sensor 3 have a value other than 99%, a short circuit exists or the PCM is malfunctioning. Repair the circuit or replace the PCM, and repeat step 14. 18. Modify the original APPS by cutting the connector housing off of the sensor. 19. Connect the 10 P connector to the modified APPS connector housing. Page 803 24. Verify APP Sensor 1 is between 11 and 15 percent, and APP Sensor 2 and APP Sensor 3 are between 89 and 85 percent with the pedal up (closed throttle). If not, loosen the mounting screws on the APPS sensor, and go to step 14. 25. Clear all DTCs with the PGM Tester. 26. Turn off the ignition switch, and disconnect the PGM Tester. Page 6746 Testing For A Short With A Self-Powered Test Light or DVOM 1. Remove the blown fuse and disconnect the battery and load. 2. Connect one lead of a self-powered test light or digital volt/ohmmeter (DVOM) (switched to the lowest "OHMS" range) to the fuse terminal on the load side. 3. Connect the other lead to a known good ground. 4. Beginning near the fuse box, wiggle the harness. Continue this at convenient points about six inches apart while watching the test light or DVOM. 5. If the self-powered test light goes on or the DVOM displays a low reading or no reading (zero), there is a short to ground in the wiring near that point. Testing for a Short with a Test Light or DVOM 1. Remove the blown fuse and disconnect the load. 2. Connect a test light or digital volt/ohmmeter (DVOM), switched to the appropriate DC volts range, across the fuse terminals to make sure voltage is present. You might have to turn the ignition switch to ON; check the schematic to see. 3. Beginning near the fuse box, wiggle the harness. Continue this at convenient points about six inches apart while watching the test light or DVOM. 4. Where the test light goes , or the DVOM voltage drops to zero, there is a short to ground in the wiring near that point. NOTE: Always use a DVOM on high impedance circuits. A test light may not glow (even with battery voltage present). Testing For A Short With A Short Circuit Locator (Short Finder) 1. Remove the blown fuse. Leave the battery connected. Page 2930 H/C 4408092 Defect Code: 017 Contention Code: C99 Skill Level: Repair Technician Out of warranty: Any repair performed after warranty expiration may be eligible for goodwill consideration by the District Service Manager or your Zone Office. You must request consideration, and get a decision, before starting work. DISCLAIMER Service Precautions Jump Starting: Service Precautions Jump Starting Jump Starting with an Auxiliary (Booster) Battery CAUTION: Never push or tow the vehicle in an attempt to start it. Serious damage to the emission system as well as other vehicle parts will result. Treat both the discharged battery and the booster battery with great care when using jumper cables. Carefully follow the jump starting procedure, being careful at all times to avoid sparking. WARNING: FAILURE TO CAREFULLY FOLLOW THE JUMP STARTING PROCEDURE COULD RESULT IN THE FOLLOWING: 1. Serous personal injury, particularly to your eyes. 2. Property damage from a battery explosion, battery acid, or an electrical fire. 3. Damage to the electronic components of one or both vehicles particularly. Never expose the battery to an open flame or electrical spark. Gas generated by the battery may catch fire or explode. Remove any rings, watches, or other jewelry before working around the battery. Protect your eyes by wearing an approved set of goggles. Never allow battery fluid to come in contact with your eyes or skin. Never allow battery fluid to come in contact with fabrics or painted surfaces. Battery fluid is a highly corrosive acid. Should battery fluid come in contact with your eyes, skin, fabric, or a painted surface, immediately and thoroughly rinse the affected area with clean tap water. Never allow metal tools or jumper cables to come in contact with the positive battery terminal, or any other metal surface of the vehicle. This will protect against a short circuit. Always keep batteries out of reach of young children. Page 6103 Page 2887 Fuel Tank Pressure Sensor: Service and Repair REMOVAL PROCEDURE 1. Remove the fuel pump assembly. Refer to Fuel Tank. 2. Carefully pry the fuel tank pressure sensor out of the top of the fuel pump assembly. INSTALLATION PROCEDURE 1. Install the rubber grommet on the fuel pump assembly. 2. Install the fuel tank vapor pressure sensor on the fuel pump assembly. 3. Insert the sensor nipple firmly into the grommet. 4. Keep twisting and pushing the sensor until the wide portion of the nipple shows on the other side of the grommet. 5. Install the fuel pump assembly on the fuel tank. Page 6613 - The name as it appears on the credit card - Signature (authorized card holder) - Phone number - Authorized charge amount NOTE: If you send in a faulty unit without a check or complete credit card information, the manufacturer may send it back to you unrepaired, or they may repair it and send it back to you C.O.D. ^ Print two copies of the completed Out-of-Warranty/New Replacement component repair form. Keep one copy with the repair order, and include the other copy with the faulty unit when you send it to the manufacturer. 8. Carefully pack the faulty unit and the paperwork in a suitable box, and label the box clearly. You are responsible for lost or damaged units; keep all shipping documents and insurance receipts. 9. Ship the faulty unit to the appropriate manufacturer via UPS. Alpine Electronics of America c/o Standard Radio Engineering Corp. 2012 Abalone Ave., Unit D Torrance, CA 90501 800-421-2284, Ext. 860304 Bose Corporation Automotive Systems Division-Service Framingham, MA 01701-9168 800-231-2673 S3 Clarion Factory Service Center 241 Beaver Rd. Walton, KY 41094 800-347-8667 (You must get authorization from Clarion before shipping units) Fujitsu Ten 19600 5. Vermont Ave. Torrance, CA 90502 800-237-5413 FTH Group Inc. (Kenwood Accessory Parts) 16685 E. Johnson Dr. City of Industry, CA 91745 626-333-2435 (You must get an RMA authorization number from www.fthgroupinc.com; from the home page, select Consumer Products) Komtec Electronics (Panasonic) 6590 Darin Way Cypress, CA 90630 714-903-3300 (Make sure your check is made out to Komtec) * Pioneer Electronics Service, Inc. 1925 E. Dominguez St. Long Beach, CA 90801 800-553-3756* Visteon c/o Model Electronics 615 E. Crescent Ave. Page 8085 Test Equipment CAUTION: Most circuits include solid-state devices. Test the voltages in these circuits only with a 10-megaohm or higher impedance digital multimeter. Never use a test light or analog meter on circuits that contain solid-state devices. Damage to the devices may result. Test Light and DVOM On circuits without solid-state devices, use a test light to check for voltage. A test light is made up of a 12 volt bulb with a pair of leads attached. After grounding one lead, touch the other lead to various points along the circuit where voltage should be present. The bulb will go on if there is voltage at the point being tested. If you need to know how much voltage is present, use a digital volt/ohmmeter (DVOM). Self-Powered Test Light and DVOM Use a self-powered test light to check for continuity. This tool is made up of a light bulb, battery, and two leads. To test it, touch the leads together: the light should go on. Use a self-powered test light only on an unpowered circuit. First, disconnect the battery, or remove the fuse that feeds the circuit you are working on. Select two points in the circuit between which you want to check continuity. Connect one lead of the self-powered test light to each point. If there is continuity, the test light's circuit will be completed, and the light will go on. If, in addition, you need to know exactly how much resistance there is between two points, use a digital volt/ohmmeter (DVOM). In the "OHMS" range, the DVOM will measure resistance between two points along a circuit. Low resistance means good continuity. Diodes and solid-state devices in a circuit can make a DVOM give a false reading. To check a reading, reverse the leads, and take a second reading. If the readings differ, the component is affecting the measurement. Jumper Wire Use a jumper wire to bypass an open circuit. A jumper wire is made up of an in-line fuse holder connected to a set of test leads. It should have a five ampere fuse. Never connect a jumper wire across a short circuit. The direct battery short will blow the fuse. Short Finder (Short Circuit Locator) Short finders are available to locate shorts to ground. The short finder creates a pulsing magnetic field in the shorted circuit which you can follow to the location of the short. To order any test equipment shown above, contact your local tool supplier. For a list of suppliers and tool numbers, refer to Honda Required Special Tools and Equipment Service Bulletin. Page 4711 If there is no photo number below or beside a component name or a connector, ground, or terminal number, look up that name or number in the appropriate Connector Identification Chart. The chart lists how many cavities a connector has, where it's located, and what it connects to. The related illustration shows the connector's location on the harness, and the harness routing. NOTE: Photos listed by number are located at Locations / Components / Photograohs. See: Locations/Component Locations/Photographs Circuit Schematics Page 4682 and the fuses. From Fuses to Relays and Components The second half of Power Distribution shows the wiring "From Fuses to Relays and Components." This can speed your troubleshooting by showing which circuits share fuses. If Power Distribution shows that an inoperative circuit and another circuit share a fuse, check a component in the other circuit. If it works, you know the fuse is good and power is available to the inoperative circuit. Ground Distribution Schematics Locations Relay Box: Locations General Precautions Air Bag(s) Arming and Disarming: Service Precautions General Precautions General Precautions Please read the following precautions carefully before performing the airbag system service. Observe the instructions described or the airbags could accidentally deploy and cause damage or injuries. Except when performing electrical inspections, always turn the ignition switch OFF and disconnect the negative cable from the battery, and wait at least three minutes before beginning work. NOTE: The contents in the memory is not erased even if the ignition switch is turned OFF or the battery cables are disconnected from the battery. Use the replacement parts which are manufactured to the same standards as the original parts and quality. Do not install used SRS parts from another vehicle. Use only new parts when making SRS repairs. Carefully inspect any SRS part before you install it. Do not install any part that shows signs of being dropped or improperly handled, such as dents, cracks or deformation. Before removing any of the SRS parts (including the disconnection of the connectors), always disconnect the SRS connector. Use only a digital multimeter to check the system. If it is not a Honda multimeter, make sure its output is 10 mA (0.01 A) or less when switched to the lowest value in the ohmmeter range. A tester with a higher output could cause accidental deployment and possible injury. Do not put objects on the front passenger's airbag. The original radio has a coded theft protection circuit. Be sure to get the customer's radio code before disconnecting the battery cable. Page 7307 Tailgate Lock Cylinder: Service and Repair Tailgate Lock and Hatchgate Lock (SWB) Removal 1. Disconnect the battery ground cable. 2. Remove the tailgate glass assembly and tailgate glass stay. 3. Remove the tailgate trim cover assembly. - Remove the two screws fixing the trim cover assembly and pull up the trim cover after detaching the clips from tailgate panel. 4. Remove the waterproof sheet. - Remove the waterproof sheet, taking special care so as not to break it. 5. Remove the key cylinder. - Disconnect the lock links. - Remove the key cylinder retaining clip with screw driver to remove the key cylinder. 6. Remove the hatchgate lock actuator assembly. - Disconnect the actuator harness connector. - Remove the two nuts holding hatchgate lock actuator assembly from inside. 7. Remove the outside handle. - Disconnect the lock link. - Remove the two bolts holding the outside handle from inside. 8. Remove the tailgate lock assembly. - Remove the three screws holding the lock assembly. Installation To install, follow the removal steps in the reverse order, noting the following points: 1. Apply chassis grease to the lock assembly and striker moving surface. 2. Tighten the hatchgate lock assembly fixing screws to the specified torque. Torque 7 Nm (61 lb in) 3. Check that the tailgate lock operates correctly after installing it. Tailgate Lock and Hatchgate Lock (LWB) Removal 1. Disconnect the battery ground cable. 2. Remove the tailgate trim cover assembly (3). - Remove the 2 screws (2) holding the hatch gate lock assembly (1) first, and pull up the trim cover while detaching the clips from tailgate panel. Page 1256 Refrigerant Oil: Service and Repair Contamination of Compressor Oil Contamination of Compressor Oil Unlike engine oil, no cleaning agent is added to the compressor oil. Even if the compressor runs for a long period of time (approximately one season), the oil never becomes contaminated as long as there is nothing wrong with the compressor or its method of use. Inspect the extracted oil for any of the following conditions: - The capacity of the oil has increased. - The oil has changed to red. - Foreign substances, metal powder, etc., are present in the oil. If any of these conditions exists, the compressor oil is contaminated. Whenever contaminated compressor oil is discovered, the receiver/drier must be replaced. Page 6781 2. Connect the short finder across the battery terminals and the load (component) side of the fuse terminal. 3. Close all switches in the circuit you're testing. 4. Turn on the short finder. This creates a pulsing magnetic field around the wiring between the fuse box and the short. 5. Beginning at the fuse box, slowly move the short finder along the circuit wiring. The meter will read current pulses through sheet metal and body trim. As long as the meter is between the fuse and the short, the needle will move with each current pulse. Once you move the meter past the point of the short, the needle will stop moving. Check the wiring and connectors in this area to locate the cause of the short. Testing For Continuity When testing for continuity at a connector without wire seals, you do not have to separate the two halves of the connector. Instead, probe the connector from the back. Always check both sides of the connector because dirty, corroded, and bent terminals can cause problems (no electrical contact = an open). 1. Disconnect the negative cable from the car battery. If you're using a DVOM, place it in the lowest "OHMS" range. Page 5005 1. O-ring (1) must be set onto the fluid reservoir (2), before installing. fluid reservoir. Page 3398 the component if the component only has one connector, or by a capital letter (A, B, C, etc.) if the component has more than one connector. Below most connector numbers and component names are PHOTO and VIEW numbers. The PHOTO number refers to a photo in the back of the book that shows the connector's location on the car. The VIEW number refers to an illustration in the back of the book that shows the connector face, wire colors, connector cavity numbers, and other details. The connector cavity numbering sequence begins at the top left corner of the connector. Disregard any numbers molded into the connector housing. Wires Wires are identified by the abbreviated names of their colors; the second color is the color of the stripe. Wires are also identified by their location in a connector. The number "2" next to the male and female wire terminals at C416, for example, means those terminals join in cavity 2 of connector C416. Symbols A complete description of schematic symbols is given under wire color abbreviation. Power Distribution Schematics Power Distribution schematics show how power is supplied from the positive battery terminal to various circuits in the car. Refer to the Power Distribution section to get a more detailed picture of how power is supplied to the circuit you're working on. From Battery to Ignition Switch, Fuses, and Relays Individual circuit schematics begin with a fuse. The first half of Power Distribution, however, shows the wiring "upstream" between the battery Page 2285 129 - Below Left Side Of I/P Procedures Console: Procedures Removal 1. Disconnect the battery ground cable. 2. Remove the shift knob (M/T) / transfer knob (4x4). 3. Remove the rear console assembly. - Open the rear console lid and remove two screws. - Disconnect the switch connector. 4. Remove the front console assembly. - Remove six fixing screws and disconnect the accessory socket connectors. Installation To install, follow the removal steps in the reverse order. Page 3600 2. Connect one lead of a self-powered test light or DVOM to one end of the part of the circuit you want to test. 3. Connect the other lead to the other end. 4. If the self-powered test light glows, there is continuity. If you're using a DVOM, a low reading or no reading (zero), means good continuity. Testing For Voltage When testing for voltage at a connector without wire seals, you do not have to separate the two halves of the connector. Instead, probe the connector from the back. Always check both sides of the connector because dirty, corroded, and bent terminals can cause problems (no electrical contact = an open). 1. Connect one lead of the lest light to a known good ground, or, if you're using a digital volt ohmmeter (DVOM), place it in the appropriate DC volts range, and connect its negative lead to ground. 2. Connect the other lead of the test light or DVOM to the point you want to check. 3. If the test light glows, there is voltage present. If you're using a DVOM, note the voltage reading. It should be within one volt of measured battery voltage. A loss of more than one volt indicates a problem. NOTE: Always use a DVOM on high impedance circuits. A test light may not glow (even with battery voltage present). Testing For Voltage Drop Wires, connectors, and switches are designed to conduct current with a minimum loss of voltage. A voltage drop of more than one volt indicates a problem. 1. Place the digital volt/ohmmeter (DVOM) in the appropriate DC volts range. Connect the positive lead to the end of the wire (or to the connector or switch) closest to the battery. 2. Connect the negative lead to the other end of the wire (or the other side of the connector or switch). 3. Turn on the components in the circuit. 4. The DVOM will show the difference in voltage between the two points. A difference, or drop, of more than one volt indicates a problem. Check the circuit for loose, dirty, or bent terminals. Page 2013 Terminals - "T" Each "T" terminal (ring type) is numbered for reference and location. A "T" terminal is secured with a screw or bolt. Wires Page 2618 the component if the component only has one connector, or by a capital letter (A, B, C, etc.) if the component has more than one connector. Below most connector numbers and component names are PHOTO and VIEW numbers. The PHOTO number refers to a photo in the back of the book that shows the connector's location on the car. The VIEW number refers to an illustration in the back of the book that shows the connector face, wire colors, connector cavity numbers, and other details. The connector cavity numbering sequence begins at the top left corner of the connector. Disregard any numbers molded into the connector housing. Wires Wires are identified by the abbreviated names of their colors; the second color is the color of the stripe. Wires are also identified by their location in a connector. The number "2" next to the male and female wire terminals at C416, for example, means those terminals join in cavity 2 of connector C416. Symbols A complete description of schematic symbols is given under wire color abbreviation. Power Distribution Schematics Power Distribution schematics show how power is supplied from the positive battery terminal to various circuits in the car. Refer to the Power Distribution section to get a more detailed picture of how power is supplied to the circuit you're working on. From Battery to Ignition Switch, Fuses, and Relays Individual circuit schematics begin with a fuse. The first half of Power Distribution, however, shows the wiring "upstream" between the battery Page 1308 Auto Light Sensor Connector Ambient Light Sensor: Locations Auto Light Sensor Connector Behind Gauge Assembly Page 1041 Alignment: Specifications Trim Height Trim Height .......................................................................................................................................... ................................. 119 +/- 5 mm (4.69 +/- 0.2 in.) Page 5347 H/C 4408092 Defect Code: 017 Contention Code: C99 Skill Level: Repair Technician Out of warranty: Any repair performed after warranty expiration may be eligible for goodwill consideration by the District Service Manager or your Zone Office. You must request consideration, and get a decision, before starting work. DISCLAIMER Page 5759 26. Using a 3/8 in. drill motor, a 1/4 in. drill guide, and a 1/4 in. bit, drill 16 pilot holes into the frame rail, through each hole in the type B reinforcement bracket. 27. Using a 1/4 in. bit, drill a pilot hole into the passenger's side frame rail, through the type B reinforcement bracket brake clip mounting hole. 28. Remove both type B reinforcement brackets. Save the body mount studs and nuts for the final installation. 29. Using a 1/2 in. drill motor and a 33/64 in. bit, final drill the pilot hole you made in step 27, then mark the hole with tape or chalk. This hole creates the clearance needed for the passenger's side brake line clip. NOTE: Do not install a pop nut into this hole. 30. Using the 1/2 in. drill motor and the 33/64 in. bit, drill 32 final holes (16 per bracket) where you made the pilot holes. 31. Test fit a pop nut into each of the 32 holes to be sure drilling is complete. NOTE: If a pop nut doesn't fit, don't try to try to enlarge the hole by pivoting the drill bit. Doing this creates an uneven seating surface for the pop nut. If the pop nut doesn't fit, your drill bit is worn out; sharpen or replace the drill bit, then red redrill the affected final hole(s). 32. Insert an air gun into the frame rail hole, and blow up and down the inside of the frame rails to move any rust or metal debris away from the area. 33. Attach the pop nut installer to shop air, and adjust the tool's air pressure regulator to between 72 and 87 psi. NOTE: ^ The tool's air pressure is critical: if it's too low, the pop nuts cannot be correctly installed; if it's too high, the tool will be damaged. Locations Camshaft Position Sensor Locations Main Relay (Computer/Fuel System): Locations 9. Fuse/Relay Box (Cover Removed) Fuse/Relay Box (Cover Removed) Page 3009 Distinct Of Circuit By Wire Base Color All wires have color-coded insulation. Wires belonging to a system's main harness will have a single color. Wires belonging to a system's sub-circuits will have a colored stripe. Striped wires use the codes found in the chart to show wire size and colors. Abbreviations are used to indicate wire color within a circuit diagram. How to Identify Connector Terminals How to Identify Connector Terminals Cavity Numbering System The cavities (and wire terminals) in each connector are numbered starting from the upper left, looking at the male terminals from the terminal side (or looking at the female terminals from the wire side. Both views are in the same direction so the numbers are the same.) All actual cavities are numbered, even if they have no wire terminals in them. NOTE: Data Link Connector (DLC) terminals are numbered according to SAE standard J1962, not the Honda standard. The numbers of the four end terminals are molded into the corners of the connector face. The connector cavity number is listed next to each terminal on the circuit schematic. The cavity / terminal shown is # 6. Using/Identifying Connector Terminal Views How to Use Connector Terminal Views To see the configuration of a connector's cavities, look up its view number in the Connector Views. Each view includes the color of the connector, where Page 3822 4. Remove the fuel pressure regulator from the fuel rail. 5. Remove the fuel return line from the regulator. 6. Install the new fuel pressure regulator in the reverse order of removal. 7. Use the Smart Cable to reprogram the PCM with the latest software from the June 2001 or later HONDANET CD-ROM. Refer to Service Bulletin 99-005, Updating the Passport PCM, filed under Tools. 8. Use the PGM Tester to clear any DTCs. 9. Use the PGM Tester to check the broadcast code. Make sure the broadcast code matches the one you selected from the CD-ROM. WARRANTY CLAIM INFORMATION In warranty: The normal warranty applies. Failed Part: P/N 8-17113-398-0 H/C 5504386 Defect Code: 092 Contention Code: C99 Skill Level: Repair Technician Out of warranty: Any repair performed after warranty expiration may be eligible for goodwill consideration by the District Service Manager or your Zone Office. You must request consideration, and get a decision, before starting work. REPAIR PROCEDURE - POWER STEERING SWITCH 1. Drain the power steering fluid out of the system. 2. Remove the power steering fluid reservoir. Clean the reservoir with solvent, then with soap and water. Rinse and dry it thoroughly. 3. Reinstall the reservoir. Do not connect the return hose. 4. Remove the power steering pressure switch, then clean it with brake cleaner and a scraper. Reinstall the switch, and torque it to 20 N.m (14 lb-ft). 5. Cover the unconnected end of the reservoir with your finger, then fill the reservoir with Dexron III ATF Page 7911 Wires Wire insulation can be one color, or one color with another color stripe. (The second color is the stripe.) This circuit continues on another image. (The arrow shows direction of current flow.) To follow the RED/BLK wire in this example, you would turn to "Fuel and Emissions" and look for the "A" arrow. Description and Operation Electric Load Sensor: Description and Operation Electrical Load Detector (ELD) Since the early ’90s, Honda vehicles have come with an electrical load detector (ELD) unit in the under-hood fuse/relay box. This unit allows the ECM/PCM to regulate the alternator (switch it between high output and low output) to provide the best combination of fuel economy and electrical system operation. The ELD sends a signal to the ECM/PCM that is proportional to the electrical demand. The ECM/PCM switches the alternator between high output and low output depending on several factors, which include electrical demand, battery charge level, and the driving cycle. When the alternator is in low output, the engine load is reduced and fuel economy improves. Page 6222 Housing Assembly HVAC: Service and Repair Heater Mode Control Link Unit Heater Mode Control Link Unit Removal 1. Disconnect the battery ground cable. 2. Drain engine coolant. 3. Discharge and recover refrigerant (with air conditioning) 4. Remove heater unit. 5. Remove the case (Mode control) from heater unit. 6. Remove washer and the mode main lever. 7. Remove rod. 8. Press the tab of the sub-lever inward, and take out the sub-lever. Page 8080 Wires Wire insulation can be one color, or one color with another color stripe. (The second color is the stripe.) This circuit continues on another image. (The arrow shows direction of current flow.) To follow the RED/BLK wire in this example, you would turn to "Fuel and Emissions" and look for the "A" arrow. Page 2090 14. While watching the APP Sensor values in the Engine Data List, adjust the APPS by turning it until the values are within the ranges shown at closed throttle and wide open throttle (accelerator pedal pushed all the way down), then tighten the mounting screws and recheck the values. ^ If all three sensors are within range, go to step 23. ^ If APP Sensor 1 APP Sensor 2, and/or APP Sensor 3 cannot be brought into range, go to step 15. 15. Troubleshoot for an open circuit or a PCM malfunction. ^ If APP Sensor 1 has a value of 0% or APP Sensor 2 and/or APP Sensor 3 have a value of 99%, an open circuit exists or the PCM is malfunctioning. Repair the circuit or replace the PCM, and repeat step 14. ^ If you don't find a problem, go to step 16. 16. Disconnect the 10 P connector from the APPS. 17. View the APP Sensor values in the Engine Data List. ^ If APP Sensor 1 has a value of 0% or APP Sensor 2 and/or APP Sensor 3 have a value of 99%, go to step 18. ^ If APP Sensor 1 has a value other than 0%, or APP Sensor 2 and/or APP Sensor 3 have a value other than 99%, a short circuit exists or the PCM is malfunctioning. Repair the circuit or replace the PCM, and repeat step 14. 18. Modify the original APPS by cutting the connector housing off of the sensor. 19. Connect the 10 P connector to the modified APPS connector housing. Control Lever Assembly and/or Control Cable Air Door Cable: Service and Repair Control Lever Assembly and/or Control Cable Removal 1. Disconnect the battery ground cable. 2. Remove instrument panel driver lower cover assembly. 3. Remove meter cluster assembly. 4. Remove glove box. 5. Remove the control lever attaching screws. Page 2837 24. Verify APP Sensor 1 is between 11 and 15 percent, and APP Sensor 2 and APP Sensor 3 are between 89 and 85 percent with the pedal up (closed throttle). If not, loosen the mounting screws on the APPS sensor, and go to step 14. 25. Clear all DTCs with the PGM Tester. 26. Turn off the ignition switch, and disconnect the PGM Tester. Component Locations 4WD Motor Actuator: Component Locations Beneath Center of Vehicle, on Transfer Case (A/T) Page 4339 2. Tighten the hub nut to the value given below, using a spring scale on the wheel pin. New bearing and New oil seal Bearing Preload: 20 N - 25 N (4.4 lbs. - 5.5 lbs.) Used bearing and New oil seal Bearing Preload: 12 N - 18 N (2.6 lbs. - 4.0 lbs.) If the measured bearing preload is outside the specifications, adjust it by loosening or tightening the bearing nut. 9. Install lock washer and lock screw in the following manner. - Turn the side with larger diameter of the tapered bore to the vehicle outer side, then attach the washer. - If the bolt holes in the lock plate are not aligned with the corresponding holes in the nut, reverse the lock plate. - If the bolt holes are still out of alignment, turn in the nut just enough to obtain alignment. - Screw is to be fastened tightly so its head may come lower than the surface of the washer. 10. Apply adhesive (LOCTITE 515 or equivalent) to both joining flange faces then install hub flange. 11. Install snap ring and shim. Adjust the clearance between the freewheeling hub body and the snap ring. Clearance: 0 mm - 0.3 mm (0 inch - 0.012 inch) Shims Available: 0.2 mm, 0.3 mm, 0.5 mm, 1.0 mm (0.008 inch, 0.012 inch, 0.020 inch, 0.039 inch) 12. Install hub cap. Page 4908 Brake Rotor/Disc: Description and Operation Lateral Runout LATERAL RUNOUT Lateral runout is the movement of the rotor from side to side as it rotates on the spindle. This could also be referred to as "rotor wobble". This movement causes the piston to be knocked back into its bore. This results in additional pedal travel and a vibration during braking. Page 8160 Liftgate Window Glass: Adjustments Rear Hatchgate Adjustment - Hatchgate alignment is obtained by moving hatchgate hinges. Page 258 Each schematic represents one circuit. A circuit's wires and components are arranged to show current flow, from power at the top of the page, to ground, at the bottom. Shared Circuits Other circuits may share power or ground terminals or wiring with the circuit shown. A wire that connects one circuit to another, for example, is cut short and has an arrowhead at the end of it pointing in the direction of current flow. Next to the arrowhead is the name of the circuit or component which shares that wiring. To quickly check shared wiring, check the operation of a component it serves. If that component works, you know the shared wiring is OK. Connectors All in-line and junction connectors are numbered (C725, C416, etc.). Component connectors are not numbered but are identified either by the name of Page 2464 14. While watching the APP Sensor values in the Engine Data List, adjust the APPS by turning it until the values are within the ranges shown at closed throttle and wide open throttle (accelerator pedal pushed all the way down), then tighten the mounting screws and recheck the values. ^ If all three sensors are within range, go to step 23. ^ If APP Sensor 1 APP Sensor 2, and/or APP Sensor 3 cannot be brought into range, go to step 15. 15. Troubleshoot for an open circuit or a PCM malfunction. ^ If APP Sensor 1 has a value of 0% or APP Sensor 2 and/or APP Sensor 3 have a value of 99%, an open circuit exists or the PCM is malfunctioning. Repair the circuit or replace the PCM, and repeat step 14. ^ If you don't find a problem, go to step 16. 16. Disconnect the 10 P connector from the APPS. 17. View the APP Sensor values in the Engine Data List. ^ If APP Sensor 1 has a value of 0% or APP Sensor 2 and/or APP Sensor 3 have a value of 99%, go to step 18. ^ If APP Sensor 1 has a value other than 0%, or APP Sensor 2 and/or APP Sensor 3 have a value other than 99%, a short circuit exists or the PCM is malfunctioning. Repair the circuit or replace the PCM, and repeat step 14. 18. Modify the original APPS by cutting the connector housing off of the sensor. 19. Connect the 10 P connector to the modified APPS connector housing. Page 5859 Tires: Service Precautions CAUTION: Always use the correct fastener in the proper location. When you replace a fastener, use ONLY the exact part number for that application. Honda will call out those fasteners that require a replacement after removal. Honda will also call out the fasteners that require thread lockers or thread sealant. Unless otherwise specified, do not use supplemental coatings (Paints, greases, or other corrosion inhibitors) on threaded fasteners or fastener joint interfaces. Generally, such coatings adversely affect the fastener torque and the joint clamping force, and may damage the fastener. When you install fasteners, use the correct tightening sequence and specifications. Following these instructions can help you avoid damage to parts and systems. Page 2984 Page 3411 Test Equipment CAUTION: Most circuits include solid-state devices. Test the voltages in these circuits only with a 10-megaohm or higher impedance digital multimeter. Never use a test light or analog meter on circuits that contain solid-state devices. Damage to the devices may result. Test Light and DVOM On circuits without solid-state devices, use a test light to check for voltage. A test light is made up of a 12 volt bulb with a pair of leads attached. After grounding one lead, touch the other lead to various points along the circuit where voltage should be present. The bulb will go on if there is voltage at the point being tested. If you need to know how much voltage is present, use a digital volt/ohmmeter (DVOM). Self-Powered Test Light and DVOM Use a self-powered test light to check for continuity. This tool is made up of a light bulb, battery, and two leads. To test it, touch the leads together: the light should go on. Use a self-powered test light only on an unpowered circuit. First, disconnect the battery, or remove the fuse that feeds the circuit you are working on. Select two points in the circuit between which you want to check continuity. Connect one lead of the self-powered test light to each point. If there is continuity, the test light's circuit will be completed, and the light will go on. If, in addition, you need to know exactly how much resistance there is between two points, use a digital volt/ohmmeter (DVOM). In the "OHMS" range, the DVOM will measure resistance between two points along a circuit. Low resistance means good continuity. Diodes and solid-state devices in a circuit can make a DVOM give a false reading. To check a reading, reverse the leads, and take a second reading. If the readings differ, the component is affecting the measurement. Jumper Wire Use a jumper wire to bypass an open circuit. A jumper wire is made up of an in-line fuse holder connected to a set of test leads. It should have a five ampere fuse. Never connect a jumper wire across a short circuit. The direct battery short will blow the fuse. Short Finder (Short Circuit Locator) Short finders are available to locate shorts to ground. The short finder creates a pulsing magnetic field in the shorted circuit which you can follow to the location of the short. To order any test equipment shown above, contact your local tool supplier. For a list of suppliers and tool numbers, refer to Honda Required Special Tools and Equipment Service Bulletin. Page 5752 ^ Reinstall the lower half of body mount #4 on both sides of the vehicle. Torque the nuts to 50 Nm (37 Ib-ft). 23. Remove the ratcheting straps. 24. Lower the vehicle to the ground, then torque the lower trailing link front mounting bolts to 165-180 Nm (122-133 Ib-ft). 25. If the side steps or the running boards were removed, reinstall them. 26. Fill out the information on a campaign completion label. Stick this label to the back edge of the driver's door, just below the door latch. *NOTE: If you need more labels, order them from Helm using reorder number Y0895.* Stage 4 Repair STAGE 4 REPAIR *NOTE: ^ If the vehicle requires a STAGE 4 repair or had a prior repair resulting in a modification to the lower trailing link front bracket area, an additional Page 3297 Splices Splices are shown as a dot. Their location and the number of wires may vary depending on the harness manufacturer. Switches Switches These switches move together; the broken straight line between them means they are mechanically connected. Other types of switches are controlled by a coil or a solid state circuit. Unless otherwise noted, all switches are shown in their normal (rest) position, with power off. Terminal "T" Page 5548 Power Steering Pressure Switch: Locations 27. Left Side of Engine Left Side Of Engine Capacity Specifications Refrigerant: Capacity Specifications HVAC SYSTEM HVAC SYSTEM ITEM SPECIFICATION Refrigerant Type HFC - 134a (R-134a) Capacity of Systems 700 g (1.54 lbs) Page 3534 Ignition Cable: Testing and Inspection Spark Plug Cables NOTE: Never puncture the spark plug cable's insulation with a needle or the pointed end of a probe into the cable. An increase in resistance would be created which would cause the cable to become defective. 1. If the cable has broken or cracked insulation, it must be replaced. 2. If the terminals are corroded or loose, the cable must be replaced. 3. Check that the cable resistance does not exceed 10 kOHM per foot. Page 1512 Note: Take care not to confuse the alignment mark (2) and the size mark (1) during the installation procedure. Reassembly 1. Install connecting rod 2. Install piston 3. Install piston pin - Apply a thin coat of engine oil to the piston pin. Try to insert the piston pin into the piston pin hole with normal finger pressure. Note: When changing piston/connecting rod combinations, do not change the piston/piston pin combination and do not reuse the old piston pin. - Attach the piston to the connecting rod with the piston front mark and the connecting rod front mark on the same side. Page 3481 Throttle Position Sensor: Service and Repair REMOVAL PROCEDURE 1. Disconnect the negative battery cable. 2. Disconnect the TPS electrical connector. 3. Remove the bolts and the TP sensor from the throttle body. NOTE: Do not clean the TP sensor by soaking it in solvent. The sensor will be damaged as a result. INSTALLATION PROCEDURE 1. Install the TP sensor on the throttle body with the bolts. 2. Connect the TP electrical connector. 3. Install the negative battery cable. Page 6468 Air Bag(s) Arming and Disarming: Service Precautions Precautions For Electrical Inspections Precautions For Electrical Inspections When using electrical test equipment, insert the probe of the tester into the wire side of the connector. Do not insert the probe of the tester into the terminal side of the connector, and do not tamper with the connector. Use a U-shaped probe. Do not insert the probe forcibly. Use specified service connectors in troubleshooting. Using improper tools could cause an error in inspection due to poor metal-to-metal contact. Page 2142 Fuel Tank Pressure Sensor: Service and Repair REMOVAL PROCEDURE 1. Remove the fuel pump assembly. Refer to Fuel Tank. 2. Carefully pry the fuel tank pressure sensor out of the top of the fuel pump assembly. INSTALLATION PROCEDURE 1. Install the rubber grommet on the fuel pump assembly. 2. Install the fuel tank vapor pressure sensor on the fuel pump assembly. 3. Insert the sensor nipple firmly into the grommet. 4. Keep twisting and pushing the sensor until the wide portion of the nipple shows on the other side of the grommet. 5. Install the fuel pump assembly on the fuel tank. Page 3798 2. Unfasten C123 from the side of the engine compartment using a 90-degree pick. 3. Disconnect C123, and clean the terminals on both sides of the connector with contact cleaner. Shake the residue out of the connector. Allow the contact cleaner to evaporate for at least 3 minutes, then reconnect C123. 4. Fasten C123 to the left side of the engine compartment, and reinstall the air cleaner housing cover. 5. Remove the connector position assurance (CPA) clip from the APPS connector. 6. Disconnect the lop connector from the APPS. 7. Clean the terminals of the 10P APPS connector (harness side) with contact cleaner. Shake out residue from the connector, and allow the contact cleaner to evaporate for at least 3 minutes, then reconnect it. 8. Use the Smart Cable to reprogram the PCM with the latest software from the June 2001 or later HONDANET CD-ROM. Refer to Service Bulletin 99-005, Updating the Passport PCM, filed under Tools. 9. Use the PGM Tester to clear any DTCs. Page 4702 Axle Disconnect Control Control Unit: Service and Repair SHIFT ON THE FLY CONTROLLER AND ASSOCIATED PARTS REMOVAL 1. Disconnect the battery ground cable. 2. Remove the front console assembly. 3. Disconnect the connector from the controller. 4. Remove the nut. 5. Remove the controller. INSTALLATION 1. To install, follow the removal steps in the reverse order, noting the following points. Torque: Nut (1) 8 Nm (69 inch lbs.) Page 1294 Air Bag(s) Arming and Disarming: Service and Repair Connector Disconnection / Connection REMOVAL To remove the connector, hold the cover insulator(l) and pull it. The cover insulator slides and lock will be released. Do not hold the socket insulator(2). INSTALLATION Brake Line Brake Hose/Line: Service and Repair Brake Line Removal 1. Raise the vehicle and support it with suitable safety stands. 2. Remove wheel and tire assembly as necessary. 3. Clean dirt, grease, and other foreign material off the pipe fittings at both ends. 4. Remove brake pipe (1). 5. Remove plastic clip (2). Installation To install, follow the removal steps in the reverse order, noting the following points. 1. Tighten the brake pipes to the specified torque. Master cylinder and P & B valve sides Torque: 12 Nm (104 inch lbs.) Others Torque: 16 Nm (12 ft. lbs.) After installing the brake pipes, bleed the brakes as described. Page 5563 Air Bag(s) Arming and Disarming: Description and Operation General Description General Description Restraint Devices The Supplemental Restraint System (SRS) helps supplement the protection offered by the driver and front passenger seat belts by deploying an air bag from the center of the steering wheel and from the top of the right side of the instrument panel. The air bag deploys when the vehicle is involved in a frontal crash of sufficient force up to 30 degrees off the centerline of the vehicle; To further absorb the crash energy there is a knee bolster located beneath the instrument panel for both the driver and passenger, and the steering column is collapsible. Description and Operation Temperature Gauge: Description and Operation The engine coolant temperature gauge consists of two intersecting coils wound around a permanent magnet rotor. When voltage from fuse 11 is applied to the coils, a magnetic field is generated. This causes the rotor to rotate and the gauge needle to move. The magnetic field is controlled by the sender. As the resistance in the sender varies, current through the gauge coils changes. The gauge needle moves according to the changing magnetic field. Page 4533 4WD Motor Actuator: Connector Locations Beneath Center of Vehicle, on Transfer Case (A/T) Page 5575 If there is no photo number below or beside a component name or a connector, ground, or terminal number, look up that name or number in the appropriate Connector Identification Chart. The chart lists how many cavities a connector has, where it's located, and what it connects to. The related illustration shows the connector's location on the harness, and the harness routing. NOTE: Photos listed by number are located at Locations / Components / Photograohs. See: Locations/Component Locations/Photographs Circuit Schematics Page 6770 The connector cavity number is listed next to each terminal on the circuit schematic. The cavity / terminal shown is # 6. Diodes A rectifier diode works like a one way valve. It allows current to flow only in the direction of the arrow. A Zener diode blocks reverse current at normal voltages just like a rectifier diode. At high voltages, however, a Zener diode allows current to flow in reverse. Fuses Page 2553 Crankshaft Position Sensor: Testing and Inspection 1. Inspect the sensor O-ring for cracks or leaks. 2. Replace the O-ring if it is worn or damaged. 3. Lubricate the new O-ring with engine oil. 4. Install the lubricated O-ring. Page 274 2. Connect the short finder across the battery terminals and the load (component) side of the fuse terminal. 3. Close all switches in the circuit you're testing. 4. Turn on the short finder. This creates a pulsing magnetic field around the wiring between the fuse box and the short. 5. Beginning at the fuse box, slowly move the short finder along the circuit wiring. The meter will read current pulses through sheet metal and body trim. As long as the meter is between the fuse and the short, the needle will move with each current pulse. Once you move the meter past the point of the short, the needle will stop moving. Check the wiring and connectors in this area to locate the cause of the short. Testing For Continuity When testing for continuity at a connector without wire seals, you do not have to separate the two halves of the connector. Instead, probe the connector from the back. Always check both sides of the connector because dirty, corroded, and bent terminals can cause problems (no electrical contact = an open). 1. Disconnect the negative cable from the car battery. If you're using a DVOM, place it in the lowest "OHMS" range. Page 4223 Wire Color Abbreviations The following abbreviations are used to identify wire colors in the circuit schematics: WHT................................... White YEL................................... Yellow BLK................................... Black BLU................................... Blue GRN................................... Green RED................................... Red ORN................................... Orange PNK................................... Pink BRN................................... Brown GRY................................... Gray PUR................................... Purple LT BLU................................... Light Blue LT GRN................................... Light Green Page 5562 A battery voltage (B+) circuit which is only powered with the ignition switch in the ON, or START positions. Initiator The electrical component inside the air bag assembly which, when sufficient current flows, sets off the chemical reaction that inflates the air bag. "Initiator Assembly Resistance Test" Tests performed once each ignition cycle when no malfunctions are detected during "Turn-ON" or "Continuous Monitoring." This test checks for the correct SDM configuration for the vehicle, shorts to "Ignition 1 in the deployment loops, high resistance or opens in the "Driver Side High", "Driver Side Low", "Passenger Side High" and "Passenger Side Low" circuits and measures the resistance of the inflator assembly consisting of: 1. Initiators. 2. SRS coil assembly (driver side only). 3. Connectors and associated wiring. Normal Operating Voltage Range The voltage measured between the SDM "Ignition 1" terminals and "Ground" terminals is between 9 and 16 volts. Passenger Current Source An output of the SDM which applies current into the passenger air bag assembly circuit during the "Initiator Assembly Resistance Test". Passenger Air Bag Assembly An assembly located in the right side of the instrument panel consisting of an inflatable bag, an inflator and an initiator. Scan Tool An external computer used to read diagnostic information from on-board computers via the data link connector. SDM Sensing and Diagnostic Module which provides reserve energy to the deployment loops, deploys the air bags when required and performs diagnostic monitoring of all SRS components. Serial Data Information representing the status of the SRS. SRS Supplemental Restraint System. SRS Coil Assembly An assembly of two current-carrying coils in the driver deployment loop that allows the rotation of the steering wheel while maintaining the continuous contact of the driver deployment loop to the driver air bag assembly. SRS Wiring Harness The wires and connectors that electrically connect the components in the SRS. "Turn-ON" Test which the SDM performs on the SRS once during each ignition cycle immediately after "Ignition 1" voltage is applied to the SDM and before "Continuous Monitoring". Page 3013 the component if the component only has one connector, or by a capital letter (A, B, C, etc.) if the component has more than one connector. Below most connector numbers and component names are PHOTO and VIEW numbers. The PHOTO number refers to a photo in the back of the book that shows the connector's location on the car. The VIEW number refers to an illustration in the back of the book that shows the connector face, wire colors, connector cavity numbers, and other details. The connector cavity numbering sequence begins at the top left corner of the connector. Disregard any numbers molded into the connector housing. Wires Wires are identified by the abbreviated names of their colors; the second color is the color of the stripe. Wires are also identified by their location in a connector. The number "2" next to the male and female wire terminals at C416, for example, means those terminals join in cavity 2 of connector C416. Symbols A complete description of schematic symbols is given under wire color abbreviation. Power Distribution Schematics Power Distribution schematics show how power is supplied from the positive battery terminal to various circuits in the car. Refer to the Power Distribution section to get a more detailed picture of how power is supplied to the circuit you're working on. From Battery to Ignition Switch, Fuses, and Relays Individual circuit schematics begin with a fuse. The first half of Power Distribution, however, shows the wiring "upstream" between the battery Page 7381 The name of the component appears next to it followed by notes about its function along with any photo and connector view references. Connector "C" How to Identify Connector Terminals Cavity Numbering System The cavities (and wire terminals) in each connector are numbered starting from the upper left, looking at the male terminals from the terminal side (or looking at the female terminals from the wire side. Both views are in the same direction so the numbers are the same.) All actual cavities are numbered, even if they have no wire terminals in them. NOTE: Data Link Connector (DLC) terminals are numbered according to SAE standard J1962, not the Honda standard. The numbers of the four end terminals are molded into the corners of the connector face. Page 3320 Fuel Rail: Service and Repair Fuel Rail Assembly REMOVAL PROCEDURE NOTE: - Do not attempt to remove the fuel inlet fitting on the fuel rail. It is staked in place. Removing the fuel inlet fitting will result in damage to the fuel rail or the internal O-ring seal. - Use care when removing the fuel rail assembly in order to prevent damage to the injector electrical connector terminals and the injector spray tips. - Fittings should be capped and holes plugged during servicing to prevent dirt and other contaminants from entering open lines and passages. IMPORTANT: An eight-digit identification number is stamped on the side of the fuel rail. Refer to this number when you service the fuel rail or when a replacement part is required. Before removal, the fuel rail assembly may be cleaned with a spray type engine cleaner. Follow the spray package instructions. Do not immerse the fuel rails in liquid cleaning solvent. 1. Depressurize the fuel system. Refer to Fuel Pressure Relief Procedure. 2. Disconnect the negative battery cable. 3. Remove the engine cover. 4. Disconnect the throttle position sensor electrical connector from throttle body. 5. Disconnect the connectors from manifold absolute pressure sensor, solenoid valve, electric vacuum sensing valve. 6. Disconnect the vacuum hose on canister VSV and positive crankcase ventilation hose. 7. Remove the common chamber. - Lift up carefully on the fuel injectors. Do not separate the fuel injectors from the fuel rail. - If an injector becomes separated from the fuel rail, the infector O-ring seals and the retainer clip must be replaced. - Drain residual fuel into an approved container. 8. If removal of the fuel pressure regulator is necessary. 9. If removal of the fuel injectors is necessary. Page 7710 and the fuses. From Fuses to Relays and Components The second half of Power Distribution shows the wiring "From Fuses to Relays and Components." This can speed your troubleshooting by showing which circuits share fuses. If Power Distribution shows that an inoperative circuit and another circuit share a fuse, check a component in the other circuit. If it works, you know the fuse is good and power is available to the inoperative circuit. Ground Distribution Schematics Page 7917 Testing For A Short With A Self-Powered Test Light or DVOM 1. Remove the blown fuse and disconnect the battery and load. 2. Connect one lead of a self-powered test light or digital volt/ohmmeter (DVOM) (switched to the lowest "OHMS" range) to the fuse terminal on the load side. 3. Connect the other lead to a known good ground. 4. Beginning near the fuse box, wiggle the harness. Continue this at convenient points about six inches apart while watching the test light or DVOM. 5. If the self-powered test light goes on or the DVOM displays a low reading or no reading (zero), there is a short to ground in the wiring near that point. Testing for a Short with a Test Light or DVOM 1. Remove the blown fuse and disconnect the load. 2. Connect a test light or digital volt/ohmmeter (DVOM), switched to the appropriate DC volts range, across the fuse terminals to make sure voltage is present. You might have to turn the ignition switch to ON; check the schematic to see. 3. Beginning near the fuse box, wiggle the harness. Continue this at convenient points about six inches apart while watching the test light or DVOM. 4. Where the test light goes , or the DVOM voltage drops to zero, there is a short to ground in the wiring near that point. NOTE: Always use a DVOM on high impedance circuits. A test light may not glow (even with battery voltage present). Testing For A Short With A Short Circuit Locator (Short Finder) 1. Remove the blown fuse. Leave the battery connected. Page 990 1. Place the vehicle on a commercially available, computerized, four-wheel alignment rack, and record the following measurements. Follow the equipment manufacturer's instructions. NOTE: Enter each reading in decimal degrees. Example 30' = 0.50. 2. If any measurement is out of specification, inspect the front suspension for any damage. Repair any damaged parts before continuing your diagnosis. 3. Determine how the front wheel camber is affecting the pull. Pick the combination of left- and right-front camber that best matches the vehicle you are repairing, then note the camber thrust direction for that combination: NOTE: ^ If the camber of both front wheels is negative, but one wheel is grossly more negative than the other, the camber thrust direction will be opposite the wheel with more negative camber (for example, if the left-front wheel is more negative, the camber thrust direction is right). ^ If the camber of both front wheels is positive, but one wheel is grossly more positive than the other, the camber thrust direction will be the same as the wheel with more positive camber (for example, if the left-front wheel is more positive, the camber thrust direction is left). 4. Determine how the camber needs to be adjusted. 5. Adjust the camber as needed. Front Camber Adjustment, Double Wishbone Suspension Page 2330 7. When installing the steering column cover, be sure to wire (through each harness) as illustrated so that the harnesses starter switch, combination switch and SRS coil may not catch wiring. 8. Install steering wheel by aligning the setting marks made during removal. CAUTION: Never apply force to the steering wheel in direction of the shaft by using a hammer or other impact tools in an attempt to remove the steering wheel. The steering shaft is designed as an energy absorbing unit. 9. Tighten the steering wheel fixing nut to the specified torque. Torque: 34 Nm (25 ft. lbs.) 10. Support inflator module and carefully connect the SRS connector and horn lead, then install inflator module. NOTE: Pass the lead wire through the tabs on the plastic cover (wire protector) of inflator to prevent lead wire from being pinched. 11. Tighten fixing bolts to specified torque. Torque: 9 Nm (78 inch lbs.) 12. Install driver knee bolster (reinforcement). 13. Install instrument panel lower cover, then install the engine hood opening lever. 14. Connect the yellow 2-way SRS connector located under the steering column. 15. Connect the battery "-" terminal cable. Page 8054 1. Install combination switch and SRS coil assembly. After installation of combination switch assembly, connect the combination switch wiring harness connector and the SRS 2-way connector located under the steering column. Then turn the SRS coil counterclockwise to full, return about 3 turns and align the neutral mark. CAUTION: When turning the SRS coil counterclockwise to full, stop turning if resistance is felt. Forced further turning may damage to the cable in the SRS coil. 2. When installing the steering column cover, be sure to route each wire harness as illustrated so that the harnesses do not catch on any moving parts. 3. Align the setting marks made when removing then install steering wheel. CAUTION: Never apply force to the steering wheel in direction of the shaft by using a hammer or other impact tools in an attempt to remove the steering wheel. The steering shaft is designed as an energy absorbing unit. 4. Tighten the steering wheel fixing nut to the specified torque. Torque: 34 Nm (25 ft. lbs.) 5. Support the inflator module and carefully connect the SRS connector and horn lead. NOTE: Pass the lead wire through the tabs on the plastic cover (wire protector) of inflator to prevent lead wire from being pinched. 6. Tighten bolts to specified torque. Torque: 9 Nm (78 inch lbs.) 7. Install driver knee bolster (reinforcement). 8. Install instrument panel lower cover then install the engine hood opening lever. 9. Connect the SRS connector. 10. Connect the battery "-" terminal cable. Page 5183 Check for continuity between commutator and shaft. Also, check for continuity between commutator and armature core,armature core and shaft. Replace commutator if there is continuity (i.e., internally grounded). Measure runout of armature core and commutator with a dial gauge. Repair or replace, if it exceeds the limit. Armature Standard: 0.05 mm (0.002 in) Max. Limit: 0.10 mm (0.004 in) Commutator Standard: 0.05 mm (0.002 in) Max. Limit: 0.10 mm (0.004 in) Page 5653 Without Torque Specifications Page 3703 The connector cavity number is listed next to each terminal on the circuit schematic. The cavity / terminal shown is # 6. Diodes A rectifier diode works like a one way valve. It allows current to flow only in the direction of the arrow. A Zener diode blocks reverse current at normal voltages just like a rectifier diode. At high voltages, however, a Zener diode allows current to flow in reverse. Fuses Page 7602 Terminals - "T" Each "T" terminal (ring type) is numbered for reference and location. A "T" terminal is secured with a screw or bolt. Wires Service and Repair Rear Bumper Bracket: Service and Repair Rear Bumper Slider Removal 1. Remove the rear bumper. 2. Remove the rear bumper slider(1). - Remove the three bolts(2). Installation To install, follow the removal steps in reverse order, noting the following point. 1. Apply chassis grease to the slider and the slider bracket moving surface. Locations Combination Switch: Locations Driver's Inflator Module Connector Page 3851 SMART CABLE DIAGNOSIS If the red light (# 3) on the Smart Cable came on or was flashing while updating the PCM, do this: *1. If not already done, load the May 1999 or later DOS CD onto your DOS workstation. Loading instructions were included in the CD'S mailing.* 2. Disconnect the Smart Cable from the vehicle's DLC. *3. Connect the Smart Cable to the DOS workstation (see steps 2 and 3 of REPROGRAMMING A SMART CABLE).* 4. Connect the 110 VAC/12 VAC power supply to the Smart Cable box and to 110 VAC power. *5. Log in to HONDANET 2000. 6. From the choices across the top of the HONDANET 2000 screen, click on Service Bay, and then click on Smart Cable from the drop-down menu. 7. Click on View Err at the bottom of the screen to display the problem encountered while the Smart Cable was connected to the vehicle. SMART CABLE ASSISTANCE For questions when loading the DCS CD, contact the HONDANET 2000 Support Center at 800-245-4343. For questions or problems on Smart Cable hardware and Smart Cable usage, contact American Honda Special Tools at 800-345-8327.* Disclaimer Page 959 Blower (Heater) Motor Gets Hot and Blows A Fuse Blower Motor: All Technical Service Bulletins Blower (Heater) Motor Gets Hot and Blows A Fuse SOURCE: Honda Service News November 2003 TITLE: Heater Blower Motor Gets Hot or Blows a Fuse APPLIES TO: 1990-04 Accords, 1992-04 Civics, 1997-04 CR-Vs, 2003 Elements, 2000-04 Insights, 1995-04 Odysseys, 1996-02 Passports, 2003-04 Pilots, 1997-01 Preludes, and 2000-04 S2000s SERVICE TIP: A blocked cooling hose for the heater blower motor can cause the motor to overheat, draw more current, blow a fuse, or even melt its plastic impeller. Before you order a replacement blower motor, make sure the cooling hose isn't blocked. On some models, you'll find the cooling hose molded into the blower motor housing; on other models, it's a separate piece. Check the S/M for the vehicle you're working on to determine the actual location of the cooling hose. Page 4697 2. Connect one lead of a self-powered test light or DVOM to one end of the part of the circuit you want to test. 3. Connect the other lead to the other end. 4. If the self-powered test light glows, there is continuity. If you're using a DVOM, a low reading or no reading (zero), means good continuity. Testing For Voltage When testing for voltage at a connector without wire seals, you do not have to separate the two halves of the connector. Instead, probe the connector from the back. Always check both sides of the connector because dirty, corroded, and bent terminals can cause problems (no electrical contact = an open). 1. Connect one lead of the lest light to a known good ground, or, if you're using a digital volt ohmmeter (DVOM), place it in the appropriate DC volts range, and connect its negative lead to ground. 2. Connect the other lead of the test light or DVOM to the point you want to check. 3. If the test light glows, there is voltage present. If you're using a DVOM, note the voltage reading. It should be within one volt of measured battery voltage. A loss of more than one volt indicates a problem. NOTE: Always use a DVOM on high impedance circuits. A test light may not glow (even with battery voltage present). Testing For Voltage Drop Wires, connectors, and switches are designed to conduct current with a minimum loss of voltage. A voltage drop of more than one volt indicates a problem. 1. Place the digital volt/ohmmeter (DVOM) in the appropriate DC volts range. Connect the positive lead to the end of the wire (or to the connector or switch) closest to the battery. 2. Connect the negative lead to the other end of the wire (or the other side of the connector or switch). 3. Turn on the components in the circuit. 4. The DVOM will show the difference in voltage between the two points. A difference, or drop, of more than one volt indicates a problem. Check the circuit for loose, dirty, or bent terminals. Page 7179 Sun Shade: Service and Repair Removal 1. Tilt the sunroof. 2. Disconnect the battery ground cable. 3. Remove the sunroof glass. 4. Pull the sight shield upward using screwdriver. 5. Remove 2 sunshade stopper fixing screws and remove sunshade stopper (1). Page 6106 Distinct Of Circuit By Wire Base Color All wires have color-coded insulation. Wires belonging to a system's main harness will have a single color. Wires belonging to a system's sub-circuits will have a colored stripe. Striped wires use the codes found in the chart to show wire size and colors. Abbreviations are used to indicate wire color within a circuit diagram. How to Identify Connector Terminals How to Identify Connector Terminals Cavity Numbering System The cavities (and wire terminals) in each connector are numbered starting from the upper left, looking at the male terminals from the terminal side (or looking at the female terminals from the wire side. Both views are in the same direction so the numbers are the same.) All actual cavities are numbered, even if they have no wire terminals in them. NOTE: Data Link Connector (DLC) terminals are numbered according to SAE standard J1962, not the Honda standard. The numbers of the four end terminals are molded into the corners of the connector face. The connector cavity number is listed next to each terminal on the circuit schematic. The cavity / terminal shown is # 6. Using/Identifying Connector Terminal Views How to Use Connector Terminal Views To see the configuration of a connector's cavities, look up its view number in the Connector Views. Each view includes the color of the connector, where Page 257 If there is no photo number below or beside a component name or a connector, ground, or terminal number, look up that name or number in the appropriate Connector Identification Chart. The chart lists how many cavities a connector has, where it's located, and what it connects to. The related illustration shows the connector's location on the harness, and the harness routing. NOTE: Photos listed by number are located at Locations / Components / Photograohs. See: Locations/Component Locations/Photographs Circuit Schematics Windshield Wiper Blade: Service and Repair Windshield Windshield Wiper Arm/Blade Windshield Wiper Arm/Blade Removal 1. Pry the cap(2) off with the tip of a screwdriver. 2. Remove the nut. 3. Remove the wiper arm/blade(1). Installation To install, follow the removal steps in the reverse order, noting the following points: 1. Before installing the wiper arm/blade to the shaft, confirm that the motor stops at the autostop position. 2. Set the wiper arm/blade so that the tips of both blades are positioned about 40 mm (1.57 in) from the upper edge of the cowl cover as shown in the figure. 3. Tighten the nuts to the specified torque. Torque: 23 Nm (17 lb.ft) Windshield Wiper Blade Rubber Removal Page 1251 Refrigerant Oil: Description and Operation Compressor Oil Oil Specification The HFC-134a system requires a synthetic (PAG) compressor oil whereas the R-12 system requires a mineral compressor oil. The two oils must never be mixed. Compressor (PAG) oil varies according to compressor model. Be sure to use oil specified for the model of compressor. Always use HFC-134a Vane Rotary Type Compressor Oil (AIPDN Part No.2-90188-301-0) Handling of Oil The oil should be free from moisture, dust, metal powder, etc. Do not mix with other oil. The water content in the oil increases when exposed to the air. After use, seal oil from air immediately. (HFC-134a Vane Rotary Compressor Oil absorbs moisture very easily.) The compressor oil must be stored in steel containers, not in plastic containers. Compressor Oil Check The oil used to lubricate the compressor is circulating with the refrigerant. Whenever replacing any component of the system or a large amount of gas leakage occurs, add oil to maintain the original amount of oil. Oil Capacity Capacity total in system: 150 cc (5.0 fl.oz) Compressor (Service parts) charging amount: 150 cc (5.0 fl.oz) Specifications Compression Check: Specifications Compression Pressure 145 psi. kg/cm2 at 300 rpm Page 3479 Throttle Position Sensor: Description and Operation Throttle Position (TP) Sensor The throttle position (TP) sensor is a potentiometer connected to the throttle shaft on the throttle body. The PCM monitors the voltage on the signal line and calculates throttle position. As the throttle valve angle is changed (accelerator pedal moved), the TP sensor signal also changes. At a closed throttle position, the output of the TP1 sensor is low. As the throttle valve opens, the output increases so that at wide open throttle (WOT), the output voltage should be above 92 % (Tech 2 Display). The PCM calculates fuel delivery based on throttle valve angle (driver demand). A broken or loose TP sensor may cause intermittent bursts of fuel from an injector and unstable idle because the PCM thinks the throttle is moving. Specifications Compressor Clutch: Specifications Pulley-to-Pressure Plate Clearance 0.015 +/- 0.005 in Diagrams Power Window Switch: Diagrams Fuel Control Heated Oxygen Sensors Oxygen Sensor: Description and Operation Fuel Control Heated Oxygen Sensors Fuel Control Heated Oxygen Sensors The fuel control heated oxygen sensors (Bank 1 HO2S 1 and Bank 2 HO2S 1) are mounted in the exhaust stream where they can monitor the oxygen content of the exhaust gas. The oxygen present in the exhaust gas reacts with the sensor to produce a voltage output. This voltage should constantly fluctuate from approximately 100 mV to 900 mV. The heated oxygen sensor voltage can be monitored with a Tech 2. By monitoring the voltage output of the oxygen sensor, the PCM calculates the pulse width command for the injectors to produce the proper combustion chamber mixture. - Low HO2S voltage is a lean mixture which will result in a rich command to compensate. - High HO2S voltage is a rich mixture which will result in a lean command to compensate. An open Bank 1 HO2S 1 signal circuit will set a DTC P0134 and the Tech 2 will display a constant voltage between 400 - 500 mV. A constant voltage below 300 mV in the sensor circuit (circuit grounded) will set DTC P0131. A constant voltage above 800 mV in the circuit will set DTC P0132. Faults in the Bank 2 HO2S 1 signal circuit will cause DTC 0154 (open circuit), DTC P0151 (grounded circuit), or DTC P0152 (signal voltage high) to set. A Fault in the Bank 1 HO2S 1 heater circuit will cause DTC P0135 to set. A fault in the Bank 2 HO2S 1 heater circuit will cause DTC P0155 to set. The PCM can also detect HO2S response problems. If the response time of an HO2S is determined to be too slow, the PCM will store a DTC that indicates degraded HO2S performance. Page 618 1. Install the MAF sensor on the air cleaner with the clamp. 2. Install the intake air duct and the clamp on the MAF sensor. 3. Tighten the clamps to secure the MAF sensor to the intake air duct and the air cleaner. 4. Connect the MAF electrical connector. 5. Connect the negative battery cable. Page 2409 24. Verify APP Sensor 1 is between 11 and 15 percent, and APP Sensor 2 and APP Sensor 3 are between 89 and 85 percent with the pedal up (closed throttle). If not, loosen the mounting screws on the APPS sensor, and go to step 14. 25. Clear all DTCs with the PGM Tester. 26. Turn off the ignition switch, and disconnect the PGM Tester. Page 5952 Air Register: Service and Repair Rear Heater Duct, Defroster Nozzle and Ventilation Duct Removal 1. Disconnect the battery ground cable. 2. Remove instrument panel assembly. 3. Remove center ventilation duct and side defroster duct. - Remove 5 screws. 4. Remove instrument panel brackets. 5. Remove cross beam assembly. 6. Remove ventilation lower duct. 7. Remove rear heater duct. - Remove foot rest carpet and 3 clips. 8. Remove defroster nozzle. Installation To install, follow the removal steps in the reverse order, noting the following point: 1. Connect each duct and nozzle securely leaving no clearance between them and making no improper matching. Page 5489 Page 5431 TOOL INFORMATION Centering Tape (enough to diagnose 240 vehicles): T/N O7AAJ-001A300 Steering Drift Set Level: T/N 07AAJ-00100 Steering Drift Set: T/N O7MJ-001A140 Replacement Weight for Steering Drift Set: T/N 07AAJ-001A400 WARRANTY CLAIM INFORMATION In warranty: The normal warranty applies. Failed Part: P/N 53560-SDA-AO1 H/C 7139652 Defect Code: 07406 Symptom Code: 03602 Skill Level: Repair Technician Diagnostic Trouble Code: To create the 15-digit DTC, see the applicable repair procedure. Out of warranty: Any repair performed after warranty expiration may be eligible for goodwill consideration by the District Parts and Service Manager or your Zone Office. You must request consideration, and get a decision, before starting work. TOOL DESCRIPTIONS The holding force gauge measures the amount of pull on the vehicle. It is a bracket that counts as one weight, plus five removable weights. Page 2514 Wires Wire insulation can be one color, or one color with another color stripe. (The second color is the stripe.) This circuit continues on another image. (The arrow shows direction of current flow.) To follow the RED/BLK wire in this example, you would turn to "Fuel and Emissions" and look for the "A" arrow. Page 1489 4. Piston and connecting rod assembly (8) - Apply engine oil to the cylinder bores, the connecting rod bearings and the crankshaft pins. Check to see that the piston ring end gaps are correctly positioned. - Insert the piston/connecting rod assemblies into each cylinder with the piston ring compressor. The front marks must be facing the front of the engine. - Match the numbered caps with the numbers on the connecting rods. Align the punched marks on the connecting rods and caps. - Apply engine oil to the threads and seating faces of the nuts. - Tighten the nuts. Torque: 54 Nm (40 ft. lbs.) After tightening the cap nuts, check to see that the crankshaft rotates smoothly. Note: Do not apply engine oil to the bearing back faces. Page 2718 4. Remove the sensor from the exhaust pipe. Because of the expansion and contraction of the metal in the exhaust system over time, this may be difficult if the engine temperature is below 48 ° C (120 °F). INSTALLATION PROCEDURE IMPORTANT: - A special anti-seize compound on the HO2S threads. This compound consists of glass beads suspended in a liquid graphite solution. The graphite burns away with engine heat, but the glass beads will remain, making the sensor easier to remove. - New or service sensors will already have the compound applied to the threads. If a sensor is removed and is to be reinstalled for any reason, the threads must have anti-seize compound applied. 1. Apply anti-seize compound or the equivalent to the threads of the oxygen sensor, if necessary. 2. Install the oxygen sensor on the exhaust pipe in its original position. Tighten Tighten the oxygen sensor to 55 N.m (40 lb ft.). 3. Connect the pigtail to the wiring harness. 4. Connect the negative battery cable. Page 5240 Page 610 129 - Below Left Side Of I/P Page 7387 This means the branch of the wire connects to another circuit. The arrow points to the name of the circuit branch where the wire continues. Page 987 The steering wheel offset gauge is a sticker that attaches to the steering wheel and the steering column cover. Place the sticker on the steering wheel when the steering wheel is straight. When you test-drive the vehicle, you can read how many millimeters the steering wheel is off-center. NOTE: If the vehicle is pulling, repairing the pull may correct the steering wheel offset. Diagrams Body Mounting Locations Vapor Pressure Sensor / Fuel Gauge And Fuel Pump Connector Page 5795 26. Using a 3/8 in. drill motor, a 1/4 in. drill guide, and a 1/4 in. bit, drill 16 pilot holes into the frame rail, through each hole in the type B reinforcement bracket. 27. Using a 1/4 in. bit, drill a pilot hole into the passenger's side frame rail, through the type B reinforcement bracket brake clip mounting hole. 28. Remove both type B reinforcement brackets. Save the body mount studs and nuts for the final installation. 29. Using a 1/2 in. drill motor and a 33/64 in. bit, final drill the pilot hole you made in step 27, then mark the hole with tape or chalk. This hole creates the clearance needed for the passenger's side brake line clip. NOTE: Do not install a pop nut into this hole. 30. Using the 1/2 in. drill motor and the 33/64 in. bit, drill 32 final holes (16 per bracket) where you made the pilot holes. 31. Test fit a pop nut into each of the 32 holes to be sure drilling is complete. NOTE: If a pop nut doesn't fit, don't try to try to enlarge the hole by pivoting the drill bit. Doing this creates an uneven seating surface for the pop nut. If the pop nut doesn't fit, your drill bit is worn out; sharpen or replace the drill bit, then red redrill the affected final hole(s). 32. Insert an air gun into the frame rail hole, and blow up and down the inside of the frame rails to move any rust or metal debris away from the area. 33. Attach the pop nut installer to shop air, and adjust the tool's air pressure regulator to between 72 and 87 psi. NOTE: ^ The tool's air pressure is critical: if it's too low, the pop nuts cannot be correctly installed; if it's too high, the tool will be damaged. Page 584 14. While watching the APP Sensor values in the Engine Data List, adjust the APPS by turning it until the values are within the ranges shown at closed throttle and wide open throttle (accelerator pedal pushed all the way down), then tighten the mounting screws and recheck the values. ^ If all three sensors are within range, go to step 23. ^ If APP Sensor 1 APP Sensor 2, and/or APP Sensor 3 cannot be brought into range, go to step 15. 15. Troubleshoot for an open circuit or a PCM malfunction. ^ If APP Sensor 1 has a value of 0% or APP Sensor 2 and/or APP Sensor 3 have a value of 99%, an open circuit exists or the PCM is malfunctioning. Repair the circuit or replace the PCM, and repeat step 14. ^ If you don't find a problem, go to step 16. 16. Disconnect the 10 P connector from the APPS. 17. View the APP Sensor values in the Engine Data List. ^ If APP Sensor 1 has a value of 0% or APP Sensor 2 and/or APP Sensor 3 have a value of 99%, go to step 18. ^ If APP Sensor 1 has a value other than 0%, or APP Sensor 2 and/or APP Sensor 3 have a value other than 99%, a short circuit exists or the PCM is malfunctioning. Repair the circuit or replace the PCM, and repeat step 14. 18. Modify the original APPS by cutting the connector housing off of the sensor. 19. Connect the 10 P connector to the modified APPS connector housing. Page 4915 - Wrench: J-36827. 7. Hub and Disc Assembly. 8. ABS Sensor Ring (if so equipped). 9. Outer Bearing Outer Race. 10. Oil Seal. 11. Inner Bearing Outer Race. 12. Bolt. If necessary, replace the wheel stud in the following manner: a. Apply a scribe mark to disc to hub. b. Clamp the hub and disc assembly in a vise, using protective pads. Remove the 6 disc-to-hub retaining bolts. 13. wheel stud. Place hub on a suitable work surface and remove the wheel studs, as required, using a hammer. INSPECTION AND REPAIR Make necessary correction or parts replacement if wear, damage, corrosion or any other abnormal condition are found through inspection. Check the following parts: Hub - Hub bearing oil seal Knuckle spindle - Disc - Caliper Shift on the fly system parts (Cap, Hub flange, Shim, Snap ring) - ABS sensor ring (If so equipped) Installation TOOLS REQUIRED - J-36829 Installer - J-8092 Grip - J-36828 Installer - J-36830 Installer - Or Equivalent Accelerator Pedal Assembly/Sensor - Adjustment Update Accelerator Pedal Position Sensor: All Technical Service Bulletins Accelerator Pedal Assembly/Sensor - Adjustment Update 00-045 August 14, 2001 Applies To: 2000-02 Passport - ALL Service Manual Update: Accelerator Pedal Position Sensor (APPS) (Supersedes 00-045, dated May 23, 2000) Updated information is shown by asterisks and black bars. BACKGROUND When the accelerator pedal position sensor (APPS) or the accelerator pedal assembly is replaced for any reason, you must adjust the APPS. *This procedure is missing in the 2000 service manual and is wrong in the 2001 and 2002 service manuals. Make a note on page 6E2-539 of the 2000 Passport Fuel and Emissions manual, on page 6E2-553 of the 2001 Passport Fuel and Emissions manual, and on page 6E2-545 of the 2002 Passport Fuel and Emissions manual to refer to this bulletin.* ADJUSTMENT PROCEDURE 1. Replace the APPS or the accelerator pedal assembly, and leave the mounting screws for the APPS loose. 2. Connect the PGM Tester to the data link connector (DLC), and turn the ignition switch to ON (II). *3. While watching the APP Sensor values in the Engine Data List, adjust the APPS by turning it until the values are within the ranges shown at closed pushed all the way down), then tighten the throttle and wide open throttle (accelerator pedal mounting screws and recheck the values. ^ If all three sensors are within range, go to step 12. ^ If APP Sensor 1, APP Sensor 2, and/or APP Sensor 3 cannot be brought into range, go to step 4. 4. Troubleshoot for an open circuit or a PCM malfunction. ^ If APP Sensor 1 has a value of 0% or APP Sensor 2 and/or APP Sensor 3 have a value of 99%, an open circuit exists or the PCM is malfunctioning. Repair the circuit or replace the PCM, and repeat step 3. ^ If you don't find a problem, go to step 5. 5. Disconnect the 10P connector from the APPS. 6. View the APP Sensor values in the Engine Data List. ^ If APP Sensor 1 has a value of 0% or APP Sensor 2 and/or APP Sensor 3 have a value of 99%, go to step 7. ^ If APP Sensor 1 has a value other than 0%, or APP Sensor 2 and/or APP Sensor 3 have a value other than 99%, a short circuit exists or the PCM is malfunctioning. Repair the circuit or replace the PCM, and repeat step 3. Page 6772 Splices Splices are shown as a dot. Their location and the number of wires may vary depending on the harness manufacturer. Switches Switches These switches move together; the broken straight line between them means they are mechanically connected. Other types of switches are controlled by a coil or a solid state circuit. Unless otherwise noted, all switches are shown in their normal (rest) position, with power off. Terminal "T" Page 4588 it is located, and what it connects to. Use the Connector Views to help locate the proper cavity when you need to probe a connector. It can be especially helpful if the connector has more than one wire of the same color. A dash symbol (-) indicates that the cavity is empty. Connector views can also be used to help diagnose multiple symptoms in separate circuits which could be caused by a single problem in a connector shared by those circuits. Here's an example: 1. Pick one of the multiple symptoms and look up the schematic for that circuit. 2. Make a list of all the in-line and fuse box connectors in that schematic , 3. Then, in the Connector Views, look up each connector on your list to see if circuits related to the other symptoms run through one of them. If they do, inspect that connector for the problem. Example: The blower, rear window defogger, and the windshield wiper don't work. List all in-line and fuse box connectors in the blower controls circuit and then check the Connector View (see the sample). You find that C324 is common to the blower controls, rear window defogger, and wiper/washer, so you inspect C324 and find the problem, bent terminals. Finding Component/Connector Locations Finding Component/Connector Locations To see where a component or connector is located on the car, look up its photo number in the "Component Location". The photo will also tell you the color of the connector, and how many cavities it has. Engine Controls - High/Erratic Engine Idle Power Steering Pressure Switch: All Technical Service Bulletins Engine Controls - High/Erratic Engine Idle 01-080 August 14, 2001 Applies To: 2000-02 Passport - ALL 2000-02 Passport: High or Erratic Idle SYMPTOM The engine occasionally idles at too high a speed, or the idle speed fluctuates. PROBABLE CAUSES The symptom could be the result of any of these conditions: ^ Loose or corroded engine or body ground ^ High resistance in the APPS ground circuit ^ PSP (power steering pressure) switch is internally shorted to ground ^ Fuel pressure regulator is leaking fuel into the intake manifold CORRECTIVE ACTION Diagnose the cause of the idle condition, and select the proper REPAIR PROCEDURE. PARTS INFORMATION REQUIRED MATERIALS REQUIRED SOFTWARE Each REPAIR PROCEDURE requires you to use the Smart Cable to reprogram the PCM with the latest software. To select the latest software from the CDROM, enter the year, model, engine, transmission, and emissions type (49-state or California). This gives you a list of broadcast codes. Select the broadcast code at the top of the list. WARRANTY CLAIM INFORMATION Refer to the Warranty Claim Information for each Repair Procedure. DIAGNOSIS 1. Find out from the customer when the high or erratic idle condition occurs and what the RPM range is: ^ Within 20 minutes of a cold start ^ After braking to a stop ^ All the time ^ Intermittently, with no set pattern Page 3552 If there is no photo number below or beside a component name or a connector, ground, or terminal number, look up that name or number in the appropriate Connector Identification Chart. The chart lists how many cavities a connector has, where it's located, and what it connects to. The related illustration shows the connector's location on the harness, and the harness routing. NOTE: Photos listed by number are located at Locations / Components / Photograohs. See: Locations/Component Locations/Photographs Circuit Schematics Inspection Brake Rotor/Disc: Testing and Inspection Inspection In the manufacturing of the brake rotor, all the tolerances regarding surface finish, parallelism and lateral runout are held very closely. Maintaining these tolerances provides the surface necessary to assure smooth brake operation. Page 131 2. Connect the short finder across the battery terminals and the load (component) side of the fuse terminal. 3. Close all switches in the circuit you're testing. 4. Turn on the short finder. This creates a pulsing magnetic field around the wiring between the fuse box and the short. 5. Beginning at the fuse box, slowly move the short finder along the circuit wiring. The meter will read current pulses through sheet metal and body trim. As long as the meter is between the fuse and the short, the needle will move with each current pulse. Once you move the meter past the point of the short, the needle will stop moving. Check the wiring and connectors in this area to locate the cause of the short. Testing For Continuity When testing for continuity at a connector without wire seals, you do not have to separate the two halves of the connector. Instead, probe the connector from the back. Always check both sides of the connector because dirty, corroded, and bent terminals can cause problems (no electrical contact = an open). 1. Disconnect the negative cable from the car battery. If you're using a DVOM, place it in the lowest "OHMS" range. Page 7751 Each schematic represents one circuit. A circuit's wires and components are arranged to show current flow, from power at the top of the page, to ground, at the bottom. Shared Circuits Other circuits may share power or ground terminals or wiring with the circuit shown. A wire that connects one circuit to another, for example, is cut short and has an arrowhead at the end of it pointing in the direction of current flow. Next to the arrowhead is the name of the circuit or component which shares that wiring. To quickly check shared wiring, check the operation of a component it serves. If that component works, you know the shared wiring is OK. Connectors All in-line and junction connectors are numbered (C725, C416, etc.). Component connectors are not numbered but are identified either by the name of Page 6708 Alarm/Immobilizer Control Unit: Diagrams Page 4404 Fluid - M/T: Fluid Type Specifications M/T Fluid Grade ................................................................................................................................................... ...................................... Engine oil labeled SG or SF SAE Viscosity: Above 90° F (32° C) ........................................................................................................................................................ SAE 15W-40, 20W-40 or 20W-50 Other areas ................................................................................... ............................................................................................................................... 5W-30 Page 3011 If there is no photo number below or beside a component name or a connector, ground, or terminal number, look up that name or number in the appropriate Connector Identification Chart. The chart lists how many cavities a connector has, where it's located, and what it connects to. The related illustration shows the connector's location on the harness, and the harness routing. NOTE: Photos listed by number are located at Locations / Components / Photograohs. See: Locations/Component Locations/Photographs Circuit Schematics Page 6983 Air Bag(s) Arming and Disarming: Service and Repair Connector Disconnection / Connection REMOVAL To remove the connector, hold the cover insulator(l) and pull it. The cover insulator slides and lock will be released. Do not hold the socket insulator(2). INSTALLATION Page 4844 Brake Pedal Assy: Service and Repair Removal 1. Disconnect the battery "-" terminal cable, and wait at least 5 minutes. 2. Disconnect the yellow 3 way Supplemental Restraint System (SRS) connector located under the steering column. 3. Remove the engine hood opening lever. 4. Remove lower cover (8). 5. Remove driver knee bolster (10). 6. Disconnect the stop light switch connector (3). Disconnect the anti-theft control module connector. 7. Remove snap pin (4) and push rod pin (7). 8. Remove the steering column shaft fixing bolt and nut (9) on the steering wheel side, and lower the steering column shaft. 9. Remove the brake pedal bracket assembly (1). 10. Remove return spring (5). 11. Remove fulcrum pin and nut (2). 12. Remove pedal assembly (6). Installation 1. Apply grease to the entire circumference of the fulcrum pin. 2. Install pedal assembly (6) and fulcrum pin and nut (2). Tighten the nut (2) to the specified torque. Torque: 35 Nm (26 ft. lbs.) 3. Install the brake pedal bracket assembly (1). Tighten the bolts and nuts specified torque. Torque: 15 Nm (11 ft. lbs.) 4. Install return spring (5). 5. Adjust pedal free travel. 6. Tighten the steering column fixing bolt (9) (dash panel) to the specified torque. Torque: 20 Nm (14 ft. lbs.) 7. Tighten the steering column fixing nut (9) (Cross Beam) to the specified torque. Torque: 17 Nm (12 ft. lbs.) 8. Apply grease to the entire circumference of the Push rod pin (7). 9. Install push rod pin (7). 10. Install snap pin (4). 11. Connect the anti-theft control module connector. 12. Connect the stop light switch connector (3). 13. Install driver knee bolster (10) and lower cover (8). 14. Install the engine hood opening lever. Front Differential Seals and Gaskets: Service and Repair Front Differential PINION SHAFT OIL SEAL AND ASSOCIATED PARTS REMOVAL 1. Raise the vehicle and support it at the frame. The hoist must remain under the front axle housing. 2. Drain the front axle oil by loosening the drain plug (1). 3. Remove the front drive/propeller shaft. Page 4836 Check the fluid level and replenish as necessary. If replenished, leave the system for at least one minute. 8. Depress the brake pedal slowly once and hold it depressed. 9. Completely seal the delivery port of the master cylinder with your finger, where the pipe was disconnected then release the brake pedal slowly. 10. Release your finger from the delivery port when the brake pedal returns completely. 11. Repeat steps 8 through 10 until the brake fluid comes out of the delivery port during step 8. NOTE: Do not allow the fluid level in the reservoir to go below the half-way mark. 12. Reconnect the brake pipe (1) to the master cylinder and tighten the pipe. 13. Depress the brake pedal slowly once and hold it depressed. 14. Loosen the rear wheel brake pipe (1) at the master cylinder. 15. Retighten the brake pipe, then release the brake pedal slowly. 16. Repeat steps 13 through 15 until no air comes out of the port when the brake pipe is loosened NOTE: Be very careful not to allow the brake fluid to come in contact with painted surfaces. 17. Bleed the air from the front wheel brake pipe connection (2) by repeating steps 7 through 16. BLEEDING THE CALIPER 18. Bleed the air from each wheel in the order listed: - Right rear caliper or wheel cylinder - Left rear caliper or wheel cylinder - Right front caliper - Left front caliper Conduct air bleeding from the wheels in the above order. If no brake fluid comes out, it suggests that air is mixed in the master cylinder. In this case, bleed air from the master cylinder. In this case, bleed air from the master cylinder in accordance with steps 7 through 17, and then bleed air from the caliper or wheel cylinder. 19. Place the proper size box end wrench over the bleeder screw. 20. Cover the bleeder screw with a transparent tube, and submerge the free end of the transparent tube in a transparent container containing brake fluid . 21. Pump the brake pedal slowly three (3) times (once/second), then hold it depressed. 22. Loosen the bleeder screw until fluid flows through the tube. 23. Retighten the bleeder screw. 24. Release the brake pedal slowly. 25. Repeat steps 21 through 24 until the air is completely removed. It may be necessary to repeat the bleeding procedure 10 or more times for front wheels and 15 or more times for rear wheels. 26. Go to the next wheel in the sequence after each wheel is bled. Be sure to monitor reservoir fluid level. 27. Depress the brake pedal to check if you feel "sponginess" after the air has been removed from all wheel cylinders and calipers. If the pedal feels "spongy", the entire bleeding procedure must be repeated. 28. After the bleeding operation is completed on the each individual wheel, check the level of the brake fluid in the reservoir and replenish up to the "MAX" level as necessary. 29. Attach the reservoir cap. If the diaphragm inside the cap is deformed, reform it and install. 30. Stop the engine. Page 4872 Brake Warning Indicator: Description and Operation The brake system warning light goes on to alert the driver that the parking brake is applied or that the brake fluid is low. It also lights as a bulb test when the engine is cranked. With the ignition switch in START, the brake system warning light is turned on for bulb check. During bulb check, the light is grounded through the alternator. See Indicators for further details. Page 4131 Clutch Master Cylinder: Service and Repair Clutch Control PARTS LOCATION VIEW Page 7916 Test Equipment CAUTION: Most circuits include solid-state devices. Test the voltages in these circuits only with a 10-megaohm or higher impedance digital multimeter. Never use a test light or analog meter on circuits that contain solid-state devices. Damage to the devices may result. Test Light and DVOM On circuits without solid-state devices, use a test light to check for voltage. A test light is made up of a 12 volt bulb with a pair of leads attached. After grounding one lead, touch the other lead to various points along the circuit where voltage should be present. The bulb will go on if there is voltage at the point being tested. If you need to know how much voltage is present, use a digital volt/ohmmeter (DVOM). Self-Powered Test Light and DVOM Use a self-powered test light to check for continuity. This tool is made up of a light bulb, battery, and two leads. To test it, touch the leads together: the light should go on. Use a self-powered test light only on an unpowered circuit. First, disconnect the battery, or remove the fuse that feeds the circuit you are working on. Select two points in the circuit between which you want to check continuity. Connect one lead of the self-powered test light to each point. If there is continuity, the test light's circuit will be completed, and the light will go on. If, in addition, you need to know exactly how much resistance there is between two points, use a digital volt/ohmmeter (DVOM). In the "OHMS" range, the DVOM will measure resistance between two points along a circuit. Low resistance means good continuity. Diodes and solid-state devices in a circuit can make a DVOM give a false reading. To check a reading, reverse the leads, and take a second reading. If the readings differ, the component is affecting the measurement. Jumper Wire Use a jumper wire to bypass an open circuit. A jumper wire is made up of an in-line fuse holder connected to a set of test leads. It should have a five ampere fuse. Never connect a jumper wire across a short circuit. The direct battery short will blow the fuse. Short Finder (Short Circuit Locator) Short finders are available to locate shorts to ground. The short finder creates a pulsing magnetic field in the shorted circuit which you can follow to the location of the short. To order any test equipment shown above, contact your local tool supplier. For a list of suppliers and tool numbers, refer to Honda Required Special Tools and Equipment Service Bulletin. Service and Repair Maintenance Required Lamp/Indicator: Service and Repair The OEM does not equip this model with a Maintenace Required Indicator. A/C - Refrigerant Leak Detection Refrigerant: Technical Service Bulletins A/C - Refrigerant Leak Detection 07-030 October 12, 2007 Applies To: ALL Vehicles With Conventional A/C Compressors A/C Leak Detection (Supersedes 07-030, dated June 15, 2007, to update the information marked by asterisks) The OPTIMAX Jr. (TM)A/C Leak Detection Kit for Honda vehicles, P/N TRP124893, is a new required tool. The kit is used to add small amounts of dye to A/C systems to help locate smaller leaks that an electronic leak detector might not find. When searching for leaks, always begin by using an electronic leak detector. Refer to Service Bulletin 97-027, Denso HLD-100 Halogen Leak Detector; for tips on using this tool, then follow up with the OPTIMAX Jr. This new detection kit complements but does not replace the electronic detector. The kit contains: ^ TRP8640CS, OPTIMAX Jr. (TM) cordless, fluorescent leak detection flashlight lamp (includes 3 standard AA batteries) ^ TRP38600601, (6) 0.06 oz. (1.7 g) Tracer-Stick(R) R134a/PAG A/C dye capsules with ID labels ^ TRP3887, R-134a Universal Connect Set(TM) ^ TRP120884, GLO-AWAY(TM) dye cleaner ^ TRP9940, fluorescence-enhancing glasses ^ TRP1143, (1) empty Tracer-Stick dye capsule ORDERING INFO *One OPTIMAX Jr. A/C Leak Detection Kit was shipped to each current dealer as a required special tool. Additional kits and replacement capsules may be ordered through the Honda Tool and Equipment Program. On the iN, click on Service, Service Bay, Tool and Equipment Program, Online Catalog tab, and Air Conditioning Equipment, or call.* NOTICE ^ Do not use leak-trace dye in any Honda hybrid vehicle equipped with a dual-scroll compressor This can increase the chance of electric shock. The compressor is easily identified by the orange high-voltage cable that is connected to the compressor body. ^ Only Tracer-Stick single-dose fluorescent dye capsules from Tracer Products (Tracerline(R)) are approved for use in Honda vehicles. Other dyes contain solvents that may contaminate the system's refrigerant oil, leading to component failure. ^ Adding excessive amounts of dye can lead to compressor damage and failure. USING THE OPTIMAX JR. Page 6545 BAG ASSEMBLY LEADS. DEPLOYMENT WIRES SHALL REMAIN SHORTED AND DISCONNECTED FROM ANY POWER SOURCE UNTIL THE AIRBAG IS TO BE DEPLOYED OR ACCIDENTAL AIRBAG DEPLOYMENT WILL IMMEDIATELY OCCUR. THIS MAY CAUSE PERSONAL INJURY. ALWAYS WEAR SAFETY GLASSES DURING AIRBAG DEPLOYMENT AND DISPOSAL. 19. Twist together one connector wire lead to one deployment wire. The connection should be mechanically secure. 20. Bend twisted connection made in the previous step flat and wrap tightly with electrical tape to insulate and secure. 21. Twist together, bend and tape the remaining connector wire lead to the remaining deployment wire. 22. Connect the deployment harness to the passenger air bag assembly, yellow 2 - pin connector located behind the glove box assembly. Route deployment harness out the passenger side of the vehicle. WARNING: DEPLOYMENT WIRES SHALL REMAIN SHORTED AND NOT BE CONNECTED TO A POWER SOURCE UNTIL THE AIR BAG IS TO BE DEPLOYED. THE AIR BAG ASSEMBLY WILL IMMEDIATELY DEPLOY THE AIR BAG WHEN A POWER SOURCE IS CONNECTED TO IT. CONNECTING THE DEPLOYMENT WIRES SHOULD ALWAYS BE THE FINAL STEP IN THE AIR BAG ASSEMBLY DEPLOYMENT PROCEDURE. FAILURE TO FOLLOW PROCEDURES IN THE ORDER LISTED COULD RESULT IN PERSONAL INJURY. 23. Verify that the inside of the vehicle and the area surrounding the vehicle are clear of all people and loose or flammable objects. 24. Stretch the driver and passenger deployment harness to their full length. 25. Completely cover windshield area and front door window openings with a drop cloth, blanket or similar item. This reduces the possibility of injury due to possible fragmentation of the vehicle's glass or interior. 26. Notify all people in the immediate area that you intend to deploy the air bags. The deployment will be accompanied by a substantial noise which may startle the uninformed. 27. Separate the two ends of the driver deployment harness wires. WARNING: DEPLOYMENT WIRES SHALL REMAIN SHORTED AND DISCONNECTED FROM ANY POWER SOURCE UNTIL THE AIRBAG IS TO BE DEPLOYED OR ACCIDENTAL AIRBAG DEPLOYMENT WILL IMMEDIATELY OCCUR. THIS MAY CAUSE PERSONAL INJURY. ALWAYS WEAR SAFETY GLASSES DURING AIRBAG DEPLOYMENT AND DISPOSAL. CONNECTING THE DEPLOYMENT WIRES TO THE POWER SOURCE SHOULD ALWAYS BE THE FINAL STEP IN THE AIRBAG ASSEMBLY DEPLOYMENT PROCEDURE. FAILURE TO FOLLOW PROCEDURES IN THE ORDER LISTED COULD RESULT IN PERSONAL INJURY. NOTE: When the air bag deploys, the rapid gas expansion will create a substantial noise. Notify all people in the immediate area that you intend to deploy the air bags. 28. Connect the driver deployment harness wires to a power source to immediately deploy the driver air bag assembly. Recommended application: 12 volts minimum, 2 amps minimum. A vehicle battery is suggested. 29. Separate the two ends of the passenger deployment harness wires. WARNING: DEPLOYMENT WIRES SHALL REMAIN SHORTED AND DISCONNECTED FROM ANY POWER SOURCE UNTIL THE AIRBAG IS TO BE DEPLOYED OR ACCIDENTAL AIRBAG DEPLOYMENT WILL IMMEDIATELY OCCUR. THIS MAY CAUSE PERSONAL INJURY. ALWAYS WEAR SAFETY GLASSES DURING AIRBAG DEPLOYMENT AND DISPOSAL. CONNECTING THE DEPLOYMENT WIRES TO THE POWER SOURCE SHOULD ALWAYS BE THE FINAL STEP IN THE AIRBAG ASSEMBLY DEPLOYMENT PROCEDURE. FAILURE TO FOLLOW PROCEDURES IN THE ORDER LISTED COULD RESULT IN PERSONAL INJURY. 30. Connect the passenger deployment harness wires to a power source to immediately deploy the passenger air bag assembly. Recommended application: 12 volts minimum, 2 amps minimum. A vehicle battery is suggested. (Driver air bag assembly) Put on a pair of shop gloves and safety gasses to protect your hands and eyes from possible irritation and heat when handling the deployed air bag assembly. After the air bag assembly has been deployed, the surface of the air bag may contain solid particulate. This solid particulate consists primarily of by products of the chemical Page 5557 Air Bag(s) Arming and Disarming: Service Precautions Airbag Handling and Storage Airbag Handling and Storage Do not disassemble an airbag. It has no serviceable parts. Once an airbag has been deployed, it cannot be repaired or reused. For temporary storage of the airbag during service, please observe the following precautions. - Store the removed airbag with the pad surface up. Never put anything on the removed airbag. - Keep free from any oil, grease, detergent, or water to prevent damage to the airbag assembly. - Store the removed airbag on a secure, flat surface away from any high heat source (exceeding 200 °F/93 °C). - Never perform electrical inspections to the airbags, such as measuring resistance. - Do not position yourself in front of the airbag assembly during removal, inspection, or replacement. Locations Locations Transmission Position Switch/Sensor: Locations Left Side Of Automatic Transmission Page 5980 Blower Link Unit and/or Mode Door Service and Repair Keyless Entry Transmitter Battery: Service and Repair 1. Remove a screw to remove the cover. 2. Remove the batteries. 3. Set the new batteries into the transmitter. 4. Install the cover to the transmitter. 5. Check that the keyless entry system works normally. Page 4044 ^ Gently pry out the cover to release the four clips, unplug the electrical connectors, and remove the cover. 3. Remove the seven mounting screws in the lower steering column cover. Remove the upper cover, but leave the lower cover in place. Locations 46 - Top Front Of 3.2L Engine (Intake Duct Removed) Air Bag Assembly Steering Wheel: Service and Repair Air Bag Assembly WARNING: SAFETY PRECAUTIONS MUST BE FOLLOWED WHEN HANDLING A DEPLOYED AIR BAG ASSEMBLY. AFTER DEPLOYMENT, THE AIR BAG ASSEMBLY SURFACE MAY CONTAIN A SMALL AMOUNT OF SODIUM HYDROXIDE, A BY-PRODUCT OF THE DEPLOYMENT REACTION, THAT IS IRRITATING TO THE SKIN AND EYES. MOST OF THE POWDER ON THE AIR BAG ASSEMBLY IS HARMLESS. AS A PRECAUTION, WEAR GLOVES AND SAFETY GLASSES WHEN HANDLING A DEPLOYED AIR BAG ASSEMBLY, AND WASH YOUR HANDS WITH MILD SOAP AND WATER AFTERWARDS. WHEN CARRYING A LIVE AIR BAG ASSEMBLY, MAKE SURE THE BAG AND TRIM COVER ARE POINTED AWAY FROM YOU. NEVER CARRY AIR BAG ASSEMBLY BY THE WIRES OR CONNECTOR ON THE UNDERSIDE OF MODULE. IN THE CASE OF AN ACCIDENTAL DEPLOYMENT, THE BAG WILL THEN DEPLOY WITH MINIMAL CHANCE OF INJURY. WHEN PLACING A LIVE AIR BAG ASSEMBLY ON A BENCH OR OTHER SURFACE, ALWAYS FACE BAG AND TRIM COVER UP, AWAY FROM THE SURFACE. NEVER REST A STEERING COLUMN ASSEMBLY ON THE STEERING WHEEL WITH THE AIR BAG ASSEMBLY FACE DOWN AND COLUMN VERTICAL. THIS IS NECESSARY SO THAT A FREE SPACE IS PROVIDED TO ALLOW THE AIR BAG ASSEMBLY TO EXPAND IN THE UNLIKELY EVENT OF ACCIDENTAL DEPLOYMENT. OTHERWISE, PERSONAL INJURY COULD RESULT. NOTE: In the event deployment has occurred, inspect coil assembly wire for any signs of scorching, melting or any other damage due to excessive heat. If the coil has been damaged, replace it. Removal 1. Disable the SRS. 2. Remove the air bag assembly (5) from steering wheel (6) by removing two bolts (7). Lift air bag assembly out of steering wheel. 3. Disconnect connector (2) and remove air bag assembly. 4. Disconnect horn lead (1) 5. Remove steering wheel attachment nut (4). 6. Move the tires to the straight ahead position before removing the steering wheel. Install steering wheel puller onto steering wheel and remove steering wheel with J-29752. 7. Apply a setting mark (3) across the steering wheel and shaft so parts can be reassembled in their original position. 8. Feed wiring through the wheel and remove wheel. CAUTION: Never apply force to the steering wheel in direction of the shaft by using a hammer or other impact tools in an attempt to remove the steering wheel. The steering shaft is designed as an energy absorbing unit. Installation 1. Install the steering wheel and align the setting marks (3). 2. Tighten the steering wheel fixing nut (4) to the specified torque. Torque: 34 N.m (25 lb ft) 3. Connect horn lead (1). 4. Connect air bag to wiring harness connector (2). NOTE: Pass the lead wire through the tabs on the plastic cover (wire protector) of air bag to prevent lead wire from being pinched. Page 2156 Tighten Tighten the bolt to 20 N.m (12 lb ft.). 3. Connect the MAP electrical connector. 4. Connect the negative battery cable. Page 6906 Tailgate Lock (SWB) And Associated Parts Page 1521 3. Remove oil strainer fixing bolts, remove oil strainer assembly with O-ring. 4. Remove three fixing bolts, oil pipe with O-ring. 5. Remove eight fixing bolts, oil gallery. 6. Remove piston with connecting rod assembly, before removing the bearing cap, remove carbon on the top of cylinder bore and push piston with connecting rod out from the top of cylinder bore. Installation 1. Install piston with connecting rod assembly. - Apply engine oil to cylinder bore, connecting rod bearing and crank pin. When installing the piston, its front mark must face the engine front side. - The bearing cap number must be the same as connecting rod number. - Apply engine oil to the thread and seating surface of each nut. - Tighten nuts to the specified torque. Torque: 54 Nm (40 ft. lbs.) - After tightening the nuts, make sure that the crankshaft rotates smoothly. Note: Do not apply engine oil to the bearing back faces and connecting rod bearing fitting surfaces. Page 2076 24. Verify APP Sensor 1 is between 11 and 15 percent, and APP Sensor 2 and APP Sensor 3 are between 89 and 85 percent with the pedal up (closed throttle). If not, loosen the mounting screws on the APPS sensor, and go to step 14. 25. Clear all DTCs with the PGM Tester. 26. Turn off the ignition switch, and disconnect the PGM Tester. Page 102 2. Compare the retrieved code with the listed codes. ^ If the code is in the list, go to step 3. ^ If the code is not in the list, the PCM has already been updated. Troubleshoot other causes for the detonation. NOTE: Since the Smart Cable may need to be cleared from a previous PCM update or the Smart Cable firmware may need to be reprogrammed, always begin each PCM update at the iN workstation. 3. Update the PCM software with the Smart Cable. For instructions, refer to Service Bulletin 99-005. NOTE: Make sure you select the most recent broadcast code from the list on the iN screen that applies to the model year, transmission type, and emission level. This code is not necessarily at the top of the list since the most recent code is the last one in the alphabetical sequence, letter by letter. 4. Use the PGM Tester to clear any DTCs set during programming. 5. Retrieve the broadcast code. Make sure it does not match any of the codes in the list in step 2 (indicating the PCM has been updated) and that it applies to the model year, transmission type, and emission level for the vehicle. The broadcast code should match a code in the list below. Disclaimer Page 6239 HVAC / Heating Page 5636 5. Remove upper ball joint. INSPECTION AND REPAIR Make necessary parts replacement if wear, damage, corrosion or any other abnormal conditions are found through inspection. Inspect the lower end boot for damage or grease leak. Move the ball joint as shown in the figure to confirm its normal movement. - Inspect screw/taper area of ball for damage. - If any defects are found by the above inspections, replace the ball joint assembly with new one. - After moving the ball joint 4 or 5 times, attach nut then measure the preload. Starting torque: 0.5 3.2 Nm (0.4 - 2.4 ft. lbs.). If the above limits specified are exceeded, replace the ball joint assembly. INSTALLATION 1. Install upper ball joint. 2. Install bolt and nut, then tighten them to the specified torque. Torque to 57 Nm (42 ft. lbs.). 3. Install nut and cotter pin, then tighten the nut to the specified torque with just enough additional torque to align cotter pin holes. Install new cotter pin. Torque to 98 Nm (72 ft. lbs.). Locations Safing Sensor: Locations The safing sensor is located inside the SRS Unit, refer to SRS Unit / Service and Repair. Page 2593 Steps 4 - 5 Page 8290 Page 2676 The connector cavity number is listed next to each terminal on the circuit schematic. The cavity / terminal shown is # 6. Diodes A rectifier diode works like a one way valve. It allows current to flow only in the direction of the arrow. A Zener diode blocks reverse current at normal voltages just like a rectifier diode. At high voltages, however, a Zener diode allows current to flow in reverse. Fuses Page 6151 This means the branch of the wire connects to another circuit. The arrow points to the name of the circuit branch where the wire continues. Page 6521 11. Remove the rear roof bracket (2) (Resin top model). - Remove the rear roof bracket cover (4) and remove rear roof bracket connecting with resin top (1) and rear roof trim cover (3) by removing tour fixing bolts. 12. Remove the rear roof trim cover. 13. Remove the assist grip. 14. Remove the door seal finisher. 15. Remove the upper quarter trim cover. 16. Remove the seat belt upper anchor bolt. 17. Remove the retractor fixing bolt. 18. Remove the seat belt assembly. 19. Remove the adjustable shoulder anchor assembly. e Remove two bolts. INSTALLATION To install, follow the removal steps in the reverse order, noting the following points. CAUTION: When replacing the front seat belt, always replace the seat belt with the same parts/part number. 1. Tighten the adjustable shoulder anchor assembly and retractor fixing bolts to the specified torque. Torque: 39 N.m (29 lb.ft) 2. Tighten the seat belt anchor bolts to the specified torque. Torque: 39 N.m (29 lb.ft) Specifications Wheel Fastener: Specifications Wheel Fastener 118 Nm Air Bag Disarming and Arming Air Bag(s) Arming and Disarming: Service and Repair Air Bag Disarming and Arming Disabling The SRS Removal Turn the ignition switch to "lock" and remove key. 1. Remove SRS fuse "METER" and "SRS", from left dash side lower fuse block or disconnect battery. 2. Disconnect yellow 2 - pin connector at the base of steering column. 3. Remove glove box assembly, Refer to "Passenger Air Bag Assembly Replacement". 4. Disconnect yellow 2 - pin connector behind the glove box assembly. CAUTION: With the "SRS" fuse removed and ignition switch "ON", "AIR BAG" warning lamp will be "ON". This is normal operation and does not indicate an SRS malfunction. Enabling The SRS Installation CAUTION: Never use the air bag assembly from another vehicle. Use only the air bag assembly. Turn ignition switch to "LOCK" and remove key. 1. Connect yellow 2 - pin connector passenger air bag assembly. 2. Install glove box assembly, refer to "Passenger Air Bag Assembly Replacement". 3. Connect yellow 2 - pin connector at the base of steering column. 4. Install "AIR BAG" fuse "METER" and "SRS" to left dash side lower fuse block or connect battery. Turn ignition switch to "ON" and verify that the "AIR BAG" warning lamp flashes seven times and then turns "OFF". If it does not operate as described, perform the "Supplemental Restraint System (SRS) Diagnostic System Check". Page 5217 2. Connect the short finder across the battery terminals and the load (component) side of the fuse terminal. 3. Close all switches in the circuit you're testing. 4. Turn on the short finder. This creates a pulsing magnetic field around the wiring between the fuse box and the short. 5. Beginning at the fuse box, slowly move the short finder along the circuit wiring. The meter will read current pulses through sheet metal and body trim. As long as the meter is between the fuse and the short, the needle will move with each current pulse. Once you move the meter past the point of the short, the needle will stop moving. Check the wiring and connectors in this area to locate the cause of the short. Testing For Continuity When testing for continuity at a connector without wire seals, you do not have to separate the two halves of the connector. Instead, probe the connector from the back. Always check both sides of the connector because dirty, corroded, and bent terminals can cause problems (no electrical contact = an open). 1. Disconnect the negative cable from the car battery. If you're using a DVOM, place it in the lowest "OHMS" range. Page 165 Each schematic represents one circuit. A circuit's wires and components are arranged to show current flow, from power at the top of the page, to ground, at the bottom. Shared Circuits Other circuits may share power or ground terminals or wiring with the circuit shown. A wire that connects one circuit to another, for example, is cut short and has an arrowhead at the end of it pointing in the direction of current flow. Next to the arrowhead is the name of the circuit or component which shares that wiring. To quickly check shared wiring, check the operation of a component it serves. If that component works, you know the shared wiring is OK. Connectors All in-line and junction connectors are numbered (C725, C416, etc.). Component connectors are not numbered but are identified either by the name of Page 303 4WD Control Unit: Diagnostic Aids Before Troubleshooting Before Troubleshooting See: Service Precautions/Vehicle Damage Warnings/Tips and Precautions 1. Check applicable fuses in the appropriate fuse/relay box. 2. Check the battery for damage, state of charge, and clean and tight connections. CAUTION: Do not quick-charge a battery unless the battery ground cable has been disconnected, otherwise you will damage the alternator diodes. - Do not attempt to crank the engine with the battery ground cable loosely connected or you will severely damage the wiring. While You're Working 1. Make sure connectors are clean, and have no loose terminals or receptacles. 2. Make sure that connectors without wire seals are packed with dielectric (silicone) grease. Part Number: 08798-9001. 3. When connecting a connector, push it until it "clicks" into place. CAUTION: Do not pull on the wires when disconnecting a connector. Pull only on the connector housings. - Most circuits include solid-state devices. Test the voltages in these circuits only with a 10-megaohm or higher impedance digital multi meter. Never use a test light or analog meter on circuits that contain solid-state devices. Damage to the devices may result. Five-Step Troubleshooting 1. Verify The Complaint Turn on all the components in the problem circuit to check the accuracy of the customer complaint. Note the symptoms. Do not begin disassembly or testing until you have narrowed down the problem area. 2. Analyze The Schematic Look up the schematic for the problem circuit. Determine how the circuit is supposed to work by tracing the current paths from the power source through the circuit components to ground. Also, trace circuits that share wiring with the problem circuit. The names of circuits that share the same fuse, ground, or switch, and so on, are referred to in each circuit schematic. Try to operate any shared circuits you didn't check in step 1. If the shared circuits work, the shared wiring is OK, and the cause must be in the wiring used only by the problem circuit. If several circuits fail at the same time, the fuse or ground is a likely cause. Based on the symptoms and your understanding of the circuit's operation, identify one or more possible causes. 3. Isolate The Problem By Testing The Circuit Make circuit tests to check the diagnosis you made in step 2. Keep in mind that a logical, simple procedure is the key to efficient troubleshooting. Test for the most likely cause of failure first. Try to make tests at points that are easily accessible. 4. Fix The Problem Once the specific problem is identified, make the repair. Be sure to use proper tools and safe procedures. 5. Make Sure The Circuit Works Turn on all components in the repaired circuit in all modes to make sure you've fixed the entire problem. If the problem was a blown fuse, be sure to test all of the circuits on that fuse. Make sure no new problems turn up and the original problem does not recur. Page 2045 The name of the component appears next to it followed by notes about its function along with any photo and connector view references. Connector "C" How to Identify Connector Terminals Cavity Numbering System The cavities (and wire terminals) in each connector are numbered starting from the upper left, looking at the male terminals from the terminal side (or looking at the female terminals from the wire side. Both views are in the same direction so the numbers are the same.) All actual cavities are numbered, even if they have no wire terminals in them. NOTE: Data Link Connector (DLC) terminals are numbered according to SAE standard J1962, not the Honda standard. The numbers of the four end terminals are molded into the corners of the connector face. Page 1120 NOTE: After you rotate the crankshaft, the solid white lines on the belt will not align with the camshaft pulley marks; this is normal. 10. Remove the crankshaft bolt, then install the lower, the right, and the left timing belt covers. Torque the cover bolts to 19 N.m (14 lb-ft). 11. Install the crankshaft pulley, and torque the bolt to 167 N.m (123 lb-ft). 12. Install fan pulley bracket and tighten fixing bolts to the specified torque. Torque: 22 Nm (16 ft. lbs.) 13. Install power steering pump assembly and tighten to the specified torque. Torque: M8 bolt: 22 Nm (16 ft. lbs.) M10 bolt: 46 Nm (34 ft. lbs.) 14. Install cooling fan assembly and tighten bolts/nuts to the specified torque. Torque: 22 Nm (16 ft. lbs.) for fan pulley and fan bracket. Torque: 7.5 Nm (66.4 inch lbs.) for fan and clutch assembly. Page 4478 This sample Ground Distribution schematic shows all of the components that share two ground points. Components A solid border line means the entire component is shown. A broken border line indicates that only part of the component is shown. Page 288 it is located, and what it connects to. Use the Connector Views to help locate the proper cavity when you need to probe a connector. It can be especially helpful if the connector has more than one wire of the same color. A dash symbol (-) indicates that the cavity is empty. Connector views can also be used to help diagnose multiple symptoms in separate circuits which could be caused by a single problem in a connector shared by those circuits. Here's an example: 1. Pick one of the multiple symptoms and look up the schematic for that circuit. 2. Make a list of all the in-line and fuse box connectors in that schematic , 3. Then, in the Connector Views, look up each connector on your list to see if circuits related to the other symptoms run through one of them. If they do, inspect that connector for the problem. Example: The blower, rear window defogger, and the windshield wiper don't work. List all in-line and fuse box connectors in the blower controls circuit and then check the Connector View (see the sample). You find that C324 is common to the blower controls, rear window defogger, and wiper/washer, so you inspect C324 and find the problem, bent terminals. Finding Component/Connector Locations Finding Component/Connector Locations To see where a component or connector is located on the car, look up its photo number in the "Component Location". The photo will also tell you the color of the connector, and how many cavities it has. Page 4808 Part 1 of 2 Part 2 of 2 B-21 FR Speed Sensor Missing (DTC 62/C0222, C0223) Chart B-21 FR Speed Sensor Missing (DTC 62 (Flash Out) / C0222, C0223 (Serial Communications)) Page 3125 Page 865 Clutch Switch: Adjustments 1. Turn the clutch switch (1) until the switch plunger is fully retracted against the clutch pedal arm. 2. Adjust clutch switch by backing it out half a turn and measure the clearance (4) between the clutch pedal arm (3) and the clutch switch. 3. Lock the lock nut (2). 4. Connect clutch switch connector. Clutch Switch (bolt) and Clutch Pedal Clearance 0.5 - 1.5 mm (0.020 - 0.059 in) Page 3586 This sample Ground Distribution schematic shows all of the components that share two ground points. Components A solid border line means the entire component is shown. A broken border line indicates that only part of the component is shown. Diagrams Page 4366 Drive/Propeller Shaft: Service and Repair Rear Drive Shaft REAR PROPELLER SHAFT AND ASSOCIATED PARTS REMOVAL 1. Raise the vehicle on a hoist. NOTE: Apply alignment marks on the flange at the rear propeller shaft both front and rear side. 2. Remove transfer side bolt, nut and washer (except spline yoke type). 3. Remove rear axle side bolt, nut and washer. 4. Remove rear propeller shaft. NOTE: Plug the hole of the transmission rear end to prevent oil leakage (except spline yoke type). INSTALLATION NOTE: Never install the shaft assembly backwards. Never insert bar between yoke lugs when tightening or removing bolts. Completely remove the dust or foreign matter from the connecting surface of flange coupling on each end of the propeller shaft. 1. Align the mark which is applied at removal. 2. Install rear propeller shaft and tighten the bolts to the specified torque. Torque: 63 Nm (46 Ft. lbs.) Page 130 Testing For A Short With A Self-Powered Test Light or DVOM 1. Remove the blown fuse and disconnect the battery and load. 2. Connect one lead of a self-powered test light or digital volt/ohmmeter (DVOM) (switched to the lowest "OHMS" range) to the fuse terminal on the load side. 3. Connect the other lead to a known good ground. 4. Beginning near the fuse box, wiggle the harness. Continue this at convenient points about six inches apart while watching the test light or DVOM. 5. If the self-powered test light goes on or the DVOM displays a low reading or no reading (zero), there is a short to ground in the wiring near that point. Testing for a Short with a Test Light or DVOM 1. Remove the blown fuse and disconnect the load. 2. Connect a test light or digital volt/ohmmeter (DVOM), switched to the appropriate DC volts range, across the fuse terminals to make sure voltage is present. You might have to turn the ignition switch to ON; check the schematic to see. 3. Beginning near the fuse box, wiggle the harness. Continue this at convenient points about six inches apart while watching the test light or DVOM. 4. Where the test light goes , or the DVOM voltage drops to zero, there is a short to ground in the wiring near that point. NOTE: Always use a DVOM on high impedance circuits. A test light may not glow (even with battery voltage present). Testing For A Short With A Short Circuit Locator (Short Finder) 1. Remove the blown fuse. Leave the battery connected. Page 542 Hazard Warning Switch: Service and Repair Removal 1. Disconnect the battery ground cable. 2. Remove the meter cluster assembly (1). 3. Remove the hazard warning switch (2). - Disconnect the switch connector. - To remove the switch, push the lock from the back side of the meter cluster assembly. Installation To install, follow the removal steps in the reverse order. Page 2293 1. Install the MAF sensor on the air cleaner with the clamp. 2. Install the intake air duct and the clamp on the MAF sensor. 3. Tighten the clamps to secure the MAF sensor to the intake air duct and the air cleaner. 4. Connect the MAF electrical connector. 5. Connect the negative battery cable. Diagrams Page 1741 Fuel Pressure: Service Precautions WARNING: Adhere to the following procedures any time the fuel system is being worked on in order to reduce the risk of fire and personal injury: - Keep a dry chemical (Class B) fire extinguisher near the work area. - Place a "CAUTION FLAMMABLE" sign in the work area. - Work in a well-ventilated area. Do not smoke, and keep sparks and open flames away. - Wear eye protection. - Use caution when working near the catalytic converter to prevent the possibility of burns or fire. (The temperatures within the converter can exceed 537 °C (1000 °F). - Relieve the fuel system pressure prior to disconnecting fuel system components. - Disconnect the negative battery cable except for tests where battery voltage is required. - Use a suitable container to store or catch fuel. - Do not replace fuel pipe with fuel hose. - Plug all disconnected fuel line fittings and hoses. - After making any fuel system repairs ALWAYS inspect for fuel leaks. Page 7392 Testing For A Short With A Self-Powered Test Light or DVOM 1. Remove the blown fuse and disconnect the battery and load. 2. Connect one lead of a self-powered test light or digital volt/ohmmeter (DVOM) (switched to the lowest "OHMS" range) to the fuse terminal on the load side. 3. Connect the other lead to a known good ground. 4. Beginning near the fuse box, wiggle the harness. Continue this at convenient points about six inches apart while watching the test light or DVOM. 5. If the self-powered test light goes on or the DVOM displays a low reading or no reading (zero), there is a short to ground in the wiring near that point. Testing for a Short with a Test Light or DVOM 1. Remove the blown fuse and disconnect the load. 2. Connect a test light or digital volt/ohmmeter (DVOM), switched to the appropriate DC volts range, across the fuse terminals to make sure voltage is present. You might have to turn the ignition switch to ON; check the schematic to see. 3. Beginning near the fuse box, wiggle the harness. Continue this at convenient points about six inches apart while watching the test light or DVOM. 4. Where the test light goes , or the DVOM voltage drops to zero, there is a short to ground in the wiring near that point. NOTE: Always use a DVOM on high impedance circuits. A test light may not glow (even with battery voltage present). Testing For A Short With A Short Circuit Locator (Short Finder) 1. Remove the blown fuse. Leave the battery connected. Page 2268 11. Using a jumper wire, connect the reference voltage of each circuit to its signal input and view the APP Sensor values in the Engine Data List. APP Sensor 1 should have a value of 99%, and APP Sensor 2 and APP Sensor 3 should each have a value of 0%. ^ If the values are not as specified, troubleshoot for high resistance on the signal input or a PCM malfunction. Repair the circuit or replace the PCM, then repeat step 3. ^ If the values are as specified, the problem may be intermittent. Disconnect the 10P connector from the modified APPS, and connect it to the new APPS; then repeat step 3. Wiggle the APPS wires as you go through the adjustment procedure to find the intermittent problem. 12. Turn off the ignition switch, and disconnect the PGM Tester.* DISCLAIMER Page 7260 Power Mirror Switch: Removal and Replacement Door Mirror Switch Removal 1. Disconnect the battery ground cable. 2. Remove the instrument panel lower cover (2). 3. Remove the door mirror switch (1). Accelerator Pedal Position Sensor - MIL ON/DTC's Set Technical Service Bulletin # 01-047 Date: 010814 Accelerator Pedal Position Sensor - MIL ON/DTC's Set 01-047 August 14, 2001 Applies To: 2000-01 Passport - ALL MIL Comes On With Accelerator Pedal Position Sensor DTC(s) P1271, P1273, P1275, P1280, and/or P1285 SYMPTOM The MIL is on with DTC P1271, P1273, P1275, P1280, or P1285 (various accelerator pedal position sensor problems) stored. The REDUCED POWER indicator may also be on; and the engine may occasionally idle too high, or the idle may fluctuate. PROBABLE CAUSE Contaminated grease on the potentiometer circuit board of the accelerator pedal position sensor (APPS) causes high resistance in the APPS circuit. CORRECTIVE ACTION Replace and adjust the APPS, remove all grease from the accelerator link, and clean the APPS harness connector and connector C123. PARTS INFORMATION Accelerator Pedal Position Sensor: P/N 8-97193-713-0, H/C 6198311 REQUIRED MATERIALS CAIG DeoxIT D5-S6 Contact Cleaner: P/N 341-200 (available from www.partsexpress.com) or Permatex Electrical Contact Cleaner: Permatex P/N 24379 WARRANTY CLAIM INFORMATION In warranty: The normal warranty applies. Operation Number: 122114 Flat Rate Time: 0.5 hour Failed Part: P/N 8-97220-540-0 H/C 6202436 Defect Code: 091 Contention Code: C99 Template ID: 01-047A Skill Level: Repair Technician Out of warranty: Any repair performed after warranty expiration may be eligible for goodwill consideration by the District Service Manager or your Zone Office. You must request consideration, and get a decision, before starting work. Specifications Fuel Pressure: Specifications PRESSURE PRESSURE With Regulator Vacuume Hose Disconnected 42-55 Psi. Page 138 Powertrain Control Module: Service Precautions Reprogramming the PCM Reprogramming the PCM Reprogramming of the PCM is done without removing it from the vehicle . This provides a flexible and cost-effective method of making changes in software calibrations. Refer to the latest Techline information on reprogramming or flashing procedures. Page 5660 16. Remove torsion bar arm bolt. 17. Remove lower ball joint bolt. 18. Remove front bushing by using remover J-36833. 19. Remove rear bushing by using remover J-36834. INSPECTION AND REPAIR Make necessary correction or parts replacement if wear, damage, corrosion or any other abnormal condition are found through inspection. Check the following parts: Page 1985 - Engine Coolant Temperature - Crankshaft Position - Exhaust Oxygen Content - Electronic Ignition - Manifold Absolute Pressure - Battery Voltage - Throttle Position - Vehicle Speed - Fuel Pump Voltage - Power Steering Pressure - Intake Air Temperature - Mass Air Flow - Engine knock - Camshaft Position Outputs - Systems Controlled - EVAP Canister Purge - Exhaust Gas Recirculation (EGR) - Ignition Control - Fuel Control - ION Sensing Module - Electric Fuel Pump - Air Conditioning - Diagnostics Malfunction Indicator Lamp - Data Link Connector (DLC) - Data Output - Transmission Control Module PCM Voltage Description PCM Voltage Description The PCM supplies a buffered voltage to various switches and sensors. It can do this because resistance in the PCM is so high in value that a test light may not illuminate when connected to the circuit. An ordinary shop voltmeter may not give an accurate reading because the voltmeter input impedance is too low. Use a 10 megohms input impedance digital voltmeter (such as J 39200) to assure accurate voltage readings. The input/output devices in the PCM include analog-to-digital converters, signal buffers, counters, and special drivers. The PCM controls most components with electronic switches which complete a ground circuit when turned "ON." These switches are arranged in groups of 4 and 7, called either a surface-mounted quad driver module (QDM), which can independently control up to 4 output terminals, or QDMs which can independently control up to 7 outputs. Not all outputs are always used. Powertrain Control Module (PCM) Powertrain Control Module (PCM) The powertrain control module (PCM) is located in the passenger compartment below the center console. The PCM controls the following: - Fuel metering system. - Transmission shifting (automatic transmission only). - Ignition timing. - On-board diagnostics for powertrain functions. The PCM constantly observes the information from various sensors. The PCM controls the systems that affect vehicle performance. The PCM performs the diagnostic function of the system. It can recognize operational problems, alert the driver through the MIL (Check Engine lamp), and store diagnostic trouble codes (DTCs). DTCs identify the problem areas to aid the technician in making repairs. 58X Reference PCM Input 58X Reference PCM Input The powertrain control module (PCM) uses this signal from the crankshaft position (CKP) sensor to calculate engine RPM and crankshaft position at all engine speeds. The PCM also uses the pulses on this circuit to initiate injector pulses. If the PCM receives no pulses on this circuit, DTC P0337 will set. The engine will not start and run without using the 58X reference signal. Description and Operation A/C Signal: Description and Operation A/C Request Signal This signal tells the PCM when the A/C mode is selected at the A/C control head. The PCM uses this to adjust the idle speed before turning "ON" the A/C clutch. The A/C compressor will be inoperative if this signal is not available to the PCM. Refer to A/C Clutch Circuit Diagnosis for A/C wiring diagrams and diagnosis for the A/C electrical system. Page 279 4. If the trouble occurs after the above test, charge the Axle Disconnect controller to the new one. Testing and Inspection Air Filter Element: Testing and Inspection Air Cleaner Element Check the air cleaner filter for damage or dust clogging. Replace if it is damaged, or clean if it is clogged. Page 6046 Compressor Clutch: Testing and Inspection Magnetic Clutch Assembly (DKV-14G Type) Drive Plate If the frictional surface shows signs of damage due to excessive heat, the drive plate and pulley should be replaced. Pulley Assembly Check the appearance of the pulley assembly. If the frictional surface of the pulley shows signs of excessive grooving due to slippage, both the pulley and drive plate should be replaced. The frictional surfaces of the pulley assembly should be cleaned with a suitable solvent before reinstallation. Coil Check coil for loose connector or cracked insulation. Page 1460 2. Remove cylinder head gasket (2). 3. Remove crankcase with oil pan (3). 4. Remove oil pipe and O-ring (4). 5. Remove oil strainer and O-ring (5). 6. Remove oil gallery (6). 7. Remove connecting rod cap with connecting rod lower bearing (12). 8. Remove piston and connecting rod assembly (7). Note: Before removing piston and connecting rod assembly, measure thrust clearance. - Remove any ridge or carbon build up from the top end of the cylinder. 9. Remove the piston rings (8) with a piston ring expander. Arrange the removed piston rings in the cylinder number order. Page 6926 Front Fender: Service and Repair Front Fender Panel Front Fender Panel Removal 1. Disconnect the battery ground cable. 2. Remove the radiator grille assembly. Page 2971 The connector cavity number is listed next to each terminal on the circuit schematic. The cavity / terminal shown is # 6. Diodes A rectifier diode works like a one way valve. It allows current to flow only in the direction of the arrow. A Zener diode blocks reverse current at normal voltages just like a rectifier diode. At high voltages, however, a Zener diode allows current to flow in reverse. Fuses Page 7005 SWB Starting System - Unable To Key In Ignition Switch Ignition Switch Lock Cylinder: Technical Service Bulletins Starting System - Unable To Key In Ignition Switch Can't Turn Ignition Switch? Check for Locked Steering Got a service customer complaining he or she can't turn the ignition switch to start the engine? The reason could just be the steering column lock pin is engaged with the front wheels turned. Here's what typically happens: Some folks use the steering wheel to help support themselves while climbing in or out of the vehicle. This is very common among elderly or disabled drivers. Doing this turns the front wheels, which twists the tires against the ground. The twisted tires apply torque to the steering column. With the ignition switch in LOCK (0), the steering column lock pin is engaged. But the applied torque on the steering column binds the lock pin, making it tough to turn the ignition switch. The ignition switch won't turn to ON (II) if the lock pin isn't disengaged from the steering column. Tell your customer there's nothing wrong with the ignition switch itself. All he or she needs to do is turn the steering wheel from side to side while turning the switch. This usually releases the lock pin so the engine can be started. In some cases, though, your customer may need to give a good tug on the wheel. This could easily happen when parking on a hill and the wheels are turned sharply before the engine is shut off. Page 3521 3. Connect the electrical connector to the CMP sensor. 4. Install the common chamber assembly. 5. Install the engine cover. 6. Connect the negative battery cable. Page 5447 Alignment: Service and Repair Trim Height Adjustment TRIM HEIGHT Adjust the trim height (1) by means of the adjusting bolt on the height control arms. CAUTION: When adjusting front end alignment, be sure to begin with trim height first, as it may change other adjusted alignments. 1. Check and adjust the tire inflation pressures. 2. Park the vehicle on a level ground and move the front of the vehicle up and down several times to settle the suspension. 3. Make necessary adjustment with the adjusting bolt on the height control arms. Trim height: 119 ± 5 mm (4.69 ± 0.2 inch) CASTER Page 3540 Ignition Coil: Testing and Inspection Check the ignition coil assembly for insulation. Check terminals for corrosion or damage, and replace as necessary. Measuring resistance of ignition coil assembly. Measure resistance of ignition coil assembly,and replace the ignition coil assembly if its value exceeds the standard. Page 6735 The name of the component appears next to it followed by notes about its function along with any photo and connector view references. Connector "C" How to Identify Connector Terminals Cavity Numbering System The cavities (and wire terminals) in each connector are numbered starting from the upper left, looking at the male terminals from the terminal side (or looking at the female terminals from the wire side. Both views are in the same direction so the numbers are the same.) All actual cavities are numbered, even if they have no wire terminals in them. NOTE: Data Link Connector (DLC) terminals are numbered according to SAE standard J1962, not the Honda standard. The numbers of the four end terminals are molded into the corners of the connector face. Page 694 10. Use the PGM Tester to check the broadcast code. Make sure the broadcast code matches the one you selected from the CD-ROM. WARRANTY CLAIM INFORMATION In warranty: The normal warranty applies. Failed Part: P/N 8-17087-655-0 H/C 4375820 Defect Code: 064 Contention Code: C01 Skill Level: Repair Technician Out of warranty: Any repair performed after warranty expiration may be eligible for goodwill consideration by the District Service Manager or your Zone Office. You must request consideration, and get a decision, before starting work. REPAIR PROCEDURE - ENGINE/BODY GROUND 1. Use the ETM for the appropriate year to locate these ground connectors: G101, G104, G105, G106 and G160. 2. Inspect each connector for corrosion or looseness. 3. Remove the bolt from any connector that is corroded or loose. Clean the terminal connector with a wire brush. File flat any solder bumps on the connector. 4. Clean the contact surface on the engine or body with a wire brush. 5. Replace the bolt if it is heavily corroded. Otherwise, clean it with a wire brush. 6. Apply lithium dielectric grease to both sides of the terminal connector. 7. Reinstall the bolt, torque it to 14 N.m (10 lb-ft). 8. Use the Smart Cable to reprogram the PCM with the latest software from the June 2001 or later HONDANET CD-ROM. Refer to Service Bulletin 99-005, Updating the Passport PCM, filed under Tools. 9. Use the PGM Tester to clear any DTCs. 10. Use the PGM Tester to check the broadcast code. Make sure the broadcast code matches the one you selected from the CD-ROM. WARRANTY CLAIM INFORMATION In warranty: The normal warranty applies. Failed Part: P/N 8-97086-823-0 Page 7105 Removal and Installation Powertrain Control Module: Service and Repair Removal and Installation REMOVAL 1. Disconnect the negative battery cable. 2. Remove the two screws from the PCM electrical connectors. 3. Disconnect the PCM electrical connectors. 4. After removing the clip which fixes the PCM to the bracket, remove PCM. INSTALLATION 1. Install the PCM to bracket and fix with the clip. Page 5483 H/C 4408092 Defect Code: 017 Contention Code: C99 Skill Level: Repair Technician Out of warranty: Any repair performed after warranty expiration may be eligible for goodwill consideration by the District Service Manager or your Zone Office. You must request consideration, and get a decision, before starting work. DISCLAIMER Page 7613 Low Fuel Lamp/Indicator: Description and Operation WARNING: Do not smoke while working on the fuel system. Keep open flame away from the work area. Drain fuel only into a approved container. The resistance of the fuel tank unit varies according to the float position in the tell tank. When the tell tank has an adequate amount of fuel, the low fuel indicator light circuit is open and the indicator light will not come on. The fuel level output is received by the engine or powertrain control module (ECM or PCM), and when the fuel level drops to almost empty, the ECM or PCM closes the circuit and the Low Fuel Indicator comes on to alert the driver. NOTE 1: The circuit between the PCM and the gauge can be tested with the PGM Tester. In the "ENGINE\MISC TESTS\FUEL GAUGE" menu, the PGM Tester can command the PCM to move the gauge in 10% increments. Page 1082 Ignition Cable: Testing and Inspection Spark Plug Cables NOTE: Never puncture the spark plug cable's insulation with a needle or the pointed end of a probe into the cable. An increase in resistance would be created which would cause the cable to become defective. 1. If the cable has broken or cracked insulation, it must be replaced. 2. If the terminals are corroded or loose, the cable must be replaced. 3. Check that the cable resistance does not exceed 10 kOHM per foot. Exterior Components Vacuum Brake Booster: Service and Repair Exterior Components Removal 1. Remove master cylinder. 2. Remove vacuum booster. 3. Remove yoke clevis. 4. Remove lock nut. 5. Remove retaining clip. 6. Remove valve body guard. 7. Remove silencer. 8. Remove filter. 9. Remove 2 gaskets and spacer. 10. Remove retainer, using a small screwdriver to pry out the retainer. Gently pull out the plate and seal assembly from the shell. Inspection and Repair Visual Check Make necessary parts replacement if cuts, nicks, excessive wear, or other abnormal conditions are found through inspection. Check the following parts: Yoke clevis - Valve body guard - Silencer - Filter plate and seal assembly Page 2929 10. Use the PGM Tester to check the broadcast code. Make sure the broadcast code matches the one you selected from the CD-ROM. WARRANTY CLAIM INFORMATION In warranty: The normal warranty applies. Failed Part: P/N 8-17087-655-0 H/C 4375820 Defect Code: 064 Contention Code: C01 Skill Level: Repair Technician Out of warranty: Any repair performed after warranty expiration may be eligible for goodwill consideration by the District Service Manager or your Zone Office. You must request consideration, and get a decision, before starting work. REPAIR PROCEDURE - ENGINE/BODY GROUND 1. Use the ETM for the appropriate year to locate these ground connectors: G101, G104, G105, G106 and G160. 2. Inspect each connector for corrosion or looseness. 3. Remove the bolt from any connector that is corroded or loose. Clean the terminal connector with a wire brush. File flat any solder bumps on the connector. 4. Clean the contact surface on the engine or body with a wire brush. 5. Replace the bolt if it is heavily corroded. Otherwise, clean it with a wire brush. 6. Apply lithium dielectric grease to both sides of the terminal connector. 7. Reinstall the bolt, torque it to 14 N.m (10 lb-ft). 8. Use the Smart Cable to reprogram the PCM with the latest software from the June 2001 or later HONDANET CD-ROM. Refer to Service Bulletin 99-005, Updating the Passport PCM, filed under Tools. 9. Use the PGM Tester to clear any DTCs. 10. Use the PGM Tester to check the broadcast code. Make sure the broadcast code matches the one you selected from the CD-ROM. WARRANTY CLAIM INFORMATION In warranty: The normal warranty applies. Failed Part: P/N 8-97086-823-0 Engine Controls - Engine Spark Knock Or Pinging PROM - Programmable Read Only Memory: Customer Interest Engine Controls - Engine Spark Knock Or Pinging 01-084 June 19, 2009 Applies To: 2000-02 Passport - ALL Engine Spark Knock (Pinging) (Supersedes 01-084, dated March 18, 2003, to revise the information marked by asterisks) *REVISION SUMMARY Under WARRANTY CLAIM INFORMATION, the failed part number, the Honda code, the defect code, and the symptom code have been updated.* SYMPTOM An engine spark knock (pinging). PROBABLE CAUSE The programmed ignition timing does not correct quickly enough in some climates. CORRECTIVE ACTION Update the PCM software with the Smart Cable. TOOL INFORMATION PGM Tester with software update release SN200P (9/1/01) or later. For the other tools and equipment you need to update the PCM software, refer to Service Bulletin 99-005, Updathg the Passport POM, filed under Tools. WARRANTY CLAIM INFORMATION In warranty: The normal warranty applies. Operation Number: 125517 Flat Rate Time: 0.3 hour *Failed Part: P/N 8-12212-079-0 H/C 6974992 Defect Code: 03214 Symptom Code: 09117* Template ID: 01-084A Skill Level: Repair Technician Out of warranty: Any repair performed after warranty expiration may be eligible for goodwill consideration by the District Parts and Service Manager or your Zone Office. You must request consideration, and get a decision, before starting work. REPAIR PROCEDURE 1. Retrieve the PCM broadcast code with the PGM Tester or the Smart Cable (refer to Service Bulletin 99-005, Updathg the Passport PCM). Page 1025 1. Place the vehicle on a commercially available, computerized, four-wheel alignment rack, and record the following measurements. Follow the equipment manufacturer's instructions. NOTE: Enter each reading in decimal degrees. Example 30' = 0.50. 2. If any measurement is out of specification, inspect the front suspension for any damage. Repair any damaged parts before continuing your diagnosis. 3. Determine how the front wheel camber is affecting the pull. Pick the combination of left- and right-front camber that best matches the vehicle you are repairing, then note the camber thrust direction for that combination: NOTE: ^ If the camber of both front wheels is negative, but one wheel is grossly more negative than the other, the camber thrust direction will be opposite the wheel with more negative camber (for example, if the left-front wheel is more negative, the camber thrust direction is right). ^ If the camber of both front wheels is positive, but one wheel is grossly more positive than the other, the camber thrust direction will be the same as the wheel with more positive camber (for example, if the left-front wheel is more positive, the camber thrust direction is left). 4. Determine how the camber needs to be adjusted. 5. Adjust the camber as needed. Front Camber Adjustment, Double Wishbone Suspension Page 2803 2. Connect the PCM electrical connectors. 3. Install the two screws to PCM electrical connectors. Page 7407 This sample Ground Distribution schematic shows all of the components that share two ground points. Components A solid border line means the entire component is shown. A broken border line indicates that only part of the component is shown. Page 5030 HEC ENGINE 6VD1 ENGINE Installation 1. Perform vacuum booster and vacuum booster push rod adjustment. NOTE: When replacing either the master cylinder or vacuum booster, be sure to measure push rod, and adjust if required. 2. Remove retainer from vacuum booster front shell using a small screwdriver. Then gently draw plate and seal assembly out of the shell inside. 3. Set push rod gauge J-39216 on vacuum booster, and apply negative pressure by means of vacuum pump J-23738-A so that the pressure in the vacuum booster becomes 500 mm Hg. NOTE: Be sure to apply NEGATIVE pressure after installing a push rod gauge on the vacuum booster. Page 2732 H/C 4408092 Defect Code: 017 Contention Code: C99 Skill Level: Repair Technician Out of warranty: Any repair performed after warranty expiration may be eligible for goodwill consideration by the District Service Manager or your Zone Office. You must request consideration, and get a decision, before starting work. DISCLAIMER Page 7417 Cigarette Lighter: Diagnostic Aids Before Troubleshooting Before Troubleshooting See: Service Precautions/Vehicle Damage Warnings/Tips and Precautions 1. Check applicable fuses in the appropriate fuse/relay box. 2. Check the battery for damage, state of charge, and clean and tight connections. CAUTION: Do not quick-charge a battery unless the battery ground cable has been disconnected, otherwise you will damage the alternator diodes. - Do not attempt to crank the engine with the battery ground cable loosely connected or you will severely damage the wiring. While You're Working 1. Make sure connectors are clean, and have no loose terminals or receptacles. 2. Make sure that connectors without wire seals are packed with dielectric (silicone) grease. Part Number: 08798-9001. 3. When connecting a connector, push it until it "clicks" into place. CAUTION: Do not pull on the wires when disconnecting a connector. Pull only on the connector housings. - Most circuits include solid-state devices. Test the voltages in these circuits only with a 10-megaohm or higher impedance digital multi meter. Never use a test light or analog meter on circuits that contain solid-state devices. Damage to the devices may result. Five-Step Troubleshooting 1. Verify The Complaint Turn on all the components in the problem circuit to check the accuracy of the customer complaint. Note the symptoms. Do not begin disassembly or testing until you have narrowed down the problem area. 2. Analyze The Schematic Look up the schematic for the problem circuit. Determine how the circuit is supposed to work by tracing the current paths from the power source through the circuit components to ground. Also, trace circuits that share wiring with the problem circuit. The names of circuits that share the same fuse, ground, or switch, and so on, are referred to in each circuit schematic. Try to operate any shared circuits you didn't check in step 1. If the shared circuits work, the shared wiring is OK, and the cause must be in the wiring used only by the problem circuit. If several circuits fail at the same time, the fuse or ground is a likely cause. Based on the symptoms and your understanding of the circuit's operation, identify one or more possible causes. 3. Isolate The Problem By Testing The Circuit Make circuit tests to check the diagnosis you made in step 2. Keep in mind that a logical, simple procedure is the key to efficient troubleshooting. Test for the most likely cause of failure first. Try to make tests at points that are easily accessible. 4. Fix The Problem Once the specific problem is identified, make the repair. Be sure to use proper tools and safe procedures. 5. Make Sure The Circuit Works Turn on all components in the repaired circuit in all modes to make sure you've fixed the entire problem. If the problem was a blown fuse, be sure to test all of the circuits on that fuse. Make sure no new problems turn up and the original problem does not recur. Page 1505 Piston: Service and Repair Disassembly, Inspection and Assembly Piston and Connecting Rod Disassembly 1. Remove cylinder head assembly (1). Page 6481 To install the connector, hold the socket insulator(l) and insert it. The cover insulator slides and connector will be locked. Do not hold the cover insulator(2). Engine Controls - High/Erratic Engine Idle Grounding Point: All Technical Service Bulletins Engine Controls - High/Erratic Engine Idle 01-080 August 14, 2001 Applies To: 2000-02 Passport - ALL 2000-02 Passport: High or Erratic Idle SYMPTOM The engine occasionally idles at too high a speed, or the idle speed fluctuates. PROBABLE CAUSES The symptom could be the result of any of these conditions: ^ Loose or corroded engine or body ground ^ High resistance in the APPS ground circuit ^ PSP (power steering pressure) switch is internally shorted to ground ^ Fuel pressure regulator is leaking fuel into the intake manifold CORRECTIVE ACTION Diagnose the cause of the idle condition, and select the proper REPAIR PROCEDURE. PARTS INFORMATION REQUIRED MATERIALS REQUIRED SOFTWARE Each REPAIR PROCEDURE requires you to use the Smart Cable to reprogram the PCM with the latest software. To select the latest software from the CDROM, enter the year, model, engine, transmission, and emissions type (49-state or California). This gives you a list of broadcast codes. Select the broadcast code at the top of the list. WARRANTY CLAIM INFORMATION Refer to the Warranty Claim Information for each Repair Procedure. DIAGNOSIS 1. Find out from the customer when the high or erratic idle condition occurs and what the RPM range is: ^ Within 20 minutes of a cold start ^ After braking to a stop ^ All the time ^ Intermittently, with no set pattern Page 4602 The wire insulation has one color or one color with another color stripe. The second color is the stripe. Page 6061 Condenser HVAC: Service and Repair Condenser Assembly Removal 1. Disconnect the battery ground cable. 2. Discharge and recover refrigerant. 3. Remove radiator grille. 4. Remove engine hood front end stay. 5. Remove engine hood lock. - Apply setting mark to the engine hood lock fixing position before removing it. 6. Disconnect pressure switch connector. 7. Disconnect refrigerant line. - When removing the line connector, the connecting part should immediately be plugged or capped to prevent foreign matter from being mixed into the line. 8. Remove condenser assembly. - Handle with care to prevent damaging the condenser or radiator fin. Installation 1. Install condenser assembly. - If installing a new condenser, be sure to add 30cc (1.0 fl.oz.) of new compressor oil to a new one. - Tighten the condenser fixing bolts to the specified torque. Torque: 6 Nm (52 lb in) 2. Connect refrigerant line. - Tighten the inlet line connector fixing bolt to the specified torque. Torque: 15 Nm (11 lb.ft) Page 3375 2. Connect the short finder across the battery terminals and the load (component) side of the fuse terminal. 3. Close all switches in the circuit you're testing. 4. Turn on the short finder. This creates a pulsing magnetic field around the wiring between the fuse box and the short. 5. Beginning at the fuse box, slowly move the short finder along the circuit wiring. The meter will read current pulses through sheet metal and body trim. As long as the meter is between the fuse and the short, the needle will move with each current pulse. Once you move the meter past the point of the short, the needle will stop moving. Check the wiring and connectors in this area to locate the cause of the short. Testing For Continuity When testing for continuity at a connector without wire seals, you do not have to separate the two halves of the connector. Instead, probe the connector from the back. Always check both sides of the connector because dirty, corroded, and bent terminals can cause problems (no electrical contact = an open). 1. Disconnect the negative cable from the car battery. If you're using a DVOM, place it in the lowest "OHMS" range. A/T - Fluid Leak From the Accumulator Cover Accumulator: All Technical Service Bulletins A/T - Fluid Leak From the Accumulator Cover 02-038 November 5, 2002 Applies To: 1998-02 Passport With A/T - ALL ATF Leaks From the Accumulator Cover (Supersedes 02-038, dated August 20, 2002) Updated information is shown by black bars and asterisks. SYMPTOM ATF leaks from the right side of the transmission. PROBABLE CAUSE The accumulator cover is cracked. CORRECTIVE ACTION Replace the accumulator cover. TOOL INFORMATION * Accumulator Cover Installation and Removal Tool Kit: T/N O7ZAF-IZAA12O, H/C 7259625 * NOTE: The accumulator cover installation and removal tool kit is available through the Honda Special Tool Loan Program. PARTS INFORMATION Accumulator Cover: P/N 5-96017-093-0, H/C 4555513 WARRANTY CLAIM INFORMATION In warranty: The normal warranty applies. Failed Part: P/N 5-96017-093-0 H/C 4555513 Defect Code: 051 Contention Code: B06 Skill Level: Repair Technician Out of warranty: Any repair performed after warranty expiration may be eligible for goodwill consideration by the District Parts and Service Manager or your Zone Office. You must request consideration, and get a decision, before starting work. Page 4038 16. Tear off a corner from a business card or some other suitable material. Insert the card piece between the cable slider and the interlock pin. 17. Pry out the adjuster clip, then snap it back into place. Remove the card piece. Make sure the ignition switch turns to LOCK, then press firmly on the shift lever pushbutton, and pull down on the shift lever to make sure the lever is locked in R. 18. Plug in the connectors for the accessory power outlet, then reinstall the front console. 19. On 4WD models, reinstall the knob on the transfer control lever. 20. Plug in the connectors for the POWER and WINTER switches, then reinstall the rear console. 21. Move the shift lever to L. Plug in the connectors for the cigarette lighter, then reinstall the lower cluster assembly. 22. Reinstall the upper steering column cover. 23. Reinstall the driver's dashboard lower cover. 24. Reinstall the driver's kick panel. 25. Make sure the hood is fully closed. Electrode Gap Spark Plug: Specifications Plug Gap Standard Service Limit 0.039-0.043 in (1.0-1.1 mm) 0.050 in (1.3 mm) Page 2679 Terminals - "T" Each "T" terminal (ring type) is numbered for reference and location. A "T" terminal is secured with a screw or bolt. Wires Page 216 Testing For A Short With A Self-Powered Test Light or DVOM 1. Remove the blown fuse and disconnect the battery and load. 2. Connect one lead of a self-powered test light or digital volt/ohmmeter (DVOM) (switched to the lowest "OHMS" range) to the fuse terminal on the load side. 3. Connect the other lead to a known good ground. 4. Beginning near the fuse box, wiggle the harness. Continue this at convenient points about six inches apart while watching the test light or DVOM. 5. If the self-powered test light goes on or the DVOM displays a low reading or no reading (zero), there is a short to ground in the wiring near that point. Testing for a Short with a Test Light or DVOM 1. Remove the blown fuse and disconnect the load. 2. Connect a test light or digital volt/ohmmeter (DVOM), switched to the appropriate DC volts range, across the fuse terminals to make sure voltage is present. You might have to turn the ignition switch to ON; check the schematic to see. 3. Beginning near the fuse box, wiggle the harness. Continue this at convenient points about six inches apart while watching the test light or DVOM. 4. Where the test light goes , or the DVOM voltage drops to zero, there is a short to ground in the wiring near that point. NOTE: Always use a DVOM on high impedance circuits. A test light may not glow (even with battery voltage present). Testing For A Short With A Short Circuit Locator (Short Finder) 1. Remove the blown fuse. Leave the battery connected. Page 3405 Terminals - "T" Each "T" terminal (ring type) is numbered for reference and location. A "T" terminal is secured with a screw or bolt. Wires Page 4678 it is located, and what it connects to. Use the Connector Views to help locate the proper cavity when you need to probe a connector. It can be especially helpful if the connector has more than one wire of the same color. A dash symbol (-) indicates that the cavity is empty. Connector views can also be used to help diagnose multiple symptoms in separate circuits which could be caused by a single problem in a connector shared by those circuits. Here's an example: 1. Pick one of the multiple symptoms and look up the schematic for that circuit. 2. Make a list of all the in-line and fuse box connectors in that schematic , 3. Then, in the Connector Views, look up each connector on your list to see if circuits related to the other symptoms run through one of them. If they do, inspect that connector for the problem. Example: The blower, rear window defogger, and the windshield wiper don't work. List all in-line and fuse box connectors in the blower controls circuit and then check the Connector View (see the sample). You find that C324 is common to the blower controls, rear window defogger, and wiper/washer, so you inspect C324 and find the problem, bent terminals. Finding Component/Connector Locations Finding Component/Connector Locations To see where a component or connector is located on the car, look up its photo number in the "Component Location". The photo will also tell you the color of the connector, and how many cavities it has. Service and Repair Fuel Gauge Sender: Service and Repair Removal and Installation As for removal and installation of the Fuel Gauge Unit, refer to "Fuel Tank" as the fuel gauge unit is combined with the fuel pump and sender assembly. Page 530 Combination Switch: Service and Repair REMOVAL 1. Turn the steering wheel so that the vehicle's wheels are pointing straight ahead. 2. Turn the ignition switch to "LOCK". 3. Disconnect the battery "-" terminal cable, and wait at least 5 minutes. 4. Disconnect the yellow 2-way SRS connector located under the steering column. CAUTION: The wheels of the vehicle must be straight ahead and the steering column in the "LOCK" position before disconnecting the steering wheel. Failure to do so will cause the coil assembly to become uncentered which will cause damage to the coil assembly. 5. Remove the engine hood opening lever, then remove instrument panel lower cover. 6. Remove the driver knee bolster (reinforcement). Page 7495 2. Connect the short finder across the battery terminals and the load (component) side of the fuse terminal. 3. Close all switches in the circuit you're testing. 4. Turn on the short finder. This creates a pulsing magnetic field around the wiring between the fuse box and the short. 5. Beginning at the fuse box, slowly move the short finder along the circuit wiring. The meter will read current pulses through sheet metal and body trim. As long as the meter is between the fuse and the short, the needle will move with each current pulse. Once you move the meter past the point of the short, the needle will stop moving. Check the wiring and connectors in this area to locate the cause of the short. Testing For Continuity When testing for continuity at a connector without wire seals, you do not have to separate the two halves of the connector. Instead, probe the connector from the back. Always check both sides of the connector because dirty, corroded, and bent terminals can cause problems (no electrical contact = an open). 1. Disconnect the negative cable from the car battery. If you're using a DVOM, place it in the lowest "OHMS" range. Page 7691 5. Remove the meter assembly. - Push the metal cover (6) with the screw driver (7). 6. Remove the meter rear cover. 7. Remove the meter circuit board. 8. Remove the A/T shift indicator bulb. Installation To install, follow the removal steps in the reverse order. Locations Page 7888 Headlamp Switch: Diagnostic Aids Before Troubleshooting Before Troubleshooting See: Service Precautions/Vehicle Damage Warnings/Tips and Precautions 1. Check applicable fuses in the appropriate fuse/relay box. 2. Check the battery for damage, state of charge, and clean and tight connections. CAUTION: Do not quick-charge a battery unless the battery ground cable has been disconnected, otherwise you will damage the alternator diodes. - Do not attempt to crank the engine with the battery ground cable loosely connected or you will severely damage the wiring. While You're Working 1. Make sure connectors are clean, and have no loose terminals or receptacles. 2. Make sure that connectors without wire seals are packed with dielectric (silicone) grease. Part Number: 08798-9001. 3. When connecting a connector, push it until it "clicks" into place. CAUTION: Do not pull on the wires when disconnecting a connector. Pull only on the connector housings. - Most circuits include solid-state devices. Test the voltages in these circuits only with a 10-megaohm or higher impedance digital multi meter. Never use a test light or analog meter on circuits that contain solid-state devices. Damage to the devices may result. Five-Step Troubleshooting 1. Verify The Complaint Turn on all the components in the problem circuit to check the accuracy of the customer complaint. Note the symptoms. Do not begin disassembly or testing until you have narrowed down the problem area. 2. Analyze The Schematic Look up the schematic for the problem circuit. Determine how the circuit is supposed to work by tracing the current paths from the power source through the circuit components to ground. Also, trace circuits that share wiring with the problem circuit. The names of circuits that share the same fuse, ground, or switch, and so on, are referred to in each circuit schematic. Try to operate any shared circuits you didn't check in step 1. If the shared circuits work, the shared wiring is OK, and the cause must be in the wiring used only by the problem circuit. If several circuits fail at the same time, the fuse or ground is a likely cause. Based on the symptoms and your understanding of the circuit's operation, identify one or more possible causes. 3. Isolate The Problem By Testing The Circuit Make circuit tests to check the diagnosis you made in step 2. Keep in mind that a logical, simple procedure is the key to efficient troubleshooting. Test for the most likely cause of failure first. Try to make tests at points that are easily accessible. 4. Fix The Problem Once the specific problem is identified, make the repair. Be sure to use proper tools and safe procedures. 5. Make Sure The Circuit Works Turn on all components in the repaired circuit in all modes to make sure you've fixed the entire problem. If the problem was a blown fuse, be sure to test all of the circuits on that fuse. Make sure no new problems turn up and the original problem does not recur. Page 7329 To install, follow the removal steps in the reverse order, noting the following points: 1. Install the regulator handle as shown in the figure, if equipped without power windows. 2. Check to see that the window regulator operates smoothly and the glass opens and closes properly. 3. Install the waterproof sheet tightly against the door panel. Service and Repair Turn Signal Bulb: Service and Repair Removal 1. Disconnect the battery ground cable. 2. Remove the rear combination light assembly. - Refer to the Taillight Bulb removal step. 3. Remove the bulb (1). - Remove the rear turn signal light socket by turning it counterclockwise. - Remove the bulb by turning it counterclockwise while pushing it at the same time. Installation To install, follow the removal steps in the reverse order. Accelerator Pedal Position Sensor - MIL ON/DTC's Set Technical Service Bulletin # 01-047 Date: 010814 Accelerator Pedal Position Sensor - MIL ON/DTC's Set 01-047 August 14, 2001 Applies To: 2000-01 Passport - ALL MIL Comes On With Accelerator Pedal Position Sensor DTC(s) P1271, P1273, P1275, P1280, and/or P1285 SYMPTOM The MIL is on with DTC P1271, P1273, P1275, P1280, or P1285 (various accelerator pedal position sensor problems) stored. The REDUCED POWER indicator may also be on; and the engine may occasionally idle too high, or the idle may fluctuate. PROBABLE CAUSE Contaminated grease on the potentiometer circuit board of the accelerator pedal position sensor (APPS) causes high resistance in the APPS circuit. CORRECTIVE ACTION Replace and adjust the APPS, remove all grease from the accelerator link, and clean the APPS harness connector and connector C123. PARTS INFORMATION Accelerator Pedal Position Sensor: P/N 8-97193-713-0, H/C 6198311 REQUIRED MATERIALS CAIG DeoxIT D5-S6 Contact Cleaner: P/N 341-200 (available from www.partsexpress.com) or Permatex Electrical Contact Cleaner: Permatex P/N 24379 WARRANTY CLAIM INFORMATION In warranty: The normal warranty applies. Operation Number: 122114 Flat Rate Time: 0.5 hour Failed Part: P/N 8-97220-540-0 H/C 6202436 Defect Code: 091 Contention Code: C99 Template ID: 01-047A Skill Level: Repair Technician Out of warranty: Any repair performed after warranty expiration may be eligible for goodwill consideration by the District Service Manager or your Zone Office. You must request consideration, and get a decision, before starting work. Page 5222 Auxiliary Power Outlet: Service and Repair Rear Accessory Power Socket Removal 1. Disconnect the battery ground cable. 2. Remove the quarter trim lower cover. 3. Remove the rear accessory socket (2). - Disconnect the connectors (1). - Pull out the front accessory socket from the socket cover (3). Installation To install, follow the removal steps in the reverse order, noting the following point: Page 5064 Part 1 of 2 Part 2 of 2 B-20 FL Speed Sensor Missing (DTC 61/C0226, C0227) Chart B-20 FL Speed Sensor Missing (DTC 61 (Flash Out) / C0226, C0227 (Serial Communications)) Page 5253 2. Unfasten C123 from the side of the engine compartment using a 90-degree pick. 3. Disconnect C123, and clean the terminals on both sides of the connector with contact cleaner. Shake the residue out of the connector. Allow the contact cleaner to evaporate for at least 3 minutes, then reconnect C123. 4. Fasten C123 to the left side of the engine compartment, and reinstall the air cleaner housing cover. 5. Remove the connector position assurance (CPA) clip from the APPS connector. 6. Disconnect the lop connector from the APPS. 7. Clean the terminals of the 10P APPS connector (harness side) with contact cleaner. Shake out residue from the connector, and allow the contact cleaner to evaporate for at least 3 minutes, then reconnect it. 8. Use the Smart Cable to reprogram the PCM with the latest software from the June 2001 or later HONDANET CD-ROM. Refer to Service Bulletin 99-005, Updating the Passport PCM, filed under Tools. 9. Use the PGM Tester to clear any DTCs. Page 7529 The wire insulation has one color or one color with another color stripe. The second color is the stripe. Page 5994 Splices Splices are shown as a dot. Their location and the number of wires may vary depending on the harness manufacturer. Switches Switches These switches move together; the broken straight line between them means they are mechanically connected. Other types of switches are controlled by a coil or a solid state circuit. Unless otherwise noted, all switches are shown in their normal (rest) position, with power off. Terminal "T" Page 7636 Splices Splices are shown as a dot. Their location and the number of wires may vary depending on the harness manufacturer. Switches Switches These switches move together; the broken straight line between them means they are mechanically connected. Other types of switches are controlled by a coil or a solid state circuit. Unless otherwise noted, all switches are shown in their normal (rest) position, with power off. Terminal "T" Page 3714 2. Connect the short finder across the battery terminals and the load (component) side of the fuse terminal. 3. Close all switches in the circuit you're testing. 4. Turn on the short finder. This creates a pulsing magnetic field around the wiring between the fuse box and the short. 5. Beginning at the fuse box, slowly move the short finder along the circuit wiring. The meter will read current pulses through sheet metal and body trim. As long as the meter is between the fuse and the short, the needle will move with each current pulse. Once you move the meter past the point of the short, the needle will stop moving. Check the wiring and connectors in this area to locate the cause of the short. Testing For Continuity When testing for continuity at a connector without wire seals, you do not have to separate the two halves of the connector. Instead, probe the connector from the back. Always check both sides of the connector because dirty, corroded, and bent terminals can cause problems (no electrical contact = an open). 1. Disconnect the negative cable from the car battery. If you're using a DVOM, place it in the lowest "OHMS" range. Page 2224 This sample Ground Distribution schematic shows all of the components that share two ground points. Components A solid border line means the entire component is shown. A broken border line indicates that only part of the component is shown. Page 7389 The wire insulation has one color or one color with another color stripe. The second color is the stripe. Page 4059 Shift Solenoid: Service and Repair REMOVAL 1. Raise the vehicle and support it on jack stands. 2. Disconnect battery ground cable. 3. Drain fluid. 4. Remove sixteen 10 mm screws, main case oil pan, magnet, and gasket. 5. Remove three 13 mm screws, oil filter. 6. Disconnect wiring harness from band control solenoid and shift solenoids. Pull only on connectors, not on wiring harness. 7. Remove spring pin for shift solenoid A, shift solenoid B, and band control solenoid respectively, using suitable pliers taking care not to damage solenoids. 8. Remove shift solenoid A, shift solenoid B, band control solenoid, and gaskets from main case valve body. Do not pull on wiring harness. Remove solenoids by grasping the metal tip. INSTALLATION 1. Install shift solenoid A, shift solenoid B, band control solenoid with new gaskets to main case valve body respectively. 2. Carefully install spring pin with hammer to avoid damage to valve body, etc. 3. Connect wiring harness to solenoids. 4. Install oil filter with a new gasket and the three 13 mm screws, tighten to the specified torque. Torque: 20 Nm (15 Ft. lbs.) Page 759 The wire insulation has one color or one color with another color stripe. The second color is the stripe. Page 6646 5. Insert a thin stainless steel ruler or a "Slim Jim" under the magazine, about 1-1/2" from the right side of the opening. 6. Push the ruler in until it presses against the eject lever at the back of the unit. 7. Slowly remove the ruler and magazine at the same time. Two-piece door model: 1. Remove the changer from the vehicle. 2. Remove the top cover plate from the changer, and look for a jammed tray. 3. If a tray is stuck in the player, reinstall the cover and replace the changer. If all the trays are in the magazine, insert a thin stainless steel ruler or a "Slim Jim" under the magazine, about 1/2" from the right side of the opening. 4. Push the ruler in until it presses against the eject lever at the back of the unit. 5. Slowly remove the ruler and magazine at the same time. Locations Brake Fluid Level Sensor/Switch: Locations Left Side Of Engine Compartment Locations Intake Air Temperature Sensor: Locations 26. Left Front of Engine Left Front Of Engine Locations Page 1884 catalyst is operating efficiently, the Bank 1 HO2S 1 and the Bank 2 HO2S 1 signals will be more active than the signals produced by the Bank 1 HO2S 2 and the Bank 2 HO2S 2 sensors. The catalyst monitor sensors operate the same as the fuel control sensors. The Bank 1 HO2S 2 and the Bank 2 HO2S 2 sensors" main function is catalyst monitoring, but they also have a limited role in fuel control. If a sensor output indicates a voltage either above or below the 450 mV bias voltage for an extended period of time, the PCM will make a slight adjustment to fuel trim to ensure that fuel delivery is correct for catalyst monitoring. A problem with the Bank 1 HO2S 2 signal circuit will set DTC P0137, P0138, or P0140, depending on the specific condition. A problem with the Bank 2 HO2S 2 signal circuit will set DTC P0157, P0158, or P0160, depending on the specific condition. A fault in the heated oxygen sensor heater element or its ignition feed or ground will result in lower sensor response. This may cause incorrect catalyst monitor diagnostic results. Page 5816 13. Tighten the bolts to the specified torque. Torque: 59 Nm (43 ft. lbs.) Page 6978 A battery voltage (B+) circuit which is only powered with the ignition switch in the ON, or START positions. Initiator The electrical component inside the air bag assembly which, when sufficient current flows, sets off the chemical reaction that inflates the air bag. "Initiator Assembly Resistance Test" Tests performed once each ignition cycle when no malfunctions are detected during "Turn-ON" or "Continuous Monitoring." This test checks for the correct SDM configuration for the vehicle, shorts to "Ignition 1 in the deployment loops, high resistance or opens in the "Driver Side High", "Driver Side Low", "Passenger Side High" and "Passenger Side Low" circuits and measures the resistance of the inflator assembly consisting of: 1. Initiators. 2. SRS coil assembly (driver side only). 3. Connectors and associated wiring. Normal Operating Voltage Range The voltage measured between the SDM "Ignition 1" terminals and "Ground" terminals is between 9 and 16 volts. Passenger Current Source An output of the SDM which applies current into the passenger air bag assembly circuit during the "Initiator Assembly Resistance Test". Passenger Air Bag Assembly An assembly located in the right side of the instrument panel consisting of an inflatable bag, an inflator and an initiator. Scan Tool An external computer used to read diagnostic information from on-board computers via the data link connector. SDM Sensing and Diagnostic Module which provides reserve energy to the deployment loops, deploys the air bags when required and performs diagnostic monitoring of all SRS components. Serial Data Information representing the status of the SRS. SRS Supplemental Restraint System. SRS Coil Assembly An assembly of two current-carrying coils in the driver deployment loop that allows the rotation of the steering wheel while maintaining the continuous contact of the driver deployment loop to the driver air bag assembly. SRS Wiring Harness The wires and connectors that electrically connect the components in the SRS. "Turn-ON" Test which the SDM performs on the SRS once during each ignition cycle immediately after "Ignition 1" voltage is applied to the SDM and before "Continuous Monitoring". Page 7270 Sunroof/Moonroof Limit Switch: Service and Repair Limit Switch Removal 1. Disconnect the battery ground cable. 2. Remove the sunroof drive unit assembly (1) to remove the limit switch (2). Installation To install, follow the removal steps in the reverse order. Page 3698 Each schematic represents one circuit. A circuit's wires and components are arranged to show current flow, from power at the top of the page, to ground, at the bottom. Shared Circuits Other circuits may share power or ground terminals or wiring with the circuit shown. A wire that connects one circuit to another, for example, is cut short and has an arrowhead at the end of it pointing in the direction of current flow. Next to the arrowhead is the name of the circuit or component which shares that wiring. To quickly check shared wiring, check the operation of a component it serves. If that component works, you know the shared wiring is OK. Connectors All in-line and junction connectors are numbered (C725, C416, etc.). Component connectors are not numbered but are identified either by the name of Page 8226 has a 20 mm (0.79 in) junction at middle of the base of the glass. NOTE: Apply an adhesive 3 minutes or more but within 24 hours after the application of primer. If more than 24 hours have passed, reapply primer. Adhesive should be handled as follows: 1. Use the adhesive manufactured 3 months or less ago. 2. Wipe off adhesive-stains on positions other than requires application. 7. Install the windshield. - Set the windshield with sealing adhesive applied to entire circumference in the body panel. Specifically, adjust windshield support with the upper molding making contact with the body panel, press the glass, and tighten the windshield support. NOTE: Affix the glass within 5 minutes of application. 8. Install the front cowl cover. 9. Install side molding. - Use white gasoline and a soft cloth to wipe away any excess adhesive. - Cure the bonding at a temperature of 20° C - 30 ° C (68 ° F - 86 ° F) for 24 hours. - Check that the windshield does not leak water 10. Install windshield wiper arm. Page 1358 Tires: Pressure, Vacuum and Temperature Specifications Tires Pressure (P225/75R16) Front/Rear 200 kPa Pressure (P245/70R16) Front/Rear 180 kPa Testing and Inspection Blower Motor Relay: Testing and Inspection 1. Disconnect the heater relay (X-1). - When removing the connector for relay unfasten the tank lock of the connector by using a screwdriver, then pull the relay (1) out. 2. Check for continuity between the heater relay (X-1) terminals. Page 5087 Ignition Switch Lock Cylinder: Testing and Inspection TESTING AND INSPECTION Turn the ignition switch to "ON" while watching warning light. The light should flash 7 times and then go off. Specifications Harmonic Balancer - Crankshaft Pulley: Specifications Crankshaft Pulley 167 Nm Page 4990 B-14 FR Dump Solenoid Valve Failure (DTC 44/C0242, C0244) Chart B-14 FR Dump Solenoid Coil Failure (DTC 44 (Flash Out) / C0242, C0244 (Serial Communications)) Part 1 of 2 Part 2 of 2 Page 2513 Terminals - "T" Each "T" terminal (ring type) is numbered for reference and location. A "T" terminal is secured with a screw or bolt. Wires Page 5700 4. Fit the top of the shock absorber rod in the connection part of the actuator. NOTE: The mating section is width fitting across flats. 5. If these normally fit, the distance between the actuator lower face and the bracket upper face is about 1 mm. 6. Install 2 screws then tighten it to the specified torque. Torque: 3 Nm (26 in. lbs.) 7. Connect the connector to the harness and insert the connector to the bracket. 8. Connect the actuator harness with the clip. 9. Connect the battery ground cable. Page 3414 2. Connect one lead of a self-powered test light or DVOM to one end of the part of the circuit you want to test. 3. Connect the other lead to the other end. 4. If the self-powered test light glows, there is continuity. If you're using a DVOM, a low reading or no reading (zero), means good continuity. Testing For Voltage When testing for voltage at a connector without wire seals, you do not have to separate the two halves of the connector. Instead, probe the connector from the back. Always check both sides of the connector because dirty, corroded, and bent terminals can cause problems (no electrical contact = an open). 1. Connect one lead of the lest light to a known good ground, or, if you're using a digital volt ohmmeter (DVOM), place it in the appropriate DC volts range, and connect its negative lead to ground. 2. Connect the other lead of the test light or DVOM to the point you want to check. 3. If the test light glows, there is voltage present. If you're using a DVOM, note the voltage reading. It should be within one volt of measured battery voltage. A loss of more than one volt indicates a problem. NOTE: Always use a DVOM on high impedance circuits. A test light may not glow (even with battery voltage present). Testing For Voltage Drop Wires, connectors, and switches are designed to conduct current with a minimum loss of voltage. A voltage drop of more than one volt indicates a problem. 1. Place the digital volt/ohmmeter (DVOM) in the appropriate DC volts range. Connect the positive lead to the end of the wire (or to the connector or switch) closest to the battery. 2. Connect the negative lead to the other end of the wire (or the other side of the connector or switch). 3. Turn on the components in the circuit. 4. The DVOM will show the difference in voltage between the two points. A difference, or drop, of more than one volt indicates a problem. Check the circuit for loose, dirty, or bent terminals. Page 6927 3. Remove the front turn signal light assembly. - Remove the fixing screw and disconnect the connector. 4. Remove the front mud flap. 5. Remove the inner liner. 6. Remove the antenna assembly. 7. Remove the front fender panel. - Remove the eight fixing bolts. Page 4558 The wire insulation has one color or one color with another color stripe. The second color is the stripe. Page 7384 Splices Splices are shown as a dot. Their location and the number of wires may vary depending on the harness manufacturer. Switches Switches These switches move together; the broken straight line between them means they are mechanically connected. Other types of switches are controlled by a coil or a solid state circuit. Unless otherwise noted, all switches are shown in their normal (rest) position, with power off. Terminal "T" Locations Page 7535 Headlamp Reminder Indicator: Electrical Diagrams Seat Belt, Lights-ON and Ignition Key Reminders Part 1 Of 2 Diagrams Transmission Mode Switch: Diagrams Page 5815 2. Tighten the hub nut to the value given below, using a spring scale on the wheel pin. New bearing and New oil seal Bearing Preload: 20 N - 25 N (4.4 lbs. - 5.5 lbs.) Used bearing and New oil seal Bearing Preload: 12 N - 18 N (2.6 lbs. - 4.0 lbs.) If the measured bearing preload is outside the specifications, adjust it by loosening or tightening the bearing nut. 9. Install lock washer and lock screw in the following manner. - Turn the side with larger diameter of the tapered bore to the vehicle outer side, then attach the washer. - If the bolt holes in the lock plate are not aligned with the corresponding holes in the nut, reverse the lock plate. - If the bolt holes are still out of alignment, turn in the nut just enough to obtain alignment. - Screw is to be fastened tightly so its head may come lower than the surface of the washer. 10. Apply adhesive (LOCTITE 515 or equivalent) to both joining flange faces then install hub flange. 11. Install snap ring and shim. Adjust the clearance between the freewheeling hub body and the snap ring. Clearance: 0 mm - 0.3 mm (0 inch - 0.012 inch) Shims Available: 0.2 mm, 0.3 mm, 0.5 mm, 1.0 mm (0.008 inch, 0.012 inch, 0.020 inch, 0.039 inch) 12. Install hub cap. Page 7793 The wire insulation has one color or one color with another color stripe. The second color is the stripe. Page 4258 Pinion Gear: Service and Repair For further information regarding this component and the system that it is a part of, please refer to Differential; Service and Repair; Unit Overhaul Page 1374 Tires: Service and Repair Inflation of Tires Tire pressure, in cold condition (after vehicle has set for three hours or more, and driven less than one mile) should be checked monthly or before any extended trip. Tire pressure increases approximately 15% when the tires become hot during driving. Tire pressure specification is shown on the label located on the left door lock pillar. NOTE: Check the tire pressure whenever irregular wear is found. Tire inflation greatly affects tire wear. If the alignment check does not reveal any alignment problems, check the condition of the shock absorbers and wheel/tire balance. Page 427 Fan Control Switch Page 1880 TWC RH and Forked Exhaust Pipe and Associated Parts Page 4441 it is located, and what it connects to. Use the Connector Views to help locate the proper cavity when you need to probe a connector. It can be especially helpful if the connector has more than one wire of the same color. A dash symbol (-) indicates that the cavity is empty. Connector views can also be used to help diagnose multiple symptoms in separate circuits which could be caused by a single problem in a connector shared by those circuits. Here's an example: 1. Pick one of the multiple symptoms and look up the schematic for that circuit. 2. Make a list of all the in-line and fuse box connectors in that schematic , 3. Then, in the Connector Views, look up each connector on your list to see if circuits related to the other symptoms run through one of them. If they do, inspect that connector for the problem. Example: The blower, rear window defogger, and the windshield wiper don't work. List all in-line and fuse box connectors in the blower controls circuit and then check the Connector View (see the sample). You find that C324 is common to the blower controls, rear window defogger, and wiper/washer, so you inspect C324 and find the problem, bent terminals. Finding Component/Connector Locations Finding Component/Connector Locations To see where a component or connector is located on the car, look up its photo number in the "Component Location". The photo will also tell you the color of the connector, and how many cavities it has. Page 3603 Ion Sensing Module: Service and Repair ION Sensing Module REMOVAL PROCEDURE 1. Disconnect the negative battery cable. 2. Disconnect the ION sensing module connector. 3. Remove the bolts and the ION sensing module from the common chamber. INSTALLATION PROCEDURE 1. Install the ION sensing module on the common chamber with the bolts. Tighten Tighten the ION sensing module to 4 N.m (35 lb in.). 2. Connect the ION sensing module connectors as shown in the illustration. Page 2835 14. While watching the APP Sensor values in the Engine Data List, adjust the APPS by turning it until the values are within the ranges shown at closed throttle and wide open throttle (accelerator pedal pushed all the way down), then tighten the mounting screws and recheck the values. ^ If all three sensors are within range, go to step 23. ^ If APP Sensor 1 APP Sensor 2, and/or APP Sensor 3 cannot be brought into range, go to step 15. 15. Troubleshoot for an open circuit or a PCM malfunction. ^ If APP Sensor 1 has a value of 0% or APP Sensor 2 and/or APP Sensor 3 have a value of 99%, an open circuit exists or the PCM is malfunctioning. Repair the circuit or replace the PCM, and repeat step 14. ^ If you don't find a problem, go to step 16. 16. Disconnect the 10 P connector from the APPS. 17. View the APP Sensor values in the Engine Data List. ^ If APP Sensor 1 has a value of 0% or APP Sensor 2 and/or APP Sensor 3 have a value of 99%, go to step 18. ^ If APP Sensor 1 has a value other than 0%, or APP Sensor 2 and/or APP Sensor 3 have a value other than 99%, a short circuit exists or the PCM is malfunctioning. Repair the circuit or replace the PCM, and repeat step 14. 18. Modify the original APPS by cutting the connector housing off of the sensor. 19. Connect the 10 P connector to the modified APPS connector housing. Page 2018 Fuel Pump Relay: Diagnostic Aids Before Troubleshooting Before Troubleshooting See: Service Precautions/Vehicle Damage Warnings/Tips and Precautions 1. Check applicable fuses in the appropriate fuse/relay box. 2. Check the battery for damage, state of charge, and clean and tight connections. CAUTION: Do not quick-charge a battery unless the battery ground cable has been disconnected, otherwise you will damage the alternator diodes. - Do not attempt to crank the engine with the battery ground cable loosely connected or you will severely damage the wiring. While You're Working 1. Make sure connectors are clean, and have no loose terminals or receptacles. 2. Make sure that connectors without wire seals are packed with dielectric (silicone) grease. Part Number: 08798-9001. 3. When connecting a connector, push it until it "clicks" into place. CAUTION: Do not pull on the wires when disconnecting a connector. Pull only on the connector housings. - Most circuits include solid-state devices. Test the voltages in these circuits only with a 10-megaohm or higher impedance digital multi meter. Never use a test light or analog meter on circuits that contain solid-state devices. Damage to the devices may result. Five-Step Troubleshooting 1. Verify The Complaint Turn on all the components in the problem circuit to check the accuracy of the customer complaint. Note the symptoms. Do not begin disassembly or testing until you have narrowed down the problem area. 2. Analyze The Schematic Look up the schematic for the problem circuit. Determine how the circuit is supposed to work by tracing the current paths from the power source through the circuit components to ground. Also, trace circuits that share wiring with the problem circuit. The names of circuits that share the same fuse, ground, or switch, and so on, are referred to in each circuit schematic. Try to operate any shared circuits you didn't check in step 1. If the shared circuits work, the shared wiring is OK, and the cause must be in the wiring used only by the problem circuit. If several circuits fail at the same time, the fuse or ground is a likely cause. Based on the symptoms and your understanding of the circuit's operation, identify one or more possible causes. 3. Isolate The Problem By Testing The Circuit Make circuit tests to check the diagnosis you made in step 2. Keep in mind that a logical, simple procedure is the key to efficient troubleshooting. Test for the most likely cause of failure first. Try to make tests at points that are easily accessible. 4. Fix The Problem Once the specific problem is identified, make the repair. Be sure to use proper tools and safe procedures. 5. Make Sure The Circuit Works Turn on all components in the repaired circuit in all modes to make sure you've fixed the entire problem. If the problem was a blown fuse, be sure to test all of the circuits on that fuse. Make sure no new problems turn up and the original problem does not recur. Locations Page 8145 Power Window Switch: Service and Repair Passenger's Window Switch Replacement Removal 1. Disconnect the battery ground cable. 2. Remove the switch (1). - Pull out the switch by pushing the spring with the tip of a screwdriver. - Disconnect the connector. Installation To install, follow the removal steps in the reverse order. Page 1490 5. Install oil gallery (7) and tighten the bolts in 2 steps, in the order shown. 1st step: 29 Nm (22 ft. lbs.) 2nd step: 55° - 65° 6. Cylinder block side bolts (6) - Tighten all the bolts to the specified torque in the order shown. Note: Do not apply engine oil to the crank case side bolts. Torque: 39 Nm (29 ft. lbs.) 7. Install oil pump assembly (5). 8. Install oil strainer and O-ring (4). 9. Install oil pipe and O-ring (3) and tighten the bolts. Torque: 25 Nm (18 ft. lbs.) 10. Install crankcase with oil pan (2). 1. Completely remove all residual sealant, lubricant and moisture from the sealing surfaces. The surfaces must be perfectly dry. 2. Apply a correct width bead of sealant (TB-1207C or its equivalent) to the contact surfaces of the oil pan. There must be no gaps in the bead. 3. The crankcase assembly must be installed within 5 minutes after sealant application. Page 1046 Alignment: Service and Repair Trim Height Adjustment TRIM HEIGHT Adjust the trim height (1) by means of the adjusting bolt on the height control arms. CAUTION: When adjusting front end alignment, be sure to begin with trim height first, as it may change other adjusted alignments. 1. Check and adjust the tire inflation pressures. 2. Park the vehicle on a level ground and move the front of the vehicle up and down several times to settle the suspension. 3. Make necessary adjustment with the adjusting bolt on the height control arms. Trim height: 119 ± 5 mm (4.69 ± 0.2 inch) CASTER Page 5826 Supportable Point: Rear - Position the chassis stands at the bottom of the rear axle case. A/T - Fixing Banjo Bolt Leaks Fluid Line/Hose: Technical Service Bulletins A/T - Fixing Banjo Bolt Leaks SOURCE: Honda Service News TITLE: Fixing A/T Banjo Bolt Leaks APPLIES TO: All models SERVICE TIP: Got ATF leaking from any of the A/T banjo bolts? The first thing you need to do is replace the sealing washers. Next, start threading the banjo and line bracket bolts in their holes. Finally, torque the banjo bolt to 31 Nm (22 lb-ft) and the line bracket bolt to 9.8 Nm (7.2 lb-ft.). NOTE: The banjo bolt torque spec we're recommending is slightly higher than what's listed in the S/M. This is intentional. If you torque just the banjo bolt, you won't really fix the leak. ATF leaks at the banjo bolt stem from the line bracket getting tightened before the banjo bolt. This can misalign the banjo joint, causing the banjo bolt sealing washers not to contact their mating surfaces evenly. Once the sealing washers have been used, you must replace them. Page 3434 6. Remove the connector position assurance (CPA) clip from the APPS connector. 7. Disconnect the 10 P connector from the APPS. 8. Remove the bolts, the APPS, the spacer, and the accelerator link from the accelerator pedal assembly. 9. Separate the spacer from the APPS. Clean the grease off the spacer and the accelerator link with a clean shop towel. 10. Clean the terminals of the 10 P APPS connector (harness side) with contact cleaner. Shake the residue out of the connector, and allow the contact cleaner to evaporate for at least 3 minutes before reconnecting the connector. 11. Install a new APPS, the spacer, and the accelerator link onto the accelerator pedal assembly. Leave the mounting screws loose so the sensor can be adjusted. 12. Connect the 10 P connector to the new APPS, and lock the connector in place with the CPA. 13. Connect the PGM Tester to the data link connector (DLC), and turn the ignition switch to ON (II). Page 3368 Wires Wire insulation can be one color, or one color with another color stripe. (The second color is the stripe.) This circuit continues on another image. (The arrow shows direction of current flow.) To follow the RED/BLK wire in this example, you would turn to "Fuel and Emissions" and look for the "A" arrow. Page 2976 This means the branch of the wire connects to another circuit. The arrow points to the name of the circuit branch where the wire continues. Page 706 H/C 4408092 Defect Code: 017 Contention Code: C99 Skill Level: Repair Technician Out of warranty: Any repair performed after warranty expiration may be eligible for goodwill consideration by the District Service Manager or your Zone Office. You must request consideration, and get a decision, before starting work. DISCLAIMER RH TWC and Forked Exhaust Pipe and Associated Parts Catalytic Converter: Diagrams RH TWC and Forked Exhaust Pipe and Associated Parts TWC RH and Forked Exhaust Pipe and Associated Parts Page 186 - If the data list changes, the Fuel Pump Relay is normal. Page 4975 Brake Hose/Line: Service and Repair Rear Brake Hose REMOVAL 1. Raise the vehicle and support it with suitable safety stands. 2. Remove wheel and tire assembly. 3. Clean dirt, grease, and other foreign material off the hose fittings at both ends. 4. Disconnect brake pipe. 5. Remove clip. 6. Remove brake pipe. 7. Remove bolt. 8. Remove hose. INSTALLATION To install, follow the removal steps in the reverse order noting the following points. 1. Tighten the brake pipes to the specified torque Torque: 16 Nm (12 ft. lbs.) 2. Tighten the bolt to the specified torque. Torque: 15 Nm (11 ft. lbs.) After installing the brake hoses, bleed the brakes. Page 6389 SRS-Air Bag Page 592 7. Modify the original APPS by cutting the connector housing off of the sensor. 8. Connect the 10P connector to the modified APPS connector housing. 9. Using a DVOM, check the voltage between the reference voltage pin for each sensor and ground. ^ If the sensor circuits all read 5.0 volts, go to step 11. ^ If any sensor circuit is above or below 5.0 volts, go to step 10. 10. Troubleshoot for an internal short in another sensor or a PCM malfunction. ^ To find the sensor with an internal short, monitor the incorrect reference voltage, and disconnect each sensor (FTPS, EGR, MAP, TPS, CKP, and CMP) one at a time until the reference voltage reads 5.0 volts. Replace that sensor, and repeat step 3. ^ To find a malfunctioning PCM, replace it with a known-good PCM. If all three sensors (APP Sensor 1, APP Sensor 2, and APP Sensor 3) are within range, the original PCM is faulty; replace it and repeat step 3. Locations Page 1129 Drive Belt: Service and Repair Drive Belt and Cooling Fan The drive belt adjustment is not required as automatic drive belt tensioner is equipped. Inspection Check drive belt for wear or damage, and replace with a new one as necessary. Installation 1. Install cooling fan assembly and tighten bolts/nuts to the specified torque. Torque: 22 Nm (16 ft. lbs.) for fan pulley and fan bracket. Torque: 7.5 Nm (66.4 inch lbs.) for fan and clutch assembly. Note: Fan belts for 6VD1 Gasoline Engine mounted on 98-> Passport have been brought into one. As a result, the rotating direction of a fan belt is opposite to the direction of cooling fan for <-97 Passport 3.2 with no interchangeability. Therefore, incorrect installation of a fan may cause the air for cooling to now in the opposite direction, this resulting in the poor performance of the air-conditioner and a rise temperature in engine cooling water. Locations Fan Control Switch Page 5238 Service and Repair Fuel Gauge Sender: Service and Repair Removal and Installation As for removal and installation of the Fuel Gauge Unit, refer to "Fuel Tank" as the fuel gauge unit is combined with the fuel pump and sender assembly. Page 4803 Wheel Speed Sensor: Description and Operation It consists of a sensor and a rotor. The sensor is attached to the knuckle on the front wheels and to the rear axle case on the rear differential. The rotor is press-fit in the axle shaft. The flux generated from electrodes magnetized by a magnet in the sensor varies due to rotation of the rotor, and the electromagnetic induction generates alternating voltage in the coil. This voltage draws a "sine curve" with the frequency proportional to rotor speed and it allows detection of wheel speed. Page 1207 Fluid - Differential: Fluid Type Specifications Front and Rear Differential Grade ................................................................................................................................................... ................................................................... API GL-5 Viscosity: Below 50° F (10° C) Front ................................................................................................................... ............................................................................... SAE 75W-90 synthetic Rear ................................ .............................................................................................................................................................. ........... SAE 80 or 80W-90 From 0° F to 90° F (-18° C to 32° C) Front .......................................................................................... ........................................................................................................ SAE 75W-90 synthetic Rear ....... .............................................................................................................................................................. .................................... SAE 90 or 80W-90 Above 50° F (10° C) consistently Front ............................................................................................... ...................................................................................... SAE 80W-90 or SAE 80W-140 Rear ............ .............................................................................................................................................................. ............................................... SAE 140 If your vehicle is equipped with the optional Limited Slip differential (on the rear axle), use GL-5 Limited Slip Differential Gear Lubricant together with Limited Slip Differential Gear Lubricant Additive (Part No. 8-01052-358-0) or equivalent. Use the correct viscosity for the existing ambient temperatures. Description and Operation Canister Vent Valve: Description and Operation EVAP Canister Vent Solenoid Located next to the canister, the vent solenoid opens to allow air into the EVAP system. Fresh air is necessary to completely remove gasoline fumes from the canister during purge. The EVAP vent solenoid closes to seal off the evaporative emissions system for leak testing. Page 1960 The connector cavity number is listed next to each terminal on the circuit schematic. The cavity / terminal shown is # 6. Diodes A rectifier diode works like a one way valve. It allows current to flow only in the direction of the arrow. A Zener diode blocks reverse current at normal voltages just like a rectifier diode. At high voltages, however, a Zener diode allows current to flow in reverse. Fuses Page 5869 Localized Tread Wear 1. Once spotty wear develops in tread due to hard braking or abrupt starting, localized wear tends to be promoted. Shoulder Wear (Generally Wear Develops In Outer Shoulder): 1. Camber or toe-in incorrect. 2. Shoulder wear caused by repeated hard-cornering. Wear In Shoulders At Points Opposed To Each Other 1. Tire or wheel out of round or distorted. 2. Play in bearings or ball joint. Engine Controls - High/Erratic Engine Idle Grounding Point: Customer Interest Engine Controls - High/Erratic Engine Idle 01-080 August 14, 2001 Applies To: 2000-02 Passport - ALL 2000-02 Passport: High or Erratic Idle SYMPTOM The engine occasionally idles at too high a speed, or the idle speed fluctuates. PROBABLE CAUSES The symptom could be the result of any of these conditions: ^ Loose or corroded engine or body ground ^ High resistance in the APPS ground circuit ^ PSP (power steering pressure) switch is internally shorted to ground ^ Fuel pressure regulator is leaking fuel into the intake manifold CORRECTIVE ACTION Diagnose the cause of the idle condition, and select the proper REPAIR PROCEDURE. PARTS INFORMATION REQUIRED MATERIALS REQUIRED SOFTWARE Each REPAIR PROCEDURE requires you to use the Smart Cable to reprogram the PCM with the latest software. To select the latest software from the CDROM, enter the year, model, engine, transmission, and emissions type (49-state or California). This gives you a list of broadcast codes. Select the broadcast code at the top of the list. WARRANTY CLAIM INFORMATION Refer to the Warranty Claim Information for each Repair Procedure. DIAGNOSIS 1. Find out from the customer when the high or erratic idle condition occurs and what the RPM range is: ^ Within 20 minutes of a cold start ^ After braking to a stop ^ All the time ^ Intermittently, with no set pattern Page 5913 it is located, and what it connects to. Use the Connector Views to help locate the proper cavity when you need to probe a connector. It can be especially helpful if the connector has more than one wire of the same color. A dash symbol (-) indicates that the cavity is empty. Connector views can also be used to help diagnose multiple symptoms in separate circuits which could be caused by a single problem in a connector shared by those circuits. Here's an example: 1. Pick one of the multiple symptoms and look up the schematic for that circuit. 2. Make a list of all the in-line and fuse box connectors in that schematic , 3. Then, in the Connector Views, look up each connector on your list to see if circuits related to the other symptoms run through one of them. If they do, inspect that connector for the problem. Example: The blower, rear window defogger, and the windshield wiper don't work. List all in-line and fuse box connectors in the blower controls circuit and then check the Connector View (see the sample). You find that C324 is common to the blower controls, rear window defogger, and wiper/washer, so you inspect C324 and find the problem, bent terminals. Finding Component/Connector Locations Finding Component/Connector Locations To see where a component or connector is located on the car, look up its photo number in the "Component Location". The photo will also tell you the color of the connector, and how many cavities it has. Page 6114 The connector cavity number is listed next to each terminal on the circuit schematic. The cavity / terminal shown is # 6. Diodes A rectifier diode works like a one way valve. It allows current to flow only in the direction of the arrow. A Zener diode blocks reverse current at normal voltages just like a rectifier diode. At high voltages, however, a Zener diode allows current to flow in reverse. Fuses Page 3627 INSTALLATION 1. Install lock cylinder assembly. 2. Install shift lock cable (for A/T). 3. Install cushion rubber. 4. Install snap ring. 5. Install Combination switch and SRS coil assembly. After installation of combination switch assembly, connect the combination switch wiring harness connector and the SRS 2-way connector located under the steering column. 6. Turn the SRS coil counterclockwise to full, return about 3 turns and align the neutral mark. CAUTION: When turning the SRS coil counterclockwise to full, stop turning if resistance is felt. Forced further turning may damage to the cable in the SRS coil. Page 4893 3. Use adjustable pliers to bottom the piston into the caliper bore. Be careful not to damage the piston dust boot and do not damage the flexible hose by twisting or pulling it. Install caliper assembly. Set caliper assembly in place. 4. Install lock bolt (5) and tighten the bolt to the specified torque. 5. Install wheel and tire assembly. 6. Pump the brake pedal several times to make sure that the pedal is firm. Check the brake fluid level in the reservoir after pumping the brakes. Page 7832 Testing For A Short With A Self-Powered Test Light or DVOM 1. Remove the blown fuse and disconnect the battery and load. 2. Connect one lead of a self-powered test light or digital volt/ohmmeter (DVOM) (switched to the lowest "OHMS" range) to the fuse terminal on the load side. 3. Connect the other lead to a known good ground. 4. Beginning near the fuse box, wiggle the harness. Continue this at convenient points about six inches apart while watching the test light or DVOM. 5. If the self-powered test light goes on or the DVOM displays a low reading or no reading (zero), there is a short to ground in the wiring near that point. Testing for a Short with a Test Light or DVOM 1. Remove the blown fuse and disconnect the load. 2. Connect a test light or digital volt/ohmmeter (DVOM), switched to the appropriate DC volts range, across the fuse terminals to make sure voltage is present. You might have to turn the ignition switch to ON; check the schematic to see. 3. Beginning near the fuse box, wiggle the harness. Continue this at convenient points about six inches apart while watching the test light or DVOM. 4. Where the test light goes , or the DVOM voltage drops to zero, there is a short to ground in the wiring near that point. NOTE: Always use a DVOM on high impedance circuits. A test light may not glow (even with battery voltage present). Testing For A Short With A Short Circuit Locator (Short Finder) 1. Remove the blown fuse. Leave the battery connected. Page 4812 Part 2 of 2 B-24 Wheel Speed Input Abnormality (DTC 65/C0238) Service and Repair Center Mounted Brake Lamp Bulb: Service and Repair Removal 1. Disconnect the battery ground cable. 2. Remove the cover. 3. Disconnect the connectors (2). 4. Remove the bulb (1). - Remove the socket by turning it counterclockwise. Installation To install, follow the removal steps in the reverse order. Page 3340 Splices Splices are shown as a dot. Their location and the number of wires may vary depending on the harness manufacturer. Switches Switches These switches move together; the broken straight line between them means they are mechanically connected. Other types of switches are controlled by a coil or a solid state circuit. Unless otherwise noted, all switches are shown in their normal (rest) position, with power off. Terminal "T" Page 3750 Part 2 Of 3 Page 4151 Clutch Switch: Adjustments 1. Turn the clutch switch (1) until the switch plunger is fully retracted against the clutch pedal arm. 2. Adjust clutch switch by backing it out half a turn and measure the clearance (4) between the clutch pedal arm (3) and the clutch switch. 3. Lock the lock nut (2). 4. Connect clutch switch connector. Clutch Switch (bolt) and Clutch Pedal Clearance 0.5 - 1.5 mm (0.020 - 0.059 in) Procedures Front Bumper Bracket: Procedures Removal 1. Disconnect the battery ground cable. 2. Remove the front bumper. 3. Remove the three nuts(1) and draw out the slider bracket(2). Installation To install, follow the removal steps in reverse order. Page 5607 Steering Gear: Service and Repair Overhaul DISASSEMBLY NOTE: The valve housing is made of aluminum and care should be exercised when clamping in a vise, etc. to prevent distortion or damage. 1. Loosen lock nut and remove tie-rod end. 2. Remove clip and band, then remove bellows. 3. Remove tie-rod assembly. To remove, move the boot toward the tie-rod end, then remove tab washer. 4. Remove oil line, mounting rubber and dust cover. INSPECTION AND REPAIR Inspect the following parts for wear, damage or any abnormal conditions. Tie-rod End If looseness or play is found when checked by moving the end of ball joint at tie-rod end, replace tie-rod end. Tie-rod Assembly If the resistance is insufficient or play is felt when checked by moving the ball on the tie-rod, replace the tie-rod assembly. Rubber Parts If wear or damage is found through inspection, replace with new ones. Page 2225 The name of the component appears next to it followed by notes about its function along with any photo and connector view references. Connector "C" How to Identify Connector Terminals Cavity Numbering System The cavities (and wire terminals) in each connector are numbered starting from the upper left, looking at the male terminals from the terminal side (or looking at the female terminals from the wire side. Both views are in the same direction so the numbers are the same.) All actual cavities are numbered, even if they have no wire terminals in them. NOTE: Data Link Connector (DLC) terminals are numbered according to SAE standard J1962, not the Honda standard. The numbers of the four end terminals are molded into the corners of the connector face. Page 7552 The SRS consists of the Sensing and Diagnostic Module (SDM), the driver air bag assembly, the SRS coil assembly, the passenger air bag assembly, and the "AIR BAG" warning lamp in the instrument cluster. The SDM, SRS coil assembly (driver side only), driver air bag assembly, passenger air bag assembly and connector wire make up the deployment loops. The function of the deployment loops is to supply current through air bag assembly, which will cause deployment of the air bags in the event of a frontal crash of sufficient force, up to 30 degrees off the centerline of the vehicle. The air bag assemblies are only supplied enough current to deploy when the SDM detects vehicle velocity changes severe enough to warrant deployment. The SDM contains a sensing device which converts vehicle velocity change to an electrical signal. The electrical signal generated is processed by the SDM and then compared to a value stored in memory. When the generated signal exceeds the stored value, the SDM will cause current to flow through the air bag assembly deploying the air bags. Page 5189 Measure inner diameter of bushing in the rear cover, and replace if it exceeds the limit. Standard: 12.50 mm to 12.527 mm (0.492 in to 0.4932 in) Limit: 12.60 mm (0.4961 in) Measure inner diameter of bushing in the center bracket (P), and replace if it exceeds the limit. Standard: 18.01 mm to 18.127 mm (0.7091 in to 0.7137 in) Limit: 18.15 mm (0.7146 in) Removal and Installation Valve Guide: Service and Repair Removal and Installation Valve Stem Oil Controller, Valve Spring and Valve Guide Removal 1. Disconnect battery ground cable. 2. Drain engine oil. - Drain engine coolant. 3. Remove cylinder head assembly. Refer to removal procedure for Cylinder Head. 4. Remove camshaft. Refer to removal procedure for Camshaft. 5. Remove tappets with shim. Note: Do not damage shim surface. 6. Remove valve springs using J-8062 valve spring compressor and J-42898 valve spring compressor adapter then remove upper valve spring seat and lower seat. 7. Remove oil controller using J-37281 oil controller remover, remove each valve stem oil controller. 8. Remove valve guide using J-37985 valve guide replacer. Installation 1. Install valve guide using J-42899 valve guide installer. 2. Install oil controller using J-38537 oil controller installer. 3. Install lower valve spring seat, valve spring and upper valve spring seat then put split collars on the upper spring seat, using J-8062 valve spring compressor and J-42898 valve spring compressor adapter to install the split collars. 4. Install tappet with shim. 5. Install camshaft assembly. Refer to installation procedure for Camshaft. 6. Install cylinder head assembly. Refer to installation procedure for Cylinder Head. 7. Fill engine oil until full level. 8. Fill engine coolant. Page 4350 Drive/Propeller Shaft: Specifications Shift on the Fly System SHIFT ON THE FLY SYSTEM General Specifications Right Front Drive Shaft And Shift On The Fly Assembly Torque Specifications Page 3409 The wire insulation has one color or one color with another color stripe. The second color is the stripe. Page 2369 Spark Plug: Specifications Plug Torque 13 ft lb (18 Nm) Page 852 Ignition Switch Lock Cylinder: Service and Repair REMOVAL 1. Turn the steering wheel so that the vehicle's wheels are pointing straight ahead. 2. Turn the ignition switch to "LOCK". 3. Disconnect the battery "-" terminal cable, and wait at least 5 minutes. 4. Disconnect the yellow 2-way SRS connector located under the steering column. CAUTION: The wheels of the vehicle must be straight ahead and the steering column in the "LOCK" position before disconnecting the steering wheel. Failure to do so will cause the coil assembly to become uncentered which will cause damage to the coil assembly. 5. Remove the engine hood opening lever and steering lower cover. 6. Remove knee bolster (reinforcement). Page 7390 Brake Warning Indicator: Diagnostic Aids Before Troubleshooting Before Troubleshooting See: Service Precautions/Vehicle Damage Warnings/Tips and Precautions 1. Check applicable fuses in the appropriate fuse/relay box. 2. Check the battery for damage, state of charge, and clean and tight connections. CAUTION: Do not quick-charge a battery unless the battery ground cable has been disconnected, otherwise you will damage the alternator diodes. - Do not attempt to crank the engine with the battery ground cable loosely connected or you will severely damage the wiring. While You're Working 1. Make sure connectors are clean, and have no loose terminals or receptacles. 2. Make sure that connectors without wire seals are packed with dielectric (silicone) grease. Part Number: 08798-9001. 3. When connecting a connector, push it until it "clicks" into place. CAUTION: Do not pull on the wires when disconnecting a connector. Pull only on the connector housings. - Most circuits include solid-state devices. Test the voltages in these circuits only with a 10-megaohm or higher impedance digital multi meter. Never use a test light or analog meter on circuits that contain solid-state devices. Damage to the devices may result. Five-Step Troubleshooting 1. Verify The Complaint Turn on all the components in the problem circuit to check the accuracy of the customer complaint. Note the symptoms. Do not begin disassembly or testing until you have narrowed down the problem area. 2. Analyze The Schematic Look up the schematic for the problem circuit. Determine how the circuit is supposed to work by tracing the current paths from the power source through the circuit components to ground. Also, trace circuits that share wiring with the problem circuit. The names of circuits that share the same fuse, ground, or switch, and so on, are referred to in each circuit schematic. Try to operate any shared circuits you didn't check in step 1. If the shared circuits work, the shared wiring is OK, and the cause must be in the wiring used only by the problem circuit. If several circuits fail at the same time, the fuse or ground is a likely cause. Based on the symptoms and your understanding of the circuit's operation, identify one or more possible causes. 3. Isolate The Problem By Testing The Circuit Make circuit tests to check the diagnosis you made in step 2. Keep in mind that a logical, simple procedure is the key to efficient troubleshooting. Test for the most likely cause of failure first. Try to make tests at points that are easily accessible. 4. Fix The Problem Once the specific problem is identified, make the repair. Be sure to use proper tools and safe procedures. 5. Make Sure The Circuit Works Turn on all components in the repaired circuit in all modes to make sure you've fixed the entire problem. If the problem was a blown fuse, be sure to test all of the circuits on that fuse. Make sure no new problems turn up and the original problem does not recur. Page 134 Locations Page 3292 and the fuses. From Fuses to Relays and Components The second half of Power Distribution shows the wiring "From Fuses to Relays and Components." This can speed your troubleshooting by showing which circuits share fuses. If Power Distribution shows that an inoperative circuit and another circuit share a fuse, check a component in the other circuit. If it works, you know the fuse is good and power is available to the inoperative circuit. Ground Distribution Schematics Page 3912 12. Install the new cover using the accumulator cover installation tool. 13. Reinstall the snap ring. 14. 2002 only: Reconnect the cooler return line, and tighten the bracket that secures the ATF cooler line. 15. Check the transmission fluid level, and refill as necessary with Dexron III ATF. Refer to the Automatic Transmission section of the appropriate Passport Service Manual. Disclaimer Page 1553 Valve Cover: Service and Repair Cylinder Head Cover RH Cylinder Head Cover RH Removal 1. Disconnect battery ground cable. 2. Disconnect ventilation hose from cylinder head cover. 3. Disconnect three ignition coil connectors from ignition coils and remove harness bracket bolts on cylinder head cover then remove ignition coil fixing bolts on ignition coils and remove ignition coils. 4. Remove heater pipe fixing bolts from the bracket. 5. Disconnect fuel injector harness connector then remove fuel injector harness bracket bolt. 6. Remove Exhaust Gas Recirculation (EGR) pipe. - Remove flare nut from EGR valve. - Remove fixing bolt of EGR pipe bracket on rear end cylinder head. - Remove two fixing bolt and nut on exhaust manifold. 7. Remove eight fixing bolts then the cylinder head cover. Installation Page 6729 it is located, and what it connects to. Use the Connector Views to help locate the proper cavity when you need to probe a connector. It can be especially helpful if the connector has more than one wire of the same color. A dash symbol (-) indicates that the cavity is empty. Connector views can also be used to help diagnose multiple symptoms in separate circuits which could be caused by a single problem in a connector shared by those circuits. Here's an example: 1. Pick one of the multiple symptoms and look up the schematic for that circuit. 2. Make a list of all the in-line and fuse box connectors in that schematic , 3. Then, in the Connector Views, look up each connector on your list to see if circuits related to the other symptoms run through one of them. If they do, inspect that connector for the problem. Example: The blower, rear window defogger, and the windshield wiper don't work. List all in-line and fuse box connectors in the blower controls circuit and then check the Connector View (see the sample). You find that C324 is common to the blower controls, rear window defogger, and wiper/washer, so you inspect C324 and find the problem, bent terminals. Finding Component/Connector Locations Finding Component/Connector Locations To see where a component or connector is located on the car, look up its photo number in the "Component Location". The photo will also tell you the color of the connector, and how many cavities it has. Page 4609 4WD Control Unit: Electrical Diagrams Part 1 Of 3 Fuel Control Heated Oxygen Sensors Oxygen Sensor: Description and Operation Fuel Control Heated Oxygen Sensors Fuel Control Heated Oxygen Sensors The fuel control heated oxygen sensors (Bank 1 HO2S 1 and Bank 2 HO2S 1) are mounted in the exhaust stream where they can monitor the oxygen content of the exhaust gas. The oxygen present in the exhaust gas reacts with the sensor to produce a voltage output. This voltage should constantly fluctuate from approximately 100 mV to 900 mV. The heated oxygen sensor voltage can be monitored with a Tech 2. By monitoring the voltage output of the oxygen sensor, the PCM calculates the pulse width command for the injectors to produce the proper combustion chamber mixture. - Low HO2S voltage is a lean mixture which will result in a rich command to compensate. - High HO2S voltage is a rich mixture which will result in a lean command to compensate. An open Bank 1 HO2S 1 signal circuit will set a DTC P0134 and the Tech 2 will display a constant voltage between 400 - 500 mV. A constant voltage below 300 mV in the sensor circuit (circuit grounded) will set DTC P0131. A constant voltage above 800 mV in the circuit will set DTC P0132. Faults in the Bank 2 HO2S 1 signal circuit will cause DTC 0154 (open circuit), DTC P0151 (grounded circuit), or DTC P0152 (signal voltage high) to set. A Fault in the Bank 1 HO2S 1 heater circuit will cause DTC P0135 to set. A fault in the Bank 2 HO2S 1 heater circuit will cause DTC P0155 to set. The PCM can also detect HO2S response problems. If the response time of an HO2S is determined to be too slow, the PCM will store a DTC that indicates degraded HO2S performance. Diagrams Transmission Mode Switch: Diagrams Accelerator Pedal Position Sensor - MIL ON/DTC's Set Technical Service Bulletin # 01-047 Date: 010814 Accelerator Pedal Position Sensor - MIL ON/DTC's Set 01-047 August 14, 2001 Applies To: 2000-01 Passport - ALL MIL Comes On With Accelerator Pedal Position Sensor DTC(s) P1271, P1273, P1275, P1280, and/or P1285 SYMPTOM The MIL is on with DTC P1271, P1273, P1275, P1280, or P1285 (various accelerator pedal position sensor problems) stored. The REDUCED POWER indicator may also be on; and the engine may occasionally idle too high, or the idle may fluctuate. PROBABLE CAUSE Contaminated grease on the potentiometer circuit board of the accelerator pedal position sensor (APPS) causes high resistance in the APPS circuit. CORRECTIVE ACTION Replace and adjust the APPS, remove all grease from the accelerator link, and clean the APPS harness connector and connector C123. PARTS INFORMATION Accelerator Pedal Position Sensor: P/N 8-97193-713-0, H/C 6198311 REQUIRED MATERIALS CAIG DeoxIT D5-S6 Contact Cleaner: P/N 341-200 (available from www.partsexpress.com) or Permatex Electrical Contact Cleaner: Permatex P/N 24379 WARRANTY CLAIM INFORMATION In warranty: The normal warranty applies. Operation Number: 122114 Flat Rate Time: 0.5 hour Failed Part: P/N 8-97220-540-0 H/C 6202436 Defect Code: 091 Contention Code: C99 Template ID: 01-047A Skill Level: Repair Technician Out of warranty: Any repair performed after warranty expiration may be eligible for goodwill consideration by the District Service Manager or your Zone Office. You must request consideration, and get a decision, before starting work. Page 856 7. When installing the steering column cover, be sure to wire (through each harness) as illustrated so that the harnesses starter switch, combination switch and SRS coil may not catch wiring. 8. Install steering wheel by aligning the setting marks made during removal. CAUTION: Never apply force to the steering wheel in direction of the shaft by using a hammer or other impact tools in an attempt to remove the steering wheel. The steering shaft is designed as an energy absorbing unit. 9. Tighten the steering wheel fixing nut to the specified torque. Torque: 34 Nm (25 ft. lbs.) 10. Support inflator module and carefully connect the SRS connector and horn lead, then install inflator module. NOTE: Pass the lead wire through the tabs on the plastic cover (wire protector) of inflator to prevent lead wire from being pinched. 11. Tighten fixing bolts to specified torque. Torque: 9 Nm (78 inch lbs.) 12. Install driver knee bolster (reinforcement). 13. Install instrument panel lower cover, then install the engine hood opening lever. 14. Connect the yellow 2-way SRS connector located under the steering column. 15. Connect the battery "-" terminal cable. Page 2073 6. Remove the connector position assurance (CPA) clip from the APPS connector. 7. Disconnect the 10 P connector from the APPS. 8. Remove the bolts, the APPS, the spacer, and the accelerator link from the accelerator pedal assembly. 9. Separate the spacer from the APPS. Clean the grease off the spacer and the accelerator link with a clean shop towel. 10. Clean the terminals of the 10 P APPS connector (harness side) with contact cleaner. Shake the residue out of the connector, and allow the contact cleaner to evaporate for at least 3 minutes before reconnecting the connector. 11. Install a new APPS, the spacer, and the accelerator link onto the accelerator pedal assembly. Leave the mounting screws loose so the sensor can be adjusted. 12. Connect the 10 P connector to the new APPS, and lock the connector in place with the CPA. 13. Connect the PGM Tester to the data link connector (DLC), and turn the ignition switch to ON (II). Page 7773 Brake Light Switch: Service and Repair REMOVAL 1. Disconnect connector (1) 2. Remove lock nut (3). 3. Remove switch (2). INSTALLATION 1. Adjust the stop light switch to the specified clearance (between switch housing and brake pedal) by rotating the switch housing. NOTE: Do not attempt to force the push rod into position during the stop light switch installation and adjustment procedure. 2. Connect connector (1). 3. Install lock nut (3). Page 4492 2. Connect one lead of a self-powered test light or DVOM to one end of the part of the circuit you want to test. 3. Connect the other lead to the other end. 4. If the self-powered test light glows, there is continuity. If you're using a DVOM, a low reading or no reading (zero), means good continuity. Testing For Voltage When testing for voltage at a connector without wire seals, you do not have to separate the two halves of the connector. Instead, probe the connector from the back. Always check both sides of the connector because dirty, corroded, and bent terminals can cause problems (no electrical contact = an open). 1. Connect one lead of the lest light to a known good ground, or, if you're using a digital volt ohmmeter (DVOM), place it in the appropriate DC volts range, and connect its negative lead to ground. 2. Connect the other lead of the test light or DVOM to the point you want to check. 3. If the test light glows, there is voltage present. If you're using a DVOM, note the voltage reading. It should be within one volt of measured battery voltage. A loss of more than one volt indicates a problem. NOTE: Always use a DVOM on high impedance circuits. A test light may not glow (even with battery voltage present). Testing For Voltage Drop Wires, connectors, and switches are designed to conduct current with a minimum loss of voltage. A voltage drop of more than one volt indicates a problem. 1. Place the digital volt/ohmmeter (DVOM) in the appropriate DC volts range. Connect the positive lead to the end of the wire (or to the connector or switch) closest to the battery. 2. Connect the negative lead to the other end of the wire (or the other side of the connector or switch). 3. Turn on the components in the circuit. 4. The DVOM will show the difference in voltage between the two points. A difference, or drop, of more than one volt indicates a problem. Check the circuit for loose, dirty, or bent terminals. Page 793 7. Modify the original APPS by cutting the connector housing off of the sensor. 8. Connect the 10P connector to the modified APPS connector housing. 9. Using a DVOM, check the voltage between the reference voltage pin for each sensor and ground. ^ If the sensor circuits all read 5.0 volts, go to step 11. ^ If any sensor circuit is above or below 5.0 volts, go to step 10. 10. Troubleshoot for an internal short in another sensor or a PCM malfunction. ^ To find the sensor with an internal short, monitor the incorrect reference voltage, and disconnect each sensor (FTPS, EGR, MAP, TPS, CKP, and CMP) one at a time until the reference voltage reads 5.0 volts. Replace that sensor, and repeat step 3. ^ To find a malfunctioning PCM, replace it with a known-good PCM. If all three sensors (APP Sensor 1, APP Sensor 2, and APP Sensor 3) are within range, the original PCM is faulty; replace it and repeat step 3. Page 3746 2. Connect the short finder across the battery terminals and the load (component) side of the fuse terminal. 3. Close all switches in the circuit you're testing. 4. Turn on the short finder. This creates a pulsing magnetic field around the wiring between the fuse box and the short. 5. Beginning at the fuse box, slowly move the short finder along the circuit wiring. The meter will read current pulses through sheet metal and body trim. As long as the meter is between the fuse and the short, the needle will move with each current pulse. Once you move the meter past the point of the short, the needle will stop moving. Check the wiring and connectors in this area to locate the cause of the short. Testing For Continuity When testing for continuity at a connector without wire seals, you do not have to separate the two halves of the connector. Instead, probe the connector from the back. Always check both sides of the connector because dirty, corroded, and bent terminals can cause problems (no electrical contact = an open). 1. Disconnect the negative cable from the car battery. If you're using a DVOM, place it in the lowest "OHMS" range. Page 7445 Clock: Diagnostic Aids Before Troubleshooting Before Troubleshooting See: Service Precautions/Vehicle Damage Warnings/Tips and Precautions 1. Check applicable fuses in the appropriate fuse/relay box. 2. Check the battery for damage, state of charge, and clean and tight connections. CAUTION: Do not quick-charge a battery unless the battery ground cable has been disconnected, otherwise you will damage the alternator diodes. - Do not attempt to crank the engine with the battery ground cable loosely connected or you will severely damage the wiring. While You're Working 1. Make sure connectors are clean, and have no loose terminals or receptacles. 2. Make sure that connectors without wire seals are packed with dielectric (silicone) grease. Part Number: 08798-9001. 3. When connecting a connector, push it until it "clicks" into place. CAUTION: Do not pull on the wires when disconnecting a connector. Pull only on the connector housings. - Most circuits include solid-state devices. Test the voltages in these circuits only with a 10-megaohm or higher impedance digital multi meter. Never use a test light or analog meter on circuits that contain solid-state devices. Damage to the devices may result. Five-Step Troubleshooting 1. Verify The Complaint Turn on all the components in the problem circuit to check the accuracy of the customer complaint. Note the symptoms. Do not begin disassembly or testing until you have narrowed down the problem area. 2. Analyze The Schematic Look up the schematic for the problem circuit. Determine how the circuit is supposed to work by tracing the current paths from the power source through the circuit components to ground. Also, trace circuits that share wiring with the problem circuit. The names of circuits that share the same fuse, ground, or switch, and so on, are referred to in each circuit schematic. Try to operate any shared circuits you didn't check in step 1. If the shared circuits work, the shared wiring is OK, and the cause must be in the wiring used only by the problem circuit. If several circuits fail at the same time, the fuse or ground is a likely cause. Based on the symptoms and your understanding of the circuit's operation, identify one or more possible causes. 3. Isolate The Problem By Testing The Circuit Make circuit tests to check the diagnosis you made in step 2. Keep in mind that a logical, simple procedure is the key to efficient troubleshooting. Test for the most likely cause of failure first. Try to make tests at points that are easily accessible. 4. Fix The Problem Once the specific problem is identified, make the repair. Be sure to use proper tools and safe procedures. 5. Make Sure The Circuit Works Turn on all components in the repaired circuit in all modes to make sure you've fixed the entire problem. If the problem was a blown fuse, be sure to test all of the circuits on that fuse. Make sure no new problems turn up and the original problem does not recur. Initial Inspection and Diagnostic Overview Powertrain Control Module: Initial Inspection and Diagnostic Overview 1. Perform the On-Board Diagnostic System Check. 2. Start the engine and run for one minute. 3. Scan for DTCs using the Tech 2. Service and Repair Front Door Window Glass Weatherstrip: Service and Repair Front Window Regulator, Glass and Glass Run Front Window Regulator, Glass And Glass Run Removal 1. Disconnect the battery ground cable. Page 2964 it is located, and what it connects to. Use the Connector Views to help locate the proper cavity when you need to probe a connector. It can be especially helpful if the connector has more than one wire of the same color. A dash symbol (-) indicates that the cavity is empty. Connector views can also be used to help diagnose multiple symptoms in separate circuits which could be caused by a single problem in a connector shared by those circuits. Here's an example: 1. Pick one of the multiple symptoms and look up the schematic for that circuit. 2. Make a list of all the in-line and fuse box connectors in that schematic , 3. Then, in the Connector Views, look up each connector on your list to see if circuits related to the other symptoms run through one of them. If they do, inspect that connector for the problem. Example: The blower, rear window defogger, and the windshield wiper don't work. List all in-line and fuse box connectors in the blower controls circuit and then check the Connector View (see the sample). You find that C324 is common to the blower controls, rear window defogger, and wiper/washer, so you inspect C324 and find the problem, bent terminals. Finding Component/Connector Locations Finding Component/Connector Locations To see where a component or connector is located on the car, look up its photo number in the "Component Location". The photo will also tell you the color of the connector, and how many cavities it has. Page 2953 Transmission Position Switch/Sensor: Service and Repair REMOVAL 1. Place selector lever in neutral. 2. Disconnect battery ground cable. 3. Remove mode switch cover (1). 4. Disconnect selector lever (2) from the mode switch. 5. Remove bracket with cable (3). 6. Disconnect transmission harness from the mode switch connector (4). 7. Remove bracket with mode switch connector from the transmission case. 8. Remove mode switch connector (4) from the bracket (5). 9. Remove two mode switch bolts and nut then remove mode switch (6). INSTALLATION To install, follow the removal steps in the reverse order, noting the following points; 1. Torque Mode switch bolt: 13 Nm (113 inch lbs.) Selector lever nut: 23 Nm (17 ft. lbs.) 2. Mode switch setting procedure. Perform either of the following adjustment procedures: Procedure 1 a. Place selector lever in neutral. b. Remove selector lever from the mode switch. c. Remove the mode switch cover. d. Loosen the two 10 mm screws. e. Rotate the mode switch until the slot in the mode switch housing aligns with the selector shaft bushing, and insert a 3/32 inch (2.4 mm) drill bit or punch (1) into the slot. f. Tighten the screws to 13 Nm (113 inch lbs.). g. After completing adjustment, snap the mode switch cover into place. h. Reinstall the selector lever. Procedure 2 a. Place selector lever in neutral. b. Disconnect transmission harness connector from mode switch connector. Page 836 Camshaft Position Sensor: Description and Operation Camshaft Position (CMP) Sensor and Signal The camshaft position (CMP) sensor sends a CMP signal to the PCM. The PCM uses this signal as a "sync pulse" to trigger the injectors in the proper sequence. The PCM uses the CMP signal to indicate the position of the #1 piston during its power stroke. This allows the PCM to calculate true sequential fuel injection (SFI) mode of operation. If the PCM detects an incorrect CMP signal while the engine is running, DTC P0341 will set. If the CMP signal is lost while the engine is running, the fuel injection system will shift to a calculated sequential fuel injection mode based on the last fuel injection pulse, and the engine will continue to run. As long as the fault is present, the engine can be restarted. It will run in the calculated sequential mode with a 1-in-6 chance of the injector sequence being correct. Refer to DTC P0341 for further information. CMP Signal The PCM uses this signal to determine the position of the number 1 piston during its power stroke, allowing the PCM to calculate true sequential multiport fuel injection (SFI). Loss of this signal will set a DTC P0341. If the CMP signal is lost while the engine is running, the fuel injection system will shift to a calculated sequential fuel injection based on the last fuel injection pulse, and the engine will continue to run. The engine can be restarted and will run in the calculated sequential mode as long as the fault is present, with a 1-in-6 chance of being correct. Page 2329 INSTALLATION 1. Install lock cylinder assembly. 2. Install shift lock cable (for A/T). 3. Install cushion rubber. 4. Install snap ring. 5. Install Combination switch and SRS coil assembly. After installation of combination switch assembly, connect the combination switch wiring harness connector and the SRS 2-way connector located under the steering column. 6. Turn the SRS coil counterclockwise to full, return about 3 turns and align the neutral mark. CAUTION: When turning the SRS coil counterclockwise to full, stop turning if resistance is felt. Forced further turning may damage to the cable in the SRS coil. Page 2716 Oxygen Sensor: Service and Repair HEATED OXYGEN SENSOR (HO2S) REMOVAL PROCEDURE 1. Disconnect the negative battery cable. 2. Locate the four oxygen sensors. - Bank 1 sensor 1 is mounted on the exhaust pipe ahead of the right-hand catalytic converter. - Bank 1 sensor 2 is mounted behind the right-hand catalytic converter. Page 2926 4. Remove the fuel pressure regulator from the fuel rail. 5. Remove the fuel return line from the regulator. 6. Install the new fuel pressure regulator in the reverse order of removal. 7. Use the Smart Cable to reprogram the PCM with the latest software from the June 2001 or later HONDANET CD-ROM. Refer to Service Bulletin 99-005, Updating the Passport PCM, filed under Tools. 8. Use the PGM Tester to clear any DTCs. 9. Use the PGM Tester to check the broadcast code. Make sure the broadcast code matches the one you selected from the CD-ROM. WARRANTY CLAIM INFORMATION In warranty: The normal warranty applies. Failed Part: P/N 8-17113-398-0 H/C 5504386 Defect Code: 092 Contention Code: C99 Skill Level: Repair Technician Out of warranty: Any repair performed after warranty expiration may be eligible for goodwill consideration by the District Service Manager or your Zone Office. You must request consideration, and get a decision, before starting work. REPAIR PROCEDURE - POWER STEERING SWITCH 1. Drain the power steering fluid out of the system. 2. Remove the power steering fluid reservoir. Clean the reservoir with solvent, then with soap and water. Rinse and dry it thoroughly. 3. Reinstall the reservoir. Do not connect the return hose. 4. Remove the power steering pressure switch, then clean it with brake cleaner and a scraper. Reinstall the switch, and torque it to 20 N.m (14 lb-ft). 5. Cover the unconnected end of the reservoir with your finger, then fill the reservoir with Dexron III ATF Page 3731 the component if the component only has one connector, or by a capital letter (A, B, C, etc.) if the component has more than one connector. Below most connector numbers and component names are PHOTO and VIEW numbers. The PHOTO number refers to a photo in the back of the book that shows the connector's location on the car. The VIEW number refers to an illustration in the back of the book that shows the connector face, wire colors, connector cavity numbers, and other details. The connector cavity numbering sequence begins at the top left corner of the connector. Disregard any numbers molded into the connector housing. Wires Wires are identified by the abbreviated names of their colors; the second color is the color of the stripe. Wires are also identified by their location in a connector. The number "2" next to the male and female wire terminals at C416, for example, means those terminals join in cavity 2 of connector C416. Symbols A complete description of schematic symbols is given under wire color abbreviation. Power Distribution Schematics Power Distribution schematics show how power is supplied from the positive battery terminal to various circuits in the car. Refer to the Power Distribution section to get a more detailed picture of how power is supplied to the circuit you're working on. From Battery to Ignition Switch, Fuses, and Relays Individual circuit schematics begin with a fuse. The first half of Power Distribution, however, shows the wiring "upstream" between the battery Page 2317 Crankshaft Position Sensor: Description and Operation Crankshaft Position (CKP) Sensor The crankshaft position (CKP) sensor provides a signal used by the powertrain control module (PCM) to calculate the ignition sequence. The CKP sensor initiates the 58X reference pulses which the PCM uses to calculate RPM and crankshaft position. Page 302 The wire insulation has one color or one color with another color stripe. The second color is the stripe. Page 7666 and the fuses. From Fuses to Relays and Components The second half of Power Distribution shows the wiring "From Fuses to Relays and Components." This can speed your troubleshooting by showing which circuits share fuses. If Power Distribution shows that an inoperative circuit and another circuit share a fuse, check a component in the other circuit. If it works, you know the fuse is good and power is available to the inoperative circuit. Ground Distribution Schematics Service and Repair Front Door Window Glass Weatherstrip: Service and Repair Front Window Regulator, Glass and Glass Run Front Window Regulator, Glass And Glass Run Removal 1. Disconnect the battery ground cable. Description and Operation Fuel Pump Pickup Filter: Description and Operation The filter is located on the lower end of fuel pickup tube in the fuel tank. It prevents dirt from entering the fuel pipe and also stops water unless the filter is completely submerged in the water. It is a self cleaning type, not requiring scheduled maintenance. Excess water and sediment in the tank restricts fuel supply to the engine, resulting in engine stoppage. In such a case, the tank must be cleaned thoroughly. Page 3110 Fuel Pressure: Service Precautions WARNING: Adhere to the following procedures any time the fuel system is being worked on in order to reduce the risk of fire and personal injury: - Keep a dry chemical (Class B) fire extinguisher near the work area. - Place a "CAUTION FLAMMABLE" sign in the work area. - Work in a well-ventilated area. Do not smoke, and keep sparks and open flames away. - Wear eye protection. - Use caution when working near the catalytic converter to prevent the possibility of burns or fire. (The temperatures within the converter can exceed 537 °C (1000 °F). - Relieve the fuel system pressure prior to disconnecting fuel system components. - Disconnect the negative battery cable except for tests where battery voltage is required. - Use a suitable container to store or catch fuel. - Do not replace fuel pipe with fuel hose. - Plug all disconnected fuel line fittings and hoses. - After making any fuel system repairs ALWAYS inspect for fuel leaks. Page 4230 Page 4323 12. Using snap ring pliers, install the snap ring (1) securing the ball retainer to the shaft. 13. Align the track on the ball (1) retainer with the window in the cage, and install the six balls into position. 14. Pack 150 g of the specified grease in DOJ case, then install drive shaft joint assembly. After reassembly, move the DOJ longitudinally several times to get to fit. 15. Install the circlip (1) so that open ends are positioned away from the ball groove. Page 3595 The wire insulation has one color or one color with another color stripe. The second color is the stripe. Page 8259 4. Tighten the wiper arm nut to the specified torque. Torque: 14 Nm (122 lb in) Page 4060 5. Install magnet, main case oil pan with new gasket, and sixteen 10 mm screws. Tighten the screws to the specified torque. Torque: 11 Nm (96 Inch lbs.) 6. Fill transmission through the overfill screw hole of oil pan, using ATF DEXRON-III. 7. Connect battery ground cable. Page 7681 2. Connect one lead of a self-powered test light or DVOM to one end of the part of the circuit you want to test. 3. Connect the other lead to the other end. 4. If the self-powered test light glows, there is continuity. If you're using a DVOM, a low reading or no reading (zero), means good continuity. Testing For Voltage When testing for voltage at a connector without wire seals, you do not have to separate the two halves of the connector. Instead, probe the connector from the back. Always check both sides of the connector because dirty, corroded, and bent terminals can cause problems (no electrical contact = an open). 1. Connect one lead of the lest light to a known good ground, or, if you're using a digital volt ohmmeter (DVOM), place it in the appropriate DC volts range, and connect its negative lead to ground. 2. Connect the other lead of the test light or DVOM to the point you want to check. 3. If the test light glows, there is voltage present. If you're using a DVOM, note the voltage reading. It should be within one volt of measured battery voltage. A loss of more than one volt indicates a problem. NOTE: Always use a DVOM on high impedance circuits. A test light may not glow (even with battery voltage present). Testing For Voltage Drop Wires, connectors, and switches are designed to conduct current with a minimum loss of voltage. A voltage drop of more than one volt indicates a problem. 1. Place the digital volt/ohmmeter (DVOM) in the appropriate DC volts range. Connect the positive lead to the end of the wire (or to the connector or switch) closest to the battery. 2. Connect the negative lead to the other end of the wire (or the other side of the connector or switch). 3. Turn on the components in the circuit. 4. The DVOM will show the difference in voltage between the two points. A difference, or drop, of more than one volt indicates a problem. Check the circuit for loose, dirty, or bent terminals. Page 1927 14. Working through the right front wheelwell, remove the two upper flange bolts holding the bracket to the engine. 15. Working from under the vehicle, rotate the right engine mount, and remove the two flange nuts holding the mount and the mount cover to the bracket. 16. Remove the mount, the cover, and the bracket. Discard the cover. 17. Assemble the bracket, the new cover, and the mount in the engine compartment. Secure the assembly with the two flange nuts. Torque the flange nuts to 50 N.m (37 lb-ft). Dual Pressure Switch Refrigerant Pressure Sensor / Switch: Testing and Inspection Dual Pressure Switch 1. Disconnect pressure switch connector and check for continuity between pressure switch side connector terminals (1) and (2). Page 2423 ^ Handle a CD by its edges; never touch the flat surfaces. Contamination from fingerprints, liquids, felt-tip pens, and labels can cause the CD to not play properly, or possibly jam in the drive. ^ When cleaning a disc, use a clean soft cloth. Wipe across the disc from the center to the outside. Do not wipe the disc in a circular motion. ^ A new CD may be rough on the inner and outer edges. The small plastic pieces causing this roughness can flake off and fall on the recording surface of the disc, causing skipping or other problems. Remove these pieces by rubbing the inner and outer edges with the side of a pencil or pen. ^ Various accessories are available to protect CDs and improve the sound quality of CDs. These accessories increase the thickness or diameter of the discs, and should not be used in CD changers. Disclaimer Page 2860 3. Connect the electrical connector to the CMP sensor. 4. Install the common chamber assembly. 5. Install the engine cover. 6. Connect the negative battery cable. Page 5750 20. Install the passenger's side type A reinforcement bracket using the hardware in the kit: Install the trailing link front mounting nut and bolt hand-tight, then torque the remaining bolts and nuts, in the order shown on the illustration below: ^ Torque the bracket bolts to 35 Nm (25 Ib-ft). ^ Torque the body mount stud and nut to 30 Nm (22 Ib-ft). 21. Remove the driver's side lower trailing link front mounting bolt: ^ Push the bolt out toward the fuel tank as far as possible. ^ Cut off the bolt head with a reciprocating saw. ^ Push the bolt out through the opposite side of the bracket. 22. * Install the driver's side type A reinforcement bracket using the hardware in the kit. The required parts vary, depending on the vehicle model year and frame design. To correctly install the driver's side type A reinforcement bracket, use the illustrations below for reference.* All 1998-99 models and some 2000 models require three bolts and one body mount stud and nut; some 2000 models require three bolts, one body mount stud and nut, plus one washer; all 2001-02 models require three bolts, one body mount stud and nut, plus one fuel tank protector bolt. Page 6783 Page 7429 Distinct Of Circuit By Wire Base Color All wires have color-coded insulation. Wires belonging to a system's main harness will have a single color. Wires belonging to a system's sub-circuits will have a colored stripe. Striped wires use the codes found in the chart to show wire size and colors. Abbreviations are used to indicate wire color within a circuit diagram. How to Identify Connector Terminals How to Identify Connector Terminals Cavity Numbering System The cavities (and wire terminals) in each connector are numbered starting from the upper left, looking at the male terminals from the terminal side (or looking at the female terminals from the wire side. Both views are in the same direction so the numbers are the same.) All actual cavities are numbered, even if they have no wire terminals in them. NOTE: Data Link Connector (DLC) terminals are numbered according to SAE standard J1962, not the Honda standard. The numbers of the four end terminals are molded into the corners of the connector face. The connector cavity number is listed next to each terminal on the circuit schematic. The cavity / terminal shown is # 6. Using/Identifying Connector Terminal Views How to Use Connector Terminal Views To see the configuration of a connector's cavities, look up its view number in the Connector Views. Each view includes the color of the connector, where Page 933 c. Remove mode switch connector with bracket from the transmission case. d. Connect multimeter (resistance mode) to terminals 1(E) and 4(H) on mode switch connector. e. Loosen two mounting screws. f. Rotate mode switch slightly in both directions to determine the range (approx. 5 degrees) of electrical contact. g. Position mode switch in middle of contact range. h. Tighten two mounting screws. i. Remove multimeter and install mode switch harness connector with bracket to the transmission case. j. Connect transmission harness connector to mode switch connector. Page 2235 Test Equipment CAUTION: Most circuits include solid-state devices. Test the voltages in these circuits only with a 10-megaohm or higher impedance digital multimeter. Never use a test light or analog meter on circuits that contain solid-state devices. Damage to the devices may result. Test Light and DVOM On circuits without solid-state devices, use a test light to check for voltage. A test light is made up of a 12 volt bulb with a pair of leads attached. After grounding one lead, touch the other lead to various points along the circuit where voltage should be present. The bulb will go on if there is voltage at the point being tested. If you need to know how much voltage is present, use a digital volt/ohmmeter (DVOM). Self-Powered Test Light and DVOM Use a self-powered test light to check for continuity. This tool is made up of a light bulb, battery, and two leads. To test it, touch the leads together: the light should go on. Use a self-powered test light only on an unpowered circuit. First, disconnect the battery, or remove the fuse that feeds the circuit you are working on. Select two points in the circuit between which you want to check continuity. Connect one lead of the self-powered test light to each point. If there is continuity, the test light's circuit will be completed, and the light will go on. If, in addition, you need to know exactly how much resistance there is between two points, use a digital volt/ohmmeter (DVOM). In the "OHMS" range, the DVOM will measure resistance between two points along a circuit. Low resistance means good continuity. Diodes and solid-state devices in a circuit can make a DVOM give a false reading. To check a reading, reverse the leads, and take a second reading. If the readings differ, the component is affecting the measurement. Jumper Wire Use a jumper wire to bypass an open circuit. A jumper wire is made up of an in-line fuse holder connected to a set of test leads. It should have a five ampere fuse. Never connect a jumper wire across a short circuit. The direct battery short will blow the fuse. Short Finder (Short Circuit Locator) Short finders are available to locate shorts to ground. The short finder creates a pulsing magnetic field in the shorted circuit which you can follow to the location of the short. To order any test equipment shown above, contact your local tool supplier. For a list of suppliers and tool numbers, refer to Honda Required Special Tools and Equipment Service Bulletin. Brakes - Revised Brake Bleeding Procedure Brake Bleeding: All Technical Service Bulletins Brakes - Revised Brake Bleeding Procedure 01-016 January 30, 2001 Applies To: 1998-01 Passport - ALL Service Manual Update: Revised Brake Bleeding Procedure BACKGROUND The brake bleeding procedure in the 1998 thru 2001 Passport Service Manuals is incomplete. Use this service bulletin to update the manuals. WARRANTY INFORMATION None. CORRECTIVE ACTION 1. In the 1998, 1999, 2000, and 2001 Passport Service Manuals, on pages 5A-21 and 5A-22, cross out the entire Tech 2 Service Bleed procedure. 2. In each manual, on page 5A-21, write this note: See page 5C-10 for the brake bleeding procedure 3. In each manual, on page 5C-10, between steps 1 and 2, write this note: For important additional information, see Service Bulletin 01-016, Service Manual Update: Revised Brake Bleeding Procedure, Filed under Brakes. SERVICE MANUAL UPDATE INFORMATION To avoid trapping air bubbles in the ABS hydraulic unit while bleeding the brakes, the hydraulic unit must be tilted forward at a 15-degree angle or greater. Before bleeding, check the angle of the ABS hydraulic unit with an angle locator level. If needed, raise the rear of the vehicle to get the proper Page 4017 Transmission Position Switch/Sensor: Description and Operation Transmission Range Switch IMPORTANT: The vehicle should not be driven with the transmission range switch disconnected; idle quality will be affected. The four inputs from the transmission range switch indicate to the PCM which position is selected by the transmission selector lever. This information is used for ignition timing, EVAP canister purge, EGR operation. For more information on the transmission on the transmission range switch, refer to Transmission Control System Diagnosis. See: Transmission Control Systems/Testing and Inspection Page 6689 Radio/Stereo: Diagnostic Aids Before Troubleshooting Before Troubleshooting See: Service Precautions/Vehicle Damage Warnings/Tips and Precautions 1. Check applicable fuses in the appropriate fuse/relay box. 2. Check the battery for damage, state of charge, and clean and tight connections. CAUTION: Do not quick-charge a battery unless the battery ground cable has been disconnected, otherwise you will damage the alternator diodes. - Do not attempt to crank the engine with the battery ground cable loosely connected or you will severely damage the wiring. While You're Working 1. Make sure connectors are clean, and have no loose terminals or receptacles. 2. Make sure that connectors without wire seals are packed with dielectric (silicone) grease. Part Number: 08798-9001. 3. When connecting a connector, push it until it "clicks" into place. CAUTION: Do not pull on the wires when disconnecting a connector. Pull only on the connector housings. - Most circuits include solid-state devices. Test the voltages in these circuits only with a 10-megaohm or higher impedance digital multi meter. Never use a test light or analog meter on circuits that contain solid-state devices. Damage to the devices may result. Five-Step Troubleshooting 1. Verify The Complaint Turn on all the components in the problem circuit to check the accuracy of the customer complaint. Note the symptoms. Do not begin disassembly or testing until you have narrowed down the problem area. 2. Analyze The Schematic Look up the schematic for the problem circuit. Determine how the circuit is supposed to work by tracing the current paths from the power source through the circuit components to ground. Also, trace circuits that share wiring with the problem circuit. The names of circuits that share the same fuse, ground, or switch, and so on, are referred to in each circuit schematic. Try to operate any shared circuits you didn't check in step 1. If the shared circuits work, the shared wiring is OK, and the cause must be in the wiring used only by the problem circuit. If several circuits fail at the same time, the fuse or ground is a likely cause. Based on the symptoms and your understanding of the circuit's operation, identify one or more possible causes. 3. Isolate The Problem By Testing The Circuit Make circuit tests to check the diagnosis you made in step 2. Keep in mind that a logical, simple procedure is the key to efficient troubleshooting. Test for the most likely cause of failure first. Try to make tests at points that are easily accessible. 4. Fix The Problem Once the specific problem is identified, make the repair. Be sure to use proper tools and safe procedures. 5. Make Sure The Circuit Works Turn on all components in the repaired circuit in all modes to make sure you've fixed the entire problem. If the problem was a blown fuse, be sure to test all of the circuits on that fuse. Make sure no new problems turn up and the original problem does not recur. Page 400 Coolant Temperature Sensor/Switch (For Computer): Description and Operation Engine Coolant Temperature (ECT) Sensor The engine coolant temperature (ECT) sensor is a thermistor (a resistor which changes value based on temperature) mounted in the engine coolant stream. Low coolant temperature produces a high resistance of 100,000 ohms at -40 °C (-40 °F). High temperature causes a low resistance of 70 ohms at 130 °C (266 °F). The PCM supplies a 5-volt signal to the ECT sensor through resistors in the PCM and measures the voltage. The signal voltage will be high when the engine is cold and low when the engine is hot. By measuring the voltage, the PCM calculates the engine coolant temperature. Engine coolant temperature affects most of the systems that the PCM controls. The Tech 2 displays engine coolant temperature in degrees. After engine start-up, the temperature should rise steadily to about 85 °C (185 °F). It then stabilizes when the thermostat opens. If the engine has not been run for several hours (overnight), the engine coolant temperature and intake air temperature displays should be close to each other. A hard fault in the engine coolant sensor circuit will set DTC P0177 or DTC P0118. An intermittent fault will set a DTC P1114 or P1115. A/C - Refrigerant Leak Detection Refrigerant: Technical Service Bulletins A/C - Refrigerant Leak Detection 07-030 October 12, 2007 Applies To: ALL Vehicles With Conventional A/C Compressors A/C Leak Detection (Supersedes 07-030, dated June 15, 2007, to update the information marked by asterisks) The OPTIMAX Jr. (TM)A/C Leak Detection Kit for Honda vehicles, P/N TRP124893, is a new required tool. The kit is used to add small amounts of dye to A/C systems to help locate smaller leaks that an electronic leak detector might not find. When searching for leaks, always begin by using an electronic leak detector. Refer to Service Bulletin 97-027, Denso HLD-100 Halogen Leak Detector; for tips on using this tool, then follow up with the OPTIMAX Jr. This new detection kit complements but does not replace the electronic detector. The kit contains: ^ TRP8640CS, OPTIMAX Jr. (TM) cordless, fluorescent leak detection flashlight lamp (includes 3 standard AA batteries) ^ TRP38600601, (6) 0.06 oz. (1.7 g) Tracer-Stick(R) R134a/PAG A/C dye capsules with ID labels ^ TRP3887, R-134a Universal Connect Set(TM) ^ TRP120884, GLO-AWAY(TM) dye cleaner ^ TRP9940, fluorescence-enhancing glasses ^ TRP1143, (1) empty Tracer-Stick dye capsule ORDERING INFO *One OPTIMAX Jr. A/C Leak Detection Kit was shipped to each current dealer as a required special tool. Additional kits and replacement capsules may be ordered through the Honda Tool and Equipment Program. On the iN, click on Service, Service Bay, Tool and Equipment Program, Online Catalog tab, and Air Conditioning Equipment, or call.* NOTICE ^ Do not use leak-trace dye in any Honda hybrid vehicle equipped with a dual-scroll compressor This can increase the chance of electric shock. The compressor is easily identified by the orange high-voltage cable that is connected to the compressor body. ^ Only Tracer-Stick single-dose fluorescent dye capsules from Tracer Products (Tracerline(R)) are approved for use in Honda vehicles. Other dyes contain solvents that may contaminate the system's refrigerant oil, leading to component failure. ^ Adding excessive amounts of dye can lead to compressor damage and failure. USING THE OPTIMAX JR. Page 2820 20. Using a DVOM, check the voltage between the reference voltage pin for each sensor and ground. ^ If the sensor circuits all read 5.0 volts, go to step 22. ^ If any sensor circuit is above or below 5.0 volts, go to step 21. 21. Troubleshoot for an internal short in another sensor or a PCM malfunction. ^ To find the sensor with an internal short, monitor the reference voltage, and disconnect each sensor (FTPS, EGR, MAP TPS, CKP and CMP) one at a time until the reference voltage reads 5.0 volts. Replace that sensor, and repeat step 14. ^ To find a malfunctioning PCM, replace it with a known-good PCM. If all three sensors (APP Sensor 1, APP Sensor 2, and APP Sensor 3) are within range, the original PCM is faulty; replace it and repeat step 14. 22. Using a jumper wire, connect the reference voltage of each circuit to its signal input, and view the APP Sensor values in the Engine Data List. APP Sensor 1 should have a value of 99%, and APP Sensor 2 and APP Sensor 3 should each have a value of 0%. ^ If the values are not as specified, troubleshoot for high resistance on the signal input or a PCM malfunction. Repair the circuit or replace the PCM, then repeat step 14. ^ If the values are as specified, the problem may be intermittent. Disconnect the 10 P connector from the modified APPS, and connect it to the new APPS; then repeat step 14. Wiggle the APPS wires as you go through the adjustment procedure to find the intermittent problem. 23. Install the accelerator pedal assembly, and torque the bolts to 10 N.m (7 lb-ft). Diagram Information and Instructions Fuel Pump Relay: Diagram Information and Instructions How to Identify Wiring Color-Coded Insulation Wire Color Wire Color Coding Page 6611 ^ ALO/BOA - Your order has been allocated, but not released for shipment. ^ REL/BOR - Your order has been picked, packed, and shipped. ^ INV - Your order has been invoiced to your dealer parts account. CORE RETURN INFORMATION Service Technician: 1. If the customer's media (CD, CD magazine, DVD, DVD-A, or cassette tape) is stuck inside the faulty unit, fill out a Customer Media Return Label (reorder number Y0325), and attach it to the unit. The manufacturer will remove the media, and mail it back to your dealership. 2. Use the pre paid shipping label. Each audio supplier provides a prepaid shipping label with the remanufactured audio unit. Return the core using this label to ensure it is received at the appropriate location for credit. Use the pre paid shipping labels to return audio cores to authorized locations only; do not use them for any other purpose. If you need additional prepaid shipping labels, contact Remanufactured Parts Operations. ^ Complete the shipping label with your dealership information. ^ Pack one audio unit per box, and use a separate shipping label for each one. ^ On the line requesting Your Internal Reference Information, enter YOUR DEALER NUMBER and the WARRANTY CLAIM NUMBER. 3. On the repair order, write down the warranty claim number, the original part number, the serial numbers from both the faulty and remanufactured units, and the return tracking number. 4. Ship the faulty unit in the same box the remanufactured unit came in. Make sure you include this required paperwork: ^ A copy of the Core Return Update Acknowledgement from the iN. ^ A copy of the warranty audio order. NOTE: When the Remanufacturing Center gets the faulty unit, your warranty audio order will be updated to indicate that the core was received. If the core is received 31-60 days from the order date, and you have been debited a core loss charge, your dealership will be credited back, less a $250 late fee. OUT-OF-WARRANTY REPAIR (AUDIO, NAVIGATION, AND RES UNITS PRODUCED IN 1998 OR LATER) NOTE: If you are making a repair or exchange because of a service bulletin or service campaign, do not use OUT-OF-WARRANTY procedures. Refer to IN-WARRANTY EXCHANGE for more information. Service Advisor: 1. Give your customer an estimate for repairing the unit (see step 6), plus the labor cost to replace it. For an Alpine unit, your customer has the option of contacting Alpine Electronics directly. Alpine's customer service number is 800-421-2284, Ext. 860304. Service Technician: 2. Remove the failed unit: ^ Refer to the appropriate component section of the service manual or, Page 4335 9. Use wrench J-36827, remove hub nut. 10. Remove hub and disc assembly. 11. Remove ABS sensor ring. 12. Remove outer bearing. 13. Remove oil seal. 14. Remove inner bearing. 15. Remove bolt, if necessary, replace the wheel pin in the following manner. - Apply a scribe mark (1) to disc to hub. - Clamp the hub and disc assembly in a vise, using protective pads. Remove the 6 disc-to-hub retaining bolts. - Place hub on a suitable work surface and remove the studs by using a hammer. INSPECTION AND REPAIR Make necessary correction or parts replacement if wear, damage, corrosion or any other abnormal condition are found through inspection. Check the following parts. Hub - Hub bearing oil seal - Knuckle spindle Page 7875 Each schematic represents one circuit. A circuit's wires and components are arranged to show current flow, from power at the top of the page, to ground, at the bottom. Shared Circuits Other circuits may share power or ground terminals or wiring with the circuit shown. A wire that connects one circuit to another, for example, is cut short and has an arrowhead at the end of it pointing in the direction of current flow. Next to the arrowhead is the name of the circuit or component which shares that wiring. To quickly check shared wiring, check the operation of a component it serves. If that component works, you know the shared wiring is OK. Connectors All in-line and junction connectors are numbered (C725, C416, etc.). Component connectors are not numbered but are identified either by the name of Locations Timing Marks and Indicators: Locations IGNITION IS NOT ADJUSTABLE Ignition timing is done by the electronic ignition (EI) that directly fires the spark plugs from ignition coils through spark plug wires without using a distributor. A pair of ignition coils for the cylinders having different phases by 36O° (No.1 and No.4,No.2 and No.5,No.3 and No.6) are fired simultaneously. Since the cylinder on exhaust stroke requires less energy to fire its ignition plug, energy from the ignition coils can be utilized to fire the mating cylinder on compression stroke. After additional 36O° rotation, respective cylinder strokes are reversed. The EI consists of six ignition coils,ignition control module, crank angle sensor, powertrain control module (PCM) and other components. The ignition coils are connected with the PCM by means of a 32 pin connector. The ignition control module turns on/off the primary circuit of ignition coils, and also it controls the ignition timing at the engine speed below 538 rpm. A notch in the timing disc on the crankshaft activates the crank angle sensor which then sends information such as firing order and starting timing of each ignition coil to the PCM. Further, the EI employs ignition control (IC) to control similar to a distributor system. By receiving signals such as crank position,engine speed, water temperature and Manifold Absolute Pressure (MAP), the PCM controls the ignition timing. Page 992 6. Test-drive the vehicle to make sure it no longer pulls. If the steering wheel is now off-center by more than 2 mm, go to REPAIR PROCEDURE C. 7. Use your diagnosis worksheet to fill in the following table and build your 15-digit DTC. NOTE: Enter each reading in decimal degrees. Example 30' = 0.50. REPAIR PROCEDURE C 1. Make sure the steering wheel is centered. ^ Turn the steering wheel all the way to the right until it stops. ^ Turn the steering wheel all the way to the left, and count the number of revolutions until it stops. ^ Divide the number of revolutions in half, and turn the steering wheel until it is centered. For example, if it takes four revolutions of the steering wheel to go from lock to lock, then two turns is centered. ^ If the steering wheel is off-center by a large amount (20 mm or more), it may not be centered on the steering column shaft. Reinstall the steering wheel before going to step 2. 2. Place the vehicle on a lift, turn the steering wheel until it is centered, and then raise the vehicle. 3. Adjust the tie-rods. Use your measurements from question 13 of the test-drive to make your adjustment. Service and Repair Keyless Entry Transmitter Battery: Service and Repair 1. Remove a screw to remove the cover. 2. Remove the batteries. 3. Set the new batteries into the transmitter. 4. Install the cover to the transmitter. 5. Check that the keyless entry system works normally. A/T - Identifying Shift Solenoids Shift Solenoid: Technical Service Bulletins A/T - Identifying Shift Solenoids SOURCE: Honda Service News November 2003 TITLE: Identifying A/T Shift Solenoids APPLIES TO: 1994-02 Passport SERVICE TIP: If you've ever replaced the A/T shift solenoids in a 1994-02 Passport, you're probably aware that the S/M and parts catalog descriptions for the solenoids don't exactly match. Use this handy chart when ordering replacement solenoids: When installing these solenoids in the valve body, make sure you don't get them mixed up or install them in the wrong position. It's easy to do since these solenoids look almost identical. Fortunately, each solenoid has some of its part number engraved on its connector. Solenoid A has 593; solenoid B has 224. Page 4811 Part 1 of 2 Page 2378 Cleaning Spark Plugs - Clean spark plugs with a spark plug cleaner. - Raise the ground electrode to an position of 45 to 60 degrees. If electrode is wet, dry it before cleaning. - After spark plug is thoroughly cleaned, check insulator for presence of cracks. - Clean threads and metal body with a wire brush. - File the electrode tip if electrode is extremely worn. - Bend the ground electrode to adjust the spark plug gap. Page 7309 1. When setting up links, pay attention to the position and direction of the links. 2. Apply chassis grease to the lock assembly and striker moving surface. 3. Check that the tailgate lock operates correctly after installing it. 4. Tighten the hatchgate lock assembly fixing bolts to the specified torque. Torque 7 Nm (61 lb in) Page 3649 5. Install magnet, main case oil pan with new gasket, and sixteen 10 mm screws. Tighten the screws to the specified torque. Torque: 11 Nm (96 Inch lbs.) 6. Fill transmission through the overfill screw hole of oil pan, using ATF DEXRON-III. 7. Connect battery ground cable. Locations Page 2616 If there is no photo number below or beside a component name or a connector, ground, or terminal number, look up that name or number in the appropriate Connector Identification Chart. The chart lists how many cavities a connector has, where it's located, and what it connects to. The related illustration shows the connector's location on the harness, and the harness routing. NOTE: Photos listed by number are located at Locations / Components / Photograohs. See: Locations/Component Locations/Photographs Circuit Schematics Page 5299 Ground - "G" Shielding Sheilding This represents RFI (Radio Frequency Interference) shielding around a wire. The shielding is always connected to ground. Splices Page 8083 The wire insulation has one color or one color with another color stripe. The second color is the stripe. Page 6303 2. Connect the short finder across the battery terminals and the load (component) side of the fuse terminal. 3. Close all switches in the circuit you're testing. 4. Turn on the short finder. This creates a pulsing magnetic field around the wiring between the fuse box and the short. 5. Beginning at the fuse box, slowly move the short finder along the circuit wiring. The meter will read current pulses through sheet metal and body trim. As long as the meter is between the fuse and the short, the needle will move with each current pulse. Once you move the meter past the point of the short, the needle will stop moving. Check the wiring and connectors in this area to locate the cause of the short. Testing For Continuity When testing for continuity at a connector without wire seals, you do not have to separate the two halves of the connector. Instead, probe the connector from the back. Always check both sides of the connector because dirty, corroded, and bent terminals can cause problems (no electrical contact = an open). 1. Disconnect the negative cable from the car battery. If you're using a DVOM, place it in the lowest "OHMS" range. Recall 10V436000: Rear Lower Control Arm Bracket Control Arm: All Technical Service Bulletins Recall 10V436000: Rear Lower Control Arm Bracket VEHICLE MAKE/MODEL: MODEL YEAR(S): Honda/Passport 1998-2002 Isuzu/Axiom 2002 Isuzu/Rodeo 1998-2002 MANUFACTURER: Isuzu Manufacturing Services of America MFR'S REPORT DATE: September 22, 2010 NHTSA CAMPAIGN ID NUMBER: 10V436000 NHTSA ACTION NUMBER: 2 Investigations found COMPONENT: Suspension: Rear POTENTIAL NUMBER OF UNITS AFFECTED: ? SUMMARY: Isuzu is recalling certain model year 1998-2002 Isuzu Rodeo and model year 2002 Isuzu Axiom vehicles, and Honda is recalling certain 1998-2002 Honda Passport vehicles, that were originally sold, or are currently registered, in the states of Maine, New Hampshire, Vermont, Massachusetts, Rhode Island, Connecticut, New York, New Jersey, Pennsylvania, Delaware, Maryland, The District of Columbia, West Virginia, Ohio, Indiana, Michigan, Illinois, Wisconsin, Minnesota, Iowa, Missouri, and Kentucky. Vehicles that have experienced sustained exposure to highly corrosive materials used in some jurisdictions for road deicing purposes may experience excessive corrosion in the vicinity of the forward mounting point bracket for the left or right rear suspension lower link prior to the time that such corrosion would normally be expected. CONSEQUENCE: Excessive corrosion may result in the left or right rear suspension lower link bracket becoming detached from the frame, which can affect vehicle handling and potentially cause a crash. REMEDY: Dealers will inspect the rear suspension lower link bracket area. For vehicles in which little or no corrosion is found, the area will be treated with an anti-corrosive compound. For vehicles in which corrosion has damaged the rear suspension lower link bracket and affected its connection to the vehicle frame, a reinforcement bracket will be installed. In the rare event the corrosion is so severe that the reinforcement bracket remedy would not be appropriate, Isuzu and Honda will develop an appropriate remedy. All inspections and remedies will be provided free of charge for vehicles that are 10 years old or less. For vehicles older than 10 years, Isuzu will offer a free remedy, but only if the vehicle is presented to an Isuzu service facility, or Honda dealer (as applicable), dealer within 12 months of when owner notifications were issued. The manufacturer has not yet provided an owner notification schedule. Isuzu owners may contact Isuzu at 1-800-255-6727. Honda owners may contact Honda at 1-800-999-1009. NOTES: Owners may also contact The National Highway Traffic Safety Administration's Vehicle Safety Hotline at 1-888-327-4236 (TTY 1-800-424-9153), or go to http://www.safercar.gov. Page 2242 Vehicle Speed Sensor: Service and Repair REMOVAL CAUTION: The VSS is located on the right side of the transfer case just ahead of the rear propeller shaft and very close to the exhaust pipes for 4WD and on the extension cover for 2WD. Be sure that the exhaust pipes are cool enough to touch before trying to remove the VSS. If the pipes are hot, you could be burned. 1. Disconnect the negative battery cable. 2. Disconnect the VSS electrical connector. 3. Remove the bolt and the clamp securing the VSS in place. IMPORTANT: Have a container ready to catch any fluid that leaks out when the VSS is removed from the transfer case for 4WD and on the extension cover for 2WD. 4. Remove the VSS from the transfer case by wiggling it slightly and pulling it straight out. INSTALLATION 1. Install the VSS in the transfer case with the notch for the connector facing the rear. A/T - Identifying Shift Solenoids Shift Solenoid: Technical Service Bulletins A/T - Identifying Shift Solenoids SOURCE: Honda Service News November 2003 TITLE: Identifying A/T Shift Solenoids APPLIES TO: 1994-02 Passport SERVICE TIP: If you've ever replaced the A/T shift solenoids in a 1994-02 Passport, you're probably aware that the S/M and parts catalog descriptions for the solenoids don't exactly match. Use this handy chart when ordering replacement solenoids: When installing these solenoids in the valve body, make sure you don't get them mixed up or install them in the wrong position. It's easy to do since these solenoids look almost identical. Fortunately, each solenoid has some of its part number engraved on its connector. Solenoid A has 593; solenoid B has 224. Page 673 96. Rear of Right Catalytic Converter Rear of right catalytic converter 94. Rear of Left Catalytic Converter Rear of Left Catalytic Converter Page 5999 The wire insulation has one color or one color with another color stripe. The second color is the stripe. Page 799 Disclaimer Repair Procedure 1. Unclamp the air cleaner housing cover, and move it to the side for access to connector C123 (16P BLK). 2. Unfasten C123 from the side of the engine compartment using a 90-degree pick. 3. Disconnect C123, and clean the terminals on both sides of the connector with contact cleaner. Shake the residue out of the connector. Allow the contact cleaner to evaporate for at least 3 minutes, then reconnect C123. 4. Fasten C123 to the left side of the engine compartment, then reinstall the air cleaner housing cover. 5. While supporting the accelerator pedal assembly, remove the two bolts that secure the assembly to the bulkhead. Carefully lower the assembly to gain access to the connector. Testing and Inspection Parking Brake Shoe: Testing and Inspection PARKING BRAKE LINING INSPECTION Check the shoe assemblies for wear by removing the brake drum. Replace the shoe assemblies if the lining thickness is less than 1.0 mm (0.039 inch). Page 5502 Power Steering Fluid: Fluid Type Specifications Power Steering Fluid ........................................................................................................................... ................................................................. Dexron III Page 4777 Electronic Brake Control Module: Service Precautions CONTROL MODULE PRECAUTIONS The Anti-lock Brake System interfaces directly with the Electronic Hydraulic Control Unit (EHCU) which is a control computer that is similar in some regards to the Powertrain Control Module. These modules are designed to withstand normal current draws associated with vehicle operation. However, care must be taken to avoid overloading any of the EHCU circuits. In testing for opens or shorts, do not ground or apply voltage to any of the circuits unless instructed to do so by the appropriate diagnostic procedure. These circuits should only be tested with a high impedance multimeter (J-39200) or special tools. Power should never be removed or applied to any control module with the ignition in the "ON" position. Before removing or connecting battery cables, fuses or connectors, always turn the ignition switch to the "OFF" position. Page 4244 14. Remove the lower link fixing bolt and nut (4) from the axle housing. 15. Jack down and remove the coil spring and insulator. 16. Axle housing assembly can be separated from the vehicle on completion of steps 1-15. 17. Remove the brake caliper fixing bolt, loosen the flare nut, release the clip and take out the brake caliper together with the flexible hose. 18. Remove brake disc. 19. Remove antilock brake system speed sensor fixing bolt and the clip and bracket on the axle housing. 20. Remove the brake pipe clip and fixing bolt on the axle housing and take out the brake pipe. INSTALLATION 1. Install brake pipe. 2. Connect Antilock Brake System (ABS) speed sensor and harness. 3. Install brake disc. 4. Install brake caliper. 5. Install axle housing assembly. 6. Install coil spring and insulator. 7. Install the lower link fixing bolt and nut to the axle housing. 8. Install the upper link bolt and nut to the axle housing. 9. Install the lateral rod fixing nut and bolt to the frame side. 10. Install the stabilizer linkage mounting nut and bolt to the frame side. 11. Install the shock absorber. 12. Install brake tube flare nut. 13. Install ABS connector and bracket. 14. Connect breather hose. 15. Install parking brake cable. 16. Bleed brakes. Page 8201 3. Remove the window regulator handle. - Remove the clip on the rear side of the regulator handle using a wire. 4. Remove the screw while pulling the inside lever toward you and then remove the inside handle. 5. Remove the 1 screw at the pull case. 6. Pull out the trim panel at the 8 clip positions. - Disconnect the power window switch connector. 7. Remove the power window switch and pull case, if equipped. Page 625 3. Connect the electrical connector to the CMP sensor. 4. Install the common chamber assembly. 5. Install the engine cover. 6. Connect the negative battery cable. Page 2790 Powertrain Control Module: Service Precautions Reprogramming the PCM Reprogramming the PCM Reprogramming of the PCM is done without removing it from the vehicle . This provides a flexible and cost-effective method of making changes in software calibrations. Refer to the latest Techline information on reprogramming or flashing procedures. Page 1564 2. Use a valve cutter to minimize scratches and other rough areas. This will bring the contact width back to the standard value. Remove only the scratches and rough areas. Do not cut away too much. Take care not to cut away unblemished areas of the valve seat surface. Valve seat angle degree: 90° 3. Apply abrasive compound to the valve seat insert surface. 4. Insert the valve into the valve guide. 5. Turn the valve while lapping it to fit the valve seat insert. 6. Check that the valve contact width is correct. 7. Check that the valve seat insert surface is in contact with the entire circumference of the valve. Valve Seat Insert Replacement 1. Arc weld the rod at several points. Be careful not to damage the aluminum. 2. Allow the rod to cool for a few minutes. This will cause the valve seat to shrink. 3. Strike the rod and pull it out. 4. Carefully clean the valve seat press- fit on the cylinder head side. 5. Heat the press-fit with steam or some other means to cause expansion. Cool the valve seat with dry ice or some other means. Page 1313 Page 3562 Wires Wire insulation can be one color, or one color with another color stripe. (The second color is the stripe.) This circuit continues on another image. (The arrow shows direction of current flow.) To follow the RED/BLK wire in this example, you would turn to "Fuel and Emissions" and look for the "A" arrow. SRS Operation Air Bag(s) Arming and Disarming: Description and Operation SRS Operation The SRS is a safety device which, when used in conjunction with the seat belt, is designed to help protect the driver (and front passenger) in a frontal impact exceeding a certain set limit. The system consists of the SRS unit (including safing sensor and impact sensor), the cable reel, the driver's airbag (and front passenger's airbag). Operation The main circuit in the SRS unit senses and judges the force of impact and, if necessary, ignites the inflator charge(s). If battery voltage is too low or power is disconnected due to the impact, the voltage regulator and the back-up power circuit respectively will keep voltage at a constant level. For the SRS to operate: 1. The impact sensor must activate, and send electric signals to the microprocessor. 2. The microprocessor must compute the signals, and must send signals to the airbag inflator(s). 3. The inflator(s) must ignite and deploy the airbag(s). Self-diagnosis System A self-diagnosis circuit is built into the SRS unit; when the ignition switch is turned ON (II), the SRS indicator light comes on and goes off after about six seconds if the system is operating normally. If the light does not come on, or does not go off after six seconds, or if it comes on while driving, it indicates an abnormality in the system. The system must be inspected and repaired as soon as possible. For better serviceability, the memory will store the cause of the malfunction, and the data link circuit passes on the information from the memory to the data link connector (DLC). This information can be read with the Honda PGM Tester connected to the DLC (16P). Page 758 Wire Color Abbreviations The following abbreviations are used to identify wire colors in the circuit schematics: WHT................................... White YEL................................... Yellow BLK................................... Black BLU................................... Blue GRN................................... Green RED................................... Red ORN................................... Orange PNK................................... Pink BRN................................... Brown GRY................................... Gray PUR................................... Purple LT BLU................................... Light Blue LT GRN................................... Light Green Diagrams Front Fender Panel Page 6214 Housing Assembly HVAC: Testing and Inspection Heater Core and/or Mode Door Check for foreign matter in the heater core, stain or the core fin defacement. Page 4934 angle. The angle locator level (P/N SUN-YA328A) is available through the Honda Tool and Equipment Program. To order one, call 888-424-6857. DISCLAIMER Page 6437 1. Insert horn terminal from behind black connector NO.12 until connector lock works. 2. Push white connector into the black connector for a double lock. Page 4045 4. Set the parking brake, and move the shift lever to L. Remove the ashtray. 5. Remove the lower cluster assembly (one screw and four clips), then unplug the connectors from the cigarette lighter. 6. Remove the rear console (two screws inside the storage area), then unplug the connectors from the POWER and WINTER switches. 7. On 4WD models, remove the knob from the transfer control lever. 8. Remove the front console (six screws), then unplug the connectors from the accessory power outlet. 9. Move the shift lever to P then turn the ignition switch to ACC. 10. Press and hold the shift lever pushbutton, then check the condition of the spring pin cover in the lock cylinder assembly. ^ If the cover is loose, out of position, or missing, disregard this service bulletin, and replace the lock cylinder assembly. See section 2A of the appropriate Passport Service Manual for the replacement procedure. Page 3768 Transmission Speed Sensor: Locations Top Of Transfer Case Page 5545 2. Unfasten C123 from the side of the engine compartment using a 90-degree pick. 3. Disconnect C123, and clean the terminals on both sides of the connector with contact cleaner. Shake the residue out of the connector. Allow the contact cleaner to evaporate for at least 3 minutes, then reconnect C123. 4. Fasten C123 to the left side of the engine compartment, and reinstall the air cleaner housing cover. 5. Remove the connector position assurance (CPA) clip from the APPS connector. 6. Disconnect the lop connector from the APPS. 7. Clean the terminals of the 10P APPS connector (harness side) with contact cleaner. Shake out residue from the connector, and allow the contact cleaner to evaporate for at least 3 minutes, then reconnect it. 8. Use the Smart Cable to reprogram the PCM with the latest software from the June 2001 or later HONDANET CD-ROM. Refer to Service Bulletin 99-005, Updating the Passport PCM, filed under Tools. 9. Use the PGM Tester to clear any DTCs. Page 3413 2. Connect the short finder across the battery terminals and the load (component) side of the fuse terminal. 3. Close all switches in the circuit you're testing. 4. Turn on the short finder. This creates a pulsing magnetic field around the wiring between the fuse box and the short. 5. Beginning at the fuse box, slowly move the short finder along the circuit wiring. The meter will read current pulses through sheet metal and body trim. As long as the meter is between the fuse and the short, the needle will move with each current pulse. Once you move the meter past the point of the short, the needle will stop moving. Check the wiring and connectors in this area to locate the cause of the short. Testing For Continuity When testing for continuity at a connector without wire seals, you do not have to separate the two halves of the connector. Instead, probe the connector from the back. Always check both sides of the connector because dirty, corroded, and bent terminals can cause problems (no electrical contact = an open). 1. Disconnect the negative cable from the car battery. If you're using a DVOM, place it in the lowest "OHMS" range. Page 728 Throttle Position Sensor: Testing and Inspection Function Check Use a Tech 2 to check the TP sensor output voltage at closed throttle. - The voltage should be under 0.85 volt. - If the reading is greater than 0.85 volt, check the throttle shaft to see if it is binding. Locations Behind Glove Box Page 1529 clearance exceeds the specified limit, the connecting rod must be replaced. Standard: 0.16 mm 0.35 mm (0.0063 inch - 0.0138 inch) Limit: 0.40 mm (0.0157 inch) 3. Measure the oil clearance between the connecting rod and the crankshaft. 1. Remove the connecting rod cap nuts and the rod caps (12). Arrange the removed rod Gaps in the cylinder number order. 2. Clean the rod bearings and the crankshaft pins. 3. Carefully check the rod bearings. If even one bearing is found to be damaged or badly worn, the entire bearing assembly must be replaced as a set. Reinstall the bearings in their original positions. Apply plastogene to the crank pin. 4. Reinstall the rod caps (12) to their original positions. Tighten the rod cap nuts. Torque: 54 Nm (40 ft. lbs.) Note: Do not allow the crankshaft to rotate. 5. Remove the rod caps. 6. Measure the width of the plastogene and determine the oil clearance. If the oil clearance exceeds the limit, replace the rod bearing as a set. Standard: 0.019 mm - 0.043 mm (0.0007 inch - 0.0017 inch) Limit: 0.08 mm (0.0031 inch) 7. Clean the plastogene from the bearings and the crankshaft pins. Con-rod Bearing Selection Select and install the new connecting rod bearings, paying close attention to the connecting rod big end diameter size mark (1). Page 4196 Actuator: Testing and Inspection MOTOR ACTUATOR ASSEMBLY Inspect the function of the motor actuator assembly as follows: 1. Disassemble the motor actuator from transfer rear case. 2. Connect the terminals as shown in figure. Shift rod of the motor actuator moves and stops at 4WD position. Page 4950 3. Install support bracket and tighten the bolt (7) to the specified torque. Torque: 103 Nm (76 ft. lbs.) 4. Install caliper assembly. 5. Install lock bolt and guide bolt (8) and tighten the bolt to the specified torque. Torque: 44 Nm (32 ft. lbs.) 6. Install brake flexible hose, always use new gaskets and be sure to put the hooked edge of the flexible hose end into the anti-rotation cavity then tighten the eye-bolt (9) to the specified torque. Torque: 35 Nm (26 ft. lbs.) 7. Install the wheel and tire assembly. 8. Bleed brakes. Page 164 If there is no photo number below or beside a component name or a connector, ground, or terminal number, look up that name or number in the appropriate Connector Identification Chart. The chart lists how many cavities a connector has, where it's located, and what it connects to. The related illustration shows the connector's location on the harness, and the harness routing. NOTE: Photos listed by number are located at Locations / Components / Photograohs. See: Locations/Component Locations/Photographs Circuit Schematics Page 2146 Intake Air Temperature Sensor: Description and Operation Intake Air Temperature (IAT) Sensor The intake air temperature (IAT) sensor is a thermistor which changes its resistance based on the temperature of air entering the engine. Low temperature produces a high resistance of 100,000 ohms at -40 °C (-40 °F). High temperature causes low resistance of 70 ohms at 130 °C (266 °F). The PCM supplies a 5-volt signal to the sensor through a resistor in the PCM and monitors the signal voltage. The voltage will be high when the incoming air is cold. The voltage will be low when the incoming air is hot. By measuring the voltage, the PCM calculates the incoming air temperature. The IAT sensor signal is used to adjust spark timing according to the incoming air density. The Tech 2 displays the temperature of the air entering the engine. The temperature should read close to the ambient air temperature when the engine is cold and rise as underhood temperature increases. If the engine has not been run for several hours (overnight), the IAT sensor temperature and engine coolant temperature should read close to each other. A fault in the IAT sensor circuit will set DTC P0112 or DTC P0113. Fan Control Lever (Fan Switch) Blower Motor Switch: Testing and Inspection Fan Control Lever (Fan Switch) 1. Check for continuity between the terminals of the fan switch. Page 2739 4. Remove the fuel pressure regulator from the fuel rail. 5. Remove the fuel return line from the regulator. 6. Install the new fuel pressure regulator in the reverse order of removal. 7. Use the Smart Cable to reprogram the PCM with the latest software from the June 2001 or later HONDANET CD-ROM. Refer to Service Bulletin 99-005, Updating the Passport PCM, filed under Tools. 8. Use the PGM Tester to clear any DTCs. 9. Use the PGM Tester to check the broadcast code. Make sure the broadcast code matches the one you selected from the CD-ROM. WARRANTY CLAIM INFORMATION In warranty: The normal warranty applies. Failed Part: P/N 8-17113-398-0 H/C 5504386 Defect Code: 092 Contention Code: C99 Skill Level: Repair Technician Out of warranty: Any repair performed after warranty expiration may be eligible for goodwill consideration by the District Service Manager or your Zone Office. You must request consideration, and get a decision, before starting work. REPAIR PROCEDURE - POWER STEERING SWITCH 1. Drain the power steering fluid out of the system. 2. Remove the power steering fluid reservoir. Clean the reservoir with solvent, then with soap and water. Rinse and dry it thoroughly. 3. Reinstall the reservoir. Do not connect the return hose. 4. Remove the power steering pressure switch, then clean it with brake cleaner and a scraper. Reinstall the switch, and torque it to 20 N.m (14 lb-ft). 5. Cover the unconnected end of the reservoir with your finger, then fill the reservoir with Dexron III ATF Page 7090 This sample Ground Distribution schematic shows all of the components that share two ground points. Components A solid border line means the entire component is shown. A broken border line indicates that only part of the component is shown. Page 6376 The connector cavity number is listed next to each terminal on the circuit schematic. The cavity / terminal shown is # 6. Diodes A rectifier diode works like a one way valve. It allows current to flow only in the direction of the arrow. A Zener diode blocks reverse current at normal voltages just like a rectifier diode. At high voltages, however, a Zener diode allows current to flow in reverse. Fuses Page 7781 Each schematic represents one circuit. A circuit's wires and components are arranged to show current flow, from power at the top of the page, to ground, at the bottom. Shared Circuits Other circuits may share power or ground terminals or wiring with the circuit shown. A wire that connects one circuit to another, for example, is cut short and has an arrowhead at the end of it pointing in the direction of current flow. Next to the arrowhead is the name of the circuit or component which shares that wiring. To quickly check shared wiring, check the operation of a component it serves. If that component works, you know the shared wiring is OK. Connectors All in-line and junction connectors are numbered (C725, C416, etc.). Component connectors are not numbered but are identified either by the name of Component Tests Wheel Speed Sensor: Testing and Inspection Component Tests Front INSPECTION AND REPAIR 1. Check the speed sensor pole piece for presence of foreign materials; remove any dirt, etc. 2. Check the pole piece for damage; replace speed sensor if necessary. 3. Check the speed sensor cable for short or open circuit, and replace with a new one if necessary. To check for cable short or open, bend or stretch the cable while checking for continuity. 4. Check the sensor ring for damage including tooth chipping, and if damaged, replace the sensor ring assembly. Rear INSPECTION AND REPAIR 1. Check speed sensor pole piece for presence of foreign materials; remove any dirt, etc. 2. Check the pole piece for damage, and replace speed sensor if necessary. 3. Check speed sensor cable for short or open, and replace with a new one if necessary. To check for cable short or open, bend or stretch the cable while checking for continuity. 4. Check the sensor ring for damage including tooth chipping, and if damaged, replace the axle shaft assembly. Page 7948 The connector cavity number is listed next to each terminal on the circuit schematic. The cavity / terminal shown is # 6. Diodes A rectifier diode works like a one way valve. It allows current to flow only in the direction of the arrow. A Zener diode blocks reverse current at normal voltages just like a rectifier diode. At high voltages, however, a Zener diode allows current to flow in reverse. Fuses Page 7396 Brake Warning Indicator: Description and Operation The brake system warning light goes on to alert the driver that the parking brake is applied or that the brake fluid is low. It also lights as a bulb test when the engine is cranked. With the ignition switch in START, the brake system warning light is turned on for bulb check. During bulb check, the light is grounded through the alternator. See Indicators for further details. Page 7254 Power Door Lock Switch: Service and Repair Door Switch Removal 1. Disconnect the battery ground cable. 2. Remove the door switch (2). - Remove the screw (1). - Disconnect the connector (3). Installation To install, follow the removal steps in the reverse order. Locations Timing Marks and Indicators: Locations IGNITION IS NOT ADJUSTABLE Ignition timing is done by the electronic ignition (EI) that directly fires the spark plugs from ignition coils through spark plug wires without using a distributor. A pair of ignition coils for the cylinders having different phases by 36O° (No.1 and No.4,No.2 and No.5,No.3 and No.6) are fired simultaneously. Since the cylinder on exhaust stroke requires less energy to fire its ignition plug, energy from the ignition coils can be utilized to fire the mating cylinder on compression stroke. After additional 36O° rotation, respective cylinder strokes are reversed. The EI consists of six ignition coils,ignition control module, crank angle sensor, powertrain control module (PCM) and other components. The ignition coils are connected with the PCM by means of a 32 pin connector. The ignition control module turns on/off the primary circuit of ignition coils, and also it controls the ignition timing at the engine speed below 538 rpm. A notch in the timing disc on the crankshaft activates the crank angle sensor which then sends information such as firing order and starting timing of each ignition coil to the PCM. Further, the EI employs ignition control (IC) to control similar to a distributor system. By receiving signals such as crank position,engine speed, water temperature and Manifold Absolute Pressure (MAP), the PCM controls the ignition timing. Page 1037 6. Test-drive the vehicle to make sure it no longer pulls. If the steering wheel is now off-center by more than 2 mm, go to REPAIR PROCEDURE C. 7. Use your diagnosis worksheet to fill in the following table and build your 15-digit DTC. NOTE: Enter each reading in decimal degrees. Example 30' = 0.50. REPAIR PROCEDURE C 1. Make sure the steering wheel is centered. ^ Turn the steering wheel all the way to the right until it stops. ^ Turn the steering wheel all the way to the left, and count the number of revolutions until it stops. ^ Divide the number of revolutions in half, and turn the steering wheel until it is centered. For example, if it takes four revolutions of the steering wheel to go from lock to lock, then two turns is centered. ^ If the steering wheel is off-center by a large amount (20 mm or more), it may not be centered on the steering column shaft. Reinstall the steering wheel before going to step 2. 2. Place the vehicle on a lift, turn the steering wheel until it is centered, and then raise the vehicle. 3. Adjust the tie-rods. Use your measurements from question 13 of the test-drive to make your adjustment. Page 6337 Repairs and Inspections Required After a Collision: Service and Repair Repairs and Inspections Required After an Accident Repairs and Inspections Required After an Accident NOTE: If any SRS components are damaged, they must be replaced. If SRS component mounting points are damaged, they must be replaced. - Never use SRS parts from another vehicle. This does not include remanufactured pants purchased from an authorized dealer; they may be used for SRS repairs. - Do not attempt to service the SDM, the SRS coil assembly, or the air bag assembly. Service of these items is by replacement only. - Verify the part number of replacement air bag assembly. CAUTION: Never use the air bag assembly from another vehicle. Use only the air bag assembly for UE models. CAUTION: Proper operation of the sensors and Supplemental Restraint System (SRS) requires that any repairs to the vehicle structure return it to the original production configuration. Deployment requires, at a minimum, replacement of the SDM, air bag assembly and dimensional inspection of the steering column. Any visible damage to the SDM mounting bracket (s) requires replacement, and the steering column must be dimensionally inspected, whether deployment occurred or not. Accident With Deployment - Component Replacement and Inspections Certain SRS components must be replaced or inspected for damage after a frontal crash involving air bag deployment. Those components are: - Air bag assembly - SDM CAUTION: Refer to "SDM Replacement Guidelines" below for important information on Sensing and Diagnostic Module (SDM) replacement in both deployment and non deployment crashes. - Supplemental Restraint System (SRS) coil assembly - Inspect wiring and connector for any signs of scorching, melting, or damage due to excessive heat. Replace If damaged. Refer to SRS coil assembly. See: Air Bag Systems/Clockspring Assembly / Spiral Cable Accident With or Without Deployment-Component Inspection Certain SRS and restraint system components must be inspected after any crash, whether the air bag deployed or not Those components are: - Steering column - Dimensionally inspect per "Checking Steering Column for Accident Damage". - Knee bolsters and mounting points - Inspect for any distortion, bending, cracking, or other damage. - Instrument panel steering column reinforcement plate - Inspect for any distortion, bending, cracking, or other damage. - Instrument panel braces - Inspect for any distortion, bending, cracking, or other damage. - Seat belts and mounting points - Refer to "Seat Belts". See: Seat Belt Systems SDM Replacement Guidelines SDM replacement policy requires replacement of SDM, after crash involving air bag deployment when "SRS Warning Lamp" turn "ON", "SRS Diagnosis" should be done. Wiring Damage If any SRS wire harness is damaged, it should be replaced. Don't repair SRS. SRS Connector (Plastic Body And Terminal Metal Pin) Damage If any connector or terminal in the SRS wire harness (except pigtails) is damaged, it should be replaced. SRS Wire Pigtail Damage If the wiring pigtail (a wire or wires attached directly to the device, not by a connector) is damaged, the entire component (with pigtail) must be replaced. Examples of "pigtail" components are the driver air bag assembly, the passenger air bag assembly, and the SRS coil assembly. Page 6310 Air Conditioning Switch: Testing and Inspection 1. Check for continuity between the fan switch and the A/C switch side connector terminals. Page 5059 Wheel Speed Sensor: Connector Locations Front Wheel Sensor Connector Behind Left Front Wheel (Right Wheel Similar) Rear Wheel Sensor Connector Under Rear of Vehicle (On Differential) Page 5892 13. Tighten the bolts to the specified torque. Torque: 59 Nm (43 ft. lbs.) Page 1578 2. Use a valve cutter to minimize scratches and other rough areas. This will bring the contact width back to the standard value. Remove only the scratches and rough areas. Do not cut away too much. Take care not to cut away unblemished areas of the valve seat surface. Valve seat angle degree: 90° 3. Apply abrasive compound to the valve seat insert surface. 4. Insert the valve into the valve guide. 5. Turn the valve while lapping it to fit the valve seat insert. 6. Check that the valve contact width is correct. 7. Check that the valve seat insert surface is in contact with the entire circumference of the valve. Valve Seat Insert Replacement 1. Arc weld the rod at several points. Be careful not to damage the aluminum. 2. Allow the rod to cool for a few minutes. This will cause the valve seat to shrink. 3. Strike the rod and pull it out. 4. Carefully clean the valve seat press- fit on the cylinder head side. 5. Heat the press-fit with steam or some other means to cause expansion. Cool the valve seat with dry ice or some other means. Page 234 Air Bag Control Module: Service and Repair WARNING: DURING SERVICE PROCEDURES, BE VERY CAREFUL WHEN HANDLING SDM. NEVER STRIKE OR JAR SDM. UNDER SOME CIRCUMSTANCES, IT COULD CAUSE DEPLOYMENT AND RESULT IN PERSONAL INJURY OR IMPROPER OPERATION OF THE SUPPLEMENTAL RESTRAINT SYSTEM (SRS). SDM MOUNTING BRACKET BOLTS MUST BE CAREFULLY TORQUED TO ASSURE PROPER OPERATION. THE SRS SHOULD ONLY BE CONNECTED TO A POWER SOURCE WHEN IT IS INSTALLED SECURELY IN THE VEHICLE. THE SDM MAY SUDDENLY DEPLOY THE AIRBAGS CAUSING PERSONAL INJURY WARNING: PROPER OPERATION OF THE SENSING AND DIAGNOSTIC MODULE (SDM) REQUIRES THE SDM TO BE SECURELY INSTALLED ON THE VEHICLE AND THE ARROW ON THE SENSOR MUST BE POINTING TOWARD THE FRONT OF THE VEHICLE. SDM is specifically calibrated and is keyed to the SDM location SRS wiring harness. Caution should be used to ensure proper location of the SDM. The keying of the SDM to its location and wiring harness connectors should never be modified in the field. Removal 1. Disable the SRS. 2. Remove dressing panel around the radio and disconnect cigar lighter harness 3. Remove the transfer sift lever knob. 4. Remove the center console. 5. Remove three connector from Powertrain Control Module (PCM). (Y22SE 2.2L Engine only) 6. Remove PCM with bracket. (Fixed tour bolts) (Y22SE 2.2L Engine only) 7. Remove right side stay between instrument panel and floor. 8. Remove driver and passenger seat. 9. Turn over carpet to rear side. 10. Remove air conditioning duct for rear seat. (Transform the duct during removing it) 11. Pull CPA (2) (Connector Position Assurance-red color) out and push connector lock down to disconnect the SDM harness connector (3). Page 7582 Testing For A Short With A Self-Powered Test Light or DVOM 1. Remove the blown fuse and disconnect the battery and load. 2. Connect one lead of a self-powered test light or digital volt/ohmmeter (DVOM) (switched to the lowest "OHMS" range) to the fuse terminal on the load side. 3. Connect the other lead to a known good ground. 4. Beginning near the fuse box, wiggle the harness. Continue this at convenient points about six inches apart while watching the test light or DVOM. 5. If the self-powered test light goes on or the DVOM displays a low reading or no reading (zero), there is a short to ground in the wiring near that point. Testing for a Short with a Test Light or DVOM 1. Remove the blown fuse and disconnect the load. 2. Connect a test light or digital volt/ohmmeter (DVOM), switched to the appropriate DC volts range, across the fuse terminals to make sure voltage is present. You might have to turn the ignition switch to ON; check the schematic to see. 3. Beginning near the fuse box, wiggle the harness. Continue this at convenient points about six inches apart while watching the test light or DVOM. 4. Where the test light goes , or the DVOM voltage drops to zero, there is a short to ground in the wiring near that point. NOTE: Always use a DVOM on high impedance circuits. A test light may not glow (even with battery voltage present). Testing For A Short With A Short Circuit Locator (Short Finder) 1. Remove the blown fuse. Leave the battery connected. Page 5199 it is located, and what it connects to. Use the Connector Views to help locate the proper cavity when you need to probe a connector. It can be especially helpful if the connector has more than one wire of the same color. A dash symbol (-) indicates that the cavity is empty. Connector views can also be used to help diagnose multiple symptoms in separate circuits which could be caused by a single problem in a connector shared by those circuits. Here's an example: 1. Pick one of the multiple symptoms and look up the schematic for that circuit. 2. Make a list of all the in-line and fuse box connectors in that schematic , 3. Then, in the Connector Views, look up each connector on your list to see if circuits related to the other symptoms run through one of them. If they do, inspect that connector for the problem. Example: The blower, rear window defogger, and the windshield wiper don't work. List all in-line and fuse box connectors in the blower controls circuit and then check the Connector View (see the sample). You find that C324 is common to the blower controls, rear window defogger, and wiper/washer, so you inspect C324 and find the problem, bent terminals. Finding Component/Connector Locations Finding Component/Connector Locations To see where a component or connector is located on the car, look up its photo number in the "Component Location". The photo will also tell you the color of the connector, and how many cavities it has. Page 1302 V6 Engine Room Page 2619 and the fuses. From Fuses to Relays and Components The second half of Power Distribution shows the wiring "From Fuses to Relays and Components." This can speed your troubleshooting by showing which circuits share fuses. If Power Distribution shows that an inoperative circuit and another circuit share a fuse, check a component in the other circuit. If it works, you know the fuse is good and power is available to the inoperative circuit. Ground Distribution Schematics Page 6910 Trunk / Liftgate Lock Cylinder: Service and Repair Tailgate Lock Tailgate Lock and Hatchgate Lock (SWB) Removal 1. Disconnect the battery ground cable. 2. Remove the tailgate glass assembly and tailgate glass stay. 3. Remove the tailgate trim cover assembly. - Remove the two screws fixing the trim cover assembly and pull up the trim cover after detaching the clips from tailgate panel. 4. Remove the waterproof sheet. - Remove the waterproof sheet, taking special care so as not to break it. 5. Remove the key cylinder. - Disconnect the lock links. - Remove the key cylinder retaining clip with screw driver to remove the key cylinder. 6. Remove the hatchgate lock actuator assembly. - Disconnect the actuator harness connector. - Remove the two nuts holding hatchgate lock actuator assembly from inside. 7. Remove the outside handle. - Disconnect the lock link. - Remove the two bolts holding the outside handle from inside. 8. Remove the tailgate lock assembly. - Remove the three screws holding the lock assembly. Installation To install, follow the removal steps in the reverse order, noting the following points: 1. Apply chassis grease to the lock assembly and striker moving surface. 2. Tighten the hatchgate lock assembly fixing screws to the specified torque. Torque 7 Nm (61 lb in) 3. Check that the tailgate lock operates correctly after installing it. Tailgate Lock and Hatchgate Lock (LWB) Removal 1. Disconnect the battery ground cable. 2. Remove the tailgate trim cover assembly (3). - Remove the 2 screws (2) holding the hatch gate lock assembly (1) first, and pull up the trim cover while detaching the clips from tailgate panel. A/T - Vehicle Speed Sensor Installation Precautions Transmission Speed Sensor: Technical Service Bulletins A/T - Vehicle Speed Sensor Installation Precautions Install VSS Properly to Avoid Reman A/T Damage We can't emphasize enough how important it is to follow, to the letter, the installation instructions that come with a reman A/T. These instructions help ensure that you avoid damaging the A/T and score a successful repair. This is particularly true when it comes to installing the vehicle speed sensor (VSS). Step 6 of the instructions tells you to make sure its gear is fully engaged and the VSS is fully seated before you tighten the retaining bolt. If you don't install the VSS properly, the speed sensor gear will get stripped and the A/T will be seriously damaged. So don't take risks with your customer's vehicle. Always follow these instructions to the letter. You can rest assured you're doing the job right. Page 3012 Each schematic represents one circuit. A circuit's wires and components are arranged to show current flow, from power at the top of the page, to ground, at the bottom. Shared Circuits Other circuits may share power or ground terminals or wiring with the circuit shown. A wire that connects one circuit to another, for example, is cut short and has an arrowhead at the end of it pointing in the direction of current flow. Next to the arrowhead is the name of the circuit or component which shares that wiring. To quickly check shared wiring, check the operation of a component it serves. If that component works, you know the shared wiring is OK. Connectors All in-line and junction connectors are numbered (C725, C416, etc.). Component connectors are not numbered but are identified either by the name of Page 7476 Distinct Of Circuit By Wire Base Color All wires have color-coded insulation. Wires belonging to a system's main harness will have a single color. Wires belonging to a system's sub-circuits will have a colored stripe. Striped wires use the codes found in the chart to show wire size and colors. Abbreviations are used to indicate wire color within a circuit diagram. How to Identify Connector Terminals How to Identify Connector Terminals Cavity Numbering System The cavities (and wire terminals) in each connector are numbered starting from the upper left, looking at the male terminals from the terminal side (or looking at the female terminals from the wire side. Both views are in the same direction so the numbers are the same.) All actual cavities are numbered, even if they have no wire terminals in them. NOTE: Data Link Connector (DLC) terminals are numbered according to SAE standard J1962, not the Honda standard. The numbers of the four end terminals are molded into the corners of the connector face. The connector cavity number is listed next to each terminal on the circuit schematic. The cavity / terminal shown is # 6. Using/Identifying Connector Terminal Views How to Use Connector Terminal Views To see the configuration of a connector's cavities, look up its view number in the Connector Views. Each view includes the color of the connector, where Page 6831 Front Door Window Regulator: Service and Repair Front Window Regulator, Glass and Glass Run Front Window Regulator, Glass And Glass Run Removal 1. Disconnect the battery ground cable. Page 6078 The connector cavity number is listed next to each terminal on the circuit schematic. The cavity / terminal shown is # 6. Diodes A rectifier diode works like a one way valve. It allows current to flow only in the direction of the arrow. A Zener diode blocks reverse current at normal voltages just like a rectifier diode. At high voltages, however, a Zener diode allows current to flow in reverse. Fuses Page 2091 20. Using a DVOM, check the voltage between the reference voltage pin for each sensor and ground. ^ If the sensor circuits all read 5.0 volts, go to step 22. ^ If any sensor circuit is above or below 5.0 volts, go to step 21. 21. Troubleshoot for an internal short in another sensor or a PCM malfunction. ^ To find the sensor with an internal short, monitor the reference voltage, and disconnect each sensor (FTPS, EGR, MAP TPS, CKP and CMP) one at a time until the reference voltage reads 5.0 volts. Replace that sensor, and repeat step 14. ^ To find a malfunctioning PCM, replace it with a known-good PCM. If all three sensors (APP Sensor 1, APP Sensor 2, and APP Sensor 3) are within range, the original PCM is faulty; replace it and repeat step 14. 22. Using a jumper wire, connect the reference voltage of each circuit to its signal input, and view the APP Sensor values in the Engine Data List. APP Sensor 1 should have a value of 99%, and APP Sensor 2 and APP Sensor 3 should each have a value of 0%. ^ If the values are not as specified, troubleshoot for high resistance on the signal input or a PCM malfunction. Repair the circuit or replace the PCM, then repeat step 14. ^ If the values are as specified, the problem may be intermittent. Disconnect the 10 P connector from the modified APPS, and connect it to the new APPS; then repeat step 14. Wiggle the APPS wires as you go through the adjustment procedure to find the intermittent problem. 23. Install the accelerator pedal assembly, and torque the bolts to 10 N.m (7 lb-ft). Service and Repair Band Control Solenoid Valve: Service and Repair REMOVAL 1. Raise the vehicle and support it on jack stands. 2. Disconnect battery ground cable. 3. Drain fluid. 4. Remove sixteen 10 mm screws, main case oil pan, magnet, and gasket. 5. Remove three 13 mm screws, oil filter. 6. Disconnect wiring harness from band control solenoid and shift solenoids. Pull only on connectors, not on wiring harness. 7. Remove spring pin for shift solenoid A, shift solenoid B, and band control solenoid respectively, using suitable pliers taking care not to damage solenoids. 8. Remove shift solenoid A, shift solenoid B, band control solenoid, and gaskets from main case valve body. Do not pull on wiring harness. Remove solenoids by grasping the metal tip. INSTALLATION 1. Install shift solenoid A, shift solenoid B, band control solenoid with new gaskets to main case valve body respectively. 2. Carefully install spring pin with hammer to avoid damage to valve body, etc. 3. Connect wiring harness to solenoids. 4. Install oil filter with a new gasket and the three 13 mm screws, tighten to the specified torque. Torque: 20 Nm (15 Ft. lbs.) Service and Repair Marker Lamp Bulb: Service and Repair Removal 1. Disconnect the battery ground cable. 2. Remove the radiator grille. - Refer to Engine Hood and Fender in Body Structure. 3. Remove the front combination light (2). - Remove three screws. 4. Remove the bulb (1). - Remove the side marker light socket by turning ii counterclockwise. - Remove the bulb by turning it counterclockwise while pushing it at the same time. Installation To install, follow the removal steps in the reverse order. Page 8050 Page 2049 Terminals - "T" Each "T" terminal (ring type) is numbered for reference and location. A "T" terminal is secured with a screw or bolt. Wires Page 2674 This sample Ground Distribution schematic shows all of the components that share two ground points. Components A solid border line means the entire component is shown. A broken border line indicates that only part of the component is shown. Page 8200 Rear Door Window Regulator: Service and Repair Rear Window Regulator, Glass and Glass Run Rear Window Regulator, Glass and Glass Run Removal 1. Disconnect the battery ground cable. 2. Remove the rear corner garnish. - Pull the garnish to disconnect the retaining clip. Page 1154 O-ring(2) must be fitted in the groove (1) of refrigerant line Insert the nut into the union. First, tighten the nut by hand as much as possible, then tighten the nut to the specified torque. Page 8224 - Attach some cloth tape (1) on the body for protecting the painting surface. - Clean the remaining adhesive caulking material from the area of the body which holds the windshield. Installation To install, follow the removal steps in the reverse order, noting the following points. 1. Clean the bonding surfaces of both the windshield and body panel with a soft rag and white gasoline. 2. Install the spacer. - Attach spacers in ten locations as shown in the figure. - Always use new spacer. 3. Install the windshield upper molding. - Peel off the tear-away paper from the windshield upper molding, and start applying it with one end of the glass and cut away the surplus at the other end of the glass for length adjustment. - Always use new upper molding. 4. Temporary install the windshield support. Page 7034 Rear Door Lock Assembly Page 1365 Tires: Testing and Inspection Diagnosis List If the following conditions are noted, rotation is required. 1. Front tire wear is different from rear. 2. Uneven wear exists across the tread of any tire. 3. Left and right front tire wear is unequal. 4. Left and right rear tire wear is unequal. If the following conditions are noted, check the wheel alignment. 1. Left and right front tire wear is unequal. 2. Uneven wear exists across the tread of any tire. 3. Front tire treads have scuffed appearance with "feather" edges on one side of tread ribs or blocks. 4. There is cupping, flat spotting etc. Higher than recommended pressure can cause: 1. Hard ride. 2. Poor steering stability. 3. Rapid and uneven wear at center of the tread. Lower than recommended pressure can cause: 1. Tire squeal on turns. 2. Hard steering. 3. Rapid and uneven wear on the edges of the tread. 4. Tire rim bruises and rupture. 5. Tire cord breakage. 6. High tire temperatures. 7. Reduced handling. 8. Reduced fuel economy. Unequal pressure on same axle can cause: 1. Uneven braking. 2. Steering lead. 3. Reduced handling. 4. Swerve on acceleration. Page 5924 Wires Wire insulation can be one color, or one color with another color stripe. (The second color is the stripe.) This circuit continues on another image. (The arrow shows direction of current flow.) To follow the RED/BLK wire in this example, you would turn to "Fuel and Emissions" and look for the "A" arrow. Page 6458 The SDM is connected to the SRS wiring harness by a 24 - pin connector. This harness connector uses a shorting clip across certain terminals in the contact area. This shorting clip connects the "AIR BAG" warning lamp to ground when the SDM harness connector is disconnected or Connector Position Assurance (CPA) is not inserted even If completely connected. This will cause the "AIR BAG" warning lamp to come "ON" steady whenever the ignition switch is at the ON or START positions with the SDM disconnected. Page 7067 Power Door Lock Switch: Diagrams Locations Crankshaft Position Sensor: Locations CKP Sensor 36. Bottom Right Side of Engine Bottom Right Side of Engine Page 5943 6. Pull the control lever assembly out and disconnect the fan switch and air conditioning switch connectors. 7. Remove control level assembly. 8. Disconnect control cables at each unit side. Installation To install, follow the removal steps in the reverse order, noting the following points: Page 32 Electronic Brake Control Module: Description and Operation The EHCU consists of ABS control circuits, fault detector, and a fail-safe. It drives the hydraulic unit according to the signal from each sensor, cancelling ABS to return to normal braking when a malfunction has occurred in the ABS. The EHCU has a self-diagnosing function which can indicate faulty circuits during diagnosis. The EHCU is mounted on the engine compartment rear right side. It consists of a Motor, Plunger Pump, Solenoid Valves. Solenoid Valves: Reduces or holds the caliper fluid pressure for each front disc brake or both rear disc brakes according to the signal sent from the EHCU. Reservoir: Temporarily holds the brake fluid that returns from the front and rear disc brake caliper so that pressure of front disc brake caliper can be reduced smoothly. Plunger Pump: Feeds the brake fluid held in the reservoir to the master cylinder. Motor: Drives the pump according to the signal from EHCU. Check Valve: Controls the brake fluid flow. Page 1360 Tires: Service Precautions CAUTION: Always use the correct fastener in the proper location. When you replace a fastener, use ONLY the exact part number for that application. Honda will call out those fasteners that require a replacement after removal. Honda will also call out the fasteners that require thread lockers or thread sealant. Unless otherwise specified, do not use supplemental coatings (Paints, greases, or other corrosion inhibitors) on threaded fasteners or fastener joint interfaces. Generally, such coatings adversely affect the fastener torque and the joint clamping force, and may damage the fastener. When you install fasteners, use the correct tightening sequence and specifications. Following these instructions can help you avoid damage to parts and systems. Locations Page 128 Powertrain Control Module: Diagnostic Aids Before Troubleshooting Before Troubleshooting See: Service Precautions/Vehicle Damage Warnings/Tips and Precautions 1. Check applicable fuses in the appropriate fuse/relay box. 2. Check the battery for damage, state of charge, and clean and tight connections. CAUTION: Do not quick-charge a battery unless the battery ground cable has been disconnected, otherwise you will damage the alternator diodes. - Do not attempt to crank the engine with the battery ground cable loosely connected or you will severely damage the wiring. While You're Working 1. Make sure connectors are clean, and have no loose terminals or receptacles. 2. Make sure that connectors without wire seals are packed with dielectric (silicone) grease. Part Number: 08798-9001. 3. When connecting a connector, push it until it "clicks" into place. CAUTION: Do not pull on the wires when disconnecting a connector. Pull only on the connector housings. - Most circuits include solid-state devices. Test the voltages in these circuits only with a 10-megaohm or higher impedance digital multi meter. Never use a test light or analog meter on circuits that contain solid-state devices. Damage to the devices may result. Five-Step Troubleshooting 1. Verify The Complaint Turn on all the components in the problem circuit to check the accuracy of the customer complaint. Note the symptoms. Do not begin disassembly or testing until you have narrowed down the problem area. 2. Analyze The Schematic Look up the schematic for the problem circuit. Determine how the circuit is supposed to work by tracing the current paths from the power source through the circuit components to ground. Also, trace circuits that share wiring with the problem circuit. The names of circuits that share the same fuse, ground, or switch, and so on, are referred to in each circuit schematic. Try to operate any shared circuits you didn't check in step 1. If the shared circuits work, the shared wiring is OK, and the cause must be in the wiring used only by the problem circuit. If several circuits fail at the same time, the fuse or ground is a likely cause. Based on the symptoms and your understanding of the circuit's operation, identify one or more possible causes. 3. Isolate The Problem By Testing The Circuit Make circuit tests to check the diagnosis you made in step 2. Keep in mind that a logical, simple procedure is the key to efficient troubleshooting. Test for the most likely cause of failure first. Try to make tests at points that are easily accessible. 4. Fix The Problem Once the specific problem is identified, make the repair. Be sure to use proper tools and safe procedures. 5. Make Sure The Circuit Works Turn on all components in the repaired circuit in all modes to make sure you've fixed the entire problem. If the problem was a blown fuse, be sure to test all of the circuits on that fuse. Make sure no new problems turn up and the original problem does not recur. Page 422 Fan Control Switch Page 2092 24. Verify APP Sensor 1 is between 11 and 15 percent, and APP Sensor 2 and APP Sensor 3 are between 89 and 85 percent with the pedal up (closed throttle). If not, loosen the mounting screws on the APPS sensor, and go to step 14. 25. Clear all DTCs with the PGM Tester. 26. Turn off the ignition switch, and disconnect the PGM Tester. Diagrams Page 6053 Compressor Clutch: Service and Repair Inspection and Repair Drive Plate If the frictional surface shows signs of damage due to excessive heat, the drive plate and pulley should be replaced. Pulley Assembly Check the appearance of the pulley assembly. If the frictional surface of the pulley shows signs of excessive grooving due to slippage both the pulley and drive plate should be replaced. The frictional surfaces of the pulley assembly should be cleaned with a suitable solvent before reinstallation. Coil Check coil for loose connector or cracked insulation. Page 6868 14. Remove the glass. - First, align the height of regulator to the access hole. Remove 2 screws attaching bottom channel and regulator, then remove the glass. - Remove the window glass by tilting it as necessary. 15. Remove the window regulator. - Remove the window regulator fixing bolts and pull the regulator out from the lower hole of the door panel. 16. Remove the glass run. - Pull the glass run out from the door frame. Installation Page 7157 Roof Rail Locations Service and Repair Torque Converter Clutch Solenoid: Service and Repair REMOVAL 1. Raise the vehicle and support it on jack stands. 2. Disconnect battery ground cable. 3. Drain fluid. 4. Remove twelve 10 mm adapter case oil pan fixing screws, adapter case oil pan, and gasket. NOTE: Oil pan still contains transmission fluid. Place a large drain container under the oil pan. Drain the fluid carefully. 5. Disconnect wiring harness from force motor solenoid and converter clutch solenoid. Pull only on connectors, not on wiring harness. 6. Remove seven 13 mm screws from adapter case valve body assembly, then remove transfer plate, two gaskets, and adapter case valve body. INSTALLATION 1. Inspect electrical 4 pin connector and seal of adapter case. Replace if necessary. 2. Install gasket, transfer plate, and gasket. 3. Install adapter case valve body and seven 13 mm screws. Tighten the screws to the specified torque. Torque: 20 Nm (15 Ft. lbs.) 4. Connect wiring harness assembly to converter clutch solenoid and force motor. 5. Install oil pan gasket, oil pan, and twelve 10 mm screws. Tighten the screws to the specified torque. Torque: 11 Nm (96 Ft. lbs.) 6. Fill transmission through the overfill screw hole of oil pan, using ATF DEXRON III. 7. Connect battery ground cable. Page 5804 - Install the rubber bushing by using to installer J-43008. NOTE: When mounting rubber bushings, be sure not to use grease on bushings or any other nearby part. INSTALLATION 1. Install upper link. Make sure that the upper link is in its correct position. NOTE: When mounting upper link, be sure not to use grease bushings or any other nearby part. 2. Install bolt, nut, rubber plate and protector. Tighten the bolts and nuts lightly, then retighten them to the specified torque after the vehicle is at curb height. Torque to 137 Nm (101 ft. lbs.). 3. Install speed sensor cable. 4. Install fuel tank. Page 4596 Ground - "G" Shielding Sheilding This represents RFI (Radio Frequency Interference) shielding around a wire. The shielding is always connected to ground. Splices Page 3219 Testing For A Short With A Self-Powered Test Light or DVOM 1. Remove the blown fuse and disconnect the battery and load. 2. Connect one lead of a self-powered test light or digital volt/ohmmeter (DVOM) (switched to the lowest "OHMS" range) to the fuse terminal on the load side. 3. Connect the other lead to a known good ground. 4. Beginning near the fuse box, wiggle the harness. Continue this at convenient points about six inches apart while watching the test light or DVOM. 5. If the self-powered test light goes on or the DVOM displays a low reading or no reading (zero), there is a short to ground in the wiring near that point. Testing for a Short with a Test Light or DVOM 1. Remove the blown fuse and disconnect the load. 2. Connect a test light or digital volt/ohmmeter (DVOM), switched to the appropriate DC volts range, across the fuse terminals to make sure voltage is present. You might have to turn the ignition switch to ON; check the schematic to see. 3. Beginning near the fuse box, wiggle the harness. Continue this at convenient points about six inches apart while watching the test light or DVOM. 4. Where the test light goes , or the DVOM voltage drops to zero, there is a short to ground in the wiring near that point. NOTE: Always use a DVOM on high impedance circuits. A test light may not glow (even with battery voltage present). Testing For A Short With A Short Circuit Locator (Short Finder) 1. Remove the blown fuse. Leave the battery connected. Locations Evaporator Temperature Sensor / Switch: Locations Electronic Thermostat, Evaporator Core And/Or Expansion Valve - Disassembled View Brakes - Revised Brake Bleeding Procedure Brake Bleeding: All Technical Service Bulletins Brakes - Revised Brake Bleeding Procedure 01-016 January 30, 2001 Applies To: 1998-01 Passport - ALL Service Manual Update: Revised Brake Bleeding Procedure BACKGROUND The brake bleeding procedure in the 1998 thru 2001 Passport Service Manuals is incomplete. Use this service bulletin to update the manuals. WARRANTY INFORMATION None. CORRECTIVE ACTION 1. In the 1998, 1999, 2000, and 2001 Passport Service Manuals, on pages 5A-21 and 5A-22, cross out the entire Tech 2 Service Bleed procedure. 2. In each manual, on page 5A-21, write this note: See page 5C-10 for the brake bleeding procedure 3. In each manual, on page 5C-10, between steps 1 and 2, write this note: For important additional information, see Service Bulletin 01-016, Service Manual Update: Revised Brake Bleeding Procedure, Filed under Brakes. SERVICE MANUAL UPDATE INFORMATION To avoid trapping air bubbles in the ABS hydraulic unit while bleeding the brakes, the hydraulic unit must be tilted forward at a 15-degree angle or greater. Before bleeding, check the angle of the ABS hydraulic unit with an angle locator level. If needed, raise the rear of the vehicle to get the proper Page 4655 4WD Motor Actuator: Connector Locations Beneath Center of Vehicle, on Transfer Case (A/T) Page 5556 Air Bag(s) Arming and Disarming: Service Precautions Wiring Precautions Wiring Precautions SRS wiring can be identified by special yellow outer covering (except the SRS indicator light circuit). Never attempt to modify, splice, or repair SRS wiring. If there is an open or damage in SRS wiring, replace the harness. Be sure to install the harness wires so that they are not pinched, or interfere with other parts. Make sure all SRS ground locations are clean, and grounds are securely fastened for optimum metal-to-metal contact. Poor grounding can cause intermittent problems that are difficult to diagnose. Page 5961 1. Make sure the ignition key is not in the ignition switch. 2. Open the glove box, and empty out its contents. Gently squeeze the sides of the glove box together to release the stops, then lower it all the way. 3. 2000-01 Models: Slide the intake actuator relay off its mounting bracket, and move it out of the way. 4. Unplug the 6P connector from the blower resistor, then remove and discard the resistor (two screws). 5. Unplug the 2P connector from the blower motor, then remove and discard the blower motor assembly (four screws). Page 2580 2. Connect one lead of a self-powered test light or DVOM to one end of the part of the circuit you want to test. 3. Connect the other lead to the other end. 4. If the self-powered test light glows, there is continuity. If you're using a DVOM, a low reading or no reading (zero), means good continuity. Testing For Voltage When testing for voltage at a connector without wire seals, you do not have to separate the two halves of the connector. Instead, probe the connector from the back. Always check both sides of the connector because dirty, corroded, and bent terminals can cause problems (no electrical contact = an open). 1. Connect one lead of the lest light to a known good ground, or, if you're using a digital volt ohmmeter (DVOM), place it in the appropriate DC volts range, and connect its negative lead to ground. 2. Connect the other lead of the test light or DVOM to the point you want to check. 3. If the test light glows, there is voltage present. If you're using a DVOM, note the voltage reading. It should be within one volt of measured battery voltage. A loss of more than one volt indicates a problem. NOTE: Always use a DVOM on high impedance circuits. A test light may not glow (even with battery voltage present). Testing For Voltage Drop Wires, connectors, and switches are designed to conduct current with a minimum loss of voltage. A voltage drop of more than one volt indicates a problem. 1. Place the digital volt/ohmmeter (DVOM) in the appropriate DC volts range. Connect the positive lead to the end of the wire (or to the connector or switch) closest to the battery. 2. Connect the negative lead to the other end of the wire (or the other side of the connector or switch). 3. Turn on the components in the circuit. 4. The DVOM will show the difference in voltage between the two points. A difference, or drop, of more than one volt indicates a problem. Check the circuit for loose, dirty, or bent terminals. Page 2562 If there is no photo number below or beside a component name or a connector, ground, or terminal number, look up that name or number in the appropriate Connector Identification Chart. The chart lists how many cavities a connector has, where it's located, and what it connects to. The related illustration shows the connector's location on the harness, and the harness routing. NOTE: Photos listed by number are located at Locations / Components / Photograohs. See: Locations/Component Locations/Photographs Circuit Schematics Locations 4WD Control Unit: Locations Under Center Console Service and Repair Fuel Pressure Release: Service and Repair CAUTION: To reduce the risk of fire and personal injury, there are necessary to relieve the fuel system pressure filler and gauge unit before servicing the fuel system components. CAUTION: After relieving the system pressure, a small amount of fuel may be released when servicing fuel lines or connections. Reduce the chance of personal injury by covering the fuel line fittings with a shop towel before you disconnect the fittings. The towels will absorb any fuel that may leak out. When the disconnection is completed, place the towel in an approved container. 1. Remove the fuel cap. 2. Remove the fuel pump relay from the underhood relay box. 3. Start the engine and allow it to stall. 4. Crank the engine for 30 seconds. 5. Disconnect the negative battery cable. Page 6112 This sample Ground Distribution schematic shows all of the components that share two ground points. Components A solid border line means the entire component is shown. A broken border line indicates that only part of the component is shown. Locations Roof Rail - Parts Location Page 1495 Harmonic Balancer - Crankshaft Pulley: Service and Repair Crankshaft Pulley Removal 1. Disconnect battery ground cable. 2. Remove air cleaner assembly. 3. Remove radiator upper fan shroud from radiator. Page 2008 This sample Ground Distribution schematic shows all of the components that share two ground points. Components A solid border line means the entire component is shown. A broken border line indicates that only part of the component is shown. A/T - Vehicle Speed Sensor Installation Precautions Transmission Speed Sensor: Technical Service Bulletins A/T - Vehicle Speed Sensor Installation Precautions Install VSS Properly to Avoid Reman A/T Damage We can't emphasize enough how important it is to follow, to the letter, the installation instructions that come with a reman A/T. These instructions help ensure that you avoid damaging the A/T and score a successful repair. This is particularly true when it comes to installing the vehicle speed sensor (VSS). Step 6 of the instructions tells you to make sure its gear is fully engaged and the VSS is fully seated before you tighten the retaining bolt. If you don't install the VSS properly, the speed sensor gear will get stripped and the A/T will be seriously damaged. So don't take risks with your customer's vehicle. Always follow these instructions to the letter. You can rest assured you're doing the job right. A/T - ATF Cooler Cleaner Information Transmission Cooler: Technical Service Bulletins A/T - ATF Cooler Cleaner Information Use Worm-Style Clamps With the ATF Cooler Cleaner The spring-style clamps used on the ATF cooler lines are made to hold the cooler lines to the ATF cooler under normal operating conditions. The ATF Cooler Cleaner (P/N GHTTTCF6H) uses high pressure (100 psi) to do its job. With the pump motor running, the spring-style clamps can walk off or disconnect, and you'll wind up with a real mess to clean up in your shop. In March of this year, we sent each Honda dealership a pair of high-quality worm-style clamps to replace the original spring-style clamps. These clamps were part of a cooler cleaner update kit, and securely hold the cooler line in place. They've got a blue cap for easy identification. Need some more? Just call G-TFC, Inc. Page 2542 3. Connect the electrical connector to the CMP sensor. 4. Install the common chamber assembly. 5. Install the engine cover. 6. Connect the negative battery cable. Accelerator Pedal Position Sensor - MIL ON/DTC's Set Technical Service Bulletin # 01-047 Date: 010814 Accelerator Pedal Position Sensor - MIL ON/DTC's Set 01-047 August 14, 2001 Applies To: 2000-01 Passport - ALL MIL Comes On With Accelerator Pedal Position Sensor DTC(s) P1271, P1273, P1275, P1280, and/or P1285 SYMPTOM The MIL is on with DTC P1271, P1273, P1275, P1280, or P1285 (various accelerator pedal position sensor problems) stored. The REDUCED POWER indicator may also be on; and the engine may occasionally idle too high, or the idle may fluctuate. PROBABLE CAUSE Contaminated grease on the potentiometer circuit board of the accelerator pedal position sensor (APPS) causes high resistance in the APPS circuit. CORRECTIVE ACTION Replace and adjust the APPS, remove all grease from the accelerator link, and clean the APPS harness connector and connector C123. PARTS INFORMATION Accelerator Pedal Position Sensor: P/N 8-97193-713-0, H/C 6198311 REQUIRED MATERIALS CAIG DeoxIT D5-S6 Contact Cleaner: P/N 341-200 (available from www.partsexpress.com) or Permatex Electrical Contact Cleaner: Permatex P/N 24379 WARRANTY CLAIM INFORMATION In warranty: The normal warranty applies. Operation Number: 122114 Flat Rate Time: 0.5 hour Failed Part: P/N 8-97220-540-0 H/C 6202436 Defect Code: 091 Contention Code: C99 Template ID: 01-047A Skill Level: Repair Technician Out of warranty: Any repair performed after warranty expiration may be eligible for goodwill consideration by the District Service Manager or your Zone Office. You must request consideration, and get a decision, before starting work. Page 7584 2. Connect one lead of a self-powered test light or DVOM to one end of the part of the circuit you want to test. 3. Connect the other lead to the other end. 4. If the self-powered test light glows, there is continuity. If you're using a DVOM, a low reading or no reading (zero), means good continuity. Testing For Voltage When testing for voltage at a connector without wire seals, you do not have to separate the two halves of the connector. Instead, probe the connector from the back. Always check both sides of the connector because dirty, corroded, and bent terminals can cause problems (no electrical contact = an open). 1. Connect one lead of the lest light to a known good ground, or, if you're using a digital volt ohmmeter (DVOM), place it in the appropriate DC volts range, and connect its negative lead to ground. 2. Connect the other lead of the test light or DVOM to the point you want to check. 3. If the test light glows, there is voltage present. If you're using a DVOM, note the voltage reading. It should be within one volt of measured battery voltage. A loss of more than one volt indicates a problem. NOTE: Always use a DVOM on high impedance circuits. A test light may not glow (even with battery voltage present). Testing For Voltage Drop Wires, connectors, and switches are designed to conduct current with a minimum loss of voltage. A voltage drop of more than one volt indicates a problem. 1. Place the digital volt/ohmmeter (DVOM) in the appropriate DC volts range. Connect the positive lead to the end of the wire (or to the connector or switch) closest to the battery. 2. Connect the negative lead to the other end of the wire (or the other side of the connector or switch). 3. Turn on the components in the circuit. 4. The DVOM will show the difference in voltage between the two points. A difference, or drop, of more than one volt indicates a problem. Check the circuit for loose, dirty, or bent terminals. Locations Page 2477 Manually Removing a Jammed Magazine (Passport only) One-piece door model: 1. Open the changer door. 2. Check to see if all the trays are in the magazine. ^ If a tray is stuck in the changer, replace the changer. ^ If all the trays are in the magazine, place the changer in a horizontal position, and insert a thin stainless steel ruler or a "Slim Jim" under the magazine, about 1/2" from the right side of the opening. 3. Push the ruler in until it presses against the eject lever at the back of the unit. 4. Slowly remove the ruler and magazine at the same time. Two-piece door model: 1. Remove the changer from the vehicle. 2. Remove the top cover plate from the changer, and inspect for a jammed tray. ^ If a tray is stuck in the changer, replace the changer. ^ If all the trays are in the magazine, place the changer in a horizontal position, and insert a thin stainless steel ruler or a "Slim Jim" under the magazine, about 1/2" from the right side of the opening. 3. Push the ruler in until it presses against the eject lever at the back of the unit. 4. Slowly remove the ruler and magazine at the same time. Handling and Inspecting Compact Discs Service Precautions Brake Master Cylinder: Service Precautions CAUTION: Use only specified brake fluid. Do not use any fluid which contains a petroleum base. Do not use a container which has been used for petroleum based fluids or a container which is wet with water. Petroleum based fluid will cause swelling and distortion of rubber parts in the hydraulic brake system. Water mixed with brake fluid lowers the fluid boiling point. Keep all fluid containers capped to prevent contamination. Always fill the master cylinder reservoir when the engine is cold. Never allow the brake fluid to come in contact with the painted surfaces. The master cylinder reservoir must be kept properly filled to ensure adequate reserve and to prevent air and moisture from entering the hydraulic system However, because of expansion due to heat absorbed from the brakes and the engine, the reservoir must not be overfilled. The brake fluid reservoir is on the master cylinder, which is located under the hood on the left side of the cowl. Thoroughly clean reservoir cap before removal to avoid getting dirt into reservoir. Remove the diaphragm. Add fluid as required to bring level to the "MAX" mark on the reservoir tank. Use "DOT 3" Hydraulic Brake Fluid. If the fluid cap diaphragm is stretched, return it to the original position before installing. Locations Door Switch: Locations Page 4587 Distinct Of Circuit By Wire Base Color All wires have color-coded insulation. Wires belonging to a system's main harness will have a single color. Wires belonging to a system's sub-circuits will have a colored stripe. Striped wires use the codes found in the chart to show wire size and colors. Abbreviations are used to indicate wire color within a circuit diagram. How to Identify Connector Terminals How to Identify Connector Terminals Cavity Numbering System The cavities (and wire terminals) in each connector are numbered starting from the upper left, looking at the male terminals from the terminal side (or looking at the female terminals from the wire side. Both views are in the same direction so the numbers are the same.) All actual cavities are numbered, even if they have no wire terminals in them. NOTE: Data Link Connector (DLC) terminals are numbered according to SAE standard J1962, not the Honda standard. The numbers of the four end terminals are molded into the corners of the connector face. The connector cavity number is listed next to each terminal on the circuit schematic. The cavity / terminal shown is # 6. Using/Identifying Connector Terminal Views How to Use Connector Terminal Views To see the configuration of a connector's cavities, look up its view number in the Connector Views. Each view includes the color of the connector, where Page 692 6. Place the end of the return hose in a container. Have someone start the engine, then pour ATF into the reservoir while you watch the fluid coming out of the return hose. When the fluid coming out is the same color as the new fluid, turn off the engine. 7. Reconnect the return hose to the reservoir. 8. Start the engine. Fill the power steering reservoir to the proper level with ATF then turn off the engine. 9. Use the Smart Cable to reprogram the PCM with the latest software from the June 2001 or later HONDANET CD-ROM. Refer to Service Bulletin 99-005, Updating the Passport PCM, filed under Tools. 10. Use the PGM Tester to clear any DTCs. 11. Use the PGM Tester to check the broadcast code. Make sure the broadcast code matches the one you selected from the CD-ROM. WARRANTY CLAIM INFORMATION In warranty: The normal warranty applies. Failed Part: P/N 8-97181-590-0 H/C 5698030 Defect Code: 064 Contention Code: C01 Skill Level: Repair Technician Out of warranty: Any repair performed after warranty expiration may be eligible for goodwill consideration by the District Service Manager or your Zone Office. You must request consideration, and get a decision, before starting work. REPAIR PROCEDURE - APPS GROUND 1. Unclamp the air cleaner housing cover, and move it to the side for access to connector C123 (16P BLK). Page 1554 1. Install cylinder head cover. - Clean the sealing surface of cylinder head and cylinder head cover to remove oil and sealing materials completely. Apply sealant (TB-1207B or equivalent) of bead diameter 2-3 mm at eight place of arched area of camshaft bracket on front and rear sides. - The cylinder head cover must be installed within 5 minutes after sealant application to prevent premature hardening of sealant. - Tighten bolts to the specified torque. Torque: 9 Nm (80 inch lbs.) 2. Install exhaust gas recirculation pipe and tighten to specified torque. Torque: Exhaust manifold side: 28 Nm (21 ft. lbs.) Flare nut: 44 Nm (33 ft. lbs.) Cylinder head side: 25 Nm (18 ft. lbs.) 3. Tighten fuel injector harness bracket bolts to specified torque then reconnect fuel injector harness connector. Torque: 7.8 Nm (5.7 ft. lbs.) 5. Install heater pipe bolt to the specified torque. Torque: 21 Nm (15 ft. lbs.) 6. Connect ignition coil connector and tighten ignition coil fixing bolts to specified torque. Torque: 4 Nm (35 inch lbs.) 7. Connect ventilation hose to cylinder head. Page 270 The wire insulation has one color or one color with another color stripe. The second color is the stripe. Page 5743 17. Fill out the information on a campaign completion label. Stick this label to the back edge of the driver's door, just below the door latch. * NOTE: If you need more labels, order them from Helm using reorder number Y0895.* Stage 3 Repair STAGE 3 REPAIR NOTE: Do this repair on both sides of the vehicle. 1. Remove the frame rail side hole plug from both frame rails. 2. Remove the lower trailing link front mounting nuts from both trailing links. The mounting bolts will be removed later. Service and Repair Vehicle Lifting: Service and Repair CAUTION: - If a lifting device other than the original jack is used, it is most important that the device be applied only to the correct lifting points. Raising the vehicle from any other point may result in serious damage. - When jacking or lifting a vehicle at the frame side rail or other prescribed lift points, be certain that lift pads do not contact the catalytic converter, brake pipes or cables, or fuel lines. Such contact may result in damage or unsatisfactory vehicle performance. Lifting Points And Supportive Point Locations Lifting Points and Supportable Point Locations Lifting Point: Front - When using a floor jack, lift on the Convex portion of the skid plate. Page 4781 Electronic Brake Control Module: Pinout Values and Diagnostic Parameters EHCU Connector Pin-Out Checks Part 1 of 2 Part 2 of 2 - Disconnect Electronic Hydraulic Control Module. - Perform checks with high impedance digital multimeter J-39200 or equivalent. Upper Link Trailing Arm: Service and Repair Upper Link Upper Link REMOVAL 1. Remove fuel tank. 2. Remove the speed sensor cable from the upper link. 3. Remove bolt, nut, rubber plate and protector. 4. Remove upper link. INSPECTION AND REPAIR Make necessary correction or parts replacement if wear, damage, corrosion or any other abnormal condition are found through inspection. 1. Upper link 2. Rubber bushing: - Remove the rubber bushing by using remover J-43008. Page 6912 1. When setting up links, pay attention to the position and direction of the links. 2. Apply chassis grease to the lock assembly and striker moving surface. 3. Check that the tailgate lock operates correctly after installing it. 4. Tighten the hatchgate lock assembly fixing bolts to the specified torque. Torque 7 Nm (61 lb in) Testing and Inspection Electronic Throttle Actuator: Testing and Inspection Electric Throttle Control (ETC) System Check Circuit Description - The powertrain control module (PCM) controls engine speed by adjusting the position of the throttle control valve (DC motor). The throttle motor is a DC motor driven by one coil. The PCM applies current to the DC motor coil in PWM ( %) to adjust the throttle valve into a passage in the throttle body to allow air flow. This method allows highly accurate control of engine speed and quick response to changes in engine load. - The acceleration position (AP1) sensor circuit provides a voltage signal relative to acceleration pedal angle. The acceleration pedal angle will vary about 13 % at idle position to about 87 % at wide open throttle (WOT). APS signal is used to determine which DC motor will adjust throttle position. After the APS signal has been processed by the PCM, it will command DC motor to allow movement of throttle position. Diagnostic Aids - An intermittent may be caused by a poor connection, rubbed-through wire insulation or a wire broken inside the insulation. Check for poor connections or a damaged harness. Inspect the PCM harness and connector for improper mating, broken locks, improperly formed or damaged terminals, poor terminal-to-wire connection, and damaged harness. - Throttle body - Check for objects blocking the DC motor or throttle bore, excessive deposits in the ETC passage and on the valve spring, and excessive deposits in the throttle bore and on the throttle valve plate. - Acceleration pedal - Check for objects blocking the AP sensor or pedal arm with spring, and excessive deposits in the acceleration pedal arm and on the acceleration pedal. Step 1 Locations Vapor Pressure Sensor / Fuel Gauge And Fuel Pump Connector Page 7555 Air Bag(s) Arming and Disarming: Service and Repair Connector Disconnection / Connection REMOVAL To remove the connector, hold the cover insulator(l) and pull it. The cover insulator slides and lock will be released. Do not hold the socket insulator(2). INSTALLATION Page 4315 2. Install retainer. Note direction - do not install backwards. 3. Install oil seal. Note direction. 4. Install bearing assembly, using installer and press. NOTE: Install bearing with cup towards inboard side. Page 4065 7. Remove selector lever knob and cover. 8. Disconnect select cable. 9. Disconnect shift lock cable. 10. Disconnect harness connector. 11. Remove selector lever subassembly. INSTALLATION 1. Install selector lever subassembly. 2. Connect harness connector. 3. Connect shift lock cable. Page 4301 4. Remove flange nut and washer by using pinion flange holder J-8614-01 after raising up its staked parts completely. 5. Remove flange by using SST J-8614-1-3. - Have a suitable container in place to catch lubricant. 6. Remove oil seal. 7. Remove pinion oil seal slinger. 8. Remove outer bearing by using remover J-39602. 9. Remove collapsible spacer. INSPECTION AND REPAIR Make necessary correction or parts replacement if wear, damage, corrosion or any other abnormal condition are found through inspection. Check the following parts. 1. Seal surface of the flange. 2. Cage bore for burns. INSTALLATION 1. Install collapsible spacer, discard the used collapsible spacer and install a new one. 2. Install outer bearing. Page 1316 L4 Engine Room Page 2140 Fuel Tank Pressure Sensor: Description and Operation Fuel Tank Pressure Sensor The fuel tank pressure sensor is a three-wire strain gauge sensor similar to a common MAP sensor. However, the fuel tank pressure sensor has very different electrical characteristics due to its pressure differential design. The sensor measures the difference between the air pressure (or vacuum) in the fuel tank and the outside air pressure. The sensor mounts at the top of the fuel pump assembly. A three-wire electrical harness connects it to the PCM. The PCM supplies a five-volt reference voltage and a ground to the sensor. The sensor will return a voltage between 0.1 and 4.9 volts. When the air pressure in the fuel tank is equal to the outside air pressure, such as when the fuel cap is removed, the output voltage of the sensor will be 1.3 to 1.7 volts. When the air pressure in the fuel tank is 4.5 in. H2O (1.25 kPa), the sensor output voltage will be 0.5 ± 0.2 V. When there is neither vacuum nor pressure in the fuel tank, the sensor voltage will be 1.5 V. At -14 in. H2O (-3.75 kPa), the sensor voltage will be 4.5 ± 0.2 V. Page 3088 EGR Valve: Description and Operation Linear EGR Valve Operation and Results of Incorrect Operation The linear EGR valve is designed to accurately supply EGR to the engine independent of intake manifold vacuum. The valve controls EGR flow from the exhaust to the intake manifold through an orifice with a PCM controlled pintle. During operation, the PCM controls pintle position by monitoring the pintle position feedback signal. The feedback signal can be monitored with a Tech 2 as "Actual EGR POS." "Actual EGR POS." should always be near the commanded EGR position ("Desired EGR POS."). If a problem with the EGR system will not allow the PCM to control the pintle position properly, DTC P1406 will set. The PCM also tests for EGR flow. If incorrect flow is detected, DTC P0401 will set. If DTCs P0401 and/or P1406 are set, refer to the DTC charts. The linear EGR valve is usually activated under the following conditions: - Warm engine operation. - Above-idle speed. Too much EGR flow at idle, cruise or cold operation may cause any of the following conditions to occur: - Engine stalls after a cold start. - Engine stalls at idle after deceleration. - Vehicle surges during cruise. - Rough idle. - DTC P0300 (misfire detected). Too little or no EGR flow may allow combustion temperatures to get too high. This could cause: - Spark knock (detonation). - Engine overheating. - Emission test failure. - DTC P0401 (EGR flow test). - Poor fuel economy. Page 6174 Evaporator Temperature Sensor / Switch: Service and Repair Electronic Thermostat, Evaporator Core and/or Expansion Valve Electronic Thermostat, Evaporator Core And/Or Expansion Valve - Disassembled View Removal 1. Disconnect the battery ground cable. 2. Discharge and recover refrigerant. 3. Remove evaporator assembly. 4. Remove the electronic thermostat sensor fixing clip. Pull the sensor from the evaporator assembly. 5. Remove clip. 6. Remove attaching screw. 7. Remove upper case. Page 7753 and the fuses. From Fuses to Relays and Components The second half of Power Distribution shows the wiring "From Fuses to Relays and Components." This can speed your troubleshooting by showing which circuits share fuses. If Power Distribution shows that an inoperative circuit and another circuit share a fuse, check a component in the other circuit. If it works, you know the fuse is good and power is available to the inoperative circuit. Ground Distribution Schematics Page 6898 2. When installing the hatchgate glass, first attach the hinge to the hatchgate glass. Align the stud of the hinge to the hole at body while supporting the hatchgate glass with two people at indicated positions (1), and then partially tighten the hinge to body nut (2). After adjustment (refer to Adjustment) is completed, fully tighten the nut, hinge to body nut. Hatchgate hinge assembly for left and right sides from each other. 3. When installing gas stay assembly (1), first install the gas stay onto the rear quarter panel with fixing screw (2) and fastener (3) and then attach the gas stay upper end to the ball stud by spreading the retainer with screwdriver, etc. Gas stay assemblies for left and right sides differ from each other (The letter (4) L(LH) or R(RH) is embossed on the gas stay assembly.) 4. When installing hatchgate striker assembly, first partially tighten the fixing screw and close the hatchgate and tailgate. Then fully tighten the fixing screw with the condition that the striker fits the hatchgate lock assembly at the tailgate. Make sure that clearance exists between hatchgate striker and lock assembly. After installation, again make sure that the striker fits the lock assembly properly. 5. Tighten the nuts; hinge to body (LH and RH) Torque: 6 N.m (52 lb.in) 6. Tighten the screws: glass and hinge fix (LH and RH) Torque: 6 N.m (52 lb.in) NOTE: When installing the hinge to the body, exercise special care not to damage the body paint surface. 7. Tighten the hatchgate striker fixing screws. Torque: 6 N.m (52 lb.in) Page 4290 Axle Disconnect Control Control Unit: Service and Repair SHIFT ON THE FLY CONTROLLER AND ASSOCIATED PARTS REMOVAL 1. Disconnect the battery ground cable. 2. Remove the front console assembly. 3. Disconnect the connector from the controller. 4. Remove the nut. 5. Remove the controller. INSTALLATION 1. To install, follow the removal steps in the reverse order, noting the following points. Torque: Nut (1) 8 Nm (69 inch lbs.) Diagrams Page 3436 20. Using a DVOM, check the voltage between the reference voltage pin for each sensor and ground. ^ If the sensor circuits all read 5.0 volts, go to step 22. ^ If any sensor circuit is above or below 5.0 volts, go to step 21. 21. Troubleshoot for an internal short in another sensor or a PCM malfunction. ^ To find the sensor with an internal short, monitor the reference voltage, and disconnect each sensor (FTPS, EGR, MAP TPS, CKP and CMP) one at a time until the reference voltage reads 5.0 volts. Replace that sensor, and repeat step 14. ^ To find a malfunctioning PCM, replace it with a known-good PCM. If all three sensors (APP Sensor 1, APP Sensor 2, and APP Sensor 3) are within range, the original PCM is faulty; replace it and repeat step 14. 22. Using a jumper wire, connect the reference voltage of each circuit to its signal input, and view the APP Sensor values in the Engine Data List. APP Sensor 1 should have a value of 99%, and APP Sensor 2 and APP Sensor 3 should each have a value of 0%. ^ If the values are not as specified, troubleshoot for high resistance on the signal input or a PCM malfunction. Repair the circuit or replace the PCM, then repeat step 14. ^ If the values are as specified, the problem may be intermittent. Disconnect the 10 P connector from the modified APPS, and connect it to the new APPS; then repeat step 14. Wiggle the APPS wires as you go through the adjustment procedure to find the intermittent problem. 23. Install the accelerator pedal assembly, and torque the bolts to 10 N.m (7 lb-ft). Page 4066 4. Connect select cable. 5. Install selector lever knob and cover. 6. Install center console. 7. Install rear console. 8. Install lower cluster assembly. 9. Install transfer control lever knob. 10. Connect negative (-) battery cable. 11. After installation, make sure that the selector lever operates normally, and that each selector position is properly indicated. (The red mark shows through the window.) Page 5781 7. Use a dry rag to remove any remaining dust or debris. If the area is wet, dry it with an air nozzle. 8. Temporarily install both type A reinforcement brackets using the original lower trailing link front mounting nuts, C-clamps, and new body mount studs and nuts. NOTE: ^ When securing the C-clamp on the passenger's side, be sure not to contact the brake lines on the inside of the frame rail. ^ On some 2000 models and all 2001-02 models, you need to remove the fuel tank protector mounting bolt from the driver's side. * Save the bolt; it's required for the temporary and the final installation of the driver's side type A reinforcement bracket.* Page 1284 Air Bag(s) Arming and Disarming: Service Precautions Airbag Handling and Storage Airbag Handling and Storage Do not disassemble an airbag. It has no serviceable parts. Once an airbag has been deployed, it cannot be repaired or reused. For temporary storage of the airbag during service, please observe the following precautions. - Store the removed airbag with the pad surface up. Never put anything on the removed airbag. - Keep free from any oil, grease, detergent, or water to prevent damage to the airbag assembly. - Store the removed airbag on a secure, flat surface away from any high heat source (exceeding 200 °F/93 °C). - Never perform electrical inspections to the airbags, such as measuring resistance. - Do not position yourself in front of the airbag assembly during removal, inspection, or replacement. Component Locations 4WD Motor Actuator: Component Locations Beneath Center of Vehicle, on Transfer Case (A/T) Page 6507 Seat Belt: Specifications Torque Specifications Part 1 Page 787 24. Verify APP Sensor 1 is between 11 and 15 percent, and APP Sensor 2 and APP Sensor 3 are between 89 and 85 percent with the pedal up (closed throttle). If not, loosen the mounting screws on the APPS sensor, and go to step 14. 25. Clear all DTCs with the PGM Tester. 26. Turn off the ignition switch, and disconnect the PGM Tester. Page 7440 Terminals - "T" Each "T" terminal (ring type) is numbered for reference and location. A "T" terminal is secured with a screw or bolt. Wires Removal of Fuel Tube/Quick-Connector Fittings Fuel Line Coupler: Service and Repair Removal of Fuel Tube/Quick-Connector Fittings Removal 1. Open the fuel cap to relieve the fuel pressure in the tank. If the fuel quick-connect fittings are dusty, clean with an air blower, etc. and then remove it. As some pressure may remain in the piping, cover the connector with a cloth, etc. to prevent the splashing of fuel in the first disconnection of the piping. 2. For removal of the delivery pipe (feeding fuel to the engine), hold the connector in one hand, and hold the retainer tab with the other hand and pull out the connector, as illustrated. The pipe can be removed with the retainer attached. Page 2715 Oxygen Sensor: Testing and Inspection Heated Oxygen Sensor (HO2S) All four sensors are identical. Inspect each in the same way. 1. Inspect the pigtail and the electrical connector for grease, dirt, corrosion, and bare wires or worn insulation. 2. Inspect the lowered end of the sensor for grease, dirt, or other contaminations. Page 7085 it is located, and what it connects to. Use the Connector Views to help locate the proper cavity when you need to probe a connector. It can be especially helpful if the connector has more than one wire of the same color. A dash symbol (-) indicates that the cavity is empty. Connector views can also be used to help diagnose multiple symptoms in separate circuits which could be caused by a single problem in a connector shared by those circuits. Here's an example: 1. Pick one of the multiple symptoms and look up the schematic for that circuit. 2. Make a list of all the in-line and fuse box connectors in that schematic , 3. Then, in the Connector Views, look up each connector on your list to see if circuits related to the other symptoms run through one of them. If they do, inspect that connector for the problem. Example: The blower, rear window defogger, and the windshield wiper don't work. List all in-line and fuse box connectors in the blower controls circuit and then check the Connector View (see the sample). You find that C324 is common to the blower controls, rear window defogger, and wiper/washer, so you inspect C324 and find the problem, bent terminals. Finding Component/Connector Locations Finding Component/Connector Locations To see where a component or connector is located on the car, look up its photo number in the "Component Location". The photo will also tell you the color of the connector, and how many cavities it has. Page 1796 Valve Inspection Chart Page 452 If there is no photo number below or beside a component name or a connector, ground, or terminal number, look up that name or number in the appropriate Connector Identification Chart. The chart lists how many cavities a connector has, where it's located, and what it connects to. The related illustration shows the connector's location on the harness, and the harness routing. NOTE: Photos listed by number are located at Locations / Components / Photograohs. See: Locations/Component Locations/Photographs Circuit Schematics Page 2965 If there is no photo number below or beside a component name or a connector, ground, or terminal number, look up that name or number in the appropriate Connector Identification Chart. The chart lists how many cavities a connector has, where it's located, and what it connects to. The related illustration shows the connector's location on the harness, and the harness routing. NOTE: Photos listed by number are located at Locations / Components / Photograohs. See: Locations/Component Locations/Photographs Circuit Schematics Page 7204 Sunroof / Moonroof Frame: Service and Repair Removal 1. Disconnect the battery ground cable. 2. Remove the headlining. 3. Disconnect the sunroof drain hose at the sunroof frame side as shown in the figure. 4. Disconnect the sunroof harness connection. 5. Remove two sunroof frame complete assembly fixing nuts (front side) and six fixing bolts from the frame complete assembly, and then remove the sunroof frame complete assembly. NOTE: Be sure to remove the frame complete assembly while supporting it. Installation 1. Install the sunroof frame complete assembly. 2. After installing the frame complete assembly, loosen the sunroof glass fixing nuts and adjust the sunroof glass setting position. 3. Install the sunroof drain hose. 4. Install the headlining. Page 2973 Splices Splices are shown as a dot. Their location and the number of wires may vary depending on the harness manufacturer. Switches Switches These switches move together; the broken straight line between them means they are mechanically connected. Other types of switches are controlled by a coil or a solid state circuit. Unless otherwise noted, all switches are shown in their normal (rest) position, with power off. Terminal "T" Locations Refrigerant Recovery Refrigerant: Service and Repair Refrigerant Recovery Air conditioning systems contain HFC-134a. This is a chemical mixture which requires special handling procedures to avoid personal injury. - Always wear safety goggles and protective gloves. - Always work in a well-ventilated area. Do not weld or steam clean on or near any vehicle-installed air conditioning lines or components. - If HFC-134a should come in contact with any part of the body, flush the exposed area with cold water and immediately seek medical help. - If it is necessary to transport or carry any container of HFC-134a in a vehicle, do not carry it in the passenger compartment. - If it is necessary to fill a small HFC-134a container from a large one, never fill the container completely. Space should always be allowed above the liquid for expansion. - HFC-134a and R-12 should never be mixed as their compositions are not the same. - HFC-134a PAG oil tends to absorb moisture more quickly than R-12 mineral oil and, therefore, should be handled more carefully. - Keep HFC-134a containers stored below 40 °C (100 °F). WARNING: - SHOULD HFC-134A CONTACT YOUR EYE(S), CONSULT A DOCTOR IMMEDIATELY. - DO NOT RUB THE AFFECTED EYE(S). INSTEAD, SPLASH QUANTITIES OF FRESH COLD WATER OVER THE AFFECTED AREA TO GRADUALLY RAISE THE TEMPERATURE OF THE REFRIGERANT ABOVE THE FREEZING POINT. - OBTAIN PROPER MEDICAL TREATMENT AS SOON AS POSSIBLE. SHOULD THE HFC-134A TOUCH THE SKIN, THE INJURY MUST BE TREATED THE SAME AS SKIN WHICH HAS BEEN FROSTBITTEN OR FROZEN. Refrigerant Recovery The refrigerant must be discharged and recovered by using the J-39500 (ACR4:HFC-134a Refrigerant Recovery/Recycling/Recharging/System) or equivalent before removing or mounting air conditioning parts. 1. Connect the high and low charging hoses of the ACR4 (or equivalent). 2. Recover the refrigerant by following the Manufacturer's Instructions. 3. When a part is removed, put a cap or a plug on the connecting portion so that dust, dirt or moisture cannot get into it. Refrigerant Recycling Recycle the refrigerant recovered by J-39500 (ACR4:HFC-134a Refrigerant Recovery/Recycling/Recharging/System) or equivalent. For the details of the actual operation, follow the steps in the ACR4 (or equivalent) Manufacturer's Instructions. Page 3399 and the fuses. From Fuses to Relays and Components The second half of Power Distribution shows the wiring "From Fuses to Relays and Components." This can speed your troubleshooting by showing which circuits share fuses. If Power Distribution shows that an inoperative circuit and another circuit share a fuse, check a component in the other circuit. If it works, you know the fuse is good and power is available to the inoperative circuit. Ground Distribution Schematics Page 4280 The wire insulation has one color or one color with another color stripe. The second color is the stripe. Page 5997 This means the branch of the wire connects to another circuit. The arrow points to the name of the circuit branch where the wire continues. Page 3628 7. When installing the steering column cover, be sure to wire (through each harness) as illustrated so that the harnesses starter switch, combination switch and SRS coil may not catch wiring. 8. Install steering wheel by aligning the setting marks made during removal. CAUTION: Never apply force to the steering wheel in direction of the shaft by using a hammer or other impact tools in an attempt to remove the steering wheel. The steering shaft is designed as an energy absorbing unit. 9. Tighten the steering wheel fixing nut to the specified torque. Torque: 34 Nm (25 ft. lbs.) 10. Support inflator module and carefully connect the SRS connector and horn lead, then install inflator module. NOTE: Pass the lead wire through the tabs on the plastic cover (wire protector) of inflator to prevent lead wire from being pinched. 11. Tighten fixing bolts to specified torque. Torque: 9 Nm (78 inch lbs.) 12. Install driver knee bolster (reinforcement). 13. Install instrument panel lower cover, then install the engine hood opening lever. 14. Connect the yellow 2-way SRS connector located under the steering column. 15. Connect the battery "-" terminal cable. Page 7103 2. Connect the short finder across the battery terminals and the load (component) side of the fuse terminal. 3. Close all switches in the circuit you're testing. 4. Turn on the short finder. This creates a pulsing magnetic field around the wiring between the fuse box and the short. 5. Beginning at the fuse box, slowly move the short finder along the circuit wiring. The meter will read current pulses through sheet metal and body trim. As long as the meter is between the fuse and the short, the needle will move with each current pulse. Once you move the meter past the point of the short, the needle will stop moving. Check the wiring and connectors in this area to locate the cause of the short. Testing For Continuity When testing for continuity at a connector without wire seals, you do not have to separate the two halves of the connector. Instead, probe the connector from the back. Always check both sides of the connector because dirty, corroded, and bent terminals can cause problems (no electrical contact = an open). 1. Disconnect the negative cable from the car battery. If you're using a DVOM, place it in the lowest "OHMS" range. Page 7075 8. Remove the tailgate lock assembly. - Remove the 3 screws holding the lock assembly. Installation To install, follow the removal steps in the reverse order, noting the following points: 1. When setting up links, pay attention to the position and direction of the links. 2. Apply chassis grease to the lock assembly and striker moving surface. 3. Check that the tailgate lock operates correctly after installing it. 4. Tighten the hatchgate lock assembly fixing bolts to the specified torque. Torque 7 Nm (61 lb in) Page 7321 10. Remove the 2 screws through the access hole and pull out the glass upward. 11. Remove the window regulator. - Disconnect the window regulator motor harness connector, if equipped with power windows. 12. Remove the glass run. - Pull the glass run (6) out from the door frame groove. Installation To install, follow the removal steps in the reverse order, noting the following points: Brakes - Brake Disc Refinishing Information Brake Rotor/Disc: Technical Service Bulletins Brakes - Brake Disc Refinishing Information 00-088 July 14, 2010 Applies To: ALL Models Brake Disc Refinishing Guidelines (Supersedes 00-088, dated October 6, 2006, to revise the information marked with the black bars) *REVISION SUMMARY The requirement to refinish new brake discs was removed.* American Honda does not allow replacement of brake discs under warranty unless the brake disc is beyond its service limit for refinishing. If the brake disc is within its service limit, you must refinish it. Maximum refinishing limits may be found in the Conventional Brakes section of the appropriate service manual. *Refinish brake discs only when they are scored or out of specification for runout or parallelism. See the appropriate service manual for the specifications.* American Honda requires refinishing of the front brake discs with an on-car brake lathe that mounts to the steering knuckle. Use of an on-car, steering knuckle- mounted lathe is critical because it corrects runout of the hub and disc as an assembly. Experience has shown that very small amounts of runout, not felt as brake pulsation initially, will grow and become noticeable as the discs are subjected to heat and wear over time and mileage. Two on-car brake lathes are recommended. The Kwik-Lathe, model number KWY-108000501, is supported with automatic shipments of adapters for new models, when required. The Accu-turn On-car Brake Lathe, model ACCHONOCLPKG, is also recommended. A power driver is required for the 82000 and is highly recommended for all other models. The Kwik-Lathe power driver model number is KWY-108012005; the Accu-turn lathe includes a power driver. Here are some advantages of using power drivers: ^ The disc is rotated at the optimum speed for a smooth and consistent cut. ^ There is no need to climb in and out of the vehicle to start and stop the engine or to shift the transmission. ^ Securing the opposite wheel with a tie-down strap is not required. ^ There is no waiting for the engine to return to idle and no concern about engine speed changes that can adversely affect brake disc cut and finish. ^ The Traction Control System (TCS) is not involved. ^ Consistent cutting speed increases cutting tool life. ORDERING INFORMATION Order brake lathes and power drivers through the Honda Tool and Equipment Program. To place an order, call or use the fax order form provided in your Honda Tool and Equipment Program Catalog. Phone lines are open Monday thru Friday from 7:30 a.m. to 7:00 p.m. Central Time. You can also order online through the Interactive Network (iN). Click on Service, Tool and Equipment, and then Online Catalog. Click on Alignment, Wheel, and Brake Equipment, and then On-Car Brake Lathes. WARRANTY CLAIM INFORMATION None, this bulletin is for information only. FRONT BRAKE DISCS The following guidelines show the Kwik-Way lathe setup, the Accu-turn lathe setup is similar. Setting Up the Vehicle Put the transmission in Neutral. If you are not using the power drive system, start the engine, and let it warm up to its normal operating temperature so the idle speed will stabilize to its lowest rpm. Page 273 Testing For A Short With A Self-Powered Test Light or DVOM 1. Remove the blown fuse and disconnect the battery and load. 2. Connect one lead of a self-powered test light or digital volt/ohmmeter (DVOM) (switched to the lowest "OHMS" range) to the fuse terminal on the load side. 3. Connect the other lead to a known good ground. 4. Beginning near the fuse box, wiggle the harness. Continue this at convenient points about six inches apart while watching the test light or DVOM. 5. If the self-powered test light goes on or the DVOM displays a low reading or no reading (zero), there is a short to ground in the wiring near that point. Testing for a Short with a Test Light or DVOM 1. Remove the blown fuse and disconnect the load. 2. Connect a test light or digital volt/ohmmeter (DVOM), switched to the appropriate DC volts range, across the fuse terminals to make sure voltage is present. You might have to turn the ignition switch to ON; check the schematic to see. 3. Beginning near the fuse box, wiggle the harness. Continue this at convenient points about six inches apart while watching the test light or DVOM. 4. Where the test light goes , or the DVOM voltage drops to zero, there is a short to ground in the wiring near that point. NOTE: Always use a DVOM on high impedance circuits. A test light may not glow (even with battery voltage present). Testing For A Short With A Short Circuit Locator (Short Finder) 1. Remove the blown fuse. Leave the battery connected. Page 7787 Ground - "G" Shielding Sheilding This represents RFI (Radio Frequency Interference) shielding around a wire. The shielding is always connected to ground. Splices Page 1096 Cleaning Spark Plugs - Clean spark plugs with a spark plug cleaner. - Raise the ground electrode to an position of 45 to 60 degrees. If electrode is wet, dry it before cleaning. - After spark plug is thoroughly cleaned, check insulator for presence of cracks. - Clean threads and metal body with a wire brush. - File the electrode tip if electrode is extremely worn. - Bend the ground electrode to adjust the spark plug gap. Page 3580 Distinct Of Circuit By Wire Base Color All wires have color-coded insulation. Wires belonging to a system's main harness will have a single color. Wires belonging to a system's sub-circuits will have a colored stripe. Striped wires use the codes found in the chart to show wire size and colors. Abbreviations are used to indicate wire color within a circuit diagram. How to Identify Connector Terminals How to Identify Connector Terminals Cavity Numbering System The cavities (and wire terminals) in each connector are numbered starting from the upper left, looking at the male terminals from the terminal side (or looking at the female terminals from the wire side. Both views are in the same direction so the numbers are the same.) All actual cavities are numbered, even if they have no wire terminals in them. NOTE: Data Link Connector (DLC) terminals are numbered according to SAE standard J1962, not the Honda standard. The numbers of the four end terminals are molded into the corners of the connector face. The connector cavity number is listed next to each terminal on the circuit schematic. The cavity / terminal shown is # 6. Using/Identifying Connector Terminal Views How to Use Connector Terminal Views To see the configuration of a connector's cavities, look up its view number in the Connector Views. Each view includes the color of the connector, where Page 3587 The name of the component appears next to it followed by notes about its function along with any photo and connector view references. Connector "C" How to Identify Connector Terminals Cavity Numbering System The cavities (and wire terminals) in each connector are numbered starting from the upper left, looking at the male terminals from the terminal side (or looking at the female terminals from the wire side. Both views are in the same direction so the numbers are the same.) All actual cavities are numbered, even if they have no wire terminals in them. NOTE: Data Link Connector (DLC) terminals are numbered according to SAE standard J1962, not the Honda standard. The numbers of the four end terminals are molded into the corners of the connector face. Service and Repair Windshield Washer Switch: Service and Repair Rear Wiper and Washer Switch Removal 1. Disconnect the battery ground cable. 2. Remove the dash side trim panel (1). 3. Remove the lower cover assembly (2). 4. Remove the meter cluster assembly (4). 5. Remove the rear wiper & washer switch (5). - Disconnect the connector. - Push the lock from the back side of the meter cluster assembly. Installation To install, follow the removal steps in the reverse order, noting the following point: 1. Push the switch with your fingers until it locks securely. Page 4870 2. Connect one lead of a self-powered test light or DVOM to one end of the part of the circuit you want to test. 3. Connect the other lead to the other end. 4. If the self-powered test light glows, there is continuity. If you're using a DVOM, a low reading or no reading (zero), means good continuity. Testing For Voltage When testing for voltage at a connector without wire seals, you do not have to separate the two halves of the connector. Instead, probe the connector from the back. Always check both sides of the connector because dirty, corroded, and bent terminals can cause problems (no electrical contact = an open). 1. Connect one lead of the lest light to a known good ground, or, if you're using a digital volt ohmmeter (DVOM), place it in the appropriate DC volts range, and connect its negative lead to ground. 2. Connect the other lead of the test light or DVOM to the point you want to check. 3. If the test light glows, there is voltage present. If you're using a DVOM, note the voltage reading. It should be within one volt of measured battery voltage. A loss of more than one volt indicates a problem. NOTE: Always use a DVOM on high impedance circuits. A test light may not glow (even with battery voltage present). Testing For Voltage Drop Wires, connectors, and switches are designed to conduct current with a minimum loss of voltage. A voltage drop of more than one volt indicates a problem. 1. Place the digital volt/ohmmeter (DVOM) in the appropriate DC volts range. Connect the positive lead to the end of the wire (or to the connector or switch) closest to the battery. 2. Connect the negative lead to the other end of the wire (or the other side of the connector or switch). 3. Turn on the components in the circuit. 4. The DVOM will show the difference in voltage between the two points. A difference, or drop, of more than one volt indicates a problem. Check the circuit for loose, dirty, or bent terminals. A/T Main Case Oil Plug - Fluid Leaks Fill Plug: All Technical Service Bulletins A/T Main Case Oil Plug - Fluid Leaks 01-078 October 16, 2001 Applies To: 1996-00 Passport - ALL with A/T A/T Main Case Oil Pan Plug Leaks SYMPTOM The main case oil pan appears to leak ATF at the drain plug, the fill plug, or both. PROBABLE CAUSE An irregular surface finish on the main case oil pan damages the 0-rings on the plugs. CORRECTIVE ACTION Check the drain plug and fill plug on the main case oil pan for signs of leakage. If either plug leaks, replace both plugs and gaskets with captive 0-ring plugs. PARTS INFORMATION WARRANTY CLAIM INFORMATION In warranty: The normal warranty applies. Operation Number: 218159 Flat Rate Time: 0.3 hour Failed Part: P/N 8-96015-481-0 H/C 5043229 Defect Code: 051 Contention Code: B06 Template ID: 01-078A Skill Level: Repair Technician Out of warranty: Any repair performed after warranty expiration may be eligible for goodwill consideration by the District Service Manager or your Zone Office. You must request consideration, and get a decision, before starting work. REPAIR PROCEDURE 1. Raise the vehicle on a lift, making sure the vehicle is level. 2. Clean the area around the drain plug and fill plug on the A/T main case oil pan. Page 6509 Torque Specifications Part 3 Page 3486 Throttle Body: Description and Operation Throttle Body Unit The throttle body has a throttle plate to control the amount of air delivered to the engine. The TP sensor are also mounted on the throttle body. Vacuum ports located behind the throttle plate provide the vacuum signals needed by various components. Engine coolant is directed through a coolant cavity in the throttle body to warm the throttle valve and to prevent icing. Page 1573 Valve Spring: Service and Repair Disassembly, Inspection and Assembly Valve Spring, Oil Controller, Valve, Valve Guide Disassembly 1. Remove camshaft bracket fixing bolts (1). 2. Remove camshaft assembly (intake). 3. Remove camshaft assembly (Exhaust side). 4. Remove shim (4) and tappet (5). Service and Repair Fuel Pressure Release: Service and Repair CAUTION: To reduce the risk of fire and personal injury, there are necessary to relieve the fuel system pressure filler and gauge unit before servicing the fuel system components. CAUTION: After relieving the system pressure, a small amount of fuel may be released when servicing fuel lines or connections. Reduce the chance of personal injury by covering the fuel line fittings with a shop towel before you disconnect the fittings. The towels will absorb any fuel that may leak out. When the disconnection is completed, place the towel in an approved container. 1. Remove the fuel cap. 2. Remove the fuel pump relay from the underhood relay box. 3. Start the engine and allow it to stall. 4. Crank the engine for 30 seconds. 5. Disconnect the negative battery cable. Page 151 2. Connect the PCM electrical connectors. 3. Install the two screws to PCM electrical connectors. Page 1942 2. Compare the retrieved code with the listed codes. ^ If the code is in the list, go to step 3. ^ If the code is not in the list, the PCM has already been updated. Troubleshoot other causes for the detonation. NOTE: Since the Smart Cable may need to be cleared from a previous PCM update or the Smart Cable firmware may need to be reprogrammed, always begin each PCM update at the iN workstation. 3. Update the PCM software with the Smart Cable. For instructions, refer to Service Bulletin 99-005. NOTE: Make sure you select the most recent broadcast code from the list on the iN screen that applies to the model year, transmission type, and emission level. This code is not necessarily at the top of the list since the most recent code is the last one in the alphabetical sequence, letter by letter. 4. Use the PGM Tester to clear any DTCs set during programming. 5. Retrieve the broadcast code. Make sure it does not match any of the codes in the list in step 2 (indicating the PCM has been updated) and that it applies to the model year, transmission type, and emission level for the vehicle. The broadcast code should match a code in the list below. Disclaimer Page 4234 Axle Disconnect Control Control Unit: Service and Repair SHIFT ON THE FLY CONTROLLER AND ASSOCIATED PARTS REMOVAL 1. Disconnect the battery ground cable. 2. Remove the front console assembly. 3. Disconnect the connector from the controller. 4. Remove the nut. 5. Remove the controller. INSTALLATION 1. To install, follow the removal steps in the reverse order, noting the following points. Torque: Nut (1) 8 Nm (69 inch lbs.) Page 5342 ^ If the idle speed ever exceeds 1,300 rpm 2. Remove the vacuum hose from the fuel pressure regulator, then start the engine. ^ If fuel comes out of the fuel pressure regulator vacuum hose connection, go to REPAIR PROCEDURE FUEL PRESSURE REGULATOR. ^ If no fuel comes out of the regulator, reconnect the vacuum hose and continue to step 3. 3. Connect the PGM Tester. Set it to Engine Data List. 4. Have an assistant drive the vehicle under the conditions described by the customer. 5. If the high or erratic idle condition occurs, note the values of the PSP Switch and APP Sensor 1 when it is occurring. ^ If the PSP Switch is HIGH, and you are not turning, go to REPAIR PROCEDURE POWER STEERING SWITCH. ^ If the APP Sensor 1 is greater than 15% and APP Sensor 2 and/or APP Sensor 3 are less than 85%, and the accelerator pedal is not depressed, go to REPAIR PROCEDURE APPS GROUND. ^ If the PSP Switch is reading LOW when not turning and HIGH when turning, and the APP Sensors are reading within the range shown, discontinue the test-drive and go to step 6. 6. Do these repairs: ^ REPAIR PROCEDURE APPS GROUND ^ REPAIR PROCEDURE ENGINE/BODY GROUND REPAIR PROCEDURE - FUEL PRESSURE REGULATOR 1. Relieve fuel system pressure: ^ Remove the fuel fill cap. ^ Remove the fuel pump relay. ^ Start the engine and run it until it stalls. ^ Crank the engine for 3 seconds. 2. Remove the vacuum hose from the fuel pressure regulator. 3. Remove the fuel pressure regulator shield from the common chamber (two bolts). Page 7494 Testing For A Short With A Self-Powered Test Light or DVOM 1. Remove the blown fuse and disconnect the battery and load. 2. Connect one lead of a self-powered test light or digital volt/ohmmeter (DVOM) (switched to the lowest "OHMS" range) to the fuse terminal on the load side. 3. Connect the other lead to a known good ground. 4. Beginning near the fuse box, wiggle the harness. Continue this at convenient points about six inches apart while watching the test light or DVOM. 5. If the self-powered test light goes on or the DVOM displays a low reading or no reading (zero), there is a short to ground in the wiring near that point. Testing for a Short with a Test Light or DVOM 1. Remove the blown fuse and disconnect the load. 2. Connect a test light or digital volt/ohmmeter (DVOM), switched to the appropriate DC volts range, across the fuse terminals to make sure voltage is present. You might have to turn the ignition switch to ON; check the schematic to see. 3. Beginning near the fuse box, wiggle the harness. Continue this at convenient points about six inches apart while watching the test light or DVOM. 4. Where the test light goes , or the DVOM voltage drops to zero, there is a short to ground in the wiring near that point. NOTE: Always use a DVOM on high impedance circuits. A test light may not glow (even with battery voltage present). Testing For A Short With A Short Circuit Locator (Short Finder) 1. Remove the blown fuse. Leave the battery connected. Page 6045 Magnetic Clutch Assembly (DKV-14G Type) Page 6515 Inspection of retractor 1. ELR (Emergency Locking Retractor) lock inclining angle check. - The seat belt should not lock when pulled gently at a 15 degree angle. Also, the seat belt should lock when pulled at a 45 degree angle or higher. 2. ELR lock check. - The seat belt should not lock when pulled slowly, however, the seat belt should lock when pulled quickly. 3. ALR (Automatic Locking Retractor) / ELR check (Except for driver's seat). - Make sure the seat belt is locked when pulled out fully. - Make sure the seat belt can be pulled out and retracts after when rewound fully. CAUTION: Do not disassemble the retractor. Page 3918 REPAIR PROCEDURE 1. Raise the vehicle on a hoist. 2. 2002 only: Loosen the bracket that secures the ATF cooler return line, and disconnect the line from the transmission. 3. Clean the accumulator housing. 4. Using the accumulator cover installation tool and a Phillips screwdriver to hold the tool, tap on the accumulator cover to unseat the cover from the snap ring. 5. Remove the snap ring from the accumulator housing. Page 662 Manifold Pressure/Vacuum Sensor: Testing and Inspection Manifold Absolute Pressure (MAP) Output Check Circuit Description The manifold absolute pressure (MAP) sensor measures the changes in the intake MAP which result from engine load (intake manifold vacuum) and engine speed changes; and converts these into a voltage output. The powertrain control module (PCM) sends a 5-volt reference voltage to the MAP sensor. As the MAP changes, the output voltage of the sensor also changes. By monitoring the the sensor output voltage, the PCM knows the MAP. A lower pressure (low voltage) output voltage will be about 1 - 2 volts at idle. Higher pressure (high voltage) output voltage will be about 4 - 4.8 volts at wide open throttle. The MAP sensor is also used, under certain conditions, to measure barometric pressure, allowing the PCM to make adjustments for different altitudes. The PCM uses the MAP sensor to diagnose proper operation of the EGR system, in addition to other functions. Page 5438 6. Test-drive the vehicle to make sure it no longer pulls. If the steering wheel is now off-center by more than 2 mm, go to REPAIR PROCEDURE C. 7. Use your diagnosis worksheet to fill in the following table and build your 15-digit DTC. NOTE: Enter each reading in decimal degrees. Example 30' = 0.50. REPAIR PROCEDURE C 1. Make sure the steering wheel is centered. ^ Turn the steering wheel all the way to the right until it stops. ^ Turn the steering wheel all the way to the left, and count the number of revolutions until it stops. ^ Divide the number of revolutions in half, and turn the steering wheel until it is centered. For example, if it takes four revolutions of the steering wheel to go from lock to lock, then two turns is centered. ^ If the steering wheel is off-center by a large amount (20 mm or more), it may not be centered on the steering column shaft. Reinstall the steering wheel before going to step 2. 2. Place the vehicle on a lift, turn the steering wheel until it is centered, and then raise the vehicle. 3. Adjust the tie-rods. Use your measurements from question 13 of the test-drive to make your adjustment. Page 1514 - After installation, apply engine oil to the entire circumference of the piston rings. Check to see that all the rings rotate smoothly. 5. Install piston and connecting rod assembly. - Insert the bearings into the connecting rods and caps. Apply new engine oil to the bearing faces and nuts. - Tighten the connecting rod cap nuts Torque: 54 Nm (40 ft. lbs.) Note: Do not apply engine oil to the bearing back faces. 6. Oil gallery, refer to Crankshaft and Main Bearing. 7. Oil strainer and O-ring. 8. Oil pipe and O-ring. 9. Install crankcase with oil pan. 10. Install cylinder head gasket. 11. Install cylinder head assembly. - Refer to Cylinder Head. Page 7721 Transmission Shift Position Indicator Lamp: Diagnostic Aids Before Troubleshooting Before Troubleshooting See: Service Precautions/Vehicle Damage Warnings/Tips and Precautions 1. Check applicable fuses in the appropriate fuse/relay box. 2. Check the battery for damage, state of charge, and clean and tight connections. CAUTION: Do not quick-charge a battery unless the battery ground cable has been disconnected, otherwise you will damage the alternator diodes. - Do not attempt to crank the engine with the battery ground cable loosely connected or you will severely damage the wiring. While You're Working 1. Make sure connectors are clean, and have no loose terminals or receptacles. 2. Make sure that connectors without wire seals are packed with dielectric (silicone) grease. Part Number: 08798-9001. 3. When connecting a connector, push it until it "clicks" into place. CAUTION: Do not pull on the wires when disconnecting a connector. Pull only on the connector housings. - Most circuits include solid-state devices. Test the voltages in these circuits only with a 10-megaohm or higher impedance digital multi meter. Never use a test light or analog meter on circuits that contain solid-state devices. Damage to the devices may result. Five-Step Troubleshooting 1. Verify The Complaint Turn on all the components in the problem circuit to check the accuracy of the customer complaint. Note the symptoms. Do not begin disassembly or testing until you have narrowed down the problem area. 2. Analyze The Schematic Look up the schematic for the problem circuit. Determine how the circuit is supposed to work by tracing the current paths from the power source through the circuit components to ground. Also, trace circuits that share wiring with the problem circuit. The names of circuits that share the same fuse, ground, or switch, and so on, are referred to in each circuit schematic. Try to operate any shared circuits you didn't check in step 1. If the shared circuits work, the shared wiring is OK, and the cause must be in the wiring used only by the problem circuit. If several circuits fail at the same time, the fuse or ground is a likely cause. Based on the symptoms and your understanding of the circuit's operation, identify one or more possible causes. 3. Isolate The Problem By Testing The Circuit Make circuit tests to check the diagnosis you made in step 2. Keep in mind that a logical, simple procedure is the key to efficient troubleshooting. Test for the most likely cause of failure first. Try to make tests at points that are easily accessible. 4. Fix The Problem Once the specific problem is identified, make the repair. Be sure to use proper tools and safe procedures. 5. Make Sure The Circuit Works Turn on all components in the repaired circuit in all modes to make sure you've fixed the entire problem. If the problem was a blown fuse, be sure to test all of the circuits on that fuse. Make sure no new problems turn up and the original problem does not recur. Page 6488 To install, follow the removal steps in the reverse order, noting the following points. 1. Install the lower anchorage strikers with matching the inside of the tab and the trim edge of the body floor panel. 2. Tighten the lower anchorage striker fixing bolts to the specified torque. Torque: 25 N.m (18 lb.ft) Child Seat Tether Anchorage Bracket And Associated Parts REMOVAL 1. Open the tether anchorage bracket cover. Page 6252 Refrigerant Oil: Fluid Type Specifications A/C Oil Specifications A/C Oil Specifications Lubricant Type Poly Alkaline Glycol (PAG) Page 2141 Fuel Tank Pressure Sensor: Testing and Inspection 1. Inspect the vapor pressure sensor for cracks in the housing and corrosion on the electrical terminals. 2. Inspect the rubber grommet for tears and signs of rot. Page 532 8. Apply a setting mark (1) across the steering wheel and shaft so parts can be reassembled in their original position. Move the front wheels to the straight ahead position, then use steering wheel remover J-29752 to remove the steering wheel. CAUTION: Never apply force to the steering wheel in direction of the shaft by using a hammer or other impact tools in an attempt to remove the steering wheel. The steering shaft is designed as an energy absorbing unit. 9. Remove steering column cover. 10. Disconnect the wiring harness connectors located under the steering column, then remove combination switch and SRS coil assembly. NOTE: The SRS coil is a part of the combination switch assembly, which can not be replaced separately. Therefore, be sure not to remove the SRS coil from the combination switch assembly. INSTALLATION Page 6000 Blower Motor: Diagnostic Aids Before Troubleshooting Before Troubleshooting See: Service Precautions/Vehicle Damage Warnings/Tips and Precautions 1. Check applicable fuses in the appropriate fuse/relay box. 2. Check the battery for damage, state of charge, and clean and tight connections. CAUTION: Do not quick-charge a battery unless the battery ground cable has been disconnected, otherwise you will damage the alternator diodes. - Do not attempt to crank the engine with the battery ground cable loosely connected or you will severely damage the wiring. While You're Working 1. Make sure connectors are clean, and have no loose terminals or receptacles. 2. Make sure that connectors without wire seals are packed with dielectric (silicone) grease. Part Number: 08798-9001. 3. When connecting a connector, push it until it "clicks" into place. CAUTION: Do not pull on the wires when disconnecting a connector. Pull only on the connector housings. - Most circuits include solid-state devices. Test the voltages in these circuits only with a 10-megaohm or higher impedance digital multi meter. Never use a test light or analog meter on circuits that contain solid-state devices. Damage to the devices may result. Five-Step Troubleshooting 1. Verify The Complaint Turn on all the components in the problem circuit to check the accuracy of the customer complaint. Note the symptoms. Do not begin disassembly or testing until you have narrowed down the problem area. 2. Analyze The Schematic Look up the schematic for the problem circuit. Determine how the circuit is supposed to work by tracing the current paths from the power source through the circuit components to ground. Also, trace circuits that share wiring with the problem circuit. The names of circuits that share the same fuse, ground, or switch, and so on, are referred to in each circuit schematic. Try to operate any shared circuits you didn't check in step 1. If the shared circuits work, the shared wiring is OK, and the cause must be in the wiring used only by the problem circuit. If several circuits fail at the same time, the fuse or ground is a likely cause. Based on the symptoms and your understanding of the circuit's operation, identify one or more possible causes. 3. Isolate The Problem By Testing The Circuit Make circuit tests to check the diagnosis you made in step 2. Keep in mind that a logical, simple procedure is the key to efficient troubleshooting. Test for the most likely cause of failure first. Try to make tests at points that are easily accessible. 4. Fix The Problem Once the specific problem is identified, make the repair. Be sure to use proper tools and safe procedures. 5. Make Sure The Circuit Works Turn on all components in the repaired circuit in all modes to make sure you've fixed the entire problem. If the problem was a blown fuse, be sure to test all of the circuits on that fuse. Make sure no new problems turn up and the original problem does not recur. Page 331 Hood Sensor/Switch (For Alarm): Service and Repair Removal 1. Disconnect the battery ground cable. 2. Disconnect the connector. 3. Remove the engine hood switch (1). Installation To install, follow the removal steps in the reverse order. Page 3336 This sample Ground Distribution schematic shows all of the components that share two ground points. Components A solid border line means the entire component is shown. A broken border line indicates that only part of the component is shown. Page 1458 2. Install oil gallery and tighten the bolts in two steps, in the order shown in illustration. Torque: 1st step: 29 Nm (21 ft. lbs.) 2nd step: 55° - 65° 3. Install oil pipe with O-ring. - Torque: 10 Nm (89 inch lbs.) 4. Install oil strainer assembly with O-ring. Torque: 25 Nm (18 ft. lbs.) 5. Install crankcase with oil pan. 6. Install cylinder head assembly. Page 3469 1. Install the MAF sensor on the air cleaner with the clamp. 2. Install the intake air duct and the clamp on the MAF sensor. 3. Tighten the clamps to secure the MAF sensor to the intake air duct and the air cleaner. 4. Connect the MAF electrical connector. 5. Connect the negative battery cable. Page 2907 Oxygen Sensor: Connector Locations 95. Right Front Exhaust Downpipe Right Front Exhaust Downpipe 93. Left Front Exhaust Downpipe Left Front Exhaust Downpipe Page 6314 Fan Control Switch Page 6390 Air Bag: Service Precautions Live (Undeployed) Air Bag Assembly Special care is necessary when handling and storing a live (undeployed) air bag assembly. The rapid gas generation produced during deployment of the air bag could cause the air bag assembly, or an object in front of the air bag assembly, to be thrown through the air in the unlikely event of an accidental deployment. WARNING: WHEN CARRYING A LIVE AIR BAG ASSEMBLY, MAKE SURE THE BAG OPENING IS POINTED AWAY FROM YOU. IN CASE OF AN ACCIDENTAL DEPLOYMENT, THE BAG WILL THEN DEPLOY WITH MINIMAL CHANCE OF INJURY. NEVER CARRY THE AIR BAG ASSEMBLY BY THE WIRES OR CONNECTOR ON THE UNDERSIDE OF THE MODULE. Air Bag Assembly Shipping Procedure For Live (Undeployed) Air Bag Assemblies Service personnel should refer to the latest Service Bulletins for proper Supplemental Restraint System (SRS) air bag assembly shipping procedures. Service personnel should refer to the latest Service Bulletins for proper Supplemental Restraint System (SRS) air bag assembly shipping procedures. Page 2168 Oxygen Sensor: Testing and Inspection Heated Oxygen Sensor (HO2S) All four sensors are identical. Inspect each in the same way. 1. Inspect the pigtail and the electrical connector for grease, dirt, corrosion, and bare wires or worn insulation. 2. Inspect the lowered end of the sensor for grease, dirt, or other contaminations. Page 7883 Terminals - "T" Each "T" terminal (ring type) is numbered for reference and location. A "T" terminal is secured with a screw or bolt. Wires Page 7442 This means the branch of the wire connects to another circuit. The arrow points to the name of the circuit branch where the wire continues. Page 6402 Air Bag: Service and Repair Airbag Handling and Storage Do not disassemble the airbags. It has no serviceable parts. Once an airbag has been deployed, it cannot be repaired or reused. For temporary storage of the airbag during service, please observe the following precautions. Store the removed airbag with the pad surface up. Never put any things on the removed airbag. Keep free from any oil, grease, detergent, or water to prevent damage to the airbag assembly. Store the removed airbag on a secure, flat surface away from any high heat source (exceeding 200°F / 93°C). Never perform electrical inspections to the airbags, such as measuring resistance. Page 7943 Each schematic represents one circuit. A circuit's wires and components are arranged to show current flow, from power at the top of the page, to ground, at the bottom. Shared Circuits Other circuits may share power or ground terminals or wiring with the circuit shown. A wire that connects one circuit to another, for example, is cut short and has an arrowhead at the end of it pointing in the direction of current flow. Next to the arrowhead is the name of the circuit or component which shares that wiring. To quickly check shared wiring, check the operation of a component it serves. If that component works, you know the shared wiring is OK. Connectors All in-line and junction connectors are numbered (C725, C416, etc.). Component connectors are not numbered but are identified either by the name of Page 7877 and the fuses. From Fuses to Relays and Components The second half of Power Distribution shows the wiring "From Fuses to Relays and Components." This can speed your troubleshooting by showing which circuits share fuses. If Power Distribution shows that an inoperative circuit and another circuit share a fuse, check a component in the other circuit. If it works, you know the fuse is good and power is available to the inoperative circuit. Ground Distribution Schematics Page 5353 ^ If the idle speed ever exceeds 1,300 rpm 2. Remove the vacuum hose from the fuel pressure regulator, then start the engine. ^ If fuel comes out of the fuel pressure regulator vacuum hose connection, go to REPAIR PROCEDURE FUEL PRESSURE REGULATOR. ^ If no fuel comes out of the regulator, reconnect the vacuum hose and continue to step 3. 3. Connect the PGM Tester. Set it to Engine Data List. 4. Have an assistant drive the vehicle under the conditions described by the customer. 5. If the high or erratic idle condition occurs, note the values of the PSP Switch and APP Sensor 1 when it is occurring. ^ If the PSP Switch is HIGH, and you are not turning, go to REPAIR PROCEDURE POWER STEERING SWITCH. ^ If the APP Sensor 1 is greater than 15% and APP Sensor 2 and/or APP Sensor 3 are less than 85%, and the accelerator pedal is not depressed, go to REPAIR PROCEDURE APPS GROUND. ^ If the PSP Switch is reading LOW when not turning and HIGH when turning, and the APP Sensors are reading within the range shown, discontinue the test-drive and go to step 6. 6. Do these repairs: ^ REPAIR PROCEDURE APPS GROUND ^ REPAIR PROCEDURE ENGINE/BODY GROUND REPAIR PROCEDURE - FUEL PRESSURE REGULATOR 1. Relieve fuel system pressure: ^ Remove the fuel fill cap. ^ Remove the fuel pump relay. ^ Start the engine and run it until it stalls. ^ Crank the engine for 3 seconds. 2. Remove the vacuum hose from the fuel pressure regulator. 3. Remove the fuel pressure regulator shield from the common chamber (two bolts). Accelerator Pedal Assembly/Sensor - Adjustment Update Accelerator Pedal Position Sensor: All Technical Service Bulletins Accelerator Pedal Assembly/Sensor - Adjustment Update 00-045 August 14, 2001 Applies To: 2000-02 Passport - ALL Service Manual Update: Accelerator Pedal Position Sensor (APPS) (Supersedes 00-045, dated May 23, 2000) Updated information is shown by asterisks and black bars. BACKGROUND When the accelerator pedal position sensor (APPS) or the accelerator pedal assembly is replaced for any reason, you must adjust the APPS. *This procedure is missing in the 2000 service manual and is wrong in the 2001 and 2002 service manuals. Make a note on page 6E2-539 of the 2000 Passport Fuel and Emissions manual, on page 6E2-553 of the 2001 Passport Fuel and Emissions manual, and on page 6E2-545 of the 2002 Passport Fuel and Emissions manual to refer to this bulletin.* ADJUSTMENT PROCEDURE 1. Replace the APPS or the accelerator pedal assembly, and leave the mounting screws for the APPS loose. 2. Connect the PGM Tester to the data link connector (DLC), and turn the ignition switch to ON (II). *3. While watching the APP Sensor values in the Engine Data List, adjust the APPS by turning it until the values are within the ranges shown at closed pushed all the way down), then tighten the throttle and wide open throttle (accelerator pedal mounting screws and recheck the values. ^ If all three sensors are within range, go to step 12. ^ If APP Sensor 1, APP Sensor 2, and/or APP Sensor 3 cannot be brought into range, go to step 4. 4. Troubleshoot for an open circuit or a PCM malfunction. ^ If APP Sensor 1 has a value of 0% or APP Sensor 2 and/or APP Sensor 3 have a value of 99%, an open circuit exists or the PCM is malfunctioning. Repair the circuit or replace the PCM, and repeat step 3. ^ If you don't find a problem, go to step 5. 5. Disconnect the 10P connector from the APPS. 6. View the APP Sensor values in the Engine Data List. ^ If APP Sensor 1 has a value of 0% or APP Sensor 2 and/or APP Sensor 3 have a value of 99%, go to step 7. ^ If APP Sensor 1 has a value other than 0%, or APP Sensor 2 and/or APP Sensor 3 have a value other than 99%, a short circuit exists or the PCM is malfunctioning. Repair the circuit or replace the PCM, and repeat step 3. Accelerator Pedal Assembly/Sensor - Adjustment Update Accelerator Pedal Position Sensor: All Technical Service Bulletins Accelerator Pedal Assembly/Sensor - Adjustment Update 00-045 August 14, 2001 Applies To: 2000-02 Passport - ALL Service Manual Update: Accelerator Pedal Position Sensor (APPS) (Supersedes 00-045, dated May 23, 2000) Updated information is shown by asterisks and black bars. BACKGROUND When the accelerator pedal position sensor (APPS) or the accelerator pedal assembly is replaced for any reason, you must adjust the APPS. *This procedure is missing in the 2000 service manual and is wrong in the 2001 and 2002 service manuals. Make a note on page 6E2-539 of the 2000 Passport Fuel and Emissions manual, on page 6E2-553 of the 2001 Passport Fuel and Emissions manual, and on page 6E2-545 of the 2002 Passport Fuel and Emissions manual to refer to this bulletin.* ADJUSTMENT PROCEDURE 1. Replace the APPS or the accelerator pedal assembly, and leave the mounting screws for the APPS loose. 2. Connect the PGM Tester to the data link connector (DLC), and turn the ignition switch to ON (II). *3. While watching the APP Sensor values in the Engine Data List, adjust the APPS by turning it until the values are within the ranges shown at closed pushed all the way down), then tighten the throttle and wide open throttle (accelerator pedal mounting screws and recheck the values. ^ If all three sensors are within range, go to step 12. ^ If APP Sensor 1, APP Sensor 2, and/or APP Sensor 3 cannot be brought into range, go to step 4. 4. Troubleshoot for an open circuit or a PCM malfunction. ^ If APP Sensor 1 has a value of 0% or APP Sensor 2 and/or APP Sensor 3 have a value of 99%, an open circuit exists or the PCM is malfunctioning. Repair the circuit or replace the PCM, and repeat step 3. ^ If you don't find a problem, go to step 5. 5. Disconnect the 10P connector from the APPS. 6. View the APP Sensor values in the Engine Data List. ^ If APP Sensor 1 has a value of 0% or APP Sensor 2 and/or APP Sensor 3 have a value of 99%, go to step 7. ^ If APP Sensor 1 has a value other than 0%, or APP Sensor 2 and/or APP Sensor 3 have a value other than 99%, a short circuit exists or the PCM is malfunctioning. Repair the circuit or replace the PCM, and repeat step 3. Page 5633 Ball Joint: Specifications Ball Joint, Lower Castle Nut 147 Nm Attaching Bolts 116 Nm Preload Torque 0.5 - 6.4 Nm Page 7901 If there is no photo number below or beside a component name or a connector, ground, or terminal number, look up that name or number in the appropriate Connector Identification Chart. The chart lists how many cavities a connector has, where it's located, and what it connects to. The related illustration shows the connector's location on the harness, and the harness routing. NOTE: Photos listed by number are located at Locations / Components / Photograohs. See: Locations/Component Locations/Photographs Circuit Schematics Page 3747 2. Connect one lead of a self-powered test light or DVOM to one end of the part of the circuit you want to test. 3. Connect the other lead to the other end. 4. If the self-powered test light glows, there is continuity. If you're using a DVOM, a low reading or no reading (zero), means good continuity. Testing For Voltage When testing for voltage at a connector without wire seals, you do not have to separate the two halves of the connector. Instead, probe the connector from the back. Always check both sides of the connector because dirty, corroded, and bent terminals can cause problems (no electrical contact = an open). 1. Connect one lead of the lest light to a known good ground, or, if you're using a digital volt ohmmeter (DVOM), place it in the appropriate DC volts range, and connect its negative lead to ground. 2. Connect the other lead of the test light or DVOM to the point you want to check. 3. If the test light glows, there is voltage present. If you're using a DVOM, note the voltage reading. It should be within one volt of measured battery voltage. A loss of more than one volt indicates a problem. NOTE: Always use a DVOM on high impedance circuits. A test light may not glow (even with battery voltage present). Testing For Voltage Drop Wires, connectors, and switches are designed to conduct current with a minimum loss of voltage. A voltage drop of more than one volt indicates a problem. 1. Place the digital volt/ohmmeter (DVOM) in the appropriate DC volts range. Connect the positive lead to the end of the wire (or to the connector or switch) closest to the battery. 2. Connect the negative lead to the other end of the wire (or the other side of the connector or switch). 3. Turn on the components in the circuit. 4. The DVOM will show the difference in voltage between the two points. A difference, or drop, of more than one volt indicates a problem. Check the circuit for loose, dirty, or bent terminals. Page 1426 4. Install camshaft assembly and camshaft brackets, tighten twenty bolts on one side bank to the specified torque. 1. Apply engine oil to camshaft journal and bearing surface of camshaft bracket. 2. Align timing mark on intake camshaft (one dot for right bank, two dot for left bank) and exhaust camshaft (one dot for right bank, two dots for left bank) to timing mark on camshaft drive gear (one dot). 3. Tighten twenty bolts on numerical order an one side bank as shown in the illustration. Torque :10 Nm (89 inch lbs.) 5. Install cylinder head cover RH. Refer to installation procedure for Cylinder Head Cover RH. 6. Install cylinder head cover LH. Refer to installation procedure for Cylinder Head Cover LH. 7. Install timing belt. Refer to installation procedure for Timing Belt. 8. Install crankshaft pulley. Refer to installation procedure for Crankshaft Pulley. Accelerator pedal cable adjustment 1. Loosen adjusting nut and lock nut. 2. Pull outer cable while closing fully the throttle valve. 3. Tighten adjusting nut and lock nut temporarily. Diagram Information and Instructions Blower Motor: Diagram Information and Instructions How to Identify Wiring Color-Coded Insulation Wire Color Wire Color Coding Initial Inspection and Diagnostic Overview Powertrain Control Module: Initial Inspection and Diagnostic Overview 1. Perform the On-Board Diagnostic System Check. 2. Start the engine and run for one minute. 3. Scan for DTCs using the Tech 2. Description and Operation Fuel Level Sensor: Description and Operation Fuel Level Sensor The fuel level sensor is an important input to the PCM for the enhanced EVAP system diagnostic. The PCM needs fuel level information to know the volume of fuel in the tank. The fuel level affects the rate of change of air pressure in the EVAP system. Several of the enhanced EVAP system diagnostic sub-tests are dependent upon correct fuel level information. The diagnostic will not run when the tank is less than 15 % or more than 85 % full. Be sure to diagnose any Fuel Level Sensor DTCs first, as they can cause other DTCs to set. Page 1257 Refrigerant Oil: Service and Repair Oil Return Operation Oil Return Operation There is close affinity between the oil and the refrigerant. During normal operation, part of the oil recirculates with the refrigerant in the system. When checking the amount of oil in the system, or replacing any component of the system, the compressor must be run in advance for oil return operation. The procedure is as follows: 1. Open all the doors and the engine hood. 2. Start the engine and air conditioning switch to "ON" and set the fan control knob at its highest position. 3. Run the compressor for more than 20 minutes between 800 and 1,000 rpm in order to operate the system. 4. Stop the engine. Page 5745 7. Use a dry rag to remove any remaining dust or debris. If the area is wet, dry it with an air nozzle. 8. Temporarily install both type A reinforcement brackets using the original lower trailing link front mounting nuts, C-clamps, and new body mount studs and nuts. NOTE: ^ When securing the C-clamp on the passenger's side, be sure not to contact the brake lines on the inside of the frame rail. ^ On some 2000 models and all 2001-02 models, you need to remove the fuel tank protector mounting bolt from the driver's side. * Save the bolt; it's required for the temporary and the final installation of the driver's side type A reinforcement bracket.* Page 6596 ^ Select About. - What iTunes version are you using? - What TTS software version is installed? ^ Make sure you have the customer's iPod for troubleshooting. ^ Turn on the iPod, and verify its battery is fully charged before testing. If the battery is low, the iPod will not "make up" when connected. ^ Some iPod protective cases cause the Music Link iPod connector to be installed crookedly or not fully engaged. Be sure to remove the protective case before troubleshooting. ^ Go to http//musiclink.honda.com/Tech Faq.html to view technical FAQs and troubleshooting. TROUBLESHOOTING Check mark is not shown on the iPod display screen, radio will not switch to CD-C or CD-4 mode. NOTE: Remove the iPod protective case, if installed. 1. At the Music Link interface unit, make sure both connectors are fully engaged, and the cables do not have any broken or bent pins. NOTE: To release the Music Link interface unit connectors, you must pull back on the lock sleeves. Does either cable have the connector partially disengaged, or are any pins broken or bent? Yes - Reconnect or replace the loose or damaged cable. No - Go to step 2. 2. At the audio unit, make sure the cable connectors and the connector pin fits are tight. Also check that the optional Y-bus harness (if installed) connector and connector pin fits are tight. Do the cable connections and pins fit properly? Yes - Replace the Music Link interface unit and the cable. No - Repair the faulty connection at the audio unit. Static, or weak or no volume over speakers only in Music Link mode. NOTE: Remove iPod protective case, if installed. Page 3128 Accelerator Pedal: Vehicle Damage Warnings Caution: Always use the correct fastener in the proper location. When you replace a fastener, use ONLY the exact part number for that application. HONDA will call out those fasteners that require a replacement after removal. HONDA will also call out the fasteners that require thread lockers or thread sealant. UNLESS OTHERWISE SPECIFIED, do not use supplemental coatings (Paints, greases, or other corrosion inhibitors) on threaded fasteners or fastener joint interfaces. Generally, such coatings adversely affect the fastener torque and the joint clamping force, and may damage the fastener. When you install fasteners, use the correct tightening sequence and specifications. Following these instructions can help you avoid damage to parts and systems. Page 548 it is located, and what it connects to. Use the Connector Views to help locate the proper cavity when you need to probe a connector. It can be especially helpful if the connector has more than one wire of the same color. A dash symbol (-) indicates that the cavity is empty. Connector views can also be used to help diagnose multiple symptoms in separate circuits which could be caused by a single problem in a connector shared by those circuits. Here's an example: 1. Pick one of the multiple symptoms and look up the schematic for that circuit. 2. Make a list of all the in-line and fuse box connectors in that schematic , 3. Then, in the Connector Views, look up each connector on your list to see if circuits related to the other symptoms run through one of them. If they do, inspect that connector for the problem. Example: The blower, rear window defogger, and the windshield wiper don't work. List all in-line and fuse box connectors in the blower controls circuit and then check the Connector View (see the sample). You find that C324 is common to the blower controls, rear window defogger, and wiper/washer, so you inspect C324 and find the problem, bent terminals. Finding Component/Connector Locations Finding Component/Connector Locations To see where a component or connector is located on the car, look up its photo number in the "Component Location". The photo will also tell you the color of the connector, and how many cavities it has. Page 2774 Splices Splices are shown as a dot. Their location and the number of wires may vary depending on the harness manufacturer. Switches Switches These switches move together; the broken straight line between them means they are mechanically connected. Other types of switches are controlled by a coil or a solid state circuit. Unless otherwise noted, all switches are shown in their normal (rest) position, with power off. Terminal "T" Page 1429 2. Remove twenty fixing bolts from inlet and exhaust camshaft bracket on one side bank, then camshaft brackets (2). 3. Remove camshaft assembly (3), (4). 4. Remove three fixing bolts (7) from camshaft drive gear retainer (8), then camshaft drive gear assembly. INSPECTION AND REPAIR 1. Use a micrometer to measure the cam lobe height and uneven wear. Replace the camshaft if either the lobe height or the uneven wear exceeds the specified limit. Lobe height: 44.709 mm (1.7602 inch) Uneven wear: 0.05 mm (0.0020 inch) 2. Use a micrometer to measure the diameter and the uneven wear of the camshaft journals. Replace the camshaft if the diameter or the uneven wear exceeds the specified limit. Journal Diameter Standard: 25.972 mm - 25.993 mm (1.0225 inch - 1.0233 inch) Limit: 25.8 mm (1.0157 inch) Page 6124 Testing For A Short With A Self-Powered Test Light or DVOM 1. Remove the blown fuse and disconnect the battery and load. 2. Connect one lead of a self-powered test light or digital volt/ohmmeter (DVOM) (switched to the lowest "OHMS" range) to the fuse terminal on the load side. 3. Connect the other lead to a known good ground. 4. Beginning near the fuse box, wiggle the harness. Continue this at convenient points about six inches apart while watching the test light or DVOM. 5. If the self-powered test light goes on or the DVOM displays a low reading or no reading (zero), there is a short to ground in the wiring near that point. Testing for a Short with a Test Light or DVOM 1. Remove the blown fuse and disconnect the load. 2. Connect a test light or digital volt/ohmmeter (DVOM), switched to the appropriate DC volts range, across the fuse terminals to make sure voltage is present. You might have to turn the ignition switch to ON; check the schematic to see. 3. Beginning near the fuse box, wiggle the harness. Continue this at convenient points about six inches apart while watching the test light or DVOM. 4. Where the test light goes , or the DVOM voltage drops to zero, there is a short to ground in the wiring near that point. NOTE: Always use a DVOM on high impedance circuits. A test light may not glow (even with battery voltage present). Testing For A Short With A Short Circuit Locator (Short Finder) 1. Remove the blown fuse. Leave the battery connected. Page 3142 24. Verify APP Sensor 1 is between 11 and 15 percent, and APP Sensor 2 and APP Sensor 3 are between 89 and 85 percent with the pedal up (closed throttle). If not, loosen the mounting screws on the APPS sensor, and go to step 14. 25. Clear all DTCs with the PGM Tester. 26. Turn off the ignition switch, and disconnect the PGM Tester. Page 2548 3. Connect the electrical connector. 4. Fill the radiator with coolant. Refer to Draining and Refilling Cooling System. 5. Connect the negative battery cable. Page 7098 Wire Color Abbreviations The following abbreviations are used to identify wire colors in the circuit schematics: WHT................................... White YEL................................... Yellow BLK................................... Black BLU................................... Blue GRN................................... Green RED................................... Red ORN................................... Orange PNK................................... Pink BRN................................... Brown GRY................................... Gray PUR................................... Purple LT BLU................................... Light Blue LT GRN................................... Light Green Diagram Information and Instructions Auxiliary Power Outlet: Diagram Information and Instructions How to Identify Wiring Color-Coded Insulation Wire Color Wire Color Coding PCM Service Precautions Powertrain Control Module: Service Precautions PCM Service Precautions PCM Service Precautions The PCM is designed to withstand normal current draws associated with vehicle operation. Avoid overloading any circuit. When testing for opens and shorts, do not ground or apply voltage to any of the PCM's circuits unless instructed to do so. These circuits should only be tested using digital voltmeter J 39200. The PCM should remain connected to the PCM or to a recommended breakout box. Page 5725 4. Apply the setting marks (3) to the torsion bar and lower control arm, then remove torsion bar. INSPECTION AND REPAIR Make necessary correction or parts replacement if wear, damage, corrosion or any other abnormal condition are found through inspection. Check the following parts: Torsion bar - Height control arm - Adjust bolt - Rubber seat INSTALLATION 1. Apply grease to the serrated portions, then install torsion bar. Make sure the bars are on their correct respective sides and align the setting marks (3). Page 6702 Speaker: Service and Repair Tweeter Removal 1. Disconnect the battery ground cable. 2. Remove the front door trim pad (2). 3. Remove the tweeter (1). - Disconnect the connector. Installation To install, follow the removal steps in the reverse order, noting the following point: Page 6139 it is located, and what it connects to. Use the Connector Views to help locate the proper cavity when you need to probe a connector. It can be especially helpful if the connector has more than one wire of the same color. A dash symbol (-) indicates that the cavity is empty. Connector views can also be used to help diagnose multiple symptoms in separate circuits which could be caused by a single problem in a connector shared by those circuits. Here's an example: 1. Pick one of the multiple symptoms and look up the schematic for that circuit. 2. Make a list of all the in-line and fuse box connectors in that schematic , 3. Then, in the Connector Views, look up each connector on your list to see if circuits related to the other symptoms run through one of them. If they do, inspect that connector for the problem. Example: The blower, rear window defogger, and the windshield wiper don't work. List all in-line and fuse box connectors in the blower controls circuit and then check the Connector View (see the sample). You find that C324 is common to the blower controls, rear window defogger, and wiper/washer, so you inspect C324 and find the problem, bent terminals. Finding Component/Connector Locations Finding Component/Connector Locations To see where a component or connector is located on the car, look up its photo number in the "Component Location". The photo will also tell you the color of the connector, and how many cavities it has. Circuit Operation Powertrain Control Module: Description and Operation Circuit Operation The engine or powertrain control module (ECM or PCM) receives inputs from the engine sensors and switches, controlling the functions of the engine. It also turns on the malfunction indicator "check engine" light whenever a malfunction or abnormal engine performance is detected, and allows for diagnostic testing through the data link connector (DLC). Page 2680 Wires Wire insulation can be one color, or one color with another color stripe. (The second color is the stripe.) This circuit continues on another image. (The arrow shows direction of current flow.) To follow the RED/BLK wire in this example, you would turn to "Fuel and Emissions" and look for the "A" arrow. Page 3468 Air Flow Meter/Sensor: Service and Repair Mass Air Flow (MAF) Sensor REMOVAL PROCEDURE 1. Disconnect the negative battery cable. 2. Disconnect the electrical connector from the MAF sensor. 3. Loosen the clamps which secure the intake air duct and the air cleaner to the MAF sensor. 4. Remove the intake air duct from the MAF sensor. 5. Remove the MAF sensor from the air cleaner. INSTALLATION PROCEDURE Page 7950 Splices Splices are shown as a dot. Their location and the number of wires may vary depending on the harness manufacturer. Switches Switches These switches move together; the broken straight line between them means they are mechanically connected. Other types of switches are controlled by a coil or a solid state circuit. Unless otherwise noted, all switches are shown in their normal (rest) position, with power off. Terminal "T" Page 8086 Testing For A Short With A Self-Powered Test Light or DVOM 1. Remove the blown fuse and disconnect the battery and load. 2. Connect one lead of a self-powered test light or digital volt/ohmmeter (DVOM) (switched to the lowest "OHMS" range) to the fuse terminal on the load side. 3. Connect the other lead to a known good ground. 4. Beginning near the fuse box, wiggle the harness. Continue this at convenient points about six inches apart while watching the test light or DVOM. 5. If the self-powered test light goes on or the DVOM displays a low reading or no reading (zero), there is a short to ground in the wiring near that point. Testing for a Short with a Test Light or DVOM 1. Remove the blown fuse and disconnect the load. 2. Connect a test light or digital volt/ohmmeter (DVOM), switched to the appropriate DC volts range, across the fuse terminals to make sure voltage is present. You might have to turn the ignition switch to ON; check the schematic to see. 3. Beginning near the fuse box, wiggle the harness. Continue this at convenient points about six inches apart while watching the test light or DVOM. 4. Where the test light goes , or the DVOM voltage drops to zero, there is a short to ground in the wiring near that point. NOTE: Always use a DVOM on high impedance circuits. A test light may not glow (even with battery voltage present). Testing For A Short With A Short Circuit Locator (Short Finder) 1. Remove the blown fuse. Leave the battery connected. Page 2231 This means the branch of the wire connects to another circuit. The arrow points to the name of the circuit branch where the wire continues. Page 7687 Parking Brake Warning Switch: Description and Operation The brake system warning light goes on to alert the driver that the parking brake is applied or that the brake fluid is low. It also lights as a bulb test when the engine is cranked. With the ignition switch in ON or START, battery voltage is applied through fuse 11 to the brake system warning light. When the parking brake is applied, the parking brake switch closes and provides a ground for the light. The brake system warning light goes on to remind the driver that the parking brake is applied. Page 3281 Fuel Pressure: Testing and Inspection Fuel System Pressure Test A fuel system pressure test is part of several of the diagnostic charts and symptom checks. To perform this test, refer to Fuel Systems Diagnosis. Page 4710 it is located, and what it connects to. Use the Connector Views to help locate the proper cavity when you need to probe a connector. It can be especially helpful if the connector has more than one wire of the same color. A dash symbol (-) indicates that the cavity is empty. Connector views can also be used to help diagnose multiple symptoms in separate circuits which could be caused by a single problem in a connector shared by those circuits. Here's an example: 1. Pick one of the multiple symptoms and look up the schematic for that circuit. 2. Make a list of all the in-line and fuse box connectors in that schematic , 3. Then, in the Connector Views, look up each connector on your list to see if circuits related to the other symptoms run through one of them. If they do, inspect that connector for the problem. Example: The blower, rear window defogger, and the windshield wiper don't work. List all in-line and fuse box connectors in the blower controls circuit and then check the Connector View (see the sample). You find that C324 is common to the blower controls, rear window defogger, and wiper/washer, so you inspect C324 and find the problem, bent terminals. Finding Component/Connector Locations Finding Component/Connector Locations To see where a component or connector is located on the car, look up its photo number in the "Component Location". The photo will also tell you the color of the connector, and how many cavities it has. Locations Diode: Locations Tires - Tubless Tire Repair Information Tires: All Technical Service Bulletins Tires - Tubless Tire Repair Information 06-082 December 15, 2006 Applies To: ALL Tubeless Tire Repair Information This service bulletin provides the resource information required to repair tubeless tires on Honda automobiles and light trucks. To properly repair a tire, follow the Rubber Manufacturers Association (RMA) "Puncture Repair Procedures for Passenger and Light Truck Tires" outlined on the RMA wall poster. One wall poster has been provided to your dealership. Additional posters can be ordered through Helm, the RMA website, www.rma.org, or the tire manufacturers. Michelin(R) PAX System(TM), tires can be repaired using the same repair procedures described on the RMA poster. Whenever you repair a PAX System tire, you must inspect the support ring. Refer to the PAX System support ring section of this service bulletin for inspection procedures. WARRANTY CLAIM INFORMATION Refer to the tire manufacturer for warranty information. REQUIRED MATERIALS ^ 1/8 inch Patch-plug with lead wire ^ 1/4 inch Patch-plug with lead wire ^ 1/8 inch Plugs (stem)* ^ 1/4 inch Plugs (stem)* ^ 1/4 inch Patches* ^ 3/4 inch Patches* ^ Chemical cement ^ Liquid buffer ^ Rim-bead sealer ^ Inner liner sealer REQUIRED TOOLS ^ Tire stitcher, 1-1/2 inch wheel ^ Tire crayons ^ Tire test tank ^ Awl or probe ^ Flexible blade skiving knife ^ 1/8 inch Carbide tire tool with adapter ^ 1/4 inch Carbide tire tool with adapter ^ Low speed buffer with quick release chuck and exhaust hose ^ Carbide buffing wheel with adapter Page 3232 5. Select injector number and push "injector off" soft key. - Make sure of engine speed change. - If engine speed changes, the injector electric circuit is normal. - If engine speed does not change, the injector electric circuit or the injector itself is not normal. Rough Idle And/Or Diagnostic Trouble Code (DTC) stored Intake Manifold Gasket: All Technical Service Bulletins Rough Idle And/Or Diagnostic Trouble Code (DTC) stored 00-010 February 1, 2000 Applies To: 1998-99 Passport-ALL 2000 Passport-From VIN 4S6..58W..Y4400001 Thru VIN 456..58W..Y4407271 Rough Idle and/or DTCs P0171, P0174, or P1171 SYMPTOM Intermittent rough idle and/or the MIL is on with DTC P0171 (Fuel Trim System Lean Bank 1), P0174 (Fuel Trim System Lean Bank 2), or P1171 (Fuel Trim System Lean During Acceleration), and normal troubleshooting procedures have not resolved the problem. PROBABLE CAUSE Cracked intake manifold gasket(s). CORRECTIVE ACTION Replace both intake manifold gaskets. PARTS INFORMATION Intake Manifold Gasket (2 required): P/N 8-97237-538-0, H/C 6312086 EGR Valve Gasket: P/N 8-97104-317-1, H/C 4909776 Throttle Body Gasket, 1998-99 models: P/N 8-94389-939-0, H/C 4389037 Throttle Body Gasket, 2000 models: P/N 8-97193-729-1, H/C 6198329 WARRANTY CLAIM INFORMATION In warranty: The normal warranty applies. Operation Number: 111115 Flat Rate Time: 1.1 hour Failed Part: P/N 8-97131-894-2 H/C 5510771 Defect Code: 017 Contention Code: C99 Template ID: 00-010 A (1998-99 Models) 00-010 B (2000 Models) Skill Level: Repair Technician Out of warranty: Any repair performed after warranty expiration may be eligible for goodwill consideration by the District Service Manager or your Zone Office. You must request consideration, and get a decision, before starting work. REPAIR PROCEDURE Refer to page 6A-22 of the 1998,1999, or 2000 Passport Service Manual. 1. Remove the intake manifold from the cylinder heads. Separating the upper and lower intake manifold sections is not necessary. 2. Remove both old intake manifold gaskets. Be sure to carefully remove all of the old gasket material. Page 4534 Page 5993 Ground - "G" Shielding Sheilding This represents RFI (Radio Frequency Interference) shielding around a wire. The shielding is always connected to ground. Splices Page 1164 Brake Fluid: Vehicle Damage Warnings Deterioration of Brake Fluid Using any other brake fluid than specified or brake fluid with mineral oil or water mixed in will drop the boiling point of brake fluid. It may, in turn, result in vapor lock or deteriorated rubber parts of the hydraulic system. Be sure to change the brake fluid at specified intervals. If the rubber parts are deteriorated, remove all the system parts and clean them with alcohol. Prior to reassembly, dry the cleaned parts with air to remove the alcohol. Replace all the hoses and rubber parts of the system. Page 3584 the component if the component only has one connector, or by a capital letter (A, B, C, etc.) if the component has more than one connector. Below most connector numbers and component names are PHOTO and VIEW numbers. The PHOTO number refers to a photo in the back of the book that shows the connector's location on the car. The VIEW number refers to an illustration in the back of the book that shows the connector face, wire colors, connector cavity numbers, and other details. The connector cavity numbering sequence begins at the top left corner of the connector. Disregard any numbers molded into the connector housing. Wires Wires are identified by the abbreviated names of their colors; the second color is the color of the stripe. Wires are also identified by their location in a connector. The number "2" next to the male and female wire terminals at C416, for example, means those terminals join in cavity 2 of connector C416. Symbols A complete description of schematic symbols is given under wire color abbreviation. Power Distribution Schematics Power Distribution schematics show how power is supplied from the positive battery terminal to various circuits in the car. Refer to the Power Distribution section to get a more detailed picture of how power is supplied to the circuit you're working on. From Battery to Ignition Switch, Fuses, and Relays Individual circuit schematics begin with a fuse. The first half of Power Distribution, however, shows the wiring "upstream" between the battery Page 6194 Heater Core: Testing and Inspection Heater Core and/or Mode Door Check for foreign matter in the heater core, stain or the core fin defacement. Page 501 Key Reminder Switch: Diagnostic Aids Before Troubleshooting Before Troubleshooting See: Service Precautions/Vehicle Damage Warnings/Tips and Precautions 1. Check applicable fuses in the appropriate fuse/relay box. 2. Check the battery for damage, state of charge, and clean and tight connections. CAUTION: Do not quick-charge a battery unless the battery ground cable has been disconnected, otherwise you will damage the alternator diodes. - Do not attempt to crank the engine with the battery ground cable loosely connected or you will severely damage the wiring. While You're Working 1. Make sure connectors are clean, and have no loose terminals or receptacles. 2. Make sure that connectors without wire seals are packed with dielectric (silicone) grease. Part Number: 08798-9001. 3. When connecting a connector, push it until it "clicks" into place. CAUTION: Do not pull on the wires when disconnecting a connector. Pull only on the connector housings. - Most circuits include solid-state devices. Test the voltages in these circuits only with a 10-megaohm or higher impedance digital multi meter. Never use a test light or analog meter on circuits that contain solid-state devices. Damage to the devices may result. Five-Step Troubleshooting 1. Verify The Complaint Turn on all the components in the problem circuit to check the accuracy of the customer complaint. Note the symptoms. Do not begin disassembly or testing until you have narrowed down the problem area. 2. Analyze The Schematic Look up the schematic for the problem circuit. Determine how the circuit is supposed to work by tracing the current paths from the power source through the circuit components to ground. Also, trace circuits that share wiring with the problem circuit. The names of circuits that share the same fuse, ground, or switch, and so on, are referred to in each circuit schematic. Try to operate any shared circuits you didn't check in step 1. If the shared circuits work, the shared wiring is OK, and the cause must be in the wiring used only by the problem circuit. If several circuits fail at the same time, the fuse or ground is a likely cause. Based on the symptoms and your understanding of the circuit's operation, identify one or more possible causes. 3. Isolate The Problem By Testing The Circuit Make circuit tests to check the diagnosis you made in step 2. Keep in mind that a logical, simple procedure is the key to efficient troubleshooting. Test for the most likely cause of failure first. Try to make tests at points that are easily accessible. 4. Fix The Problem Once the specific problem is identified, make the repair. Be sure to use proper tools and safe procedures. 5. Make Sure The Circuit Works Turn on all components in the repaired circuit in all modes to make sure you've fixed the entire problem. If the problem was a blown fuse, be sure to test all of the circuits on that fuse. Make sure no new problems turn up and the original problem does not recur. Page 5081 Clutch Switch: Adjustments 1. Turn the clutch switch (1) until the switch plunger is fully retracted against the clutch pedal arm. 2. Adjust clutch switch by backing it out half a turn and measure the clearance (4) between the clutch pedal arm (3) and the clutch switch. 3. Lock the lock nut (2). 4. Connect clutch switch connector. Clutch Switch (bolt) and Clutch Pedal Clearance 0.5 - 1.5 mm (0.020 - 0.059 in) Page 4163 Pressure Plate: Service and Repair For further information regarding this component and the system that it is a part of, please refer to Clutch; Service and Repair; Unit Overhaul Page 280 Axle Disconnect Control Control Unit: Service and Repair SHIFT ON THE FLY CONTROLLER AND ASSOCIATED PARTS REMOVAL 1. Disconnect the battery ground cable. 2. Remove the front console assembly. 3. Disconnect the connector from the controller. 4. Remove the nut. 5. Remove the controller. INSTALLATION 1. To install, follow the removal steps in the reverse order, noting the following points. Torque: Nut (1) 8 Nm (69 inch lbs.) Page 2328 10. Move the front wheels to the straight ahead position, then use steering wheel remover J-29752 to remove the steering wheel CAUTION: Never apply force to the steering wheel in direction of the shaft by using a hammer or other impact tools in an attempt to remove the steering wheel. The steering shaft is designed as an energy absorbing unit. WARNING: THE INFLATOR MODULE SHOULD ALWAYS BE CARRIED WITH THE URETHANE COVER AWAY FROM YOUR BODY AND SHOULD ALWAYS BE LAID ON A FLAT SURFACE WITH THE URETHANE SIDE UP. THIS IS NECESSARY BECAUSE A FREE SPACE IS PROVIDED TO ALLOW THE AIR CUSHION TO EXPAND IN THE UNLIKELY EVENT OF ACCIDENTAL DEPLOYMENT. OTHERWISE. PERSONAL INJURY MAY RESULT. 11. .Remove steering column cover. 12. Disconnect the wiring harness connectors located under the steering column. 13. Remove the combination switch assembly with SRS coil. NOTE: The SRS coil is a part of the combination switch assembly, which can not be replaced separately. Therefore, be sure not to remove the SRS coil from the combination switch assembly. 14. Remove snap ring. 15. Remove cushion rubber. 16. Remove shift lock cable (for A/T). 17. Disconnect the starter switch harness connector located under the steering column, then remove lock cylinder assembly. Page 6421 Air Bag Control Module: Service and Repair WARNING: DURING SERVICE PROCEDURES, BE VERY CAREFUL WHEN HANDLING SDM. NEVER STRIKE OR JAR SDM. UNDER SOME CIRCUMSTANCES, IT COULD CAUSE DEPLOYMENT AND RESULT IN PERSONAL INJURY OR IMPROPER OPERATION OF THE SUPPLEMENTAL RESTRAINT SYSTEM (SRS). SDM MOUNTING BRACKET BOLTS MUST BE CAREFULLY TORQUED TO ASSURE PROPER OPERATION. THE SRS SHOULD ONLY BE CONNECTED TO A POWER SOURCE WHEN IT IS INSTALLED SECURELY IN THE VEHICLE. THE SDM MAY SUDDENLY DEPLOY THE AIRBAGS CAUSING PERSONAL INJURY WARNING: PROPER OPERATION OF THE SENSING AND DIAGNOSTIC MODULE (SDM) REQUIRES THE SDM TO BE SECURELY INSTALLED ON THE VEHICLE AND THE ARROW ON THE SENSOR MUST BE POINTING TOWARD THE FRONT OF THE VEHICLE. SDM is specifically calibrated and is keyed to the SDM location SRS wiring harness. Caution should be used to ensure proper location of the SDM. The keying of the SDM to its location and wiring harness connectors should never be modified in the field. Removal 1. Disable the SRS. 2. Remove dressing panel around the radio and disconnect cigar lighter harness 3. Remove the transfer sift lever knob. 4. Remove the center console. 5. Remove three connector from Powertrain Control Module (PCM). (Y22SE 2.2L Engine only) 6. Remove PCM with bracket. (Fixed tour bolts) (Y22SE 2.2L Engine only) 7. Remove right side stay between instrument panel and floor. 8. Remove driver and passenger seat. 9. Turn over carpet to rear side. 10. Remove air conditioning duct for rear seat. (Transform the duct during removing it) 11. Pull CPA (2) (Connector Position Assurance-red color) out and push connector lock down to disconnect the SDM harness connector (3). Page 2273 Disclaimer Repair Procedure 1. Unclamp the air cleaner housing cover, and move it to the side for access to connector C123 (16P BLK). 2. Unfasten C123 from the side of the engine compartment using a 90-degree pick. 3. Disconnect C123, and clean the terminals on both sides of the connector with contact cleaner. Shake the residue out of the connector. Allow the contact cleaner to evaporate for at least 3 minutes, then reconnect C123. 4. Fasten C123 to the left side of the engine compartment, then reinstall the air cleaner housing cover. 5. While supporting the accelerator pedal assembly, remove the two bolts that secure the assembly to the bulkhead. Carefully lower the assembly to gain access to the connector. Page 5788 ^ Reinstall the lower half of body mount #4 on both sides of the vehicle. Torque the nuts to 50 Nm (37 Ib-ft). 23. Remove the ratcheting straps. 24. Lower the vehicle to the ground, then torque the lower trailing link front mounting bolts to 165-180 Nm (122-133 Ib-ft). 25. If the side steps or the running boards were removed, reinstall them. 26. Fill out the information on a campaign completion label. Stick this label to the back edge of the driver's door, just below the door latch. *NOTE: If you need more labels, order them from Helm using reorder number Y0895.* Stage 4 Repair STAGE 4 REPAIR *NOTE: ^ If the vehicle requires a STAGE 4 repair or had a prior repair resulting in a modification to the lower trailing link front bracket area, an additional Page 666 Tighten Tighten the bolt to 20 N.m (12 lb ft.). 3. Connect the MAP electrical connector. 4. Connect the negative battery cable. Page 3154 Disclaimer Repair Procedure 1. Unclamp the air cleaner housing cover, and move it to the side for access to connector C123 (16P BLK). 2. Unfasten C123 from the side of the engine compartment using a 90-degree pick. 3. Disconnect C123, and clean the terminals on both sides of the connector with contact cleaner. Shake the residue out of the connector. Allow the contact cleaner to evaporate for at least 3 minutes, then reconnect C123. 4. Fasten C123 to the left side of the engine compartment, then reinstall the air cleaner housing cover. 5. While supporting the accelerator pedal assembly, remove the two bolts that secure the assembly to the bulkhead. Carefully lower the assembly to gain access to the connector. Page 6211 Page 5591 Testing For A Short With A Self-Powered Test Light or DVOM 1. Remove the blown fuse and disconnect the battery and load. 2. Connect one lead of a self-powered test light or digital volt/ohmmeter (DVOM) (switched to the lowest "OHMS" range) to the fuse terminal on the load side. 3. Connect the other lead to a known good ground. 4. Beginning near the fuse box, wiggle the harness. Continue this at convenient points about six inches apart while watching the test light or DVOM. 5. If the self-powered test light goes on or the DVOM displays a low reading or no reading (zero), there is a short to ground in the wiring near that point. Testing for a Short with a Test Light or DVOM 1. Remove the blown fuse and disconnect the load. 2. Connect a test light or digital volt/ohmmeter (DVOM), switched to the appropriate DC volts range, across the fuse terminals to make sure voltage is present. You might have to turn the ignition switch to ON; check the schematic to see. 3. Beginning near the fuse box, wiggle the harness. Continue this at convenient points about six inches apart while watching the test light or DVOM. 4. Where the test light goes , or the DVOM voltage drops to zero, there is a short to ground in the wiring near that point. NOTE: Always use a DVOM on high impedance circuits. A test light may not glow (even with battery voltage present). Testing For A Short With A Short Circuit Locator (Short Finder) 1. Remove the blown fuse. Leave the battery connected. Page 1225 Power Steering Fluid: Service Precautions Use Genuine Honda Power Steering Fluid, or another brand of power steering fluid as a temporary replacement. Page 349 Power Seat Switch Page 3280 Fuel Pressure: Service Precautions WARNING: Adhere to the following procedures any time the fuel system is being worked on in order to reduce the risk of fire and personal injury: - Keep a dry chemical (Class B) fire extinguisher near the work area. - Place a "CAUTION FLAMMABLE" sign in the work area. - Work in a well-ventilated area. Do not smoke, and keep sparks and open flames away. - Wear eye protection. - Use caution when working near the catalytic converter to prevent the possibility of burns or fire. (The temperatures within the converter can exceed 537 °C (1000 °F). - Relieve the fuel system pressure prior to disconnecting fuel system components. - Disconnect the negative battery cable except for tests where battery voltage is required. - Use a suitable container to store or catch fuel. - Do not replace fuel pipe with fuel hose. - Plug all disconnected fuel line fittings and hoses. - After making any fuel system repairs ALWAYS inspect for fuel leaks. Page 2899 3. Check the vacuum hose to the sensor for leaking or restriction, Be sure that no other vacuum devices are connected to the MAP hose. IMPORTANT: Make sure the electrical connector remains securely fastened. 4. Disconnect the sensor from the bracket. Twist the sensor with your hand to check for an intermittent connection. Output changes greater than 0.10 volt indicate a bad sensor. Locations Page 813 Accelerator Pedal Position Sensor: Service and Repair Accelerator Position Sensor Replacement CAUTION: Remove the Accelerator (A) pedal assembly as a unit to have it services. Do not remove the Accelerator Position (AP) sensor on the A pedal. If the AP sensor is removed for emergency cause, refer to following Items as necessary. Removal Procedure 1. Disconnect the negative battery cable. 2. Disconnect the electrical harness from the AP sensor. 3. Remove the AP sensor. Installation Procedure 1. Install the accelerator position (AP) sensor to bolts with accelerator (A) pedal. 2. Connect the connector to AP sensor. 3. Install the negative battery cable. Page 550 Each schematic represents one circuit. A circuit's wires and components are arranged to show current flow, from power at the top of the page, to ground, at the bottom. Shared Circuits Other circuits may share power or ground terminals or wiring with the circuit shown. A wire that connects one circuit to another, for example, is cut short and has an arrowhead at the end of it pointing in the direction of current flow. Next to the arrowhead is the name of the circuit or component which shares that wiring. To quickly check shared wiring, check the operation of a component it serves. If that component works, you know the shared wiring is OK. Connectors All in-line and junction connectors are numbered (C725, C416, etc.). Component connectors are not numbered but are identified either by the name of Page 298 Terminals - "T" Each "T" terminal (ring type) is numbered for reference and location. A "T" terminal is secured with a screw or bolt. Wires Page 3849 This is the same power supply used by the PGM Tester. *The PC Interface Kit and the 110 VAC/12 VDC Power Supply can be ordered through the Honda Tool and Equipment Program at 888-424-6857. ^ Dealer Communications System (DCS) CD: May 1999 or later ^ HONDANET DCS Workstation (not the master terminal) ^ PGM Tester with SN902 or later software: The Tester can be used to retrieve PCM broadcast codes if you aren't using the Smart Cable to retrieve codes.* *USING A PROGRAMMED SMART CABLE NOTES: * If the PCM broadcast code stored in the Smart Cable is different than the code needed by the PCM, go to REPROGRAMMING A SMART CABLE.* ^ If the red light (# 3) on the Smart Cable comes on or flashes at any time during the procedure, the update was not completed. Go to SMART CABLE DIAGNOSIS. 1. Turn the ignition switch ON (II). 2. Connect the Smart Cable's large blue connector to the vehicle's DLC (data link connector). Connect the other end of the Smart Cable to the DLC port on the Smart Cable box. The green light (# 1) on the Smart Cable flashes, then glows steadily. *NOTES: If the yellow (# 2) and green lights flash and then glow steadily, the PCM broadcast code already matches the code in the Smart Cable. Go to steps 5.* 3. Momentarily push and release the START button on the Smart Cable to begin the PCM update. While updating the PCM, the yellow light on the Smart Cable flashes, and the green light glows steadily. *NOTICE To avoid permanent PCM damage, do not disconnect the Smart Cable or turn the ignition switch OFF while the yellow light is flashing.* 4. After 1 to 3 minutes, note that both the yellow and green lights glow steadily to indicate that the update is complete. 5. Disconnect the Smart Cable from the DLC. 6. If the vehicle still has the problem you tried to correct with the update, refer to the appropriate service manual or ETM for troubleshooting information. *REPROGRAMMING A SMART CABLE 1. If not already done, load the May 1999 or later DCS CD onto your DCS workstation. Loading instructions were included in the CD's mailing. It you have questions when loading the CD, contact the HONDANET 2000 Support Center at 800-245-4343. 2. Connect the small end of the PC interface kit to the PC port on the Smart Cable box. (Some kits have a yellow label near the small end to help you Page 7605 Wire Color Abbreviations The following abbreviations are used to identify wire colors in the circuit schematics: WHT................................... White YEL................................... Yellow BLK................................... Black BLU................................... Blue GRN................................... Green RED................................... Red ORN................................... Orange PNK................................... Pink BRN................................... Brown GRY................................... Gray PUR................................... Purple LT BLU................................... Light Blue LT GRN................................... Light Green Page 2979 Vehicle Speed Sensor: Diagnostic Aids Before Troubleshooting Before Troubleshooting See: Service Precautions/Vehicle Damage Warnings/Tips and Precautions 1. Check applicable fuses in the appropriate fuse/relay box. 2. Check the battery for damage, state of charge, and clean and tight connections. CAUTION: Do not quick-charge a battery unless the battery ground cable has been disconnected, otherwise you will damage the alternator diodes. - Do not attempt to crank the engine with the battery ground cable loosely connected or you will severely damage the wiring. While You're Working 1. Make sure connectors are clean, and have no loose terminals or receptacles. 2. Make sure that connectors without wire seals are packed with dielectric (silicone) grease. Part Number: 08798-9001. 3. When connecting a connector, push it until it "clicks" into place. CAUTION: Do not pull on the wires when disconnecting a connector. Pull only on the connector housings. - Most circuits include solid-state devices. Test the voltages in these circuits only with a 10-megaohm or higher impedance digital multi meter. Never use a test light or analog meter on circuits that contain solid-state devices. Damage to the devices may result. Five-Step Troubleshooting 1. Verify The Complaint Turn on all the components in the problem circuit to check the accuracy of the customer complaint. Note the symptoms. Do not begin disassembly or testing until you have narrowed down the problem area. 2. Analyze The Schematic Look up the schematic for the problem circuit. Determine how the circuit is supposed to work by tracing the current paths from the power source through the circuit components to ground. Also, trace circuits that share wiring with the problem circuit. The names of circuits that share the same fuse, ground, or switch, and so on, are referred to in each circuit schematic. Try to operate any shared circuits you didn't check in step 1. If the shared circuits work, the shared wiring is OK, and the cause must be in the wiring used only by the problem circuit. If several circuits fail at the same time, the fuse or ground is a likely cause. Based on the symptoms and your understanding of the circuit's operation, identify one or more possible causes. 3. Isolate The Problem By Testing The Circuit Make circuit tests to check the diagnosis you made in step 2. Keep in mind that a logical, simple procedure is the key to efficient troubleshooting. Test for the most likely cause of failure first. Try to make tests at points that are easily accessible. 4. Fix The Problem Once the specific problem is identified, make the repair. Be sure to use proper tools and safe procedures. 5. Make Sure The Circuit Works Turn on all components in the repaired circuit in all modes to make sure you've fixed the entire problem. If the problem was a blown fuse, be sure to test all of the circuits on that fuse. Make sure no new problems turn up and the original problem does not recur. Page 1707 2. Use a valve cutter to minimize scratches and other rough areas. This will bring the contact width back to the standard value. Remove only the scratches and rough areas. Do not cut away too much. Take care not to cut away unblemished areas of the valve seat surface. Valve seat angle degree: 90° 3. Apply abrasive compound to the valve seat insert surface. 4. Insert the valve into the valve guide. 5. Turn the valve while lapping it to fit the valve seat insert. 6. Check that the valve contact width is correct. 7. Check that the valve seat insert surface is in contact with the entire circumference of the valve. Valve Seat Insert Replacement 1. Arc weld the rod at several points. Be careful not to damage the aluminum. 2. Allow the rod to cool for a few minutes. This will cause the valve seat to shrink. 3. Strike the rod and pull it out. 4. Carefully clean the valve seat press- fit on the cylinder head side. 5. Heat the press-fit with steam or some other means to cause expansion. Cool the valve seat with dry ice or some other means. Page 271 Axle Disconnect Control Control Unit: Diagnostic Aids Before Troubleshooting Before Troubleshooting See: Service Precautions/Vehicle Damage Warnings/Tips and Precautions 1. Check applicable fuses in the appropriate fuse/relay box. 2. Check the battery for damage, state of charge, and clean and tight connections. CAUTION: Do not quick-charge a battery unless the battery ground cable has been disconnected, otherwise you will damage the alternator diodes. - Do not attempt to crank the engine with the battery ground cable loosely connected or you will severely damage the wiring. While You're Working 1. Make sure connectors are clean, and have no loose terminals or receptacles. 2. Make sure that connectors without wire seals are packed with dielectric (silicone) grease. Part Number: 08798-9001. 3. When connecting a connector, push it until it "clicks" into place. CAUTION: Do not pull on the wires when disconnecting a connector. Pull only on the connector housings. - Most circuits include solid-state devices. Test the voltages in these circuits only with a 10-megaohm or higher impedance digital multi meter. Never use a test light or analog meter on circuits that contain solid-state devices. Damage to the devices may result. Five-Step Troubleshooting 1. Verify The Complaint Turn on all the components in the problem circuit to check the accuracy of the customer complaint. Note the symptoms. Do not begin disassembly or testing until you have narrowed down the problem area. 2. Analyze The Schematic Look up the schematic for the problem circuit. Determine how the circuit is supposed to work by tracing the current paths from the power source through the circuit components to ground. Also, trace circuits that share wiring with the problem circuit. The names of circuits that share the same fuse, ground, or switch, and so on, are referred to in each circuit schematic. Try to operate any shared circuits you didn't check in step 1. If the shared circuits work, the shared wiring is OK, and the cause must be in the wiring used only by the problem circuit. If several circuits fail at the same time, the fuse or ground is a likely cause. Based on the symptoms and your understanding of the circuit's operation, identify one or more possible causes. 3. Isolate The Problem By Testing The Circuit Make circuit tests to check the diagnosis you made in step 2. Keep in mind that a logical, simple procedure is the key to efficient troubleshooting. Test for the most likely cause of failure first. Try to make tests at points that are easily accessible. 4. Fix The Problem Once the specific problem is identified, make the repair. Be sure to use proper tools and safe procedures. 5. Make Sure The Circuit Works Turn on all components in the repaired circuit in all modes to make sure you've fixed the entire problem. If the problem was a blown fuse, be sure to test all of the circuits on that fuse. Make sure no new problems turn up and the original problem does not recur. Page 1541 Valve Inspection Chart Diagram Information and Instructions Key Reminder Switch: Diagram Information and Instructions How to Identify Wiring Color-Coded Insulation Wire Color Wire Color Coding Page 4891 Brake Pad: Service and Repair REMOVAL NOTE: If a squealing noise occurs from the rear brake while driving, check the pad wear indicator plate. If the indicator plate contacts the rotor, the disc pad assembly should be replaced. - Draw out two-thirds of the brake fluid from the reservoir. - Raise the vehicle and support it with suitable safety stands. 1. Remove wheel and tire assembly. 2. Remove lock bolt (1). 3. Rotate caliper assembly and support the caliper assembly so that the brake hose is not stretched or damaged. 4. Remove pad assembly with shim. 5. Remove clip. INSTALLATION Page 5357 10. Use the PGM Tester to check the broadcast code. Make sure the broadcast code matches the one you selected from the CD-ROM. WARRANTY CLAIM INFORMATION In warranty: The normal warranty applies. Failed Part: P/N 8-17087-655-0 H/C 4375820 Defect Code: 064 Contention Code: C01 Skill Level: Repair Technician Out of warranty: Any repair performed after warranty expiration may be eligible for goodwill consideration by the District Service Manager or your Zone Office. You must request consideration, and get a decision, before starting work. REPAIR PROCEDURE - ENGINE/BODY GROUND 1. Use the ETM for the appropriate year to locate these ground connectors: G101, G104, G105, G106 and G160. 2. Inspect each connector for corrosion or looseness. 3. Remove the bolt from any connector that is corroded or loose. Clean the terminal connector with a wire brush. File flat any solder bumps on the connector. 4. Clean the contact surface on the engine or body with a wire brush. 5. Replace the bolt if it is heavily corroded. Otherwise, clean it with a wire brush. 6. Apply lithium dielectric grease to both sides of the terminal connector. 7. Reinstall the bolt, torque it to 14 N.m (10 lb-ft). 8. Use the Smart Cable to reprogram the PCM with the latest software from the June 2001 or later HONDANET CD-ROM. Refer to Service Bulletin 99-005, Updating the Passport PCM, filed under Tools. 9. Use the PGM Tester to clear any DTCs. 10. Use the PGM Tester to check the broadcast code. Make sure the broadcast code matches the one you selected from the CD-ROM. WARRANTY CLAIM INFORMATION In warranty: The normal warranty applies. Failed Part: P/N 8-97086-823-0 Page 6795 Front Bumper Bracket: Removal and Replacement Front Bumper Slider Bracket Removal 1. Disconnect the battery ground cable. 2. Remove the front bumper. 3. Remove the three nuts(1) and draw out the slider bracket(2). Installation To install, follow the removal steps in reverse order. Engine Controls - Engine Spark Knock Or Pinging Powertrain Control Module: All Technical Service Bulletins Engine Controls - Engine Spark Knock Or Pinging 01-084 June 19, 2009 Applies To: 2000-02 Passport - ALL Engine Spark Knock (Pinging) (Supersedes 01-084, dated March 18, 2003, to revise the information marked by asterisks) *REVISION SUMMARY Under WARRANTY CLAIM INFORMATION, the failed part number, the Honda code, the defect code, and the symptom code have been updated.* SYMPTOM An engine spark knock (pinging). PROBABLE CAUSE The programmed ignition timing does not correct quickly enough in some climates. CORRECTIVE ACTION Update the PCM software with the Smart Cable. TOOL INFORMATION PGM Tester with software update release SN200P (9/1/01) or later. For the other tools and equipment you need to update the PCM software, refer to Service Bulletin 99-005, Updathg the Passport POM, filed under Tools. WARRANTY CLAIM INFORMATION In warranty: The normal warranty applies. Operation Number: 125517 Flat Rate Time: 0.3 hour *Failed Part: P/N 8-12212-079-0 H/C 6974992 Defect Code: 03214 Symptom Code: 09117* Template ID: 01-084A Skill Level: Repair Technician Out of warranty: Any repair performed after warranty expiration may be eligible for goodwill consideration by the District Parts and Service Manager or your Zone Office. You must request consideration, and get a decision, before starting work. REPAIR PROCEDURE 1. Retrieve the PCM broadcast code with the PGM Tester or the Smart Cable (refer to Service Bulletin 99-005, Updathg the Passport PCM). Page 1459 Connecting Rod: Service and Repair Disassembly, Inspection and Assembly Piston and Connecting Rod Disassembly 1. Remove cylinder head assembly (1). Page 217 2. Connect the short finder across the battery terminals and the load (component) side of the fuse terminal. 3. Close all switches in the circuit you're testing. 4. Turn on the short finder. This creates a pulsing magnetic field around the wiring between the fuse box and the short. 5. Beginning at the fuse box, slowly move the short finder along the circuit wiring. The meter will read current pulses through sheet metal and body trim. As long as the meter is between the fuse and the short, the needle will move with each current pulse. Once you move the meter past the point of the short, the needle will stop moving. Check the wiring and connectors in this area to locate the cause of the short. Testing For Continuity When testing for continuity at a connector without wire seals, you do not have to separate the two halves of the connector. Instead, probe the connector from the back. Always check both sides of the connector because dirty, corroded, and bent terminals can cause problems (no electrical contact = an open). 1. Disconnect the negative cable from the car battery. If you're using a DVOM, place it in the lowest "OHMS" range. Page 4086 Transmission Cooler: Technical Service Bulletins A/T - Cooler Flushing Equipment Information 89-022 May 16, 2008 Applies To: Vehicles With an In-Radiator ATF Cooler - ALL ATF Cooler Cleaner (Supersedes 89-022, dated June 18, 2004, to update the information marked by asterisks) Before installing an overhauled or remanufactured A/T, you must thoroughly clean the ATF cooler to prevent system contamination. Failure to do so could cause a repeat A/T failure. The ATF Cooler Cleaner (PIN GTHTTCF6H) is a portable, electrically operated special tool that cleans the ATF cooler with high- pressure, heated ATF. This cleaning action melts down waxy varnish residue left by burnt ATF and purges metal particles, clutch material, and other contaminants. The ATF Cooler Cleaner has these features: ^ Quick-connect fittings and color-coded hoses for easy hookup. ^ Uses about 9.5 gallons of Honda ATF-Z1, which gets filtered and recirculated. ^ Heats ATF to a temperature of 1400 to 150°F and then pumps it through the ATF cooler at high pressure (100 psi) using a pulsating action and air purging. Switching the hoses cleans the ATF cooler in the reverse direction. ^ Two magnetic nonbypass spin-on filters to trap purged contaminants. ^ Built-in tool tray. This service bulletin gives you information for ordering and servicing this special tool, and guides you through the entire ATF cooler cleaning process. *REQUIRED MATERIALS Honda ATF-Z1: P/N 08200-9001 Magnetic Nonbypass Spin-On Filter: T/N GTHNBP12 (12-pack) T/N GTHNBP2 (6-pack) T/N GTHGNBP22 (2-pack) ORDERING INFORMATION Additional ATF cooler cleaners or magnetic nonbypass spin-on filters can be ordered through the Honda Tool and Equipment Program. To order on the iN, click on SERVICE, then Service Bay, then Tool and Equipment Program. From the Tool and Equipment Program menu, click on the Online Catalog tab, and then search for the desired filter pack by part number.* Page 2738 ^ If the idle speed ever exceeds 1,300 rpm 2. Remove the vacuum hose from the fuel pressure regulator, then start the engine. ^ If fuel comes out of the fuel pressure regulator vacuum hose connection, go to REPAIR PROCEDURE FUEL PRESSURE REGULATOR. ^ If no fuel comes out of the regulator, reconnect the vacuum hose and continue to step 3. 3. Connect the PGM Tester. Set it to Engine Data List. 4. Have an assistant drive the vehicle under the conditions described by the customer. 5. If the high or erratic idle condition occurs, note the values of the PSP Switch and APP Sensor 1 when it is occurring. ^ If the PSP Switch is HIGH, and you are not turning, go to REPAIR PROCEDURE POWER STEERING SWITCH. ^ If the APP Sensor 1 is greater than 15% and APP Sensor 2 and/or APP Sensor 3 are less than 85%, and the accelerator pedal is not depressed, go to REPAIR PROCEDURE APPS GROUND. ^ If the PSP Switch is reading LOW when not turning and HIGH when turning, and the APP Sensors are reading within the range shown, discontinue the test-drive and go to step 6. 6. Do these repairs: ^ REPAIR PROCEDURE APPS GROUND ^ REPAIR PROCEDURE ENGINE/BODY GROUND REPAIR PROCEDURE - FUEL PRESSURE REGULATOR 1. Relieve fuel system pressure: ^ Remove the fuel fill cap. ^ Remove the fuel pump relay. ^ Start the engine and run it until it stalls. ^ Crank the engine for 3 seconds. 2. Remove the vacuum hose from the fuel pressure regulator. 3. Remove the fuel pressure regulator shield from the common chamber (two bolts). Page 7072 Tailgate Lock (SWB) And Associated Parts Page 4451 Terminals - "T" Each "T" terminal (ring type) is numbered for reference and location. A "T" terminal is secured with a screw or bolt. Wires Page 8028 2. Connect one lead of a self-powered test light or DVOM to one end of the part of the circuit you want to test. 3. Connect the other lead to the other end. 4. If the self-powered test light glows, there is continuity. If you're using a DVOM, a low reading or no reading (zero), means good continuity. Testing For Voltage When testing for voltage at a connector without wire seals, you do not have to separate the two halves of the connector. Instead, probe the connector from the back. Always check both sides of the connector because dirty, corroded, and bent terminals can cause problems (no electrical contact = an open). 1. Connect one lead of the lest light to a known good ground, or, if you're using a digital volt ohmmeter (DVOM), place it in the appropriate DC volts range, and connect its negative lead to ground. 2. Connect the other lead of the test light or DVOM to the point you want to check. 3. If the test light glows, there is voltage present. If you're using a DVOM, note the voltage reading. It should be within one volt of measured battery voltage. A loss of more than one volt indicates a problem. NOTE: Always use a DVOM on high impedance circuits. A test light may not glow (even with battery voltage present). Testing For Voltage Drop Wires, connectors, and switches are designed to conduct current with a minimum loss of voltage. A voltage drop of more than one volt indicates a problem. 1. Place the digital volt/ohmmeter (DVOM) in the appropriate DC volts range. Connect the positive lead to the end of the wire (or to the connector or switch) closest to the battery. 2. Connect the negative lead to the other end of the wire (or the other side of the connector or switch). 3. Turn on the components in the circuit. 4. The DVOM will show the difference in voltage between the two points. A difference, or drop, of more than one volt indicates a problem. Check the circuit for loose, dirty, or bent terminals. Page 6082 Wires Wire insulation can be one color, or one color with another color stripe. (The second color is the stripe.) This circuit continues on another image. (The arrow shows direction of current flow.) To follow the RED/BLK wire in this example, you would turn to "Fuel and Emissions" and look for the "A" arrow. Locations Page 7096 Wires Wire insulation can be one color, or one color with another color stripe. (The second color is the stripe.) This circuit continues on another image. (The arrow shows direction of current flow.) To follow the RED/BLK wire in this example, you would turn to "Fuel and Emissions" and look for the "A" arrow. Page 7526 Wires Wire insulation can be one color, or one color with another color stripe. (The second color is the stripe.) This circuit continues on another image. (The arrow shows direction of current flow.) To follow the RED/BLK wire in this example, you would turn to "Fuel and Emissions" and look for the "A" arrow. Page 1728 NOTE: After you rotate the crankshaft, the solid white lines on the belt will not align with the camshaft pulley marks; this is normal. 10. Remove the crankshaft bolt, then install the lower, the right, and the left timing belt covers. Torque the cover bolts to 19 N.m (14 lb-ft). 11. Install the crankshaft pulley, and torque the bolt to 167 N.m (123 lb-ft). 12. Install fan pulley bracket and tighten fixing bolts to the specified torque. Torque: 22 Nm (16 ft. lbs.) 13. Install power steering pump assembly and tighten to the specified torque. Torque: M8 bolt: 22 Nm (16 ft. lbs.) M10 bolt: 46 Nm (34 ft. lbs.) 14. Install cooling fan assembly and tighten bolts/nuts to the specified torque. Torque: 22 Nm (16 ft. lbs.) for fan pulley and fan bracket. Torque: 7.5 Nm (66.4 inch lbs.) for fan and clutch assembly. Page 6176 - Tear off the insulator carefully. - Remove the sensor fixing clip. - Use a back-up wrench when disconnecting all refrigerant pipes. Installation To install, follow the removal steps in the reverse order, noting the following points: 1. The sensor is installed on the core with the clip. 2. The sensor must not interfere with the evaporator core. 3. When installing the new evaporator core, install the duct sensor (2) to the evaporator core (1) specified position with the clip in the illustration. 4. O-rings cannot be reused. Always replace with new ones. 5. Be sure to apply new compressor oil to the O-ring when connecting lines. 6. Be sure to install the sensor and the insulator on the place where they were before. 7. To install a new evaporator core, add 50cc (1.7 fl.oz.) of new compressor oil to the new core. 8. Tighten the refrigerant lines to the specified torque. Refer to Main Data and Specifications for Torque Specifications. 9. Apply an adhesive to the parting face of the lining when assembling the evaporator assembly. Page 1511 clearance exceeds the specified limit, the connecting rod must be replaced. Standard: 0.16 mm 0.35 mm (0.0063 inch - 0.0138 inch) Limit: 0.40 mm (0.0157 inch) 3. Measure the oil clearance between the connecting rod and the crankshaft. 1. Remove the connecting rod cap nuts and the rod caps (12). Arrange the removed rod Gaps in the cylinder number order. 2. Clean the rod bearings and the crankshaft pins. 3. Carefully check the rod bearings. If even one bearing is found to be damaged or badly worn, the entire bearing assembly must be replaced as a set. Reinstall the bearings in their original positions. Apply plastogene to the crank pin. 4. Reinstall the rod caps (12) to their original positions. Tighten the rod cap nuts. Torque: 54 Nm (40 ft. lbs.) Note: Do not allow the crankshaft to rotate. 5. Remove the rod caps. 6. Measure the width of the plastogene and determine the oil clearance. If the oil clearance exceeds the limit, replace the rod bearing as a set. Standard: 0.019 mm - 0.043 mm (0.0007 inch - 0.0017 inch) Limit: 0.08 mm (0.0031 inch) 7. Clean the plastogene from the bearings and the crankshaft pins. Con-rod Bearing Selection Select and install the new connecting rod bearings, paying close attention to the connecting rod big end diameter size mark (1). Page 200 If there is no photo number below or beside a component name or a connector, ground, or terminal number, look up that name or number in the appropriate Connector Identification Chart. The chart lists how many cavities a connector has, where it's located, and what it connects to. The related illustration shows the connector's location on the harness, and the harness routing. NOTE: Photos listed by number are located at Locations / Components / Photograohs. See: Locations/Component Locations/Photographs Circuit Schematics Safety Stop Switch Sunroof/Moonroof Limit Switch: Service and Repair Safety Stop Switch Removal 1. Disconnect the battery ground cable. 2. Remove the sunroof drive unit assembly (1) to remove the safety stop switch (2). Installation To install, follow the removal steps in the reverse order Procedures Power Mirror Switch: Procedures Removal 1. Disconnect the battery ground cable. 2. Remove the instrument panel lower cover (2). 3. Remove the door mirror switch (1). Page 3518 Camshaft Position Sensor: Description and Operation Camshaft Position (CMP) Sensor and Signal The camshaft position (CMP) sensor sends a CMP signal to the PCM. The PCM uses this signal as a "sync pulse" to trigger the injectors in the proper sequence. The PCM uses the CMP signal to indicate the position of the #1 piston during its power stroke. This allows the PCM to calculate true sequential fuel injection (SFI) mode of operation. If the PCM detects an incorrect CMP signal while the engine is running, DTC P0341 will set. If the CMP signal is lost while the engine is running, the fuel injection system will shift to a calculated sequential fuel injection mode based on the last fuel injection pulse, and the engine will continue to run. As long as the fault is present, the engine can be restarted. It will run in the calculated sequential mode with a 1-in-6 chance of the injector sequence being correct. Refer to DTC P0341 for further information. CMP Signal The PCM uses this signal to determine the position of the number 1 piston during its power stroke, allowing the PCM to calculate true sequential multiport fuel injection (SFI). Loss of this signal will set a DTC P0341. If the CMP signal is lost while the engine is running, the fuel injection system will shift to a calculated sequential fuel injection based on the last fuel injection pulse, and the engine will continue to run. The engine can be restarted and will run in the calculated sequential mode as long as the fault is present, with a 1-in-6 chance of being correct. Page 2703 Tighten Tighten the bolt to 20 N.m (12 lb ft.). 3. Connect the MAP electrical connector. 4. Connect the negative battery cable. Page 2377 Spark Plug: Service and Repair Inspection and Repair Inspection and Repair The spark plug affects entire engine performance and therefore its inspection is very important. - Check electrode and insulator for presence of cracks, and replace if any. - Check electrode for wear, and replace if necessary.. - Check gasket for damage, and replace if necessary. - Measure insulation resistance with an ohmmeter, and replace if faulty. - Adjust spark plug gap to 1.0 mm (0.040 in) to 1.1 mm (0.043 in). - Check fuel and electrical systems if spark plug is extremely dirty. - Use spark plugs having low heat value (hot type plug) if fuel and electrical systems are normal. - Use spark plugs having high heat value (cold type plug) if insulator and electrode are extremely burned. Sooty Spark Plugs Much deposit of carbon or oil on the electrode and insulator of spark plug reduces the engine performance. Possible causes: - Too rich mixture - Presence of oil in combustion chamber - Incorrectly adjusted spark plug gap Burning Electrodes This fault is characterized by scorched or heavily oxidized electrode or blistered insulator nose. Possible causes: - Too lean mixture - Improper heat value Measuring Insulation Resistance - Measure insulation resistance using a 500 volt megaohm meter. - Replace spark plugs if measured value is out of standard. Insulation resistance: 50 Mohm or more. Page 5811 9. Use wrench J-36827, remove hub nut. 10. Remove hub and disc assembly. 11. Remove ABS sensor ring. 12. Remove outer bearing. 13. Remove oil seal. 14. Remove inner bearing. 15. Remove bolt, if necessary, replace the wheel pin in the following manner. - Apply a scribe mark (1) to disc to hub. - Clamp the hub and disc assembly in a vise, using protective pads. Remove the 6 disc-to-hub retaining bolts. - Place hub on a suitable work surface and remove the studs by using a hammer. INSPECTION AND REPAIR Make necessary correction or parts replacement if wear, damage, corrosion or any other abnormal condition are found through inspection. Check the following parts. Hub - Hub bearing oil seal - Knuckle spindle Specifications Camshaft Bearing: Specifications Camshaft Bearing Cap Fixing Bolt 10 Nm Page 2770 This sample Ground Distribution schematic shows all of the components that share two ground points. Components A solid border line means the entire component is shown. A broken border line indicates that only part of the component is shown. Page 4986 Hydraulic Control Assembly - Antilock Brakes: Testing and Inspection B-11 FL Isolation Solenoid Valve Failure (DTC 41/C0245, C0247) Chart B-11 FL Isolation Solenoid Coil Failure (DTC 41 (Flash Out) / C0245, C0247 (Serial Communications)) Part 1 of 2 Part 2 of 2 Page 5355 6. Place the end of the return hose in a container. Have someone start the engine, then pour ATF into the reservoir while you watch the fluid coming out of the return hose. When the fluid coming out is the same color as the new fluid, turn off the engine. 7. Reconnect the return hose to the reservoir. 8. Start the engine. Fill the power steering reservoir to the proper level with ATF then turn off the engine. 9. Use the Smart Cable to reprogram the PCM with the latest software from the June 2001 or later HONDANET CD-ROM. Refer to Service Bulletin 99-005, Updating the Passport PCM, filed under Tools. 10. Use the PGM Tester to clear any DTCs. 11. Use the PGM Tester to check the broadcast code. Make sure the broadcast code matches the one you selected from the CD-ROM. WARRANTY CLAIM INFORMATION In warranty: The normal warranty applies. Failed Part: P/N 8-97181-590-0 H/C 5698030 Defect Code: 064 Contention Code: C01 Skill Level: Repair Technician Out of warranty: Any repair performed after warranty expiration may be eligible for goodwill consideration by the District Service Manager or your Zone Office. You must request consideration, and get a decision, before starting work. REPAIR PROCEDURE - APPS GROUND 1. Unclamp the air cleaner housing cover, and move it to the side for access to connector C123 (16P BLK). Page 4890 Brake Pad: Testing and Inspection Brake Pads Inspection Check the outer pads by looking at each caliper from above. Check the thickness on the inner pad by looking down through the inspection hole in the top of the caliper. Whenever the pad is worn to about the thickness of the pad base, the pad should be removed for further measurements. The pad should be replaced anytime the pad thickness (1) is worn to within 1.0 mm (0.039 inch) of the pad itself. The disc pads have a wear indicator that makes a noise when the pad wears to where replacement is required. Page 2390 Valve Inspection Chart Page 122 Splices Splices are shown as a dot. Their location and the number of wires may vary depending on the harness manufacturer. Switches Switches These switches move together; the broken straight line between them means they are mechanically connected. Other types of switches are controlled by a coil or a solid state circuit. Unless otherwise noted, all switches are shown in their normal (rest) position, with power off. Terminal "T" Page 6391 Deployed Air Bag Assembly "You should wear gloves and glasses. After the air bag assembly has been deployed, the surface of the air bag may contain solid particulate. This solid particulate consists primarily of by products of the chemical reaction, Potassium Chloride and copper metal dust. Compounds of Potassium Borate, Strontium Chloride, Copper Chloride, and Ammonium Chloride may be found in amounts of about 1 % (each) of the total particulate." Air Bag Assembly Scrapping Procedure During the course of a vehicle's useful life, certain situations may arise which will necessitate the disposal of a live (undeployed) air bag assembly. This information covers proper procedures for disposing of a live air bag assembly. Before a live air bag assembly can be disposed of, it must be deployed. Alive air bag assembly must not be disposed of through normal refuse channels. WARNING: FAILURE TO FOLLOW PROPER SRS AIR BAG ASSEMBLY DISPOSAL PROCEDURES CAN RESULT IN AIR BAG DEPLOYMENT WHICH MAY CAUSE PERSONAL INJURY. AN UNDEPLOYED AIR BAG ASSEMBLY MUST NOT BE DISPOSED OF THROUGH NORMAL REFUSE CHANNELS. THE UNDEPLOYED AIR BAG ASSEMBLY CONTAINS SUBSTANCES THAT CAN CAUSE SEVERE ILLNESS OR PERSONAL INJURY IF THE SEALED CONTAINER IS DAMAGED DURING DISPOSAL. DISPOSAL IN ANY MANNER INCONSISTENT WITH PROPER PROCEDURES MAY BE A VIOLATION OF FEDERAL, STATE, AND I OR LOCAL LAW. In situations which require deployment of a live air bag assembly module, deployment may be accomplished inside or outside the vehicle. The method employed depends upon the final disposition of the particular vehicle, as noted in "Deployment Outside Vehicle" and "Deployment Inside Vehicle". Put on a pair of shop gloves and safety glasses to protect your hands and eyes from possible irritation and heat when handling the deployed air bag assembly. After the air bag assembly has been deployed, the surface of the air bag may contain solid particulate. This solid particulate consists primarily of by products of the chemical reaction, Potassium Chloride and copper metal dust. Compounds of Potassium Borate, Strontium Chloride, Copper Chloride, and Ammonium Chloride may be found in amounts of about 1 % (each) of the total particulate. (Passenger air bag assembly) Put on a pair of shop gloves and safety glasses to protect your hands and eyes from possible irritation and heat when handling the deployed air bag assembly. After the air bag assembly has been deployed, the surface of the air bag may contain a powdery residue. This powder consists primarily of cornstarch (used to lubricate the bag as it inflates) and by products of the chemical reaction. Sodium hydroxide dust (similar to lye soap) is produced as a by product of the deployment reaction. The sodium hydroxide then quickly reacts with atmospheric moisture and is converted to sodium carbonate and sodium bicarbonate (baking soda). Therefore, it is unlikely that sodium hydroxide will be present after deployment. Deployed Air Bag Assembly Handling Put on a pair of shop gloves and safety glasses to protect your hands and eyes from possible irritation and heat when handling the deployed air bag assembly. After the air bag assembly has been deployed, the surface of the air bag may contain solid particulate. This solid particulate consists primarily of by products of the chemical reaction, Potassium Chloride and copper metal dust. Compounds of Potassium Borate, Strontium Chloride, Copper Chloride, and Ammonium Chloride may be found in amounts of about 1 % (each) of the total particulate. (Passenger air bag assembly) Put on a pair of shop gloves and safety glasses to protect your hands and eyes from possible irritation and heat when handling the deployed air bag assembly. After the air bag assembly has been deployed, the surface of the air bag may contain a powdery residue. This powder consists primarily of cornstarch (used to lubricate the bag as it inflates) and by products of the chemical reaction. Sodium hydroxide dust (similar to lye soap) is produced as a by product of the deployment reaction. The sodium hydroxide then quickly reacts with atmospheric moisture and is converted to sodium carbonate and sodium bicarbonate (baking soda). Therefore, it is unlikely that sodium hydroxide will be present after deployment. Page 54 If there is no photo number below or beside a component name or a connector, ground, or terminal number, look up that name or number in the appropriate Connector Identification Chart. The chart lists how many cavities a connector has, where it's located, and what it connects to. The related illustration shows the connector's location on the harness, and the harness routing. NOTE: Photos listed by number are located at Locations / Components / Photograohs. See: Locations/Component Locations/Photographs Circuit Schematics Service and Repair Pinion Bearing: Service and Repair For further information regarding this component and the system that it is a part of, please refer to Differential; Service and Repair; Unit Overhaul ATF Level Check Fluid - A/T: Service and Repair ATF Level Check CHECKING TRANSMISSION FLUID LEVEL AND CONDITION Checking fluid level and condition (color and odor) at regular intervals will provide early diagnosis information about the transmission. This information may be used to correct a condition that, if not detected early, could result in major transmission repairs. IMPORTANT: When new, automatic transmission fluid is red in color. As the vehicle is driven, the transmission fluid will begin to look darker in color. The color may eventually appear light brown. A dark brown color with burnt odor may indicate excessive fluid deterioration and signal a need for fluid change. FLUID LEVEL When adding or changing fluid, use only DEXRON III. CAUTION: DO NOT OVERFILL. Overfilling will cause foaming, loss of fluid, abnormal shifting and possible damage to the transmission. 1. Park the vehicle on level ground and apply the parking brake firmly. 2. Check fluid level with engine running at idle. NOTE: Be sure that transmission fluid temperature is below 30°C (86°F). 3. Move the selector lever through all gear ranges. 4. Move the selector lever to "Park". 5. Let engine idle for 3 minutes and open the overfill screw (1). 6. Add released transmission fluid until it flows out over the overfill screw opening. 7. Let engine idle until a fluid temperature between 32°C (90°F) and 57°C (135°F) is reached, then close the overfill screw (1). Torque: 38 Nm (28 ft. lbs.) NOTE: To prevent fluid leaks, the overfill screw and oil drain screws gasket must be replaced each time these screws are removed. NOTE: Check transmission fluid temperature with scan tool. Minimum fluid level 57°C (135°F) Maximum fluid level 32°C (90°F) CAUTION: Do not open overfill screw with engine stopped. CAUTION: DO NOT CHECK FLUID LEVEL UNDER THESE CONDITIONS: Immediately after driving at sustained highway speeds. - In heavy city traffic during hot weather. - If vehicle is towing a trailer. If the vehicle has been operated under these conditions, shut the engine off and allow the vehicle to "cool" for thirty (30) minutes. After the cool down period, restart the vehicle and continue from step 2 above. Page 7481 and the fuses. From Fuses to Relays and Components The second half of Power Distribution shows the wiring "From Fuses to Relays and Components." This can speed your troubleshooting by showing which circuits share fuses. If Power Distribution shows that an inoperative circuit and another circuit share a fuse, check a component in the other circuit. If it works, you know the fuse is good and power is available to the inoperative circuit. Ground Distribution Schematics Page 7437 The connector cavity number is listed next to each terminal on the circuit schematic. The cavity / terminal shown is # 6. Diodes A rectifier diode works like a one way valve. It allows current to flow only in the direction of the arrow. A Zener diode blocks reverse current at normal voltages just like a rectifier diode. At high voltages, however, a Zener diode allows current to flow in reverse. Fuses Page 1622 11. Working through the right front wheelwell, remove the two flange bolts holding the engine mount to the chassis. Repeat this on the left side. 12. Working from under the vehicle, remove the two lower flange bolts holding the right engine bracket to the engine. 13. Use the powertrain lift to raise the engine until both engine mounts clear the chassis. Page 3220 2. Connect the short finder across the battery terminals and the load (component) side of the fuse terminal. 3. Close all switches in the circuit you're testing. 4. Turn on the short finder. This creates a pulsing magnetic field around the wiring between the fuse box and the short. 5. Beginning at the fuse box, slowly move the short finder along the circuit wiring. The meter will read current pulses through sheet metal and body trim. As long as the meter is between the fuse and the short, the needle will move with each current pulse. Once you move the meter past the point of the short, the needle will stop moving. Check the wiring and connectors in this area to locate the cause of the short. Testing For Continuity When testing for continuity at a connector without wire seals, you do not have to separate the two halves of the connector. Instead, probe the connector from the back. Always check both sides of the connector because dirty, corroded, and bent terminals can cause problems (no electrical contact = an open). 1. Disconnect the negative cable from the car battery. If you're using a DVOM, place it in the lowest "OHMS" range. Page 1560 5. Use the J-8062 valve spring compressor and J-42898 valve spring compressor adapter to remove split collar. 6. Remove valve spring. 7. Remove valve. 8. Remove oil controller and spring lower seat. 9. Remove the valve guide using the J-42899 valve guide replacer. Inspection and Repair Valve Spring Caution: Visually inspect the valve springs and replace them if damage or abnormal wear is evident. 1. Measure the free height of the springs. The springs must be replaced if the free height is below the specified limit. Standard: 44.6 mm (1.756 inch) Limit: 43.6 mm (1.717 inch) Page 6138 Distinct Of Circuit By Wire Base Color All wires have color-coded insulation. Wires belonging to a system's main harness will have a single color. Wires belonging to a system's sub-circuits will have a colored stripe. Striped wires use the codes found in the chart to show wire size and colors. Abbreviations are used to indicate wire color within a circuit diagram. How to Identify Connector Terminals How to Identify Connector Terminals Cavity Numbering System The cavities (and wire terminals) in each connector are numbered starting from the upper left, looking at the male terminals from the terminal side (or looking at the female terminals from the wire side. Both views are in the same direction so the numbers are the same.) All actual cavities are numbered, even if they have no wire terminals in them. NOTE: Data Link Connector (DLC) terminals are numbered according to SAE standard J1962, not the Honda standard. The numbers of the four end terminals are molded into the corners of the connector face. The connector cavity number is listed next to each terminal on the circuit schematic. The cavity / terminal shown is # 6. Using/Identifying Connector Terminal Views How to Use Connector Terminal Views To see the configuration of a connector's cavities, look up its view number in the Connector Views. Each view includes the color of the connector, where Locations Page 4920 Brake Rotor/Disc: Service and Repair Refinishing Brake Rotors Accurate control of the rotor tolerances is necessary for proper performance of the disc brakes. Machining of the rotor should be done only with precision equipment. All brake rotors have a minimum thickness dimension cast into them. This dimension is the minimum wear dimension and not a refinish dimension. The minimum wear dimension is 24.60 mm (0.969 inch). The minimum refinish dimension is 24.97 mm (0.983 inch). When refinishing rotors, always use sharp cutting tools or bits. Dull or worn tools leave a poor surface finish which will affect initial braking performance. Vibration dampening attachments should always be used when refinishing braking surfaces. These attachments eliminate tool chatter and will result in better surface finish. After refinishing, replace any rotor that does not meet the minimum thickness of 24.97 mm (0.983 inch). Do not use a brake rotor that will not meet the specification. Minimum wear dimension: 24.60 mm (0.969 inch) Refinish dimension: 24.97 mm (0.983 inch) Service and Repair Heated Glass Element Switch: Service and Repair Removal 1. Disconnect the battery ground cable. 2. Remove the meter cluster assembly (1). 3. Remove the rear defogger switch (2). - Disconnect the switch connector. - To remove the switch, push the lock from the back side of the meter cluster assembly. Installation To install, follow the removal steps in the reverse order. Page 1918 18. Reinstall the bracket on the engine. Torque the flange bolts to 50 N.m (37 lb-ft). Be careful not to pinch the crankshaft position sensor harness, and on A/T models, the ATF cooler lines. 19. Lower the engine into position. Do it slowly to avoid wedging it between the mounts; if you lower it too fast, you will compress the mounts. If you compress the mounts, they will not be able to isolate noise and absorb vibration. 20. Reinstall the engine mounts on the chassis. Torque the flange bolts to 41 N.m (30 lb-ft). 21. Reinstall the crankshaft position sensor. Torque the bolt to 9 N.m (7 lb-ft). 22. Plug the 3P connector into the crankshaft position sensor. 23. Reinstall the crankshaft position sensor harness clamp. 24. Models With A/T: Reinstall the front and rear clamps for the A/T cooler lines. 25. Models With 4WD: Reinstall the front skid plate. 26. Reinstall the front wheels. Torque the lug nuts to 118 N.m (87 lb-ft). 27. Lower the vehicle. 28. Reconnect the negative cable to the battery. 29. Enter your customer's radio station presets and mode settings. Set the clock. Disclaimer Page 6626 ^ Click on Returns and Surplus. ^ Click on Audio Core Return. ^ Select the appropriate VIN to view the Update Core Return information screen. ^ Review the form, then print out a copy by clicking on the printer icon. 14. Place the printed copies of the Warranty Audio/Navigation/RES Unit Order form and the Core Return Update Acknowledgement into the core return box with the failed audio/navigation/RES unit core. NOTE: If you return a failed audio/navigation/RES core without the proper forms, your warranty claim will be debited and the core will be sent back to your dealership. 15. Ship the failed audio/navigation/RES unit core to the appropriate location by using the prepaid shipping label that came with the remanufactured audio/navigation/RES unit. NOTE: If the failed audio/navigation/RES unit core is not received at the specified address within 30 days from the order date of the remanufactured audio/navigation/RES unit, your warranty claim will be debited, and your dealership will be issued a core loss charge ranging between $800 and $2,500. If you know that you cannot return the core within 30 days, call the Remanufactured Parts Dealer Service Group, and ask for an extension. ^ If you call for an extension and the core is not received within 60 days from the order date, you will be debited the full amount of the warranty claim. ^ If you do not call for an extension, and the core is received between 31 and 60 days from the order date of the remanufactured audio/navigation/RES unit, a $250 late core charge will be assessed. WARRANTY AUDIO ORDER PROGRAM FREQUENTLY ASKED QUESTIONS Here is a list of answers to the most frequently asked questions about the warranty audio order program: Question: When do I use the warranty audio order program? Answer: Use the program when you are replacing an audio/navigation/RES unit under warranty (including goodwill) that has an internal failure. NOTE: The customer's media (CD, CD magazine, DVD, DVD-A, cassette tape, etc.) is removed by the supplier at tear down and inspection of the failed unit, and mailed to your dealership. Any failed audio/navigation/RES unit core that is returned disassembled is considered an unusable core, and your dealership will be issued a core loss charge ranging between $800 and $2,500. Remanufactured audio/navigation/RES units are not available for non-warranty repairs. New components should be used to repair new, unsold vehicles. A new component may be used to repair a customer's vehicle only if the remanufactured component is currently unavailable from American Honda. Your DPSM must authorize ordering a new component. Question: How do I order a remanufactured audio/navigation/RES unit? Answer: For a warranty replacement, use the ordering information IN WARRANTY EXCHANGE. For goodwill repair, contact your DPSM. For a non-warranty repair, see OUT-OF-WARRANTY REPAIR. Question: Who do I call for questions on the Warranty Audio Order Program? Answer: For administrative questions, call the Remanufactured Parts Dealer Service Group. Specifications Lateral Stabilizer Rod: Specifications Lateral Stabilizer Rod Frame Side Nut 137 Nm Axle Side Nut 78 Nm Page 2162 Oxygen Sensor: Connector Locations 95. Right Front Exhaust Downpipe Right Front Exhaust Downpipe 93. Left Front Exhaust Downpipe Left Front Exhaust Downpipe Locations Air Flow Meter/Sensor: Locations 28. Left Side of Engine Compartment Left Side Of Engine Compartment Page 7570 This sample Ground Distribution schematic shows all of the components that share two ground points. Components A solid border line means the entire component is shown. A broken border line indicates that only part of the component is shown. Component Locations Power Seat Motor: Component Locations 105. Left Side of Driver's Seat 106. Under Driver's Seat Service and Repair Damping Control Actuator: Service and Repair FRONT ACTUATOR RH Page 3235 3. Install the fuel injector on the fuel rail. 4. Use new fuel injector retainer clips to retain the fuel injector to the fuel rail. 5. Coat the end of the fuel injector with gasoline. 6. Install the fuel rail. 7. Install the common chamber. 8. Install the engine cover. 9. Connect the negative battery cable. Page 1958 This sample Ground Distribution schematic shows all of the components that share two ground points. Components A solid border line means the entire component is shown. A broken border line indicates that only part of the component is shown. Page 6259 Refrigerant Oil: Service and Repair Oil Return Operation Oil Return Operation There is close affinity between the oil and the refrigerant. During normal operation, part of the oil recirculates with the refrigerant in the system. When checking the amount of oil in the system, or replacing any component of the system, the compressor must be run in advance for oil return operation. The procedure is as follows: 1. Open all the doors and the engine hood. 2. Start the engine and air conditioning switch to "ON" and set the fan control knob at its highest position. 3. Run the compressor for more than 20 minutes between 800 and 1,000 rpm in order to operate the system. 4. Stop the engine. A/T - Vehicle Speed Sensor Installation Precautions Transmission Speed Sensor: Technical Service Bulletins A/T - Vehicle Speed Sensor Installation Precautions Install VSS Properly to Avoid Reman A/T Damage We can't emphasize enough how important it is to follow, to the letter, the installation instructions that come with a reman A/T. These instructions help ensure that you avoid damaging the A/T and score a successful repair. This is particularly true when it comes to installing the vehicle speed sensor (VSS). Step 6 of the instructions tells you to make sure its gear is fully engaged and the VSS is fully seated before you tighten the retaining bolt. If you don't install the VSS properly, the speed sensor gear will get stripped and the A/T will be seriously damaged. So don't take risks with your customer's vehicle. Always follow these instructions to the letter. You can rest assured you're doing the job right. Page 6212 Page 6021 1. Make sure the ignition key is not in the ignition switch. 2. Open the glove box, and empty out its contents. Gently squeeze the sides of the glove box together to release the stops, then lower it all the way. 3. 2000-01 Models: Slide the intake actuator relay off its mounting bracket, and move it out of the way. 4. Unplug the 6P connector from the blower resistor, then remove and discard the resistor (two screws). 5. Unplug the 2P connector from the blower motor, then remove and discard the blower motor assembly (four screws). Page 5756 11. Remove the body mount mounting nuts (mounts No. 1, 2, 3, and 5) and bolt (mount No. 4). 12. Using two ratcheting straps, lash up both sides of the rear axle to support it during the following steps: ^ Attach one end of the strap above the axle at the driver's side inside frame rail. ^ Route the other end of the strap down, underneath the rear axle, and then back up above the outside of the driver's side frame rail. ^ Connect both ends of the strap together and remove any slack. ^ Attach the other ratcheting strap to the passenger's side the same way as the driver's side. 13. Lower the vehicle to the ground. 14. Carefully raise the rear of the body about 10 inches off the frame, and temporarily support it. The equipment/method used to raise the body off the frame include, but are not limited to, one of these options: ^ Raise the body at the rear wheelwells using a vehicle hoist with padded swing arms. ^ Raise the body at the bottom of the rear swing out door using a 4x4 in. piece of wood (running the width of the body) and a forklift. To prevent injury or vehicle damage, be sure to chose the safest possible method for your particular situation. 15. Remove the mounting bolts for the left and right side No.5 body mounts, then remove the mounts. Refer to step 11. Page 5776 3. Using an air nozzle, blow into the frame rail hole, up and down inside the frame, to move any debris away from the trailing link bracket area. 4. Using a wire brush and a scraper, remove any loose frame coating and rust from the outside frame rail and the lower trailing link frame bracket in the 20-inch (500 mm) section shown below. 5. Use a dry rag to remove any remaining dust or debris. If the area is wet, dry it with an air nozzle. 6. Attach the long nozzle to the Noxudol 700 can, then use a pen or tape to mark the nozzle at 12 inches (300 mm) and at 7 inches (200 mm) from the nozzle end. These marks indicate how far you will insert the nozzle into the frame rails for some of the following steps. 7. Place a drain pan below the frame's drain hole next to the trailing link bracket. This will catch the excess Noxudol 700 that runs out of the frame's drain hole, which is expected and normal. 8. Insert the Noxudol 700 spray nozzle about 12 inches (300 mm) into the frame drain hole located on the bottom of the frame rail, toward the rear of the vehicle. Then spray the Noxudol while drawing out the nozzle. Spray two times. Page 5531 ^ If the idle speed ever exceeds 1,300 rpm 2. Remove the vacuum hose from the fuel pressure regulator, then start the engine. ^ If fuel comes out of the fuel pressure regulator vacuum hose connection, go to REPAIR PROCEDURE FUEL PRESSURE REGULATOR. ^ If no fuel comes out of the regulator, reconnect the vacuum hose and continue to step 3. 3. Connect the PGM Tester. Set it to Engine Data List. 4. Have an assistant drive the vehicle under the conditions described by the customer. 5. If the high or erratic idle condition occurs, note the values of the PSP Switch and APP Sensor 1 when it is occurring. ^ If the PSP Switch is HIGH, and you are not turning, go to REPAIR PROCEDURE POWER STEERING SWITCH. ^ If the APP Sensor 1 is greater than 15% and APP Sensor 2 and/or APP Sensor 3 are less than 85%, and the accelerator pedal is not depressed, go to REPAIR PROCEDURE APPS GROUND. ^ If the PSP Switch is reading LOW when not turning and HIGH when turning, and the APP Sensors are reading within the range shown, discontinue the test-drive and go to step 6. 6. Do these repairs: ^ REPAIR PROCEDURE APPS GROUND ^ REPAIR PROCEDURE ENGINE/BODY GROUND REPAIR PROCEDURE - FUEL PRESSURE REGULATOR 1. Relieve fuel system pressure: ^ Remove the fuel fill cap. ^ Remove the fuel pump relay. ^ Start the engine and run it until it stalls. ^ Crank the engine for 3 seconds. 2. Remove the vacuum hose from the fuel pressure regulator. 3. Remove the fuel pressure regulator shield from the common chamber (two bolts). Page 6385 Test Equipment CAUTION: Most circuits include solid-state devices. Test the voltages in these circuits only with a 10-megaohm or higher impedance digital multimeter. Never use a test light or analog meter on circuits that contain solid-state devices. Damage to the devices may result. Test Light and DVOM On circuits without solid-state devices, use a test light to check for voltage. A test light is made up of a 12 volt bulb with a pair of leads attached. After grounding one lead, touch the other lead to various points along the circuit where voltage should be present. The bulb will go on if there is voltage at the point being tested. If you need to know how much voltage is present, use a digital volt/ohmmeter (DVOM). Self-Powered Test Light and DVOM Use a self-powered test light to check for continuity. This tool is made up of a light bulb, battery, and two leads. To test it, touch the leads together: the light should go on. Use a self-powered test light only on an unpowered circuit. First, disconnect the battery, or remove the fuse that feeds the circuit you are working on. Select two points in the circuit between which you want to check continuity. Connect one lead of the self-powered test light to each point. If there is continuity, the test light's circuit will be completed, and the light will go on. If, in addition, you need to know exactly how much resistance there is between two points, use a digital volt/ohmmeter (DVOM). In the "OHMS" range, the DVOM will measure resistance between two points along a circuit. Low resistance means good continuity. Diodes and solid-state devices in a circuit can make a DVOM give a false reading. To check a reading, reverse the leads, and take a second reading. If the readings differ, the component is affecting the measurement. Jumper Wire Use a jumper wire to bypass an open circuit. A jumper wire is made up of an in-line fuse holder connected to a set of test leads. It should have a five ampere fuse. Never connect a jumper wire across a short circuit. The direct battery short will blow the fuse. Short Finder (Short Circuit Locator) Short finders are available to locate shorts to ground. The short finder creates a pulsing magnetic field in the shorted circuit which you can follow to the location of the short. To order any test equipment shown above, contact your local tool supplier. For a list of suppliers and tool numbers, refer to Honda Required Special Tools and Equipment Service Bulletin. Page 4694 Test Equipment CAUTION: Most circuits include solid-state devices. Test the voltages in these circuits only with a 10-megaohm or higher impedance digital multimeter. Never use a test light or analog meter on circuits that contain solid-state devices. Damage to the devices may result. Test Light and DVOM On circuits without solid-state devices, use a test light to check for voltage. A test light is made up of a 12 volt bulb with a pair of leads attached. After grounding one lead, touch the other lead to various points along the circuit where voltage should be present. The bulb will go on if there is voltage at the point being tested. If you need to know how much voltage is present, use a digital volt/ohmmeter (DVOM). Self-Powered Test Light and DVOM Use a self-powered test light to check for continuity. This tool is made up of a light bulb, battery, and two leads. To test it, touch the leads together: the light should go on. Use a self-powered test light only on an unpowered circuit. First, disconnect the battery, or remove the fuse that feeds the circuit you are working on. Select two points in the circuit between which you want to check continuity. Connect one lead of the self-powered test light to each point. If there is continuity, the test light's circuit will be completed, and the light will go on. If, in addition, you need to know exactly how much resistance there is between two points, use a digital volt/ohmmeter (DVOM). In the "OHMS" range, the DVOM will measure resistance between two points along a circuit. Low resistance means good continuity. Diodes and solid-state devices in a circuit can make a DVOM give a false reading. To check a reading, reverse the leads, and take a second reading. If the readings differ, the component is affecting the measurement. Jumper Wire Use a jumper wire to bypass an open circuit. A jumper wire is made up of an in-line fuse holder connected to a set of test leads. It should have a five ampere fuse. Never connect a jumper wire across a short circuit. The direct battery short will blow the fuse. Short Finder (Short Circuit Locator) Short finders are available to locate shorts to ground. The short finder creates a pulsing magnetic field in the shorted circuit which you can follow to the location of the short. To order any test equipment shown above, contact your local tool supplier. For a list of suppliers and tool numbers, refer to Honda Required Special Tools and Equipment Service Bulletin. Page 2983 2. Connect one lead of a self-powered test light or DVOM to one end of the part of the circuit you want to test. 3. Connect the other lead to the other end. 4. If the self-powered test light glows, there is continuity. If you're using a DVOM, a low reading or no reading (zero), means good continuity. Testing For Voltage When testing for voltage at a connector without wire seals, you do not have to separate the two halves of the connector. Instead, probe the connector from the back. Always check both sides of the connector because dirty, corroded, and bent terminals can cause problems (no electrical contact = an open). 1. Connect one lead of the lest light to a known good ground, or, if you're using a digital volt ohmmeter (DVOM), place it in the appropriate DC volts range, and connect its negative lead to ground. 2. Connect the other lead of the test light or DVOM to the point you want to check. 3. If the test light glows, there is voltage present. If you're using a DVOM, note the voltage reading. It should be within one volt of measured battery voltage. A loss of more than one volt indicates a problem. NOTE: Always use a DVOM on high impedance circuits. A test light may not glow (even with battery voltage present). Testing For Voltage Drop Wires, connectors, and switches are designed to conduct current with a minimum loss of voltage. A voltage drop of more than one volt indicates a problem. 1. Place the digital volt/ohmmeter (DVOM) in the appropriate DC volts range. Connect the positive lead to the end of the wire (or to the connector or switch) closest to the battery. 2. Connect the negative lead to the other end of the wire (or the other side of the connector or switch). 3. Turn on the components in the circuit. 4. The DVOM will show the difference in voltage between the two points. A difference, or drop, of more than one volt indicates a problem. Check the circuit for loose, dirty, or bent terminals. Service Precautions Suspension Control Module: Service Precautions The Intelligent Suspension System interfaces directly with the Control Unit which is a control computer that is similar in some regards to the Powertrain Control Module. These modules are designed to withstand normal current draws associated with vehicle operation. However, care must be taken to avoid overloading any of the Control Unit circuits. In testing for opens or shorts, do not ground or apply voltage to any of the circuits unless instructed to do so by the appropriate diagnostic procedure. These circuits should only be tested with a high impedance multimeter (J-39200) or special tools. Power should never be removed or applied to any control module with the ignition in the "ON" position. Before removing or connecting battery cables, fuses or connectors, always turn the ignition switch to the "OFF" position. Page 2804 Powertrain Control Module: Service and Repair Reprogramming the PCM Electrically Erasable Programmable Read Only Memory (EEPROM) The electrically erasable programmable read only memory (EEPROM) is a permanent memory chip that is physically soldered within the PCM. The EEPROM contains the program and the calibration information that the PCM needs to control powertrain operation. Unlike the PROM used in past applications, the EEPROM is not replaceable. If the PCM is replaced, the new PCM will need to be programmed. Equipment containing the correct program and calibration for the vehicle is required to program the PCM. EEPROM Programming 1. Set-up - Ensure that the following conditions have been met: - The battery is fully charged. - The ignition is "ON." - The Vehicle Interface Module cable connection at the DLC is secure. 2. Program the PCM using the latest software matching the vehicle. Refer to up-to-date Techline equipment user's instructions. 3. If the PCM fails to program, proceed as follows: - Ensure that all PCM connections are OK. - Check the Techline equipment for the latest software version. - Attempt to program the PCM. If the PCM still cannot be programmed properly, replace the PCM. The replacement PCM must be programmed. Functional Check 1. Perform the On-Board Diagnostic System Check. 2. Start the engine and run for least one minute. 3. Check for DTCs using Scan Tool. 4. If the PCM fails to program, proceed as follow: - Ensure that all PCM connections are OK. - Check the ITCS for latest version software. - Attempt to program PCM again. If PCM still cannot be programmed properly, replace PCM. The replacement PCM must be programmed. Page 3005 Torque Specifications Page 3140 14. While watching the APP Sensor values in the Engine Data List, adjust the APPS by turning it until the values are within the ranges shown at closed throttle and wide open throttle (accelerator pedal pushed all the way down), then tighten the mounting screws and recheck the values. ^ If all three sensors are within range, go to step 23. ^ If APP Sensor 1 APP Sensor 2, and/or APP Sensor 3 cannot be brought into range, go to step 15. 15. Troubleshoot for an open circuit or a PCM malfunction. ^ If APP Sensor 1 has a value of 0% or APP Sensor 2 and/or APP Sensor 3 have a value of 99%, an open circuit exists or the PCM is malfunctioning. Repair the circuit or replace the PCM, and repeat step 14. ^ If you don't find a problem, go to step 16. 16. Disconnect the 10 P connector from the APPS. 17. View the APP Sensor values in the Engine Data List. ^ If APP Sensor 1 has a value of 0% or APP Sensor 2 and/or APP Sensor 3 have a value of 99%, go to step 18. ^ If APP Sensor 1 has a value other than 0%, or APP Sensor 2 and/or APP Sensor 3 have a value other than 99%, a short circuit exists or the PCM is malfunctioning. Repair the circuit or replace the PCM, and repeat step 14. 18. Modify the original APPS by cutting the connector housing off of the sensor. 19. Connect the 10 P connector to the modified APPS connector housing. Page 6148 Splices Splices are shown as a dot. Their location and the number of wires may vary depending on the harness manufacturer. Switches Switches These switches move together; the broken straight line between them means they are mechanically connected. Other types of switches are controlled by a coil or a solid state circuit. Unless otherwise noted, all switches are shown in their normal (rest) position, with power off. Terminal "T" Page 5325 L4 Engine Room Circuit Operation Powertrain Control Module: Description and Operation Circuit Operation The engine or powertrain control module (ECM or PCM) receives inputs from the engine sensors and switches, controlling the functions of the engine. It also turns on the malfunction indicator "check engine" light whenever a malfunction or abnormal engine performance is detected, and allows for diagnostic testing through the data link connector (DLC). Description and Operation Fuel Level Sensor: Description and Operation Fuel Level Sensor The fuel level sensor is an important input to the PCM for the enhanced EVAP system diagnostic. The PCM needs fuel level information to know the volume of fuel in the tank. The fuel level affects the rate of change of air pressure in the EVAP system. Several of the enhanced EVAP system diagnostic sub-tests are dependent upon correct fuel level information. The diagnostic will not run when the tank is less than 15 % or more than 85 % full. Be sure to diagnose any Fuel Level Sensor DTCs first, as they can cause other DTCs to set. Page 3201 Distinct Of Circuit By Wire Base Color All wires have color-coded insulation. Wires belonging to a system's main harness will have a single color. Wires belonging to a system's sub-circuits will have a colored stripe. Striped wires use the codes found in the chart to show wire size and colors. Abbreviations are used to indicate wire color within a circuit diagram. How to Identify Connector Terminals How to Identify Connector Terminals Cavity Numbering System The cavities (and wire terminals) in each connector are numbered starting from the upper left, looking at the male terminals from the terminal side (or looking at the female terminals from the wire side. Both views are in the same direction so the numbers are the same.) All actual cavities are numbered, even if they have no wire terminals in them. NOTE: Data Link Connector (DLC) terminals are numbered according to SAE standard J1962, not the Honda standard. The numbers of the four end terminals are molded into the corners of the connector face. The connector cavity number is listed next to each terminal on the circuit schematic. The cavity / terminal shown is # 6. Using/Identifying Connector Terminal Views How to Use Connector Terminal Views To see the configuration of a connector's cavities, look up its view number in the Connector Views. Each view includes the color of the connector, where Page 7822 The connector cavity number is listed next to each terminal on the circuit schematic. The cavity / terminal shown is # 6. Diodes A rectifier diode works like a one way valve. It allows current to flow only in the direction of the arrow. A Zener diode blocks reverse current at normal voltages just like a rectifier diode. At high voltages, however, a Zener diode allows current to flow in reverse. Fuses Page 3207 This sample Ground Distribution schematic shows all of the components that share two ground points. Components A solid border line means the entire component is shown. A broken border line indicates that only part of the component is shown. Page 755 Terminals - "T" Each "T" terminal (ring type) is numbered for reference and location. A "T" terminal is secured with a screw or bolt. Wires Page 7765 Test Equipment CAUTION: Most circuits include solid-state devices. Test the voltages in these circuits only with a 10-megaohm or higher impedance digital multimeter. Never use a test light or analog meter on circuits that contain solid-state devices. Damage to the devices may result. Test Light and DVOM On circuits without solid-state devices, use a test light to check for voltage. A test light is made up of a 12 volt bulb with a pair of leads attached. After grounding one lead, touch the other lead to various points along the circuit where voltage should be present. The bulb will go on if there is voltage at the point being tested. If you need to know how much voltage is present, use a digital volt/ohmmeter (DVOM). Self-Powered Test Light and DVOM Use a self-powered test light to check for continuity. This tool is made up of a light bulb, battery, and two leads. To test it, touch the leads together: the light should go on. Use a self-powered test light only on an unpowered circuit. First, disconnect the battery, or remove the fuse that feeds the circuit you are working on. Select two points in the circuit between which you want to check continuity. Connect one lead of the self-powered test light to each point. If there is continuity, the test light's circuit will be completed, and the light will go on. If, in addition, you need to know exactly how much resistance there is between two points, use a digital volt/ohmmeter (DVOM). In the "OHMS" range, the DVOM will measure resistance between two points along a circuit. Low resistance means good continuity. Diodes and solid-state devices in a circuit can make a DVOM give a false reading. To check a reading, reverse the leads, and take a second reading. If the readings differ, the component is affecting the measurement. Jumper Wire Use a jumper wire to bypass an open circuit. A jumper wire is made up of an in-line fuse holder connected to a set of test leads. It should have a five ampere fuse. Never connect a jumper wire across a short circuit. The direct battery short will blow the fuse. Short Finder (Short Circuit Locator) Short finders are available to locate shorts to ground. The short finder creates a pulsing magnetic field in the shorted circuit which you can follow to the location of the short. To order any test equipment shown above, contact your local tool supplier. For a list of suppliers and tool numbers, refer to Honda Required Special Tools and Equipment Service Bulletin. Page 752 The connector cavity number is listed next to each terminal on the circuit schematic. The cavity / terminal shown is # 6. Diodes A rectifier diode works like a one way valve. It allows current to flow only in the direction of the arrow. A Zener diode blocks reverse current at normal voltages just like a rectifier diode. At high voltages, however, a Zener diode allows current to flow in reverse. Fuses Page 2620 This sample Ground Distribution schematic shows all of the components that share two ground points. Components A solid border line means the entire component is shown. A broken border line indicates that only part of the component is shown. A/T - Fluid Leak From the Accumulator Cover Accumulator: Customer Interest A/T - Fluid Leak From the Accumulator Cover 02-038 November 5, 2002 Applies To: 1998-02 Passport With A/T - ALL ATF Leaks From the Accumulator Cover (Supersedes 02-038, dated August 20, 2002) Updated information is shown by black bars and asterisks. SYMPTOM ATF leaks from the right side of the transmission. PROBABLE CAUSE The accumulator cover is cracked. CORRECTIVE ACTION Replace the accumulator cover. TOOL INFORMATION * Accumulator Cover Installation and Removal Tool Kit: T/N O7ZAF-IZAA12O, H/C 7259625 * NOTE: The accumulator cover installation and removal tool kit is available through the Honda Special Tool Loan Program. PARTS INFORMATION Accumulator Cover: P/N 5-96017-093-0, H/C 4555513 WARRANTY CLAIM INFORMATION In warranty: The normal warranty applies. Failed Part: P/N 5-96017-093-0 H/C 4555513 Defect Code: 051 Contention Code: B06 Skill Level: Repair Technician Out of warranty: Any repair performed after warranty expiration may be eligible for goodwill consideration by the District Parts and Service Manager or your Zone Office. You must request consideration, and get a decision, before starting work. Component Locations Page 1703 5. Use the J-8062 valve spring compressor and J-42898 valve spring compressor adapter to remove split collar. 6. Remove valve spring. 7. Remove valve. 8. Remove oil controller and spring lower seat. 9. Remove the valve guide using the J-42899 valve guide replacer. Inspection and Repair Valve Spring Caution: Visually inspect the valve springs and replace them if damage or abnormal wear is evident. 1. Measure the free height of the springs. The springs must be replaced if the free height is below the specified limit. Standard: 44.6 mm (1.756 inch) Limit: 43.6 mm (1.717 inch) Page 1870 Water Pump: Service and Repair Water Pump Removal 1. Disconnect battery ground cable. 2. Drain coolant. 3. Radiator hose (on inlet pipe side). 4. Remove timing belt. 5. Remove Idle pulley. 6. Remove water pump assembly. 7. Remove gasket. Inspection Make necessary repair and parts replacement if extreme wear or damage is found during inspection. Should any of the following problems occur, the entire water pump assembly must be replaced. Crack in the water pump body - EC leakage from the seal unit - Play or abnormal noise in the bearing - Cracks or corrosion in the impeller Installation 1. Install gasket, clean the mating surface of gasket before installation. Diagram Information and Instructions Fuel Pump Relay: Diagram Information and Instructions How to Identify Wiring Color-Coded Insulation Wire Color Wire Color Coding Page 6086 Condenser Fan: Diagnostic Aids Before Troubleshooting Before Troubleshooting See: Service Precautions/Vehicle Damage Warnings/Tips and Precautions 1. Check applicable fuses in the appropriate fuse/relay box. 2. Check the battery for damage, state of charge, and clean and tight connections. CAUTION: Do not quick-charge a battery unless the battery ground cable has been disconnected, otherwise you will damage the alternator diodes. - Do not attempt to crank the engine with the battery ground cable loosely connected or you will severely damage the wiring. While You're Working 1. Make sure connectors are clean, and have no loose terminals or receptacles. 2. Make sure that connectors without wire seals are packed with dielectric (silicone) grease. Part Number: 08798-9001. 3. When connecting a connector, push it until it "clicks" into place. CAUTION: Do not pull on the wires when disconnecting a connector. Pull only on the connector housings. - Most circuits include solid-state devices. Test the voltages in these circuits only with a 10-megaohm or higher impedance digital multi meter. Never use a test light or analog meter on circuits that contain solid-state devices. Damage to the devices may result. Five-Step Troubleshooting 1. Verify The Complaint Turn on all the components in the problem circuit to check the accuracy of the customer complaint. Note the symptoms. Do not begin disassembly or testing until you have narrowed down the problem area. 2. Analyze The Schematic Look up the schematic for the problem circuit. Determine how the circuit is supposed to work by tracing the current paths from the power source through the circuit components to ground. Also, trace circuits that share wiring with the problem circuit. The names of circuits that share the same fuse, ground, or switch, and so on, are referred to in each circuit schematic. Try to operate any shared circuits you didn't check in step 1. If the shared circuits work, the shared wiring is OK, and the cause must be in the wiring used only by the problem circuit. If several circuits fail at the same time, the fuse or ground is a likely cause. Based on the symptoms and your understanding of the circuit's operation, identify one or more possible causes. 3. Isolate The Problem By Testing The Circuit Make circuit tests to check the diagnosis you made in step 2. Keep in mind that a logical, simple procedure is the key to efficient troubleshooting. Test for the most likely cause of failure first. Try to make tests at points that are easily accessible. 4. Fix The Problem Once the specific problem is identified, make the repair. Be sure to use proper tools and safe procedures. 5. Make Sure The Circuit Works Turn on all components in the repaired circuit in all modes to make sure you've fixed the entire problem. If the problem was a blown fuse, be sure to test all of the circuits on that fuse. Make sure no new problems turn up and the original problem does not recur. Page 4269 the component if the component only has one connector, or by a capital letter (A, B, C, etc.) if the component has more than one connector. Below most connector numbers and component names are PHOTO and VIEW numbers. The PHOTO number refers to a photo in the back of the book that shows the connector's location on the car. The VIEW number refers to an illustration in the back of the book that shows the connector face, wire colors, connector cavity numbers, and other details. The connector cavity numbering sequence begins at the top left corner of the connector. Disregard any numbers molded into the connector housing. Wires Wires are identified by the abbreviated names of their colors; the second color is the color of the stripe. Wires are also identified by their location in a connector. The number "2" next to the male and female wire terminals at C416, for example, means those terminals join in cavity 2 of connector C416. Symbols A complete description of schematic symbols is given under wire color abbreviation. Power Distribution Schematics Power Distribution schematics show how power is supplied from the positive battery terminal to various circuits in the car. Refer to the Power Distribution section to get a more detailed picture of how power is supplied to the circuit you're working on. From Battery to Ignition Switch, Fuses, and Relays Individual circuit schematics begin with a fuse. The first half of Power Distribution, however, shows the wiring "upstream" between the battery Page 3371 The wire insulation has one color or one color with another color stripe. The second color is the stripe. Page 2834 6. Remove the connector position assurance (CPA) clip from the APPS connector. 7. Disconnect the 10 P connector from the APPS. 8. Remove the bolts, the APPS, the spacer, and the accelerator link from the accelerator pedal assembly. 9. Separate the spacer from the APPS. Clean the grease off the spacer and the accelerator link with a clean shop towel. 10. Clean the terminals of the 10 P APPS connector (harness side) with contact cleaner. Shake the residue out of the connector, and allow the contact cleaner to evaporate for at least 3 minutes before reconnecting the connector. 11. Install a new APPS, the spacer, and the accelerator link onto the accelerator pedal assembly. Leave the mounting screws loose so the sensor can be adjusted. 12. Connect the 10 P connector to the new APPS, and lock the connector in place with the CPA. 13. Connect the PGM Tester to the data link connector (DLC), and turn the ignition switch to ON (II). Page 5374 L4 Engine Room Page 3215 Wire Color Abbreviations The following abbreviations are used to identify wire colors in the circuit schematics: WHT................................... White YEL................................... Yellow BLK................................... Black BLU................................... Blue GRN................................... Green RED................................... Red ORN................................... Orange PNK................................... Pink BRN................................... Brown GRY................................... Gray PUR................................... Purple LT BLU................................... Light Blue LT GRN................................... Light Green Page 3752 4WD Control Unit: Service and Repair 4WD CONTROL UNIT ASSOCIATED PARTS REMOVAL 1. Remove center console assembly. 2. Remove two screws and harness connector (1) from 4WD control unit. INSTALLATION 1. Connect harness connector, then install 4WD control unit. 2. Install center console assembly. Page 1706 Limit: 39.47 mm (1.5539 inch) Exhaust Standard: 39.3 mm (1.5472 inch) Limit: 39.45 mm (1.5531 inch) 2. Measure the valve seat contact width. Make the necessary corrections if the seat contact surface is damaged or rough or if the contact width wear exceeds the limit. Valve seat contact width Standard: 1.1 mm (0.0433 inch) Limit: 1.7 mm (0.0669 inch) Contact Surface Angle on Valve Seat on Valve 1. Measure contact surface angle on valve seat. 2. If the measured value exceeds the limit, replace valve, valve guide and valve seat as a set. Valve contact surface angle: 45° Valve Seat Insert Correction 1. Remove the carbon from the valve seat insert surface. Page 3730 Each schematic represents one circuit. A circuit's wires and components are arranged to show current flow, from power at the top of the page, to ground, at the bottom. Shared Circuits Other circuits may share power or ground terminals or wiring with the circuit shown. A wire that connects one circuit to another, for example, is cut short and has an arrowhead at the end of it pointing in the direction of current flow. Next to the arrowhead is the name of the circuit or component which shares that wiring. To quickly check shared wiring, check the operation of a component it serves. If that component works, you know the shared wiring is OK. Connectors All in-line and junction connectors are numbered (C725, C416, etc.). Component connectors are not numbered but are identified either by the name of Page 3599 2. Connect the short finder across the battery terminals and the load (component) side of the fuse terminal. 3. Close all switches in the circuit you're testing. 4. Turn on the short finder. This creates a pulsing magnetic field around the wiring between the fuse box and the short. 5. Beginning at the fuse box, slowly move the short finder along the circuit wiring. The meter will read current pulses through sheet metal and body trim. As long as the meter is between the fuse and the short, the needle will move with each current pulse. Once you move the meter past the point of the short, the needle will stop moving. Check the wiring and connectors in this area to locate the cause of the short. Testing For Continuity When testing for continuity at a connector without wire seals, you do not have to separate the two halves of the connector. Instead, probe the connector from the back. Always check both sides of the connector because dirty, corroded, and bent terminals can cause problems (no electrical contact = an open). 1. Disconnect the negative cable from the car battery. If you're using a DVOM, place it in the lowest "OHMS" range. Page 2011 Ground - "G" Shielding Sheilding This represents RFI (Radio Frequency Interference) shielding around a wire. The shielding is always connected to ground. Splices Page 1232 1. Before adding any leak-detection dye, check to see if there is dye in the system now. ^ Check for a label in the engine compartment indicating that fluorescent leak-detection dye has been added to the system. ^ Dye may have been added even though no label is present. To confirm this: - Put on the fluorescence-enhancing glasses, and remove the low-side service port sealing cap. - Direct the ultraviolet lamp into the valve stem area. If dye has been previously added, the lubricant traces will have a bright yellow fluorescent glow. You may need to press the port's valve stem briefly to release some lubricant and dye from the system. ^ If there is no dye in the system, go to step 2. ^ If there is dye in the system, go to step 5. Do not add more dye. 2. Add the dye. NOTE: Air and moisture must be evacuated from the universal connect set if it is being used for the first time, or if it has been stored with the control valve open. If the air and moisture have been evacuated, go to step 3; otherwise do the following: (a) Attach the empty dye capsule (provided in the dye kit) to the control valve fitting. (b) Attach the service valve fitting (provided in the kit) to the empty dye capsule. (c) Attach the low-side hose of the A/C recovery and charging station, and open the quick coupler's hand-wheel valve. Then open the control valve (black knob) on the universal connect set. (d) Following the manufacturer's instructions for your recovery and charging station, evacuate the universal connect set for approximately 3 minutes. (e) When evacuation is complete, be sure the set's control valve is closed (finger tight), and disconnect the NC recovery and charging station. (f) Remove the service valve fitting and the empty dye capsule from the set, and store them for future use. NOTE: ^ Check the refrigerant charge level. There must be enough refrigerant in the system to operate the A/C compressor and to circulate refrigerant oil. ^ If the refrigerant charge is too low, recover the remaining amount and recharge the system before adding any dye. (g) Start the vehicle and operate the A/C system. Follow your A/C refrigerant recovery and charging station's operating instructions for low-side charging to install the dye. * NOTE: Only 0.05 lb (0.02 kg) of refrigerant is needed to push the dye into the A/C system.* (h) Once the refrigerant charge is programmed, open the control valve on the set to allow the dye to enter the system. (i) After the dye capsule clears, allow the low-side of the A/C system to reach its lowest operating pressure, then quickly close both the service equipment's low-side coupler valve and the control valve on the set. (j) Remove the set from the vehicle by releasing its quick coupler. Remove the empty dye capsule from the service valve fitting. Return the hose, control valve, and service-valve fitting to the storage case. * NOTE: Store the hose with the control valve closed. This will retain a small amount of refrigerant in the hose so it does not have to be evacuated the next time you use it.* (k) Fill out an identification label (provided in the kit), and attach it to a location near the A/C charge label. Page 5020 Parking Brake Warning Switch: Description and Operation The brake system warning light goes on to alert the driver that the parking brake is applied or that the brake fluid is low. It also lights as a bulb test when the engine is cranked. With the ignition switch in ON or START, battery voltage is applied through fuse 11 to the brake system warning light. When the parking brake is applied, the parking brake switch closes and provides a ground for the light. The brake system warning light goes on to remind the driver that the parking brake is applied. Page 4709 Distinct Of Circuit By Wire Base Color All wires have color-coded insulation. Wires belonging to a system's main harness will have a single color. Wires belonging to a system's sub-circuits will have a colored stripe. Striped wires use the codes found in the chart to show wire size and colors. Abbreviations are used to indicate wire color within a circuit diagram. How to Identify Connector Terminals How to Identify Connector Terminals Cavity Numbering System The cavities (and wire terminals) in each connector are numbered starting from the upper left, looking at the male terminals from the terminal side (or looking at the female terminals from the wire side. Both views are in the same direction so the numbers are the same.) All actual cavities are numbered, even if they have no wire terminals in them. NOTE: Data Link Connector (DLC) terminals are numbered according to SAE standard J1962, not the Honda standard. The numbers of the four end terminals are molded into the corners of the connector face. The connector cavity number is listed next to each terminal on the circuit schematic. The cavity / terminal shown is # 6. Using/Identifying Connector Terminal Views How to Use Connector Terminal Views To see the configuration of a connector's cavities, look up its view number in the Connector Views. Each view includes the color of the connector, where Page 5151 7. When installing the steering column cover, be sure to wire (through each harness) as illustrated so that the harnesses starter switch, combination switch and SRS coil may not catch wiring. 8. Install steering wheel by aligning the setting marks made during removal. CAUTION: Never apply force to the steering wheel in direction of the shaft by using a hammer or other impact tools in an attempt to remove the steering wheel. The steering shaft is designed as an energy absorbing unit. 9. Tighten the steering wheel fixing nut to the specified torque. Torque: 34 Nm (25 ft. lbs.) 10. Support inflator module and carefully connect the SRS connector and horn lead, then install inflator module. NOTE: Pass the lead wire through the tabs on the plastic cover (wire protector) of inflator to prevent lead wire from being pinched. 11. Tighten fixing bolts to specified torque. Torque: 9 Nm (78 inch lbs.) 12. Install driver knee bolster (reinforcement). 13. Install instrument panel lower cover, then install the engine hood opening lever. 14. Connect the yellow 2-way SRS connector located under the steering column. 15. Connect the battery "-" terminal cable. Accelerator Pedal Position Sensor - MIL ON/DTC's Set Technical Service Bulletin # 01-047 Date: 010814 Accelerator Pedal Position Sensor - MIL ON/DTC's Set 01-047 August 14, 2001 Applies To: 2000-01 Passport - ALL MIL Comes On With Accelerator Pedal Position Sensor DTC(s) P1271, P1273, P1275, P1280, and/or P1285 SYMPTOM The MIL is on with DTC P1271, P1273, P1275, P1280, or P1285 (various accelerator pedal position sensor problems) stored. The REDUCED POWER indicator may also be on; and the engine may occasionally idle too high, or the idle may fluctuate. PROBABLE CAUSE Contaminated grease on the potentiometer circuit board of the accelerator pedal position sensor (APPS) causes high resistance in the APPS circuit. CORRECTIVE ACTION Replace and adjust the APPS, remove all grease from the accelerator link, and clean the APPS harness connector and connector C123. PARTS INFORMATION Accelerator Pedal Position Sensor: P/N 8-97193-713-0, H/C 6198311 REQUIRED MATERIALS CAIG DeoxIT D5-S6 Contact Cleaner: P/N 341-200 (available from www.partsexpress.com) or Permatex Electrical Contact Cleaner: Permatex P/N 24379 WARRANTY CLAIM INFORMATION In warranty: The normal warranty applies. Operation Number: 122114 Flat Rate Time: 0.5 hour Failed Part: P/N 8-97220-540-0 H/C 6202436 Defect Code: 091 Contention Code: C99 Template ID: 01-047A Skill Level: Repair Technician Out of warranty: Any repair performed after warranty expiration may be eligible for goodwill consideration by the District Service Manager or your Zone Office. You must request consideration, and get a decision, before starting work. Removal and Installation Alternator: Service and Repair Removal and Installation Removal 1. Disconnect battery ground cable. 2. Move drive belt tensioner to loose side using wrench then remove drive belt (1). 3. Disconnect the wire from terminal "B" and disconnect the connector (4). 4. Remove generator fixing bolt (3). 5. Remove generator assembly (2). Installation 1. Install generator assembly to the position. 2. Install generator assembly and tighten the fixing bolts to the specified torque. Torque: M10 bolt: 41 Nm (30 lb.ft) M8 bolt: 21 Nm (15 lb.ft) 3. Connect wiring harness connector and direct terminal 4. Move drive belt tensioner to loose side using wrench then install drive belt to normal position. 5. Reconnect battery ground cable. Capacity Specifications Fluid - M/T: Capacity Specifications M/T Fluid Capacity ............................................................................................................................................... ......................................................................... 2.95L Page 7566 If there is no photo number below or beside a component name or a connector, ground, or terminal number, look up that name or number in the appropriate Connector Identification Chart. The chart lists how many cavities a connector has, where it's located, and what it connects to. The related illustration shows the connector's location on the harness, and the harness routing. NOTE: Photos listed by number are located at Locations / Components / Photograohs. See: Locations/Component Locations/Photographs Circuit Schematics Locations Front Window Regulator, Glass And Glass Run Service and Repair Band Control Solenoid Valve: Service and Repair REMOVAL 1. Raise the vehicle and support it on jack stands. 2. Disconnect battery ground cable. 3. Drain fluid. 4. Remove sixteen 10 mm screws, main case oil pan, magnet, and gasket. 5. Remove three 13 mm screws, oil filter. 6. Disconnect wiring harness from band control solenoid and shift solenoids. Pull only on connectors, not on wiring harness. 7. Remove spring pin for shift solenoid A, shift solenoid B, and band control solenoid respectively, using suitable pliers taking care not to damage solenoids. 8. Remove shift solenoid A, shift solenoid B, band control solenoid, and gaskets from main case valve body. Do not pull on wiring harness. Remove solenoids by grasping the metal tip. INSTALLATION 1. Install shift solenoid A, shift solenoid B, band control solenoid with new gaskets to main case valve body respectively. 2. Carefully install spring pin with hammer to avoid damage to valve body, etc. 3. Connect wiring harness to solenoids. 4. Install oil filter with a new gasket and the three 13 mm screws, tighten to the specified torque. Torque: 20 Nm (15 Ft. lbs.) Page 7532 Testing For A Short With A Self-Powered Test Light or DVOM 1. Remove the blown fuse and disconnect the battery and load. 2. Connect one lead of a self-powered test light or digital volt/ohmmeter (DVOM) (switched to the lowest "OHMS" range) to the fuse terminal on the load side. 3. Connect the other lead to a known good ground. 4. Beginning near the fuse box, wiggle the harness. Continue this at convenient points about six inches apart while watching the test light or DVOM. 5. If the self-powered test light goes on or the DVOM displays a low reading or no reading (zero), there is a short to ground in the wiring near that point. Testing for a Short with a Test Light or DVOM 1. Remove the blown fuse and disconnect the load. 2. Connect a test light or digital volt/ohmmeter (DVOM), switched to the appropriate DC volts range, across the fuse terminals to make sure voltage is present. You might have to turn the ignition switch to ON; check the schematic to see. 3. Beginning near the fuse box, wiggle the harness. Continue this at convenient points about six inches apart while watching the test light or DVOM. 4. Where the test light goes , or the DVOM voltage drops to zero, there is a short to ground in the wiring near that point. NOTE: Always use a DVOM on high impedance circuits. A test light may not glow (even with battery voltage present). Testing For A Short With A Short Circuit Locator (Short Finder) 1. Remove the blown fuse. Leave the battery connected. Page 5868 Abnormal Tire Ahead Wear and Major Causes TYPICAL EXAMPLES OF ABNORMAL TIRE AHEAD WEAR AND MAJOR CAUSES: CAUTION: Similar wear patterns can be caused by worn suspension parts, misalignment of wheels and tires, and other suspension related problems. Spotty Wear Wear localized on shoulder sections, and in an extreme cases, the tire becomes polygonal in shape. 1. Tire or wheel out of round or distorted. 2. Hub or knuckle out of round or distorted. 3. Play in hub bearings or ball joint. 4. Rotating parts out of balance. Tread Wear One-Sided 1. Rotating parts out of balance. 2. Tire or wheel out of round. 3. Hub or knuckle out of round or distorted. Vibration When Idling Muffler: All Technical Service Bulletins Vibration When Idling 00-040 April 11, 2000 Applies To: 1998-99 Passport - ALL 2000 Passport-From VIN 4S6..58W.Y4400001 thru 4S6..58W.Y4400051 Vibration When Idling SYMPTOM Harsh vibration comes from the body, the steering wheel, the seats, or the floor when the transmission is in Drive with the engine idling. The vibration is worse when the engine is cold. Sometimes, you can hear banging while starting the engine. PROBABLE CAUSE The right engine mount cover hits the chassis side of the engine mount. CORRECTIVE ACTION Shift the engine assembly slightly forward using REPAIR PROCEDURE A. If the vibration is still there, replace the right engine mount cover using REPAIR PROCEDURE B. PARTS INFORMATION Engine Mount Cover: P/N 8-97241-056-0, H/C 6362701 WARRANTY CLAIM INFORMATION In warranty: The normal warranty applies. REPAIR PROCEDURE A Operation Number: 112010 Flat Rate Time: 0.2 hour Failed Part: P/N 8-97125-561-7 H/C 6360812 Detect Code: 045 Contention Code: B99 Template ID: 00-040A Skill Level: Repair Technician REPAIR PROCEDURE B Operation Number: 112125 Flat Rate Time: 1.5 hours Failed Part: P/N 8-97125-306-0 H/C 5508981 Defect Code: 045 Contention Code: B99 Template ID: 00-040B Skill Level: Repair Technician Out of warranty: Any repair performed after warranty expiration may be eligible for goodwill consideration by the District Service Manager or your Zone Office. You must request consideration, and get a decision, before starting work. REPAIR PROCEDURE A 1. Raise the vehicle on a lift. Page 5039 Electronic Brake Control Module: Description and Operation The EHCU consists of ABS control circuits, fault detector, and a fail-safe. It drives the hydraulic unit according to the signal from each sensor, cancelling ABS to return to normal braking when a malfunction has occurred in the ABS. The EHCU has a self-diagnosing function which can indicate faulty circuits during diagnosis. The EHCU is mounted on the engine compartment rear right side. It consists of a Motor, Plunger Pump, Solenoid Valves. Solenoid Valves: Reduces or holds the caliper fluid pressure for each front disc brake or both rear disc brakes according to the signal sent from the EHCU. Reservoir: Temporarily holds the brake fluid that returns from the front and rear disc brake caliper so that pressure of front disc brake caliper can be reduced smoothly. Plunger Pump: Feeds the brake fluid held in the reservoir to the master cylinder. Motor: Drives the pump according to the signal from EHCU. Check Valve: Controls the brake fluid flow. Page 7706 it is located, and what it connects to. Use the Connector Views to help locate the proper cavity when you need to probe a connector. It can be especially helpful if the connector has more than one wire of the same color. A dash symbol (-) indicates that the cavity is empty. Connector views can also be used to help diagnose multiple symptoms in separate circuits which could be caused by a single problem in a connector shared by those circuits. Here's an example: 1. Pick one of the multiple symptoms and look up the schematic for that circuit. 2. Make a list of all the in-line and fuse box connectors in that schematic , 3. Then, in the Connector Views, look up each connector on your list to see if circuits related to the other symptoms run through one of them. If they do, inspect that connector for the problem. Example: The blower, rear window defogger, and the windshield wiper don't work. List all in-line and fuse box connectors in the blower controls circuit and then check the Connector View (see the sample). You find that C324 is common to the blower controls, rear window defogger, and wiper/washer, so you inspect C324 and find the problem, bent terminals. Finding Component/Connector Locations Finding Component/Connector Locations To see where a component or connector is located on the car, look up its photo number in the "Component Location". The photo will also tell you the color of the connector, and how many cavities it has. Page 6244 Refrigerant: Service and Repair System Evacuation Evacuation Of The Refrigerant System NOTE: Explained below is a method using a vacuum pump. Refer to the ACR(4)(or equivalent) manufacturer's instructions when evacuating the system with a ACR(4)(or equivalent). Air and moisture in the refrigerant will cause problems in the air conditioning system. Therefore, before charging the refrigerant, be sure to evacuate air and moisture thoroughly from the system. 1. Connect the gauge manifold. - High-pressure valve (HI) - Discharge-side. - Low-pressure valve (LOW) - Suction-side. 2. Discharge and recover the refrigerant. 3. Connect the center hose of the gauge manifold set to the vacuum pump inlet. 4. Operate the vacuum pump, open shutoff valve and then open both hand valves. 5. When the low-pressure gauge indicates approximately 750 mmHg (30 inHg), continue the evacuation for 5 minutes or more. 6. Close both hand valves and stop the vacuum pump. 7. Check to ensure that the pressure does not change after 10 minutes or more. - If the pressure changes, check the system for leaks. - If leaks occur, retighten the refrigerant line connections and repeat the evacuation steps. 8. If no leaks are found, again operate the vacuum pump for 20 minutes or more. After confirming that the gauge manifold pressure is at 750 mmHg (30 inHg), close both hand valves. 9. Close positive shutoff valve. Stop the vacuum pump and disconnect the center hose from the vacuum pump. Page 7779 it is located, and what it connects to. Use the Connector Views to help locate the proper cavity when you need to probe a connector. It can be especially helpful if the connector has more than one wire of the same color. A dash symbol (-) indicates that the cavity is empty. Connector views can also be used to help diagnose multiple symptoms in separate circuits which could be caused by a single problem in a connector shared by those circuits. Here's an example: 1. Pick one of the multiple symptoms and look up the schematic for that circuit. 2. Make a list of all the in-line and fuse box connectors in that schematic , 3. Then, in the Connector Views, look up each connector on your list to see if circuits related to the other symptoms run through one of them. If they do, inspect that connector for the problem. Example: The blower, rear window defogger, and the windshield wiper don't work. List all in-line and fuse box connectors in the blower controls circuit and then check the Connector View (see the sample). You find that C324 is common to the blower controls, rear window defogger, and wiper/washer, so you inspect C324 and find the problem, bent terminals. Finding Component/Connector Locations Finding Component/Connector Locations To see where a component or connector is located on the car, look up its photo number in the "Component Location". The photo will also tell you the color of the connector, and how many cavities it has. Initial Inspection and Diagnostic Overview Powertrain Control Module: Initial Inspection and Diagnostic Overview 1. Perform the On-Board Diagnostic System Check. 2. Start the engine and run for one minute. 3. Scan for DTCs using the Tech 2. Page 4494 4WD Control Unit: Electrical Diagrams Part 1 Of 3 Page 2374 Cleaning Spark Plugs - Clean spark plugs with a spark plug cleaner. - Raise the ground electrode to an position of 45 to 60 degrees. If electrode is wet, dry it before cleaning. - After spark plug is thoroughly cleaned, check insulator for presence of cracks. - Clean threads and metal body with a wire brush. - File the electrode tip if electrode is extremely worn. - Bend the ground electrode to adjust the spark plug gap. Page 4445 and the fuses. From Fuses to Relays and Components The second half of Power Distribution shows the wiring "From Fuses to Relays and Components." This can speed your troubleshooting by showing which circuits share fuses. If Power Distribution shows that an inoperative circuit and another circuit share a fuse, check a component in the other circuit. If it works, you know the fuse is good and power is available to the inoperative circuit. Ground Distribution Schematics Page 794 11. Using a jumper wire, connect the reference voltage of each circuit to its signal input and view the APP Sensor values in the Engine Data List. APP Sensor 1 should have a value of 99%, and APP Sensor 2 and APP Sensor 3 should each have a value of 0%. ^ If the values are not as specified, troubleshoot for high resistance on the signal input or a PCM malfunction. Repair the circuit or replace the PCM, then repeat step 3. ^ If the values are as specified, the problem may be intermittent. Disconnect the 10P connector from the modified APPS, and connect it to the new APPS; then repeat step 3. Wiggle the APPS wires as you go through the adjustment procedure to find the intermittent problem. 12. Turn off the ignition switch, and disconnect the PGM Tester.* DISCLAIMER Page 310 Part 2 Of 3 Page 1123 2. On the right cylinder bank, turn the camshaft pulley until its green mark is at 12 o'clock in relation to the head surface, at the center of the head. Turning the pulley brings the timing dots on the camshaft drive gear into their correct position: to the left and right of the gear's centerline. 3. On the left cylinder bank, turn the camshaft pulley until its green mark is at 12 o'clock in relation to the head surface, at the center of the head. Then turn the pulley counterclockwise until its green mark points close to the timing belt cover bolt hole. Turning the pulley brings the timing dots on the camshaft drive gear into their correct position: to the left and right of the gear's centerline. 4. Install the intake and exhaust camshafts in the right cylinder bank: - Set the camshaft marked "RI" into the intake side of the head. Make sure the single timing dot on the camshaft gear aligns with the timing dot on the camshaft drive gear. Locations Page 7514 Distinct Of Circuit By Wire Base Color All wires have color-coded insulation. Wires belonging to a system's main harness will have a single color. Wires belonging to a system's sub-circuits will have a colored stripe. Striped wires use the codes found in the chart to show wire size and colors. Abbreviations are used to indicate wire color within a circuit diagram. How to Identify Connector Terminals How to Identify Connector Terminals Cavity Numbering System The cavities (and wire terminals) in each connector are numbered starting from the upper left, looking at the male terminals from the terminal side (or looking at the female terminals from the wire side. Both views are in the same direction so the numbers are the same.) All actual cavities are numbered, even if they have no wire terminals in them. NOTE: Data Link Connector (DLC) terminals are numbered according to SAE standard J1962, not the Honda standard. The numbers of the four end terminals are molded into the corners of the connector face. The connector cavity number is listed next to each terminal on the circuit schematic. The cavity / terminal shown is # 6. Using/Identifying Connector Terminal Views How to Use Connector Terminal Views To see the configuration of a connector's cavities, look up its view number in the Connector Views. Each view includes the color of the connector, where Page 68 Control Module HVAC: Diagnostic Aids Before Troubleshooting Before Troubleshooting See: Service Precautions/Vehicle Damage Warnings/Tips and Precautions 1. Check applicable fuses in the appropriate fuse/relay box. 2. Check the battery for damage, state of charge, and clean and tight connections. CAUTION: Do not quick-charge a battery unless the battery ground cable has been disconnected, otherwise you will damage the alternator diodes. - Do not attempt to crank the engine with the battery ground cable loosely connected or you will severely damage the wiring. While You're Working 1. Make sure connectors are clean, and have no loose terminals or receptacles. 2. Make sure that connectors without wire seals are packed with dielectric (silicone) grease. Part Number: 08798-9001. 3. When connecting a connector, push it until it "clicks" into place. CAUTION: Do not pull on the wires when disconnecting a connector. Pull only on the connector housings. - Most circuits include solid-state devices. Test the voltages in these circuits only with a 10-megaohm or higher impedance digital multi meter. Never use a test light or analog meter on circuits that contain solid-state devices. Damage to the devices may result. Five-Step Troubleshooting 1. Verify The Complaint Turn on all the components in the problem circuit to check the accuracy of the customer complaint. Note the symptoms. Do not begin disassembly or testing until you have narrowed down the problem area. 2. Analyze The Schematic Look up the schematic for the problem circuit. Determine how the circuit is supposed to work by tracing the current paths from the power source through the circuit components to ground. Also, trace circuits that share wiring with the problem circuit. The names of circuits that share the same fuse, ground, or switch, and so on, are referred to in each circuit schematic. Try to operate any shared circuits you didn't check in step 1. If the shared circuits work, the shared wiring is OK, and the cause must be in the wiring used only by the problem circuit. If several circuits fail at the same time, the fuse or ground is a likely cause. Based on the symptoms and your understanding of the circuit's operation, identify one or more possible causes. 3. Isolate The Problem By Testing The Circuit Make circuit tests to check the diagnosis you made in step 2. Keep in mind that a logical, simple procedure is the key to efficient troubleshooting. Test for the most likely cause of failure first. Try to make tests at points that are easily accessible. 4. Fix The Problem Once the specific problem is identified, make the repair. Be sure to use proper tools and safe procedures. 5. Make Sure The Circuit Works Turn on all components in the repaired circuit in all modes to make sure you've fixed the entire problem. If the problem was a blown fuse, be sure to test all of the circuits on that fuse. Make sure no new problems turn up and the original problem does not recur. Page 185 5. Select F0 : Fuel Pump Relay. 6. Push "On" soft key. 7. Control Fuel Pump Relay and check data list. - If the data list changes, the Fuel Pump Relay is normal. 8. Select F1 : A/C Clutch Relay. 9. Run the Engine at idle. 10. Turn on Air Conditioning. 11. Turn "On" and "Off" A/C Switch. 12. Control A/C Clutch Relay and check data list. Locations Condenser HVAC: Locations Condenser Assembly Locations Page 123 Terminals - "T" Each "T" terminal (ring type) is numbered for reference and location. A "T" terminal is secured with a screw or bolt. Wires Page 2221 Each schematic represents one circuit. A circuit's wires and components are arranged to show current flow, from power at the top of the page, to ground, at the bottom. Shared Circuits Other circuits may share power or ground terminals or wiring with the circuit shown. A wire that connects one circuit to another, for example, is cut short and has an arrowhead at the end of it pointing in the direction of current flow. Next to the arrowhead is the name of the circuit or component which shares that wiring. To quickly check shared wiring, check the operation of a component it serves. If that component works, you know the shared wiring is OK. Connectors All in-line and junction connectors are numbered (C725, C416, etc.). Component connectors are not numbered but are identified either by the name of Page 1777 Spark Plug: Description and Operation Spark Plug Although worn or dirty spark plugs may give satisfactory operation at idling speed, they frequency fail at higher engine speeds. Faulty spark plugs may cause poor fuel economy, power loss, loss of speed, hard starting and generally poor engine performance. Follow the scheduled maintenance service recommendations to ensure satisfactory spark plug performance. Refer to Maintenance and Lubrication. Normal spark plug operation will result in brown to grayish-tan deposits appearing on the insulator portion of the spark plug. A small amount of red-brown, yellow, and white powdery material may also be present on the insulator tip around the center electrode. These deposits are normal combustion by-products of fuels and lubricating oils with additives. Some electrode wear will also occur. Engines which are not running properly are often referred to as "misfiring." This means the ignition spark is not igniting the air/fuel mixture at the proper time. While other ignition and fuel system causes must also be considered, possible causes include ignition system conditions which allow the spark voltage to reach ground in some other manner than by jumping across the air gap at the tip of the spark plug, leaving the air/fuel mixture unburned. Refer to DTC P0300. Misfiring may also occur when the tip of the spark plug becomes overheated and ignites the mixture before the spark jumps. This is referred to as "pre-ignition." Spark plugs may also misfire due to fouling, excessive gap, or a cracked or broken insulator. If misfiring occurs before the recommended replacement interval, locate and correct the cause. Carbon fouling of the spark plug is indicated by dry, black carbon (soot) deposits on the portion of the spark plug in the cylinder. Excessive idling and slow speeds under light engine loads can keep the spark plug temperatures so low that these deposits are not burned off. Very rich fuel mixtures or poor ignition system output may also be the cause. Refer to DTC P0172. Oil fouling of the spark plug is indicated by wet oily deposits on the portion of the spark plug in the cylinder, usually with little electrode wear. This may be caused by oil during break-in of new or newly overhauled engines. Deposit fouling of the spark plug occurs when the normal red-brown, yellow or white deposits of combustion by products become sufficient to cause misfiring. In some cases, these deposits may melt and form a shiny glaze on the insulator around the center electrode. If the fouling is found in only one or two cylinders, valve stem clearances or intake valve seals may be allowing excess lubricating oil to enter the cylinder, particularly if the deposits are heavier on the side of the spark plug facing the intake valve. Excessive gap means that the air space between the center and the side electrodes at the bottom of the spark plug is too wide for consistent firing. This Specifications Engine Oil Pressure: Specifications Oil Pressure 392-550 kPa at 3000 rpm Page 3226 Step 1 Step 2 Page 2947 Throttle Position Sensor: Testing and Inspection Function Check Use a Tech 2 to check the TP sensor output voltage at closed throttle. - The voltage should be under 0.85 volt. - If the reading is greater than 0.85 volt, check the throttle shaft to see if it is binding. Page 3365 Ground - "G" Shielding Sheilding This represents RFI (Radio Frequency Interference) shielding around a wire. The shielding is always connected to ground. Splices Page 4447 The name of the component appears next to it followed by notes about its function along with any photo and connector view references. Connector "C" How to Identify Connector Terminals Cavity Numbering System The cavities (and wire terminals) in each connector are numbered starting from the upper left, looking at the male terminals from the terminal side (or looking at the female terminals from the wire side. Both views are in the same direction so the numbers are the same.) All actual cavities are numbered, even if they have no wire terminals in them. NOTE: Data Link Connector (DLC) terminals are numbered according to SAE standard J1962, not the Honda standard. The numbers of the four end terminals are molded into the corners of the connector face. Page 2021 2. Connect the short finder across the battery terminals and the load (component) side of the fuse terminal. 3. Close all switches in the circuit you're testing. 4. Turn on the short finder. This creates a pulsing magnetic field around the wiring between the fuse box and the short. 5. Beginning at the fuse box, slowly move the short finder along the circuit wiring. The meter will read current pulses through sheet metal and body trim. As long as the meter is between the fuse and the short, the needle will move with each current pulse. Once you move the meter past the point of the short, the needle will stop moving. Check the wiring and connectors in this area to locate the cause of the short. Testing For Continuity When testing for continuity at a connector without wire seals, you do not have to separate the two halves of the connector. Instead, probe the connector from the back. Always check both sides of the connector because dirty, corroded, and bent terminals can cause problems (no electrical contact = an open). 1. Disconnect the negative cable from the car battery. If you're using a DVOM, place it in the lowest "OHMS" range. Page 2896 Manifold Pressure/Vacuum Sensor: Description and Operation Manifold Absolute Pressure (MAP) Sensor The manifold absolute pressure (MAP) sensor responds to changes in intake manifold pressure (vacuum). The MAP sensor signal voltage to the PCM varies from below 2 volts at idle (high vacuum) to above 4 volts with the ignition ON, engine not running or at wide-open throttle (low vacuum). The MAP sensor is used to determine the following: - Manifold pressure changes while the linear EGR flow test diagnostic is being run. Refer to DTC P0401. - Barometric pressure (BARO). If the PCM detects a voltage that is lower than the possible range of the MAP sensor, DTC P0107 will be set. A signal voltage higher than the possible range of the sensor will set DTC P0108. An intermittent low or high voltage will set DTC P1107, respectively. The PCM can detect a shifted MAP sensor. The PCM compares the MAP sensor signal to a calculated MAP based on throttle position and various engine load factors. If the PCM detects a MAP signal that varies excessively above or below the calculated value, DTC P0106 will set. Page 2582 Data Link Connector: Description and Operation Data Link Connector (DLC) The provision for communication with the control module is the Data Link Connector (DLC). It is located at the tower left of the instrument panel behind a small square cover. The DLC is used to connect to the Tech 2 Scan Tool. Some common uses of the Tech 2 are listed below: - Identifying stored Diagnostic Trouble Codes (DTCs). - Clearing DTCs. - Performing output control tests. - Reading serial data. Page 6076 This sample Ground Distribution schematic shows all of the components that share two ground points. Components A solid border line means the entire component is shown. A broken border line indicates that only part of the component is shown. Front Wipers (In Combination Switch) Page 8009 it is located, and what it connects to. Use the Connector Views to help locate the proper cavity when you need to probe a connector. It can be especially helpful if the connector has more than one wire of the same color. A dash symbol (-) indicates that the cavity is empty. Connector views can also be used to help diagnose multiple symptoms in separate circuits which could be caused by a single problem in a connector shared by those circuits. Here's an example: 1. Pick one of the multiple symptoms and look up the schematic for that circuit. 2. Make a list of all the in-line and fuse box connectors in that schematic , 3. Then, in the Connector Views, look up each connector on your list to see if circuits related to the other symptoms run through one of them. If they do, inspect that connector for the problem. Example: The blower, rear window defogger, and the windshield wiper don't work. List all in-line and fuse box connectors in the blower controls circuit and then check the Connector View (see the sample). You find that C324 is common to the blower controls, rear window defogger, and wiper/washer, so you inspect C324 and find the problem, bent terminals. Finding Component/Connector Locations Finding Component/Connector Locations To see where a component or connector is located on the car, look up its photo number in the "Component Location". The photo will also tell you the color of the connector, and how many cavities it has. Page 8195 10. Remove the 2 screws through the access hole and pull out the glass upward. 11. Remove the window regulator. - Disconnect the window regulator motor harness connector, if equipped with power windows. 12. Remove the glass run. - Pull the glass run (6) out from the door frame groove. Installation To install, follow the removal steps in the reverse order, noting the following points: Page 1106 6. Lock the camshaft gear to its subgear with a 5 x 0.5 mm bolt through either side of the hole in the gears. This holds the spring-loaded subgear in place so you can remove the camshaft. Do this for each camshaft you need to remove. 7. Remove the camshaft bearing caps, noting the location and direction of each cap. 8. Remove the camshaft(s). 9. For each valve needing adjustment, do steps 10 thru 13. 10. Insert a pick or a small screwdriver into the tappet notch, and pry out the shim. 11. Wipe oft the shim, then write its number on the Valve Inspection Chart for that valve and cylinder. If there is no number on the shim, measure its thickness with a micrometer, and write down the measurement on the Valve Inspection Chart. 12. Follow the directions on the Valve Shim Replacement Chart to select the correct shim. 13. Insert the correct shim, number side down, into the tappet. Make sure the shim is fully seated. 14. Install the camshafts (see steps 2 thru 9 of CAMSHAFT SUBGEAR PRELOADING, GEAR TIMING, AND CAMSHAFT INSTALLATION). 15. Rotate the camshaft pulleys a few turns to ensure the new shims are fully seated. 16. Recheck the clearances of the valves you adjusted with the Go/No-Go method (see step 3). If any clearances are incorrect, readjust them. Page 1779 Spark Plug: Testing and Inspection Inspection and Repair The spark plug affects entire engine performance and therefore its inspection is very important. - Check electrode and insulator for presence of cracks, and replace if any. - Check electrode for wear, and replace if necessary.. - Check gasket for damage, and replace if necessary. - Measure insulation resistance with an ohmmeter, and replace if faulty. - Adjust spark plug gap to 1.0 mm (0.040 in) to 1.1 mm (0.043 in). - Check fuel and electrical systems if spark plug is extremely dirty. - Use spark plugs having low heat value (hot type plug) if fuel and electrical systems are normal. - Use spark plugs having high heat value (cold type plug) if insulator and electrode are extremely burned. Sooty Spark Plugs Much deposit of carbon or oil on the electrode and insulator of spark plug reduces the engine performance. Possible causes: - Too rich mixture - Presence of oil in combustion chamber - Incorrectly adjusted spark plug gap Burning Electrodes This fault is characterized by scorched or heavily oxidized electrode or blistered insulator nose. Possible causes: - Too lean mixture - Improper heat value Measuring Insulation Resistance - Measure insulation resistance using a 500 volt megaohm meter. - Replace spark plugs if measured value is out of standard. Insulation resistance: 50 Mohm or more. Page 7601 Splices Splices are shown as a dot. Their location and the number of wires may vary depending on the harness manufacturer. Switches Switches These switches move together; the broken straight line between them means they are mechanically connected. Other types of switches are controlled by a coil or a solid state circuit. Unless otherwise noted, all switches are shown in their normal (rest) position, with power off. Terminal "T" Diagram Information and Instructions Control Module HVAC: Diagram Information and Instructions How to Identify Wiring Color-Coded Insulation Wire Color Wire Color Coding Page 2182 6. Place the end of the return hose in a container. Have someone start the engine, then pour ATF into the reservoir while you watch the fluid coming out of the return hose. When the fluid coming out is the same color as the new fluid, turn off the engine. 7. Reconnect the return hose to the reservoir. 8. Start the engine. Fill the power steering reservoir to the proper level with ATF then turn off the engine. 9. Use the Smart Cable to reprogram the PCM with the latest software from the June 2001 or later HONDANET CD-ROM. Refer to Service Bulletin 99-005, Updating the Passport PCM, filed under Tools. 10. Use the PGM Tester to clear any DTCs. 11. Use the PGM Tester to check the broadcast code. Make sure the broadcast code matches the one you selected from the CD-ROM. WARRANTY CLAIM INFORMATION In warranty: The normal warranty applies. Failed Part: P/N 8-97181-590-0 H/C 5698030 Defect Code: 064 Contention Code: C01 Skill Level: Repair Technician Out of warranty: Any repair performed after warranty expiration may be eligible for goodwill consideration by the District Service Manager or your Zone Office. You must request consideration, and get a decision, before starting work. REPAIR PROCEDURE - APPS GROUND 1. Unclamp the air cleaner housing cover, and move it to the side for access to connector C123 (16P BLK). Page 2442 20. Using a DVOM, check the voltage between the reference voltage pin for each sensor and ground. ^ If the sensor circuits all read 5.0 volts, go to step 22. ^ If any sensor circuit is above or below 5.0 volts, go to step 21. 21. Troubleshoot for an internal short in another sensor or a PCM malfunction. ^ To find the sensor with an internal short, monitor the reference voltage, and disconnect each sensor (FTPS, EGR, MAP TPS, CKP and CMP) one at a time until the reference voltage reads 5.0 volts. Replace that sensor, and repeat step 14. ^ To find a malfunctioning PCM, replace it with a known-good PCM. If all three sensors (APP Sensor 1, APP Sensor 2, and APP Sensor 3) are within range, the original PCM is faulty; replace it and repeat step 14. 22. Using a jumper wire, connect the reference voltage of each circuit to its signal input, and view the APP Sensor values in the Engine Data List. APP Sensor 1 should have a value of 99%, and APP Sensor 2 and APP Sensor 3 should each have a value of 0%. ^ If the values are not as specified, troubleshoot for high resistance on the signal input or a PCM malfunction. Repair the circuit or replace the PCM, then repeat step 14. ^ If the values are as specified, the problem may be intermittent. Disconnect the 10 P connector from the modified APPS, and connect it to the new APPS; then repeat step 14. Wiggle the APPS wires as you go through the adjustment procedure to find the intermittent problem. 23. Install the accelerator pedal assembly, and torque the bolts to 10 N.m (7 lb-ft). Page 1291 The SRS consists of the Sensing and Diagnostic Module (SDM), the driver air bag assembly, the SRS coil assembly, the passenger air bag assembly, and the "AIR BAG" warning lamp in the instrument cluster. The SDM, SRS coil assembly (driver side only), driver air bag assembly, passenger air bag assembly and connector wire make up the deployment loops. The function of the deployment loops is to supply current through air bag assembly, which will cause deployment of the air bags in the event of a frontal crash of sufficient force, up to 30 degrees off the centerline of the vehicle. The air bag assemblies are only supplied enough current to deploy when the SDM detects vehicle velocity changes severe enough to warrant deployment. The SDM contains a sensing device which converts vehicle velocity change to an electrical signal. The electrical signal generated is processed by the SDM and then compared to a value stored in memory. When the generated signal exceeds the stored value, the SDM will cause current to flow through the air bag assembly deploying the air bags. Page 6477 The SRS consists of the Sensing and Diagnostic Module (SDM), the driver air bag assembly, the SRS coil assembly, the passenger air bag assembly, and the "AIR BAG" warning lamp in the instrument cluster. The SDM, SRS coil assembly (driver side only), driver air bag assembly, passenger air bag assembly and connector wire make up the deployment loops. The function of the deployment loops is to supply current through air bag assembly, which will cause deployment of the air bags in the event of a frontal crash of sufficient force, up to 30 degrees off the centerline of the vehicle. The air bag assemblies are only supplied enough current to deploy when the SDM detects vehicle velocity changes severe enough to warrant deployment. The SDM contains a sensing device which converts vehicle velocity change to an electrical signal. The electrical signal generated is processed by the SDM and then compared to a value stored in memory. When the generated signal exceeds the stored value, the SDM will cause current to flow through the air bag assembly deploying the air bags. Testing and Inspection Shifter A/T: Testing and Inspection SELECTOR LEVER INSPECTION 1. Make sure that when the shifter control lever is shifted from "P" to "L", a "clicking" can be felt at each shift position. Make sure that the gear corresponds to that of the position plate indicator. 2. Check to see if the shifter lever can be shifted as shown in illustration. Page 7740 Backup Lamp Switch: Service and Repair Removal 1. Disconnect the battery ground cable. 2. Remove the backup light switch (1). - Disconnect the connector (2). Installation To install, follow the removal steps in the reverse order, noting the following point. 1. Apply liquid gasket to the screw portion of the switch to prevent oil leak. Page 1117 NOTE: You may need to rotate the camshaft pulley up to four complete turns before its green mark aligns directly with the bolt hole. 4. Rotate the left cylinder bank's camshaft pulley clockwise another 1/4 turn to align its green mark with the valve cover timing mark. Locations Window Track: Locations Front Window Regulator, Glass And Glass Run Page 3065 3. Connect the vacuum hoses to the EVAP canister purge solenoid. 4. Connect the electrical connector to the EVAP canister purge solenoid. Page 5503 Power Steering Fluid: Service Precautions Use Genuine Honda Power Steering Fluid, or another brand of power steering fluid as a temporary replacement. Page 4225 Axle Disconnect Control Control Unit: Diagnostic Aids Before Troubleshooting Before Troubleshooting See: Service Precautions/Vehicle Damage Warnings/Tips and Precautions 1. Check applicable fuses in the appropriate fuse/relay box. 2. Check the battery for damage, state of charge, and clean and tight connections. CAUTION: Do not quick-charge a battery unless the battery ground cable has been disconnected, otherwise you will damage the alternator diodes. - Do not attempt to crank the engine with the battery ground cable loosely connected or you will severely damage the wiring. While You're Working 1. Make sure connectors are clean, and have no loose terminals or receptacles. 2. Make sure that connectors without wire seals are packed with dielectric (silicone) grease. Part Number: 08798-9001. 3. When connecting a connector, push it until it "clicks" into place. CAUTION: Do not pull on the wires when disconnecting a connector. Pull only on the connector housings. - Most circuits include solid-state devices. Test the voltages in these circuits only with a 10-megaohm or higher impedance digital multi meter. Never use a test light or analog meter on circuits that contain solid-state devices. Damage to the devices may result. Five-Step Troubleshooting 1. Verify The Complaint Turn on all the components in the problem circuit to check the accuracy of the customer complaint. Note the symptoms. Do not begin disassembly or testing until you have narrowed down the problem area. 2. Analyze The Schematic Look up the schematic for the problem circuit. Determine how the circuit is supposed to work by tracing the current paths from the power source through the circuit components to ground. Also, trace circuits that share wiring with the problem circuit. The names of circuits that share the same fuse, ground, or switch, and so on, are referred to in each circuit schematic. Try to operate any shared circuits you didn't check in step 1. If the shared circuits work, the shared wiring is OK, and the cause must be in the wiring used only by the problem circuit. If several circuits fail at the same time, the fuse or ground is a likely cause. Based on the symptoms and your understanding of the circuit's operation, identify one or more possible causes. 3. Isolate The Problem By Testing The Circuit Make circuit tests to check the diagnosis you made in step 2. Keep in mind that a logical, simple procedure is the key to efficient troubleshooting. Test for the most likely cause of failure first. Try to make tests at points that are easily accessible. 4. Fix The Problem Once the specific problem is identified, make the repair. Be sure to use proper tools and safe procedures. 5. Make Sure The Circuit Works Turn on all components in the repaired circuit in all modes to make sure you've fixed the entire problem. If the problem was a blown fuse, be sure to test all of the circuits on that fuse. Make sure no new problems turn up and the original problem does not recur. Page 1295 To install the connector, hold the socket insulator(l) and insert it. The cover insulator slides and connector will be locked. Do not hold the cover insulator(2). Page 845 Crankshaft Position Sensor: Service and Repair REMOVAL 1. Disconnect the negative battery cable. 2. Disconnect the wiring connector from crankshaft position sensor. 3. Remove one bolt and remove the CKP sensor from the right side of the engine block, just behind the mount. NOTE: Use caution to avoid any hot oil that might drip out. INSTALLATION 1. Apply a small amount of engine oil to the O-ring and install the CKP sensor in the engine block. 2. Install the CKP sensor mounting bolt. 3. Tighten the mounting bolt to 10 Nm (89 lb in.). 4. Connect the wiring connector to the CKP sensor. 5. Connect the negative battery cable. Page 8132 Diagram Information and Instructions Fuel Tank Unit: Diagram Information and Instructions How to Identify Wiring Color-Coded Insulation Wire Color Wire Color Coding Page 5573 Distinct Of Circuit By Wire Base Color All wires have color-coded insulation. Wires belonging to a system's main harness will have a single color. Wires belonging to a system's sub-circuits will have a colored stripe. Striped wires use the codes found in the chart to show wire size and colors. Abbreviations are used to indicate wire color within a circuit diagram. How to Identify Connector Terminals How to Identify Connector Terminals Cavity Numbering System The cavities (and wire terminals) in each connector are numbered starting from the upper left, looking at the male terminals from the terminal side (or looking at the female terminals from the wire side. Both views are in the same direction so the numbers are the same.) All actual cavities are numbered, even if they have no wire terminals in them. NOTE: Data Link Connector (DLC) terminals are numbered according to SAE standard J1962, not the Honda standard. The numbers of the four end terminals are molded into the corners of the connector face. The connector cavity number is listed next to each terminal on the circuit schematic. The cavity / terminal shown is # 6. Using/Identifying Connector Terminal Views How to Use Connector Terminal Views To see the configuration of a connector's cavities, look up its view number in the Connector Views. Each view includes the color of the connector, where Page 7942 If there is no photo number below or beside a component name or a connector, ground, or terminal number, look up that name or number in the appropriate Connector Identification Chart. The chart lists how many cavities a connector has, where it's located, and what it connects to. The related illustration shows the connector's location on the harness, and the harness routing. NOTE: Photos listed by number are located at Locations / Components / Photograohs. See: Locations/Component Locations/Photographs Circuit Schematics Page 1904 Exhaust Pipe: Service and Repair Three Way Catalytic Converter (LH) Three Way Catalytic Converter LH and Forked Exhaust Pipe Removal 1. Disconnect battery ground cable. 2. Lift up the vehicle and support with suitable safety stands. 3. Disconnect O2 sensor harness connectors (7) (9). 4. Remove the forked exhaust pipe fixing bolts and nuts (1) (3) (5) and the exhaust silencer fixing nuts (4), then remove the forked exhaust pipe (2). 5. Remove the three way catalytic converter fixing nuts (10) and the mounting rubber (6), then remove the three way catalytic converter (8). Installation 1. Install the three way catalytic converter (8) and the mounting rubber (6), and tighten the fixing nuts (10) to the specific torque. Torque Nuts: 67 Nm (49 ft. lbs.) 2. Install the forked exhaust pipe (2) and tighten the fixing bolts (1) (5) and nuts (3) (4) to the specified torque. Torque Bolts & Nuts: 43 Nm (32 ft. lbs.) Nuts: 43 Nm (32 ft. lbs.) 3. Connect the O2 sensor connectors (7) (9). Page 1853 Coolant Temperature Sensor/Switch (For Computer): Service and Repair ENGINE COOLANT TEMPERATURE (ECT) SENSOR REMOVAL PROCEDURE NOTE: Care must be taken when handling the engine coolant temperature (ECT) sensor. Damage to the ECT sensor will affect proper operation of the fuel injection system. 1. Disconnect the negative battery cable. 2. Drain the radiator coolant. Refer to Draining and Refilling Cooling System. 3. Disconnect the electrical connector. 4. Remove the ECT sensor from the coolant crossover. INSTALLATION PROCEDURE 1. Apply sealer or the equivalent to the threads of the ECT sensor. 2. Install the ECT sensor in the coolant crossover. Tighten Tighten the ECT sensor to 30 N.m (22 lb ft.). Page 58 This sample Ground Distribution schematic shows all of the components that share two ground points. Components A solid border line means the entire component is shown. A broken border line indicates that only part of the component is shown. Locations Locations Page 2391 Page 208 Splices Splices are shown as a dot. Their location and the number of wires may vary depending on the harness manufacturer. Switches Switches These switches move together; the broken straight line between them means they are mechanically connected. Other types of switches are controlled by a coil or a solid state circuit. Unless otherwise noted, all switches are shown in their normal (rest) position, with power off. Terminal "T" Page 4481 Ground - "G" Shielding Sheilding This represents RFI (Radio Frequency Interference) shielding around a wire. The shielding is always connected to ground. Splices Page 6253 Refrigerant Oil: Description and Operation Compressor Oil Oil Specification The HFC-134a system requires a synthetic (PAG) compressor oil whereas the R-12 system requires a mineral compressor oil. The two oils must never be mixed. Compressor (PAG) oil varies according to compressor model. Be sure to use oil specified for the model of compressor. Always use HFC-134a Vane Rotary Type Compressor Oil (AIPDN Part No.2-90188-301-0) Handling of Oil The oil should be free from moisture, dust, metal powder, etc. Do not mix with other oil. The water content in the oil increases when exposed to the air. After use, seal oil from air immediately. (HFC-134a Vane Rotary Compressor Oil absorbs moisture very easily.) The compressor oil must be stored in steel containers, not in plastic containers. Compressor Oil Check The oil used to lubricate the compressor is circulating with the refrigerant. Whenever replacing any component of the system or a large amount of gas leakage occurs, add oil to maintain the original amount of oil. Oil Capacity Capacity total in system: 150 cc (5.0 fl.oz) Compressor (Service parts) charging amount: 150 cc (5.0 fl.oz) Page 1439 Camshaft: Service and Repair Camshaft Replacement Camshaft Removal 1. Disconnect battery ground cable. 2. Remove crankshaft pulley. 3. Remove timing belt. 4. Remove cylinder head cover LH. 5. Remove cylinder head cover RH. Adjustments Brake Switch (Cruise Control): Adjustments 1. Check that the brake pedal (3) is fully returned by pedal return spring. 2. Disconnect the switch connector. 3. Loosen the lock nut (2). 4. Rotate the brake switch (1) by hand until push rod disappears from brake switch tip (4). 5. Return the brake switch by a half turn. 6. Tighten the lock nut. 7. Connect the switch connector. Diagram Information and Instructions Cigarette Lighter: Diagram Information and Instructions How to Identify Wiring Color-Coded Insulation Wire Color Wire Color Coding Page 4488 4WD Control Unit: Diagnostic Aids Before Troubleshooting Before Troubleshooting See: Service Precautions/Vehicle Damage Warnings/Tips and Precautions 1. Check applicable fuses in the appropriate fuse/relay box. 2. Check the battery for damage, state of charge, and clean and tight connections. CAUTION: Do not quick-charge a battery unless the battery ground cable has been disconnected, otherwise you will damage the alternator diodes. - Do not attempt to crank the engine with the battery ground cable loosely connected or you will severely damage the wiring. While You're Working 1. Make sure connectors are clean, and have no loose terminals or receptacles. 2. Make sure that connectors without wire seals are packed with dielectric (silicone) grease. Part Number: 08798-9001. 3. When connecting a connector, push it until it "clicks" into place. CAUTION: Do not pull on the wires when disconnecting a connector. Pull only on the connector housings. - Most circuits include solid-state devices. Test the voltages in these circuits only with a 10-megaohm or higher impedance digital multi meter. Never use a test light or analog meter on circuits that contain solid-state devices. Damage to the devices may result. Five-Step Troubleshooting 1. Verify The Complaint Turn on all the components in the problem circuit to check the accuracy of the customer complaint. Note the symptoms. Do not begin disassembly or testing until you have narrowed down the problem area. 2. Analyze The Schematic Look up the schematic for the problem circuit. Determine how the circuit is supposed to work by tracing the current paths from the power source through the circuit components to ground. Also, trace circuits that share wiring with the problem circuit. The names of circuits that share the same fuse, ground, or switch, and so on, are referred to in each circuit schematic. Try to operate any shared circuits you didn't check in step 1. If the shared circuits work, the shared wiring is OK, and the cause must be in the wiring used only by the problem circuit. If several circuits fail at the same time, the fuse or ground is a likely cause. Based on the symptoms and your understanding of the circuit's operation, identify one or more possible causes. 3. Isolate The Problem By Testing The Circuit Make circuit tests to check the diagnosis you made in step 2. Keep in mind that a logical, simple procedure is the key to efficient troubleshooting. Test for the most likely cause of failure first. Try to make tests at points that are easily accessible. 4. Fix The Problem Once the specific problem is identified, make the repair. Be sure to use proper tools and safe procedures. 5. Make Sure The Circuit Works Turn on all components in the repaired circuit in all modes to make sure you've fixed the entire problem. If the problem was a blown fuse, be sure to test all of the circuits on that fuse. Make sure no new problems turn up and the original problem does not recur. Page 1486 Note: Take care to ensure the bearings are positioned correctly. Reassembly 1. Crankshaft (12) - Install the main bearings to the cylinder block and the main bearing caps. - Be sure that they are positioned correctly. - Apply new engine oil to the upper and lower main bearing faces. Note: Do not apply engine oil to the main bearing back faces. - Carefully mount the crankshaft. - Apply engine oil to the thrust washer. Page 2430 11. Using a jumper wire, connect the reference voltage of each circuit to its signal input and view the APP Sensor values in the Engine Data List. APP Sensor 1 should have a value of 99%, and APP Sensor 2 and APP Sensor 3 should each have a value of 0%. ^ If the values are not as specified, troubleshoot for high resistance on the signal input or a PCM malfunction. Repair the circuit or replace the PCM, then repeat step 3. ^ If the values are as specified, the problem may be intermittent. Disconnect the 10P connector from the modified APPS, and connect it to the new APPS; then repeat step 3. Wiggle the APPS wires as you go through the adjustment procedure to find the intermittent problem. 12. Turn off the ignition switch, and disconnect the PGM Tester.* DISCLAIMER Page 1107 Valve Shims (While 41 shims are available, the 10 sizes will cover most valve adjustments): Page 3217 Fuel Injector: Diagnostic Aids Before Troubleshooting Before Troubleshooting See: Service Precautions/Vehicle Damage Warnings/Tips and Precautions 1. Check applicable fuses in the appropriate fuse/relay box. 2. Check the battery for damage, state of charge, and clean and tight connections. CAUTION: Do not quick-charge a battery unless the battery ground cable has been disconnected, otherwise you will damage the alternator diodes. - Do not attempt to crank the engine with the battery ground cable loosely connected or you will severely damage the wiring. While You're Working 1. Make sure connectors are clean, and have no loose terminals or receptacles. 2. Make sure that connectors without wire seals are packed with dielectric (silicone) grease. Part Number: 08798-9001. 3. When connecting a connector, push it until it "clicks" into place. CAUTION: Do not pull on the wires when disconnecting a connector. Pull only on the connector housings. - Most circuits include solid-state devices. Test the voltages in these circuits only with a 10-megaohm or higher impedance digital multi meter. Never use a test light or analog meter on circuits that contain solid-state devices. Damage to the devices may result. Five-Step Troubleshooting 1. Verify The Complaint Turn on all the components in the problem circuit to check the accuracy of the customer complaint. Note the symptoms. Do not begin disassembly or testing until you have narrowed down the problem area. 2. Analyze The Schematic Look up the schematic for the problem circuit. Determine how the circuit is supposed to work by tracing the current paths from the power source through the circuit components to ground. Also, trace circuits that share wiring with the problem circuit. The names of circuits that share the same fuse, ground, or switch, and so on, are referred to in each circuit schematic. Try to operate any shared circuits you didn't check in step 1. If the shared circuits work, the shared wiring is OK, and the cause must be in the wiring used only by the problem circuit. If several circuits fail at the same time, the fuse or ground is a likely cause. Based on the symptoms and your understanding of the circuit's operation, identify one or more possible causes. 3. Isolate The Problem By Testing The Circuit Make circuit tests to check the diagnosis you made in step 2. Keep in mind that a logical, simple procedure is the key to efficient troubleshooting. Test for the most likely cause of failure first. Try to make tests at points that are easily accessible. 4. Fix The Problem Once the specific problem is identified, make the repair. Be sure to use proper tools and safe procedures. 5. Make Sure The Circuit Works Turn on all components in the repaired circuit in all modes to make sure you've fixed the entire problem. If the problem was a blown fuse, be sure to test all of the circuits on that fuse. Make sure no new problems turn up and the original problem does not recur. A/C - Heater Blows Cold Air/A/C Blows Hot Air Heater Control Valve Cable: Technical Service Bulletins A/C - Heater Blows Cold Air/A/C Blows Hot Air Heater Blows Cold Air; A/C Blows Warm Air NOTE: This article applies to all A/C-equipped Honda models that use a heater valve cable. Got a vehicle in your shop that blows cold air from the heater or warm air from the A/C? The problem could just be the heater valve cable has slipped off the heater valve arm. There's a real easy fix for this problem. Slip the heater valve cable back onto the heater valve arm. Then cut yourself a 10 mm length of 3.5 mm vacuum hose (P/N 95005-35008-10M, H/C 2325058), and slide it onto the arm. This holds the cable on the arm nice and snug so it won't slip off. Page 7135 Page 4912 Brake Rotor/Disc: Testing and Inspection Rear Drum (In Disc) Inside Diameter Check Check the rear drum inside diameter by measuring at more than two portions as shown in the illustration. If the inside diameter is greater than the limit, replace the rear rotor. Standard: 210.0 mm (8.27 inch) Limit: 211.4 mm (8.32 inch) Page 783 Disclaimer Repair Procedure 1. Unclamp the air cleaner housing cover, and move it to the side for access to connector C123 (16P BLK). 2. Unfasten C123 from the side of the engine compartment using a 90-degree pick. 3. Disconnect C123, and clean the terminals on both sides of the connector with contact cleaner. Shake the residue out of the connector. Allow the contact cleaner to evaporate for at least 3 minutes, then reconnect C123. 4. Fasten C123 to the left side of the engine compartment, then reinstall the air cleaner housing cover. 5. While supporting the accelerator pedal assembly, remove the two bolts that secure the assembly to the bulkhead. Carefully lower the assembly to gain access to the connector. Page 5583 Splices Splices are shown as a dot. Their location and the number of wires may vary depending on the harness manufacturer. Switches Switches These switches move together; the broken straight line between them means they are mechanically connected. Other types of switches are controlled by a coil or a solid state circuit. Unless otherwise noted, all switches are shown in their normal (rest) position, with power off. Terminal "T" Page 7102 Testing For A Short With A Self-Powered Test Light or DVOM 1. Remove the blown fuse and disconnect the battery and load. 2. Connect one lead of a self-powered test light or digital volt/ohmmeter (DVOM) (switched to the lowest "OHMS" range) to the fuse terminal on the load side. 3. Connect the other lead to a known good ground. 4. Beginning near the fuse box, wiggle the harness. Continue this at convenient points about six inches apart while watching the test light or DVOM. 5. If the self-powered test light goes on or the DVOM displays a low reading or no reading (zero), there is a short to ground in the wiring near that point. Testing for a Short with a Test Light or DVOM 1. Remove the blown fuse and disconnect the load. 2. Connect a test light or digital volt/ohmmeter (DVOM), switched to the appropriate DC volts range, across the fuse terminals to make sure voltage is present. You might have to turn the ignition switch to ON; check the schematic to see. 3. Beginning near the fuse box, wiggle the harness. Continue this at convenient points about six inches apart while watching the test light or DVOM. 4. Where the test light goes , or the DVOM voltage drops to zero, there is a short to ground in the wiring near that point. NOTE: Always use a DVOM on high impedance circuits. A test light may not glow (even with battery voltage present). Testing For A Short With A Short Circuit Locator (Short Finder) 1. Remove the blown fuse. Leave the battery connected. Page 306 2. Connect the short finder across the battery terminals and the load (component) side of the fuse terminal. 3. Close all switches in the circuit you're testing. 4. Turn on the short finder. This creates a pulsing magnetic field around the wiring between the fuse box and the short. 5. Beginning at the fuse box, slowly move the short finder along the circuit wiring. The meter will read current pulses through sheet metal and body trim. As long as the meter is between the fuse and the short, the needle will move with each current pulse. Once you move the meter past the point of the short, the needle will stop moving. Check the wiring and connectors in this area to locate the cause of the short. Testing For Continuity When testing for continuity at a connector without wire seals, you do not have to separate the two halves of the connector. Instead, probe the connector from the back. Always check both sides of the connector because dirty, corroded, and bent terminals can cause problems (no electrical contact = an open). 1. Disconnect the negative cable from the car battery. If you're using a DVOM, place it in the lowest "OHMS" range. Page 1983 Powertrain Control Module: Description and Operation PCM Function PCM Function The PCM supplies either 5 or 12 volts to power various sensors or switches. The power is supplied through resistances in the PCM which are so high in value that a test light will not light when connected to the circuit. In some cases, even an ordinary shop voltmeter will not give an accurate reading because its resistance is too low. Therefore, a digital voltmeter with at least 10 megohms input impedance is required to ensure accurate voltage readings. Tool J 39200 meets this requirement. The PCM controls output circuits such as the injectors, fan relays, etc., by controlling the ground or the power feed circuit through transistors or through either of the following two devices: - Output Driver Module (0DM) - Quad Driver Module (QDM) Page 2153 Steps 1 - 3 Steps 4 - 7 Test Description IMPORTANT: Be sure to used the same diagnostic test equipment for all measurements. The Number(s) below refer to the step number(s) on the Diagnostic Chart. 2. Applying 34 kPa (10 Hg) vacuum to the MAP sensor should cause the voltage to be 1.5 - 2.1 volts less than the voltage at step 1. Upon applying vacuum to the sensor, the change in voltage should be instantaneous. A slow voltage change indicates a faulty sensor. Page 5688 Stabilizer Bar: Service and Repair Rear REMOVAL 1. Raise the vehicle and support the frame with suitable safety stands. 2. Remove wheel and tire assembly. 3. Remove bolt and nut. 4. Remove link. CAUTION: Be careful not to damage the ball joint boot. 5. Remove bracket. 6. Remove rubber bushing. INSPECTION AND REPAIR Make necessary correction or parts replacement if wear, damage, corrosion or any other abnormal condition are found through inspection. Check the following parts: Stabilizer bar - Rubber bushing - Link INSTALLATION 1. Install rubber bushing. 2. Install bracket to axle housing and tighten to the specified torque. Torque to 25 Nm (19 ft. lbs.). 3. Install link. Page 1595 spring compressor and J42898 valve spring compressor adapter to install the split collars. 6. Install tappet with shim. 7. Install camshaft assembly. - Refer to installation procedure for Camshaft. Valve Clearance Adjustments Note: To adjust valve clearance, apply engine oil to the cam as well as to the adjusting shim (2) with the cylinder head built on the cylinder block, give a few turns to the camshaft by means of timing pulley tightening bolt, and measure valve clearance when the nose of cam is just opposite to maximum cam lift (1) as shown in illustration. Valve Clearance Standard Value (cold) Intake: 0.23 mm - 0.33 mm (0.0091 inch - 0.01 30 inch) Exhaust: 0.25 mm-0.35 mm (0.0098 in-0.0138 inch) Selection of Adjusting Shim Shim to be selected = (Thickness of removed shim) + (Valve clearance measurement - Standard value) Based on the above formula, the best suited shim should be selected from 41 sorts of shim (differently thick at 0.02 mm (0.0008 inch) intervals from 2.40 mm (0.0945 inch) through 3.2 mm (0.1260 inch) thick). Install the shim and check valve clearance. Replacement of Shim Page 2318 Crankshaft Position Sensor: Testing and Inspection 1. Inspect the sensor O-ring for cracks or leaks. 2. Replace the O-ring if it is worn or damaged. 3. Lubricate the new O-ring with engine oil. 4. Install the lubricated O-ring. Page 1974 Page 5449 CAUTION: Left and right side must be equal within 30'. NOTE: Overall thickness of caster shim and camber shim should be 10.8 mm (0.425 inch) or less. Tighten the fulcrum pin bolt to the specified torque. Torque to 152 Nm (112 ft. lbs.) TOE-IN 1. To adjust the toe-in angle, loosen the lock nuts (2) on the tie rod (1) and turn the tie rod. Turn both rods the same amount, to keep the steering wheel centered . Toe-in: 0 ± 2 mm (0 ± 0.08 inch) 2. Tighten the lock nut to the specified torque. Torque to 98 Nm (72 ft. lbs.) Page 2518 Headlamp Switch: Diagnostic Aids Before Troubleshooting Before Troubleshooting See: Service Precautions/Vehicle Damage Warnings/Tips and Precautions 1. Check applicable fuses in the appropriate fuse/relay box. 2. Check the battery for damage, state of charge, and clean and tight connections. CAUTION: Do not quick-charge a battery unless the battery ground cable has been disconnected, otherwise you will damage the alternator diodes. - Do not attempt to crank the engine with the battery ground cable loosely connected or you will severely damage the wiring. While You're Working 1. Make sure connectors are clean, and have no loose terminals or receptacles. 2. Make sure that connectors without wire seals are packed with dielectric (silicone) grease. Part Number: 08798-9001. 3. When connecting a connector, push it until it "clicks" into place. CAUTION: Do not pull on the wires when disconnecting a connector. Pull only on the connector housings. - Most circuits include solid-state devices. Test the voltages in these circuits only with a 10-megaohm or higher impedance digital multi meter. Never use a test light or analog meter on circuits that contain solid-state devices. Damage to the devices may result. Five-Step Troubleshooting 1. Verify The Complaint Turn on all the components in the problem circuit to check the accuracy of the customer complaint. Note the symptoms. Do not begin disassembly or testing until you have narrowed down the problem area. 2. Analyze The Schematic Look up the schematic for the problem circuit. Determine how the circuit is supposed to work by tracing the current paths from the power source through the circuit components to ground. Also, trace circuits that share wiring with the problem circuit. The names of circuits that share the same fuse, ground, or switch, and so on, are referred to in each circuit schematic. Try to operate any shared circuits you didn't check in step 1. If the shared circuits work, the shared wiring is OK, and the cause must be in the wiring used only by the problem circuit. If several circuits fail at the same time, the fuse or ground is a likely cause. Based on the symptoms and your understanding of the circuit's operation, identify one or more possible causes. 3. Isolate The Problem By Testing The Circuit Make circuit tests to check the diagnosis you made in step 2. Keep in mind that a logical, simple procedure is the key to efficient troubleshooting. Test for the most likely cause of failure first. Try to make tests at points that are easily accessible. 4. Fix The Problem Once the specific problem is identified, make the repair. Be sure to use proper tools and safe procedures. 5. Make Sure The Circuit Works Turn on all components in the repaired circuit in all modes to make sure you've fixed the entire problem. If the problem was a blown fuse, be sure to test all of the circuits on that fuse. Make sure no new problems turn up and the original problem does not recur. Page 756 Wires Wire insulation can be one color, or one color with another color stripe. (The second color is the stripe.) This circuit continues on another image. (The arrow shows direction of current flow.) To follow the RED/BLK wire in this example, you would turn to "Fuel and Emissions" and look for the "A" arrow. Page 3141 20. Using a DVOM, check the voltage between the reference voltage pin for each sensor and ground. ^ If the sensor circuits all read 5.0 volts, go to step 22. ^ If any sensor circuit is above or below 5.0 volts, go to step 21. 21. Troubleshoot for an internal short in another sensor or a PCM malfunction. ^ To find the sensor with an internal short, monitor the reference voltage, and disconnect each sensor (FTPS, EGR, MAP TPS, CKP and CMP) one at a time until the reference voltage reads 5.0 volts. Replace that sensor, and repeat step 14. ^ To find a malfunctioning PCM, replace it with a known-good PCM. If all three sensors (APP Sensor 1, APP Sensor 2, and APP Sensor 3) are within range, the original PCM is faulty; replace it and repeat step 14. 22. Using a jumper wire, connect the reference voltage of each circuit to its signal input, and view the APP Sensor values in the Engine Data List. APP Sensor 1 should have a value of 99%, and APP Sensor 2 and APP Sensor 3 should each have a value of 0%. ^ If the values are not as specified, troubleshoot for high resistance on the signal input or a PCM malfunction. Repair the circuit or replace the PCM, then repeat step 14. ^ If the values are as specified, the problem may be intermittent. Disconnect the 10 P connector from the modified APPS, and connect it to the new APPS; then repeat step 14. Wiggle the APPS wires as you go through the adjustment procedure to find the intermittent problem. 23. Install the accelerator pedal assembly, and torque the bolts to 10 N.m (7 lb-ft). Page 5588 The wire insulation has one color or one color with another color stripe. The second color is the stripe. Page 3072 2. Slide the EVAP canister vent solenoid into mounting bracket. 3. Connect the negative battery cable. Page 1503 3. Remove oil strainer fixing bolts, remove oil strainer assembly with O-ring. 4. Remove three fixing bolts, oil pipe with O-ring. 5. Remove eight fixing bolts, oil gallery. 6. Remove piston with connecting rod assembly, before removing the bearing cap, remove carbon on the top of cylinder bore and push piston with connecting rod out from the top of cylinder bore. Installation 1. Install piston with connecting rod assembly. - Apply engine oil to cylinder bore, connecting rod bearing and crank pin. When installing the piston, its front mark must face the engine front side. - The bearing cap number must be the same as connecting rod number. - Apply engine oil to the thread and seating surface of each nut. - Tighten nuts to the specified torque. Torque: 54 Nm (40 ft. lbs.) - After tightening the nuts, make sure that the crankshaft rotates smoothly. Note: Do not apply engine oil to the bearing back faces and connecting rod bearing fitting surfaces. Page 809 7. Modify the original APPS by cutting the connector housing off of the sensor. 8. Connect the 10P connector to the modified APPS connector housing. 9. Using a DVOM, check the voltage between the reference voltage pin for each sensor and ground. ^ If the sensor circuits all read 5.0 volts, go to step 11. ^ If any sensor circuit is above or below 5.0 volts, go to step 10. 10. Troubleshoot for an internal short in another sensor or a PCM malfunction. ^ To find the sensor with an internal short, monitor the incorrect reference voltage, and disconnect each sensor (FTPS, EGR, MAP, TPS, CKP, and CMP) one at a time until the reference voltage reads 5.0 volts. Replace that sensor, and repeat step 3. ^ To find a malfunctioning PCM, replace it with a known-good PCM. If all three sensors (APP Sensor 1, APP Sensor 2, and APP Sensor 3) are within range, the original PCM is faulty; replace it and repeat step 3. Page 2313 3. Connect the electrical connector to the CMP sensor. 4. Install the common chamber assembly. 5. Install the engine cover. 6. Connect the negative battery cable. Page 5617 Steering Wheel: Testing and Inspection Steering Wheel Free Play Inspection 1. With the tires in the straight-ahead position, check the amount of steering wheel play by turning the wheel in both directions until the tires begin to move. NOTE: The wheel free play should be checked with the engine running. Free play: 0 - 3Omm (0 - 1.18in) 2. Also check the steering wheel for play and looseness in the mount by moving it back and forth and sideways. When test driving, check for hard steering, steering shimmy and tendency to pull to one side. Page 2767 Each schematic represents one circuit. A circuit's wires and components are arranged to show current flow, from power at the top of the page, to ground, at the bottom. Shared Circuits Other circuits may share power or ground terminals or wiring with the circuit shown. A wire that connects one circuit to another, for example, is cut short and has an arrowhead at the end of it pointing in the direction of current flow. Next to the arrowhead is the name of the circuit or component which shares that wiring. To quickly check shared wiring, check the operation of a component it serves. If that component works, you know the shared wiring is OK. Connectors All in-line and junction connectors are numbered (C725, C416, etc.). Component connectors are not numbered but are identified either by the name of Page 2901 Tighten Tighten the bolt to 20 N.m (12 lb ft.). 3. Connect the MAP electrical connector. 4. Connect the negative battery cable. Page 3740 This means the branch of the wire connects to another circuit. The arrow points to the name of the circuit branch where the wire continues. Testing and Inspection Air Filter Element: Testing and Inspection Air Cleaner Element Check the air cleaner filter for damage or dust clogging. Replace if it is damaged, or clean if it is clogged. Page 2914 Oxygen Sensor: Service and Repair HEATED OXYGEN SENSOR (HO2S) REMOVAL PROCEDURE 1. Disconnect the negative battery cable. 2. Locate the four oxygen sensors. - Bank 1 sensor 1 is mounted on the exhaust pipe ahead of the right-hand catalytic converter. - Bank 1 sensor 2 is mounted behind the right-hand catalytic converter. Page 3495 Throttle Position Sensor: Service and Repair REMOVAL PROCEDURE 1. Disconnect the negative battery cable. 2. Disconnect the TPS electrical connector. 3. Remove the bolts and the TP sensor from the throttle body. NOTE: Do not clean the TP sensor by soaking it in solvent. The sensor will be damaged as a result. INSTALLATION PROCEDURE 1. Install the TP sensor on the throttle body with the bolts. 2. Connect the TP electrical connector. 3. Install the negative battery cable. Page 6764 If there is no photo number below or beside a component name or a connector, ground, or terminal number, look up that name or number in the appropriate Connector Identification Chart. The chart lists how many cavities a connector has, where it's located, and what it connects to. The related illustration shows the connector's location on the harness, and the harness routing. NOTE: Photos listed by number are located at Locations / Components / Photograohs. See: Locations/Component Locations/Photographs Circuit Schematics General Precautions Air Bag(s) Arming and Disarming: Service Precautions General Precautions General Precautions Please read the following precautions carefully before performing the airbag system service. Observe the instructions described or the airbags could accidentally deploy and cause damage or injuries. Except when performing electrical inspections, always turn the ignition switch OFF and disconnect the negative cable from the battery, and wait at least three minutes before beginning work. NOTE: The contents in the memory is not erased even if the ignition switch is turned OFF or the battery cables are disconnected from the battery. Use the replacement parts which are manufactured to the same standards as the original parts and quality. Do not install used SRS parts from another vehicle. Use only new parts when making SRS repairs. Carefully inspect any SRS part before you install it. Do not install any part that shows signs of being dropped or improperly handled, such as dents, cracks or deformation. Before removing any of the SRS parts (including the disconnection of the connectors), always disconnect the SRS connector. Use only a digital multimeter to check the system. If it is not a Honda multimeter, make sure its output is 10 mA (0.01 A) or less when switched to the lowest value in the ohmmeter range. A tester with a higher output could cause accidental deployment and possible injury. Do not put objects on the front passenger's airbag. The original radio has a coded theft protection circuit. Be sure to get the customer's radio code before disconnecting the battery cable. SRS Coil Assembly Clockspring Assembly / Spiral Cable: Service and Repair SRS Coil Assembly WARNING: SAFETY PRECAUTIONS MUST BE FOLLOWED WHEN HANDLING A DEPLOYED AIR BAG ASSEMBLY. AFTER DEPLOYMENT, THE AIR BAG ASSEMBLY SURFACE MAY CONTAIN A SMALL AMOUNT OF SODIUM HYDROXIDE, A BY - PRODUCT OF THE DEPLOYMENT REACTION, THAT IS IRRITATING TO THE SKIN AND EYES. MOST OF THE POWDER ON THE AIR BAG ASSEMBLY IS HARMLESS. AS A PRECAUTION, WEAR GLOVES AND SAFETY GLASSES WHEN HANDLING A DEPLOYED AIR BAG ASSEMBLY, AND WASH YOUR HANDS WITH MILD SOAP AND WATER AFTERWARDS. WARNING: WHEN CARRYING A LIVE AIR BAG ASSEMBLY, MAKE SURE THE BAG AND TRIM COVER ARE POINTED AWAY FROM YOU. NEVER CARRY AIR BAG ASSEMBLY BY THE WIRES OR CONNECTOR ON THE UNDERSIDE OF MODULE. IN THE CASE OF AN ACCIDENTAL DEPLOYMENT, THE BAG WILL THEN DEPLOY WITH MINIMAL CHANCE OF INJURY. WHEN PLACING A LIVE AIR BAG ASSEMBLY ON A BENCH OR OTHER SURFACE, ALWAYS FACE BAG AND TRIM COVER UP AWAY FROM THE SURFACE. NEVER REST A STEERING COLUMN ASSEMBLY ON THE STEERING WHEEL WITH THE AIR BAG ASSEMBLY FACE DOWN AND COLUMN VERTICAL. THIS IS NECESSARY SO THAT A FREE SPACE IS PROVIDED TO ALLOW THE AIR BAG ASSEMBLY TO EXPAND IN THE UNLIKELY EVENT OF ACCIDENTAL DEPLOYMENT. OTHERWISE, PERSONAL INJURY COULD RESULT. NOTE: In the event deployment has occurred, inspect coil assembly wire for any signs of scorching, melting or any other damage due to excessive heat. If the coil has been damaged, replace it. Removal 1. Disable the SRS. (Refer to "Disabling the SRS".) See: Air Bag(s) Arming and Disarming Testing and Inspection Mechanical Diagnosis Page 8087 2. Connect the short finder across the battery terminals and the load (component) side of the fuse terminal. 3. Close all switches in the circuit you're testing. 4. Turn on the short finder. This creates a pulsing magnetic field around the wiring between the fuse box and the short. 5. Beginning at the fuse box, slowly move the short finder along the circuit wiring. The meter will read current pulses through sheet metal and body trim. As long as the meter is between the fuse and the short, the needle will move with each current pulse. Once you move the meter past the point of the short, the needle will stop moving. Check the wiring and connectors in this area to locate the cause of the short. Testing For Continuity When testing for continuity at a connector without wire seals, you do not have to separate the two halves of the connector. Instead, probe the connector from the back. Always check both sides of the connector because dirty, corroded, and bent terminals can cause problems (no electrical contact = an open). 1. Disconnect the negative cable from the car battery. If you're using a DVOM, place it in the lowest "OHMS" range. Page 2372 may be due to improper gap adjustment or to excessive wear of the electrode during use. A check of the gap size and comparison to the gap specified for the vehicle in Maintenance and Lubrication will tell if the gap is too wide. A spark plug gap that is too small may cause an unstable idle condition. Excessive gap wear can be an indication of continuous operation at high speeds or with engine loads, causing the spark to run too hot. Another possible cause is an excessively lean fuel mixture. Low or high spark plug installation torque or improper seating can result in the spark plug running too hot and can cause excessive center electrode wear. The plug and the cylinder head seats must be in good contact for proper heat transfer and spark plug cooling. Dirty or damaged threads in the head or on the spark plug can keep it from seating even though the proper torque is applied. Once spark plugs are properly seated, tighten them to the torque shown in the Specifications Table. Low torque may result in poor contact of the seats due to a loose spark plug. Overtightening may cause the spark plug shell to be stretched and will result in poor contact between the seats. In extreme cases, exhaust blow-by and damage beyond simple gap wear may occur. Cracked or broken insulators may be the result of improper installation, damage during spark plug re-gapping, or heat shock to the insulator material. Upper insulators can be broken when a poorly fitting tool is used during installation or removal, when the spark plug is hit from the outside, or is dropped on a hard surface. Cracks in the upper insulator may be inside the shell and not visible. Also, the breakage may not cause problems until oil or moisture penetrates the crack later. A broken or cracked lower insulator tip (around the center electrode) may result from damage during re-gapping or from "heat shock" (spark plug suddenly operating too hot). - Damage during re-gapping can happen if the gapping tool is pushed against the center electrode or the insulator around it, causing the insulator to crack. When re-gapping a spark plug, make the adjustment by bending only the ground side terminal, keeping the tool clear of other parts. - "Heat shock" breakage in the lower insulator tip generally occurs during several engine operating conditions (high speeds or heavy loading) and may be caused by over-advanced timing or low grade fuels. Heat shock refers to a rapid increase in the tip temperature that causes the insulator material to crack. Spark plugs with less than the recommended amount of service can sometimes be cleaned and re-gapped then returned to service. However, if there is any doubt about the serviceability of a spark plug, replace it. Spark plugs with cracked or broken insulators should always be replaced. Page 6094 Condenser Fan: Service and Repair Removal 1. Disconnect the battery ground cable. 2. Discharge and recover refrigerant. 3. Remove radiator grille. 4. Remove condenser fan assembly. - Disconnect the fan motor connector and remove the 4 fixing bolts. 5. Remove shroud. - Remove the 3 fixing nuts. - Loosen the condenser fixing nut and disconnect the fan motor connector from bracket. 6. Remove fan. - Remove the fan fixing C-ring and plate. 7. Remove condenser fan motor. Installation To install, follow the removal steps in the reverse order, noting the following point. 1. Route the fan motor harness in its previous position, and fix it securely with clip and bracket. Page 8171 Rear Quarter Glass (Resin Top) Page 7433 the component if the component only has one connector, or by a capital letter (A, B, C, etc.) if the component has more than one connector. Below most connector numbers and component names are PHOTO and VIEW numbers. The PHOTO number refers to a photo in the back of the book that shows the connector's location on the car. The VIEW number refers to an illustration in the back of the book that shows the connector face, wire colors, connector cavity numbers, and other details. The connector cavity numbering sequence begins at the top left corner of the connector. Disregard any numbers molded into the connector housing. Wires Wires are identified by the abbreviated names of their colors; the second color is the color of the stripe. Wires are also identified by their location in a connector. The number "2" next to the male and female wire terminals at C416, for example, means those terminals join in cavity 2 of connector C416. Symbols A complete description of schematic symbols is given under wire color abbreviation. Power Distribution Schematics Power Distribution schematics show how power is supplied from the positive battery terminal to various circuits in the car. Refer to the Power Distribution section to get a more detailed picture of how power is supplied to the circuit you're working on. From Battery to Ignition Switch, Fuses, and Relays Individual circuit schematics begin with a fuse. The first half of Power Distribution, however, shows the wiring "upstream" between the battery Locations Crankshaft Position Sensor: Locations CKP Sensor 36. Bottom Right Side of Engine Bottom Right Side of Engine Locations Oil Pressure Switch (For Fuel Pump): Locations Bottom Center Front of Engine Page 5535 10. Use the PGM Tester to check the broadcast code. Make sure the broadcast code matches the one you selected from the CD-ROM. WARRANTY CLAIM INFORMATION In warranty: The normal warranty applies. Failed Part: P/N 8-17087-655-0 H/C 4375820 Defect Code: 064 Contention Code: C01 Skill Level: Repair Technician Out of warranty: Any repair performed after warranty expiration may be eligible for goodwill consideration by the District Service Manager or your Zone Office. You must request consideration, and get a decision, before starting work. REPAIR PROCEDURE - ENGINE/BODY GROUND 1. Use the ETM for the appropriate year to locate these ground connectors: G101, G104, G105, G106 and G160. 2. Inspect each connector for corrosion or looseness. 3. Remove the bolt from any connector that is corroded or loose. Clean the terminal connector with a wire brush. File flat any solder bumps on the connector. 4. Clean the contact surface on the engine or body with a wire brush. 5. Replace the bolt if it is heavily corroded. Otherwise, clean it with a wire brush. 6. Apply lithium dielectric grease to both sides of the terminal connector. 7. Reinstall the bolt, torque it to 14 N.m (10 lb-ft). 8. Use the Smart Cable to reprogram the PCM with the latest software from the June 2001 or later HONDANET CD-ROM. Refer to Service Bulletin 99-005, Updating the Passport PCM, filed under Tools. 9. Use the PGM Tester to clear any DTCs. 10. Use the PGM Tester to check the broadcast code. Make sure the broadcast code matches the one you selected from the CD-ROM. WARRANTY CLAIM INFORMATION In warranty: The normal warranty applies. Failed Part: P/N 8-97086-823-0 A/T - Vehicle Speed Sensor Installation Precautions Vehicle Speed Sensor: Technical Service Bulletins A/T - Vehicle Speed Sensor Installation Precautions Install VSS Properly to Avoid Reman A/T Damage We can't emphasize enough how important it is to follow, to the letter, the installation instructions that come with a reman A/T. These instructions help ensure that you avoid damaging the A/T and score a successful repair. This is particularly true when it comes to installing the vehicle speed sensor (VSS). Step 6 of the instructions tells you to make sure its gear is fully engaged and the VSS is fully seated before you tighten the retaining bolt. If you don't install the VSS properly, the speed sensor gear will get stripped and the A/T will be seriously damaged. So don't take risks with your customer's vehicle. Always follow these instructions to the letter. You can rest assured you're doing the job right. Page 4477 and the fuses. From Fuses to Relays and Components The second half of Power Distribution shows the wiring "From Fuses to Relays and Components." This can speed your troubleshooting by showing which circuits share fuses. If Power Distribution shows that an inoperative circuit and another circuit share a fuse, check a component in the other circuit. If it works, you know the fuse is good and power is available to the inoperative circuit. Ground Distribution Schematics Page 3396 If there is no photo number below or beside a component name or a connector, ground, or terminal number, look up that name or number in the appropriate Connector Identification Chart. The chart lists how many cavities a connector has, where it's located, and what it connects to. The related illustration shows the connector's location on the harness, and the harness routing. NOTE: Photos listed by number are located at Locations / Components / Photograohs. See: Locations/Component Locations/Photographs Circuit Schematics PCM Service Precautions Powertrain Control Module: Service Precautions PCM Service Precautions PCM Service Precautions The PCM is designed to withstand normal current draws associated with vehicle operation. Avoid overloading any circuit. When testing for opens and shorts, do not ground or apply voltage to any of the PCM's circuits unless instructed to do so. These circuits should only be tested using digital voltmeter J 39200. The PCM should remain connected to the PCM or to a recommended breakout box. Component Locations 54. Below Center of Dash (Console Removed) Page 6961 Consoles Service Precautions Jump Starting: Service Precautions Jump Starting Jump Starting with an Auxiliary (Booster) Battery CAUTION: Never push or tow the vehicle in an attempt to start it. Serious damage to the emission system as well as other vehicle parts will result. Treat both the discharged battery and the booster battery with great care when using jumper cables. Carefully follow the jump starting procedure, being careful at all times to avoid sparking. WARNING: FAILURE TO CAREFULLY FOLLOW THE JUMP STARTING PROCEDURE COULD RESULT IN THE FOLLOWING: 1. Serous personal injury, particularly to your eyes. 2. Property damage from a battery explosion, battery acid, or an electrical fire. 3. Damage to the electronic components of one or both vehicles particularly. Never expose the battery to an open flame or electrical spark. Gas generated by the battery may catch fire or explode. Remove any rings, watches, or other jewelry before working around the battery. Protect your eyes by wearing an approved set of goggles. Never allow battery fluid to come in contact with your eyes or skin. Never allow battery fluid to come in contact with fabrics or painted surfaces. Battery fluid is a highly corrosive acid. Should battery fluid come in contact with your eyes, skin, fabric, or a painted surface, immediately and thoroughly rinse the affected area with clean tap water. Never allow metal tools or jumper cables to come in contact with the positive battery terminal, or any other metal surface of the vehicle. This will protect against a short circuit. Always keep batteries out of reach of young children. Starting System - Unable To Key In Ignition Switch Ignition Switch Lock Cylinder: Technical Service Bulletins Starting System - Unable To Key In Ignition Switch Can't Turn Ignition Switch? Check for Locked Steering Got a service customer complaining he or she can't turn the ignition switch to start the engine? The reason could just be the steering column lock pin is engaged with the front wheels turned. Here's what typically happens: Some folks use the steering wheel to help support themselves while climbing in or out of the vehicle. This is very common among elderly or disabled drivers. Doing this turns the front wheels, which twists the tires against the ground. The twisted tires apply torque to the steering column. With the ignition switch in LOCK (0), the steering column lock pin is engaged. But the applied torque on the steering column binds the lock pin, making it tough to turn the ignition switch. The ignition switch won't turn to ON (II) if the lock pin isn't disengaged from the steering column. Tell your customer there's nothing wrong with the ignition switch itself. All he or she needs to do is turn the steering wheel from side to side while turning the switch. This usually releases the lock pin so the engine can be started. In some cases, though, your customer may need to give a good tug on the wheel. This could easily happen when parking on a hill and the wheels are turned sharply before the engine is shut off. Page 1116 11. Remove the timing belt covers in this order: right, left, then lower. 12. Loosen (don't remove) the tensioner pulley bolt. 13. Remove the idler pulley bolt, and let the idler pulley pivot towards the crankshaft timing pulley. 14. Remove the lower tensioner bolt and the tensioner pusher. 15. Carefully remove the timing belt from the pulleys. ENGINE TIMING 1. Turn the crankshaft timing pulley until its notch aligns with the mark on the oil pump housing. NOTE: The crankshaft timing pulley may have a green mark 150 degrees from its keyway. Do not use this mark to set the crankshaft position. 2. Turn the right cylinder bank's camshaft pulley clockwise with a socket and ratchet. (The pulley clicks and stops several times.) Stop the pulley when its green mark aligns with the valve cover timing mark. NOTE: You may need to rotate the camshaft pulley up to four complete turns before its green mark aligns directly with the valve cover timing mark. 3. Turn the left cylinder bank's camshaft pulley clockwise with a socket and ratchet. (The pulley clicks and stops several times.) Stop the pulley when its green mark aligns with the timing belt cover bolt hole. Page 7140 Roll Bar: Service and Repair Removal 1. Disconnect the battery ground cable. 2. Remove the soft top assembly or resin top Assembly. 3. Remove the luggage side lid (2). 4. Remove the luggage side upper cover (3). 5. Remove the luggage side front cover (4). 6. Remove the canopy cover (1) (Resin top model). 7. Remove the left and right quarter side moldings (Soft top model). - Remove the six bolts and six screws. 8. Remove the weather strip. 9. Remove the rear end floor trim cover. - Remove the five fixing screws. Page 785 14. While watching the APP Sensor values in the Engine Data List, adjust the APPS by turning it until the values are within the ranges shown at closed throttle and wide open throttle (accelerator pedal pushed all the way down), then tighten the mounting screws and recheck the values. ^ If all three sensors are within range, go to step 23. ^ If APP Sensor 1 APP Sensor 2, and/or APP Sensor 3 cannot be brought into range, go to step 15. 15. Troubleshoot for an open circuit or a PCM malfunction. ^ If APP Sensor 1 has a value of 0% or APP Sensor 2 and/or APP Sensor 3 have a value of 99%, an open circuit exists or the PCM is malfunctioning. Repair the circuit or replace the PCM, and repeat step 14. ^ If you don't find a problem, go to step 16. 16. Disconnect the 10 P connector from the APPS. 17. View the APP Sensor values in the Engine Data List. ^ If APP Sensor 1 has a value of 0% or APP Sensor 2 and/or APP Sensor 3 have a value of 99%, go to step 18. ^ If APP Sensor 1 has a value other than 0%, or APP Sensor 2 and/or APP Sensor 3 have a value other than 99%, a short circuit exists or the PCM is malfunctioning. Repair the circuit or replace the PCM, and repeat step 14. 18. Modify the original APPS by cutting the connector housing off of the sensor. 19. Connect the 10 P connector to the modified APPS connector housing. Page 6622 1. Print out the appropriate system worksheet from an Interactive Network (iN) workstation. ^ From the iN main menu, click on SERVICE. ^ Click on (ISIS) Service Publications. ^ Click on SEARCH BY PUBLICATION. ^ Click on Job Aids. ^ Click on Audio System Worksheet, Navigation System Worksheet, or Rear Entertainment System Worksheet. 2. Duplicate and confirm the problem using the customer information written on the repair order or have the customer demonstrate the problem, then write down the results on the worksheet. Using the SYMPTOM TROUBLESHOOTING INDEX or the DTC INDEX (if applicable) in the applicable service manual, find the symptom that matches the customers complaint, and follow the diagnostic procedure: ^ Refer to the appropriate section in the service manual, or ^ From the iN main menu: - Click on SERVICE. - Click on ISIS (Service Publications). - Click on SEARCH BY VEHICLE. - Enter the model and the model year. - Enter a keyword: AUDIO, NAVIGATION, or RES, and the DTC (if applicable) - Select the appropriate Service Bulletin, ServiceNews article, or Symptom Troubleshooting from the list. 3. Repair the vehicle according to your diagnosis, then confirm the repair by trying to duplicate the customer's original complaint, or check to see if the DTC returns: ^ If the problem is gone, return the vehicle to the customer. ^ If the problem is still there, go to step 4. 4. Replace the audio/navigation/RES unit with a remanufactured unit: Capacity Specifications Engine Oil: Capacity Specifications Engine Oil For oil change, including filter .............................................................................................................. ....................................................................... 5.0 Qt For oil change, without filter ................................................................................................................. ....................................................................... 4.2 Qt NOTE: Listed capacities are approximate. Check fluid level after filling. Removal and Installation Steering Gear: Service and Repair Removal and Installation REMOVAL 1. Remove the stone guard. 2. Remove the transfer gear assembly. Make a setting mark across the coupling flange and steering unit to ensure reassembly of the parts in the original position. 3. Drain power steering fluid. 4. Remove the tie rod end assembly from knuckle. Use tie rod end remover J-29107. Page 566 2. Connect the short finder across the battery terminals and the load (component) side of the fuse terminal. 3. Close all switches in the circuit you're testing. 4. Turn on the short finder. This creates a pulsing magnetic field around the wiring between the fuse box and the short. 5. Beginning at the fuse box, slowly move the short finder along the circuit wiring. The meter will read current pulses through sheet metal and body trim. As long as the meter is between the fuse and the short, the needle will move with each current pulse. Once you move the meter past the point of the short, the needle will stop moving. Check the wiring and connectors in this area to locate the cause of the short. Testing For Continuity When testing for continuity at a connector without wire seals, you do not have to separate the two halves of the connector. Instead, probe the connector from the back. Always check both sides of the connector because dirty, corroded, and bent terminals can cause problems (no electrical contact = an open). 1. Disconnect the negative cable from the car battery. If you're using a DVOM, place it in the lowest "OHMS" range. Page 2239 Page 2768 the component if the component only has one connector, or by a capital letter (A, B, C, etc.) if the component has more than one connector. Below most connector numbers and component names are PHOTO and VIEW numbers. The PHOTO number refers to a photo in the back of the book that shows the connector's location on the car. The VIEW number refers to an illustration in the back of the book that shows the connector face, wire colors, connector cavity numbers, and other details. The connector cavity numbering sequence begins at the top left corner of the connector. Disregard any numbers molded into the connector housing. Wires Wires are identified by the abbreviated names of their colors; the second color is the color of the stripe. Wires are also identified by their location in a connector. The number "2" next to the male and female wire terminals at C416, for example, means those terminals join in cavity 2 of connector C416. Symbols A complete description of schematic symbols is given under wire color abbreviation. Power Distribution Schematics Power Distribution schematics show how power is supplied from the positive battery terminal to various circuits in the car. Refer to the Power Distribution section to get a more detailed picture of how power is supplied to the circuit you're working on. From Battery to Ignition Switch, Fuses, and Relays Individual circuit schematics begin with a fuse. The first half of Power Distribution, however, shows the wiring "upstream" between the battery Page 1001 The steering wheel offset gauge is a sticker that attaches to the steering wheel and the steering column cover. Place the sticker on the steering wheel when the steering wheel is straight. When you test-drive the vehicle, you can read how many millimeters the steering wheel is off-center. NOTE: If the vehicle is pulling, repairing the pull may correct the steering wheel offset. Page 3867 5. Install magnet, main case oil pan with new gasket, and sixteen 10 mm screws. Tighten the screws to the specified torque. Torque: 11 Nm (96 Inch lbs.) 6. Fill transmission through the overfill screw hole of oil pan, using ATF DEXRON-III. 7. Connect battery ground cable. Page 7881 Ground - "G" Shielding Sheilding This represents RFI (Radio Frequency Interference) shielding around a wire. The shielding is always connected to ground. Splices Page 3748 Service and Repair Backup Light Bulb: Service and Repair Removal 1. Disconnect the battery ground cable. 2. Remove the rear combination light assembly. - Refer to the Taillight Bulb removal step 2. 3. Remove the bulb (1). - Remove the backup light socket by turning it counterclockwise. - Remove the bulb by turning it counterclockwise while pushing it at the same time. Installation To install, follow the removal steps in the reverse order. Page 6625 NOTE: Once you submit your order, you can track it using the Warranty Audio VIN Inquiry screen on the iN. For details, go to WARRANTY AUDIO ORDER PROGRAM FREQUENTLY ASKED QUESTIONS in this service bulletin. 7. You will receive a remanufactured audio/navigation/RES unit packed in a reusable shipping box. Save this box and the packing materials. You must return the failed audio/navigation/RES unit core in this box. Otherwise your dealership risks being billed a core loss charge, ranging from $800 to $2,500, depending on the unit. 8. Remove the failed audio/navigation/RES unit: ^ Refer to the appropriate component section of the service manual or, ^ Online, enter a keyword: AUDIO, NAVIGATION, or RES. Select the appropriate removal procedure from the list. 9. Install the remanufactured audio/navigation/RES unit: ^ Refer to the appropriate component section of the service manual or ^ Online, enter a keyword: AUDIO, NAVIGATION, or RES. Select the appropriate installation procedure from the list. 10. If the remanufactured unit has a shipping cover and shipping screws, make sure you transfer them to the faulty unit being returned. Also be sure to transfer all of the mounting brackets to the replacement unit. Failure to do this may result in dash squeaks and rattles. NOTE: If the customer's media (CD, CD magazine, DVD, DVD-A, cassette tape, etc.) is stuck in the unit, leave it there for these reasons: ^ The manufacturer needs it for diagnosis and testing. ^ Any failed audio/navigation/RES unit core that is returned disassembled is considered an unusable core. Customer media (CDs, CD magazines, DVDs, DVD-As, cassette tapes, etc.) will be properly removed by the supplier at the point of tear down and inspection of the failed unit, and mailed to your dealer. Make sure the failed audio/navigation/RES unit core is not disassembled! If the core is disassembled, your dealership will be debited a core loss charge ranging from $800 to $2,500, depending on the unit. 11. Put the failed audio/navigation/RES unit core in the same box that the remanufactured unit came in. NOTE: If you do not return the failed audio/navigation/RES unit core in this same box, your warranty claim will be debited and the core will be sent back to your dealership. Parts Manager: 12. The Warranty Audio/Navigation/RES Unit Order form you submitted is kept on the iN for 60 days. Print out a copy to put in the box with your core return: ^ From the iN main menu, click on SERVICE. ^ Click on Transactions. ^ Click on Advanced Search, and enter a date range. ^ Click on Filtered by Service. ^ Under Transaction Description, click on Warranty Audio Order, then go back to the top of the page and click on Search. ^ Scroll down to the appropriate VIN, then select it to view the form. ^ Review the form, then print out a copy by clicking on the printer icon. 13. Print out a copy of the Core Return Update Acknowledgement to put in the box with your core return: ^ From the iN main menu, click on PARTS. Page 5190 Starter Motor: Service and Repair Removal And Installation Removal 1. Battery ground cable. 2. Disconnect Heated O2 Sensor connector (1). 3. Remove exhaust front left pipe(2). 4. Remove heat protector(3). 5. Disconnect starter wiring connector from terminals "B" and "S"(4). 6. Remove starter assembly mounting bolts on inside and outside(5). 7. Remove starter assembly toward the bottom of engine(6). Installation 1. Install starter assembly(6). 2. Install mounting bolts and tighten bolts to specified torque(5). Torque: 40 Nm (30 lb.ft) 3. Reconnect the connectors to terminals "B" and "S" and tighten Terminals "B" to specified torque. Torque: 9 Nm (80 lb in) Alignment Page 7755 The name of the component appears next to it followed by notes about its function along with any photo and connector view references. Connector "C" How to Identify Connector Terminals Cavity Numbering System The cavities (and wire terminals) in each connector are numbered starting from the upper left, looking at the male terminals from the terminal side (or looking at the female terminals from the wire side. Both views are in the same direction so the numbers are the same.) All actual cavities are numbered, even if they have no wire terminals in them. NOTE: Data Link Connector (DLC) terminals are numbered according to SAE standard J1962, not the Honda standard. The numbers of the four end terminals are molded into the corners of the connector face. Page 3240 Fuel Line Coupler: Vehicle Damage Warnings FUEL TUBE/QUICK - CONNECTOR FITTINGS Cautions During Work Do not expose the assembly to battery electrolyte or do not wipe the assembly with a cloth used to wipe off spilt battery electrolyte. The piping wet with battery electrolyte cannot be used. Be careful not to give a bending or twisting force to the piping during the work. If deformed, replace with a new piping. Locations Locations Fuel Pump Relay: Locations Fuse/Relay Box (Cover Removed) Page 2283 7. Modify the original APPS by cutting the connector housing off of the sensor. 8. Connect the 10P connector to the modified APPS connector housing. 9. Using a DVOM, check the voltage between the reference voltage pin for each sensor and ground. ^ If the sensor circuits all read 5.0 volts, go to step 11. ^ If any sensor circuit is above or below 5.0 volts, go to step 10. 10. Troubleshoot for an internal short in another sensor or a PCM malfunction. ^ To find the sensor with an internal short, monitor the incorrect reference voltage, and disconnect each sensor (FTPS, EGR, MAP, TPS, CKP, and CMP) one at a time until the reference voltage reads 5.0 volts. Replace that sensor, and repeat step 3. ^ To find a malfunctioning PCM, replace it with a known-good PCM. If all three sensors (APP Sensor 1, APP Sensor 2, and APP Sensor 3) are within range, the original PCM is faulty; replace it and repeat step 3. Page 6993 1. Remove the rear console assembly. 2. Remove the ashtray/rear beverage holder assembly from the rear console. 3. Open the beverage holder lid, and move the beverage holder swing arm to a position halfway between open and closed. Page 460 Splices Splices are shown as a dot. Their location and the number of wires may vary depending on the harness manufacturer. Switches Switches These switches move together; the broken straight line between them means they are mechanically connected. Other types of switches are controlled by a coil or a solid state circuit. Unless otherwise noted, all switches are shown in their normal (rest) position, with power off. Terminal "T" Page 133 Powertrain Control Module: Connector Views Page 1697 H/C 4408092 Defect Code: 017 Contention Code: C99 Skill Level: Repair Technician Out of warranty: Any repair performed after warranty expiration may be eligible for goodwill consideration by the District Service Manager or your Zone Office. You must request consideration, and get a decision, before starting work. DISCLAIMER Page 7757 Ground - "G" Shielding Sheilding This represents RFI (Radio Frequency Interference) shielding around a wire. The shielding is always connected to ground. Splices Page 5937 Page 7891 2. Connect the short finder across the battery terminals and the load (component) side of the fuse terminal. 3. Close all switches in the circuit you're testing. 4. Turn on the short finder. This creates a pulsing magnetic field around the wiring between the fuse box and the short. 5. Beginning at the fuse box, slowly move the short finder along the circuit wiring. The meter will read current pulses through sheet metal and body trim. As long as the meter is between the fuse and the short, the needle will move with each current pulse. Once you move the meter past the point of the short, the needle will stop moving. Check the wiring and connectors in this area to locate the cause of the short. Testing For Continuity When testing for continuity at a connector without wire seals, you do not have to separate the two halves of the connector. Instead, probe the connector from the back. Always check both sides of the connector because dirty, corroded, and bent terminals can cause problems (no electrical contact = an open). 1. Disconnect the negative cable from the car battery. If you're using a DVOM, place it in the lowest "OHMS" range. Page 1965 This means the branch of the wire connects to another circuit. The arrow points to the name of the circuit branch where the wire continues. Page 6131 6. Pull the control lever assembly out and disconnect the fan switch and air conditioning switch connectors. 7. Remove control level assembly. 8. Disconnect control cables at each unit side. Installation To install, follow the removal steps in the reverse order, noting the following points: Page 4210 it is located, and what it connects to. Use the Connector Views to help locate the proper cavity when you need to probe a connector. It can be especially helpful if the connector has more than one wire of the same color. A dash symbol (-) indicates that the cavity is empty. Connector views can also be used to help diagnose multiple symptoms in separate circuits which could be caused by a single problem in a connector shared by those circuits. Here's an example: 1. Pick one of the multiple symptoms and look up the schematic for that circuit. 2. Make a list of all the in-line and fuse box connectors in that schematic , 3. Then, in the Connector Views, look up each connector on your list to see if circuits related to the other symptoms run through one of them. If they do, inspect that connector for the problem. Example: The blower, rear window defogger, and the windshield wiper don't work. List all in-line and fuse box connectors in the blower controls circuit and then check the Connector View (see the sample). You find that C324 is common to the blower controls, rear window defogger, and wiper/washer, so you inspect C324 and find the problem, bent terminals. Finding Component/Connector Locations Finding Component/Connector Locations To see where a component or connector is located on the car, look up its photo number in the "Component Location". The photo will also tell you the color of the connector, and how many cavities it has. Diagrams Exhaust Pipe: Diagrams Page 1577 Limit: 39.47 mm (1.5539 inch) Exhaust Standard: 39.3 mm (1.5472 inch) Limit: 39.45 mm (1.5531 inch) 2. Measure the valve seat contact width. Make the necessary corrections if the seat contact surface is damaged or rough or if the contact width wear exceeds the limit. Valve seat contact width Standard: 1.1 mm (0.0433 inch) Limit: 1.7 mm (0.0669 inch) Contact Surface Angle on Valve Seat on Valve 1. Measure contact surface angle on valve seat. 2. If the measured value exceeds the limit, replace valve, valve guide and valve seat as a set. Valve contact surface angle: 45° Valve Seat Insert Correction 1. Remove the carbon from the valve seat insert surface. Page 6085 The wire insulation has one color or one color with another color stripe. The second color is the stripe. Page 3417 5. Select F0 : Fuel Pump Relay. 6. Push "On" soft key. 7. Control Fuel Pump Relay and check data list. - If the data list changes, the Fuel Pump Relay is normal. 8. Select F1 : A/C Clutch Relay. 9. Run the Engine at idle. 10. Turn on Air Conditioning. 11. Turn "On" and "Off" A/C Switch. 12. Control A/C Clutch Relay and check data list. Page 4868 Testing For A Short With A Self-Powered Test Light or DVOM 1. Remove the blown fuse and disconnect the battery and load. 2. Connect one lead of a self-powered test light or digital volt/ohmmeter (DVOM) (switched to the lowest "OHMS" range) to the fuse terminal on the load side. 3. Connect the other lead to a known good ground. 4. Beginning near the fuse box, wiggle the harness. Continue this at convenient points about six inches apart while watching the test light or DVOM. 5. If the self-powered test light goes on or the DVOM displays a low reading or no reading (zero), there is a short to ground in the wiring near that point. Testing for a Short with a Test Light or DVOM 1. Remove the blown fuse and disconnect the load. 2. Connect a test light or digital volt/ohmmeter (DVOM), switched to the appropriate DC volts range, across the fuse terminals to make sure voltage is present. You might have to turn the ignition switch to ON; check the schematic to see. 3. Beginning near the fuse box, wiggle the harness. Continue this at convenient points about six inches apart while watching the test light or DVOM. 4. Where the test light goes , or the DVOM voltage drops to zero, there is a short to ground in the wiring near that point. NOTE: Always use a DVOM on high impedance circuits. A test light may not glow (even with battery voltage present). Testing For A Short With A Short Circuit Locator (Short Finder) 1. Remove the blown fuse. Leave the battery connected. Page 7422 Page 387 Part 1 of 2 Page 8213 - Pull the glass run (6) out from the door frame groove. Installation To install, follow the removal steps in the reverse order, noting the following points: 1. Install the regulator handle as shown in the illustration, if equipped without power windows. 2. Check to see that the window regulator operates smoothly and the glass opens and closes properly. Install the waterproof sheet with to clearance between the door panel and the water proof sheet. Page 4943 Check the fluid level and replenish as necessary. If replenished, leave the system for at least one minute. 8. Depress the brake pedal slowly once and hold it depressed. 9. Completely seal the delivery port of the master cylinder with your finger, where the pipe was disconnected then release the brake pedal slowly. 10. Release your finger from the delivery port when the brake pedal returns completely. 11. Repeat steps 8 through 10 until the brake fluid comes out of the delivery port during step 8. NOTE: Do not allow the fluid level in the reservoir to go below the half-way mark. 12. Reconnect the brake pipe (1) to the master cylinder and tighten the pipe. 13. Depress the brake pedal slowly once and hold it depressed. 14. Loosen the rear wheel brake pipe (1) at the master cylinder. 15. Retighten the brake pipe, then release the brake pedal slowly. 16. Repeat steps 13 through 15 until no air comes out of the port when the brake pipe is loosened NOTE: Be very careful not to allow the brake fluid to come in contact with painted surfaces. 17. Bleed the air from the front wheel brake pipe connection (2) by repeating steps 7 through 16. BLEEDING THE CALIPER 18. Bleed the air from each wheel in the order listed: - Right rear caliper or wheel cylinder - Left rear caliper or wheel cylinder - Right front caliper - Left front caliper Conduct air bleeding from the wheels in the above order. If no brake fluid comes out, it suggests that air is mixed in the master cylinder. In this case, bleed air from the master cylinder. In this case, bleed air from the master cylinder in accordance with steps 7 through 17, and then bleed air from the caliper or wheel cylinder. 19. Place the proper size box end wrench over the bleeder screw. 20. Cover the bleeder screw with a transparent tube, and submerge the free end of the transparent tube in a transparent container containing brake fluid . 21. Pump the brake pedal slowly three (3) times (once/second), then hold it depressed. 22. Loosen the bleeder screw until fluid flows through the tube. 23. Retighten the bleeder screw. 24. Release the brake pedal slowly. 25. Repeat steps 21 through 24 until the air is completely removed. It may be necessary to repeat the bleeding procedure 10 or more times for front wheels and 15 or more times for rear wheels. 26. Go to the next wheel in the sequence after each wheel is bled. Be sure to monitor reservoir fluid level. 27. Depress the brake pedal to check if you feel "sponginess" after the air has been removed from all wheel cylinders and calipers. If the pedal feels "spongy", the entire bleeding procedure must be repeated. 28. After the bleeding operation is completed on the each individual wheel, check the level of the brake fluid in the reservoir and replenish up to the "MAX" level as necessary. 29. Attach the reservoir cap. If the diaphragm inside the cap is deformed, reform it and install. 30. Stop the engine. Page 1977 Powertrain Control Module: Service Precautions Electrostatic Discharge Damage Electrostatic Discharge Damage Electronic components used in the PCM are often designed to carry very low voltage. Electronic components are susceptible to damage caused by electrostatic discharge. Less than 100 volts of static electricity can cause damage to some electronic components. By comparison, it takes as much as 4000 volts for a person to feel even the zap of a static discharge. There are several ways for a person to become statically charged. The most common methods of charging are by friction and induction. - An example of charging by friction is a person sliding across a vehicle seat. - Charge by induction occurs when a person with well insulated shoes stands near a highly charged object and momentary touches ground. Charges of the same polarity are drained off leaving the person highly charged with the opposite polarity. Static charges can cause damage, therefore it is important to use care when handling and testing electronic components. NOTE: To prevent possible electrostatic discharge damage, follow these guidelines: - Do not touch the PCM connector pins or soldered components on the PCM circuit board. - Do not open the replacement part package until the part is ready to be installed. - Before removing the pan: from the package, ground the package to a known good ground on the vehicle. - If the part has been handled while sliding across the seat, while sitting down from a standing position, or while walking a distance, touch a known good ground before installing the part. Locations Shift Interlock Relay: Locations Under Center Console Page 2604 2. Compare the retrieved code with the listed codes. ^ If the code is in the list, go to step 3. ^ If the code is not in the list, the PCM has already been updated. Troubleshoot other causes for the detonation. NOTE: Since the Smart Cable may need to be cleared from a previous PCM update or the Smart Cable firmware may need to be reprogrammed, always begin each PCM update at the iN workstation. 3. Update the PCM software with the Smart Cable. For instructions, refer to Service Bulletin 99-005. NOTE: Make sure you select the most recent broadcast code from the list on the iN screen that applies to the model year, transmission type, and emission level. This code is not necessarily at the top of the list since the most recent code is the last one in the alphabetical sequence, letter by letter. 4. Use the PGM Tester to clear any DTCs set during programming. 5. Retrieve the broadcast code. Make sure it does not match any of the codes in the list in step 2 (indicating the PCM has been updated) and that it applies to the model year, transmission type, and emission level for the vehicle. The broadcast code should match a code in the list below. Disclaimer Page 5105 The Honda Computer Memory Saver is indeed a real time saver, but here's a word of caution: Don't let the positive battery cable touch any body ground. It will cause a short that will either blow the fuse in the tool or cause a drop in system voltage resulting in the loss of any data that 5 in volatile memory. The Honda Computer Memory Saver is available through the Honda Tool and Equipment Program. To order one, just call and ask for FZRMS4000H. Page 3168 Accelerator Pedal Position Sensor: Service and Repair Accelerator Position Sensor Replacement CAUTION: Remove the Accelerator (A) pedal assembly as a unit to have it services. Do not remove the Accelerator Position (AP) sensor on the A pedal. If the AP sensor is removed for emergency cause, refer to following Items as necessary. Removal Procedure 1. Disconnect the negative battery cable. 2. Disconnect the electrical harness from the AP sensor. 3. Remove the AP sensor. Installation Procedure 1. Install the accelerator position (AP) sensor to bolts with accelerator (A) pedal. 2. Connect the connector to AP sensor. 3. Install the negative battery cable. Page 477 Door Switch: Service and Repair Removal 1. Disconnect the battery ground cable. 2. Remove the door switch (2). - Remove the screw (1). - Disconnect the connector (3). Installation To install, follow the removal steps in the reverse order. Page 127 The wire insulation has one color or one color with another color stripe. The second color is the stripe. Page 7120 Paint: Technical Service Bulletins Air Fresheners - Bad News For Paint Or Plastic SOURCE: Honda Service News November 2003 TITLE: Hanging Air Fresheners: Bad News for Paint or Plastic APPLIES TO: All Models SERVICE TIP: Never let hanging air fresheners come in contact with painted or plastic surfaces. The chemicals used in them can eat into paint or permanently mar the plastic. Most of these air fresheners actually state on their packages to avoid contact with any surface. Advise your customers to heed those words. Page 2571 Terminals - "T" Each "T" terminal (ring type) is numbered for reference and location. A "T" terminal is secured with a screw or bolt. Wires Audio System - CD/DVD Precautions Compact Disc Player (CD): All Technical Service Bulletins Audio System - CD/DVD Precautions Adhesive Labels or Protective Disc Covers on CDs or DVDs: A Big Taboo NOTE: This article applies to all Honda models with a factory- or dealer-installed CD/DVD player or changer. We can't emphasize this enough: Never put adhesive labels or protective disc covers on recordable CDs or DVDs to be used in automotive CD/DVD players or changers. Here's why: ^ Recordable CDs and DVDs are actually thicker than their pre-recorded brethern. Automotive players and changers use rollers to draw the disc into the unit. The added thickness of an adhesive label or a protective disc cover can cause the disc to jam when it's loaded into or ejected from the unit. ^ CD/DVD players or changers are exposed to high temperatures inside the vehicle. High temperature can cause the label adhesive to soften. This can cause the label to curl on the edges and even form bubbles. Curled edges can catch on the rollers and bubbles add thickness to the disc. Either one can cause the disc to jam. To cut down on customer-caused damage, all '05 and later 0/Ms include this notice: Do not use CDs with adhesive labels. The label can curl up and cause the CD to jam in the unit. Anytime a service customer comes in with a loading or ejecting problem for a CD/DVD player or changer, ask if he or she used any discs with adhesive labels or protective disc covers. If the answer is yes, contact your DPSM for possible goodwill assistance. If the answer is no, then replace the audio unit under normal warranty. Page 6542 Front Passenger's Airbag: - Disconnect the 2P connector between the front passenger's airbag and SRS main harness. When disconnected, the airbag connector is automatically shorted. Seat Belt Tensioner: Remove the left and (or) right center pillar lower trim panels. - Disconnect the seat belt tensioner 2P connectors from the left side wire harness (driver's side) and (or) the right side wire harness (front passenger's side). When disconnected, the seat belt tensioner is automatically shorted. Page 227 Driver's Inflator Module Connector Page 6432 12. Disconnect the wiring harness connectors (10) located at the base of steering column. 13. Disconnect the horn terminal NO.2 from connector and remove the tape binding harness. 14. Remove tour bolts of combination switch assembly (0) attached to steering lock and remove the combination switch assembly (with SRS coil) from steering shaft. Page 6299 The wire insulation has one color or one color with another color stripe. The second color is the stripe. Page 2885 Fuel Tank Pressure Sensor: Description and Operation Fuel Tank Pressure Sensor The fuel tank pressure sensor is a three-wire strain gauge sensor similar to a common MAP sensor. However, the fuel tank pressure sensor has very different electrical characteristics due to its pressure differential design. The sensor measures the difference between the air pressure (or vacuum) in the fuel tank and the outside air pressure. The sensor mounts at the top of the fuel pump assembly. A three-wire electrical harness connects it to the PCM. The PCM supplies a five-volt reference voltage and a ground to the sensor. The sensor will return a voltage between 0.1 and 4.9 volts. When the air pressure in the fuel tank is equal to the outside air pressure, such as when the fuel cap is removed, the output voltage of the sensor will be 1.3 to 1.7 volts. When the air pressure in the fuel tank is 4.5 in. H2O (1.25 kPa), the sensor output voltage will be 0.5 ± 0.2 V. When there is neither vacuum nor pressure in the fuel tank, the sensor voltage will be 1.5 V. At -14 in. H2O (-3.75 kPa), the sensor voltage will be 4.5 ± 0.2 V. Page 5088 Ignition Switch Lock Cylinder: Service and Repair REMOVAL 1. Turn the steering wheel so that the vehicle's wheels are pointing straight ahead. 2. Turn the ignition switch to "LOCK". 3. Disconnect the battery "-" terminal cable, and wait at least 5 minutes. 4. Disconnect the yellow 2-way SRS connector located under the steering column. CAUTION: The wheels of the vehicle must be straight ahead and the steering column in the "LOCK" position before disconnecting the steering wheel. Failure to do so will cause the coil assembly to become uncentered which will cause damage to the coil assembly. 5. Remove the engine hood opening lever and steering lower cover. 6. Remove knee bolster (reinforcement). Page 6594 P/N 08A31-0F1-000, H/C 7512999 Music Link Interface Unit: P/N 08-8-1H1-10101, H/C 8582603 WARRANTY CLAIM INFORMATION In warranty: The normal warranty applies. FLAT RATE TIMES Failed Part: P/N 08~8-1H1-10031 H/C 8387052 Defect Code: 03214 Symptom Code: 01201 Skill Level: Repair Technician Out of warranty: Any repair performed after warranty expiration may be eligible for goodwill consideration by the District Parts and Service Manager or your Zone Office. You must request consideration, and get a decision, before starting work. Disclaimer General Information Music Link iPod Information Resources ^ Online at http//musiclink.honda.com/Tech Faq.html ^ Music Link Information Sheet (Honda ServiceNews, March 2006) ^ Music Link Frequently Asked Questions (Honda ServiceNews, March 2006) ^ Quick Reference Guide (supplied in Music Link kit) ^ User's Guide and Quick Reference Guide are available online: http://musiclink.honda.com/Down_Ref.html ^ General information: www.apple.com, then select support. ^ iPod firmware (unit software) version information: www.apple.com, then select Support. ^ To find out what (unit software) is loaded on the iPod: - Go to the Main Menu. Page 4598 Terminals - "T" Each "T" terminal (ring type) is numbered for reference and location. A "T" terminal is secured with a screw or bolt. Wires Page 6505 2. Soak a clean cloth in the cleaner. Insert the cloth between the seat belt and metal loop on the upper anchor. Use a credit card or similar item to help insert the cloth into the loop. Work the cloth back and forth to clean the dirt out of the inside of the loop. 3. Pull the seat belt out fully. Soak a clean cloth in the cleaner, and clean both sides of the seat belt webbing. Dry the webbing thoroughly with a clean cloth. Do not use a hair dryer or similar device. 4. Test the belt for proper retraction by pulling the latch plate down to the floor of the vehicle and then releasing it. The belt should retract fully in 4 seconds or less. Three-Point Passive Seat Belts 1. Clean the metal loop in the upper anchor as described for Three-Point Active Seat Belts. 2. Remove the door panel and the seat belt guide. Refer to the appropriate service manual. 3. Soak a clean cloth in the cleaner, and clean both sides of the seat belt webbing. Dry the webbing thoroughly with a clean cloth. Do not use a hair dryer or similar device. Page 3554 the component if the component only has one connector, or by a capital letter (A, B, C, etc.) if the component has more than one connector. Below most connector numbers and component names are PHOTO and VIEW numbers. The PHOTO number refers to a photo in the back of the book that shows the connector's location on the car. The VIEW number refers to an illustration in the back of the book that shows the connector face, wire colors, connector cavity numbers, and other details. The connector cavity numbering sequence begins at the top left corner of the connector. Disregard any numbers molded into the connector housing. Wires Wires are identified by the abbreviated names of their colors; the second color is the color of the stripe. Wires are also identified by their location in a connector. The number "2" next to the male and female wire terminals at C416, for example, means those terminals join in cavity 2 of connector C416. Symbols A complete description of schematic symbols is given under wire color abbreviation. Power Distribution Schematics Power Distribution schematics show how power is supplied from the positive battery terminal to various circuits in the car. Refer to the Power Distribution section to get a more detailed picture of how power is supplied to the circuit you're working on. From Battery to Ignition Switch, Fuses, and Relays Individual circuit schematics begin with a fuse. The first half of Power Distribution, however, shows the wiring "upstream" between the battery Page 4852 If there is no photo number below or beside a component name or a connector, ground, or terminal number, look up that name or number in the appropriate Connector Identification Chart. The chart lists how many cavities a connector has, where it's located, and what it connects to. The related illustration shows the connector's location on the harness, and the harness routing. NOTE: Photos listed by number are located at Locations / Components / Photograohs. See: Locations/Component Locations/Photographs Circuit Schematics Page 2015 This means the branch of the wire connects to another circuit. The arrow points to the name of the circuit branch where the wire continues. Page 4243 8. Disconnect the ABS connectors (1) and remove the brackets attached to the frame and center link. 9. Loosen the brake tube flare nut, remove the clip and take out the brake tube. 10. Remove the shock absorber. 11. Remove the stabilizer linkage mounting bolts and nuts (2) from the frame side. 12. Remove the lateral rod fixing bolt and nut from the frame. 13. Remove the upper link mounting bolt and nut (3) from the axle housing. Page 2312 Camshaft Position Sensor: Service and Repair REMOVAL PROCEDURE 1. Disconnect the negative battery cable. 2. Remove the engine cover. 3. Remove the common chamber assembly. 4. Disconnect the electrical connector to the CMP sensor. 5. Remove the CMP retaining bolt from the side of left cylinder head. 6. Remove the CMP sensor from the cylinder head. INSTALLATION PROCEDURE 1. Install the CMP sensor in the cylinder head. 2. Install the CMP sensor retaining bolt. Tighten Tighten the retaining screw to 9 N.m (78 lb in.). Locations ECT Sensor Page 3165 11. Using a jumper wire, connect the reference voltage of each circuit to its signal input and view the APP Sensor values in the Engine Data List. APP Sensor 1 should have a value of 99%, and APP Sensor 2 and APP Sensor 3 should each have a value of 0%. ^ If the values are not as specified, troubleshoot for high resistance on the signal input or a PCM malfunction. Repair the circuit or replace the PCM, then repeat step 3. ^ If the values are as specified, the problem may be intermittent. Disconnect the 10P connector from the modified APPS, and connect it to the new APPS; then repeat step 3. Wiggle the APPS wires as you go through the adjustment procedure to find the intermittent problem. 12. Turn off the ignition switch, and disconnect the PGM Tester.* DISCLAIMER Page 5302 Wires Wire insulation can be one color, or one color with another color stripe. (The second color is the stripe.) This circuit continues on another image. (The arrow shows direction of current flow.) To follow the RED/BLK wire in this example, you would turn to "Fuel and Emissions" and look for the "A" arrow. Page 630 Coolant Temperature Sensor/Switch (For Computer): Service and Repair ENGINE COOLANT TEMPERATURE (ECT) SENSOR REMOVAL PROCEDURE NOTE: Care must be taken when handling the engine coolant temperature (ECT) sensor. Damage to the ECT sensor will affect proper operation of the fuel injection system. 1. Disconnect the negative battery cable. 2. Drain the radiator coolant. Refer to Draining and Refilling Cooling System. 3. Disconnect the electrical connector. 4. Remove the ECT sensor from the coolant crossover. INSTALLATION PROCEDURE 1. Apply sealer or the equivalent to the threads of the ECT sensor. 2. Install the ECT sensor in the coolant crossover. Tighten Tighten the ECT sensor to 30 N.m (22 lb ft.). Page 8012 the component if the component only has one connector, or by a capital letter (A, B, C, etc.) if the component has more than one connector. Below most connector numbers and component names are PHOTO and VIEW numbers. The PHOTO number refers to a photo in the back of the book that shows the connector's location on the car. The VIEW number refers to an illustration in the back of the book that shows the connector face, wire colors, connector cavity numbers, and other details. The connector cavity numbering sequence begins at the top left corner of the connector. Disregard any numbers molded into the connector housing. Wires Wires are identified by the abbreviated names of their colors; the second color is the color of the stripe. Wires are also identified by their location in a connector. The number "2" next to the male and female wire terminals at C416, for example, means those terminals join in cavity 2 of connector C416. Symbols A complete description of schematic symbols is given under wire color abbreviation. Power Distribution Schematics Power Distribution schematics show how power is supplied from the positive battery terminal to various circuits in the car. Refer to the Power Distribution section to get a more detailed picture of how power is supplied to the circuit you're working on. From Battery to Ignition Switch, Fuses, and Relays Individual circuit schematics begin with a fuse. The first half of Power Distribution, however, shows the wiring "upstream" between the battery Page 585 20. Using a DVOM, check the voltage between the reference voltage pin for each sensor and ground. ^ If the sensor circuits all read 5.0 volts, go to step 22. ^ If any sensor circuit is above or below 5.0 volts, go to step 21. 21. Troubleshoot for an internal short in another sensor or a PCM malfunction. ^ To find the sensor with an internal short, monitor the reference voltage, and disconnect each sensor (FTPS, EGR, MAP TPS, CKP and CMP) one at a time until the reference voltage reads 5.0 volts. Replace that sensor, and repeat step 14. ^ To find a malfunctioning PCM, replace it with a known-good PCM. If all three sensors (APP Sensor 1, APP Sensor 2, and APP Sensor 3) are within range, the original PCM is faulty; replace it and repeat step 14. 22. Using a jumper wire, connect the reference voltage of each circuit to its signal input, and view the APP Sensor values in the Engine Data List. APP Sensor 1 should have a value of 99%, and APP Sensor 2 and APP Sensor 3 should each have a value of 0%. ^ If the values are not as specified, troubleshoot for high resistance on the signal input or a PCM malfunction. Repair the circuit or replace the PCM, then repeat step 14. ^ If the values are as specified, the problem may be intermittent. Disconnect the 10 P connector from the modified APPS, and connect it to the new APPS; then repeat step 14. Wiggle the APPS wires as you go through the adjustment procedure to find the intermittent problem. 23. Install the accelerator pedal assembly, and torque the bolts to 10 N.m (7 lb-ft). Page 2634 2. Connect one lead of a self-powered test light or DVOM to one end of the part of the circuit you want to test. 3. Connect the other lead to the other end. 4. If the self-powered test light glows, there is continuity. If you're using a DVOM, a low reading or no reading (zero), means good continuity. Testing For Voltage When testing for voltage at a connector without wire seals, you do not have to separate the two halves of the connector. Instead, probe the connector from the back. Always check both sides of the connector because dirty, corroded, and bent terminals can cause problems (no electrical contact = an open). 1. Connect one lead of the lest light to a known good ground, or, if you're using a digital volt ohmmeter (DVOM), place it in the appropriate DC volts range, and connect its negative lead to ground. 2. Connect the other lead of the test light or DVOM to the point you want to check. 3. If the test light glows, there is voltage present. If you're using a DVOM, note the voltage reading. It should be within one volt of measured battery voltage. A loss of more than one volt indicates a problem. NOTE: Always use a DVOM on high impedance circuits. A test light may not glow (even with battery voltage present). Testing For Voltage Drop Wires, connectors, and switches are designed to conduct current with a minimum loss of voltage. A voltage drop of more than one volt indicates a problem. 1. Place the digital volt/ohmmeter (DVOM) in the appropriate DC volts range. Connect the positive lead to the end of the wire (or to the connector or switch) closest to the battery. 2. Connect the negative lead to the other end of the wire (or the other side of the connector or switch). 3. Turn on the components in the circuit. 4. The DVOM will show the difference in voltage between the two points. A difference, or drop, of more than one volt indicates a problem. Check the circuit for loose, dirty, or bent terminals. Service and Repair Security Lamp/Indicator: Service and Repair Removal 1. Disconnect the battery ground cable. 2. Remove the instrument panel driver lower cover assembly (1). 3. Remove the anti-theft indicator (2). - To remove the indicator, push the lock from the back side of the instrument panel driver lower cover assembly. Installation To install, follow the removal steps in the reverse order. Page 2669 it is located, and what it connects to. Use the Connector Views to help locate the proper cavity when you need to probe a connector. It can be especially helpful if the connector has more than one wire of the same color. A dash symbol (-) indicates that the cavity is empty. Connector views can also be used to help diagnose multiple symptoms in separate circuits which could be caused by a single problem in a connector shared by those circuits. Here's an example: 1. Pick one of the multiple symptoms and look up the schematic for that circuit. 2. Make a list of all the in-line and fuse box connectors in that schematic , 3. Then, in the Connector Views, look up each connector on your list to see if circuits related to the other symptoms run through one of them. If they do, inspect that connector for the problem. Example: The blower, rear window defogger, and the windshield wiper don't work. List all in-line and fuse box connectors in the blower controls circuit and then check the Connector View (see the sample). You find that C324 is common to the blower controls, rear window defogger, and wiper/washer, so you inspect C324 and find the problem, bent terminals. Finding Component/Connector Locations Finding Component/Connector Locations To see where a component or connector is located on the car, look up its photo number in the "Component Location". The photo will also tell you the color of the connector, and how many cavities it has. Locations Page 4806 Wheel Speed Sensor: Testing and Inspection Related Diagnostic Procedures B-19 Rear Speed Sensor Open or Shorted (DTC 53/C0235) Chart B-19 Rear Speed Sensor Open Or Shorted (DTC 53 (Flash Out) / C0235 (Serial Communications)) Locations ECT Sensor Locations Diagram Information and Instructions Headlamp Reminder Indicator: Diagram Information and Instructions How to Identify Wiring Color-Coded Insulation Wire Color Wire Color Coding Page 2408 20. Using a DVOM, check the voltage between the reference voltage pin for each sensor and ground. ^ If the sensor circuits all read 5.0 volts, go to step 22. ^ If any sensor circuit is above or below 5.0 volts, go to step 21. 21. Troubleshoot for an internal short in another sensor or a PCM malfunction. ^ To find the sensor with an internal short, monitor the reference voltage, and disconnect each sensor (FTPS, EGR, MAP TPS, CKP and CMP) one at a time until the reference voltage reads 5.0 volts. Replace that sensor, and repeat step 14. ^ To find a malfunctioning PCM, replace it with a known-good PCM. If all three sensors (APP Sensor 1, APP Sensor 2, and APP Sensor 3) are within range, the original PCM is faulty; replace it and repeat step 14. 22. Using a jumper wire, connect the reference voltage of each circuit to its signal input, and view the APP Sensor values in the Engine Data List. APP Sensor 1 should have a value of 99%, and APP Sensor 2 and APP Sensor 3 should each have a value of 0%. ^ If the values are not as specified, troubleshoot for high resistance on the signal input or a PCM malfunction. Repair the circuit or replace the PCM, then repeat step 14. ^ If the values are as specified, the problem may be intermittent. Disconnect the 10 P connector from the modified APPS, and connect it to the new APPS; then repeat step 14. Wiggle the APPS wires as you go through the adjustment procedure to find the intermittent problem. 23. Install the accelerator pedal assembly, and torque the bolts to 10 N.m (7 lb-ft). Page 2422 Manually Removing a Jammed Magazine (Passport only) One-piece door model: 1. Open the changer door. 2. Check to see if all the trays are in the magazine. ^ If a tray is stuck in the changer, replace the changer. ^ If all the trays are in the magazine, place the changer in a horizontal position, and insert a thin stainless steel ruler or a "Slim Jim" under the magazine, about 1/2" from the right side of the opening. 3. Push the ruler in until it presses against the eject lever at the back of the unit. 4. Slowly remove the ruler and magazine at the same time. Two-piece door model: 1. Remove the changer from the vehicle. 2. Remove the top cover plate from the changer, and inspect for a jammed tray. ^ If a tray is stuck in the changer, replace the changer. ^ If all the trays are in the magazine, place the changer in a horizontal position, and insert a thin stainless steel ruler or a "Slim Jim" under the magazine, about 1/2" from the right side of the opening. 3. Push the ruler in until it presses against the eject lever at the back of the unit. 4. Slowly remove the ruler and magazine at the same time. Handling and Inspecting Compact Discs Service and Repair Clutch Release Bearing: Service and Repair For further information regarding this component and the system that it is a part of, please refer to Clutch; Service and Repair; Unit Overhaul Page 233 The SDM is connected to the SRS wiring harness by a 24 - pin connector. This harness connector uses a shorting clip across certain terminals in the contact area. This shorting clip connects the "AIR BAG" warning lamp to ground when the SDM harness connector is disconnected or Connector Position Assurance (CPA) is not inserted even If completely connected. This will cause the "AIR BAG" warning lamp to come "ON" steady whenever the ignition switch is at the ON or START positions with the SDM disconnected. Page 6615 Specifications Child Seat Tether Attachment Page 3227 Steps 3 - 5 Page 6980 The SRS consists of the Sensing and Diagnostic Module (SDM), the driver air bag assembly, the SRS coil assembly, the passenger air bag assembly, and the "AIR BAG" warning lamp in the instrument cluster. The SDM, SRS coil assembly (driver side only), driver air bag assembly, passenger air bag assembly and connector wire make up the deployment loops. The function of the deployment loops is to supply current through air bag assembly, which will cause deployment of the air bags in the event of a frontal crash of sufficient force, up to 30 degrees off the centerline of the vehicle. The air bag assemblies are only supplied enough current to deploy when the SDM detects vehicle velocity changes severe enough to warrant deployment. The SDM contains a sensing device which converts vehicle velocity change to an electrical signal. The electrical signal generated is processed by the SDM and then compared to a value stored in memory. When the generated signal exceeds the stored value, the SDM will cause current to flow through the air bag assembly deploying the air bags. Page 1053 Fuel Pressure: Service Precautions WARNING: Adhere to the following procedures any time the fuel system is being worked on in order to reduce the risk of fire and personal injury: - Keep a dry chemical (Class B) fire extinguisher near the work area. - Place a "CAUTION FLAMMABLE" sign in the work area. - Work in a well-ventilated area. Do not smoke, and keep sparks and open flames away. - Wear eye protection. - Use caution when working near the catalytic converter to prevent the possibility of burns or fire. (The temperatures within the converter can exceed 537 °C (1000 °F). - Relieve the fuel system pressure prior to disconnecting fuel system components. - Disconnect the negative battery cable except for tests where battery voltage is required. - Use a suitable container to store or catch fuel. - Do not replace fuel pipe with fuel hose. - Plug all disconnected fuel line fittings and hoses. - After making any fuel system repairs ALWAYS inspect for fuel leaks. Page 2963 Distinct Of Circuit By Wire Base Color All wires have color-coded insulation. Wires belonging to a system's main harness will have a single color. Wires belonging to a system's sub-circuits will have a colored stripe. Striped wires use the codes found in the chart to show wire size and colors. Abbreviations are used to indicate wire color within a circuit diagram. How to Identify Connector Terminals How to Identify Connector Terminals Cavity Numbering System The cavities (and wire terminals) in each connector are numbered starting from the upper left, looking at the male terminals from the terminal side (or looking at the female terminals from the wire side. Both views are in the same direction so the numbers are the same.) All actual cavities are numbered, even if they have no wire terminals in them. NOTE: Data Link Connector (DLC) terminals are numbered according to SAE standard J1962, not the Honda standard. The numbers of the four end terminals are molded into the corners of the connector face. The connector cavity number is listed next to each terminal on the circuit schematic. The cavity / terminal shown is # 6. Using/Identifying Connector Terminal Views How to Use Connector Terminal Views To see the configuration of a connector's cavities, look up its view number in the Connector Views. Each view includes the color of the connector, where Page 5118 4. Check for continuity between slip ring and rotor core. In case of continuity, replace the rotor assembly. Stator Coil 1. Check for continuity across the stator coils. If no continuity exists, replace the coils. Resistance value at 20°C. Standard: Approx. 0.07 ohms A/T - Vehicle Speed Sensor Installation Precautions Transmission Speed Sensor: Technical Service Bulletins A/T - Vehicle Speed Sensor Installation Precautions Install VSS Properly to Avoid Reman A/T Damage We can't emphasize enough how important it is to follow, to the letter, the installation instructions that come with a reman A/T. These instructions help ensure that you avoid damaging the A/T and score a successful repair. This is particularly true when it comes to installing the vehicle speed sensor (VSS). Step 6 of the instructions tells you to make sure its gear is fully engaged and the VSS is fully seated before you tighten the retaining bolt. If you don't install the VSS properly, the speed sensor gear will get stripped and the A/T will be seriously damaged. So don't take risks with your customer's vehicle. Always follow these instructions to the letter. You can rest assured you're doing the job right. Page 4859 Ground - "G" Shielding Sheilding This represents RFI (Radio Frequency Interference) shielding around a wire. The shielding is always connected to ground. Splices Page 7815 it is located, and what it connects to. Use the Connector Views to help locate the proper cavity when you need to probe a connector. It can be especially helpful if the connector has more than one wire of the same color. A dash symbol (-) indicates that the cavity is empty. Connector views can also be used to help diagnose multiple symptoms in separate circuits which could be caused by a single problem in a connector shared by those circuits. Here's an example: 1. Pick one of the multiple symptoms and look up the schematic for that circuit. 2. Make a list of all the in-line and fuse box connectors in that schematic , 3. Then, in the Connector Views, look up each connector on your list to see if circuits related to the other symptoms run through one of them. If they do, inspect that connector for the problem. Example: The blower, rear window defogger, and the windshield wiper don't work. List all in-line and fuse box connectors in the blower controls circuit and then check the Connector View (see the sample). You find that C324 is common to the blower controls, rear window defogger, and wiper/washer, so you inspect C324 and find the problem, bent terminals. Finding Component/Connector Locations Finding Component/Connector Locations To see where a component or connector is located on the car, look up its photo number in the "Component Location". The photo will also tell you the color of the connector, and how many cavities it has. Page 5234 V6 Engine Room Page 844 Crankshaft Position Sensor: Testing and Inspection 1. Inspect the sensor O-ring for cracks or leaks. 2. Replace the O-ring if it is worn or damaged. 3. Lubricate the new O-ring with engine oil. 4. Install the lubricated O-ring. Specifications Flex Plate: Specifications Flywheel Fixing Bolts 54 Nm -- Do not reuse the bolts. Do not apply oil or thread lock to the bolts. Locations Locations Crankshaft Position Sensor: Locations CKP Sensor 36. Bottom Right Side of Engine Bottom Right Side of Engine Page 7043 2. Install the regulator handle as shown in the illustration, if equipped without power windows. 3. Tighten the door lock assembly fixing screws to the specified torque. Torque 7 Nm (61 lb in) 4. Check that the door lock operates smoothly. Page 4856 This sample Ground Distribution schematic shows all of the components that share two ground points. Components A solid border line means the entire component is shown. A broken border line indicates that only part of the component is shown. Page 5174 A/T - Vehicle Speed Sensor Installation Precautions Transmission Speed Sensor: Technical Service Bulletins A/T - Vehicle Speed Sensor Installation Precautions Install VSS Properly to Avoid Reman A/T Damage We can't emphasize enough how important it is to follow, to the letter, the installation instructions that come with a reman A/T. These instructions help ensure that you avoid damaging the A/T and score a successful repair. This is particularly true when it comes to installing the vehicle speed sensor (VSS). Step 6 of the instructions tells you to make sure its gear is fully engaged and the VSS is fully seated before you tighten the retaining bolt. If you don't install the VSS properly, the speed sensor gear will get stripped and the A/T will be seriously damaged. So don't take risks with your customer's vehicle. Always follow these instructions to the letter. You can rest assured you're doing the job right. Page 6111 and the fuses. From Fuses to Relays and Components The second half of Power Distribution shows the wiring "From Fuses to Relays and Components." This can speed your troubleshooting by showing which circuits share fuses. If Power Distribution shows that an inoperative circuit and another circuit share a fuse, check a component in the other circuit. If it works, you know the fuse is good and power is available to the inoperative circuit. Ground Distribution Schematics Page 7661 Distinct Of Circuit By Wire Base Color All wires have color-coded insulation. Wires belonging to a system's main harness will have a single color. Wires belonging to a system's sub-circuits will have a colored stripe. Striped wires use the codes found in the chart to show wire size and colors. Abbreviations are used to indicate wire color within a circuit diagram. How to Identify Connector Terminals How to Identify Connector Terminals Cavity Numbering System The cavities (and wire terminals) in each connector are numbered starting from the upper left, looking at the male terminals from the terminal side (or looking at the female terminals from the wire side. Both views are in the same direction so the numbers are the same.) All actual cavities are numbered, even if they have no wire terminals in them. NOTE: Data Link Connector (DLC) terminals are numbered according to SAE standard J1962, not the Honda standard. The numbers of the four end terminals are molded into the corners of the connector face. The connector cavity number is listed next to each terminal on the circuit schematic. The cavity / terminal shown is # 6. Using/Identifying Connector Terminal Views How to Use Connector Terminal Views To see the configuration of a connector's cavities, look up its view number in the Connector Views. Each view includes the color of the connector, where Page 5590 Test Equipment CAUTION: Most circuits include solid-state devices. Test the voltages in these circuits only with a 10-megaohm or higher impedance digital multimeter. Never use a test light or analog meter on circuits that contain solid-state devices. Damage to the devices may result. Test Light and DVOM On circuits without solid-state devices, use a test light to check for voltage. A test light is made up of a 12 volt bulb with a pair of leads attached. After grounding one lead, touch the other lead to various points along the circuit where voltage should be present. The bulb will go on if there is voltage at the point being tested. If you need to know how much voltage is present, use a digital volt/ohmmeter (DVOM). Self-Powered Test Light and DVOM Use a self-powered test light to check for continuity. This tool is made up of a light bulb, battery, and two leads. To test it, touch the leads together: the light should go on. Use a self-powered test light only on an unpowered circuit. First, disconnect the battery, or remove the fuse that feeds the circuit you are working on. Select two points in the circuit between which you want to check continuity. Connect one lead of the self-powered test light to each point. If there is continuity, the test light's circuit will be completed, and the light will go on. If, in addition, you need to know exactly how much resistance there is between two points, use a digital volt/ohmmeter (DVOM). In the "OHMS" range, the DVOM will measure resistance between two points along a circuit. Low resistance means good continuity. Diodes and solid-state devices in a circuit can make a DVOM give a false reading. To check a reading, reverse the leads, and take a second reading. If the readings differ, the component is affecting the measurement. Jumper Wire Use a jumper wire to bypass an open circuit. A jumper wire is made up of an in-line fuse holder connected to a set of test leads. It should have a five ampere fuse. Never connect a jumper wire across a short circuit. The direct battery short will blow the fuse. Short Finder (Short Circuit Locator) Short finders are available to locate shorts to ground. The short finder creates a pulsing magnetic field in the shorted circuit which you can follow to the location of the short. To order any test equipment shown above, contact your local tool supplier. For a list of suppliers and tool numbers, refer to Honda Required Special Tools and Equipment Service Bulletin. Page 2387 17. Recheck the valve clearance using the Go/No-Go method (see step 4). - If the clearance is OK, repeat steps 6 thru 17 for the other valves needing adjustment. - If the clearance is still incorrect, repeat steps 6 through 17 until it is correct, then adjust the remaining valves. 18. Turn the camshaft pulleys until the single timing dot (right cylinder bank) and dual timing dots (left cylinder bank) align with the single timing dots on the camshaft drive gears. 19. Install the cylinder head covers with new gaskets. Torque the cover bolts to 9 N.m (6.5 lb-ft). Off-Vehicle Valve Adjustment 1. Make a copy of the Valve Inspection Chart. 2. Make a copy of the Valve Shim Replacement Chart, then tape the pages together, side-by-side. 3. Measure the valve clearances using the Go/No-Go method (see the note below). The clearances must be - Intake valves: 0.25 mm +0.05 mm - Exhaust valves: 0.30 mm +0.05 mm NOTE: - To measure with the Go/No-Go method, use two feeler gauges, one to measure the smallest allowable clearance, and the other to measure the largest. - If the small gauge fits and the large gauge doesn't, the valve adjustment is OK. - If the small gauge doesn't fit, or if the large gauge slides easily, the valve needs adjustment. - The feeler gauges slide through the clearance gap at a slight angle, making the drag a little more than it would be on other engines. 4. For valves with the correct clearance, draw an "X" in the appropriate circle on the Valve Inspection Chart. For valves with incorrect clearances, write down the clearance you measured in the circle. 5. Rotate the camshaft pulley until the dual timing dots (exhaust camshaft) and single timing dot (intake camshaft) align with the timing dots on the camshaft drive gear. Page 4792 B-14 FR Dump Solenoid Valve Failure (DTC 44/C0242, C0244) Chart B-14 FR Dump Solenoid Coil Failure (DTC 44 (Flash Out) / C0242, C0244 (Serial Communications)) Part 1 of 2 Part 2 of 2 Page 8216 11. Remove the fixed glass. - Remove one bolt and screw as shown in the figure, then pull it upward. 12. Remove the glass. - First, align the height of regulator to the access hole. Remove 2 screws attaching bottom channel and regulator, then remove the glass. - Remove the window glass by tilting it as necessary. Page 6117 Terminals - "T" Each "T" terminal (ring type) is numbered for reference and location. A "T" terminal is secured with a screw or bolt. Wires Diagram Information and Instructions Vanity Lamp: Diagram Information and Instructions How to Identify Wiring Color-Coded Insulation Wire Color Wire Color Coding Page 2022 2. Connect one lead of a self-powered test light or DVOM to one end of the part of the circuit you want to test. 3. Connect the other lead to the other end. 4. If the self-powered test light glows, there is continuity. If you're using a DVOM, a low reading or no reading (zero), means good continuity. Testing For Voltage When testing for voltage at a connector without wire seals, you do not have to separate the two halves of the connector. Instead, probe the connector from the back. Always check both sides of the connector because dirty, corroded, and bent terminals can cause problems (no electrical contact = an open). 1. Connect one lead of the lest light to a known good ground, or, if you're using a digital volt ohmmeter (DVOM), place it in the appropriate DC volts range, and connect its negative lead to ground. 2. Connect the other lead of the test light or DVOM to the point you want to check. 3. If the test light glows, there is voltage present. If you're using a DVOM, note the voltage reading. It should be within one volt of measured battery voltage. A loss of more than one volt indicates a problem. NOTE: Always use a DVOM on high impedance circuits. A test light may not glow (even with battery voltage present). Testing For Voltage Drop Wires, connectors, and switches are designed to conduct current with a minimum loss of voltage. A voltage drop of more than one volt indicates a problem. 1. Place the digital volt/ohmmeter (DVOM) in the appropriate DC volts range. Connect the positive lead to the end of the wire (or to the connector or switch) closest to the battery. 2. Connect the negative lead to the other end of the wire (or the other side of the connector or switch). 3. Turn on the components in the circuit. 4. The DVOM will show the difference in voltage between the two points. A difference, or drop, of more than one volt indicates a problem. Check the circuit for loose, dirty, or bent terminals. Page 7876 the component if the component only has one connector, or by a capital letter (A, B, C, etc.) if the component has more than one connector. Below most connector numbers and component names are PHOTO and VIEW numbers. The PHOTO number refers to a photo in the back of the book that shows the connector's location on the car. The VIEW number refers to an illustration in the back of the book that shows the connector face, wire colors, connector cavity numbers, and other details. The connector cavity numbering sequence begins at the top left corner of the connector. Disregard any numbers molded into the connector housing. Wires Wires are identified by the abbreviated names of their colors; the second color is the color of the stripe. Wires are also identified by their location in a connector. The number "2" next to the male and female wire terminals at C416, for example, means those terminals join in cavity 2 of connector C416. Symbols A complete description of schematic symbols is given under wire color abbreviation. Power Distribution Schematics Power Distribution schematics show how power is supplied from the positive battery terminal to various circuits in the car. Refer to the Power Distribution section to get a more detailed picture of how power is supplied to the circuit you're working on. From Battery to Ignition Switch, Fuses, and Relays Individual circuit schematics begin with a fuse. The first half of Power Distribution, however, shows the wiring "upstream" between the battery Page 3558 The connector cavity number is listed next to each terminal on the circuit schematic. The cavity / terminal shown is # 6. Diodes A rectifier diode works like a one way valve. It allows current to flow only in the direction of the arrow. A Zener diode blocks reverse current at normal voltages just like a rectifier diode. At high voltages, however, a Zener diode allows current to flow in reverse. Fuses Locations Page 7999 Door Switch: Service and Repair Removal 1. Disconnect the battery ground cable. 2. Remove the door switch (2). - Remove the screw (1). - Disconnect the connector (3). Installation To install, follow the removal steps in the reverse order. Locations Transmission Position Switch/Sensor: Locations Left Side Of Automatic Transmission Page 2181 4. Remove the fuel pressure regulator from the fuel rail. 5. Remove the fuel return line from the regulator. 6. Install the new fuel pressure regulator in the reverse order of removal. 7. Use the Smart Cable to reprogram the PCM with the latest software from the June 2001 or later HONDANET CD-ROM. Refer to Service Bulletin 99-005, Updating the Passport PCM, filed under Tools. 8. Use the PGM Tester to clear any DTCs. 9. Use the PGM Tester to check the broadcast code. Make sure the broadcast code matches the one you selected from the CD-ROM. WARRANTY CLAIM INFORMATION In warranty: The normal warranty applies. Failed Part: P/N 8-17113-398-0 H/C 5504386 Defect Code: 092 Contention Code: C99 Skill Level: Repair Technician Out of warranty: Any repair performed after warranty expiration may be eligible for goodwill consideration by the District Service Manager or your Zone Office. You must request consideration, and get a decision, before starting work. REPAIR PROCEDURE - POWER STEERING SWITCH 1. Drain the power steering fluid out of the system. 2. Remove the power steering fluid reservoir. Clean the reservoir with solvent, then with soap and water. Rinse and dry it thoroughly. 3. Reinstall the reservoir. Do not connect the return hose. 4. Remove the power steering pressure switch, then clean it with brake cleaner and a scraper. Reinstall the switch, and torque it to 20 N.m (14 lb-ft). 5. Cover the unconnected end of the reservoir with your finger, then fill the reservoir with Dexron III ATF Page 701 ^ If the idle speed ever exceeds 1,300 rpm 2. Remove the vacuum hose from the fuel pressure regulator, then start the engine. ^ If fuel comes out of the fuel pressure regulator vacuum hose connection, go to REPAIR PROCEDURE FUEL PRESSURE REGULATOR. ^ If no fuel comes out of the regulator, reconnect the vacuum hose and continue to step 3. 3. Connect the PGM Tester. Set it to Engine Data List. 4. Have an assistant drive the vehicle under the conditions described by the customer. 5. If the high or erratic idle condition occurs, note the values of the PSP Switch and APP Sensor 1 when it is occurring. ^ If the PSP Switch is HIGH, and you are not turning, go to REPAIR PROCEDURE POWER STEERING SWITCH. ^ If the APP Sensor 1 is greater than 15% and APP Sensor 2 and/or APP Sensor 3 are less than 85%, and the accelerator pedal is not depressed, go to REPAIR PROCEDURE APPS GROUND. ^ If the PSP Switch is reading LOW when not turning and HIGH when turning, and the APP Sensors are reading within the range shown, discontinue the test-drive and go to step 6. 6. Do these repairs: ^ REPAIR PROCEDURE APPS GROUND ^ REPAIR PROCEDURE ENGINE/BODY GROUND REPAIR PROCEDURE - FUEL PRESSURE REGULATOR 1. Relieve fuel system pressure: ^ Remove the fuel fill cap. ^ Remove the fuel pump relay. ^ Start the engine and run it until it stalls. ^ Crank the engine for 3 seconds. 2. Remove the vacuum hose from the fuel pressure regulator. 3. Remove the fuel pressure regulator shield from the common chamber (two bolts). Page 1432 2. Tighten sub gear setting bolt. 1. Use J-42686 to turn sub gear to right direction until the M5 bolt hole aligns between camshaft driven gear and sub gear. 2. Tighten M5 bolt suitable torque for prevent moving the sub gear. Page 6749 Page 6687 Wire Color Abbreviations The following abbreviations are used to identify wire colors in the circuit schematics: WHT................................... White YEL................................... Yellow BLK................................... Black BLU................................... Blue GRN................................... Green RED................................... Red ORN................................... Orange PNK................................... Pink BRN................................... Brown GRY................................... Gray PUR................................... Purple LT BLU................................... Light Blue LT GRN................................... Light Green Page 1930 Muffler: Service and Repair Exhaust Silencer Removal 1. Disconnect battery ground cable. 2. Lift up the vehicle and support with suitable safety stands. 3. Remove the support rubber fixing nuts (2), the exhaust silencer fixing nuts (4) and rear exhaust pipe fixing nuts (5), then remove the exhaust silencer (3). Installation 1. Install the exhaust silencer (3) and tighten the fixing nuts (4) (5) to the specified torque. Torque Nuts: 43 Nm (32 ft. lbs.) 2. Tighten the support rubber fixing nuts (2) to the specified torque. Torque Bolts: 15 Nm (11 ft. lbs.) Page 7431 If there is no photo number below or beside a component name or a connector, ground, or terminal number, look up that name or number in the appropriate Connector Identification Chart. The chart lists how many cavities a connector has, where it's located, and what it connects to. The related illustration shows the connector's location on the harness, and the harness routing. NOTE: Photos listed by number are located at Locations / Components / Photograohs. See: Locations/Component Locations/Photographs Circuit Schematics Page 608 7. Modify the original APPS by cutting the connector housing off of the sensor. 8. Connect the 10P connector to the modified APPS connector housing. 9. Using a DVOM, check the voltage between the reference voltage pin for each sensor and ground. ^ If the sensor circuits all read 5.0 volts, go to step 11. ^ If any sensor circuit is above or below 5.0 volts, go to step 10. 10. Troubleshoot for an internal short in another sensor or a PCM malfunction. ^ To find the sensor with an internal short, monitor the incorrect reference voltage, and disconnect each sensor (FTPS, EGR, MAP, TPS, CKP, and CMP) one at a time until the reference voltage reads 5.0 volts. Replace that sensor, and repeat step 3. ^ To find a malfunctioning PCM, replace it with a known-good PCM. If all three sensors (APP Sensor 1, APP Sensor 2, and APP Sensor 3) are within range, the original PCM is faulty; replace it and repeat step 3. Page 3824 2. Unfasten C123 from the side of the engine compartment using a 90-degree pick. 3. Disconnect C123, and clean the terminals on both sides of the connector with contact cleaner. Shake the residue out of the connector. Allow the contact cleaner to evaporate for at least 3 minutes, then reconnect C123. 4. Fasten C123 to the left side of the engine compartment, and reinstall the air cleaner housing cover. 5. Remove the connector position assurance (CPA) clip from the APPS connector. 6. Disconnect the lop connector from the APPS. 7. Clean the terminals of the 10P APPS connector (harness side) with contact cleaner. Shake out residue from the connector, and allow the contact cleaner to evaporate for at least 3 minutes, then reconnect it. 8. Use the Smart Cable to reprogram the PCM with the latest software from the June 2001 or later HONDANET CD-ROM. Refer to Service Bulletin 99-005, Updating the Passport PCM, filed under Tools. 9. Use the PGM Tester to clear any DTCs. Audio Unit with CD Player/Changer - Error Codes Compact Disc Player (CD): All Technical Service Bulletins Audio Unit with CD Player/Changer Error Codes 00-015 March 14, 2000 Applies To: All with CD Player/Changer Audio Unit Error Codes (Replaces 91-007, dated October 6, 1997) *If the audio unit displays an error code, use the troubleshooting tables in this service bulletin to troubleshoot the problem. Refer to service bulletin 98-019 for CD Player/Changer exchange information.* Page 402 3. Connect the electrical connector. 4. Fill the radiator with coolant. Refer to Draining and Refilling Cooling System. 5. Connect the negative battery cable. Page 4745 c. Remove mode switch connector with bracket from the transmission case. d. Connect multimeter (resistance mode) to terminals 1(E) and 4(H) on mode switch connector. e. Loosen two mounting screws. f. Rotate mode switch slightly in both directions to determine the range (approx. 5 degrees) of electrical contact. g. Position mode switch in middle of contact range. h. Tighten two mounting screws. i. Remove multimeter and install mode switch harness connector with bracket to the transmission case. j. Connect transmission harness connector to mode switch connector. Page 4951 Brake Caliper: Service and Repair Disassembly and Reassembly DISASSEMBLY 1. Remove guide bolt. 2. Remove lock bolt. 3. Remove dust boot; guide bolt and lock bolt. 4. Remove dust boot ring, using a small screwdriver. Page 6623 ^ For warranty repairs, go to the IN-WARRANTY EXCHANGE procedure. ^ For vehicle service contract (VSC) and certified used car (CUC) repairs, call. ^ For goodwill repairs, contact your dealership's District Parts and Service Manager (DPSM). IN-WARRANTY EXCHANGE Service Technician: NOTE: ^ Use the iN to order a remanufactured audio, navigation, or RES unit. Do not call the Remanufactured Parts Dealer Service Group. ^ A Tech Line reference number is not required to submit the order. Check Yes, and enter the Reference Number only when there is a preexisting Tech Line contact. 1. With your completed Audio/Navigation/RES Worksheet, go to an iN workstation. 2. From the iN main menu, click on SERVICE, then click on AUDIO, then select Warranty Audio Order. 3. Select the model, year, and keyword (AUDIO, NAVIGATION, or RES) for the vehicle you are working on, then click on Search. 4. Review all displayed publications for additional repair information. If you cannot repair the problem, go to step 5. Page 2628 Wire Color Abbreviations The following abbreviations are used to identify wire colors in the circuit schematics: WHT................................... White YEL................................... Yellow BLK................................... Black BLU................................... Blue GRN................................... Green RED................................... Red ORN................................... Orange PNK................................... Pink BRN................................... Brown GRY................................... Gray PUR................................... Purple LT BLU................................... Light Blue LT GRN................................... Light Green Accelerator Pedal Position Sensor - MIL ON/DTC's Set Technical Service Bulletin # 01-047 Date: 010814 Accelerator Pedal Position Sensor - MIL ON/DTC's Set 01-047 August 14, 2001 Applies To: 2000-01 Passport - ALL MIL Comes On With Accelerator Pedal Position Sensor DTC(s) P1271, P1273, P1275, P1280, and/or P1285 SYMPTOM The MIL is on with DTC P1271, P1273, P1275, P1280, or P1285 (various accelerator pedal position sensor problems) stored. The REDUCED POWER indicator may also be on; and the engine may occasionally idle too high, or the idle may fluctuate. PROBABLE CAUSE Contaminated grease on the potentiometer circuit board of the accelerator pedal position sensor (APPS) causes high resistance in the APPS circuit. CORRECTIVE ACTION Replace and adjust the APPS, remove all grease from the accelerator link, and clean the APPS harness connector and connector C123. PARTS INFORMATION Accelerator Pedal Position Sensor: P/N 8-97193-713-0, H/C 6198311 REQUIRED MATERIALS CAIG DeoxIT D5-S6 Contact Cleaner: P/N 341-200 (available from www.partsexpress.com) or Permatex Electrical Contact Cleaner: Permatex P/N 24379 WARRANTY CLAIM INFORMATION In warranty: The normal warranty applies. Operation Number: 122114 Flat Rate Time: 0.5 hour Failed Part: P/N 8-97220-540-0 H/C 6202436 Defect Code: 091 Contention Code: C99 Template ID: 01-047A Skill Level: Repair Technician Out of warranty: Any repair performed after warranty expiration may be eligible for goodwill consideration by the District Service Manager or your Zone Office. You must request consideration, and get a decision, before starting work. Page 3718 Axle Disconnect Control Control Unit: Testing and Inspection AXLE DISCONNECT CONTROLLER 1. Connect 12 V with terminal (3) and the ground with the terminal (6). 2. Send the signal to the terminal (4). 2WD - 4WD less than 2.4 V 4WD - 2WD more than 9.0 V 3. Confirm the output signal from the terminals (1) & (2) (2 seconds output). Page 733 Transmission Position Switch/Sensor: Description and Operation Transmission Range Switch IMPORTANT: The vehicle should not be driven with the transmission range switch disconnected; idle quality will be affected. The four inputs from the transmission range switch indicate to the PCM which position is selected by the transmission selector lever. This information is used for ignition timing, EVAP canister purge, EGR operation. For more information on the transmission on the transmission range switch, refer to Transmission Control System Diagnosis. See: Powertrain Management/Transmission Control Systems/Testing and Inspection Page 5389 NOTE: Do this repair procedure if, after doing step 10 of the test-drive, the vehicle pulled in the opposite direction after you swapped the front tires. 1. Swap wheels 2 and 4 on the passenger's side of the vehicle, and test-drive again. ^ If the pull goes away, replace the tire on wheel 2, then go to step 3. ^ If the pull does not go away, put wheels 2 and 4 back to their original positions, and go to step 2. 2. Swap wheels 1 and 3 on the driver's side of the vehicle, and test-drive again. ^ If the pull goes away, replace the tire on wheel 1, then go to step 3. ^ If the pull does not go away, use a known-good tire in position 1 and continue diagnosis. 3. Use your diagnosis worksheet to fill in the following table and build your 15-digit DTC. REPAIR PROCEDURE B Page 7568 the component if the component only has one connector, or by a capital letter (A, B, C, etc.) if the component has more than one connector. Below most connector numbers and component names are PHOTO and VIEW numbers. The PHOTO number refers to a photo in the back of the book that shows the connector's location on the car. The VIEW number refers to an illustration in the back of the book that shows the connector face, wire colors, connector cavity numbers, and other details. The connector cavity numbering sequence begins at the top left corner of the connector. Disregard any numbers molded into the connector housing. Wires Wires are identified by the abbreviated names of their colors; the second color is the color of the stripe. Wires are also identified by their location in a connector. The number "2" next to the male and female wire terminals at C416, for example, means those terminals join in cavity 2 of connector C416. Symbols A complete description of schematic symbols is given under wire color abbreviation. Power Distribution Schematics Power Distribution schematics show how power is supplied from the positive battery terminal to various circuits in the car. Refer to the Power Distribution section to get a more detailed picture of how power is supplied to the circuit you're working on. From Battery to Ignition Switch, Fuses, and Relays Individual circuit schematics begin with a fuse. The first half of Power Distribution, however, shows the wiring "upstream" between the battery Page 3241 Fuel Line Coupler: Testing and Inspection FUEL TUBE/QUICK - CONNECTOR FITTINGS Assembling Advice Application of engine oil or light oil to the pipe facilitates connecting work. The work should be started immediately after lubrication, since dust may stick to the pipe surface to cause poor sealability if a long time passes after lubrication. Test/Inspection After Assembling 1. Reconnect the battery negative cable. 2. Turn the ignition key to the "ON" position and check pump startup sound. As the pump is actuated to raise fuel pressure, check and see fuel leak from the piping system. 3. Make sure of no fuel leakage by conducting the above fuel leak check a few times. 4. Start the engine and make sure of stable idling speed and normal vehicle run.The entry of dust during the work may sometimes affect the fuel injection system. Page 5074 Wheel Speed Sensor: Service and Repair Rear REMOVAL 1. Disconnect harness connector (1). 2. Remove sensor fixing bolt (2). 3. Remove speed sensor (3). Page 2119 Coolant Temperature Sensor/Switch (For Computer): Description and Operation Engine Coolant Temperature (ECT) Sensor The engine coolant temperature (ECT) sensor is a thermistor (a resistor which changes value based on temperature) mounted in the engine coolant stream. Low coolant temperature produces a high resistance of 100,000 ohms at -40 °C (-40 °F). High temperature causes a low resistance of 70 ohms at 130 °C (266 °F). The PCM supplies a 5-volt signal to the ECT sensor through resistors in the PCM and measures the voltage. The signal voltage will be high when the engine is cold and low when the engine is hot. By measuring the voltage, the PCM calculates the engine coolant temperature. Engine coolant temperature affects most of the systems that the PCM controls. The Tech 2 displays engine coolant temperature in degrees. After engine start-up, the temperature should rise steadily to about 85 °C (185 °F). It then stabilizes when the thermostat opens. If the engine has not been run for several hours (overnight), the engine coolant temperature and intake air temperature displays should be close to each other. A hard fault in the engine coolant sensor circuit will set DTC P0177 or DTC P0118. An intermittent fault will set a DTC P1114 or P1115. Page 2121 3. Connect the electrical connector. 4. Fill the radiator with coolant. Refer to Draining and Refilling Cooling System. 5. Connect the negative battery cable. Description and Operation EGR Valve Position Sensor: Description and Operation EGR Pintle Position Sensor The PCM monitors the EGR valve pintle position input to endure that the valve responds properly to commands from the PCM and to detect a fault if the pintle position sensor and control circuits are open or shorted. If the PCM detects a pintle position signal voltage outside the normal range of the pintle position sensor, or a signal voltage that is not within a tolerance considered acceptable for proper EGR system operation, the PCM will set DTC P1406. Page 5203 and the fuses. From Fuses to Relays and Components The second half of Power Distribution shows the wiring "From Fuses to Relays and Components." This can speed your troubleshooting by showing which circuits share fuses. If Power Distribution shows that an inoperative circuit and another circuit share a fuse, check a component in the other circuit. If it works, you know the fuse is good and power is available to the inoperative circuit. Ground Distribution Schematics Page 4562 2. Connect the short finder across the battery terminals and the load (component) side of the fuse terminal. 3. Close all switches in the circuit you're testing. 4. Turn on the short finder. This creates a pulsing magnetic field around the wiring between the fuse box and the short. 5. Beginning at the fuse box, slowly move the short finder along the circuit wiring. The meter will read current pulses through sheet metal and body trim. As long as the meter is between the fuse and the short, the needle will move with each current pulse. Once you move the meter past the point of the short, the needle will stop moving. Check the wiring and connectors in this area to locate the cause of the short. Testing For Continuity When testing for continuity at a connector without wire seals, you do not have to separate the two halves of the connector. Instead, probe the connector from the back. Always check both sides of the connector because dirty, corroded, and bent terminals can cause problems (no electrical contact = an open). 1. Disconnect the negative cable from the car battery. If you're using a DVOM, place it in the lowest "OHMS" range. Page 4215 This sample Ground Distribution schematic shows all of the components that share two ground points. Components A solid border line means the entire component is shown. A broken border line indicates that only part of the component is shown. Page 1832 Heater Core: Testing and Inspection Heater Core and/or Mode Door Check for foreign matter in the heater core, stain or the core fin defacement. Front Seat Belt Buckles Seat Belt Buckle: Service and Repair Front Seat Belt Buckles Removal 1. Disconnect the battery ground cable. 2. Disconnect the seat belt warning connector (driver's side) and remove a clip. 3. Remove the front seat buckle assembly (1). Installation To install, follow the removal steps in the reverse order, noting the following point. 1. Tighten the buckle anchor bolt to the specified torque. Torque: 39 N.m (29 lb ft) Page 6547 The following procedure requires use of J-42986 Supplemental Restraint System (SRS) Deployment Harness with the appropriate pigtail adapter. The procedure also requires the use of J-41497 Driver Side SRS Deployment Fixture. Do not attempt this procedure without J-42986 and fixture J-41497. WARNING: FAILURE TO FOLLOW PROCEDURES IN THE ORDER LISTED MAY RESULT IN PERSONAL INJURY. NEVER CONNECT DEPLOYMENT HARNESS TO ANY POWER SOURCE BEFORE CONNECTING DEPLOYMENT HARNESS TO THE DRIVER AIR BAG ASSEMBLY. DEPLOYMENT HARNESS SHALL REMAIN SHORTED AND NOT BE CONNECTED TO A POWER SOURCE UNTIL THE AIR BAG IS TO BE DEPLOYED. THE AIR BAG ASSEMBLY WILL IMMEDIATELY DEPLOY THE AIR BAG WHEN A POWER SOURCE IS CONNECTED TO IT. WEAR SAFETY GLASSES THROUGHOUT THIS ENTIRE DEPLOYMENT AND DISPOSAL PROCEDURE. NOTE: This information applies only to driver air bag assembly Refer to "Deployment Outside Vehicle (Passenger Air Bag Assembly)" for information on passenger air bag assembly scrapping. 1. Turn ignition switch to "LOCK", remove key and put on safety glasses. 2. Inspect J-41434 SRS Deployment Harness and appropriate pigtail adapter for damage. If harness or pigtail adapter is damaged, discard and obtain a replacement. 3. Short the two SRS deployment harness leads together by fully seating one banana plug into the other. SRS deployment harness shall remain shorted and not be connected to a power source until the air bag is to be deployed. Page 5919 The name of the component appears next to it followed by notes about its function along with any photo and connector view references. Connector "C" How to Identify Connector Terminals Cavity Numbering System The cavities (and wire terminals) in each connector are numbered starting from the upper left, looking at the male terminals from the terminal side (or looking at the female terminals from the wire side. Both views are in the same direction so the numbers are the same.) All actual cavities are numbered, even if they have no wire terminals in them. NOTE: Data Link Connector (DLC) terminals are numbered according to SAE standard J1962, not the Honda standard. The numbers of the four end terminals are molded into the corners of the connector face. Page 5120 1. Measure the resistance between each diode terminal and aluminum diode fin in forward and reverse directions with the connection of the tester leads switched. The diodes are normal if resistance is nearly zero ohms in one direction and is infinitely high in the other direction. 2. If a diode has no resistance or equal resistance in both directions, it is defective and should be replaced together with the holder. IC Regulator Assembly Connect a variable resistor, two 12V batteries, a fixed resistor, and a voltmeter to the IC regulator as shown in illustration. a. Measuring equipment specifications 1. Fixed resistor (R1) :10 Ohms /3 W 2. Variable resistor (Rv) : 0 - 300 Ohms/12 W 3. Batteries (BAT1 BAT2) :12 V (2 Batteries) 4. DC voltmeter: 0 - 50 V/0.5 steps (4 Check points) b. Measuring procedure 1. Measure the voltage "V1" across the first battery (BAT1). If the reading is between 10 and 13 volts, the battery is normal. 2. Measure the voltage "V3" across both the batteries (BAT1, BAT2). If the reading is between 20 and 26 bolts, the batteries are normal. 3. Gradually increase the resistance of the variable resistor from zero. Measure the voltage "V2" (the voltage across the F and E terminals). Check to see that the voltage across "Vi" changes at this time. If there is no change, the voltage regulator is faulty and must be replaced. 4. Measure the voltage at "V4" (the voltage across the variable resistor center tap and terminal E with the variable resistor resistance held constant). The measure voltage should be within the specified (14.4 ± 0.3 volts) limits. If it is not, the regulator must be replaced. Page 6396 20. Bend twisted connection made in the previous step flat and wrap tightly with electrical tape to insulate and secure. 21. Twist together, bend and tape the remaining connector wire lead to the remaining deployment wire. 22. Connect the deployment harness to the passenger air bag assembly, yellow 2 - pin connector located behind the glove box assembly. Route deployment harness out the passenger side of the vehicle. WARNING: DEPLOYMENT WIRES SHALL REMAIN SHORTED AND NOT BE CONNECTED TO A POWER SOURCE UNTIL THE AIR BAG IS TO BE DEPLOYED. THE AIR BAG ASSEMBLY WILL IMMEDIATELY DEPLOY THE AIR BAG WHEN A POWER SOURCE IS CONNECTED TO IT. CONNECTING THE DEPLOYMENT WIRES SHOULD ALWAYS BE THE FINAL STEP IN THE AIR BAG ASSEMBLY DEPLOYMENT PROCEDURE. FAILURE TO FOLLOW PROCEDURES IN THE ORDER LISTED COULD RESULT IN PERSONAL INJURY. 23. Verify that the inside of the vehicle and the area surrounding the vehicle are clear of all people and loose or flammable objects. 24. Stretch the driver and passenger deployment harness to their full length. 25. Completely cover windshield area and front door window openings with a drop cloth, blanket or similar item. This reduces the possibility of injury due to possible fragmentation of the vehicle's glass or interior. 26. Notify all people in the immediate area that you intend to deploy the air bags. The deployment will be accompanied by a substantial noise which may startle the uninformed. 27. Separate the two ends of the driver deployment harness wires. WARNING: DEPLOYMENT WIRES SHALL REMAIN SHORTED AND DISCONNECTED FROM ANY POWER SOURCE UNTIL THE AIRBAG IS TO BE DEPLOYED OR ACCIDENTAL AIRBAG DEPLOYMENT WILL IMMEDIATELY OCCUR. THIS MAY CAUSE PERSONAL INJURY. ALWAYS WEAR SAFETY GLASSES DURING AIRBAG DEPLOYMENT AND DISPOSAL. CONNECTING THE DEPLOYMENT WIRES TO THE POWER SOURCE SHOULD ALWAYS BE THE FINAL STEP IN THE AIRBAG ASSEMBLY DEPLOYMENT PROCEDURE. FAILURE TO FOLLOW PROCEDURES IN THE ORDER LISTED COULD RESULT IN PERSONAL INJURY. NOTE: When the air bag deploys, the rapid gas expansion will create a substantial noise. Notify all people in the immediate area that you intend to deploy the air bags. 28. Connect the driver deployment harness wires to a power source to immediately deploy the driver air bag assembly. Recommended application: 12 volts minimum, 2 amps minimum. A vehicle battery is suggested. 29. Separate the two ends of the passenger deployment harness wires. WARNING: DEPLOYMENT WIRES SHALL REMAIN SHORTED AND DISCONNECTED FROM ANY POWER SOURCE UNTIL THE AIRBAG IS TO BE DEPLOYED OR ACCIDENTAL AIRBAG DEPLOYMENT WILL IMMEDIATELY OCCUR. THIS MAY CAUSE PERSONAL INJURY. ALWAYS WEAR SAFETY GLASSES DURING AIRBAG DEPLOYMENT AND DISPOSAL. CONNECTING THE DEPLOYMENT WIRES TO THE POWER SOURCE SHOULD ALWAYS BE THE FINAL STEP IN THE AIRBAG ASSEMBLY DEPLOYMENT PROCEDURE. FAILURE TO FOLLOW PROCEDURES IN THE ORDER LISTED COULD RESULT IN PERSONAL INJURY. 30. Connect the passenger deployment harness wires to a power source to immediately deploy the passenger air bag assembly. Recommended application: 12 volts minimum, 2 amps minimum. A vehicle battery is suggested. (Driver air bag assembly) Put on a pair of shop gloves and safety gasses to protect your hands and eyes from possible irritation and heat when handling the deployed air bag assembly. After the air bag assembly has been deployed, the surface of the air bag may contain solid particulate. This solid particulate consists primarily of by products of the chemical reaction, Potassium Chloride and copper metal dust. Compounds of Potassium Borate, Strontium Chloride, Copper Chloride, and Ammonium Chloride may be found in amounts of about 1% (each) of the total particulate. (Passenger air bag assembly) Put on a pair of shop gloves and safety glasses to protect your hands and eyes from possible irritation and heat when handling the deployed air bag assembly. After the air bag assembly has been deployed, the surface of the air bag may contain a powdery residue. This powder consists primarily of cornstarch (used to lubricate the bag as it inflates) and by products of the chemical reaction. Sodium hydroxide dust (similar to lye soap) is Page 5065 Part 1 of 2 Part 2 of 2 B-21 FR Speed Sensor Missing (DTC 62/C0222, C0223) Chart B-21 FR Speed Sensor Missing (DTC 62 (Flash Out) / C0222, C0223 (Serial Communications)) Page 2552 Crankshaft Position Sensor: Description and Operation Crankshaft Position (CKP) Sensor The crankshaft position (CKP) sensor provides a signal used by the powertrain control module (PCM) to calculate the ignition sequence. The CKP sensor initiates the 58X reference pulses which the PCM uses to calculate RPM and crankshaft position. Page 6614 Ramsey, NJ 07446 800-433-9657 (Visteon offers an open line of credit. Call their 800 number to establish an account.) NOTE: ^ The manufacturer will repair the unit and ship it back within 5-7 working days, via UPS ground prepaid or 2nd Day Air (whichever you requested). Do not forget to include the shipping cost in your dealership payment. Units damaged by misuse or mishandling cannot be shipped back within the usual 5-7 days. ^ Each manufacturer's guarantee for the repair differs. To confirm the repair guarantee, contact the manufacturer using the phone number listed above. 10. To check on the status of your repair order, call the manufacturer. If your customer has any further questions or concerns, have them call Automobile Customer Service at 800-999-1009. NOTE: A damaged unit may need extra repair. If so, the manufacturer will call you with an estimate of any added charges. ^ If you accept the estimate, mail a dealership check for the additional amount to the manufacturer, authorize the increased amount to be applied to the credit card payment, or have the manufacturer ship the unit back to you, and you pay the difference upon arrival (C.O.D.). ^ If you reject the estimate, the faulty unit will be returned to you along with a refund. However, you will be charged $30.00 (C.O.D.) for diagnosis, shipping, and handling. The unit will be shipped back to you, via UPS Ground. COMPLETING THE OUT-OF-WARRANTY/NEW REPLACEMENT AUDIO SYSTEM COMPONENT REPAIR FORM Page 5659 Control Arm: Service and Repair Lower Arm REMOVAL 1. Raise the vehicle and support the frame with suitable safety stands. 2. Remove wheel and tire assembly. 3. Remove the tie-rod end from the knuckle. 4. Remove the retaining ring from the front axle driving shaft to release the shaft from hub. 5. Support lower control arm with a jack. 6. Remove front nut. 7. Remove rear nut. 8. Remove torsion bar. 9. Remove torsion bar arm bracket. 10. Disconnect the stabilizer link at the lower control arm. 11. Remove the shock absorber lower end from the lower control arm. 12. Remove the lower ball joint from the lower control arm. 13. Remove front bolt. 14. Remove rear bolt. 15. Remove lower control arm. Service and Repair Input Shaft: Service and Repair For further information regarding this component and the system that it is a part of, please refer to Manual Transmission/Transaxle; Service and Repair; Unit Overhaul Page 2938 6. Place the end of the return hose in a container. Have someone start the engine, then pour ATF into the reservoir while you watch the fluid coming out of the return hose. When the fluid coming out is the same color as the new fluid, turn off the engine. 7. Reconnect the return hose to the reservoir. 8. Start the engine. Fill the power steering reservoir to the proper level with ATF then turn off the engine. 9. Use the Smart Cable to reprogram the PCM with the latest software from the June 2001 or later HONDANET CD-ROM. Refer to Service Bulletin 99-005, Updating the Passport PCM, filed under Tools. 10. Use the PGM Tester to clear any DTCs. 11. Use the PGM Tester to check the broadcast code. Make sure the broadcast code matches the one you selected from the CD-ROM. WARRANTY CLAIM INFORMATION In warranty: The normal warranty applies. Failed Part: P/N 8-97181-590-0 H/C 5698030 Defect Code: 064 Contention Code: C01 Skill Level: Repair Technician Out of warranty: Any repair performed after warranty expiration may be eligible for goodwill consideration by the District Service Manager or your Zone Office. You must request consideration, and get a decision, before starting work. REPAIR PROCEDURE - APPS GROUND 1. Unclamp the air cleaner housing cover, and move it to the side for access to connector C123 (16P BLK). Removal and Installation Piston Ring: Service and Repair Removal and Installation Piston, Piston Ring and Connecting Rod Removal 1. Remove cylinder head assembly. - Refer to removal procedure for Cylinder Head. 2. Remove crankcase with oil pan. - Refer to removal procedure for Oil Pan and Crankcase. Page 6348 - Refer to the scrapping procedures for disposal of the damaged airbag. Page 8008 Distinct Of Circuit By Wire Base Color All wires have color-coded insulation. Wires belonging to a system's main harness will have a single color. Wires belonging to a system's sub-circuits will have a colored stripe. Striped wires use the codes found in the chart to show wire size and colors. Abbreviations are used to indicate wire color within a circuit diagram. How to Identify Connector Terminals How to Identify Connector Terminals Cavity Numbering System The cavities (and wire terminals) in each connector are numbered starting from the upper left, looking at the male terminals from the terminal side (or looking at the female terminals from the wire side. Both views are in the same direction so the numbers are the same.) All actual cavities are numbered, even if they have no wire terminals in them. NOTE: Data Link Connector (DLC) terminals are numbered according to SAE standard J1962, not the Honda standard. The numbers of the four end terminals are molded into the corners of the connector face. The connector cavity number is listed next to each terminal on the circuit schematic. The cavity / terminal shown is # 6. Using/Identifying Connector Terminal Views How to Use Connector Terminal Views To see the configuration of a connector's cavities, look up its view number in the Connector Views. Each view includes the color of the connector, where Locations Trailer Connector: Locations Left Rear of Cargo Compartment Left Rear of Cargo Compartment Below Left side of Rear Bumper Page 1732 - Set the camshaft marked "RE" and "LE into the exhaust side of the cylinder bank, with "RE" at the 12 o'clock position. Make sure the single timing dot on the camshaft gear aligns with the timing dot on the camshaft drive gear. 5. Install the left cylinder bank intake and exhaust camshafts: - Set the camshaft marked "LI" into the intake side of the head. Make sure the dual timing dots on the camshaft gear align with the timing dot on the camshaft drive gear. - Set the camshaft marked "LE" and "RE," into the exhaust side of the cylinder bank, with "LE" at the 12 o'clock position. Make sure the dual timing dots on the camshaft gear align with the timing dot on the camshaft drive gear. 6. Install the camshaft bearing caps in the same locations and directions they were before you removed them. NOTE: On the right cylinder bank, the directional arrows on the bearing caps should point towards the front of the engine. On the left bank, the arrows should point towards the rear of the engine. 7. Install the bearing cap bolts, then torque them to 10 N.m (7 lb-ft) in the sequence shown below. Circuit Operation Powertrain Control Module: Description and Operation Circuit Operation The engine or powertrain control module (ECM or PCM) receives inputs from the engine sensors and switches, controlling the functions of the engine. It also turns on the malfunction indicator "check engine" light whenever a malfunction or abnormal engine performance is detected, and allows for diagnostic testing through the data link connector (DLC). Page 1327 Supportable Point: Rear - Position the chassis stands at the bottom of the rear axle case. Page 3875 Actuator: Testing and Inspection MOTOR ACTUATOR ASSEMBLY Inspect the function of the motor actuator assembly as follows: 1. Disassemble the motor actuator from transfer rear case. 2. Connect the terminals as shown in figure. Shift rod of the motor actuator moves and stops at 4WD position. Specifications Piston Ring: Specifications Ring End Gap Compression Ring 1st Ring Stadnard 0.300 - 0.400 mm Limit 1.0 mm 2nd Ring Standard 0.450 - 0.600 mm Limit 1.2 mm Oil Ring Standard 0.150 - 0.450 mm Limit 1.05 mm Ring Groove Clearance Compression Ring Clearance Standard 0.025 - 0.065 mm Limit 0.1 mm Page 3218 Test Equipment CAUTION: Most circuits include solid-state devices. Test the voltages in these circuits only with a 10-megaohm or higher impedance digital multimeter. Never use a test light or analog meter on circuits that contain solid-state devices. Damage to the devices may result. Test Light and DVOM On circuits without solid-state devices, use a test light to check for voltage. A test light is made up of a 12 volt bulb with a pair of leads attached. After grounding one lead, touch the other lead to various points along the circuit where voltage should be present. The bulb will go on if there is voltage at the point being tested. If you need to know how much voltage is present, use a digital volt/ohmmeter (DVOM). Self-Powered Test Light and DVOM Use a self-powered test light to check for continuity. This tool is made up of a light bulb, battery, and two leads. To test it, touch the leads together: the light should go on. Use a self-powered test light only on an unpowered circuit. First, disconnect the battery, or remove the fuse that feeds the circuit you are working on. Select two points in the circuit between which you want to check continuity. Connect one lead of the self-powered test light to each point. If there is continuity, the test light's circuit will be completed, and the light will go on. If, in addition, you need to know exactly how much resistance there is between two points, use a digital volt/ohmmeter (DVOM). In the "OHMS" range, the DVOM will measure resistance between two points along a circuit. Low resistance means good continuity. Diodes and solid-state devices in a circuit can make a DVOM give a false reading. To check a reading, reverse the leads, and take a second reading. If the readings differ, the component is affecting the measurement. Jumper Wire Use a jumper wire to bypass an open circuit. A jumper wire is made up of an in-line fuse holder connected to a set of test leads. It should have a five ampere fuse. Never connect a jumper wire across a short circuit. The direct battery short will blow the fuse. Short Finder (Short Circuit Locator) Short finders are available to locate shorts to ground. The short finder creates a pulsing magnetic field in the shorted circuit which you can follow to the location of the short. To order any test equipment shown above, contact your local tool supplier. For a list of suppliers and tool numbers, refer to Honda Required Special Tools and Equipment Service Bulletin. Page 1834 7. Remove case (Temperature control) separate two halves of core case. 8. Remove heater core (1). 9. Pull out the mode door while raising up the catch of the door lever. Installation Page 495 Splices Splices are shown as a dot. Their location and the number of wires may vary depending on the harness manufacturer. Switches Switches These switches move together; the broken straight line between them means they are mechanically connected. Other types of switches are controlled by a coil or a solid state circuit. Unless otherwise noted, all switches are shown in their normal (rest) position, with power off. Terminal "T" Locations Fan Control Switch Page 7294 4. Align the template on the mud flap. Mark the area on the mud flap that needs to be cut away with a pencil or scribe. 5. Use a utility knife to remove the marked area. 6. Repeat steps 4 and 5 on the other mud flap. 7. Reinstall the mud flaps on the vehicle. DISCLAIMER Accelerator Pedal Assembly/Sensor - Adjustment Update Accelerator Pedal Position Sensor: All Technical Service Bulletins Accelerator Pedal Assembly/Sensor - Adjustment Update 00-045 August 14, 2001 Applies To: 2000-02 Passport - ALL Service Manual Update: Accelerator Pedal Position Sensor (APPS) (Supersedes 00-045, dated May 23, 2000) Updated information is shown by asterisks and black bars. BACKGROUND When the accelerator pedal position sensor (APPS) or the accelerator pedal assembly is replaced for any reason, you must adjust the APPS. *This procedure is missing in the 2000 service manual and is wrong in the 2001 and 2002 service manuals. Make a note on page 6E2-539 of the 2000 Passport Fuel and Emissions manual, on page 6E2-553 of the 2001 Passport Fuel and Emissions manual, and on page 6E2-545 of the 2002 Passport Fuel and Emissions manual to refer to this bulletin.* ADJUSTMENT PROCEDURE 1. Replace the APPS or the accelerator pedal assembly, and leave the mounting screws for the APPS loose. 2. Connect the PGM Tester to the data link connector (DLC), and turn the ignition switch to ON (II). *3. While watching the APP Sensor values in the Engine Data List, adjust the APPS by turning it until the values are within the ranges shown at closed pushed all the way down), then tighten the throttle and wide open throttle (accelerator pedal mounting screws and recheck the values. ^ If all three sensors are within range, go to step 12. ^ If APP Sensor 1, APP Sensor 2, and/or APP Sensor 3 cannot be brought into range, go to step 4. 4. Troubleshoot for an open circuit or a PCM malfunction. ^ If APP Sensor 1 has a value of 0% or APP Sensor 2 and/or APP Sensor 3 have a value of 99%, an open circuit exists or the PCM is malfunctioning. Repair the circuit or replace the PCM, and repeat step 3. ^ If you don't find a problem, go to step 5. 5. Disconnect the 10P connector from the APPS. 6. View the APP Sensor values in the Engine Data List. ^ If APP Sensor 1 has a value of 0% or APP Sensor 2 and/or APP Sensor 3 have a value of 99%, go to step 7. ^ If APP Sensor 1 has a value other than 0%, or APP Sensor 2 and/or APP Sensor 3 have a value other than 99%, a short circuit exists or the PCM is malfunctioning. Repair the circuit or replace the PCM, and repeat step 3. Service and Repair Fuel Pressure Release: Service and Repair CAUTION: To reduce the risk of fire and personal injury, there are necessary to relieve the fuel system pressure filler and gauge unit before servicing the fuel system components. CAUTION: After relieving the system pressure, a small amount of fuel may be released when servicing fuel lines or connections. Reduce the chance of personal injury by covering the fuel line fittings with a shop towel before you disconnect the fittings. The towels will absorb any fuel that may leak out. When the disconnection is completed, place the towel in an approved container. 1. Remove the fuel cap. 2. Remove the fuel pump relay from the underhood relay box. 3. Start the engine and allow it to stall. 4. Crank the engine for 30 seconds. 5. Disconnect the negative battery cable. Locations Shift Interlock Relay: Locations Under Center Console Page 740 Torque Specifications Page 5842 ^ Reversible drill motor (800 RPM MAX) ^ Tire spreader ^ Inspection lamp * For repairable injuries that exceed 25 degrees TIRE REPAIR GUIDELINES Never repair tires worn below 2/32 inch of tread. Never repair a tire without removing the tire from the wheel for internal inspection. Never repair a tire with a tread injury larger than 1/4 inch (6 mm). Never use only a plug (stem) or a patch only to repair a tire injury. NOTE: If the angle of the tire injury exceeds 25 degrees, you must use the two-piece repair system as recommended by the RMA. MICHELIN PAX SYSTEM SUPPORT RING INSPECTION PAX System support rings are not repairable, under any circumstances, but they can be reused if no damage is found during a thorough inspection. If a PAX System tire ran flat or underinflated, dismount the tire from the wheel and inspect the wheel, tire, and support ring for damage. Refer to the Michelin PAX Support Rings Technical Bulletin in ISIS. Enter SEARCH BY PUBLICATION, select Job Aids, then select Michelin PAX Support Rings Technical Bulletin from the list. Disclaimer Page 2371 Spark Plug: Description and Operation Spark Plug Although worn or dirty spark plugs may give satisfactory operation at idling speed, they frequency fail at higher engine speeds. Faulty spark plugs may cause poor fuel economy, power loss, loss of speed, hard starting and generally poor engine performance. Follow the scheduled maintenance service recommendations to ensure satisfactory spark plug performance. Refer to Maintenance and Lubrication. Normal spark plug operation will result in brown to grayish-tan deposits appearing on the insulator portion of the spark plug. A small amount of red-brown, yellow, and white powdery material may also be present on the insulator tip around the center electrode. These deposits are normal combustion by-products of fuels and lubricating oils with additives. Some electrode wear will also occur. Engines which are not running properly are often referred to as "misfiring." This means the ignition spark is not igniting the air/fuel mixture at the proper time. While other ignition and fuel system causes must also be considered, possible causes include ignition system conditions which allow the spark voltage to reach ground in some other manner than by jumping across the air gap at the tip of the spark plug, leaving the air/fuel mixture unburned. Refer to DTC P0300. Misfiring may also occur when the tip of the spark plug becomes overheated and ignites the mixture before the spark jumps. This is referred to as "pre-ignition." Spark plugs may also misfire due to fouling, excessive gap, or a cracked or broken insulator. If misfiring occurs before the recommended replacement interval, locate and correct the cause. Carbon fouling of the spark plug is indicated by dry, black carbon (soot) deposits on the portion of the spark plug in the cylinder. Excessive idling and slow speeds under light engine loads can keep the spark plug temperatures so low that these deposits are not burned off. Very rich fuel mixtures or poor ignition system output may also be the cause. Refer to DTC P0172. Oil fouling of the spark plug is indicated by wet oily deposits on the portion of the spark plug in the cylinder, usually with little electrode wear. This may be caused by oil during break-in of new or newly overhauled engines. Deposit fouling of the spark plug occurs when the normal red-brown, yellow or white deposits of combustion by products become sufficient to cause misfiring. In some cases, these deposits may melt and form a shiny glaze on the insulator around the center electrode. If the fouling is found in only one or two cylinders, valve stem clearances or intake valve seals may be allowing excess lubricating oil to enter the cylinder, particularly if the deposits are heavier on the side of the spark plug facing the intake valve. Excessive gap means that the air space between the center and the side electrodes at the bottom of the spark plug is too wide for consistent firing. This Page 7488 Wires Wire insulation can be one color, or one color with another color stripe. (The second color is the stripe.) This circuit continues on another image. (The arrow shows direction of current flow.) To follow the RED/BLK wire in this example, you would turn to "Fuel and Emissions" and look for the "A" arrow. Page 906 H/C 4408092 Defect Code: 017 Contention Code: C99 Skill Level: Repair Technician Out of warranty: Any repair performed after warranty expiration may be eligible for goodwill consideration by the District Service Manager or your Zone Office. You must request consideration, and get a decision, before starting work. DISCLAIMER Page 3800 H/C 4408092 Defect Code: 017 Contention Code: C99 Skill Level: Repair Technician Out of warranty: Any repair performed after warranty expiration may be eligible for goodwill consideration by the District Service Manager or your Zone Office. You must request consideration, and get a decision, before starting work. DISCLAIMER Page 3312 Fuel Pump Relay: Service and Repair REMOVAL PROCEDURE 1. Remove the fuse and relay box cover from under the hood. 2. Consult the diagram on the cover to determine which is the correct relay. 3. Insert a small screwdriver into the catch slot on the forward side of the fuel pump relay. 4. The screwdriver blade will release the catch inside. 5. Pull the relay straight up and out of the fuse and relay box. INSTALLATION PROCEDURE 1. Insert the relay into the correct place in the fuse and relay box with the catch slot facing forward. 2. Press down until the catch engages. - An audible "click" will be heard. Page 4717 The connector cavity number is listed next to each terminal on the circuit schematic. The cavity / terminal shown is # 6. Diodes A rectifier diode works like a one way valve. It allows current to flow only in the direction of the arrow. A Zener diode blocks reverse current at normal voltages just like a rectifier diode. At high voltages, however, a Zener diode allows current to flow in reverse. Fuses Description and Operation Vacuum Brake Booster: Description and Operation This booster is a tandem vacuum unit with a diaphragm effective diameter 205 mm + 230 mm. In normal operating mode, with the service brakes in the released position, the tandem vacuum booster operates with vacuum on both sides of its diaphragms When the brakes are applied, air at atmospheric pressure is admitted to one side of each diaphragm to provide the power assist When the service brake is released, the atmospheric air is shut off from the one side of each diaphragm The air is then drawn from the booster through the vacuum check valve to the vacuum source. CAUTION: 1. If any hydraulic component is removed or disconnected, it may be necessary to bleed all or part of the brake system. 2. The torque values specified are for dry, unlubricated fasteners. 3. The vacuum booster is not repairable and must be replaced as complete assembly. Page 3210 Ground - "G" Shielding Sheilding This represents RFI (Radio Frequency Interference) shielding around a wire. The shielding is always connected to ground. Splices Page 8144 Power Window Switch: Service and Repair Master Switch Replacement Removal 1. Disconnect the battery ground cable. 2. Remove the switch (1). - Pull out the switch by pushing the spring with the tip of a screwdriver. - Disconnect the connector. Installation To install, follow the removal steps in the reverse order. Page 1189 Fluid - A/T: Fluid Type Specifications A/T Fluid Type ..................................................................................................................................................... .............................................. ATF DEXRON (R) III Page 2568 The connector cavity number is listed next to each terminal on the circuit schematic. The cavity / terminal shown is # 6. Diodes A rectifier diode works like a one way valve. It allows current to flow only in the direction of the arrow. A Zener diode blocks reverse current at normal voltages just like a rectifier diode. At high voltages, however, a Zener diode allows current to flow in reverse. Fuses Specifications Clutch Release Fork: Specifications Throw-out Fork Attaching Bolt 38 Nm Page 2284 11. Using a jumper wire, connect the reference voltage of each circuit to its signal input and view the APP Sensor values in the Engine Data List. APP Sensor 1 should have a value of 99%, and APP Sensor 2 and APP Sensor 3 should each have a value of 0%. ^ If the values are not as specified, troubleshoot for high resistance on the signal input or a PCM malfunction. Repair the circuit or replace the PCM, then repeat step 3. ^ If the values are as specified, the problem may be intermittent. Disconnect the 10P connector from the modified APPS, and connect it to the new APPS; then repeat step 3. Wiggle the APPS wires as you go through the adjustment procedure to find the intermittent problem. 12. Turn off the ignition switch, and disconnect the PGM Tester.* DISCLAIMER Page 8003 Hazard Warning Switch: Service and Repair Removal 1. Disconnect the battery ground cable. 2. Remove the meter cluster assembly (1). 3. Remove the hazard warning switch (2). - Disconnect the switch connector. - To remove the switch, push the lock from the back side of the meter cluster assembly. Installation To install, follow the removal steps in the reverse order. Page 7191 Page 8072 the component if the component only has one connector, or by a capital letter (A, B, C, etc.) if the component has more than one connector. Below most connector numbers and component names are PHOTO and VIEW numbers. The PHOTO number refers to a photo in the back of the book that shows the connector's location on the car. The VIEW number refers to an illustration in the back of the book that shows the connector face, wire colors, connector cavity numbers, and other details. The connector cavity numbering sequence begins at the top left corner of the connector. Disregard any numbers molded into the connector housing. Wires Wires are identified by the abbreviated names of their colors; the second color is the color of the stripe. Wires are also identified by their location in a connector. The number "2" next to the male and female wire terminals at C416, for example, means those terminals join in cavity 2 of connector C416. Symbols A complete description of schematic symbols is given under wire color abbreviation. Power Distribution Schematics Power Distribution schematics show how power is supplied from the positive battery terminal to various circuits in the car. Refer to the Power Distribution section to get a more detailed picture of how power is supplied to the circuit you're working on. From Battery to Ignition Switch, Fuses, and Relays Individual circuit schematics begin with a fuse. The first half of Power Distribution, however, shows the wiring "upstream" between the battery Page 6427 Clockspring Assembly / Spiral Cable: Description and Operation SRS Coil Assembly The SRS coil assembly consists of two current carrying coils. This is attached to the steering column and allow rogation of the steering wheel while maintaining continuous contact of the driver deployment loop to the driver air bag assembly. There is a shorting clip on the yellow 2 - pin connector near the base of steering column which connects the SRS coil to the SRS wiring harness. The shorting clip shorts to the SRS coil and driver air bag assembly when the yellow 2 - pin connector is disconnected. The circuit to the driver air bag assembly is shorted in this way to help prevent unwanted deployment of the air bag when servicing the steering column or other SRS components. Refer to the "STEERING". Page 6835 1. Install the regulator handle as shown in the figure, if equipped without Dower windows. 2. Check to see that the window regulator operates smoothly and the glass opens and closes properly. 3. Install the waterproof sheet tightly against the door panel. Page 6070 Distinct Of Circuit By Wire Base Color All wires have color-coded insulation. Wires belonging to a system's main harness will have a single color. Wires belonging to a system's sub-circuits will have a colored stripe. Striped wires use the codes found in the chart to show wire size and colors. Abbreviations are used to indicate wire color within a circuit diagram. How to Identify Connector Terminals How to Identify Connector Terminals Cavity Numbering System The cavities (and wire terminals) in each connector are numbered starting from the upper left, looking at the male terminals from the terminal side (or looking at the female terminals from the wire side. Both views are in the same direction so the numbers are the same.) All actual cavities are numbered, even if they have no wire terminals in them. NOTE: Data Link Connector (DLC) terminals are numbered according to SAE standard J1962, not the Honda standard. The numbers of the four end terminals are molded into the corners of the connector face. The connector cavity number is listed next to each terminal on the circuit schematic. The cavity / terminal shown is # 6. Using/Identifying Connector Terminal Views How to Use Connector Terminal Views To see the configuration of a connector's cavities, look up its view number in the Connector Views. Each view includes the color of the connector, where Locations Sunroof Frame Complete Assembly (LWB) And Associated Parts Paint Code List Page 6073 Each schematic represents one circuit. A circuit's wires and components are arranged to show current flow, from power at the top of the page, to ground, at the bottom. Shared Circuits Other circuits may share power or ground terminals or wiring with the circuit shown. A wire that connects one circuit to another, for example, is cut short and has an arrowhead at the end of it pointing in the direction of current flow. Next to the arrowhead is the name of the circuit or component which shares that wiring. To quickly check shared wiring, check the operation of a component it serves. If that component works, you know the shared wiring is OK. Connectors All in-line and junction connectors are numbered (C725, C416, etc.). Component connectors are not numbered but are identified either by the name of Page 6527 11. Remove the shoulder anchor cover (2). - Release the hooked portion of cover from the shoulder anchor (1). 12. Remove the seat belt upper anchor bolt. 13. Remove the retractor. 14. Remove the rear seat belt assembly. INSTALLATION To install, follow the removal steps in the reverse order, noting the following points. 1. Align the projection of the retractor to the square hole of the seat belt cross bar assembly bracket. 2. Tighten the retractor fixing bolts to the specified torque. Torque: 39 N.m (29 lb.ft) 3. Tighten the seat belt anchor bolt to the specified torque. Torque: 39 N.m (29 lb.ft) Page 4687 Splices Splices are shown as a dot. Their location and the number of wires may vary depending on the harness manufacturer. Switches Switches These switches move together; the broken straight line between them means they are mechanically connected. Other types of switches are controlled by a coil or a solid state circuit. Unless otherwise noted, all switches are shown in their normal (rest) position, with power off. Terminal "T" Page 6933 Body / Frame Mount Bushing: Service and Repair Body Mounting Body Mounting Tightening Torque 1. Tighten the body mounting bolts to specified torque. Torque: 50 N.m (41 lb.ft) * mark position (LWB)Torque: 50 N.m (41 lb.ft) (SWB)Torque: 103 N.m (76 lb.ft) Page 6742 Wire Color Abbreviations The following abbreviations are used to identify wire colors in the circuit schematics: WHT................................... White YEL................................... Yellow BLK................................... Black BLU................................... Blue GRN................................... Green RED................................... Red ORN................................... Orange PNK................................... Pink BRN................................... Brown GRY................................... Gray PUR................................... Purple LT BLU................................... Light Blue LT GRN................................... Light Green Page 5306 Auxiliary Power Outlet: Diagnostic Aids Before Troubleshooting Before Troubleshooting See: Service Precautions/Vehicle Damage Warnings/Tips and Precautions 1. Check applicable fuses in the appropriate fuse/relay box. 2. Check the battery for damage, state of charge, and clean and tight connections. CAUTION: Do not quick-charge a battery unless the battery ground cable has been disconnected, otherwise you will damage the alternator diodes. - Do not attempt to crank the engine with the battery ground cable loosely connected or you will severely damage the wiring. While You're Working 1. Make sure connectors are clean, and have no loose terminals or receptacles. 2. Make sure that connectors without wire seals are packed with dielectric (silicone) grease. Part Number: 08798-9001. 3. When connecting a connector, push it until it "clicks" into place. CAUTION: Do not pull on the wires when disconnecting a connector. Pull only on the connector housings. - Most circuits include solid-state devices. Test the voltages in these circuits only with a 10-megaohm or higher impedance digital multi meter. Never use a test light or analog meter on circuits that contain solid-state devices. Damage to the devices may result. Five-Step Troubleshooting 1. Verify The Complaint Turn on all the components in the problem circuit to check the accuracy of the customer complaint. Note the symptoms. Do not begin disassembly or testing until you have narrowed down the problem area. 2. Analyze The Schematic Look up the schematic for the problem circuit. Determine how the circuit is supposed to work by tracing the current paths from the power source through the circuit components to ground. Also, trace circuits that share wiring with the problem circuit. The names of circuits that share the same fuse, ground, or switch, and so on, are referred to in each circuit schematic. Try to operate any shared circuits you didn't check in step 1. If the shared circuits work, the shared wiring is OK, and the cause must be in the wiring used only by the problem circuit. If several circuits fail at the same time, the fuse or ground is a likely cause. Based on the symptoms and your understanding of the circuit's operation, identify one or more possible causes. 3. Isolate The Problem By Testing The Circuit Make circuit tests to check the diagnosis you made in step 2. Keep in mind that a logical, simple procedure is the key to efficient troubleshooting. Test for the most likely cause of failure first. Try to make tests at points that are easily accessible. 4. Fix The Problem Once the specific problem is identified, make the repair. Be sure to use proper tools and safe procedures. 5. Make Sure The Circuit Works Turn on all components in the repaired circuit in all modes to make sure you've fixed the entire problem. If the problem was a blown fuse, be sure to test all of the circuits on that fuse. Make sure no new problems turn up and the original problem does not recur. Page 4134 3. With clutch switch. 1. Turn the clutch switch until the switch bolt just touches the clutch pedal arm. 2. Adjust clutch switch by backing it out half a turn, and measure the clearance between the clutch pedal arm and the clutch switch bolt end. 3. Lock the lock nut. 4. Connect clutch switch connector. Clutch Switch and Clutch Pedal Clearance: 0.5 - 1.5 mm (0.020 - 0.059 inch) 4. After adjusting the clutch pedal height, push the clutch pedal by hand to ensure the clutch pedal free play is within specification. Pedal Free Play: 5 - 15 mm (0.20 - 0.59 inch) 5. Perform clutch pedal engagement height inspection: 1. Operate the parking brake lever and block the wheels. 2. Start the engine, fully step on the clutch pedal slowly and move the shift lever 1st position. 3. With the engine idling, release the clutch pedal slowly and measure its stroke - just prior to its clutching position. Clutch Pedal Engagement Height (H3): MIN. 30 mm (1.18 inch) 6. If the measured value exceeds the specified limit, check the following points and repair if necessary: - Hydraulic circuit for fluid leakage or air in circuit. - Clutch disc warped. - Diaphragm spring weakened or tip of fingers worn. - Driven plate sticking on splines. - Release bearing worn or damaged. - Master cylinder and slave cylinder worn. Torque Page 7550 A battery voltage (B+) circuit which is only powered with the ignition switch in the ON, or START positions. Initiator The electrical component inside the air bag assembly which, when sufficient current flows, sets off the chemical reaction that inflates the air bag. "Initiator Assembly Resistance Test" Tests performed once each ignition cycle when no malfunctions are detected during "Turn-ON" or "Continuous Monitoring." This test checks for the correct SDM configuration for the vehicle, shorts to "Ignition 1 in the deployment loops, high resistance or opens in the "Driver Side High", "Driver Side Low", "Passenger Side High" and "Passenger Side Low" circuits and measures the resistance of the inflator assembly consisting of: 1. Initiators. 2. SRS coil assembly (driver side only). 3. Connectors and associated wiring. Normal Operating Voltage Range The voltage measured between the SDM "Ignition 1" terminals and "Ground" terminals is between 9 and 16 volts. Passenger Current Source An output of the SDM which applies current into the passenger air bag assembly circuit during the "Initiator Assembly Resistance Test". Passenger Air Bag Assembly An assembly located in the right side of the instrument panel consisting of an inflatable bag, an inflator and an initiator. Scan Tool An external computer used to read diagnostic information from on-board computers via the data link connector. SDM Sensing and Diagnostic Module which provides reserve energy to the deployment loops, deploys the air bags when required and performs diagnostic monitoring of all SRS components. Serial Data Information representing the status of the SRS. SRS Supplemental Restraint System. SRS Coil Assembly An assembly of two current-carrying coils in the driver deployment loop that allows the rotation of the steering wheel while maintaining the continuous contact of the driver deployment loop to the driver air bag assembly. SRS Wiring Harness The wires and connectors that electrically connect the components in the SRS. "Turn-ON" Test which the SDM performs on the SRS once during each ignition cycle immediately after "Ignition 1" voltage is applied to the SDM and before "Continuous Monitoring". Diagram Information and Instructions Ion Sensing Module: Diagram Information and Instructions How to Identify Wiring Color-Coded Insulation Wire Color Wire Color Coding Locations 17. Front of Engine Page 4721 Wires Wire insulation can be one color, or one color with another color stripe. (The second color is the stripe.) This circuit continues on another image. (The arrow shows direction of current flow.) To follow the RED/BLK wire in this example, you would turn to "Fuel and Emissions" and look for the "A" arrow. Page 7725 2. Connect one lead of a self-powered test light or DVOM to one end of the part of the circuit you want to test. 3. Connect the other lead to the other end. 4. If the self-powered test light glows, there is continuity. If you're using a DVOM, a low reading or no reading (zero), means good continuity. Testing For Voltage When testing for voltage at a connector without wire seals, you do not have to separate the two halves of the connector. Instead, probe the connector from the back. Always check both sides of the connector because dirty, corroded, and bent terminals can cause problems (no electrical contact = an open). 1. Connect one lead of the lest light to a known good ground, or, if you're using a digital volt ohmmeter (DVOM), place it in the appropriate DC volts range, and connect its negative lead to ground. 2. Connect the other lead of the test light or DVOM to the point you want to check. 3. If the test light glows, there is voltage present. If you're using a DVOM, note the voltage reading. It should be within one volt of measured battery voltage. A loss of more than one volt indicates a problem. NOTE: Always use a DVOM on high impedance circuits. A test light may not glow (even with battery voltage present). Testing For Voltage Drop Wires, connectors, and switches are designed to conduct current with a minimum loss of voltage. A voltage drop of more than one volt indicates a problem. 1. Place the digital volt/ohmmeter (DVOM) in the appropriate DC volts range. Connect the positive lead to the end of the wire (or to the connector or switch) closest to the battery. 2. Connect the negative lead to the other end of the wire (or the other side of the connector or switch). 3. Turn on the components in the circuit. 4. The DVOM will show the difference in voltage between the two points. A difference, or drop, of more than one volt indicates a problem. Check the circuit for loose, dirty, or bent terminals. Page 2635 Powertrain Control Module: Connector Views Locations 46 - Top Front Of 3.2L Engine (Intake Duct Removed) Page 5652 Control Arm: Specifications Control Arm Upper Attaching Nuts 108 Nm Lower Attaching Nuts/Bolts Front Nut 190 Nm Rear Nut 235 Nm Lower Stop Bolts 42 Nm Page 5089 7. Loosen the inflator module fixing bolt from behind the steering wheel assembly using a TORE driver or equivalent until the inflator module can be released from steering assembly. 8. Disconnect the yellow 2-way SRS connector and horn lead located behind the inflator module. 9. Apply a setting mark (1) across the steering wheel and shaft so parts can be reassembled in their original position. Accelerator Pedal Assembly/Sensor - Adjustment Update Accelerator Pedal Position Sensor: All Technical Service Bulletins Accelerator Pedal Assembly/Sensor - Adjustment Update 00-045 August 14, 2001 Applies To: 2000-02 Passport - ALL Service Manual Update: Accelerator Pedal Position Sensor (APPS) (Supersedes 00-045, dated May 23, 2000) Updated information is shown by asterisks and black bars. BACKGROUND When the accelerator pedal position sensor (APPS) or the accelerator pedal assembly is replaced for any reason, you must adjust the APPS. *This procedure is missing in the 2000 service manual and is wrong in the 2001 and 2002 service manuals. Make a note on page 6E2-539 of the 2000 Passport Fuel and Emissions manual, on page 6E2-553 of the 2001 Passport Fuel and Emissions manual, and on page 6E2-545 of the 2002 Passport Fuel and Emissions manual to refer to this bulletin.* ADJUSTMENT PROCEDURE 1. Replace the APPS or the accelerator pedal assembly, and leave the mounting screws for the APPS loose. 2. Connect the PGM Tester to the data link connector (DLC), and turn the ignition switch to ON (II). *3. While watching the APP Sensor values in the Engine Data List, adjust the APPS by turning it until the values are within the ranges shown at closed pushed all the way down), then tighten the throttle and wide open throttle (accelerator pedal mounting screws and recheck the values. ^ If all three sensors are within range, go to step 12. ^ If APP Sensor 1, APP Sensor 2, and/or APP Sensor 3 cannot be brought into range, go to step 4. 4. Troubleshoot for an open circuit or a PCM malfunction. ^ If APP Sensor 1 has a value of 0% or APP Sensor 2 and/or APP Sensor 3 have a value of 99%, an open circuit exists or the PCM is malfunctioning. Repair the circuit or replace the PCM, and repeat step 3. ^ If you don't find a problem, go to step 5. 5. Disconnect the 10P connector from the APPS. 6. View the APP Sensor values in the Engine Data List. ^ If APP Sensor 1 has a value of 0% or APP Sensor 2 and/or APP Sensor 3 have a value of 99%, go to step 7. ^ If APP Sensor 1 has a value other than 0%, or APP Sensor 2 and/or APP Sensor 3 have a value other than 99%, a short circuit exists or the PCM is malfunctioning. Repair the circuit or replace the PCM, and repeat step 3. Page 213 The wire insulation has one color or one color with another color stripe. The second color is the stripe. Page 5263 6. Place the end of the return hose in a container. Have someone start the engine, then pour ATF into the reservoir while you watch the fluid coming out of the return hose. When the fluid coming out is the same color as the new fluid, turn off the engine. 7. Reconnect the return hose to the reservoir. 8. Start the engine. Fill the power steering reservoir to the proper level with ATF then turn off the engine. 9. Use the Smart Cable to reprogram the PCM with the latest software from the June 2001 or later HONDANET CD-ROM. Refer to Service Bulletin 99-005, Updating the Passport PCM, filed under Tools. 10. Use the PGM Tester to clear any DTCs. 11. Use the PGM Tester to check the broadcast code. Make sure the broadcast code matches the one you selected from the CD-ROM. WARRANTY CLAIM INFORMATION In warranty: The normal warranty applies. Failed Part: P/N 8-97181-590-0 H/C 5698030 Defect Code: 064 Contention Code: C01 Skill Level: Repair Technician Out of warranty: Any repair performed after warranty expiration may be eligible for goodwill consideration by the District Service Manager or your Zone Office. You must request consideration, and get a decision, before starting work. REPAIR PROCEDURE - APPS GROUND 1. Unclamp the air cleaner housing cover, and move it to the side for access to connector C123 (16P BLK). Page 6675 If there is no photo number below or beside a component name or a connector, ground, or terminal number, look up that name or number in the appropriate Connector Identification Chart. The chart lists how many cavities a connector has, where it's located, and what it connects to. The related illustration shows the connector's location on the harness, and the harness routing. NOTE: Photos listed by number are located at Locations / Components / Photograohs. See: Locations/Component Locations/Photographs Circuit Schematics Page 2941 H/C 4408092 Defect Code: 017 Contention Code: C99 Skill Level: Repair Technician Out of warranty: Any repair performed after warranty expiration may be eligible for goodwill consideration by the District Service Manager or your Zone Office. You must request consideration, and get a decision, before starting work. DISCLAIMER Page 3494 Throttle Position Sensor: Testing and Inspection Function Check Use a Tech 2 to check the TP sensor output voltage at closed throttle. - The voltage should be under 0.85 volt. - If the reading is greater than 0.85 volt, check the throttle shaft to see if it is binding. Page 2699 Manifold Pressure/Vacuum Sensor: Testing and Inspection Manifold Absolute Pressure (MAP) Output Check Circuit Description The manifold absolute pressure (MAP) sensor measures the changes in the intake MAP which result from engine load (intake manifold vacuum) and engine speed changes; and converts these into a voltage output. The powertrain control module (PCM) sends a 5-volt reference voltage to the MAP sensor. As the MAP changes, the output voltage of the sensor also changes. By monitoring the the sensor output voltage, the PCM knows the MAP. A lower pressure (low voltage) output voltage will be about 1 - 2 volts at idle. Higher pressure (high voltage) output voltage will be about 4 - 4.8 volts at wide open throttle. The MAP sensor is also used, under certain conditions, to measure barometric pressure, allowing the PCM to make adjustments for different altitudes. The PCM uses the MAP sensor to diagnose proper operation of the EGR system, in addition to other functions. Page 2310 Camshaft Position Sensor: Description and Operation Camshaft Position (CMP) Sensor and Signal The camshaft position (CMP) sensor sends a CMP signal to the PCM. The PCM uses this signal as a "sync pulse" to trigger the injectors in the proper sequence. The PCM uses the CMP signal to indicate the position of the #1 piston during its power stroke. This allows the PCM to calculate true sequential fuel injection (SFI) mode of operation. If the PCM detects an incorrect CMP signal while the engine is running, DTC P0341 will set. If the CMP signal is lost while the engine is running, the fuel injection system will shift to a calculated sequential fuel injection mode based on the last fuel injection pulse, and the engine will continue to run. As long as the fault is present, the engine can be restarted. It will run in the calculated sequential mode with a 1-in-6 chance of the injector sequence being correct. Refer to DTC P0341 for further information. CMP Signal The PCM uses this signal to determine the position of the number 1 piston during its power stroke, allowing the PCM to calculate true sequential multiport fuel injection (SFI). Loss of this signal will set a DTC P0341. If the CMP signal is lost while the engine is running, the fuel injection system will shift to a calculated sequential fuel injection based on the last fuel injection pulse, and the engine will continue to run. The engine can be restarted and will run in the calculated sequential mode as long as the fault is present, with a 1-in-6 chance of being correct. Page 3006 Vehicle Speed Sensor: Locations 92. Beneath Center of Vehicle, on Transfer Case (A/T) Beneath Center of Vehicle, on Transfer Case (A/T) Hatchgate Lock Trunk / Liftgate Lock Cylinder: Service and Repair Hatchgate Lock Tailgate Lock and Hatchgate Lock (LWB) Removal 1. Disconnect the battery ground cable. 2. Remove the tailgate trim cover assembly (3). - Remove the 2 screws (2) holding the hatch gate lock assembly (1) first, and pull up the trim cover while detaching the clips from tailgate panel. 3. Remove the waterproof sheet. - Remove the waterproof sheet, taking special care so as not to break it. 4. Remove the hatchgate lock. - Disconnect the lock link and connector and remove the 3 fixing bolts. 5. Remove the key cylinder. - Disconnect the lock links. - Remove the key cylinder retaining clip with screw driver to remove the key cylinder. 6. Remove the hatchgate lock actuator assembly. - Disconnect the actuator harness connector. - Remove the 2 bolts holding hatchgate lock actuator assembly from inside. 7. Remove the outside handle. - Remove the 2 bolts holding the outside handle from inside. Page 1254 Refrigerant Oil: Service and Repair Checking/Adjusting Oil For Used Compressor Checking and Adjusting Oil Quantity for Used Compressor 1. Perform oil return operation. Refer to Oil Return Operation. 2. Discharge and recover refrigerant and remove the compressor. 3. Drain the compressor oil and measure the extracted oil with a measuring cylinder. 4. If the amount of oil drained is much less than 90 cc (3.0 fl.oz.), some refrigerant may have leaked out. Conduct a leak tests on the connections of each system, and if necessary, repair or replace faulty parts. 5. Check the compressor oil contamination. (Refer to Contamination of Compressor Oil.) 6. Adjust the oil level following the next procedure below. 7. Install the compressor, then evacuate, charge and perform the oil return operation. 8. Check system operation. When it is impossible to perform oil return operation, the compressor oil should be checked in the following order: 1. Discharge and recover refrigerant and remove the compressor. 2. Drain the compressor oil and measure the extracted oil with a measuring cylinder. 3. Check the oil for contamination. 4. If more than 90 cc (3.0 fl.oz.) of oil is extracted from the compressor, supply the same amount of oil to the compressor to be installed. 5. If the amount of oil extracted is less than 90 cc (3.0 fl oz.), recheck the compressor oil in the following order 6. Supply 90 cc (3.0 fl.oz.) of oil to the compressor and install it onto the vehicle. 7. Evacuate and recharge with the proper amount 0 refrigerant. 8. Perform the oil return operation. 9. Remove the compressor and recheck the amount of oil. 10. Adjust the compressor oil, if necessary. Service and Repair Maintenance Required Lamp/Indicator: Service and Repair The OEM does not equip this model with a Maintenace Required Indicator. Page 7499 Dimmer Switch: Service and Repair Removal 1. Disconnect the battery ground cable. 2. Remove the instrument panel driver lower cover assembly (3). 3. Remove the illumination controller (2). - Disconnect the controller connector. - Remove the controller knob (1). - Remove the nut. - Remove the controller from the back side of the instrument panel driver lower cover assembly. Installation To install, follow the removal steps in the reverse order. Page 3462 Accelerator Pedal Position Sensor: Adjustments Accelerator Position Sensor Adjustment AP sensor is controlled three multiple control system, and adjust the idle position and WOT position are between A and B for AP sensor 1, AP sensor 2, and AP sensor 3. Refer to "How to adjust for AP sensor". How To Adjust For AP Sensor 1. Connect the Tech 2 to DLC on vehicle. 2. Ignition "ON," engine "OFF". 3. Display the APS date list. Check the following item for AP position (%). 4. If the problem was found, adjust as necessary. Page 7784 This sample Ground Distribution schematic shows all of the components that share two ground points. Components A solid border line means the entire component is shown. A broken border line indicates that only part of the component is shown. Page 4112 4. Install seven 13 mm screws, and tighten them to the specified torque. Torque: 20 Nm (15 Ft. lbs.) 5. Remove two guide pins from main case. Torque: 20 Nm (15 Ft. lbs.) 6. Install servo cover gasket, cover, and four 13 mm screws. Tighten the screws to the specified torque. Torque: 25 Nm (18 Ft. lbs.) 7. Connect wiring harness to band control and shift solenoids. 8. Install roller and spring assembly to manual detent. - Install two 13 mm screws, and tighten them to the specified torque. Torque: 20 Nm (15 Ft. lbs.) 9. Install oil filter and three 13 mm screws. Tighten to the specified torque. Torque: 20 Nm (15 Ft. lbs.) 10. Install oil pan gasket, magnet, oil pan and sixteen 10 mm screws. Tighten the screws to the specified torque. Torque: 11 Nm (96 Inch lbs.) 11. Fill transmission through overfill screw hole of oil pan, using ATF DEXRON III. 12. Connect battery ground cable. Valve Body Assembly (Adapter Case) REMOVAL 1. Raise the vehicle and support it on jack stands. 2. Disconnect battery ground cable. 3. Drain fluid. 4. Remove twelve 10 mm adapter case oil pan fixing screws, adapter case oil pan, and gasket. NOTE: Oil pan still contains transmission fluid. Place a large drain container under the oil pan. Drain the fluid carefully. 5. Disconnect wiring harness from force motor solenoid and converter clutch solenoid. Pull only on connectors, not on wiring harness. 6. Remove seven 13 mm screws from adapter case valve body assembly, then remove transfer plate, two gaskets, and adapter case valve body. INSTALLATION 1. Inspect electrical 4 pin connector and seal of adapter case. Replace if necessary. 2. Install gasket, transfer plate, and gasket. 3. Install adapter case valve body and seven 13 mm screws. Tighten the screws to the specified torque. Torque: 20 Nm (15 Ft. lbs.) 4. Connect wiring harness assembly to converter clutch solenoid and force motor. 5. Install oil pan gasket, oil pan, and twelve 10 mm screws. Tighten the screws to the specified torque. Torque: 11 Nm (96 Ft. lbs.) 6. Fill transmission through the overfill screw hole of oil pan, using ATF DEXRON III. 7. Connect battery ground cable. Page 466 Dimmer Switch: Diagnostic Aids Before Troubleshooting Before Troubleshooting See: Service Precautions/Vehicle Damage Warnings/Tips and Precautions 1. Check applicable fuses in the appropriate fuse/relay box. 2. Check the battery for damage, state of charge, and clean and tight connections. CAUTION: Do not quick-charge a battery unless the battery ground cable has been disconnected, otherwise you will damage the alternator diodes. - Do not attempt to crank the engine with the battery ground cable loosely connected or you will severely damage the wiring. While You're Working 1. Make sure connectors are clean, and have no loose terminals or receptacles. 2. Make sure that connectors without wire seals are packed with dielectric (silicone) grease. Part Number: 08798-9001. 3. When connecting a connector, push it until it "clicks" into place. CAUTION: Do not pull on the wires when disconnecting a connector. Pull only on the connector housings. - Most circuits include solid-state devices. Test the voltages in these circuits only with a 10-megaohm or higher impedance digital multi meter. Never use a test light or analog meter on circuits that contain solid-state devices. Damage to the devices may result. Five-Step Troubleshooting 1. Verify The Complaint Turn on all the components in the problem circuit to check the accuracy of the customer complaint. Note the symptoms. Do not begin disassembly or testing until you have narrowed down the problem area. 2. Analyze The Schematic Look up the schematic for the problem circuit. Determine how the circuit is supposed to work by tracing the current paths from the power source through the circuit components to ground. Also, trace circuits that share wiring with the problem circuit. The names of circuits that share the same fuse, ground, or switch, and so on, are referred to in each circuit schematic. Try to operate any shared circuits you didn't check in step 1. If the shared circuits work, the shared wiring is OK, and the cause must be in the wiring used only by the problem circuit. If several circuits fail at the same time, the fuse or ground is a likely cause. Based on the symptoms and your understanding of the circuit's operation, identify one or more possible causes. 3. Isolate The Problem By Testing The Circuit Make circuit tests to check the diagnosis you made in step 2. Keep in mind that a logical, simple procedure is the key to efficient troubleshooting. Test for the most likely cause of failure first. Try to make tests at points that are easily accessible. 4. Fix The Problem Once the specific problem is identified, make the repair. Be sure to use proper tools and safe procedures. 5. Make Sure The Circuit Works Turn on all components in the repaired circuit in all modes to make sure you've fixed the entire problem. If the problem was a blown fuse, be sure to test all of the circuits on that fuse. Make sure no new problems turn up and the original problem does not recur. Page 7604 This means the branch of the wire connects to another circuit. The arrow points to the name of the circuit branch where the wire continues. Page 2089 6. Remove the connector position assurance (CPA) clip from the APPS connector. 7. Disconnect the 10 P connector from the APPS. 8. Remove the bolts, the APPS, the spacer, and the accelerator link from the accelerator pedal assembly. 9. Separate the spacer from the APPS. Clean the grease off the spacer and the accelerator link with a clean shop towel. 10. Clean the terminals of the 10 P APPS connector (harness side) with contact cleaner. Shake the residue out of the connector, and allow the contact cleaner to evaporate for at least 3 minutes before reconnecting the connector. 11. Install a new APPS, the spacer, and the accelerator link onto the accelerator pedal assembly. Leave the mounting screws loose so the sensor can be adjusted. 12. Connect the 10 P connector to the new APPS, and lock the connector in place with the CPA. 13. Connect the PGM Tester to the data link connector (DLC), and turn the ignition switch to ON (II). Page 7597 This sample Ground Distribution schematic shows all of the components that share two ground points. Components A solid border line means the entire component is shown. A broken border line indicates that only part of the component is shown. Page 624 Camshaft Position Sensor: Service and Repair REMOVAL PROCEDURE 1. Disconnect the negative battery cable. 2. Remove the engine cover. 3. Remove the common chamber assembly. 4. Disconnect the electrical connector to the CMP sensor. 5. Remove the CMP retaining bolt from the side of left cylinder head. 6. Remove the CMP sensor from the cylinder head. INSTALLATION PROCEDURE 1. Install the CMP sensor in the cylinder head. 2. Install the CMP sensor retaining bolt. Tighten Tighten the retaining screw to 9 N.m (78 lb in.). Page 3406 Wires Wire insulation can be one color, or one color with another color stripe. (The second color is the stripe.) This circuit continues on another image. (The arrow shows direction of current flow.) To follow the RED/BLK wire in this example, you would turn to "Fuel and Emissions" and look for the "A" arrow. Accelerator Pedal Position Sensor - MIL ON/DTC's Set Technical Service Bulletin # 01-047 Date: 010814 Accelerator Pedal Position Sensor - MIL ON/DTC's Set 01-047 August 14, 2001 Applies To: 2000-01 Passport - ALL MIL Comes On With Accelerator Pedal Position Sensor DTC(s) P1271, P1273, P1275, P1280, and/or P1285 SYMPTOM The MIL is on with DTC P1271, P1273, P1275, P1280, or P1285 (various accelerator pedal position sensor problems) stored. The REDUCED POWER indicator may also be on; and the engine may occasionally idle too high, or the idle may fluctuate. PROBABLE CAUSE Contaminated grease on the potentiometer circuit board of the accelerator pedal position sensor (APPS) causes high resistance in the APPS circuit. CORRECTIVE ACTION Replace and adjust the APPS, remove all grease from the accelerator link, and clean the APPS harness connector and connector C123. PARTS INFORMATION Accelerator Pedal Position Sensor: P/N 8-97193-713-0, H/C 6198311 REQUIRED MATERIALS CAIG DeoxIT D5-S6 Contact Cleaner: P/N 341-200 (available from www.partsexpress.com) or Permatex Electrical Contact Cleaner: Permatex P/N 24379 WARRANTY CLAIM INFORMATION In warranty: The normal warranty applies. Operation Number: 122114 Flat Rate Time: 0.5 hour Failed Part: P/N 8-97220-540-0 H/C 6202436 Defect Code: 091 Contention Code: C99 Template ID: 01-047A Skill Level: Repair Technician Out of warranty: Any repair performed after warranty expiration may be eligible for goodwill consideration by the District Service Manager or your Zone Office. You must request consideration, and get a decision, before starting work. Page 6071 it is located, and what it connects to. Use the Connector Views to help locate the proper cavity when you need to probe a connector. It can be especially helpful if the connector has more than one wire of the same color. A dash symbol (-) indicates that the cavity is empty. Connector views can also be used to help diagnose multiple symptoms in separate circuits which could be caused by a single problem in a connector shared by those circuits. Here's an example: 1. Pick one of the multiple symptoms and look up the schematic for that circuit. 2. Make a list of all the in-line and fuse box connectors in that schematic , 3. Then, in the Connector Views, look up each connector on your list to see if circuits related to the other symptoms run through one of them. If they do, inspect that connector for the problem. Example: The blower, rear window defogger, and the windshield wiper don't work. List all in-line and fuse box connectors in the blower controls circuit and then check the Connector View (see the sample). You find that C324 is common to the blower controls, rear window defogger, and wiper/washer, so you inspect C324 and find the problem, bent terminals. Finding Component/Connector Locations Finding Component/Connector Locations To see where a component or connector is located on the car, look up its photo number in the "Component Location". The photo will also tell you the color of the connector, and how many cavities it has. Right Side Removal and Installation Catalytic Converter: Service and Repair Right Side Removal and Installation TWC RH and Forked Exhaust Pipe and Associated Parts REMOVAL 1. Disconnect battery ground cable. 2. Lift up the vehicle and support with suitable safety stands. 3. Disconnect O2 sensor harness connectors (2) (6). 4. Remove the forked exhaust pipe fixing bolts and nuts (5) (9) (11) and the exhaust silencer fixing nuts (10), then remove the forked exhaust pipe (8) and the mass damper. 5. Remove the three way catalytic converter fixing nuts (1) and the mounting rubber (4), then remove the three way catalytic converter (3). INSTALLATION 1. Install the three way catalytic converter (3) and the mounting rubber (4), and tighten the fixing nuts (1) to the specified torque. Torque Nuts: 67 Nm (49 ft. lbs.) 2. Install the forked exhaust pipe (8) and the mass damper (7), and tighten the fixing bolts (5) & nuts (9) (10) to the specified torque. Torque Bolts & Nuts: 43 Nm (32 ft. lbs.) Nuts: 43 Nm (32 ft. lbs.) 3. Connect the O2 sensor connectors (2) (6). Page 2098 7. Modify the original APPS by cutting the connector housing off of the sensor. 8. Connect the 10P connector to the modified APPS connector housing. 9. Using a DVOM, check the voltage between the reference voltage pin for each sensor and ground. ^ If the sensor circuits all read 5.0 volts, go to step 11. ^ If any sensor circuit is above or below 5.0 volts, go to step 10. 10. Troubleshoot for an internal short in another sensor or a PCM malfunction. ^ To find the sensor with an internal short, monitor the incorrect reference voltage, and disconnect each sensor (FTPS, EGR, MAP, TPS, CKP, and CMP) one at a time until the reference voltage reads 5.0 volts. Replace that sensor, and repeat step 3. ^ To find a malfunctioning PCM, replace it with a known-good PCM. If all three sensors (APP Sensor 1, APP Sensor 2, and APP Sensor 3) are within range, the original PCM is faulty; replace it and repeat step 3. Page 264 Ground - "G" Shielding Sheilding This represents RFI (Radio Frequency Interference) shielding around a wire. The shielding is always connected to ground. Splices Page 5724 Torsion Bar: Service and Repair REMOVAL 1. Raise the vehicle and support the frame with suitable safety stands. 2. Apply the setting marks (1) to the adjust bolt and end piece, then remove adjust bolt, end piece and seat. 3. Apply the setting marks (2) to the height control arm and torsion bar, then remove height control arm. Page 4793 B-16 Rear Dump Solenoid Valve Failure (DTC 46/C0252, C0254) Chart B-16 Rear Dump Solenoid Coil Failure (DTC 46 (Flash Out) / C0252, C0254 (Serial Communications)) Part 1 of 2 Part 2 of 2 Page 1387 Wheel Bearing: Service and Repair DISASSEMBLED VIEW DISASSEMBLY 1. Before disassembly, select the 2WD position with the 4WD switch. 2. Jack up the front of vehicle and support frame with jack stands. 3. Remove the disc brake caliper assembly and hang it on the frame with wires. 4. Remove bolt. 5. Remove cap. 6. Remove snap ring and shim. 7. Remove hub flange. 8. Remove lock washer and lock screw. Page 1104 7. Turn the valve tappet with a pick or a small screwdriver until the tappet notch is within the indentation in the head. 8. Turn the crankshaft (or camshaft) pulley clockwise until the cam lobe presses the valve fully open. 9. On the tappet side closest to the bearing cap, insert the valve adjuster holder (T/N J-42659-AH) between the camshaft and the tappet. The tool should rest on the edge of the tappet without touching the shim. 10. Slowly turn the crankshaft (or camshaft) pulley counterclockwise so that when the valve closes, the tool catches between the camshaft and the tappet, holding the valve slightly open. NOTE: Do not turn the crankshaft (or camshaft) pulley too far or in the wrong direction. If you do, you might break the tool, or worse yet, damage the cylinder head. 11. Insert a pick or a small screwdriver into the tappet notch, and pry out the shim. 12. Wipe off the shim, then write its number on the Valve Inspection Chart for that valve and cylinder. If there is no number on the shim, measure its thickness with a micrometer, and write down the measurement on the Valve Inspection Chart. 13. Follow the directions on the Valve Shim Replacement Chart to select the correct shim. 14. Insert the correct shim, number side down, into the tappet. Make sure the shim is fully seated. 15. Release and remove the tool by turning the crankshaft (or camshaft) pulley clockwise. 16. Turn the crankshaft (or camshaft) pulley clockwise until the cam lobe again points away from the valve. Page 4994 Hydraulic Control Assembly - Antilock Brakes: Service and Repair Removal and Installation HYDRAULIC CONTROL UNIT REMOVAL 1. Remove brake pipes. - After disconnecting brake pipe, cap or tape the openings of the brake pipe to prevent the entry of foreign matter. 2. Remove three brake fixing bolts. 3. Disconnect red clip from harness connector. 4. Remove harness connector. 5. Remove EHCU ASM. 6. Remove EHCU. INSTALLATION To install, follow the removal steps in the reverse order, noting the following points: Torque: Hydraulic unit fixing nuts: 22 Nm (16 ft. lbs.) Ground cable: 14 Nm (10 ft. lbs.) Brake pipe (joint bolts): 16 Nm (12 ft. lbs.) - After installing the hydraulic unit, bleed brakes completely. Locations Fuel Pressure Sensor/Switch: Locations Top Rear of Fuel Tank Page 3181 1. Install the MAF sensor on the air cleaner with the clamp. 2. Install the intake air duct and the clamp on the MAF sensor. 3. Tighten the clamps to secure the MAF sensor to the intake air duct and the air cleaner. 4. Connect the MAF electrical connector. 5. Connect the negative battery cable. Page 1031 During the test-drive, attach the bracket and the weights to the steering wheel on the side opposite the pulling direction. For example, if the vehicle pulls to the right, attach the bracket and weights to the left side of the steering wheel. Start with the maximum amount of weight on the steering wheel, and remove the weights until the vehicle drives in a straight line. When recording the pull on the worksheet, write down the direction of the pull (lefi or right) and the number of weights required to balance the pull (one through six). For example, if you have the bracket and two weights on the steering wheel, then record this as three weights. NOTE: The bracket counts as one weight. The road crown gauge measures the amount of road crown. Almost all roads have a crown to help drain water during rainstorms. Use the suction cup to attach the road crown gauge bracket to the vehicle in a vertical position. If necessary, bend the bracket until the gauge is vertical. Once you attach and align the road crown gauge, calibrate the gauge to zero. There are two ways to calibrate the gauge: ^ Park the vehicle on a level surface, such as an alignment rack, and calibrate the gauge by moving the gauge until the ball is on the zero mark. ^ If you do not have a perfectly flat surface, park the vehicle on a reasonably flat surface and note the gauge reading. Turn the vehicle 1800 and, with the tires in the same spot, note the new gauge reading. Then move the gauge half of the difference. For example, if your first reading is +3 and, after moving the vehicle, the gauge reads -1, then the difference is 4 degrees. Position the gauge to read +1. Page 5038 Electronic Brake Control Module: Service Precautions CONTROL MODULE PRECAUTIONS The Anti-lock Brake System interfaces directly with the Electronic Hydraulic Control Unit (EHCU) which is a control computer that is similar in some regards to the Powertrain Control Module. These modules are designed to withstand normal current draws associated with vehicle operation. However, care must be taken to avoid overloading any of the EHCU circuits. In testing for opens or shorts, do not ground or apply voltage to any of the circuits unless instructed to do so by the appropriate diagnostic procedure. These circuits should only be tested with a high impedance multimeter (J-39200) or special tools. Power should never be removed or applied to any control module with the ignition in the "ON" position. Before removing or connecting battery cables, fuses or connectors, always turn the ignition switch to the "OFF" position. Page 7629 Each schematic represents one circuit. A circuit's wires and components are arranged to show current flow, from power at the top of the page, to ground, at the bottom. Shared Circuits Other circuits may share power or ground terminals or wiring with the circuit shown. A wire that connects one circuit to another, for example, is cut short and has an arrowhead at the end of it pointing in the direction of current flow. Next to the arrowhead is the name of the circuit or component which shares that wiring. To quickly check shared wiring, check the operation of a component it serves. If that component works, you know the shared wiring is OK. Connectors All in-line and junction connectors are numbered (C725, C416, etc.). Component connectors are not numbered but are identified either by the name of Page 2517 The wire insulation has one color or one color with another color stripe. The second color is the stripe. Upper Ball Joint: Specifications Ball Joint, Upper Castle Nut 98 Nm Attaching Bolts 57 Nm Preload Torque 0.5 - 3.2 Nm Page 1366 Tires: Testing and Inspection Radial Tire Waddle Waddle is side-to-side movement at the front and/or rear of the car. It can be caused by the steel belt not being straight within the tire, or by excessive lateral runout of the tire or wheel. It is most noticeable at low speed, about 8 to 48 km/h (5 to 30 mph). It may also cause rough ride at 80 to 113 km/h (50 to 70 mph). The car can be road tested to see which end of the car has the faulty tire. If the tire causing the waddle is on the rear, the rear end of the car will "waddle". From the driver's seat, it feels as if someone is pushing on the side of the car. If the faulty tire is on the front, the waddle is more easily seen. The front sheet metal appears to be moving back and forth. It feels as if the driver's seat is the pivot point in the car. Another more time-consuming method of determining the faulty tire is substituting tire and wheel assemblies that are known to be good. Follow these steps: 1. Drive the car to determine if the waddle is coming from the front or rear. 2. Install tire and wheel assemblies known to be good (from a similar car) in place of those on the end of the car which is waddling. If the waddle cannot be isolated to front or rear, start with the rear tires. 3. Road test again. If improvement is noted, install the original tire and wheel assemblies one at a time until the faulty tire is found. If no improvement is noted, install tires known to be good in place of all four. Then, install the originals one at a time until the faulty tire is found. Page 7630 the component if the component only has one connector, or by a capital letter (A, B, C, etc.) if the component has more than one connector. Below most connector numbers and component names are PHOTO and VIEW numbers. The PHOTO number refers to a photo in the back of the book that shows the connector's location on the car. The VIEW number refers to an illustration in the back of the book that shows the connector face, wire colors, connector cavity numbers, and other details. The connector cavity numbering sequence begins at the top left corner of the connector. Disregard any numbers molded into the connector housing. Wires Wires are identified by the abbreviated names of their colors; the second color is the color of the stripe. Wires are also identified by their location in a connector. The number "2" next to the male and female wire terminals at C416, for example, means those terminals join in cavity 2 of connector C416. Symbols A complete description of schematic symbols is given under wire color abbreviation. Power Distribution Schematics Power Distribution schematics show how power is supplied from the positive battery terminal to various circuits in the car. Refer to the Power Distribution section to get a more detailed picture of how power is supplied to the circuit you're working on. From Battery to Ignition Switch, Fuses, and Relays Individual circuit schematics begin with a fuse. The first half of Power Distribution, however, shows the wiring "upstream" between the battery Locations Page 470 2. Connect one lead of a self-powered test light or DVOM to one end of the part of the circuit you want to test. 3. Connect the other lead to the other end. 4. If the self-powered test light glows, there is continuity. If you're using a DVOM, a low reading or no reading (zero), means good continuity. Testing For Voltage When testing for voltage at a connector without wire seals, you do not have to separate the two halves of the connector. Instead, probe the connector from the back. Always check both sides of the connector because dirty, corroded, and bent terminals can cause problems (no electrical contact = an open). 1. Connect one lead of the lest light to a known good ground, or, if you're using a digital volt ohmmeter (DVOM), place it in the appropriate DC volts range, and connect its negative lead to ground. 2. Connect the other lead of the test light or DVOM to the point you want to check. 3. If the test light glows, there is voltage present. If you're using a DVOM, note the voltage reading. It should be within one volt of measured battery voltage. A loss of more than one volt indicates a problem. NOTE: Always use a DVOM on high impedance circuits. A test light may not glow (even with battery voltage present). Testing For Voltage Drop Wires, connectors, and switches are designed to conduct current with a minimum loss of voltage. A voltage drop of more than one volt indicates a problem. 1. Place the digital volt/ohmmeter (DVOM) in the appropriate DC volts range. Connect the positive lead to the end of the wire (or to the connector or switch) closest to the battery. 2. Connect the negative lead to the other end of the wire (or the other side of the connector or switch). 3. Turn on the components in the circuit. 4. The DVOM will show the difference in voltage between the two points. A difference, or drop, of more than one volt indicates a problem. Check the circuit for loose, dirty, or bent terminals. Page 5779 17. Fill out the information on a campaign completion label. Stick this label to the back edge of the driver's door, just below the door latch. * NOTE: If you need more labels, order them from Helm using reorder number Y0895.* Stage 3 Repair STAGE 3 REPAIR NOTE: Do this repair on both sides of the vehicle. 1. Remove the frame rail side hole plug from both frame rails. 2. Remove the lower trailing link front mounting nuts from both trailing links. The mounting bolts will be removed later. Page 5777 9. Insert the Noxudol 700 spray nozzle about 12 inches (300 mm) into the frame rail side hole, toward the front of the vehicle. Then spray the Noxudol while drawing out the nozzle. Spray four times. 10. Insert the Noxudol 700 spray nozzle about 7 inches (200 mm) into the frame rail side hole, toward the rear of the vehicle. Then spray the Noxudol while pulling out the nozzle. Spray four times. 11. Insert the Noxudol 700 spray nozzle into the frame rail side hole, pointing up, until it touches the top of the frame. Spray the Noxudol upward while pulling out the nozzle. Spray two times. Locations Door Switch: Locations Page 4242 Differential Axle Housing: Service and Repair Rear Differential AXLE HOUSING AND ASSOCIATED PARTS REMOVAL 1. Raise the vehicle and support it with suitable safety stands. The hoist must remain under the rear axle housing. 2. Take out brake fluid. 3. Remove rear wheels and tires. 4. Remove drive/propeller shaft. 5. Drain the rear axle oil into a proper container. 6. Remove parking brake cable, release the connection between the cable fixing clip equalizer. 7. Move the clip aside and pull out the breather hose. Page 744 Distinct Of Circuit By Wire Base Color All wires have color-coded insulation. Wires belonging to a system's main harness will have a single color. Wires belonging to a system's sub-circuits will have a colored stripe. Striped wires use the codes found in the chart to show wire size and colors. Abbreviations are used to indicate wire color within a circuit diagram. How to Identify Connector Terminals How to Identify Connector Terminals Cavity Numbering System The cavities (and wire terminals) in each connector are numbered starting from the upper left, looking at the male terminals from the terminal side (or looking at the female terminals from the wire side. Both views are in the same direction so the numbers are the same.) All actual cavities are numbered, even if they have no wire terminals in them. NOTE: Data Link Connector (DLC) terminals are numbered according to SAE standard J1962, not the Honda standard. The numbers of the four end terminals are molded into the corners of the connector face. The connector cavity number is listed next to each terminal on the circuit schematic. The cavity / terminal shown is # 6. Using/Identifying Connector Terminal Views How to Use Connector Terminal Views To see the configuration of a connector's cavities, look up its view number in the Connector Views. Each view includes the color of the connector, where Page 1978 Powertrain Control Module: Service Precautions Reprogramming the PCM Reprogramming the PCM Reprogramming of the PCM is done without removing it from the vehicle . This provides a flexible and cost-effective method of making changes in software calibrations. Refer to the latest Techline information on reprogramming or flashing procedures. Page 5386 The road crown gauge measures the amount of road crown. Almost all roads have a crown to help drain water during rainstorms. Use the suction cup to attach the road crown gauge bracket to the vehicle in a vertical position. If necessary, bend the bracket until the gauge is vertical. Once you attach and align the road crown gauge, calibrate the gauge to zero. There are two ways to calibrate the gauge: ^ Park the vehicle on a level surface, such as an alignment rack, and calibrate the gauge by moving the gauge until the ball is on the zero mark. ^ If you do not have a perfectly flat surface, park the vehicle on a reasonably flat surface and note the gauge reading. Turn the vehicle 1800 and, with the tires in the same spot, note the new gauge reading. Then move the gauge half of the difference. For example, if your first reading is +3 and, after moving the vehicle, the gauge reads -1, then the difference is 4 degrees. Position the gauge to read +1. NOTE: You must calibrate the gauge with the same weight in the vehicle that you will use for the test-drive. If you plan to have an assistant help you during the test-drive, calibrate the gauge while both of you are sitting in the vehicle. Page 7638 Wires Wire insulation can be one color, or one color with another color stripe. (The second color is the stripe.) This circuit continues on another image. (The arrow shows direction of current flow.) To follow the RED/BLK wire in this example, you would turn to "Fuel and Emissions" and look for the "A" arrow. Page 2099 11. Using a jumper wire, connect the reference voltage of each circuit to its signal input and view the APP Sensor values in the Engine Data List. APP Sensor 1 should have a value of 99%, and APP Sensor 2 and APP Sensor 3 should each have a value of 0%. ^ If the values are not as specified, troubleshoot for high resistance on the signal input or a PCM malfunction. Repair the circuit or replace the PCM, then repeat step 3. ^ If the values are as specified, the problem may be intermittent. Disconnect the 10P connector from the modified APPS, and connect it to the new APPS; then repeat step 3. Wiggle the APPS wires as you go through the adjustment procedure to find the intermittent problem. 12. Turn off the ignition switch, and disconnect the PGM Tester.* DISCLAIMER Page 4887 Brake Pad: Specifications Pad Dimension 33 cm2 Electrode Gap Spark Plug: Specifications Plug Gap Standard Service Limit 0.039-0.043 in (1.0-1.1 mm) 0.050 in (1.3 mm) Page 3625 7. Loosen the inflator module fixing bolt from behind the steering wheel assembly using a TORE driver or equivalent until the inflator module can be released from steering assembly. 8. Disconnect the yellow 2-way SRS connector and horn lead located behind the inflator module. 9. Apply a setting mark (1) across the steering wheel and shaft so parts can be reassembled in their original position. Page 3467 Air Flow Meter/Sensor: Description and Operation Mass Air Flow (MAF) Sensor The mass air flow (MAF) sensor measures the difference between the volume and the quantity of air that enters the engine. "Volume" means the size of the space to be filled. "Quantity" means the number of air molecules that will fit into the space. This information is important to the PCM because heavier, denser air will hold more fuel than lighter, thinner air. The PCM adjusts the air/fuel ratio as needed depending on the MAF value. The Tech 2 reads the MAF value and displays it in terms of grams per second (g/sec). At idle, the Tech 2 should read between 4 - 7 g/sec on a fully warmed up engine. Values should change quickly on acceleration. Values should remain stable at any given RPM. A failure in the MAF sensor or circuit will set DTC P0101, DTC P0102, or DTC P0103. Page 3307 2. Connect one lead of a self-powered test light or DVOM to one end of the part of the circuit you want to test. 3. Connect the other lead to the other end. 4. If the self-powered test light glows, there is continuity. If you're using a DVOM, a low reading or no reading (zero), means good continuity. Testing For Voltage When testing for voltage at a connector without wire seals, you do not have to separate the two halves of the connector. Instead, probe the connector from the back. Always check both sides of the connector because dirty, corroded, and bent terminals can cause problems (no electrical contact = an open). 1. Connect one lead of the lest light to a known good ground, or, if you're using a digital volt ohmmeter (DVOM), place it in the appropriate DC volts range, and connect its negative lead to ground. 2. Connect the other lead of the test light or DVOM to the point you want to check. 3. If the test light glows, there is voltage present. If you're using a DVOM, note the voltage reading. It should be within one volt of measured battery voltage. A loss of more than one volt indicates a problem. NOTE: Always use a DVOM on high impedance circuits. A test light may not glow (even with battery voltage present). Testing For Voltage Drop Wires, connectors, and switches are designed to conduct current with a minimum loss of voltage. A voltage drop of more than one volt indicates a problem. 1. Place the digital volt/ohmmeter (DVOM) in the appropriate DC volts range. Connect the positive lead to the end of the wire (or to the connector or switch) closest to the battery. 2. Connect the negative lead to the other end of the wire (or the other side of the connector or switch). 3. Turn on the components in the circuit. 4. The DVOM will show the difference in voltage between the two points. A difference, or drop, of more than one volt indicates a problem. Check the circuit for loose, dirty, or bent terminals. Page 6079 Ground - "G" Shielding Sheilding This represents RFI (Radio Frequency Interference) shielding around a wire. The shielding is always connected to ground. Splices Page 6498 2. Soak a clean cloth in the cleaner. Insert the cloth between the seat belt and metal loop on the upper anchor. Use a credit card or similar item to help insert the cloth into the loop. Work the cloth back and forth to clean the dirt out of the inside of the loop. 3. Pull the seat belt out fully. Soak a clean cloth in the cleaner, and clean both sides of the seat belt webbing. Dry the webbing thoroughly with a clean cloth. Do not use a hair dryer or similar device. 4. Test the belt for proper retraction by pulling the latch plate down to the floor of the vehicle and then releasing it. The belt should retract fully in 4 seconds or less. Three-Point Passive Seat Belts 1. Clean the metal loop in the upper anchor as described for Three-Point Active Seat Belts. 2. Remove the door panel and the seat belt guide. Refer to the appropriate service manual. 3. Soak a clean cloth in the cleaner, and clean both sides of the seat belt webbing. Dry the webbing thoroughly with a clean cloth. Do not use a hair dryer or similar device. Page 3043 TWC RH and Forked Exhaust Pipe and Associated Parts Page 4102 c. Remove mode switch connector with bracket from the transmission case. d. Connect multimeter (resistance mode) to terminals 1(E) and 4(H) on mode switch connector. e. Loosen two mounting screws. f. Rotate mode switch slightly in both directions to determine the range (approx. 5 degrees) of electrical contact. g. Position mode switch in middle of contact range. h. Tighten two mounting screws. i. Remove multimeter and install mode switch harness connector with bracket to the transmission case. j. Connect transmission harness connector to mode switch connector. Service and Repair Oil Filter: Service and Repair Oil Filter Removal 1. Disconnect battery ground cable. 2. Drain engine oil. 3. Remove oil filter using J-36390 filter wrench. Installation 1. Clean filter fitting surface and apply small amount of engine oil to sealing surface. 2. Install oil filter cartridge by hand until it comes in contact with sealing surface then rotate additional 2/3 turn to tighten using J-36390 filter wrench. 3. Fill engine oil until full level on dipstick. 4. Reconnect battery ground cable. Page 4354 cancel each other out. In comparison, this would be the same as the universal joints on a propeller shaft. A total cancellation of vibration produces a smooth flow of power in the driveline. It is very important to apply a reference mark to the propeller shaft before removal, to assure installation alignment. UNIVERSAL JOINT A universal joint consists of two Y-shaped yokes connected by a crossmember called a spider. The spider is shaped like a cross. Universal joints are designed to handle the effects of various loadings and front or rear axle windup during acceleration. Within the designed angle variations, the universal joint will operate efficiently and safely. When the design angle is changed or exceeded the operational life of the joint may decrease. The bearings used in universal joints are of the needle roller type. The needle rollers are held in place on the trunnions by round bearing cups. The bearing cups are held in the yokes by snap rings. Page 7758 Splices Splices are shown as a dot. Their location and the number of wires may vary depending on the harness manufacturer. Switches Switches These switches move together; the broken straight line between them means they are mechanically connected. Other types of switches are controlled by a coil or a solid state circuit. Unless otherwise noted, all switches are shown in their normal (rest) position, with power off. Terminal "T" Page 2891 Intake Air Temperature Sensor: Description and Operation Intake Air Temperature (IAT) Sensor The intake air temperature (IAT) sensor is a thermistor which changes its resistance based on the temperature of air entering the engine. Low temperature produces a high resistance of 100,000 ohms at -40 °C (-40 °F). High temperature causes low resistance of 70 ohms at 130 °C (266 °F). The PCM supplies a 5-volt signal to the sensor through a resistor in the PCM and monitors the signal voltage. The voltage will be high when the incoming air is cold. The voltage will be low when the incoming air is hot. By measuring the voltage, the PCM calculates the incoming air temperature. The IAT sensor signal is used to adjust spark timing according to the incoming air density. The Tech 2 displays the temperature of the air entering the engine. The temperature should read close to the ambient air temperature when the engine is cold and rise as underhood temperature increases. If the engine has not been run for several hours (overnight), the IAT sensor temperature and engine coolant temperature should read close to each other. A fault in the IAT sensor circuit will set DTC P0112 or DTC P0113. Page 4227 Testing For A Short With A Self-Powered Test Light or DVOM 1. Remove the blown fuse and disconnect the battery and load. 2. Connect one lead of a self-powered test light or digital volt/ohmmeter (DVOM) (switched to the lowest "OHMS" range) to the fuse terminal on the load side. 3. Connect the other lead to a known good ground. 4. Beginning near the fuse box, wiggle the harness. Continue this at convenient points about six inches apart while watching the test light or DVOM. 5. If the self-powered test light goes on or the DVOM displays a low reading or no reading (zero), there is a short to ground in the wiring near that point. Testing for a Short with a Test Light or DVOM 1. Remove the blown fuse and disconnect the load. 2. Connect a test light or digital volt/ohmmeter (DVOM), switched to the appropriate DC volts range, across the fuse terminals to make sure voltage is present. You might have to turn the ignition switch to ON; check the schematic to see. 3. Beginning near the fuse box, wiggle the harness. Continue this at convenient points about six inches apart while watching the test light or DVOM. 4. Where the test light goes , or the DVOM voltage drops to zero, there is a short to ground in the wiring near that point. NOTE: Always use a DVOM on high impedance circuits. A test light may not glow (even with battery voltage present). Testing For A Short With A Short Circuit Locator (Short Finder) 1. Remove the blown fuse. Leave the battery connected. Page 1613 14. Working through the right front wheelwell, remove the two upper flange bolts holding the bracket to the engine. 15. Working from under the vehicle, rotate the right engine mount, and remove the two flange nuts holding the mount and the mount cover to the bracket. 16. Remove the mount, the cover, and the bracket. Discard the cover. 17. Assemble the bracket, the new cover, and the mount in the engine compartment. Secure the assembly with the two flange nuts. Torque the flange nuts to 50 N.m (37 lb-ft). Page 4809 Part 1 of 2 Part 2 of 2 B-22 Rear Speed Sensor Missing (DTC 63/C0237) Chart B-22 Rear Speed Sensor Missing (DTC 63 (Flash Out) / C0236, C0237 (Serial Communications)) Page 2970 The name of the component appears next to it followed by notes about its function along with any photo and connector view references. Connector "C" How to Identify Connector Terminals Cavity Numbering System The cavities (and wire terminals) in each connector are numbered starting from the upper left, looking at the male terminals from the terminal side (or looking at the female terminals from the wire side. Both views are in the same direction so the numbers are the same.) All actual cavities are numbered, even if they have no wire terminals in them. NOTE: Data Link Connector (DLC) terminals are numbered according to SAE standard J1962, not the Honda standard. The numbers of the four end terminals are molded into the corners of the connector face. Page 1967 The wire insulation has one color or one color with another color stripe. The second color is the stripe. Page 6606 ^ For warranty repairs, go to the IN-WARRANTY EXCHANGE procedure. ^ For vehicle service contract (VSC) and certified used car (CUC) repairs, call. ^ For goodwill repairs, contact your dealership's District Parts and Service Manager (DPSM). IN-WARRANTY EXCHANGE Service Technician: NOTE: ^ Use the iN to order a remanufactured audio, navigation, or RES unit. Do not call the Remanufactured Parts Dealer Service Group. ^ A Tech Line reference number is not required to submit the order. Check Yes, and enter the Reference Number only when there is a preexisting Tech Line contact. 1. With your completed Audio/Navigation/RES Worksheet, go to an iN workstation. 2. From the iN main menu, click on SERVICE, then click on AUDIO, then select Warranty Audio Order. 3. Select the model, year, and keyword (AUDIO, NAVIGATION, or RES) for the vehicle you are working on, then click on Search. 4. Review all displayed publications for additional repair information. If you cannot repair the problem, go to step 5. Page 4340 13. Tighten the bolts to the specified torque. Torque: 59 Nm (43 ft. lbs.) Locations Oil Pressure Switch (For Fuel Pump): Locations Bottom Center Front of Engine Locations Throttle Body: Locations Top Front of Engine (Intake Duct Removed) Page 2052 Wire Color Abbreviations The following abbreviations are used to identify wire colors in the circuit schematics: WHT................................... White YEL................................... Yellow BLK................................... Black BLU................................... Blue GRN................................... Green RED................................... Red ORN................................... Orange PNK................................... Pink BRN................................... Brown GRY................................... Gray PUR................................... Purple LT BLU................................... Light Blue LT GRN................................... Light Green Page 3866 Shift Solenoid: Service and Repair REMOVAL 1. Raise the vehicle and support it on jack stands. 2. Disconnect battery ground cable. 3. Drain fluid. 4. Remove sixteen 10 mm screws, main case oil pan, magnet, and gasket. 5. Remove three 13 mm screws, oil filter. 6. Disconnect wiring harness from band control solenoid and shift solenoids. Pull only on connectors, not on wiring harness. 7. Remove spring pin for shift solenoid A, shift solenoid B, and band control solenoid respectively, using suitable pliers taking care not to damage solenoids. 8. Remove shift solenoid A, shift solenoid B, band control solenoid, and gaskets from main case valve body. Do not pull on wiring harness. Remove solenoids by grasping the metal tip. INSTALLATION 1. Install shift solenoid A, shift solenoid B, band control solenoid with new gaskets to main case valve body respectively. 2. Carefully install spring pin with hammer to avoid damage to valve body, etc. 3. Connect wiring harness to solenoids. 4. Install oil filter with a new gasket and the three 13 mm screws, tighten to the specified torque. Torque: 20 Nm (15 Ft. lbs.) Page 2541 Camshaft Position Sensor: Service and Repair REMOVAL PROCEDURE 1. Disconnect the negative battery cable. 2. Remove the engine cover. 3. Remove the common chamber assembly. 4. Disconnect the electrical connector to the CMP sensor. 5. Remove the CMP retaining bolt from the side of left cylinder head. 6. Remove the CMP sensor from the cylinder head. INSTALLATION PROCEDURE 1. Install the CMP sensor in the cylinder head. 2. Install the CMP sensor retaining bolt. Tighten Tighten the retaining screw to 9 N.m (78 lb in.). Page 721 6. Screw the accumulator cover removal tool clockwise into the accumulator cover. 7. Using a 22 mm wrench, continue turning the tool clockwise until the accumulator cover turns in the housing. 8. Position a drain pan under the transmission. 9. Using the 22 mm wrench as a lever and the transmission case as the fulcrum, pry the accumulator cover out of the housing. NOTE: For maximum leverage, do not fully seat the 22 mm wrench against the removal tool. Line up the end of the wrench with the center of the tool. 10. Clean the accumulator housing. 11. Lubricate the accumulator housing and the accumulator cover with clean ATF. NOTE: The accumulator cover is rubber coated and does not require an 0-ring or sealant. Page 115 Each schematic represents one circuit. A circuit's wires and components are arranged to show current flow, from power at the top of the page, to ground, at the bottom. Shared Circuits Other circuits may share power or ground terminals or wiring with the circuit shown. A wire that connects one circuit to another, for example, is cut short and has an arrowhead at the end of it pointing in the direction of current flow. Next to the arrowhead is the name of the circuit or component which shares that wiring. To quickly check shared wiring, check the operation of a component it serves. If that component works, you know the shared wiring is OK. Connectors All in-line and junction connectors are numbered (C725, C416, etc.). Component connectors are not numbered but are identified either by the name of Locations Page 1367 Tires: Testing and Inspection Irregular and Premature Wear Irregular and/or premature wear has many causes. Some of them are incorrect inflation pressures, lack of tire rotation, poor driving habits or improper wheel alignment. Incorrect inflation is common cause of tire premature wear. NOTE: Due to their design, radial tires tend to wear faster in the shoulder area, particularly on the front tires. This makes regular rotation especially necessary. After rotation, be sure to check wheel nut torque, and set tire pressures. Tread Wear Indicators Tread Wear Indicators The original equipment tires have built-in tread wear indicators (l) to show when tires need replacement. These indicators may appear as wide bands. When the indicators appear in two or more grooves at three locations, tire replacement is recommended. Diagnosis List If the following conditions are noted, rotation is required. 1. Front tire wear is different from rear. 2. Uneven wear exists across the tread of any tire. 3. Left and right front tire wear is unequal. 4. Left and right rear tire wear is unequal. If the following conditions are noted, check the wheel alignment. 1. Left and right front tire wear is unequal. 2. Uneven wear exists across the tread of any tire. 3. Front tire treads have scuffed appearance with "feather" edges on one side of tread ribs or blocks. 4. There is cupping, flat spotting etc. Higher than recommended pressure can cause: 1. Hard ride. Page 931 Transmission Position Switch/Sensor: Description and Operation Transmission Range Switch IMPORTANT: The vehicle should not be driven with the transmission range switch disconnected; idle quality will be affected. The four inputs from the transmission range switch indicate to the PCM which position is selected by the transmission selector lever. This information is used for ignition timing, EVAP canister purge, EGR operation. For more information on the transmission on the transmission range switch, refer to Transmission Control System Diagnosis. See: Powertrain Management/Transmission Control Systems/Testing and Inspection Page 2488 CD Changer Troubleshooting (All except Passport) CD Player Troubleshooting (All except Passport) Radio Troubleshooting (All except Passport) Diagram Information and Instructions Trailer Connector: Diagram Information and Instructions How to Identify Wiring Color-Coded Insulation Wire Color Wire Color Coding Page 3841 This is the same power supply used by the PGM Tester. *The PC Interface Kit and the 110 VAC/12 VDC Power Supply can be ordered through the Honda Tool and Equipment Program at 888-424-6857. ^ Dealer Communications System (DCS) CD: May 1999 or later ^ HONDANET DCS Workstation (not the master terminal) ^ PGM Tester with SN902 or later software: The Tester can be used to retrieve PCM broadcast codes if you aren't using the Smart Cable to retrieve codes.* *USING A PROGRAMMED SMART CABLE NOTES: * If the PCM broadcast code stored in the Smart Cable is different than the code needed by the PCM, go to REPROGRAMMING A SMART CABLE.* ^ If the red light (# 3) on the Smart Cable comes on or flashes at any time during the procedure, the update was not completed. Go to SMART CABLE DIAGNOSIS. 1. Turn the ignition switch ON (II). 2. Connect the Smart Cable's large blue connector to the vehicle's DLC (data link connector). Connect the other end of the Smart Cable to the DLC port on the Smart Cable box. The green light (# 1) on the Smart Cable flashes, then glows steadily. *NOTES: If the yellow (# 2) and green lights flash and then glow steadily, the PCM broadcast code already matches the code in the Smart Cable. Go to steps 5.* 3. Momentarily push and release the START button on the Smart Cable to begin the PCM update. While updating the PCM, the yellow light on the Smart Cable flashes, and the green light glows steadily. *NOTICE To avoid permanent PCM damage, do not disconnect the Smart Cable or turn the ignition switch OFF while the yellow light is flashing.* 4. After 1 to 3 minutes, note that both the yellow and green lights glow steadily to indicate that the update is complete. 5. Disconnect the Smart Cable from the DLC. 6. If the vehicle still has the problem you tried to correct with the update, refer to the appropriate service manual or ETM for troubleshooting information. *REPROGRAMMING A SMART CABLE 1. If not already done, load the May 1999 or later DCS CD onto your DCS workstation. Loading instructions were included in the CD's mailing. It you have questions when loading the CD, contact the HONDANET 2000 Support Center at 800-245-4343. 2. Connect the small end of the PC interface kit to the PC port on the Smart Cable box. (Some kits have a yellow label near the small end to help you Page 2766 If there is no photo number below or beside a component name or a connector, ground, or terminal number, look up that name or number in the appropriate Connector Identification Chart. The chart lists how many cavities a connector has, where it's located, and what it connects to. The related illustration shows the connector's location on the harness, and the harness routing. NOTE: Photos listed by number are located at Locations / Components / Photograohs. See: Locations/Component Locations/Photographs Circuit Schematics Page 890 ^ If the idle speed ever exceeds 1,300 rpm 2. Remove the vacuum hose from the fuel pressure regulator, then start the engine. ^ If fuel comes out of the fuel pressure regulator vacuum hose connection, go to REPAIR PROCEDURE FUEL PRESSURE REGULATOR. ^ If no fuel comes out of the regulator, reconnect the vacuum hose and continue to step 3. 3. Connect the PGM Tester. Set it to Engine Data List. 4. Have an assistant drive the vehicle under the conditions described by the customer. 5. If the high or erratic idle condition occurs, note the values of the PSP Switch and APP Sensor 1 when it is occurring. ^ If the PSP Switch is HIGH, and you are not turning, go to REPAIR PROCEDURE POWER STEERING SWITCH. ^ If the APP Sensor 1 is greater than 15% and APP Sensor 2 and/or APP Sensor 3 are less than 85%, and the accelerator pedal is not depressed, go to REPAIR PROCEDURE APPS GROUND. ^ If the PSP Switch is reading LOW when not turning and HIGH when turning, and the APP Sensors are reading within the range shown, discontinue the test-drive and go to step 6. 6. Do these repairs: ^ REPAIR PROCEDURE APPS GROUND ^ REPAIR PROCEDURE ENGINE/BODY GROUND REPAIR PROCEDURE - FUEL PRESSURE REGULATOR 1. Relieve fuel system pressure: ^ Remove the fuel fill cap. ^ Remove the fuel pump relay. ^ Start the engine and run it until it stalls. ^ Crank the engine for 3 seconds. 2. Remove the vacuum hose from the fuel pressure regulator. 3. Remove the fuel pressure regulator shield from the common chamber (two bolts). Page 459 Ground - "G" Shielding Sheilding This represents RFI (Radio Frequency Interference) shielding around a wire. The shielding is always connected to ground. Splices Page 5740 3. Using an air nozzle, blow into the frame rail hole, up and down inside the frame, to move any debris away from the trailing link bracket area. 4. Using a wire brush and a scraper, remove any loose frame coating and rust from the outside frame rail and the lower trailing link frame bracket in the 20-inch (500 mm) section shown below. 5. Use a dry rag to remove any remaining dust or debris. If the area is wet, dry it with an air nozzle. 6. Attach the long nozzle to the Noxudol 700 can, then use a pen or tape to mark the nozzle at 12 inches (300 mm) and at 7 inches (200 mm) from the nozzle end. These marks indicate how far you will insert the nozzle into the frame rails for some of the following steps. 7. Place a drain pan below the frame's drain hole next to the trailing link bracket. This will catch the excess Noxudol 700 that runs out of the frame's drain hole, which is expected and normal. 8. Insert the Noxudol 700 spray nozzle about 12 inches (300 mm) into the frame drain hole located on the bottom of the frame rail, toward the rear of the vehicle. Then spray the Noxudol while drawing out the nozzle. Spray two times. Diagram Information and Instructions Headlamp Switch: Diagram Information and Instructions How to Identify Wiring Color-Coded Insulation Wire Color Wire Color Coding Page 5363 Page 1729 15. Move drive belt tensioner to loose side using wrench, then install drive belt to normal position. 16. Install radiator upper fan shroud. 17. Install air cleaner assembly. Page 5272 Page 4731 4WD Control Unit: Electrical Diagrams Part 1 Of 3 Page 5929 Test Equipment CAUTION: Most circuits include solid-state devices. Test the voltages in these circuits only with a 10-megaohm or higher impedance digital multimeter. Never use a test light or analog meter on circuits that contain solid-state devices. Damage to the devices may result. Test Light and DVOM On circuits without solid-state devices, use a test light to check for voltage. A test light is made up of a 12 volt bulb with a pair of leads attached. After grounding one lead, touch the other lead to various points along the circuit where voltage should be present. The bulb will go on if there is voltage at the point being tested. If you need to know how much voltage is present, use a digital volt/ohmmeter (DVOM). Self-Powered Test Light and DVOM Use a self-powered test light to check for continuity. This tool is made up of a light bulb, battery, and two leads. To test it, touch the leads together: the light should go on. Use a self-powered test light only on an unpowered circuit. First, disconnect the battery, or remove the fuse that feeds the circuit you are working on. Select two points in the circuit between which you want to check continuity. Connect one lead of the self-powered test light to each point. If there is continuity, the test light's circuit will be completed, and the light will go on. If, in addition, you need to know exactly how much resistance there is between two points, use a digital volt/ohmmeter (DVOM). In the "OHMS" range, the DVOM will measure resistance between two points along a circuit. Low resistance means good continuity. Diodes and solid-state devices in a circuit can make a DVOM give a false reading. To check a reading, reverse the leads, and take a second reading. If the readings differ, the component is affecting the measurement. Jumper Wire Use a jumper wire to bypass an open circuit. A jumper wire is made up of an in-line fuse holder connected to a set of test leads. It should have a five ampere fuse. Never connect a jumper wire across a short circuit. The direct battery short will blow the fuse. Short Finder (Short Circuit Locator) Short finders are available to locate shorts to ground. The short finder creates a pulsing magnetic field in the shorted circuit which you can follow to the location of the short. To order any test equipment shown above, contact your local tool supplier. For a list of suppliers and tool numbers, refer to Honda Required Special Tools and Equipment Service Bulletin. Page 3608 Camshaft Position Sensor: Description and Operation Camshaft Position (CMP) Sensor and Signal The camshaft position (CMP) sensor sends a CMP signal to the PCM. The PCM uses this signal as a "sync pulse" to trigger the injectors in the proper sequence. The PCM uses the CMP signal to indicate the position of the #1 piston during its power stroke. This allows the PCM to calculate true sequential fuel injection (SFI) mode of operation. If the PCM detects an incorrect CMP signal while the engine is running, DTC P0341 will set. If the CMP signal is lost while the engine is running, the fuel injection system will shift to a calculated sequential fuel injection mode based on the last fuel injection pulse, and the engine will continue to run. As long as the fault is present, the engine can be restarted. It will run in the calculated sequential mode with a 1-in-6 chance of the injector sequence being correct. Refer to DTC P0341 for further information. CMP Signal The PCM uses this signal to determine the position of the number 1 piston during its power stroke, allowing the PCM to calculate true sequential multiport fuel injection (SFI). Loss of this signal will set a DTC P0341. If the CMP signal is lost while the engine is running, the fuel injection system will shift to a calculated sequential fuel injection based on the last fuel injection pulse, and the engine will continue to run. The engine can be restarted and will run in the calculated sequential mode as long as the fault is present, with a 1-in-6 chance of being correct. Page 838 Camshaft Position Sensor: Service and Repair REMOVAL PROCEDURE 1. Disconnect the negative battery cable. 2. Remove the engine cover. 3. Remove the common chamber assembly. 4. Disconnect the electrical connector to the CMP sensor. 5. Remove the CMP retaining bolt from the side of left cylinder head. 6. Remove the CMP sensor from the cylinder head. INSTALLATION PROCEDURE 1. Install the CMP sensor in the cylinder head. 2. Install the CMP sensor retaining bolt. Tighten Tighten the retaining screw to 9 N.m (78 lb in.). Page 1991 2. Connect the PCM electrical connectors. 3. Install the two screws to PCM electrical connectors. Page 66 Wire Color Abbreviations The following abbreviations are used to identify wire colors in the circuit schematics: WHT................................... White YEL................................... Yellow BLK................................... Black BLU................................... Blue GRN................................... Green RED................................... Red ORN................................... Orange PNK................................... Pink BRN................................... Brown GRY................................... Gray PUR................................... Purple LT BLU................................... Light Blue LT GRN................................... Light Green Page 1343 ^ Reversible drill motor (800 RPM MAX) ^ Tire spreader ^ Inspection lamp * For repairable injuries that exceed 25 degrees TIRE REPAIR GUIDELINES Never repair tires worn below 2/32 inch of tread. Never repair a tire without removing the tire from the wheel for internal inspection. Never repair a tire with a tread injury larger than 1/4 inch (6 mm). Never use only a plug (stem) or a patch only to repair a tire injury. NOTE: If the angle of the tire injury exceeds 25 degrees, you must use the two-piece repair system as recommended by the RMA. MICHELIN PAX SYSTEM SUPPORT RING INSPECTION PAX System support rings are not repairable, under any circumstances, but they can be reused if no damage is found during a thorough inspection. If a PAX System tire ran flat or underinflated, dismount the tire from the wheel and inspect the wheel, tire, and support ring for damage. Refer to the Michelin PAX Support Rings Technical Bulletin in ISIS. Enter SEARCH BY PUBLICATION, select Job Aids, then select Michelin PAX Support Rings Technical Bulletin from the list. Disclaimer Service Precautions Suspension Control Module: Service Precautions The Intelligent Suspension System interfaces directly with the Control Unit which is a control computer that is similar in some regards to the Powertrain Control Module. These modules are designed to withstand normal current draws associated with vehicle operation. However, care must be taken to avoid overloading any of the Control Unit circuits. In testing for opens or shorts, do not ground or apply voltage to any of the circuits unless instructed to do so by the appropriate diagnostic procedure. These circuits should only be tested with a high impedance multimeter (J-39200) or special tools. Power should never be removed or applied to any control module with the ignition in the "ON" position. Before removing or connecting battery cables, fuses or connectors, always turn the ignition switch to the "OFF" position. Page 7821 The name of the component appears next to it followed by notes about its function along with any photo and connector view references. Connector "C" How to Identify Connector Terminals Cavity Numbering System The cavities (and wire terminals) in each connector are numbered starting from the upper left, looking at the male terminals from the terminal side (or looking at the female terminals from the wire side. Both views are in the same direction so the numbers are the same.) All actual cavities are numbered, even if they have no wire terminals in them. NOTE: Data Link Connector (DLC) terminals are numbered according to SAE standard J1962, not the Honda standard. The numbers of the four end terminals are molded into the corners of the connector face. Page 5857 Tires: Pressure, Vacuum and Temperature Specifications Tires Pressure (P225/75R16) Front/Rear 200 kPa Pressure (P245/70R16) Front/Rear 180 kPa Page 2662 Fuel Tank Pressure Sensor: Testing and Inspection 1. Inspect the vapor pressure sensor for cracks in the housing and corrosion on the electrical terminals. 2. Inspect the rubber grommet for tears and signs of rot. Page 6775 This means the branch of the wire connects to another circuit. The arrow points to the name of the circuit branch where the wire continues. Page 1137 Air Filter Element: Service and Repair Cleaning Method Air Cleaner Element Tap the air cleaner filter gently so as not to damage the paper filter, or clean the element by blowing with compressed air of about 490 kPa (71 psi) from the clean side if it is extremely dirty. Page 6001 Test Equipment CAUTION: Most circuits include solid-state devices. Test the voltages in these circuits only with a 10-megaohm or higher impedance digital multimeter. Never use a test light or analog meter on circuits that contain solid-state devices. Damage to the devices may result. Test Light and DVOM On circuits without solid-state devices, use a test light to check for voltage. A test light is made up of a 12 volt bulb with a pair of leads attached. After grounding one lead, touch the other lead to various points along the circuit where voltage should be present. The bulb will go on if there is voltage at the point being tested. If you need to know how much voltage is present, use a digital volt/ohmmeter (DVOM). Self-Powered Test Light and DVOM Use a self-powered test light to check for continuity. This tool is made up of a light bulb, battery, and two leads. To test it, touch the leads together: the light should go on. Use a self-powered test light only on an unpowered circuit. First, disconnect the battery, or remove the fuse that feeds the circuit you are working on. Select two points in the circuit between which you want to check continuity. Connect one lead of the self-powered test light to each point. If there is continuity, the test light's circuit will be completed, and the light will go on. If, in addition, you need to know exactly how much resistance there is between two points, use a digital volt/ohmmeter (DVOM). In the "OHMS" range, the DVOM will measure resistance between two points along a circuit. Low resistance means good continuity. Diodes and solid-state devices in a circuit can make a DVOM give a false reading. To check a reading, reverse the leads, and take a second reading. If the readings differ, the component is affecting the measurement. Jumper Wire Use a jumper wire to bypass an open circuit. A jumper wire is made up of an in-line fuse holder connected to a set of test leads. It should have a five ampere fuse. Never connect a jumper wire across a short circuit. The direct battery short will blow the fuse. Short Finder (Short Circuit Locator) Short finders are available to locate shorts to ground. The short finder creates a pulsing magnetic field in the shorted circuit which you can follow to the location of the short. To order any test equipment shown above, contact your local tool supplier. For a list of suppliers and tool numbers, refer to Honda Required Special Tools and Equipment Service Bulletin. Page 6381 This means the branch of the wire connects to another circuit. The arrow points to the name of the circuit branch where the wire continues. Page 4299 5. Install flange nut, refer to Differential; Service and Repair; Unit Overhaul for flange nut reassembly. NOTE: Discard the used nut and install a new one. Page 8268 2. Finally, check that the click of the stay has caught in the hole of the rubber. Page 7282 1. Open the hatch gate and tail gate. 2. Remove the spare tire (3). - Put the spare tire handle (1) to the center of upper side of rear bumper (2) and turn counterclockwise. Put spare tire down. 3. Remove the spare tire support. - Remove the four bolts that are fixed to frame cross member. 4. Remove the spare tire hanger assembly. - Remove the two fixing bolts. Installation To install, follow the removal steps in the reverse order, noting the following points. 1. Install the spare tire firmly. 2. Tighten the spare tire support fixing bolts to the specified torque. Torque: 40 N.m (30 lb.ft) 3. Tighten the spare tire hanger fixing bolts to the specified torque. Torque: 19 N.m (14 lb.ft) Spare Tire Carrier Spare Tire Carrier Page 3025 Vehicle Speed Sensor: Diagnostic Aids Before Troubleshooting Before Troubleshooting See: Service Precautions/Vehicle Damage Warnings/Tips and Precautions 1. Check applicable fuses in the appropriate fuse/relay box. 2. Check the battery for damage, state of charge, and clean and tight connections. CAUTION: Do not quick-charge a battery unless the battery ground cable has been disconnected, otherwise you will damage the alternator diodes. - Do not attempt to crank the engine with the battery ground cable loosely connected or you will severely damage the wiring. While You're Working 1. Make sure connectors are clean, and have no loose terminals or receptacles. 2. Make sure that connectors without wire seals are packed with dielectric (silicone) grease. Part Number: 08798-9001. 3. When connecting a connector, push it until it "clicks" into place. CAUTION: Do not pull on the wires when disconnecting a connector. Pull only on the connector housings. - Most circuits include solid-state devices. Test the voltages in these circuits only with a 10-megaohm or higher impedance digital multi meter. Never use a test light or analog meter on circuits that contain solid-state devices. Damage to the devices may result. Five-Step Troubleshooting 1. Verify The Complaint Turn on all the components in the problem circuit to check the accuracy of the customer complaint. Note the symptoms. Do not begin disassembly or testing until you have narrowed down the problem area. 2. Analyze The Schematic Look up the schematic for the problem circuit. Determine how the circuit is supposed to work by tracing the current paths from the power source through the circuit components to ground. Also, trace circuits that share wiring with the problem circuit. The names of circuits that share the same fuse, ground, or switch, and so on, are referred to in each circuit schematic. Try to operate any shared circuits you didn't check in step 1. If the shared circuits work, the shared wiring is OK, and the cause must be in the wiring used only by the problem circuit. If several circuits fail at the same time, the fuse or ground is a likely cause. Based on the symptoms and your understanding of the circuit's operation, identify one or more possible causes. 3. Isolate The Problem By Testing The Circuit Make circuit tests to check the diagnosis you made in step 2. Keep in mind that a logical, simple procedure is the key to efficient troubleshooting. Test for the most likely cause of failure first. Try to make tests at points that are easily accessible. 4. Fix The Problem Once the specific problem is identified, make the repair. Be sure to use proper tools and safe procedures. 5. Make Sure The Circuit Works Turn on all components in the repaired circuit in all modes to make sure you've fixed the entire problem. If the problem was a blown fuse, be sure to test all of the circuits on that fuse. Make sure no new problems turn up and the original problem does not recur. Page 3635 Spark Plug: Description and Operation Spark Plug Although worn or dirty spark plugs may give satisfactory operation at idling speed, they frequency fail at higher engine speeds. Faulty spark plugs may cause poor fuel economy, power loss, loss of speed, hard starting and generally poor engine performance. Follow the scheduled maintenance service recommendations to ensure satisfactory spark plug performance. Refer to Maintenance and Lubrication. Normal spark plug operation will result in brown to grayish-tan deposits appearing on the insulator portion of the spark plug. A small amount of red-brown, yellow, and white powdery material may also be present on the insulator tip around the center electrode. These deposits are normal combustion by-products of fuels and lubricating oils with additives. Some electrode wear will also occur. Engines which are not running properly are often referred to as "misfiring." This means the ignition spark is not igniting the air/fuel mixture at the proper time. While other ignition and fuel system causes must also be considered, possible causes include ignition system conditions which allow the spark voltage to reach ground in some other manner than by jumping across the air gap at the tip of the spark plug, leaving the air/fuel mixture unburned. Refer to DTC P0300. Misfiring may also occur when the tip of the spark plug becomes overheated and ignites the mixture before the spark jumps. This is referred to as "pre-ignition." Spark plugs may also misfire due to fouling, excessive gap, or a cracked or broken insulator. If misfiring occurs before the recommended replacement interval, locate and correct the cause. Carbon fouling of the spark plug is indicated by dry, black carbon (soot) deposits on the portion of the spark plug in the cylinder. Excessive idling and slow speeds under light engine loads can keep the spark plug temperatures so low that these deposits are not burned off. Very rich fuel mixtures or poor ignition system output may also be the cause. Refer to DTC P0172. Oil fouling of the spark plug is indicated by wet oily deposits on the portion of the spark plug in the cylinder, usually with little electrode wear. This may be caused by oil during break-in of new or newly overhauled engines. Deposit fouling of the spark plug occurs when the normal red-brown, yellow or white deposits of combustion by products become sufficient to cause misfiring. In some cases, these deposits may melt and form a shiny glaze on the insulator around the center electrode. If the fouling is found in only one or two cylinders, valve stem clearances or intake valve seals may be allowing excess lubricating oil to enter the cylinder, particularly if the deposits are heavier on the side of the spark plug facing the intake valve. Excessive gap means that the air space between the center and the side electrodes at the bottom of the spark plug is too wide for consistent firing. This Page 6984 To install the connector, hold the socket insulator(l) and insert it. The cover insulator slides and connector will be locked. Do not hold the cover insulator(2). Page 3289 If there is no photo number below or beside a component name or a connector, ground, or terminal number, look up that name or number in the appropriate Connector Identification Chart. The chart lists how many cavities a connector has, where it's located, and what it connects to. The related illustration shows the connector's location on the harness, and the harness routing. NOTE: Photos listed by number are located at Locations / Components / Photograohs. See: Locations/Component Locations/Photographs Circuit Schematics Page 8126 Page 6470 Air Bag(s) Arming and Disarming: Service Precautions Airbag Handling and Storage Airbag Handling and Storage Do not disassemble an airbag. It has no serviceable parts. Once an airbag has been deployed, it cannot be repaired or reused. For temporary storage of the airbag during service, please observe the following precautions. - Store the removed airbag with the pad surface up. Never put anything on the removed airbag. - Keep free from any oil, grease, detergent, or water to prevent damage to the airbag assembly. - Store the removed airbag on a secure, flat surface away from any high heat source (exceeding 200 °F/93 °C). - Never perform electrical inspections to the airbags, such as measuring resistance. - Do not position yourself in front of the airbag assembly during removal, inspection, or replacement. Page 2742 10. Use the PGM Tester to check the broadcast code. Make sure the broadcast code matches the one you selected from the CD-ROM. WARRANTY CLAIM INFORMATION In warranty: The normal warranty applies. Failed Part: P/N 8-17087-655-0 H/C 4375820 Defect Code: 064 Contention Code: C01 Skill Level: Repair Technician Out of warranty: Any repair performed after warranty expiration may be eligible for goodwill consideration by the District Service Manager or your Zone Office. You must request consideration, and get a decision, before starting work. REPAIR PROCEDURE - ENGINE/BODY GROUND 1. Use the ETM for the appropriate year to locate these ground connectors: G101, G104, G105, G106 and G160. 2. Inspect each connector for corrosion or looseness. 3. Remove the bolt from any connector that is corroded or loose. Clean the terminal connector with a wire brush. File flat any solder bumps on the connector. 4. Clean the contact surface on the engine or body with a wire brush. 5. Replace the bolt if it is heavily corroded. Otherwise, clean it with a wire brush. 6. Apply lithium dielectric grease to both sides of the terminal connector. 7. Reinstall the bolt, torque it to 14 N.m (10 lb-ft). 8. Use the Smart Cable to reprogram the PCM with the latest software from the June 2001 or later HONDANET CD-ROM. Refer to Service Bulletin 99-005, Updating the Passport PCM, filed under Tools. 9. Use the PGM Tester to clear any DTCs. 10. Use the PGM Tester to check the broadcast code. Make sure the broadcast code matches the one you selected from the CD-ROM. WARRANTY CLAIM INFORMATION In warranty: The normal warranty applies. Failed Part: P/N 8-97086-823-0 Page 1820 3. Connect the electrical connector. 4. Fill the radiator with coolant. Refer to Draining and Refilling Cooling System. 5. Connect the negative battery cable. Page 3091 EGR Valve: Service and Repair REMOVAL PROCEDURE 1. Disconnect the negative battery cable. 2. Disconnect the electrical connector at the EGR valve. 3. Remove the bolts from the common chamber. 4. Remove the EGR valve from the common chamber manifold. 5. Remove the gasket from the common chamber manifold. INSTALLATION PROCEDURE 1. Install the gasket on the common chamber. 2. Install the EGR valve on the common chamber. Page 7820 This sample Ground Distribution schematic shows all of the components that share two ground points. Components A solid border line means the entire component is shown. A broken border line indicates that only part of the component is shown. Page 6052 7. Install drive plate bolt by using drive plate holder J-33939 (1) to prevent the drive plate from rotating. - Tighten the drive plate bolt to the specified torque. Torque: 13 Nm (113 lb in) - After tightening the drive plate bolt, check to be sure the pulley rotates smoothly. - Check to be sure that the clutch clearance is between 0.3 - 0.6 mm (0.01 - 0.02 in.) - If necessary, install adjusting shim(s). - Adjusting shims are available in the following thickness. Thickness 0.1 mm (0.0039 in.) - 0.3 mm (0.0118 in.) - 0.5 mm (0.0197 in.) Page 7545 Air Bag(s) Arming and Disarming: Service Precautions Airbag Handling and Storage Airbag Handling and Storage Do not disassemble an airbag. It has no serviceable parts. Once an airbag has been deployed, it cannot be repaired or reused. For temporary storage of the airbag during service, please observe the following precautions. - Store the removed airbag with the pad surface up. Never put anything on the removed airbag. - Keep free from any oil, grease, detergent, or water to prevent damage to the airbag assembly. - Store the removed airbag on a secure, flat surface away from any high heat source (exceeding 200 °F/93 °C). - Never perform electrical inspections to the airbags, such as measuring resistance. - Do not position yourself in front of the airbag assembly during removal, inspection, or replacement. Page 4695 Testing For A Short With A Self-Powered Test Light or DVOM 1. Remove the blown fuse and disconnect the battery and load. 2. Connect one lead of a self-powered test light or digital volt/ohmmeter (DVOM) (switched to the lowest "OHMS" range) to the fuse terminal on the load side. 3. Connect the other lead to a known good ground. 4. Beginning near the fuse box, wiggle the harness. Continue this at convenient points about six inches apart while watching the test light or DVOM. 5. If the self-powered test light goes on or the DVOM displays a low reading or no reading (zero), there is a short to ground in the wiring near that point. Testing for a Short with a Test Light or DVOM 1. Remove the blown fuse and disconnect the load. 2. Connect a test light or digital volt/ohmmeter (DVOM), switched to the appropriate DC volts range, across the fuse terminals to make sure voltage is present. You might have to turn the ignition switch to ON; check the schematic to see. 3. Beginning near the fuse box, wiggle the harness. Continue this at convenient points about six inches apart while watching the test light or DVOM. 4. Where the test light goes , or the DVOM voltage drops to zero, there is a short to ground in the wiring near that point. NOTE: Always use a DVOM on high impedance circuits. A test light may not glow (even with battery voltage present). Testing For A Short With A Short Circuit Locator (Short Finder) 1. Remove the blown fuse. Leave the battery connected. Locations Fuel Pressure Sensor/Switch: Locations Top Rear of Fuel Tank Page 7404 Each schematic represents one circuit. A circuit's wires and components are arranged to show current flow, from power at the top of the page, to ground, at the bottom. Shared Circuits Other circuits may share power or ground terminals or wiring with the circuit shown. A wire that connects one circuit to another, for example, is cut short and has an arrowhead at the end of it pointing in the direction of current flow. Next to the arrowhead is the name of the circuit or component which shares that wiring. To quickly check shared wiring, check the operation of a component it serves. If that component works, you know the shared wiring is OK. Connectors All in-line and junction connectors are numbered (C725, C416, etc.). Component connectors are not numbered but are identified either by the name of Page 2581 ATF Level Check Fluid - A/T: Service and Repair ATF Level Check CHECKING TRANSMISSION FLUID LEVEL AND CONDITION Checking fluid level and condition (color and odor) at regular intervals will provide early diagnosis information about the transmission. This information may be used to correct a condition that, if not detected early, could result in major transmission repairs. IMPORTANT: When new, automatic transmission fluid is red in color. As the vehicle is driven, the transmission fluid will begin to look darker in color. The color may eventually appear light brown. A dark brown color with burnt odor may indicate excessive fluid deterioration and signal a need for fluid change. FLUID LEVEL When adding or changing fluid, use only DEXRON III. CAUTION: DO NOT OVERFILL. Overfilling will cause foaming, loss of fluid, abnormal shifting and possible damage to the transmission. 1. Park the vehicle on level ground and apply the parking brake firmly. 2. Check fluid level with engine running at idle. NOTE: Be sure that transmission fluid temperature is below 30°C (86°F). 3. Move the selector lever through all gear ranges. 4. Move the selector lever to "Park". 5. Let engine idle for 3 minutes and open the overfill screw (1). 6. Add released transmission fluid until it flows out over the overfill screw opening. 7. Let engine idle until a fluid temperature between 32°C (90°F) and 57°C (135°F) is reached, then close the overfill screw (1). Torque: 38 Nm (28 ft. lbs.) NOTE: To prevent fluid leaks, the overfill screw and oil drain screws gasket must be replaced each time these screws are removed. NOTE: Check transmission fluid temperature with scan tool. Minimum fluid level 57°C (135°F) Maximum fluid level 32°C (90°F) CAUTION: Do not open overfill screw with engine stopped. CAUTION: DO NOT CHECK FLUID LEVEL UNDER THESE CONDITIONS: Immediately after driving at sustained highway speeds. - In heavy city traffic during hot weather. - If vehicle is towing a trailer. If the vehicle has been operated under these conditions, shut the engine off and allow the vehicle to "cool" for thirty (30) minutes. After the cool down period, restart the vehicle and continue from step 2 above. Page 5546 10. Use the PGM Tester to check the broadcast code. Make sure the broadcast code matches the one you selected from the CD-ROM. WARRANTY CLAIM INFORMATION In warranty: The normal warranty applies. Failed Part: P/N 8-17087-655-0 H/C 4375820 Defect Code: 064 Contention Code: C01 Skill Level: Repair Technician Out of warranty: Any repair performed after warranty expiration may be eligible for goodwill consideration by the District Service Manager or your Zone Office. You must request consideration, and get a decision, before starting work. REPAIR PROCEDURE - ENGINE/BODY GROUND 1. Use the ETM for the appropriate year to locate these ground connectors: G101, G104, G105, G106 and G160. 2. Inspect each connector for corrosion or looseness. 3. Remove the bolt from any connector that is corroded or loose. Clean the terminal connector with a wire brush. File flat any solder bumps on the connector. 4. Clean the contact surface on the engine or body with a wire brush. 5. Replace the bolt if it is heavily corroded. Otherwise, clean it with a wire brush. 6. Apply lithium dielectric grease to both sides of the terminal connector. 7. Reinstall the bolt, torque it to 14 N.m (10 lb-ft). 8. Use the Smart Cable to reprogram the PCM with the latest software from the June 2001 or later HONDANET CD-ROM. Refer to Service Bulletin 99-005, Updating the Passport PCM, filed under Tools. 9. Use the PGM Tester to clear any DTCs. 10. Use the PGM Tester to check the broadcast code. Make sure the broadcast code matches the one you selected from the CD-ROM. WARRANTY CLAIM INFORMATION In warranty: The normal warranty applies. Failed Part: P/N 8-97086-823-0 Page 5371 Blower Motor - Will Not Run In One Or More Settings Blower Motor Resistor: All Technical Service Bulletins Blower Motor - Will Not Run In One Or More Settings 01-007 October 16, 2001 Applies To: 1998-01 Passport - ALL Blower Does Not Run in One or More Settings (Supersedes 01-007, dated July 3, 2001) SYMPTOM The blower does not run in one or more fan control lever positions. PROBABLE CAUSE A high current draw on the blower resistor causes it overheat and to become electrically "open." This high current draw is usually caused by high friction in the blower motor bearings and/or debris in the blower assembly housing, which jams or slows the blower motor and damages its commutator. CORRECTIVE ACTION Replace the blower resistor and the blower motor assembly. Clean out all debris from inside the blower assembly housing. PARTS INFORMATION Blower Resistor (1998-99 models): P/N 8-97078-452-1, H/C 4906202 Blower Resistor (2000-01 models): P/N 8-97260-283-0, H/C 6633390 Blower Motor Assembly (1998-99 models): P/N 8-97231-642-0, H/C 6447544 Blower Motor Assembly (2000-01 models): P/N 8-97229-613-1, H/C 6262083 WARRANTY CLAIM INFORMATION In warranty: The normal warranty applies. Operation Number: 612109 Flat Rate Time: 0.4 hour Failed Part: P/N 8-97046-497-0 H/C 4402186 Defect Code: 032 Contention Code: B01 Template ID: 01-007A (1998-99 models) 01-007B (2000-01 models) Skill Level: Repair Technician Out of warranty: Any repair performed after warranty expiration may be eligible for goodwill consideration by the District Service Manager or your Zone Office. You must request consideration, and get a decision, before starting work. REPAIR PROCEDURE Page 6681 The connector cavity number is listed next to each terminal on the circuit schematic. The cavity / terminal shown is # 6. Diodes A rectifier diode works like a one way valve. It allows current to flow only in the direction of the arrow. A Zener diode blocks reverse current at normal voltages just like a rectifier diode. At high voltages, however, a Zener diode allows current to flow in reverse. Fuses Page 182 2. Connect one lead of a self-powered test light or DVOM to one end of the part of the circuit you want to test. 3. Connect the other lead to the other end. 4. If the self-powered test light glows, there is continuity. If you're using a DVOM, a low reading or no reading (zero), means good continuity. Testing For Voltage When testing for voltage at a connector without wire seals, you do not have to separate the two halves of the connector. Instead, probe the connector from the back. Always check both sides of the connector because dirty, corroded, and bent terminals can cause problems (no electrical contact = an open). 1. Connect one lead of the lest light to a known good ground, or, if you're using a digital volt ohmmeter (DVOM), place it in the appropriate DC volts range, and connect its negative lead to ground. 2. Connect the other lead of the test light or DVOM to the point you want to check. 3. If the test light glows, there is voltage present. If you're using a DVOM, note the voltage reading. It should be within one volt of measured battery voltage. A loss of more than one volt indicates a problem. NOTE: Always use a DVOM on high impedance circuits. A test light may not glow (even with battery voltage present). Testing For Voltage Drop Wires, connectors, and switches are designed to conduct current with a minimum loss of voltage. A voltage drop of more than one volt indicates a problem. 1. Place the digital volt/ohmmeter (DVOM) in the appropriate DC volts range. Connect the positive lead to the end of the wire (or to the connector or switch) closest to the battery. 2. Connect the negative lead to the other end of the wire (or the other side of the connector or switch). 3. Turn on the components in the circuit. 4. The DVOM will show the difference in voltage between the two points. A difference, or drop, of more than one volt indicates a problem. Check the circuit for loose, dirty, or bent terminals. Page 1457 3. Remove oil strainer fixing bolts, remove oil strainer assembly with O-ring. 4. Remove three fixing bolts, oil pipe with O-ring. 5. Remove eight fixing bolts, oil gallery. 6. Remove piston with connecting rod assembly, before removing the bearing cap, remove carbon on the top of cylinder bore and push piston with connecting rod out from the top of cylinder bore. Installation 1. Install piston with connecting rod assembly. - Apply engine oil to cylinder bore, connecting rod bearing and crank pin. When installing the piston, its front mark must face the engine front side. - The bearing cap number must be the same as connecting rod number. - Apply engine oil to the thread and seating surface of each nut. - Tighten nuts to the specified torque. Torque: 54 Nm (40 ft. lbs.) - After tightening the nuts, make sure that the crankshaft rotates smoothly. Note: Do not apply engine oil to the bearing back faces and connecting rod bearing fitting surfaces. Page 2060 Ion Sensing Module: Description and Operation ION Sensing Module ION Sensing Module This module has the function to energize and de-energize the primary ignition coil in response to signals from the PCM. Page 5479 4. Remove the fuel pressure regulator from the fuel rail. 5. Remove the fuel return line from the regulator. 6. Install the new fuel pressure regulator in the reverse order of removal. 7. Use the Smart Cable to reprogram the PCM with the latest software from the June 2001 or later HONDANET CD-ROM. Refer to Service Bulletin 99-005, Updating the Passport PCM, filed under Tools. 8. Use the PGM Tester to clear any DTCs. 9. Use the PGM Tester to check the broadcast code. Make sure the broadcast code matches the one you selected from the CD-ROM. WARRANTY CLAIM INFORMATION In warranty: The normal warranty applies. Failed Part: P/N 8-17113-398-0 H/C 5504386 Defect Code: 092 Contention Code: C99 Skill Level: Repair Technician Out of warranty: Any repair performed after warranty expiration may be eligible for goodwill consideration by the District Service Manager or your Zone Office. You must request consideration, and get a decision, before starting work. REPAIR PROCEDURE - POWER STEERING SWITCH 1. Drain the power steering fluid out of the system. 2. Remove the power steering fluid reservoir. Clean the reservoir with solvent, then with soap and water. Rinse and dry it thoroughly. 3. Reinstall the reservoir. Do not connect the return hose. 4. Remove the power steering pressure switch, then clean it with brake cleaner and a scraper. Reinstall the switch, and torque it to 20 N.m (14 lb-ft). 5. Cover the unconnected end of the reservoir with your finger, then fill the reservoir with Dexron III ATF Page 5206 The connector cavity number is listed next to each terminal on the circuit schematic. The cavity / terminal shown is # 6. Diodes A rectifier diode works like a one way valve. It allows current to flow only in the direction of the arrow. A Zener diode blocks reverse current at normal voltages just like a rectifier diode. At high voltages, however, a Zener diode allows current to flow in reverse. Fuses Page 1881 Catalytic Converter: Diagrams LH TWC and Forked Exhaust Pipe and Associated Parts TWC LH and Forked Exhaust Pipe and Associated Parts Page 6433 15. Remove tour bolts of SRS coil assembly and remove the SRS coil assembly from the combination switch. Installation 1. Set cancel cam and SRS coil in position and install the SRS coil to combination switch by tightening the tour bolts to a specified tightening torque with tour bolts. Torque. 0.5 N.m (0.05 kg.m / 0.4 lb.ft) 2. Insert the horn terminal into the connector NO.12 and bind the combination switch harness and SRS coil harness with a tape. 3. Install the combination switch assembly (with SRS coil) to steering lock of steering shaft and tighten the tour bolts to a specified tightening torque. 4. Connect the wiring harness connectors (10) located at the base of steering column. 5. Turn the SRS coil clockwise to full, return about 3 turns and align the neutral mark. Page 6974 - Refer to the scrapping procedures for disposal of the damaged airbag. Page 262 The name of the component appears next to it followed by notes about its function along with any photo and connector view references. Connector "C" How to Identify Connector Terminals Cavity Numbering System The cavities (and wire terminals) in each connector are numbered starting from the upper left, looking at the male terminals from the terminal side (or looking at the female terminals from the wire side. Both views are in the same direction so the numbers are the same.) All actual cavities are numbered, even if they have no wire terminals in them. NOTE: Data Link Connector (DLC) terminals are numbered according to SAE standard J1962, not the Honda standard. The numbers of the four end terminals are molded into the corners of the connector face. Page 6346 Air Bag(s) Arming and Disarming: Service Precautions Wiring Precautions Wiring Precautions SRS wiring can be identified by special yellow outer covering (except the SRS indicator light circuit). Never attempt to modify, splice, or repair SRS wiring. If there is an open or damage in SRS wiring, replace the harness. Be sure to install the harness wires so that they are not pinched, or interfere with other parts. Make sure all SRS ground locations are clean, and grounds are securely fastened for optimum metal-to-metal contact. Poor grounding can cause intermittent problems that are difficult to diagnose. Page 741 Vehicle Speed Sensor: Locations 92. Beneath Center of Vehicle, on Transfer Case (A/T) Beneath Center of Vehicle, on Transfer Case (A/T) Page 1614 18. Reinstall the bracket on the engine. Torque the flange bolts to 50 N.m (37 lb-ft). Be careful not to pinch the crankshaft position sensor harness, and on A/T models, the ATF cooler lines. 19. Lower the engine into position. Do it slowly to avoid wedging it between the mounts; if you lower it too fast, you will compress the mounts. If you compress the mounts, they will not be able to isolate noise and absorb vibration. 20. Reinstall the engine mounts on the chassis. Torque the flange bolts to 41 N.m (30 lb-ft). 21. Reinstall the crankshaft position sensor. Torque the bolt to 9 N.m (7 lb-ft). 22. Plug the 3P connector into the crankshaft position sensor. 23. Reinstall the crankshaft position sensor harness clamp. 24. Models With A/T: Reinstall the front and rear clamps for the A/T cooler lines. 25. Models With 4WD: Reinstall the front skid plate. 26. Reinstall the front wheels. Torque the lug nuts to 118 N.m (87 lb-ft). 27. Lower the vehicle. 28. Reconnect the negative cable to the battery. 29. Enter your customer's radio station presets and mode settings. Set the clock. Disclaimer Page 1862 Thermostat: Pressure, Vacuum and Temperature Specifications Valve Opening Temperature 74.5 - 78.5 deg C Valve Full Open Temperature and Lift More Than 8.5 mm at 90 deg C Thermostat Wax Pellet Type With Air Hole Page 695 H/C 4408092 Defect Code: 017 Contention Code: C99 Skill Level: Repair Technician Out of warranty: Any repair performed after warranty expiration may be eligible for goodwill consideration by the District Service Manager or your Zone Office. You must request consideration, and get a decision, before starting work. DISCLAIMER Ignition Switch - Won't Turn To The Lock Position Technical Service Bulletin # 02-005 Date: 020212 Ignition Switch - Won't Turn To The Lock Position 02-005 February 12, 2002 Applies To: 1998-02 Passport - ALL with A/T Ignition Switch Does Not Turn to the LOCK Position SYMPTOM The ignition switch does not turn to the LOCK position; as if the shift lever is not in Park. The ignition key cannot be removed. PROBABLE CAUSE The shift lock cable between the lock cylinder assembly (ignition lock assembly) and the shift lever is out of adjustment. CORRECTIVE ACTION Check and, if necessary, adjust the shift lock cable. WARRANTY CLAIM INFORMATION In warranty: The normal warranty applies. Operation Number: 745301 Flat Rate Time: 0.3 hour Failed Part: P/N 8-97178-564-0 H/C 5650262 Defect Code: 032 Contention Code: B01 Template ID: 02-005A Skill Level: Repair Technician Out of warranty: Any repair performed after warranty expiration may be eligible for goodwill consideration by the District Service Manager or your Zone Office. You must request consideration, and get a decision, before starting work. Disclaimer Repair Procedure 1. Remove the driver's kick panel (two clips). 2. Remove the driver's dashboard lower cover: ^ Remove the two mounting screws for the hood release lever and the mounting screw on the lower right corner of the cover. ^ Pull the hood release lever forward, and turn it sideways to unclip it from the cover. Page 4565 4WD Control Unit: Electrical Diagrams Part 1 Of 3 Page 6787 Trailer Connector: Description and Operation With the converter jumper installed, a power wire must be spliced into the RED/WHT wire above the cargo area light to ensure that the converter is powered with 12 V at all times. Diagrams Rear Door Trim Panel Page 6471 - Refer to the scrapping procedures for disposal of the damaged airbag. Page 4316 5. Install retainer ring, using installer and press. 6. Install snap ring. 7. Install axle shaft assembly into housing. 8. Install bolts, lockwashers, and nuts. Tighten the retainer nuts to the specified torque. Torque: 75 Nm (55 ft. lbs.) Page 1731 2. On the right cylinder bank, turn the camshaft pulley until its green mark is at 12 o'clock in relation to the head surface, at the center of the head. Turning the pulley brings the timing dots on the camshaft drive gear into their correct position: to the left and right of the gear's centerline. 3. On the left cylinder bank, turn the camshaft pulley until its green mark is at 12 o'clock in relation to the head surface, at the center of the head. Then turn the pulley counterclockwise until its green mark points close to the timing belt cover bolt hole. Turning the pulley brings the timing dots on the camshaft drive gear into their correct position: to the left and right of the gear's centerline. 4. Install the intake and exhaust camshafts in the right cylinder bank: - Set the camshaft marked "RI" into the intake side of the head. Make sure the single timing dot on the camshaft gear aligns with the timing dot on the camshaft drive gear. Diagrams Power Window Switch Driver Seat Side Power Window Switch: Service and Repair Power Window Switch Driver Seat Side Power Window Switch Driver Seat Side Removal 1. Disconnect the battery ground cable. 2. Remove the switch (1). - Pull out the switch by pushing the spring with the tip of a screwdriver. - Disconnect the connector. Installation To install, follow the removal steps in the reverse order. Front Passenger Seat Side Removal 1. Disconnect the battery ground cable. 2. Remove the switch (1). - Pull out the switch by pushing the spring with the tip of a screwdriver. - Disconnect the connector. Installation Page 8116 To install, follow the removal steps in the reverse order. Rear-Left and Right Sides Removal 1. Disconnect the battery ground cable. 2. Remove the rear door trim pad (2). - Disconnect the rear power window switch (1) connector. 3. Remove the rear power window switch (1). - Remove the switch fixing screw from the back side of the rear door trim (2). Installation To install, follow the removal steps in the reverse order. Page 3296 Ground - "G" Shielding Sheilding This represents RFI (Radio Frequency Interference) shielding around a wire. The shielding is always connected to ground. Splices Page 7874 If there is no photo number below or beside a component name or a connector, ground, or terminal number, look up that name or number in the appropriate Connector Identification Chart. The chart lists how many cavities a connector has, where it's located, and what it connects to. The related illustration shows the connector's location on the harness, and the harness routing. NOTE: Photos listed by number are located at Locations / Components / Photograohs. See: Locations/Component Locations/Photographs Circuit Schematics Page 7040 7. Remove the 5 screws (1), (3) and pull out the door trim panel at the 6 clip (2) positions. 8. Remove the waterproof sheet. - Taking notice of the door harness, peel the waterproof sheet off the door panel carefully. 9. Raise the glass up to the uppermost position, and then remove the rear guide rail. 10. Disconnect the locking links then remove the door lock assembly fixing screws and door lock assembly. Installation To install, follow the removal steps in the reverse order, noting the following points: 1. Apply chassis grease to the lock assembly and striker moving surface. 2. Install the regulator handle as shown in the illustration, if equipped without power windows. 3. Tighten the door lock assembly fixing screws to the specified torque. Torque 7 Nm (61 lb in) 4. Check that the door lock operates smoothly. Page 2647 - Engine Coolant Temperature - Crankshaft Position - Exhaust Oxygen Content - Electronic Ignition - Manifold Absolute Pressure - Battery Voltage - Throttle Position - Vehicle Speed - Fuel Pump Voltage - Power Steering Pressure - Intake Air Temperature - Mass Air Flow - Engine knock - Camshaft Position Outputs - Systems Controlled - EVAP Canister Purge - Exhaust Gas Recirculation (EGR) - Ignition Control - Fuel Control - ION Sensing Module - Electric Fuel Pump - Air Conditioning - Diagnostics Malfunction Indicator Lamp - Data Link Connector (DLC) - Data Output - Transmission Control Module PCM Voltage Description PCM Voltage Description The PCM supplies a buffered voltage to various switches and sensors. It can do this because resistance in the PCM is so high in value that a test light may not illuminate when connected to the circuit. An ordinary shop voltmeter may not give an accurate reading because the voltmeter input impedance is too low. Use a 10 megohms input impedance digital voltmeter (such as J 39200) to assure accurate voltage readings. The input/output devices in the PCM include analog-to-digital converters, signal buffers, counters, and special drivers. The PCM controls most components with electronic switches which complete a ground circuit when turned "ON." These switches are arranged in groups of 4 and 7, called either a surface-mounted quad driver module (QDM), which can independently control up to 4 output terminals, or QDMs which can independently control up to 7 outputs. Not all outputs are always used. Powertrain Control Module (PCM) Powertrain Control Module (PCM) The powertrain control module (PCM) is located in the passenger compartment below the center console. The PCM controls the following: - Fuel metering system. - Transmission shifting (automatic transmission only). - Ignition timing. - On-board diagnostics for powertrain functions. The PCM constantly observes the information from various sensors. The PCM controls the systems that affect vehicle performance. The PCM performs the diagnostic function of the system. It can recognize operational problems, alert the driver through the MIL (Check Engine lamp), and store diagnostic trouble codes (DTCs). DTCs identify the problem areas to aid the technician in making repairs. 58X Reference PCM Input 58X Reference PCM Input The powertrain control module (PCM) uses this signal from the crankshaft position (CKP) sensor to calculate engine RPM and crankshaft position at all engine speeds. The PCM also uses the pulses on this circuit to initiate injector pulses. If the PCM receives no pulses on this circuit, DTC P0337 will set. The engine will not start and run without using the 58X reference signal. Page 760 Vehicle Speed Sensor: Diagnostic Aids Before Troubleshooting Before Troubleshooting See: Service Precautions/Vehicle Damage Warnings/Tips and Precautions 1. Check applicable fuses in the appropriate fuse/relay box. 2. Check the battery for damage, state of charge, and clean and tight connections. CAUTION: Do not quick-charge a battery unless the battery ground cable has been disconnected, otherwise you will damage the alternator diodes. - Do not attempt to crank the engine with the battery ground cable loosely connected or you will severely damage the wiring. While You're Working 1. Make sure connectors are clean, and have no loose terminals or receptacles. 2. Make sure that connectors without wire seals are packed with dielectric (silicone) grease. Part Number: 08798-9001. 3. When connecting a connector, push it until it "clicks" into place. CAUTION: Do not pull on the wires when disconnecting a connector. Pull only on the connector housings. - Most circuits include solid-state devices. Test the voltages in these circuits only with a 10-megaohm or higher impedance digital multi meter. Never use a test light or analog meter on circuits that contain solid-state devices. Damage to the devices may result. Five-Step Troubleshooting 1. Verify The Complaint Turn on all the components in the problem circuit to check the accuracy of the customer complaint. Note the symptoms. Do not begin disassembly or testing until you have narrowed down the problem area. 2. Analyze The Schematic Look up the schematic for the problem circuit. Determine how the circuit is supposed to work by tracing the current paths from the power source through the circuit components to ground. Also, trace circuits that share wiring with the problem circuit. The names of circuits that share the same fuse, ground, or switch, and so on, are referred to in each circuit schematic. Try to operate any shared circuits you didn't check in step 1. If the shared circuits work, the shared wiring is OK, and the cause must be in the wiring used only by the problem circuit. If several circuits fail at the same time, the fuse or ground is a likely cause. Based on the symptoms and your understanding of the circuit's operation, identify one or more possible causes. 3. Isolate The Problem By Testing The Circuit Make circuit tests to check the diagnosis you made in step 2. Keep in mind that a logical, simple procedure is the key to efficient troubleshooting. Test for the most likely cause of failure first. Try to make tests at points that are easily accessible. 4. Fix The Problem Once the specific problem is identified, make the repair. Be sure to use proper tools and safe procedures. 5. Make Sure The Circuit Works Turn on all components in the repaired circuit in all modes to make sure you've fixed the entire problem. If the problem was a blown fuse, be sure to test all of the circuits on that fuse. Make sure no new problems turn up and the original problem does not recur. Page 5536 H/C 4408092 Defect Code: 017 Contention Code: C99 Skill Level: Repair Technician Out of warranty: Any repair performed after warranty expiration may be eligible for goodwill consideration by the District Service Manager or your Zone Office. You must request consideration, and get a decision, before starting work. DISCLAIMER Page 5757 16. Remove the top of body mount No. 4 from the left and right sides. Refer to step 11. 17. Insert wood blocks at the No. 4 and 5 body mounts to support the body off of the frame, and provide access for the following steps. The No. 4 body mount should be about 7 inches (175 mm) above the frame, and the No. 5 body mounts should be about 10.25 inches (260 mm) above the frame. 18. Remove both lower trailing link front mounting nuts and bolts. Discard the nuts and the bolts; new ones are included in the bracket kit. 19. Raise the vehicle on a lift. 20. Cut off the driver's side and the passenger's side lower trailing link front brackets from the frame: ^ Using a cutting wheel, cut just below or through the bracket weld to remove the bracket. ^ Once the bracket is removed, use a disk grinder to remove any excess material and smooth out the frame. Page 1012 12. Test-drive your customer¡C■s vehicle on the same road you used earlier. - If the drift is now within spec, swap the tires back to the donor vehicle one at a time, and test-drive your customer¡C■s vehicle on the same road you used earlier. Do this until the drift comes back. Replace the bad tire(s), then return the vehicle to your customer. - If the drift is still out of spec using the donor vehicle tires, contact Tech Line for further action. Page 623 Camshaft Position Sensor: Testing and Inspection 1. Inspect the sensor O-ring for cracks or leaks. 2. Replace the O-ring if it is worn or damaged. 3. Lubricate the new O-ring with engine oil. 4. Install the lubricated O-ring. Page 4606 2. Connect the short finder across the battery terminals and the load (component) side of the fuse terminal. 3. Close all switches in the circuit you're testing. 4. Turn on the short finder. This creates a pulsing magnetic field around the wiring between the fuse box and the short. 5. Beginning at the fuse box, slowly move the short finder along the circuit wiring. The meter will read current pulses through sheet metal and body trim. As long as the meter is between the fuse and the short, the needle will move with each current pulse. Once you move the meter past the point of the short, the needle will stop moving. Check the wiring and connectors in this area to locate the cause of the short. Testing For Continuity When testing for continuity at a connector without wire seals, you do not have to separate the two halves of the connector. Instead, probe the connector from the back. Always check both sides of the connector because dirty, corroded, and bent terminals can cause problems (no electrical contact = an open). 1. Disconnect the negative cable from the car battery. If you're using a DVOM, place it in the lowest "OHMS" range. Engine Controls - High/Erratic Engine Idle Power Steering Pressure Switch: All Technical Service Bulletins Engine Controls - High/Erratic Engine Idle 01-080 August 14, 2001 Applies To: 2000-02 Passport - ALL 2000-02 Passport: High or Erratic Idle SYMPTOM The engine occasionally idles at too high a speed, or the idle speed fluctuates. PROBABLE CAUSES The symptom could be the result of any of these conditions: ^ Loose or corroded engine or body ground ^ High resistance in the APPS ground circuit ^ PSP (power steering pressure) switch is internally shorted to ground ^ Fuel pressure regulator is leaking fuel into the intake manifold CORRECTIVE ACTION Diagnose the cause of the idle condition, and select the proper REPAIR PROCEDURE. PARTS INFORMATION REQUIRED MATERIALS REQUIRED SOFTWARE Each REPAIR PROCEDURE requires you to use the Smart Cable to reprogram the PCM with the latest software. To select the latest software from the CDROM, enter the year, model, engine, transmission, and emissions type (49-state or California). This gives you a list of broadcast codes. Select the broadcast code at the top of the list. WARRANTY CLAIM INFORMATION Refer to the Warranty Claim Information for each Repair Procedure. DIAGNOSIS 1. Find out from the customer when the high or erratic idle condition occurs and what the RPM range is: ^ Within 20 minutes of a cold start ^ After braking to a stop ^ All the time ^ Intermittently, with no set pattern Locations Engine Controls - High/Erratic Engine Idle Fuel Pressure Regulator: All Technical Service Bulletins Engine Controls - High/Erratic Engine Idle 01-080 August 14, 2001 Applies To: 2000-02 Passport - ALL 2000-02 Passport: High or Erratic Idle SYMPTOM The engine occasionally idles at too high a speed, or the idle speed fluctuates. PROBABLE CAUSES The symptom could be the result of any of these conditions: ^ Loose or corroded engine or body ground ^ High resistance in the APPS ground circuit ^ PSP (power steering pressure) switch is internally shorted to ground ^ Fuel pressure regulator is leaking fuel into the intake manifold CORRECTIVE ACTION Diagnose the cause of the idle condition, and select the proper REPAIR PROCEDURE. PARTS INFORMATION REQUIRED MATERIALS REQUIRED SOFTWARE Each REPAIR PROCEDURE requires you to use the Smart Cable to reprogram the PCM with the latest software. To select the latest software from the CDROM, enter the year, model, engine, transmission, and emissions type (49-state or California). This gives you a list of broadcast codes. Select the broadcast code at the top of the list. WARRANTY CLAIM INFORMATION Refer to the Warranty Claim Information for each Repair Procedure. DIAGNOSIS 1. Find out from the customer when the high or erratic idle condition occurs and what the RPM range is: ^ Within 20 minutes of a cold start ^ After braking to a stop ^ All the time ^ Intermittently, with no set pattern Page 4442 If there is no photo number below or beside a component name or a connector, ground, or terminal number, look up that name or number in the appropriate Connector Identification Chart. The chart lists how many cavities a connector has, where it's located, and what it connects to. The related illustration shows the connector's location on the harness, and the harness routing. NOTE: Photos listed by number are located at Locations / Components / Photograohs. See: Locations/Component Locations/Photographs Circuit Schematics Page 1020 Failed Part: P/N 53560-SDA-AO1 H/C 7139652 Defect Code: 07406 Symptom Code: 03602 Skill Level: Repair Technician Diagnostic Trouble Code: To create the 15-digit DTC, see the applicable repair procedure. Out of warranty: Any repair performed after warranty expiration may be eligible for goodwill consideration by the District Parts and Service Manager or your Zone Office. You must request consideration, and get a decision, before starting work. TOOL DESCRIPTIONS The holding force gauge measures the amount of pull on the vehicle. It is a bracket that counts as one weight, plus five removable weights. During the test-drive, attach the bracket and the weights to the steering wheel on the side opposite the pulling direction. For example, if the vehicle pulls to the right, attach the bracket and weights to the left side of the steering wheel. Start with the maximum amount of weight on the steering wheel, and remove the weights until the vehicle drives in a straight line. When recording the pull on the worksheet, write down the direction of the pull (lefi or right) and the number of weights required to balance the pull (one through six). For example, if you have the bracket and two weights on the steering wheel, then record this as three weights. NOTE: The bracket counts as one weight. Page 2833 Disclaimer Repair Procedure 1. Unclamp the air cleaner housing cover, and move it to the side for access to connector C123 (16P BLK). 2. Unfasten C123 from the side of the engine compartment using a 90-degree pick. 3. Disconnect C123, and clean the terminals on both sides of the connector with contact cleaner. Shake the residue out of the connector. Allow the contact cleaner to evaporate for at least 3 minutes, then reconnect C123. 4. Fasten C123 to the left side of the engine compartment, then reinstall the air cleaner housing cover. 5. While supporting the accelerator pedal assembly, remove the two bolts that secure the assembly to the bulkhead. Carefully lower the assembly to gain access to the connector. Page 5215 Test Equipment CAUTION: Most circuits include solid-state devices. Test the voltages in these circuits only with a 10-megaohm or higher impedance digital multimeter. Never use a test light or analog meter on circuits that contain solid-state devices. Damage to the devices may result. Test Light and DVOM On circuits without solid-state devices, use a test light to check for voltage. A test light is made up of a 12 volt bulb with a pair of leads attached. After grounding one lead, touch the other lead to various points along the circuit where voltage should be present. The bulb will go on if there is voltage at the point being tested. If you need to know how much voltage is present, use a digital volt/ohmmeter (DVOM). Self-Powered Test Light and DVOM Use a self-powered test light to check for continuity. This tool is made up of a light bulb, battery, and two leads. To test it, touch the leads together: the light should go on. Use a self-powered test light only on an unpowered circuit. First, disconnect the battery, or remove the fuse that feeds the circuit you are working on. Select two points in the circuit between which you want to check continuity. Connect one lead of the self-powered test light to each point. If there is continuity, the test light's circuit will be completed, and the light will go on. If, in addition, you need to know exactly how much resistance there is between two points, use a digital volt/ohmmeter (DVOM). In the "OHMS" range, the DVOM will measure resistance between two points along a circuit. Low resistance means good continuity. Diodes and solid-state devices in a circuit can make a DVOM give a false reading. To check a reading, reverse the leads, and take a second reading. If the readings differ, the component is affecting the measurement. Jumper Wire Use a jumper wire to bypass an open circuit. A jumper wire is made up of an in-line fuse holder connected to a set of test leads. It should have a five ampere fuse. Never connect a jumper wire across a short circuit. The direct battery short will blow the fuse. Short Finder (Short Circuit Locator) Short finders are available to locate shorts to ground. The short finder creates a pulsing magnetic field in the shorted circuit which you can follow to the location of the short. To order any test equipment shown above, contact your local tool supplier. For a list of suppliers and tool numbers, refer to Honda Required Special Tools and Equipment Service Bulletin. Page 7577 This means the branch of the wire connects to another circuit. The arrow points to the name of the circuit branch where the wire continues. Page 4802 Wheel Speed Sensor: Connector Locations Front Wheel Sensor Connector Behind Left Front Wheel (Right Wheel Similar) Rear Wheel Sensor Connector Under Rear of Vehicle (On Differential) Page 4213 the component if the component only has one connector, or by a capital letter (A, B, C, etc.) if the component has more than one connector. Below most connector numbers and component names are PHOTO and VIEW numbers. The PHOTO number refers to a photo in the back of the book that shows the connector's location on the car. The VIEW number refers to an illustration in the back of the book that shows the connector face, wire colors, connector cavity numbers, and other details. The connector cavity numbering sequence begins at the top left corner of the connector. Disregard any numbers molded into the connector housing. Wires Wires are identified by the abbreviated names of their colors; the second color is the color of the stripe. Wires are also identified by their location in a connector. The number "2" next to the male and female wire terminals at C416, for example, means those terminals join in cavity 2 of connector C416. Symbols A complete description of schematic symbols is given under wire color abbreviation. Power Distribution Schematics Power Distribution schematics show how power is supplied from the positive battery terminal to various circuits in the car. Refer to the Power Distribution section to get a more detailed picture of how power is supplied to the circuit you're working on. From Battery to Ignition Switch, Fuses, and Relays Individual circuit schematics begin with a fuse. The first half of Power Distribution, however, shows the wiring "upstream" between the battery Page 4760 Gear Sensor/Switch: Testing and Inspection TRANSFER POSITION SWITCH 1. With ball being free. A-B: There is continuity. 2. With ball forced into the switch. A-B: No continuity. 3. If 1) and 2) fail, replace with a new switch. Page 2780 Powertrain Control Module: Diagnostic Aids Before Troubleshooting Before Troubleshooting See: Service Precautions/Vehicle Damage Warnings/Tips and Precautions 1. Check applicable fuses in the appropriate fuse/relay box. 2. Check the battery for damage, state of charge, and clean and tight connections. CAUTION: Do not quick-charge a battery unless the battery ground cable has been disconnected, otherwise you will damage the alternator diodes. - Do not attempt to crank the engine with the battery ground cable loosely connected or you will severely damage the wiring. While You're Working 1. Make sure connectors are clean, and have no loose terminals or receptacles. 2. Make sure that connectors without wire seals are packed with dielectric (silicone) grease. Part Number: 08798-9001. 3. When connecting a connector, push it until it "clicks" into place. CAUTION: Do not pull on the wires when disconnecting a connector. Pull only on the connector housings. - Most circuits include solid-state devices. Test the voltages in these circuits only with a 10-megaohm or higher impedance digital multi meter. Never use a test light or analog meter on circuits that contain solid-state devices. Damage to the devices may result. Five-Step Troubleshooting 1. Verify The Complaint Turn on all the components in the problem circuit to check the accuracy of the customer complaint. Note the symptoms. Do not begin disassembly or testing until you have narrowed down the problem area. 2. Analyze The Schematic Look up the schematic for the problem circuit. Determine how the circuit is supposed to work by tracing the current paths from the power source through the circuit components to ground. Also, trace circuits that share wiring with the problem circuit. The names of circuits that share the same fuse, ground, or switch, and so on, are referred to in each circuit schematic. Try to operate any shared circuits you didn't check in step 1. If the shared circuits work, the shared wiring is OK, and the cause must be in the wiring used only by the problem circuit. If several circuits fail at the same time, the fuse or ground is a likely cause. Based on the symptoms and your understanding of the circuit's operation, identify one or more possible causes. 3. Isolate The Problem By Testing The Circuit Make circuit tests to check the diagnosis you made in step 2. Keep in mind that a logical, simple procedure is the key to efficient troubleshooting. Test for the most likely cause of failure first. Try to make tests at points that are easily accessible. 4. Fix The Problem Once the specific problem is identified, make the repair. Be sure to use proper tools and safe procedures. 5. Make Sure The Circuit Works Turn on all components in the repaired circuit in all modes to make sure you've fixed the entire problem. If the problem was a blown fuse, be sure to test all of the circuits on that fuse. Make sure no new problems turn up and the original problem does not recur. Locations Page 1525 10. Remove the piston pin (9) using J-24086-C piston pin service set and piston support with a press. Note: Keep the parts removed from each cylinder separate. All parts must be reinstalled in their original positions. Heating the connecting rod will permit easy removal of the piston pin. 11. Piston (10) 12. Connecting rod (11) Inspection and Repair Pistons (10) Carefully clean away all the carbon adhering to the piston head and the piston ring grooves. Note: Never use a wire brush to clean the pistons. Damage will result Visually check each piston for cracking, scoring, and other signs of excessive wear. If any of the above conditions are found, the piston must be replaced. Piston Diameter 1. Measure the piston outside diameter with micrometer at the piston grading position and a right angle to the piston pin. Piston grading position (from piston head) Piston grading position: 43.0 mm (1.6929 inch) Locations 4WD Control Unit: Locations Under Center Console Page 4266 it is located, and what it connects to. Use the Connector Views to help locate the proper cavity when you need to probe a connector. It can be especially helpful if the connector has more than one wire of the same color. A dash symbol (-) indicates that the cavity is empty. Connector views can also be used to help diagnose multiple symptoms in separate circuits which could be caused by a single problem in a connector shared by those circuits. Here's an example: 1. Pick one of the multiple symptoms and look up the schematic for that circuit. 2. Make a list of all the in-line and fuse box connectors in that schematic , 3. Then, in the Connector Views, look up each connector on your list to see if circuits related to the other symptoms run through one of them. If they do, inspect that connector for the problem. Example: The blower, rear window defogger, and the windshield wiper don't work. List all in-line and fuse box connectors in the blower controls circuit and then check the Connector View (see the sample). You find that C324 is common to the blower controls, rear window defogger, and wiper/washer, so you inspect C324 and find the problem, bent terminals. Finding Component/Connector Locations Finding Component/Connector Locations To see where a component or connector is located on the car, look up its photo number in the "Component Location". The photo will also tell you the color of the connector, and how many cavities it has. Page 5789 inspection of the entire underside of the vehicle must be completed and any damage and/or modifications to the frame must be noted to determine if the campaign service remedy can or should be completed. ^ Contact Tech Line to open a case: - Inform them of any relevant information that may affect the completion of the repair. - Provide photos of the lower trailing link bracket area Via e-mail to Tech Line. (Include the VIN and the Tech Line reference number in the subject title of the e-mail.) - Based on your information, Tech Line will determine the vehicle's eligibility for completing a STAGE 4 repair or, if the a vehicle had a modification to the lower trailing link bracket area, determine the repair level needed. If any issues preventing completion of the repair, or any new evidence is learned during the repair that will prevent completion, contact Tech Line to report your findings. ^ Type B reinforcement brackets used in a STAGE 4 REPAIR require holes to be drilled in specific areas of the frame (inboard and outboard sides). Prior to receiving the brackets for a repair, match the locations of these holes to the frame in the illustrations below; this will help you to determine if the brackets can be installed. Photos of the inboard and outboard frame areas will show the feasibility of the installation and must be provided to Tech Line.* ^ This repair includes removing and reinstalling the fuel tank assembly, fuel lines, and vent lines. Take normal precautions during removal, storage, and reinstallation of these parts. Make sure to do this repair in a well vented area, away from any ignition sources. ^ This repair involves raising the body off the frame and cutting the original rear trailing link front mounting brackets off the frame rails. To avoid permanent frame damage that would make the vehicle unrepaired, carefully follow all of the steps. If you are unfamiliar with this type of repair, sublet it to a qualified body/frame repair shop. ^ If needed, refer to the appropriate Passport Service Manual for any steps not fully detailed. ^ Do this repair on both sides of the vehicle. 1. Remove the radiator grille. 2. Remove the linear EGR valve. 3. Remove the rear bumper assembly. 4. Remove the exhaust silencer (muffler). 5. Remove the fuel tank assembly: ^ Disconnect the fuel line at the fuel filter and the fuel return hoses. Adjustments Valve Clearance: Adjustments THIS ARTICLE HAS BEEN UPDATED BY TSB 02-047 NOTE: - Valve adjustment can be done either on-vehicle or off-vehicle. - To measure exhaust valves, you need a 0.25 mm and a 0.35 mm feeler gauge. - To measure intake valves, you need a 0.23 mm and a 0.33 mm feeler gauge. Since these are odd sizes, you may need to stack two gauges (for example, 0.11 mm and 0.12 mm to make 0.23 mm). If you do this, make sure the gauges are clean and in good condition. If you're not sure the gauge stack is correct, measure it with a micrometer. On-Vehicle Valve Adjustment 1. Make a copy of the Valve Inspection Chart. 2. Make a copy of the Valve Shim Replacement Chart, then tape the pages together, side-by-side. 3. Remove the cylinder head covers. 4. Measure the valve clearances using the Go/No-Go method (see the note below). The clearances must be - Intake valves: 0.25 mm +/- 0.05 mm - Exhaust valves: 0.30 mm +/- 0.05 mm NOTE: - To measure with the Go/No-Go method, use two feeler gauges, one to measure the smallest allowable clearance, and the other to measure the largest. - If the small gauge fits and the large gauge doesn't, the valve adjustment is OK. - If the small gauge doesn't fit, or if the large gauge slides easily, the valve needs adjustment. - The feeler gauges slide through the clearance gap at a slight angle, making the drag a little more than it would be on other engines. 5. For valves with the correct clearance, draw an "X" in the appropriate circle on the Valve Inspection Chart. For valves with incorrect clearances, write down the clearance you measured in the circle. 6. If you need to replace a valve shim, turn the crankshaft (or camshaft) until the cam lobe for the valve points away from the valve. Page 2673 and the fuses. From Fuses to Relays and Components The second half of Power Distribution shows the wiring "From Fuses to Relays and Components." This can speed your troubleshooting by showing which circuits share fuses. If Power Distribution shows that an inoperative circuit and another circuit share a fuse, check a component in the other circuit. If it works, you know the fuse is good and power is available to the inoperative circuit. Ground Distribution Schematics Page 7591 Distinct Of Circuit By Wire Base Color All wires have color-coded insulation. Wires belonging to a system's main harness will have a single color. Wires belonging to a system's sub-circuits will have a colored stripe. Striped wires use the codes found in the chart to show wire size and colors. Abbreviations are used to indicate wire color within a circuit diagram. How to Identify Connector Terminals How to Identify Connector Terminals Cavity Numbering System The cavities (and wire terminals) in each connector are numbered starting from the upper left, looking at the male terminals from the terminal side (or looking at the female terminals from the wire side. Both views are in the same direction so the numbers are the same.) All actual cavities are numbered, even if they have no wire terminals in them. NOTE: Data Link Connector (DLC) terminals are numbered according to SAE standard J1962, not the Honda standard. The numbers of the four end terminals are molded into the corners of the connector face. The connector cavity number is listed next to each terminal on the circuit schematic. The cavity / terminal shown is # 6. Using/Identifying Connector Terminal Views How to Use Connector Terminal Views To see the configuration of a connector's cavities, look up its view number in the Connector Views. Each view includes the color of the connector, where Page 4214 and the fuses. From Fuses to Relays and Components The second half of Power Distribution shows the wiring "From Fuses to Relays and Components." This can speed your troubleshooting by showing which circuits share fuses. If Power Distribution shows that an inoperative circuit and another circuit share a fuse, check a component in the other circuit. If it works, you know the fuse is good and power is available to the inoperative circuit. Ground Distribution Schematics Page 1468 - After installation, apply engine oil to the entire circumference of the piston rings. Check to see that all the rings rotate smoothly. 5. Install piston and connecting rod assembly. - Insert the bearings into the connecting rods and caps. Apply new engine oil to the bearing faces and nuts. - Tighten the connecting rod cap nuts Torque: 54 Nm (40 ft. lbs.) Note: Do not apply engine oil to the bearing back faces. 6. Oil gallery, refer to Crankshaft and Main Bearing. 7. Oil strainer and O-ring. 8. Oil pipe and O-ring. 9. Install crankcase with oil pan. 10. Install cylinder head gasket. 11. Install cylinder head assembly. - Refer to Cylinder Head. Page 7992 7. Loosen the inflator module fixing bolt from behind the steering wheel assembly using a TORX driver or equivalent until the inflator module can be released from steering assembly. Disconnect the yellow 2-way SRS connector and horn lead located behind the inflator module, then remove inflator module. WARNING: THE INFLATOR MODULE SHOULD ALWAYS BE CARRIED WITH THE URETHANE COVER AWAY FROM YOUR BODY AND SHOULD ALWAYS BE LAID ON A FLAT SURFACE WITH THE URETHANE SIDE UP. THIS IS NECESSARY BECAUSE A FREE SPACE IS PROVIDED TO ALLOW THE AIR CUSHION TO EXPAND IN THE UNLIKELY EVENT OF ACCIDENTAL DEPLOYMENT. OTHERWISE, PERSONAL INJURY MAY RESULT. Page 6256 Refrigerant Oil: Service and Repair Checking/Adjusting Oil For Used Compressor Checking and Adjusting Oil Quantity for Used Compressor 1. Perform oil return operation. Refer to Oil Return Operation. 2. Discharge and recover refrigerant and remove the compressor. 3. Drain the compressor oil and measure the extracted oil with a measuring cylinder. 4. If the amount of oil drained is much less than 90 cc (3.0 fl.oz.), some refrigerant may have leaked out. Conduct a leak tests on the connections of each system, and if necessary, repair or replace faulty parts. 5. Check the compressor oil contamination. (Refer to Contamination of Compressor Oil.) 6. Adjust the oil level following the next procedure below. 7. Install the compressor, then evacuate, charge and perform the oil return operation. 8. Check system operation. When it is impossible to perform oil return operation, the compressor oil should be checked in the following order: 1. Discharge and recover refrigerant and remove the compressor. 2. Drain the compressor oil and measure the extracted oil with a measuring cylinder. 3. Check the oil for contamination. 4. If more than 90 cc (3.0 fl.oz.) of oil is extracted from the compressor, supply the same amount of oil to the compressor to be installed. 5. If the amount of oil extracted is less than 90 cc (3.0 fl oz.), recheck the compressor oil in the following order 6. Supply 90 cc (3.0 fl.oz.) of oil to the compressor and install it onto the vehicle. 7. Evacuate and recharge with the proper amount 0 refrigerant. 8. Perform the oil return operation. 9. Remove the compressor and recheck the amount of oil. 10. Adjust the compressor oil, if necessary. Page 3397 Each schematic represents one circuit. A circuit's wires and components are arranged to show current flow, from power at the top of the page, to ground, at the bottom. Shared Circuits Other circuits may share power or ground terminals or wiring with the circuit shown. A wire that connects one circuit to another, for example, is cut short and has an arrowhead at the end of it pointing in the direction of current flow. Next to the arrowhead is the name of the circuit or component which shares that wiring. To quickly check shared wiring, check the operation of a component it serves. If that component works, you know the shared wiring is OK. Connectors All in-line and junction connectors are numbered (C725, C416, etc.). Component connectors are not numbered but are identified either by the name of Locations Behind Glove Box Page 6544 WARNING: FAILURE TO FOLLOW PROCEDURES IN THE ORDER LISTED COULD RESULT IN PERSONAL INJURY. NEVER CONNECT DEPLOYMENT WIRES TO ANY POWER SOURCE BEFORE CONNECTING DEPLOYMENT WIRES TO THE AIR BAG ASSEMBLY LEADS. DEPLOYMENT WIRES SHALL REMAIN SHORTED AND NOT BE CONNECTED TO A POWER SOURCE UNTIL THE AIR BAG IS TO BE DEPLOYED. THE AIR BAG ASSEMBLY WILL IMMEDIATELY DEPLOY THE AIR BAG WHEN A POWER SOURCE IS CONNECTED TO IT. WEAR SAFETY GLASSES THROUGHOUT THIS ENTIRE DEPLOYMENT AND DISPOSAL PROCEDURE. 9. Twist together ore connector wire lead to one deployment wire. The connection should be mechanically secure. 10. Bend twisted connection made in the previous step flat and wrap tightly with electrical tape to insulate and secure. 11. Twist together bend and tape the remaining connector wire lead to the remaining deployment wire. 12. Connect the deployment harness to the driver air bag assembly, yellow 2 - pin connector at the base of the steering column. Route deployment harness out the driver side of the vehicle. WARNING: DEPLOYMENT WIRES SHALL REMAIN SHORTED AND NOT BE CONNECTED TO A POWER SOURCE UNTIL THE AIR BAG IS TO BE DEPLOYED. THE AIR BAG ASSEMBLY WILL IMMEDIATELY DEPLOY THE AIR BAG WHEN A POWER SOURCE IS CONNECTED TO IT. CONNECTING THE DEPLOYMENT WIRES TO THE POWER SOURCE SHOULD ALWAYS BE THE FINAL STEP IN THE AIR BAG ASSEMBLY DEPLOYMENT PROCEDURE. FAILURE TO FOLLOW PROCEDURES IN THE ORDER LISTED COULD RESULT IN PERSONAL INJURY. 13. Disconnect passenger air bag assembly. Yellow 2 - pin connector located behind glove box assembly. 14. Cut the passenger sir bag assembly harness connector from the vehicle leaving at least 16 cm (six inches) of wire at the connector. 15. Strip 13 mm (1/2 inch) of insulation from yellow - green and yellow - red wire lead of the connector. 16. Cut two 900 cm (30 feet) deployment wires from 0.8 sq.mm (18 gauge) or thicker multi-strand wire. These wires will be used to fabricate the passenger deployment harness. 17. Strip 13 mm (1/2 inch) of insulation from both ends of the wires cut in the previous step. 18. Short the wires by twisting together one end from each. Deployment wires shall remain shorted and not be connected to a power source until the air bag is to be deployed. WARNING: FAILURE TO FOLLOW PROCEDURES IN THE ORDER LISTED COULD RESULT IN PERSONAL INJURY. NEVER CONNECT DEPLOYMENT WIRES TO ANY POWER SOURCE BEFORE CONNECTING DEPLOYMENT WIRES TO THE AIR Page 5741 9. Insert the Noxudol 700 spray nozzle about 12 inches (300 mm) into the frame rail side hole, toward the front of the vehicle. Then spray the Noxudol while drawing out the nozzle. Spray four times. 10. Insert the Noxudol 700 spray nozzle about 7 inches (200 mm) into the frame rail side hole, toward the rear of the vehicle. Then spray the Noxudol while pulling out the nozzle. Spray four times. 11. Insert the Noxudol 700 spray nozzle into the frame rail side hole, pointing up, until it touches the top of the frame. Spray the Noxudol upward while pulling out the nozzle. Spray two times. Page 948 Gear Sensor/Switch: Testing and Inspection TRANSFER POSITION SWITCH 1. With ball being free. A-B: There is continuity. 2. With ball forced into the switch. A-B: No continuity. 3. If 1) and 2) fail, replace with a new switch. Page 435 8. Remove lower case. - Slit the case parting face with a knife since the lining is separated when removing the evaporator. - Lift to remove the upper case. 9. Remove evaporator core. 10. Remove expansion valve. Page 2565 and the fuses. From Fuses to Relays and Components The second half of Power Distribution shows the wiring "From Fuses to Relays and Components." This can speed your troubleshooting by showing which circuits share fuses. If Power Distribution shows that an inoperative circuit and another circuit share a fuse, check a component in the other circuit. If it works, you know the fuse is good and power is available to the inoperative circuit. Ground Distribution Schematics Page 2631 Test Equipment CAUTION: Most circuits include solid-state devices. Test the voltages in these circuits only with a 10-megaohm or higher impedance digital multimeter. Never use a test light or analog meter on circuits that contain solid-state devices. Damage to the devices may result. Test Light and DVOM On circuits without solid-state devices, use a test light to check for voltage. A test light is made up of a 12 volt bulb with a pair of leads attached. After grounding one lead, touch the other lead to various points along the circuit where voltage should be present. The bulb will go on if there is voltage at the point being tested. If you need to know how much voltage is present, use a digital volt/ohmmeter (DVOM). Self-Powered Test Light and DVOM Use a self-powered test light to check for continuity. This tool is made up of a light bulb, battery, and two leads. To test it, touch the leads together: the light should go on. Use a self-powered test light only on an unpowered circuit. First, disconnect the battery, or remove the fuse that feeds the circuit you are working on. Select two points in the circuit between which you want to check continuity. Connect one lead of the self-powered test light to each point. If there is continuity, the test light's circuit will be completed, and the light will go on. If, in addition, you need to know exactly how much resistance there is between two points, use a digital volt/ohmmeter (DVOM). In the "OHMS" range, the DVOM will measure resistance between two points along a circuit. Low resistance means good continuity. Diodes and solid-state devices in a circuit can make a DVOM give a false reading. To check a reading, reverse the leads, and take a second reading. If the readings differ, the component is affecting the measurement. Jumper Wire Use a jumper wire to bypass an open circuit. A jumper wire is made up of an in-line fuse holder connected to a set of test leads. It should have a five ampere fuse. Never connect a jumper wire across a short circuit. The direct battery short will blow the fuse. Short Finder (Short Circuit Locator) Short finders are available to locate shorts to ground. The short finder creates a pulsing magnetic field in the shorted circuit which you can follow to the location of the short. To order any test equipment shown above, contact your local tool supplier. For a list of suppliers and tool numbers, refer to Honda Required Special Tools and Equipment Service Bulletin. Page 7076 Trunk / Liftgate Lock Cylinder: Service and Repair Tailgate Lock Tailgate Lock and Hatchgate Lock (SWB) Removal 1. Disconnect the battery ground cable. 2. Remove the tailgate glass assembly and tailgate glass stay. 3. Remove the tailgate trim cover assembly. - Remove the two screws fixing the trim cover assembly and pull up the trim cover after detaching the clips from tailgate panel. 4. Remove the waterproof sheet. - Remove the waterproof sheet, taking special care so as not to break it. 5. Remove the key cylinder. - Disconnect the lock links. - Remove the key cylinder retaining clip with screw driver to remove the key cylinder. 6. Remove the hatchgate lock actuator assembly. - Disconnect the actuator harness connector. - Remove the two nuts holding hatchgate lock actuator assembly from inside. 7. Remove the outside handle. - Disconnect the lock link. - Remove the two bolts holding the outside handle from inside. 8. Remove the tailgate lock assembly. - Remove the three screws holding the lock assembly. Installation To install, follow the removal steps in the reverse order, noting the following points: 1. Apply chassis grease to the lock assembly and striker moving surface. 2. Tighten the hatchgate lock assembly fixing screws to the specified torque. Torque 7 Nm (61 lb in) 3. Check that the tailgate lock operates correctly after installing it. Tailgate Lock and Hatchgate Lock (LWB) Removal 1. Disconnect the battery ground cable. 2. Remove the tailgate trim cover assembly (3). - Remove the 2 screws (2) holding the hatch gate lock assembly (1) first, and pull up the trim cover while detaching the clips from tailgate panel. Page 117 and the fuses. From Fuses to Relays and Components The second half of Power Distribution shows the wiring "From Fuses to Relays and Components." This can speed your troubleshooting by showing which circuits share fuses. If Power Distribution shows that an inoperative circuit and another circuit share a fuse, check a component in the other circuit. If it works, you know the fuse is good and power is available to the inoperative circuit. Ground Distribution Schematics Page 6940 Grille: Removal and Replacement Radiator Grille Radiator Grille Removal 1. Open the hood. 2. Support the hood. 3. Remove radiator grille. - Raise the clips on the radiator grille and remove screw. 4. Pull out the radiator grille rubber from fender panel front lower side. Installation Diagrams Page 6386 Testing For A Short With A Self-Powered Test Light or DVOM 1. Remove the blown fuse and disconnect the battery and load. 2. Connect one lead of a self-powered test light or digital volt/ohmmeter (DVOM) (switched to the lowest "OHMS" range) to the fuse terminal on the load side. 3. Connect the other lead to a known good ground. 4. Beginning near the fuse box, wiggle the harness. Continue this at convenient points about six inches apart while watching the test light or DVOM. 5. If the self-powered test light goes on or the DVOM displays a low reading or no reading (zero), there is a short to ground in the wiring near that point. Testing for a Short with a Test Light or DVOM 1. Remove the blown fuse and disconnect the load. 2. Connect a test light or digital volt/ohmmeter (DVOM), switched to the appropriate DC volts range, across the fuse terminals to make sure voltage is present. You might have to turn the ignition switch to ON; check the schematic to see. 3. Beginning near the fuse box, wiggle the harness. Continue this at convenient points about six inches apart while watching the test light or DVOM. 4. Where the test light goes , or the DVOM voltage drops to zero, there is a short to ground in the wiring near that point. NOTE: Always use a DVOM on high impedance circuits. A test light may not glow (even with battery voltage present). Testing For A Short With A Short Circuit Locator (Short Finder) 1. Remove the blown fuse. Leave the battery connected. Blower Assembly Blower Motor: Service and Repair Blower Assembly Removal 1. Disconnect the battery ground cable. 2. Discharge and recover refrigerant (with air conditioning). 3. Remove instrument panel assembly. 4. Disconnect resistor connector. 5. Remove duct. 6. Remove evaporator assembly (A/C only). 7. Disconnect blower motor connector. 8. Remove blower assembly. Installation To install, follow the removal steps in the reverse order. Specifications Clutch Fluid: Specifications Dot 3 Hydraulic Brake Fluid Page 2617 Each schematic represents one circuit. A circuit's wires and components are arranged to show current flow, from power at the top of the page, to ground, at the bottom. Shared Circuits Other circuits may share power or ground terminals or wiring with the circuit shown. A wire that connects one circuit to another, for example, is cut short and has an arrowhead at the end of it pointing in the direction of current flow. Next to the arrowhead is the name of the circuit or component which shares that wiring. To quickly check shared wiring, check the operation of a component it serves. If that component works, you know the shared wiring is OK. Connectors All in-line and junction connectors are numbered (C725, C416, etc.). Component connectors are not numbered but are identified either by the name of Page 6006 Blower Motor: Testing and Inspection 1. Disconnect the blower motor (C-38) connector from the blower motor. 2. Connect the battery positive terminal to the No.1 terminal of the blower motor and the negative to the No.2. 3. Be sure to check to see if the blower motor operates correctly. Page 1029 9. Test-drive the vehicle on the same road you used earlier. - If the drift is now within spec, swap each rear tire back to the front, one at a time, and test-drive the vehicle on the same road you used earlier. Replace the bad tire, then return the vehicle to your customer. - If the drift is still out of spec after swapping the front and rear tires, go to step 10. 10. Test-drive a known-good donor vehicle on the same road you used earlier, and check its pull. 11. Swap all four tires from the donor vehicle with the tires on your customer¡C■s vehicle. 12. Test-drive your customer¡C■s vehicle on the same road you used earlier. - If the drift is now within spec, swap the tires back to the donor vehicle one at a time, and test-drive your customer¡C■s vehicle on the same road you used earlier. Do this until the drift comes back. Replace the bad tire(s), then return the vehicle to your customer. - If the drift is still out of spec using the donor vehicle tires, contact Tech Line for further action. Technical Service Bulletin # 06-068 Date: 090502 Steering/Suspension - Vehicle Pulls Left/Right 06-068 May 2, 2009 Applies To: ALL *Vehicle Pulls or Drifts, and/or Steering Wheel Is Off-Center (Supersedes 06-068, Vehicle Pulling or Drifting, dated October 4, 2007, to revise the information marked by asterisks) (Replaces 90-011, Steering Wheel Off-Center Adjustment at PDI)* *REVISION SUMMARY The title description was revised.* SYMPTOM While driving on a straight road, the vehicle pulls or drifts to the right or left. BACKGROUND New tools were developed to help you diagnose and correct a pulling and/or steering wheel off-center issue. There is a diagnosis worksheet included to take on your test-drive and record your findings. These values are used to build the 15-digit DTC (diagnostic trouble code) that is required for your warranty claim. The last step in each repair procedure helps you create the correct code. In the rare case that you have to repair a vehicle that pulls and has the steering wheel off-center, use REPAIR PROCEDURE B to file your warranty claim. For more information, refer to Training Module SSC 44 - Steering Drift or Pull Interactive Service Bulletin. PROBABLE CAUSES Several conditions can cause the vehicle to pull or drift: ^ Wheel alignment ^ Tires ^ Off-center steering wheel (no pulling or drifting, but a customer may believe this is the case) CORRECTIVE ACTION Diagnose the problem using the special tools and the worksheet on page 4 that guides you to one of four repair procedures. Page 7091 The name of the component appears next to it followed by notes about its function along with any photo and connector view references. Connector "C" How to Identify Connector Terminals Cavity Numbering System The cavities (and wire terminals) in each connector are numbered starting from the upper left, looking at the male terminals from the terminal side (or looking at the female terminals from the wire side. Both views are in the same direction so the numbers are the same.) All actual cavities are numbered, even if they have no wire terminals in them. NOTE: Data Link Connector (DLC) terminals are numbered according to SAE standard J1962, not the Honda standard. The numbers of the four end terminals are molded into the corners of the connector face. Page 3061 Steps 3 - 6 Page 4372 SLIP JOINT REASSEMBLY 1. Apply grease evenly to both the female and male splines. 2. Apply a small amount of grease by finger to the outer lips of the boot. 3. Slide the boot (small diameter side) onto the yoke shaft being careful not to damage the spline coating or boot. 4. Insert the yoke shaft spline into the sleeve being careful to maintain proper phasing. The spider holes should be in line and as per originally marked prior to disassembly. 5. Position boot onto sleeve and yoke shaft in final position. 6. Attach boot clamps and secure using pliers. 7. Be sure clamp is properly seated and secure. CAUTION: Use new clamp which is the same parts as original. Do not use other clamp to avoid bad balancing of shaft or the grease leakage. Page 1309 SRS Operation Air Bag(s) Arming and Disarming: Description and Operation SRS Operation The SRS is a safety device which, when used in conjunction with the seat belt, is designed to help protect the driver (and front passenger) in a frontal impact exceeding a certain set limit. The system consists of the SRS unit (including safing sensor and impact sensor), the cable reel, the driver's airbag (and front passenger's airbag). Operation The main circuit in the SRS unit senses and judges the force of impact and, if necessary, ignites the inflator charge(s). If battery voltage is too low or power is disconnected due to the impact, the voltage regulator and the back-up power circuit respectively will keep voltage at a constant level. For the SRS to operate: 1. The impact sensor must activate, and send electric signals to the microprocessor. 2. The microprocessor must compute the signals, and must send signals to the airbag inflator(s). 3. The inflator(s) must ignite and deploy the airbag(s). Self-diagnosis System A self-diagnosis circuit is built into the SRS unit; when the ignition switch is turned ON (II), the SRS indicator light comes on and goes off after about six seconds if the system is operating normally. If the light does not come on, or does not go off after six seconds, or if it comes on while driving, it indicates an abnormality in the system. The system must be inspected and repaired as soon as possible. For better serviceability, the memory will store the cause of the malfunction, and the data link circuit passes on the information from the memory to the data link connector (DLC). This information can be read with the Honda PGM Tester connected to the DLC (16P). Page 3294 The name of the component appears next to it followed by notes about its function along with any photo and connector view references. Connector "C" How to Identify Connector Terminals Cavity Numbering System The cavities (and wire terminals) in each connector are numbered starting from the upper left, looking at the male terminals from the terminal side (or looking at the female terminals from the wire side. Both views are in the same direction so the numbers are the same.) All actual cavities are numbered, even if they have no wire terminals in them. NOTE: Data Link Connector (DLC) terminals are numbered according to SAE standard J1962, not the Honda standard. The numbers of the four end terminals are molded into the corners of the connector face. Page 1588 Valve: Service and Repair Disassembly, Inspection and Assembly Valve Spring, Oil Controller, Valve, Valve Guide Disassembly 1. Remove camshaft bracket fixing bolts (1). 2. Remove camshaft assembly (intake). 3. Remove camshaft assembly (Exhaust side). 4. Remove shim (4) and tappet (5). Page 6031 Page 4071 8. Pull lock. 9. Draw select cable assembly into the interior side. Installation 1. Set selector lever in "P" position. 2. Let out select cable transmission side end from floor hole. 3. Fit outer cable into bracket in selector lever assembly. 4. Set inner cable end in selector lever and push pin into selector lever hole and inner cable end. 5. Check that lock projects. 6. Connect adjust end fitting attachment to the bracket on transmission. Page 7 Alarm/Immobilizer Control Unit: Diagrams SRS Operation Air Bag(s) Arming and Disarming: Description and Operation SRS Operation The SRS is a safety device which, when used in conjunction with the seat belt, is designed to help protect the driver (and front passenger) in a frontal impact exceeding a certain set limit. The system consists of the SRS unit (including safing sensor and impact sensor), the cable reel, the driver's airbag (and front passenger's airbag). Operation The main circuit in the SRS unit senses and judges the force of impact and, if necessary, ignites the inflator charge(s). If battery voltage is too low or power is disconnected due to the impact, the voltage regulator and the back-up power circuit respectively will keep voltage at a constant level. For the SRS to operate: 1. The impact sensor must activate, and send electric signals to the microprocessor. 2. The microprocessor must compute the signals, and must send signals to the airbag inflator(s). 3. The inflator(s) must ignite and deploy the airbag(s). Self-diagnosis System A self-diagnosis circuit is built into the SRS unit; when the ignition switch is turned ON (II), the SRS indicator light comes on and goes off after about six seconds if the system is operating normally. If the light does not come on, or does not go off after six seconds, or if it comes on while driving, it indicates an abnormality in the system. The system must be inspected and repaired as soon as possible. For better serviceability, the memory will store the cause of the malfunction, and the data link circuit passes on the information from the memory to the data link connector (DLC). This information can be read with the Honda PGM Tester connected to the DLC (16P). Page 4618 3. Use the oil seal installer J-39208 to install the rear seal (3) to the transfer rear case. 4. Install the rear companion flange (2) and O-ring (2). 5. Use the companion flange holder J-37221 to install a new end nut (2) and tighten to the specified torque. Torque: 167 Nm (123 ft. lbs.) 6. Use the punch J-39209 to stake the end nut at two spots. NOTE: Be sure to confirm that there is no crack at the staked portion of the end nut (2) after staking. 7. Connect the rear propeller shaft to the transfer case and tighten to the specified torque. Torque: 63 Nm 46 (ft. lbs.) Page 1481 Crankshaft Disassembly 1. Remove cylinder head assembly (1). 2. Remove crankcase with oil pan (2). Caution: Take care not to damage or deform the seating flange surface of crankcase. 3. Remove oil pipe and O-ring (3). 4. Remove oil strainer and O-ring (4). 5. Remove oil pump assembly (5). 6. Remove crankcase side bolts (6). 7. Remove oil gallery (7). 8. Remove piston and connecting rod assembly (8). 9. Remove flywheel (9). 10. Remove rear oil seal retainer (10). 11. Remove main bearing cap (11). 12. Remove crankshaft (12). Inspection and Repair 1. Crankshaft Set the dial indicator as shown in the illustration and measure the crankshaft thrust clearance. If the thrust clearance exceeds the specified limit, replace the thrust bearings as a set. Thrust Clearance Standard: 0.06 mm - 0.24 mm (0.0024 inch - 0.0094 inch) Limit: 0.30 mm (0.0118 inch) Main Bearing Clearance 1. Remove the bearing caps and measure the oil clearance. Page 171 Ground - "G" Shielding Sheilding This represents RFI (Radio Frequency Interference) shielding around a wire. The shielding is always connected to ground. Splices Locations Manifold Pressure/Vacuum Sensor: Locations 24. Top Rear of Engine Top Rear Of Engine Component Locations Passenger's Inflator Module Connector Page 5309 2. Connect the short finder across the battery terminals and the load (component) side of the fuse terminal. 3. Close all switches in the circuit you're testing. 4. Turn on the short finder. This creates a pulsing magnetic field around the wiring between the fuse box and the short. 5. Beginning at the fuse box, slowly move the short finder along the circuit wiring. The meter will read current pulses through sheet metal and body trim. As long as the meter is between the fuse and the short, the needle will move with each current pulse. Once you move the meter past the point of the short, the needle will stop moving. Check the wiring and connectors in this area to locate the cause of the short. Testing For Continuity When testing for continuity at a connector without wire seals, you do not have to separate the two halves of the connector. Instead, probe the connector from the back. Always check both sides of the connector because dirty, corroded, and bent terminals can cause problems (no electrical contact = an open). 1. Disconnect the negative cable from the car battery. If you're using a DVOM, place it in the lowest "OHMS" range. Page 4845 15. Connect the yellow 3 way Supplemental Restraint System (SRS) connector located under the steering column. 16. Connect the battery "-" terminal cable. Page 2258 6. Remove the connector position assurance (CPA) clip from the APPS connector. 7. Disconnect the 10 P connector from the APPS. 8. Remove the bolts, the APPS, the spacer, and the accelerator link from the accelerator pedal assembly. 9. Separate the spacer from the APPS. Clean the grease off the spacer and the accelerator link with a clean shop towel. 10. Clean the terminals of the 10 P APPS connector (harness side) with contact cleaner. Shake the residue out of the connector, and allow the contact cleaner to evaporate for at least 3 minutes before reconnecting the connector. 11. Install a new APPS, the spacer, and the accelerator link onto the accelerator pedal assembly. Leave the mounting screws loose so the sensor can be adjusted. 12. Connect the 10 P connector to the new APPS, and lock the connector in place with the CPA. 13. Connect the PGM Tester to the data link connector (DLC), and turn the ignition switch to ON (II). Locations Intake Air Temperature Sensor: Locations 26. Left Front of Engine Left Front Of Engine Page 490 and the fuses. From Fuses to Relays and Components The second half of Power Distribution shows the wiring "From Fuses to Relays and Components." This can speed your troubleshooting by showing which circuits share fuses. If Power Distribution shows that an inoperative circuit and another circuit share a fuse, check a component in the other circuit. If it works, you know the fuse is good and power is available to the inoperative circuit. Ground Distribution Schematics Component Locations Fuel Injector: Component Locations No. 1, 3, and 5 Right Side of Engine No. 2, 4, and 6 Left Side Of Engine Accelerator Pedal Assembly/Sensor - Adjustment Update Accelerator Pedal Position Sensor: All Technical Service Bulletins Accelerator Pedal Assembly/Sensor - Adjustment Update 00-045 August 14, 2001 Applies To: 2000-02 Passport - ALL Service Manual Update: Accelerator Pedal Position Sensor (APPS) (Supersedes 00-045, dated May 23, 2000) Updated information is shown by asterisks and black bars. BACKGROUND When the accelerator pedal position sensor (APPS) or the accelerator pedal assembly is replaced for any reason, you must adjust the APPS. *This procedure is missing in the 2000 service manual and is wrong in the 2001 and 2002 service manuals. Make a note on page 6E2-539 of the 2000 Passport Fuel and Emissions manual, on page 6E2-553 of the 2001 Passport Fuel and Emissions manual, and on page 6E2-545 of the 2002 Passport Fuel and Emissions manual to refer to this bulletin.* ADJUSTMENT PROCEDURE 1. Replace the APPS or the accelerator pedal assembly, and leave the mounting screws for the APPS loose. 2. Connect the PGM Tester to the data link connector (DLC), and turn the ignition switch to ON (II). *3. While watching the APP Sensor values in the Engine Data List, adjust the APPS by turning it until the values are within the ranges shown at closed pushed all the way down), then tighten the throttle and wide open throttle (accelerator pedal mounting screws and recheck the values. ^ If all three sensors are within range, go to step 12. ^ If APP Sensor 1, APP Sensor 2, and/or APP Sensor 3 cannot be brought into range, go to step 4. 4. Troubleshoot for an open circuit or a PCM malfunction. ^ If APP Sensor 1 has a value of 0% or APP Sensor 2 and/or APP Sensor 3 have a value of 99%, an open circuit exists or the PCM is malfunctioning. Repair the circuit or replace the PCM, and repeat step 3. ^ If you don't find a problem, go to step 5. 5. Disconnect the 10P connector from the APPS. 6. View the APP Sensor values in the Engine Data List. ^ If APP Sensor 1 has a value of 0% or APP Sensor 2 and/or APP Sensor 3 have a value of 99%, go to step 7. ^ If APP Sensor 1 has a value other than 0%, or APP Sensor 2 and/or APP Sensor 3 have a value other than 99%, a short circuit exists or the PCM is malfunctioning. Repair the circuit or replace the PCM, and repeat step 3. Page 6040 Blower Motor Switch: Testing and Inspection Fan Control Knob (Fan Switch) 1. Check for continuity between the fan switch and the A/C switch side connector terminals. Page 1551 7. Remove fixing bolt for fuel injector harness bracket. 8. Remove eight fixing bolts, then the cylinder head cover. Installation Page 5806 - Install the rubber bushing by using installer J-39214. NOTE: When mounting rubber bushings, be sure not to use grease on bushings or any other nearby part. INSTALLATION 1. Install trailing link. Make sure that the trailing link is in its correct position. NOTE: When mounting trailing link, be sure not to use grease on bushings or any other nearby part. 2. Install bolt, nut and protector. Tighten the bolts and nuts lightly, then retighten them to the specified torque after the vehicle is at curb height. Torque to 137 Nm (101 ft. lbs.). 3. Install parking brake cable. CAUTION: The parking brake cable should not be overstrained or slackened. Page 4686 Ground - "G" Shielding Sheilding This represents RFI (Radio Frequency Interference) shielding around a wire. The shielding is always connected to ground. Splices Page 7068 Power Door Lock Switch: Service and Repair Door Switch Removal 1. Disconnect the battery ground cable. 2. Remove the door switch (2). - Remove the screw (1). - Disconnect the connector (3). Installation To install, follow the removal steps in the reverse order. Page 4046 ^ If the cover is OK, release the shift lever pushbutton, and go to step 11. 11. Push the white plastic cable slider toward the cable until it stops, then release the slider. 12. Try turning the ignition switch to LOCK. ^ If you cannot turn the switch to LOCK because the cable slider is blocking the white plastic interlock pin, go to step 13 Diagram Information and Instructions Data Link Connector: Diagram Information and Instructions How to Identify Wiring Color-Coded Insulation Wire Color Wire Color Coding Page 5117 Alternator: Testing and Inspection Inspection and Repair Repair or replace necessary parts if extreme wear or damage is found during inspection. Rotor Assembly 1. Check the face of the slip rings for contamination and roughness. If found to be scored, dress with a fine sandpaper (#500-600). If found to be contaminated, clean with a cloth saturated with alcohol. 2. Measure the outside diameter of the slip rings. Standard: 27 mm (1.06 in) Limit: 26 mm (1.02 in) 3. Check resistance between slip rings, and replace if there is no continuity. Standard: 3.75 ohms or less Front Brake Rotor/Disc: Service and Repair Front Removal NOTE: - Before disassembly, jack up the front of vehicle and support frame with jack stands. - Remove the disc brake caliper assembly and hang it on the frame with wires. Refer to Brakes and Traction Control. 1. Bolt. Before removal, shift transfer lever into "2H" position . 2. Cap 3. Snap Ring and Shim 4. Hub flange 5. Lock Washer and Lock Screw 6. Hub Nut. Page 2700 Steps 1 - 3 Steps 4 - 7 Test Description IMPORTANT: Be sure to used the same diagnostic test equipment for all measurements. The Number(s) below refer to the step number(s) on the Diagnostic Chart. 2. Applying 34 kPa (10 Hg) vacuum to the MAP sensor should cause the voltage to be 1.5 - 2.1 volts less than the voltage at step 1. Upon applying vacuum to the sensor, the change in voltage should be instantaneous. A slow voltage change indicates a faulty sensor. Page 8051 Combination Switch: Service and Repair REMOVAL 1. Turn the steering wheel so that the vehicle's wheels are pointing straight ahead. 2. Turn the ignition switch to "LOCK". 3. Disconnect the battery "-" terminal cable, and wait at least 5 minutes. 4. Disconnect the yellow 2-way SRS connector located under the steering column. CAUTION: The wheels of the vehicle must be straight ahead and the steering column in the "LOCK" position before disconnecting the steering wheel. Failure to do so will cause the coil assembly to become uncentered which will cause damage to the coil assembly. 5. Remove the engine hood opening lever, then remove instrument panel lower cover. 6. Remove the driver knee bolster (reinforcement). Page 6452 Driver's Inflator Module Connector Capacity Specifications Coolant: Capacity Specifications Coolant Capacity Automatic Transmission 11.1 qt (US) Manual Transmission 11.2 qt (US) Page 1506 2. Remove cylinder head gasket (2). 3. Remove crankcase with oil pan (3). 4. Remove oil pipe and O-ring (4). 5. Remove oil strainer and O-ring (5). 6. Remove oil gallery (6). 7. Remove connecting rod cap with connecting rod lower bearing (12). 8. Remove piston and connecting rod assembly (7). Note: Before removing piston and connecting rod assembly, measure thrust clearance. - Remove any ridge or carbon build up from the top end of the cylinder. 9. Remove the piston rings (8) with a piston ring expander. Arrange the removed piston rings in the cylinder number order. Page 7491 The wire insulation has one color or one color with another color stripe. The second color is the stripe. Page 974 Accelerator Pedal Position Sensor - MIL ON/DTC's Set Technical Service Bulletin # 01-047 Date: 010814 Accelerator Pedal Position Sensor - MIL ON/DTC's Set 01-047 August 14, 2001 Applies To: 2000-01 Passport - ALL MIL Comes On With Accelerator Pedal Position Sensor DTC(s) P1271, P1273, P1275, P1280, and/or P1285 SYMPTOM The MIL is on with DTC P1271, P1273, P1275, P1280, or P1285 (various accelerator pedal position sensor problems) stored. The REDUCED POWER indicator may also be on; and the engine may occasionally idle too high, or the idle may fluctuate. PROBABLE CAUSE Contaminated grease on the potentiometer circuit board of the accelerator pedal position sensor (APPS) causes high resistance in the APPS circuit. CORRECTIVE ACTION Replace and adjust the APPS, remove all grease from the accelerator link, and clean the APPS harness connector and connector C123. PARTS INFORMATION Accelerator Pedal Position Sensor: P/N 8-97193-713-0, H/C 6198311 REQUIRED MATERIALS CAIG DeoxIT D5-S6 Contact Cleaner: P/N 341-200 (available from www.partsexpress.com) or Permatex Electrical Contact Cleaner: Permatex P/N 24379 WARRANTY CLAIM INFORMATION In warranty: The normal warranty applies. Operation Number: 122114 Flat Rate Time: 0.5 hour Failed Part: P/N 8-97220-540-0 H/C 6202436 Defect Code: 091 Contention Code: C99 Template ID: 01-047A Skill Level: Repair Technician Out of warranty: Any repair performed after warranty expiration may be eligible for goodwill consideration by the District Service Manager or your Zone Office. You must request consideration, and get a decision, before starting work. Service and Repair Fuel Gauge Sender: Service and Repair Removal and Installation As for removal and installation of the Fuel Gauge Unit, refer to "Fuel Tank" as the fuel gauge unit is combined with the fuel pump and sender assembly. Page 2535 Intake Air Temperature Sensor: Service and Repair INTAKE AIR TEMPERATURE (IAT) SENSOR REMOVAL PROCEDURE 1. Disconnect the negative battery cable. 2. Remove the engine cover 3. The IAT sensor is located in the intake air duct, behind the throttle body. 4. Disconnect the electrical connector from the IAT sensor. 5. Remove the IAT sensor from the intake air duct by using a rocking motion while pulling the sensor. INSTALLATION PROCEDURE 1. Install the IAT sensor into the grommet in the intake air duct. 2. Correct the IAT electrical connector. 3. Install the engine cover. 4. Connect the negative battery cable. Page 6144 This sample Ground Distribution schematic shows all of the components that share two ground points. Components A solid border line means the entire component is shown. A broken border line indicates that only part of the component is shown. Disassembly and Reassembly Starter Motor: Service and Repair Disassembly and Reassembly Disassembly 1. Loosen the nut(1) on terminal "M" of magnetic switch and disconnect the connector cable. 2. Remove bolt (2 pcs) (2). 3. Remove magnetic switch(5). 4. Remove dust cover(4). 5. Remove torsion spring bolts, then the magnetic switch assembly. 6. Remove torsion spring(3) from magnetic switch assembly(5). 7. Remove screw (2 pcs) (8). 8. Remove through bolt (2 pcs) (7). 9. Remove screws and through bolts then the rear cover(9) then remove thrust washer(10). Page 895 H/C 4408092 Defect Code: 017 Contention Code: C99 Skill Level: Repair Technician Out of warranty: Any repair performed after warranty expiration may be eligible for goodwill consideration by the District Service Manager or your Zone Office. You must request consideration, and get a decision, before starting work. DISCLAIMER Locations Canister Purge Solenoid: Locations Canister Purge Vaccum Switch 46 - Top Front Of 3.2L Engine (Intake Duct Removed) Page 6146 The connector cavity number is listed next to each terminal on the circuit schematic. The cavity / terminal shown is # 6. Diodes A rectifier diode works like a one way valve. It allows current to flow only in the direction of the arrow. A Zener diode blocks reverse current at normal voltages just like a rectifier diode. At high voltages, however, a Zener diode allows current to flow in reverse. Fuses Locations Blower Motor Switch: Locations Fan Control Switch Fan Control Switch Page 392 NOTE: Confirm that a white line marked on the cable is not twisted when connecting the speed sensor cable. 5. Install speed sensor connector. Page 1926 11. Working through the right front wheelwell, remove the two flange bolts holding the engine mount to the chassis. Repeat this on the left side. 12. Working from under the vehicle, remove the two lower flange bolts holding the right engine bracket to the engine. 13. Use the powertrain lift to raise the engine until both engine mounts clear the chassis. Removal and Installation Connecting Rod: Service and Repair Removal and Installation Piston, Piston Ring and Connecting Rod Removal 1. Remove cylinder head assembly. 2. Remove crankcase with oil pan. Page 1250 Refrigerant Oil: Fluid Type Specifications A/C Oil Specifications A/C Oil Specifications Lubricant Type Poly Alkaline Glycol (PAG) Page 637 Crankshaft Position Sensor: Service and Repair REMOVAL 1. Disconnect the negative battery cable. 2. Disconnect the wiring connector from crankshaft position sensor. 3. Remove one bolt and remove the CKP sensor from the right side of the engine block, just behind the mount. NOTE: Use caution to avoid any hot oil that might drip out. INSTALLATION 1. Apply a small amount of engine oil to the O-ring and install the CKP sensor in the engine block. 2. Install the CKP sensor mounting bolt. 3. Tighten the mounting bolt to 10 Nm (89 lb in.). 4. Connect the wiring connector to the CKP sensor. 5. Connect the negative battery cable. Page 3258 2. Unfasten C123 from the side of the engine compartment using a 90-degree pick. 3. Disconnect C123, and clean the terminals on both sides of the connector with contact cleaner. Shake the residue out of the connector. Allow the contact cleaner to evaporate for at least 3 minutes, then reconnect C123. 4. Fasten C123 to the left side of the engine compartment, and reinstall the air cleaner housing cover. 5. Remove the connector position assurance (CPA) clip from the APPS connector. 6. Disconnect the lop connector from the APPS. 7. Clean the terminals of the 10P APPS connector (harness side) with contact cleaner. Shake out residue from the connector, and allow the contact cleaner to evaporate for at least 3 minutes, then reconnect it. 8. Use the Smart Cable to reprogram the PCM with the latest software from the June 2001 or later HONDANET CD-ROM. Refer to Service Bulletin 99-005, Updating the Passport PCM, filed under Tools. 9. Use the PGM Tester to clear any DTCs. Page 383 Part 1 of 2 Part 2 of 2 B-20 FL Speed Sensor Missing (DTC 61/C0226, C0227) Chart B-20 FL Speed Sensor Missing (DTC 61 (Flash Out) / C0226, C0227 (Serial Communications)) Page 1179 2. If antifreeze solution is used at a mixing ratio higher than 60%, the specific heat of the coolant falls and the engine may be overheated. Moreover, antifreeze performance drop and the coolant may be frozen. The density of the solution must be adjusted as occasion calls. Antifreeze solution lower than 20% may not have sufficient anticorrosive performance, and therefore, please never fail to adjust as occasion demands within the range of 20% to 60%. Page 5067 Part 1 of 2 Part 2 of 2 B-23 Simultaneous Drop-Out of FT Spd Sensor Sig. (DTC 64/C0229) Chart B-23 Simultaneous Drop-Out Of Front Speed Sensor Signal (DTC 64 (Flash Out) / C0229 (Serial Communications)) Page 593 11. Using a jumper wire, connect the reference voltage of each circuit to its signal input and view the APP Sensor values in the Engine Data List. APP Sensor 1 should have a value of 99%, and APP Sensor 2 and APP Sensor 3 should each have a value of 0%. ^ If the values are not as specified, troubleshoot for high resistance on the signal input or a PCM malfunction. Repair the circuit or replace the PCM, then repeat step 3. ^ If the values are as specified, the problem may be intermittent. Disconnect the 10P connector from the modified APPS, and connect it to the new APPS; then repeat step 3. Wiggle the APPS wires as you go through the adjustment procedure to find the intermittent problem. 12. Turn off the ignition switch, and disconnect the PGM Tester.* DISCLAIMER Diagram Information and Instructions Dimmer Switch: Diagram Information and Instructions How to Identify Wiring Color-Coded Insulation Wire Color Wire Color Coding Page 3100 Positive Crankcase Ventilation Valve: Testing and Inspection Before inspecting the PCV valve, make sure that the hoses are connected properly and are in good condition. Also check that the oil pan and rocker cover gaskets are sealing properly. PCV Valve 1. Run the engine at normal operating temperature. 2. Disconnect the valve from the rocker cover. RESULT: A hissing noise should be heard from the valve. If no noise is heard, the PCV valve or hose is plugged. 3. Remove the PCV valve from the engine. a. Blow air into the rocker cover side of the valve. RESULT: Air should pass freely. b. Blow air into the air cleaner side of the valve. RESULT: Air should not pass through the valve. 4. Re-install the PCV valve and remove the oil filler cap. RESULT: A small vacuum should be felt at the oil filler hole. Page 8277 Wiper Motor: Diagrams Page 5589 Key Reminder Switch: Diagnostic Aids Before Troubleshooting Before Troubleshooting See: Service Precautions/Vehicle Damage Warnings/Tips and Precautions 1. Check applicable fuses in the appropriate fuse/relay box. 2. Check the battery for damage, state of charge, and clean and tight connections. CAUTION: Do not quick-charge a battery unless the battery ground cable has been disconnected, otherwise you will damage the alternator diodes. - Do not attempt to crank the engine with the battery ground cable loosely connected or you will severely damage the wiring. While You're Working 1. Make sure connectors are clean, and have no loose terminals or receptacles. 2. Make sure that connectors without wire seals are packed with dielectric (silicone) grease. Part Number: 08798-9001. 3. When connecting a connector, push it until it "clicks" into place. CAUTION: Do not pull on the wires when disconnecting a connector. Pull only on the connector housings. - Most circuits include solid-state devices. Test the voltages in these circuits only with a 10-megaohm or higher impedance digital multi meter. Never use a test light or analog meter on circuits that contain solid-state devices. Damage to the devices may result. Five-Step Troubleshooting 1. Verify The Complaint Turn on all the components in the problem circuit to check the accuracy of the customer complaint. Note the symptoms. Do not begin disassembly or testing until you have narrowed down the problem area. 2. Analyze The Schematic Look up the schematic for the problem circuit. Determine how the circuit is supposed to work by tracing the current paths from the power source through the circuit components to ground. Also, trace circuits that share wiring with the problem circuit. The names of circuits that share the same fuse, ground, or switch, and so on, are referred to in each circuit schematic. Try to operate any shared circuits you didn't check in step 1. If the shared circuits work, the shared wiring is OK, and the cause must be in the wiring used only by the problem circuit. If several circuits fail at the same time, the fuse or ground is a likely cause. Based on the symptoms and your understanding of the circuit's operation, identify one or more possible causes. 3. Isolate The Problem By Testing The Circuit Make circuit tests to check the diagnosis you made in step 2. Keep in mind that a logical, simple procedure is the key to efficient troubleshooting. Test for the most likely cause of failure first. Try to make tests at points that are easily accessible. 4. Fix The Problem Once the specific problem is identified, make the repair. Be sure to use proper tools and safe procedures. 5. Make Sure The Circuit Works Turn on all components in the repaired circuit in all modes to make sure you've fixed the entire problem. If the problem was a blown fuse, be sure to test all of the circuits on that fuse. Make sure no new problems turn up and the original problem does not recur. Page 4591 the component if the component only has one connector, or by a capital letter (A, B, C, etc.) if the component has more than one connector. Below most connector numbers and component names are PHOTO and VIEW numbers. The PHOTO number refers to a photo in the back of the book that shows the connector's location on the car. The VIEW number refers to an illustration in the back of the book that shows the connector face, wire colors, connector cavity numbers, and other details. The connector cavity numbering sequence begins at the top left corner of the connector. Disregard any numbers molded into the connector housing. Wires Wires are identified by the abbreviated names of their colors; the second color is the color of the stripe. Wires are also identified by their location in a connector. The number "2" next to the male and female wire terminals at C416, for example, means those terminals join in cavity 2 of connector C416. Symbols A complete description of schematic symbols is given under wire color abbreviation. Power Distribution Schematics Power Distribution schematics show how power is supplied from the positive battery terminal to various circuits in the car. Refer to the Power Distribution section to get a more detailed picture of how power is supplied to the circuit you're working on. From Battery to Ignition Switch, Fuses, and Relays Individual circuit schematics begin with a fuse. The first half of Power Distribution, however, shows the wiring "upstream" between the battery Diagram Information and Instructions Air Bag: Diagram Information and Instructions How to Identify Wiring Color-Coded Insulation Wire Color Wire Color Coding Page 2275 14. While watching the APP Sensor values in the Engine Data List, adjust the APPS by turning it until the values are within the ranges shown at closed throttle and wide open throttle (accelerator pedal pushed all the way down), then tighten the mounting screws and recheck the values. ^ If all three sensors are within range, go to step 23. ^ If APP Sensor 1 APP Sensor 2, and/or APP Sensor 3 cannot be brought into range, go to step 15. 15. Troubleshoot for an open circuit or a PCM malfunction. ^ If APP Sensor 1 has a value of 0% or APP Sensor 2 and/or APP Sensor 3 have a value of 99%, an open circuit exists or the PCM is malfunctioning. Repair the circuit or replace the PCM, and repeat step 14. ^ If you don't find a problem, go to step 16. 16. Disconnect the 10 P connector from the APPS. 17. View the APP Sensor values in the Engine Data List. ^ If APP Sensor 1 has a value of 0% or APP Sensor 2 and/or APP Sensor 3 have a value of 99%, go to step 18. ^ If APP Sensor 1 has a value other than 0%, or APP Sensor 2 and/or APP Sensor 3 have a value other than 99%, a short circuit exists or the PCM is malfunctioning. Repair the circuit or replace the PCM, and repeat step 14. 18. Modify the original APPS by cutting the connector housing off of the sensor. 19. Connect the 10 P connector to the modified APPS connector housing. Page 4271 This sample Ground Distribution schematic shows all of the components that share two ground points. Components A solid border line means the entire component is shown. A broken border line indicates that only part of the component is shown. Page 4446 This sample Ground Distribution schematic shows all of the components that share two ground points. Components A solid border line means the entire component is shown. A broken border line indicates that only part of the component is shown. Page 3360 the component if the component only has one connector, or by a capital letter (A, B, C, etc.) if the component has more than one connector. Below most connector numbers and component names are PHOTO and VIEW numbers. The PHOTO number refers to a photo in the back of the book that shows the connector's location on the car. The VIEW number refers to an illustration in the back of the book that shows the connector face, wire colors, connector cavity numbers, and other details. The connector cavity numbering sequence begins at the top left corner of the connector. Disregard any numbers molded into the connector housing. Wires Wires are identified by the abbreviated names of their colors; the second color is the color of the stripe. Wires are also identified by their location in a connector. The number "2" next to the male and female wire terminals at C416, for example, means those terminals join in cavity 2 of connector C416. Symbols A complete description of schematic symbols is given under wire color abbreviation. Power Distribution Schematics Power Distribution schematics show how power is supplied from the positive battery terminal to various circuits in the car. Refer to the Power Distribution section to get a more detailed picture of how power is supplied to the circuit you're working on. From Battery to Ignition Switch, Fuses, and Relays Individual circuit schematics begin with a fuse. The first half of Power Distribution, however, shows the wiring "upstream" between the battery Page 7814 Distinct Of Circuit By Wire Base Color All wires have color-coded insulation. Wires belonging to a system's main harness will have a single color. Wires belonging to a system's sub-circuits will have a colored stripe. Striped wires use the codes found in the chart to show wire size and colors. Abbreviations are used to indicate wire color within a circuit diagram. How to Identify Connector Terminals How to Identify Connector Terminals Cavity Numbering System The cavities (and wire terminals) in each connector are numbered starting from the upper left, looking at the male terminals from the terminal side (or looking at the female terminals from the wire side. Both views are in the same direction so the numbers are the same.) All actual cavities are numbered, even if they have no wire terminals in them. NOTE: Data Link Connector (DLC) terminals are numbered according to SAE standard J1962, not the Honda standard. The numbers of the four end terminals are molded into the corners of the connector face. The connector cavity number is listed next to each terminal on the circuit schematic. The cavity / terminal shown is # 6. Using/Identifying Connector Terminal Views How to Use Connector Terminal Views To see the configuration of a connector's cavities, look up its view number in the Connector Views. Each view includes the color of the connector, where Page 5162 Diassembled View Locations Oil Pressure Switch (For Fuel Pump): Locations Bottom Center Front of Engine Page 3304 Test Equipment CAUTION: Most circuits include solid-state devices. Test the voltages in these circuits only with a 10-megaohm or higher impedance digital multimeter. Never use a test light or analog meter on circuits that contain solid-state devices. Damage to the devices may result. Test Light and DVOM On circuits without solid-state devices, use a test light to check for voltage. A test light is made up of a 12 volt bulb with a pair of leads attached. After grounding one lead, touch the other lead to various points along the circuit where voltage should be present. The bulb will go on if there is voltage at the point being tested. If you need to know how much voltage is present, use a digital volt/ohmmeter (DVOM). Self-Powered Test Light and DVOM Use a self-powered test light to check for continuity. This tool is made up of a light bulb, battery, and two leads. To test it, touch the leads together: the light should go on. Use a self-powered test light only on an unpowered circuit. First, disconnect the battery, or remove the fuse that feeds the circuit you are working on. Select two points in the circuit between which you want to check continuity. Connect one lead of the self-powered test light to each point. If there is continuity, the test light's circuit will be completed, and the light will go on. If, in addition, you need to know exactly how much resistance there is between two points, use a digital volt/ohmmeter (DVOM). In the "OHMS" range, the DVOM will measure resistance between two points along a circuit. Low resistance means good continuity. Diodes and solid-state devices in a circuit can make a DVOM give a false reading. To check a reading, reverse the leads, and take a second reading. If the readings differ, the component is affecting the measurement. Jumper Wire Use a jumper wire to bypass an open circuit. A jumper wire is made up of an in-line fuse holder connected to a set of test leads. It should have a five ampere fuse. Never connect a jumper wire across a short circuit. The direct battery short will blow the fuse. Short Finder (Short Circuit Locator) Short finders are available to locate shorts to ground. The short finder creates a pulsing magnetic field in the shorted circuit which you can follow to the location of the short. To order any test equipment shown above, contact your local tool supplier. For a list of suppliers and tool numbers, refer to Honda Required Special Tools and Equipment Service Bulletin. Page 90 L4 Engine Room Tire Rotation Tires: Service and Repair Tire Rotation Tire rotation is recommended to equalize wear for longer life. If the following conditions are noted, rotate the tires: - Front tire wear is different from rear. - Uneven wear exists across the tread of any tire. - Left and right front tire wear is unequal. - Left and right rear tire wear is unequal. Check wheel alignment if the following conditions are noted: - Left and right front tire wear is unequal. - Wear is uneven across the tread of any front tire. - Front tire treads have a scuffed appearance with "feather" edges on one side of the tread ribs or blocks. Front Tires - Rub On Mud Flap On Sharp Turns Mud Flap: Customer Interest Front Tires - Rub On Mud Flap On Sharp Turns 01-088 September 11, 2001 Applies To: 1998-01 Passport - ALL Front Tire Rubs Against the Mud Flap PROBLEM The front tire rubs against the mud flap when the wheel is turned to full lock. CORRECTIVE ACTION Trim away part of the mud flap. WARRANTY CLAIM INFORMATION In warranty: The normal warranty applies. Operation Number: 031005 Flat Rate Time: 0.3 hour Failed Part: P/N 8-97261-990-0 H/C 6633416 Defect Code: 042 Contention Code: B07 Template ID: 01-088A Skill Level: Repair Technician Out of warranty: Any repair performed after warranty expiration may be eligible for goodwill consideration by the District Service Manager or your Zone Office. You must request consideration, and get a decision, before starting work. REPAIR PROCEDURE 1. Remove the mud flaps from the front fenders (four screws each). 2. Wipe off the mud flaps. Locations Page 2677 Ground - "G" Shielding Sheilding This represents RFI (Radio Frequency Interference) shielding around a wire. The shielding is always connected to ground. Splices Page 62 Splices Splices are shown as a dot. Their location and the number of wires may vary depending on the harness manufacturer. Switches Switches These switches move together; the broken straight line between them means they are mechanically connected. Other types of switches are controlled by a coil or a solid state circuit. Unless otherwise noted, all switches are shown in their normal (rest) position, with power off. Terminal "T" Page 7122 Page 5392 6. Test-drive the vehicle to make sure it no longer pulls. If the steering wheel is now off-center by more than 2 mm, go to REPAIR PROCEDURE C. 7. Use your diagnosis worksheet to fill in the following table and build your 15-digit DTC. NOTE: Enter each reading in decimal degrees. Example 30' = 0.50. REPAIR PROCEDURE C 1. Make sure the steering wheel is centered. ^ Turn the steering wheel all the way to the right until it stops. ^ Turn the steering wheel all the way to the left, and count the number of revolutions until it stops. ^ Divide the number of revolutions in half, and turn the steering wheel until it is centered. For example, if it takes four revolutions of the steering wheel to go from lock to lock, then two turns is centered. ^ If the steering wheel is off-center by a large amount (20 mm or more), it may not be centered on the steering column shaft. Reinstall the steering wheel before going to step 2. 2. Place the vehicle on a lift, turn the steering wheel until it is centered, and then raise the vehicle. 3. Adjust the tie-rods. Use your measurements from question 13 of the test-drive to make your adjustment. Page 8075 The name of the component appears next to it followed by notes about its function along with any photo and connector view references. Connector "C" How to Identify Connector Terminals Cavity Numbering System The cavities (and wire terminals) in each connector are numbered starting from the upper left, looking at the male terminals from the terminal side (or looking at the female terminals from the wire side. Both views are in the same direction so the numbers are the same.) All actual cavities are numbered, even if they have no wire terminals in them. NOTE: Data Link Connector (DLC) terminals are numbered according to SAE standard J1962, not the Honda standard. The numbers of the four end terminals are molded into the corners of the connector face. Locations Radiator Grille Page 7919 2. Connect one lead of a self-powered test light or DVOM to one end of the part of the circuit you want to test. 3. Connect the other lead to the other end. 4. If the self-powered test light glows, there is continuity. If you're using a DVOM, a low reading or no reading (zero), means good continuity. Testing For Voltage When testing for voltage at a connector without wire seals, you do not have to separate the two halves of the connector. Instead, probe the connector from the back. Always check both sides of the connector because dirty, corroded, and bent terminals can cause problems (no electrical contact = an open). 1. Connect one lead of the lest light to a known good ground, or, if you're using a digital volt ohmmeter (DVOM), place it in the appropriate DC volts range, and connect its negative lead to ground. 2. Connect the other lead of the test light or DVOM to the point you want to check. 3. If the test light glows, there is voltage present. If you're using a DVOM, note the voltage reading. It should be within one volt of measured battery voltage. A loss of more than one volt indicates a problem. NOTE: Always use a DVOM on high impedance circuits. A test light may not glow (even with battery voltage present). Testing For Voltage Drop Wires, connectors, and switches are designed to conduct current with a minimum loss of voltage. A voltage drop of more than one volt indicates a problem. 1. Place the digital volt/ohmmeter (DVOM) in the appropriate DC volts range. Connect the positive lead to the end of the wire (or to the connector or switch) closest to the battery. 2. Connect the negative lead to the other end of the wire (or the other side of the connector or switch). 3. Turn on the components in the circuit. 4. The DVOM will show the difference in voltage between the two points. A difference, or drop, of more than one volt indicates a problem. Check the circuit for loose, dirty, or bent terminals. Accelerator Pedal Position Sensor - MIL ON/DTC's Set Technical Service Bulletin # 01-047 Date: 010814 Accelerator Pedal Position Sensor - MIL ON/DTC's Set 01-047 August 14, 2001 Applies To: 2000-01 Passport - ALL MIL Comes On With Accelerator Pedal Position Sensor DTC(s) P1271, P1273, P1275, P1280, and/or P1285 SYMPTOM The MIL is on with DTC P1271, P1273, P1275, P1280, or P1285 (various accelerator pedal position sensor problems) stored. The REDUCED POWER indicator may also be on; and the engine may occasionally idle too high, or the idle may fluctuate. PROBABLE CAUSE Contaminated grease on the potentiometer circuit board of the accelerator pedal position sensor (APPS) causes high resistance in the APPS circuit. CORRECTIVE ACTION Replace and adjust the APPS, remove all grease from the accelerator link, and clean the APPS harness connector and connector C123. PARTS INFORMATION Accelerator Pedal Position Sensor: P/N 8-97193-713-0, H/C 6198311 REQUIRED MATERIALS CAIG DeoxIT D5-S6 Contact Cleaner: P/N 341-200 (available from www.partsexpress.com) or Permatex Electrical Contact Cleaner: Permatex P/N 24379 WARRANTY CLAIM INFORMATION In warranty: The normal warranty applies. Operation Number: 122114 Flat Rate Time: 0.5 hour Failed Part: P/N 8-97220-540-0 H/C 6202436 Defect Code: 091 Contention Code: C99 Template ID: 01-047A Skill Level: Repair Technician Out of warranty: Any repair performed after warranty expiration may be eligible for goodwill consideration by the District Service Manager or your Zone Office. You must request consideration, and get a decision, before starting work. Irregular and Premature Wear Tires: Testing and Inspection Irregular and Premature Wear Irregular and/or premature wear has many causes. Some of them are incorrect inflation pressures, lack of tire rotation, poor driving habits or improper wheel alignment. Incorrect inflation is common cause of tire premature wear. NOTE: Due to their design, radial tires tend to wear faster in the shoulder area, particularly on the front tires. This makes regular rotation especially necessary. After rotation, be sure to check wheel nut torque, and set tire pressures. Page 3023 Wire Color Abbreviations The following abbreviations are used to identify wire colors in the circuit schematics: WHT................................... White YEL................................... Yellow BLK................................... Black BLU................................... Blue GRN................................... Green RED................................... Red ORN................................... Orange PNK................................... Pink BRN................................... Brown GRY................................... Gray PUR................................... Purple LT BLU................................... Light Blue LT GRN................................... Light Green Page 2729 6. Place the end of the return hose in a container. Have someone start the engine, then pour ATF into the reservoir while you watch the fluid coming out of the return hose. When the fluid coming out is the same color as the new fluid, turn off the engine. 7. Reconnect the return hose to the reservoir. 8. Start the engine. Fill the power steering reservoir to the proper level with ATF then turn off the engine. 9. Use the Smart Cable to reprogram the PCM with the latest software from the June 2001 or later HONDANET CD-ROM. Refer to Service Bulletin 99-005, Updating the Passport PCM, filed under Tools. 10. Use the PGM Tester to clear any DTCs. 11. Use the PGM Tester to check the broadcast code. Make sure the broadcast code matches the one you selected from the CD-ROM. WARRANTY CLAIM INFORMATION In warranty: The normal warranty applies. Failed Part: P/N 8-97181-590-0 H/C 5698030 Defect Code: 064 Contention Code: C01 Skill Level: Repair Technician Out of warranty: Any repair performed after warranty expiration may be eligible for goodwill consideration by the District Service Manager or your Zone Office. You must request consideration, and get a decision, before starting work. REPAIR PROCEDURE - APPS GROUND 1. Unclamp the air cleaner housing cover, and move it to the side for access to connector C123 (16P BLK). Page 6752 Trailer Lighting Connector (Part 3 Of 3) Page 837 Camshaft Position Sensor: Testing and Inspection 1. Inspect the sensor O-ring for cracks or leaks. 2. Replace the O-ring if it is worn or damaged. 3. Lubricate the new O-ring with engine oil. 4. Install the lubricated O-ring. Page 2127 Crankshaft Position Sensor: Service and Repair REMOVAL 1. Disconnect the negative battery cable. 2. Disconnect the wiring connector from crankshaft position sensor. 3. Remove one bolt and remove the CKP sensor from the right side of the engine block, just behind the mount. NOTE: Use caution to avoid any hot oil that might drip out. INSTALLATION 1. Apply a small amount of engine oil to the O-ring and install the CKP sensor in the engine block. 2. Install the CKP sensor mounting bolt. 3. Tighten the mounting bolt to 10 Nm (89 lb in.). 4. Connect the wiring connector to the CKP sensor. 5. Connect the negative battery cable. Page 1434 5. Tighten bolt for camshaft drive gear assembly pulley to the specified torque using the J-43041 universal holder. Torque: 98 Nm (72 ft. lbs.) Page 4508 c. Remove mode switch connector with bracket from the transmission case. d. Connect multimeter (resistance mode) to terminals 1(E) and 4(H) on mode switch connector. e. Loosen two mounting screws. f. Rotate mode switch slightly in both directions to determine the range (approx. 5 degrees) of electrical contact. g. Position mode switch in middle of contact range. h. Tighten two mounting screws. i. Remove multimeter and install mode switch harness connector with bracket to the transmission case. j. Connect transmission harness connector to mode switch connector. Page 3412 Testing For A Short With A Self-Powered Test Light or DVOM 1. Remove the blown fuse and disconnect the battery and load. 2. Connect one lead of a self-powered test light or digital volt/ohmmeter (DVOM) (switched to the lowest "OHMS" range) to the fuse terminal on the load side. 3. Connect the other lead to a known good ground. 4. Beginning near the fuse box, wiggle the harness. Continue this at convenient points about six inches apart while watching the test light or DVOM. 5. If the self-powered test light goes on or the DVOM displays a low reading or no reading (zero), there is a short to ground in the wiring near that point. Testing for a Short with a Test Light or DVOM 1. Remove the blown fuse and disconnect the load. 2. Connect a test light or digital volt/ohmmeter (DVOM), switched to the appropriate DC volts range, across the fuse terminals to make sure voltage is present. You might have to turn the ignition switch to ON; check the schematic to see. 3. Beginning near the fuse box, wiggle the harness. Continue this at convenient points about six inches apart while watching the test light or DVOM. 4. Where the test light goes , or the DVOM voltage drops to zero, there is a short to ground in the wiring near that point. NOTE: Always use a DVOM on high impedance circuits. A test light may not glow (even with battery voltage present). Testing For A Short With A Short Circuit Locator (Short Finder) 1. Remove the blown fuse. Leave the battery connected. Page 2625 Terminals - "T" Each "T" terminal (ring type) is numbered for reference and location. A "T" terminal is secured with a screw or bolt. Wires Page 6434 NOTE: Whenever installing the new combination switch with SRS coil, be sure to tear off the lock pin for aligning the neutral position before it is installed to the base of steering column. CAUTION: Turn the SRS coil clockwise until a resistance is felt, do not over turn or SRS coil breakage may occur. 6. Install the steering column cover (3). CAUTION: When installing the steering column cover, be sure that all harnesses (i.e., starter switch, combination switch, and SRS coil) are not pinched and installed according to the diagram below. 7. Install the driver knee bloster assembly. 8. Install the steering lower cover. 9. Install the steering wheel and align the setting marks (4). 10. Tighten the steering wheel fixing nut (5) to the specified torque. Torque: 34 N.m (3.5 kg.m / 25 lb.ft) 11. Connect horn lead (1). 12. Concert air bag to wiring harness connector (2). NOTE: Pass the lead wire through the tabs on the plastic cover (wire protector) of air bag to prevent lead wire from being pinched. Page 5836 4. Align the template on the mud flap. Mark the area on the mud flap that needs to be cut away with a pencil or scribe. 5. Use a utility knife to remove the marked area. 6. Repeat steps 4 and 5 on the other mud flap. 7. Reinstall the mud flaps on the vehicle. DISCLAIMER Page 7459 Air Bag(s) Arming and Disarming: Service Precautions Wiring Precautions Wiring Precautions SRS wiring can be identified by special yellow outer covering (except the SRS indicator light circuit). Never attempt to modify, splice, or repair SRS wiring. If there is an open or damage in SRS wiring, replace the harness. Be sure to install the harness wires so that they are not pinched, or interfere with other parts. Make sure all SRS ground locations are clean, and grounds are securely fastened for optimum metal-to-metal contact. Poor grounding can cause intermittent problems that are difficult to diagnose. Page 2041 Each schematic represents one circuit. A circuit's wires and components are arranged to show current flow, from power at the top of the page, to ground, at the bottom. Shared Circuits Other circuits may share power or ground terminals or wiring with the circuit shown. A wire that connects one circuit to another, for example, is cut short and has an arrowhead at the end of it pointing in the direction of current flow. Next to the arrowhead is the name of the circuit or component which shares that wiring. To quickly check shared wiring, check the operation of a component it serves. If that component works, you know the shared wiring is OK. Connectors All in-line and junction connectors are numbered (C725, C416, etc.). Component connectors are not numbered but are identified either by the name of Page 7203 Sunroof Frame Complete Assembly (LWB) And Associated Parts Page 2171 4. Remove the sensor from the exhaust pipe. Because of the expansion and contraction of the metal in the exhaust system over time, this may be difficult if the engine temperature is below 48 ° C (120 °F). INSTALLATION PROCEDURE IMPORTANT: - A special anti-seize compound on the HO2S threads. This compound consists of glass beads suspended in a liquid graphite solution. The graphite burns away with engine heat, but the glass beads will remain, making the sensor easier to remove. - New or service sensors will already have the compound applied to the threads. If a sensor is removed and is to be reinstalled for any reason, the threads must have anti-seize compound applied. 1. Apply anti-seize compound or the equivalent to the threads of the oxygen sensor, if necessary. 2. Install the oxygen sensor on the exhaust pipe in its original position. Tighten Tighten the oxygen sensor to 55 N.m (40 lb ft.). 3. Connect the pigtail to the wiring harness. 4. Connect the negative battery cable. Page 6247 - Charge the refrigerant until the scale reading decreases by the amount of the charge specified. Specified amount: 650 g (1.43 lbs) - If charging the system becomes difficult: 1. Run the engine at idle and close all the vehicle doors. 2. Turn A/C switch "ON". 3. Set the fan switch to its highest position. 4. Set the air source selector lever to "CIRC". 5. Slowly open the low side valve on the manifold gauge set. WARNING: BE ABSOLUTELY SURE NOT TO OPEN THE HIGH PRESSURE VALVE OF THE MANIFOLD GAUGE. SHOULD THE HIGH PRESSURE VALVE BE OPENED, THE HIGH PRESSURE REFRIGERANT WOULD FLOW BACKWARD, AND THIS MAY CAUSE THE REFRIGERANT CONTAINER TO BURST. 8. When finished with the refrigerant charging, close the low pressure valve of the manifold gauge and container valve. 9. Check for refrigerant leaks. Page 2554 Crankshaft Position Sensor: Service and Repair REMOVAL 1. Disconnect the negative battery cable. 2. Disconnect the wiring connector from crankshaft position sensor. 3. Remove one bolt and remove the CKP sensor from the right side of the engine block, just behind the mount. NOTE: Use caution to avoid any hot oil that might drip out. INSTALLATION 1. Apply a small amount of engine oil to the O-ring and install the CKP sensor in the engine block. 2. Install the CKP sensor mounting bolt. 3. Tighten the mounting bolt to 10 Nm (89 lb in.). 4. Connect the wiring connector to the CKP sensor. 5. Connect the negative battery cable. Page 2778 Wire Color Abbreviations The following abbreviations are used to identify wire colors in the circuit schematics: WHT................................... White YEL................................... Yellow BLK................................... Black BLU................................... Blue GRN................................... Green RED................................... Red ORN................................... Orange PNK................................... Pink BRN................................... Brown GRY................................... Gray PUR................................... Purple LT BLU................................... Light Blue LT GRN................................... Light Green Page 6876 Fuel Door: Removal and Replacement Fuel Filler Door Fuel Fill Door Removal 1. Open the fuel filler door. 2. Remove the fuel filler door. - Remove the two fixing screws. 3. Pull out the fuel filler door buffer. 4. Pull out the fuel filler hinge buffer. Installation To install, follow the removal steps in the reverse order, noting the following points. 1. Install the fuel filler door to match the basic hole. Page 6543 Seat Belt Tensioner: Service and Repair Airbags/Seat Belt Tensioner Deployment and Disposal Deployment Tool Check Procedure Deployment Tool Check 1. Connect the yellow clips to both switch protector handles on the tool; connect the tool to a battery. 2. Push the operation switch: green means the tool is OK; red means the tool is faulty. 3. Disconnect the battery and the yellow clips. Damaged Airbag/Tensioner Disposal Procedure Disposal of Damaged Components 1. If installed in a vehicle, follow the removal procedure for the driver's airbag, front passenger's airbag, side airbag, and seat belt tensioner. 2. In all cases, make a short circuit by twisting together the two inflator wires. 3. Package the component in exactly the same packaging that the new replacement part came in. 4. Mark the outside of the box "DAMAGED AIRBAG NOT DEPLOYED", "DAMAGED SIDE AIRBAG NOT DEPLOYED" or "DAMAGED SEAT BELT TENSIONER NOT DEPLOYED" so it does not get confused with your parts stock. 5. Contact your Honda District Service Manager for how and where to return it for disposal. Deploying Airbags/Tensioner (Inside Vehicle) Only deploy the airbag inside the vehicle If the vehicle is to be destroyed or salvaged for component parts. This includes, but is not limited to, the following situations. 1. The vehicle has completed its useful life. 2. The vehicle has been damaged beyond repair in a non deployment type accident. 3. The vehicle has been stripped or damaged beyond repair in a theft. 4. Vehicle will be salvaged for component parts to be used on a vehicle with a different Vehicle Identification Number (VIN) as opposed to being rebuilt as same VIN. Never use SRS components from another vehicle. WARNING: FAILURE TO FOLLOW PROPER SRS AIR BAG ASSEMBLY DISPOSAL PROCEDURES CAN RESULT IN AIR BAG DEPLOYMENT WHICH MAY CAUSE PERSONAL INJURY. UNDEPLOYED AIR BAG ASSEMBLIES MUST NOT BE DISPOSED OF THROUGH NORMAL REFUSE CHANNELS. THE UNDEPLOYED AIR BAG ASSEMBLY CONTAINS SUBSTANCES THAT CAN CAUSE SEVERE ILLNESS OR PERSONAL INJURY IF THE SEALED CONTAINER IS DAMAGED DURING DISPOSAL. DISPOSAL IN ANY MANNER INCONSISTENT WITH PROPER PROCEDURES MAY BE A VIOLATION OF FEDERAL, STATE AND/OR LOCAL LAWS. 1. Turn ignition switch to "LOCK", remove key and put on safety glasses. 2. Remove all loose objects from front seats. 3. Disconnect Supplemental Restraint System (SRS) coil assembly, yellow 2 - pin connector located at the base of the steering column. 4. Cut the SRS coil assembly yellow 2 - pin harness connector from the vehicle leaving at least 16 cm (six inches) of wire at the connector. 5. Strip 13 mm (1/2 inch) of insulation from yellow - green and yellow - lack wire lead of the connector. 6. Cut two 900 cm (30 feet) deployment wires from 0.8 sq.mm (18 gauge) or thicker multi - strand wire. These wires will be used to fabricate the driver deployment harness. 7. Strip 13 mm (112 inch) of insulation from both ends of the wires cut in the previous step. 8. Short the wires by twisting together one end from each. Deployment wires shall remain shorted and not be connected to a power source until the air bag is to be deployed. Page 2474 CD Changer Troubleshooting (All except Passport) CD Player Troubleshooting (All except Passport) Radio Troubleshooting (All except Passport) Page 8264 Slide the new blade into the holder, and push from behind with your thumb until you feel the tabs snap into place. Make sure the blade is locked in place before you reinstall the blade assembly. If it's not, the blade could come off during use and the blade assembly could scratch the windshield. Page 7401 Distinct Of Circuit By Wire Base Color All wires have color-coded insulation. Wires belonging to a system's main harness will have a single color. Wires belonging to a system's sub-circuits will have a colored stripe. Striped wires use the codes found in the chart to show wire size and colors. Abbreviations are used to indicate wire color within a circuit diagram. How to Identify Connector Terminals How to Identify Connector Terminals Cavity Numbering System The cavities (and wire terminals) in each connector are numbered starting from the upper left, looking at the male terminals from the terminal side (or looking at the female terminals from the wire side. Both views are in the same direction so the numbers are the same.) All actual cavities are numbered, even if they have no wire terminals in them. NOTE: Data Link Connector (DLC) terminals are numbered according to SAE standard J1962, not the Honda standard. The numbers of the four end terminals are molded into the corners of the connector face. The connector cavity number is listed next to each terminal on the circuit schematic. The cavity / terminal shown is # 6. Using/Identifying Connector Terminal Views How to Use Connector Terminal Views To see the configuration of a connector's cavities, look up its view number in the Connector Views. Each view includes the color of the connector, where Page 5519 DISASSEMBLY 1. Clean the oil pump with solvent (plug the discharge and suction ports to prevent the entry of solvent). Be careful not to expose the oil seal of shaft assembly to solvent. 2. Remove the bolt, suction pipe and O-ring. 3. Remove the connector, O-ring, relief valve and spring. 4. Remove the pressure switch assembly. 5. Remove the bolt, rear housing and gasket. 6. Remove snap ring. 7. Remove the shaft assembly. 8. Remove the oil seal. CAUTION: When removing the oil seal, be careful not to damage the housing. 9. Remove the pump cartridge assembly from the front housing. 10. Remove two O-rings. INSPECTION AND REPAIR Make all necessary adjustments, repairs, and part replacements if wear, damage, or other problems are discovered during inspection. Rotor Check that the groove in the vane is free from excessive wear and that the vane slides smoothly. When part replacement becomes necessary, the pump cartridge should be replaced as a subassembly. Vane Sliding faces of the vane should be free from wear. (Particularly the curved face at the tip that contact with the cam should be free from wear and distortion). When part replacement becomes necessary, the pump cartridge should be replaced as a subassembly. Cam The inner face of the arm should have a uniform contact pattern without a sign of step wear. When part replacement becomes necessary, the pump cartridge should be replaced as a subassembly. Side Plate The sliding faces of parts must be free from step wear (more than 0.01 mm), which can be felt by the fingernail. The parts with minor scores may Page 1245 - Charge the refrigerant until the scale reading decreases by the amount of the charge specified. Specified amount: 650 g (1.43 lbs) - If charging the system becomes difficult: 1. Run the engine at idle and close all the vehicle doors. 2. Turn A/C switch "ON". 3. Set the fan switch to its highest position. 4. Set the air source selector lever to "CIRC". 5. Slowly open the low side valve on the manifold gauge set. WARNING: BE ABSOLUTELY SURE NOT TO OPEN THE HIGH PRESSURE VALVE OF THE MANIFOLD GAUGE. SHOULD THE HIGH PRESSURE VALVE BE OPENED, THE HIGH PRESSURE REFRIGERANT WOULD FLOW BACKWARD, AND THIS MAY CAUSE THE REFRIGERANT CONTAINER TO BURST. 8. When finished with the refrigerant charging, close the low pressure valve of the manifold gauge and container valve. 9. Check for refrigerant leaks. Service and Repair Axle Bearing: Service and Repair AXLE SHAFT, OIL SEAL AND BEARING AXLE SHAFT AND ASSOCIATED PARTS Disc Brake Model Drum Brake Model REMOVAL 1. Raise the vehicle. 2. Remove rear wheels and brake calipers or drums. Do not let calipers hang from the vehicle by the brake line or hose. Wire them to frame of vehicle to prevent damage. 3. Remove four nuts and lockwashers. 4. Remove shaft assembly from the axle housing. 5. Remove snap ring and bearing cup. Page 7768 2. Connect one lead of a self-powered test light or DVOM to one end of the part of the circuit you want to test. 3. Connect the other lead to the other end. 4. If the self-powered test light glows, there is continuity. If you're using a DVOM, a low reading or no reading (zero), means good continuity. Testing For Voltage When testing for voltage at a connector without wire seals, you do not have to separate the two halves of the connector. Instead, probe the connector from the back. Always check both sides of the connector because dirty, corroded, and bent terminals can cause problems (no electrical contact = an open). 1. Connect one lead of the lest light to a known good ground, or, if you're using a digital volt ohmmeter (DVOM), place it in the appropriate DC volts range, and connect its negative lead to ground. 2. Connect the other lead of the test light or DVOM to the point you want to check. 3. If the test light glows, there is voltage present. If you're using a DVOM, note the voltage reading. It should be within one volt of measured battery voltage. A loss of more than one volt indicates a problem. NOTE: Always use a DVOM on high impedance circuits. A test light may not glow (even with battery voltage present). Testing For Voltage Drop Wires, connectors, and switches are designed to conduct current with a minimum loss of voltage. A voltage drop of more than one volt indicates a problem. 1. Place the digital volt/ohmmeter (DVOM) in the appropriate DC volts range. Connect the positive lead to the end of the wire (or to the connector or switch) closest to the battery. 2. Connect the negative lead to the other end of the wire (or the other side of the connector or switch). 3. Turn on the components in the circuit. 4. The DVOM will show the difference in voltage between the two points. A difference, or drop, of more than one volt indicates a problem. Check the circuit for loose, dirty, or bent terminals. Page 5201 Each schematic represents one circuit. A circuit's wires and components are arranged to show current flow, from power at the top of the page, to ground, at the bottom. Shared Circuits Other circuits may share power or ground terminals or wiring with the circuit shown. A wire that connects one circuit to another, for example, is cut short and has an arrowhead at the end of it pointing in the direction of current flow. Next to the arrowhead is the name of the circuit or component which shares that wiring. To quickly check shared wiring, check the operation of a component it serves. If that component works, you know the shared wiring is OK. Connectors All in-line and junction connectors are numbered (C725, C416, etc.). Component connectors are not numbered but are identified either by the name of Page 1034 NOTE: Do this repair procedure if, after doing step 10 of the test-drive, the vehicle pulled in the opposite direction after you swapped the front tires. 1. Swap wheels 2 and 4 on the passenger's side of the vehicle, and test-drive again. ^ If the pull goes away, replace the tire on wheel 2, then go to step 3. ^ If the pull does not go away, put wheels 2 and 4 back to their original positions, and go to step 2. 2. Swap wheels 1 and 3 on the driver's side of the vehicle, and test-drive again. ^ If the pull goes away, replace the tire on wheel 1, then go to step 3. ^ If the pull does not go away, use a known-good tire in position 1 and continue diagnosis. 3. Use your diagnosis worksheet to fill in the following table and build your 15-digit DTC. REPAIR PROCEDURE B Page 2456 7. Modify the original APPS by cutting the connector housing off of the sensor. 8. Connect the 10P connector to the modified APPS connector housing. 9. Using a DVOM, check the voltage between the reference voltage pin for each sensor and ground. ^ If the sensor circuits all read 5.0 volts, go to step 11. ^ If any sensor circuit is above or below 5.0 volts, go to step 10. 10. Troubleshoot for an internal short in another sensor or a PCM malfunction. ^ To find the sensor with an internal short, monitor the incorrect reference voltage, and disconnect each sensor (FTPS, EGR, MAP, TPS, CKP, and CMP) one at a time until the reference voltage reads 5.0 volts. Replace that sensor, and repeat step 3. ^ To find a malfunctioning PCM, replace it with a known-good PCM. If all three sensors (APP Sensor 1, APP Sensor 2, and APP Sensor 3) are within range, the original PCM is faulty; replace it and repeat step 3. Page 6098 Condenser Fan Motor Relay: Testing and Inspection 1. Disconnect relays and check for continuity and resistance between relay terminals. - For handling of these relays, refer to Heater Relay. Locations 46 - Top Front Of 3.2L Engine (Intake Duct Removed) Page 2166 Oxygen Sensor: Description and Operation Catalyst Monitor Heated Oxygen Sensors Catalyst Monitor Heated Oxygen Sensors Three-way catalytic converters are used to control emissions of hydrocarbons (HC), carbon monoxide (CO), and oxides of nitrogen (NOx). The catalyst within the converters promotes a chemical reaction. This reaction oxidizes the HC and CO present in the exhaust gas and converts them into harmless water vapor and carbon dioxide. The catalyst also reduces NOx by converting it to nitrogen. The PCM can monitor this process using the Bank 1 HO2S 2 and the Bank 2 HO2S 2 heated oxygen sensors. The Bank 1 HO2S 1 and the Bank 2 HO2S 1 sensors produce an output signal which indicates the A/T - Avoiding Fluid Contamination Fluid - CVT: Technical Service Bulletins A/T - Avoiding Fluid Contamination SOURCE: Honda Service News TITLE: Avoiding Comebacks From A/T Contamination APPLIES TO: All models SERVICE TIP: Installing a reman A/T? Here are some important tips to keep in mind to ensure a first-time fix and to avoid any come-backs: - If the vehicle has an ATF cooler, make sure you clean the cooler with the ATF Cooler Cleaner (P/N GHTTTCF6H). See S/B 89-022, ATF Cooler Cleaner, for details. - If the reman A/T kit includes an in-line filter, don't forget to install it. If the vehicle already has an in-line filter from an earlier A/T replacement, then remove the existing filter, and install the new one. - Spray the driveshaft splines with solvent and compressed air before installing them in the reman A/T. If the failed A/T had a speed sensor, make sure it's clean before you install it. Debris from the failed A/T can catch in the driveshaft splines or on the speed sensor and contaminate the reman A/T. - If the reman A/T comes with a heater/cooler, make sure you install the reman A/T with that heater/cooler. Never install the heater/cooler from the failed A/T; you could contaminate the reman A/T. Page 7637 Terminals - "T" Each "T" terminal (ring type) is numbered for reference and location. A "T" terminal is secured with a screw or bolt. Wires Page 3047 catalyst is operating efficiently, the Bank 1 HO2S 1 and the Bank 2 HO2S 1 signals will be more active than the signals produced by the Bank 1 HO2S 2 and the Bank 2 HO2S 2 sensors. The catalyst monitor sensors operate the same as the fuel control sensors. The Bank 1 HO2S 2 and the Bank 2 HO2S 2 sensors" main function is catalyst monitoring, but they also have a limited role in fuel control. If a sensor output indicates a voltage either above or below the 450 mV bias voltage for an extended period of time, the PCM will make a slight adjustment to fuel trim to ensure that fuel delivery is correct for catalyst monitoring. A problem with the Bank 1 HO2S 2 signal circuit will set DTC P0137, P0138, or P0140, depending on the specific condition. A problem with the Bank 2 HO2S 2 signal circuit will set DTC P0157, P0158, or P0160, depending on the specific condition. A fault in the heated oxygen sensor heater element or its ignition feed or ground will result in lower sensor response. This may cause incorrect catalyst monitor diagnostic results. Page 6300 Control Module HVAC: Diagnostic Aids Before Troubleshooting Before Troubleshooting See: Service Precautions/Vehicle Damage Warnings/Tips and Precautions 1. Check applicable fuses in the appropriate fuse/relay box. 2. Check the battery for damage, state of charge, and clean and tight connections. CAUTION: Do not quick-charge a battery unless the battery ground cable has been disconnected, otherwise you will damage the alternator diodes. - Do not attempt to crank the engine with the battery ground cable loosely connected or you will severely damage the wiring. While You're Working 1. Make sure connectors are clean, and have no loose terminals or receptacles. 2. Make sure that connectors without wire seals are packed with dielectric (silicone) grease. Part Number: 08798-9001. 3. When connecting a connector, push it until it "clicks" into place. CAUTION: Do not pull on the wires when disconnecting a connector. Pull only on the connector housings. - Most circuits include solid-state devices. Test the voltages in these circuits only with a 10-megaohm or higher impedance digital multi meter. Never use a test light or analog meter on circuits that contain solid-state devices. Damage to the devices may result. Five-Step Troubleshooting 1. Verify The Complaint Turn on all the components in the problem circuit to check the accuracy of the customer complaint. Note the symptoms. Do not begin disassembly or testing until you have narrowed down the problem area. 2. Analyze The Schematic Look up the schematic for the problem circuit. Determine how the circuit is supposed to work by tracing the current paths from the power source through the circuit components to ground. Also, trace circuits that share wiring with the problem circuit. The names of circuits that share the same fuse, ground, or switch, and so on, are referred to in each circuit schematic. Try to operate any shared circuits you didn't check in step 1. If the shared circuits work, the shared wiring is OK, and the cause must be in the wiring used only by the problem circuit. If several circuits fail at the same time, the fuse or ground is a likely cause. Based on the symptoms and your understanding of the circuit's operation, identify one or more possible causes. 3. Isolate The Problem By Testing The Circuit Make circuit tests to check the diagnosis you made in step 2. Keep in mind that a logical, simple procedure is the key to efficient troubleshooting. Test for the most likely cause of failure first. Try to make tests at points that are easily accessible. 4. Fix The Problem Once the specific problem is identified, make the repair. Be sure to use proper tools and safe procedures. 5. Make Sure The Circuit Works Turn on all components in the repaired circuit in all modes to make sure you've fixed the entire problem. If the problem was a blown fuse, be sure to test all of the circuits on that fuse. Make sure no new problems turn up and the original problem does not recur. Page 4186 Transmission Cooler: Technical Service Bulletins A/T - Avoiding Fluid Contamination SOURCE: Honda Service News TITLE: Avoiding Comebacks From A/T Contamination APPLIES TO: All models SERVICE TIP: Installing a reman A/T? Here are some important tips to keep in mind to ensure a first-time fix and to avoid any come-backs: - If the vehicle has an ATF cooler, make sure you clean the cooler with the ATF Cooler Cleaner (P/N GHTTTCF6H). See S/B 89-022, ATF Cooler Cleaner, for details. - If the reman A/T kit includes an in-line filter, don't forget to install it. If the vehicle already has an in-line filter from an earlier A/T replacement, then remove the existing filter, and install the new one. - Spray the driveshaft splines with solvent and compressed air before installing them in the reman A/T. If the failed A/T had a speed sensor, make sure it's clean before you install it. Debris from the failed A/T can catch in the driveshaft splines or on the speed sensor and contaminate the reman A/T. - If the reman A/T comes with a heater/cooler, make sure you install the reman A/T with that heater/cooler. Never install the heater/cooler from the failed A/T; you could contaminate the reman A/T. Page 3260 H/C 4408092 Defect Code: 017 Contention Code: C99 Skill Level: Repair Technician Out of warranty: Any repair performed after warranty expiration may be eligible for goodwill consideration by the District Service Manager or your Zone Office. You must request consideration, and get a decision, before starting work. DISCLAIMER Interior - Storage Cover Lock Knob Loose/Missing Cargo Cover: Customer Interest Interior - Storage Cover Lock Knob Loose/Missing 02-033 June 11, 2002 Applies To: 2000-02 Passport - ALL Loose or Missing Lock Knob on the Storage Cover SYMPTOM The knob on the storage cover in the cargo area separates from the cover, or it is missing. PROBABLE CAUSE The stop tabs on the lock knob are broken. CORRECTIVE ACTION Replace the storage cover lock knob with the appropriate color knob, either gray or beige. PARTS INFORMATION Lock Knob, Gray: P/N 8-97394-481-1 H/C 7117617 Lock Knob, Beige: P/N 8-97394-482-1 H/C 7117625 WARRANTY CLAIM INFORMATION In warranty: The normal warranty applies. Operation Number: 523117 Flat Rate Time: 0.2 hour Failed Part: P/N 5-97195-525-2 H/C 5756554 Defect Code: 075 Contention Code: A99 Template ID: 02-033A (Lock Knob, Gray) 02-033B (Lock Knob, Beige) Skill Level: Repair Technician Out of warranty: Any repair performed after warranty expiration may be eligible for goodwill consideration by the District Parts and Service Manager or your Zone Office. You must request consideration, and get a decision, before starting work. REPAIR PROCEDURE Page 1594 6. Insert the press-fit into the valve seat horizontally. 7. Standard fitting interference: 0.14 mm 0.09 mm (0.0055 inch - 0.0035 inch) 8. After insertion, use a seat grinder to grind finish the seating face. Carefully note the seating angle, the contact width, and the depression. 9. Lap the valve and the seat. Reassembly 1. Install valve guide (1) to cylinder head. Apply engine oil to the outside of the valve guide. Using valve guide replacer J-42899, drive in a new valve guide from the camshaft side. 2. Install oil controller (3) and spring lower seat (2). Using oil controller replacer J-37281, drive in a new oil controller. 3. Install valve to valve guide. Before install valve guide apply engine oil to the outside of the valve stem. 4. Install valve spring to cylinder head. Attach the valve spring to the lower spring seat. The painted area of the valve spring should be facing downward. 5. Install lower valve spring seat, valve spring and upper valve spring seat then put split collars on the upper spring seat, using the J-8062 valve Locations Transmission Position Switch/Sensor: Locations Left Side Of Automatic Transmission Page 4911 Brake Rotor/Disc: Testing and Inspection Checking Lateral Runout 1. Adjust the wheel bearing correctly. 2. Attach a dial indicator to some portion of the suspension so that the stem contacts the rotor face about 29 mm (1.14 inch) from the rotor edge. 3. Move the rotor one complete rotation. The lateral runout should not exceed 0.13 mm (0.005 inch) Maximum runout: 0.13 mm (0.005 inch) Right Side Removal and Installation Catalytic Converter: Service and Repair Right Side Removal and Installation TWC RH and Forked Exhaust Pipe and Associated Parts REMOVAL 1. Disconnect battery ground cable. 2. Lift up the vehicle and support with suitable safety stands. 3. Disconnect O2 sensor harness connectors (2) (6). 4. Remove the forked exhaust pipe fixing bolts and nuts (5) (9) (11) and the exhaust silencer fixing nuts (10), then remove the forked exhaust pipe (8) and the mass damper. 5. Remove the three way catalytic converter fixing nuts (1) and the mounting rubber (4), then remove the three way catalytic converter (3). INSTALLATION 1. Install the three way catalytic converter (3) and the mounting rubber (4), and tighten the fixing nuts (1) to the specified torque. Torque Nuts: 67 Nm (49 ft. lbs.) 2. Install the forked exhaust pipe (8) and the mass damper (7), and tighten the fixing bolts (5) & nuts (9) (10) to the specified torque. Torque Bolts & Nuts: 43 Nm (32 ft. lbs.) Nuts: 43 Nm (32 ft. lbs.) 3. Connect the O2 sensor connectors (2) (6). Page 7025 4. Remove the inside handle fixing screw. CAUTION: Take care not to apply excessive force on the inside handle link, lest this link be elongated, which could make it impossible to operate the door with the inside handle. 5. Remove the rear door corner garnish. 6. Remove the door trim panel. - Pull out the eight clip positions from the door panel. - Disconnect the power window switch and courtesy light connectors to lift the trim panel and unlock the engagement of the waist seal section, then pass the inside lever through the mounting hole of the trim panel, and detach the trim panel. 7. Remove the inside handle. 8. Remove the power window switch. - Remove the fixing screws of switch from backside of rear door trim. Installation To install, follow the removal steps in the reverse order. Service and Repair Band Control Solenoid Valve: Service and Repair REMOVAL 1. Raise the vehicle and support it on jack stands. 2. Disconnect battery ground cable. 3. Drain fluid. 4. Remove sixteen 10 mm screws, main case oil pan, magnet, and gasket. 5. Remove three 13 mm screws, oil filter. 6. Disconnect wiring harness from band control solenoid and shift solenoids. Pull only on connectors, not on wiring harness. 7. Remove spring pin for shift solenoid A, shift solenoid B, and band control solenoid respectively, using suitable pliers taking care not to damage solenoids. 8. Remove shift solenoid A, shift solenoid B, band control solenoid, and gaskets from main case valve body. Do not pull on wiring harness. Remove solenoids by grasping the metal tip. INSTALLATION 1. Install shift solenoid A, shift solenoid B, band control solenoid with new gaskets to main case valve body respectively. 2. Carefully install spring pin with hammer to avoid damage to valve body, etc. 3. Connect wiring harness to solenoids. 4. Install oil filter with a new gasket and the three 13 mm screws, tighten to the specified torque. Torque: 20 Nm (15 Ft. lbs.) Page 7633 The name of the component appears next to it followed by notes about its function along with any photo and connector view references. Connector "C" How to Identify Connector Terminals Cavity Numbering System The cavities (and wire terminals) in each connector are numbered starting from the upper left, looking at the male terminals from the terminal side (or looking at the female terminals from the wire side. Both views are in the same direction so the numbers are the same.) All actual cavities are numbered, even if they have no wire terminals in them. NOTE: Data Link Connector (DLC) terminals are numbered according to SAE standard J1962, not the Honda standard. The numbers of the four end terminals are molded into the corners of the connector face. Locations 46 - Top Front Of 3.2L Engine (Intake Duct Removed) Page 2639 Powertrain Control Module: Service Precautions Electrostatic Discharge Damage Electrostatic Discharge Damage Electronic components used in the PCM are often designed to carry very low voltage. Electronic components are susceptible to damage caused by electrostatic discharge. Less than 100 volts of static electricity can cause damage to some electronic components. By comparison, it takes as much as 4000 volts for a person to feel even the zap of a static discharge. There are several ways for a person to become statically charged. The most common methods of charging are by friction and induction. - An example of charging by friction is a person sliding across a vehicle seat. - Charge by induction occurs when a person with well insulated shoes stands near a highly charged object and momentary touches ground. Charges of the same polarity are drained off leaving the person highly charged with the opposite polarity. Static charges can cause damage, therefore it is important to use care when handling and testing electronic components. NOTE: To prevent possible electrostatic discharge damage, follow these guidelines: - Do not touch the PCM connector pins or soldered components on the PCM circuit board. - Do not open the replacement part package until the part is ready to be installed. - Before removing the pan: from the package, ground the package to a known good ground on the vehicle. - If the part has been handled while sliding across the seat, while sitting down from a standing position, or while walking a distance, touch a known good ground before installing the part. Page 2419 CD Changer Troubleshooting (All except Passport) CD Player Troubleshooting (All except Passport) Radio Troubleshooting (All except Passport) Page 4867 Test Equipment CAUTION: Most circuits include solid-state devices. Test the voltages in these circuits only with a 10-megaohm or higher impedance digital multimeter. Never use a test light or analog meter on circuits that contain solid-state devices. Damage to the devices may result. Test Light and DVOM On circuits without solid-state devices, use a test light to check for voltage. A test light is made up of a 12 volt bulb with a pair of leads attached. After grounding one lead, touch the other lead to various points along the circuit where voltage should be present. The bulb will go on if there is voltage at the point being tested. If you need to know how much voltage is present, use a digital volt/ohmmeter (DVOM). Self-Powered Test Light and DVOM Use a self-powered test light to check for continuity. This tool is made up of a light bulb, battery, and two leads. To test it, touch the leads together: the light should go on. Use a self-powered test light only on an unpowered circuit. First, disconnect the battery, or remove the fuse that feeds the circuit you are working on. Select two points in the circuit between which you want to check continuity. Connect one lead of the self-powered test light to each point. If there is continuity, the test light's circuit will be completed, and the light will go on. If, in addition, you need to know exactly how much resistance there is between two points, use a digital volt/ohmmeter (DVOM). In the "OHMS" range, the DVOM will measure resistance between two points along a circuit. Low resistance means good continuity. Diodes and solid-state devices in a circuit can make a DVOM give a false reading. To check a reading, reverse the leads, and take a second reading. If the readings differ, the component is affecting the measurement. Jumper Wire Use a jumper wire to bypass an open circuit. A jumper wire is made up of an in-line fuse holder connected to a set of test leads. It should have a five ampere fuse. Never connect a jumper wire across a short circuit. The direct battery short will blow the fuse. Short Finder (Short Circuit Locator) Short finders are available to locate shorts to ground. The short finder creates a pulsing magnetic field in the shorted circuit which you can follow to the location of the short. To order any test equipment shown above, contact your local tool supplier. For a list of suppliers and tool numbers, refer to Honda Required Special Tools and Equipment Service Bulletin. Page 7632 This sample Ground Distribution schematic shows all of the components that share two ground points. Components A solid border line means the entire component is shown. A broken border line indicates that only part of the component is shown. Page 8023 The wire insulation has one color or one color with another color stripe. The second color is the stripe. Description and Operation Malfunction Lamp / Indicator: Description and Operation "Air Bag" Warning Lamp Ignition voltage is applied to the "AIR BAG" warning lamp when the ignition switch is at the ON or START positions. The SDM controls the lamp by providing ground with a lamp driver. The "AIR BAG" warning lamp is used in the SRS to do the following: 1. Verify lamp and SDM operation by flashing SEVEN (7) times when the ignition switch is first turned "ON". 2. Warn the vehicle driver of SRS electrical system malfunctions which could potentially affect the operation of the SRS. These malfunctions could result in nondeployment in case of a frontal crash or deployment for conditions less severe than intended. The "AIR BAG" warning lamp is the key to driver notification of SRS malfunctions. For proper lamp operation, refer to the "SRS Diagnostic System Check". Page 1178 Coolant: Description and Operation Anti Freeze Solution Relation between the mixing ratio and freezing temperature of the Engine Coolant varies with the ratio of anti-freeze solution in water. Proper mixing ratio can be determined by referring to the chart. Supplemental inhibitors or additives claiming to increase cooling capability that have not been specifically approved by Isuzu are not recommended for addition to the cooling system. - Calculating mixing ratio Notice: Antifreeze solution + Water = Total cooling system capacity. Mixing Ratio Check the specific gravity of engine coolant in the cooling system temperature ranges from O°C to 50°C using a suction type hydrometer, then determine the density of the engine coolant by referring to the table. Notice: 1. Even in the areas where the atmospheric temperature is higher than 0°C, be sure not to use antifreeze solution at a mixing ratio lower than 20% so that the inside of the engine may not be corroded. Page 7402 it is located, and what it connects to. Use the Connector Views to help locate the proper cavity when you need to probe a connector. It can be especially helpful if the connector has more than one wire of the same color. A dash symbol (-) indicates that the cavity is empty. Connector views can also be used to help diagnose multiple symptoms in separate circuits which could be caused by a single problem in a connector shared by those circuits. Here's an example: 1. Pick one of the multiple symptoms and look up the schematic for that circuit. 2. Make a list of all the in-line and fuse box connectors in that schematic , 3. Then, in the Connector Views, look up each connector on your list to see if circuits related to the other symptoms run through one of them. If they do, inspect that connector for the problem. Example: The blower, rear window defogger, and the windshield wiper don't work. List all in-line and fuse box connectors in the blower controls circuit and then check the Connector View (see the sample). You find that C324 is common to the blower controls, rear window defogger, and wiper/washer, so you inspect C324 and find the problem, bent terminals. Finding Component/Connector Locations Finding Component/Connector Locations To see where a component or connector is located on the car, look up its photo number in the "Component Location". The photo will also tell you the color of the connector, and how many cavities it has. Page 5676 Suspension Control Module: Service and Repair Page 2968 and the fuses. From Fuses to Relays and Components The second half of Power Distribution shows the wiring "From Fuses to Relays and Components." This can speed your troubleshooting by showing which circuits share fuses. If Power Distribution shows that an inoperative circuit and another circuit share a fuse, check a component in the other circuit. If it works, you know the fuse is good and power is available to the inoperative circuit. Ground Distribution Schematics Locations Relay Box: Locations Page 6327 Refrigerant Pressure Sensor / Switch: Description and Operation A/C Dual Pressure Switch (M/T) To prevent compressor damage, the dual pressure switch will open if system pressure is too low or too high: below 176.5 ± 19.6 kPa (25.6 ± 2.8 psi) or above 2943 ± 196.2 kPa (426.7 ± 28.4 psi). A/C Triple Pressure Switch (A/T) Low and high switch operation is the same as the dual pressure switch. The medium pressure switch will close when system pressure exceeds 1471.5 ± 98.1 kPa (213.3 ± 14.2 psi), turning on the condenser fan. Locations ECT Sensor Page 1428 Camshaft: Service and Repair Disassembly, Inspection and Assembly DISASSEMBLY 1. Remove fixing bolt (5) for camshaft drive gear pulley using J-43041 universal holder. Page 3626 10. Move the front wheels to the straight ahead position, then use steering wheel remover J-29752 to remove the steering wheel CAUTION: Never apply force to the steering wheel in direction of the shaft by using a hammer or other impact tools in an attempt to remove the steering wheel. The steering shaft is designed as an energy absorbing unit. WARNING: THE INFLATOR MODULE SHOULD ALWAYS BE CARRIED WITH THE URETHANE COVER AWAY FROM YOUR BODY AND SHOULD ALWAYS BE LAID ON A FLAT SURFACE WITH THE URETHANE SIDE UP. THIS IS NECESSARY BECAUSE A FREE SPACE IS PROVIDED TO ALLOW THE AIR CUSHION TO EXPAND IN THE UNLIKELY EVENT OF ACCIDENTAL DEPLOYMENT. OTHERWISE. PERSONAL INJURY MAY RESULT. 11. .Remove steering column cover. 12. Disconnect the wiring harness connectors located under the steering column. 13. Remove the combination switch assembly with SRS coil. NOTE: The SRS coil is a part of the combination switch assembly, which can not be replaced separately. Therefore, be sure not to remove the SRS coil from the combination switch assembly. 14. Remove snap ring. 15. Remove cushion rubber. 16. Remove shift lock cable (for A/T). 17. Disconnect the starter switch harness connector located under the steering column, then remove lock cylinder assembly. Page 3444 11. Using a jumper wire, connect the reference voltage of each circuit to its signal input and view the APP Sensor values in the Engine Data List. APP Sensor 1 should have a value of 99%, and APP Sensor 2 and APP Sensor 3 should each have a value of 0%. ^ If the values are not as specified, troubleshoot for high resistance on the signal input or a PCM malfunction. Repair the circuit or replace the PCM, then repeat step 3. ^ If the values are as specified, the problem may be intermittent. Disconnect the 10P connector from the modified APPS, and connect it to the new APPS; then repeat step 3. Wiggle the APPS wires as you go through the adjustment procedure to find the intermittent problem. 12. Turn off the ignition switch, and disconnect the PGM Tester.* DISCLAIMER Locations Brake Light Switch: Locations Below Left Side of Dash Page 4371 - Spider pin should be smooth and free from fretting or galling. Visible signs of needle presence is normal, but wear should not be felt. - Preload of the universal joint. Preload should be 0 to 24.9 kg (0 to 11.3 lbs.). Joints should rotate smoothly and freely and should exhibit no rough or ratchety movement. - Inspect splines for wear. The nylon-coated spline should be free from nicks and dings and the underlying steel spline should not be visible. After cleaning the nylon coating spline, the coating should exhibit only slight indicator of wear. Grease volume is approximately 10 grams of grease in total. Grease should be evenly applied to both the female and the male slip splines using a small brush. After assembly of the slip joint, the sliding joint should be fully worked from the full collapsed to the full extended position. - Aluminum tube type only: Inspect the aluminum tubing for surface scratches and dents. These scratches may not exceed 0.2 mm (0.008 inch) in depth. - Aluminum tube type only: Visually inspect the circle welds and fittings for any signs of cracks or signs of deterioration. If there are any cracks that exceed 0.2 mm (0.008 inch) in depth, the assembly must be replaced. - Aluminum tube type only: Check to be sure there are no missing balance weights. If balance weights are missing and void has occurred in the aluminum tubing greater than 0.2 mm (0.008 inch), the assembly must be replaced. UNIVERSAL JOINT REASSEMBLY 1. Pack the four grease cavities of the spider with a high quality, extreme pressure N.L.G.I. Grade 2 grease. Do not add additional grease to bearing cup assembly. 2. Move one end of the spider to cause a trunnion to project through the spider hole beyond the outer machined face of the yoke lug. Place a bearing over the trunnion diameter and align it to the spider hole. Using an arbor press, hold the trunnion in alignment with the spider hole and place a solid plug on the upper bearing. Press the bearing into the spider hole enough to install snap ring. 3. Install a snap ring. NOTE: Be sure the snap rings are properly seated in the grooves. 4. Repeat steps 2 and 3 to install the opposite bearing. If the joint is stiff, strike the yoke ears with a soft hammer to seat the bearing. 5. Align the setting marks and join the yokes. Page 7106 Heated Element: Description and Operation Voltage is applied at all times through fuse 19 to the rear window defogger relay coil. With the ignition switch in ON, voltage is applied through fuse 16 to the rear window defogger relay contacts. When you depress the rear window defogger switch, the ECM or PCM receives a ground input from the switch and, in turn, the ECM or PCM provides ground to the coils of the rear window defogger relay. The contacts close, applying ignition voltage to the rear window defogger, rear window defogger indicator light (through fuses 9 and 10), and the left and right power mirror defoggers (through fuse 8). The ECM or PCM acts as the timer for the rear window defogger relay and keeps the contacts closed, thus maintaining the operation of the rear window defogger, left and right mirror defoggers, and indicator light for 10 minutes or until the ignition switch is turned to "ACC" or "OFF", or the rear window defogger switch is depressed again. The rear window and mirrors heat to remove any fog from the glass and the indicator stays on to remind the driver that it is in use. Page 5922 Splices Splices are shown as a dot. Their location and the number of wires may vary depending on the harness manufacturer. Switches Switches These switches move together; the broken straight line between them means they are mechanically connected. Other types of switches are controlled by a coil or a solid state circuit. Unless otherwise noted, all switches are shown in their normal (rest) position, with power off. Terminal "T" Page 3566 Ion Sensing Module: Diagnostic Aids Before Troubleshooting Before Troubleshooting See: Service Precautions/Vehicle Damage Warnings/Tips and Precautions 1. Check applicable fuses in the appropriate fuse/relay box. 2. Check the battery for damage, state of charge, and clean and tight connections. CAUTION: Do not quick-charge a battery unless the battery ground cable has been disconnected, otherwise you will damage the alternator diodes. - Do not attempt to crank the engine with the battery ground cable loosely connected or you will severely damage the wiring. While You're Working 1. Make sure connectors are clean, and have no loose terminals or receptacles. 2. Make sure that connectors without wire seals are packed with dielectric (silicone) grease. Part Number: 08798-9001. 3. When connecting a connector, push it until it "clicks" into place. CAUTION: Do not pull on the wires when disconnecting a connector. Pull only on the connector housings. - Most circuits include solid-state devices. Test the voltages in these circuits only with a 10-megaohm or higher impedance digital multi meter. Never use a test light or analog meter on circuits that contain solid-state devices. Damage to the devices may result. Five-Step Troubleshooting 1. Verify The Complaint Turn on all the components in the problem circuit to check the accuracy of the customer complaint. Note the symptoms. Do not begin disassembly or testing until you have narrowed down the problem area. 2. Analyze The Schematic Look up the schematic for the problem circuit. Determine how the circuit is supposed to work by tracing the current paths from the power source through the circuit components to ground. Also, trace circuits that share wiring with the problem circuit. The names of circuits that share the same fuse, ground, or switch, and so on, are referred to in each circuit schematic. Try to operate any shared circuits you didn't check in step 1. If the shared circuits work, the shared wiring is OK, and the cause must be in the wiring used only by the problem circuit. If several circuits fail at the same time, the fuse or ground is a likely cause. Based on the symptoms and your understanding of the circuit's operation, identify one or more possible causes. 3. Isolate The Problem By Testing The Circuit Make circuit tests to check the diagnosis you made in step 2. Keep in mind that a logical, simple procedure is the key to efficient troubleshooting. Test for the most likely cause of failure first. Try to make tests at points that are easily accessible. 4. Fix The Problem Once the specific problem is identified, make the repair. Be sure to use proper tools and safe procedures. 5. Make Sure The Circuit Works Turn on all components in the repaired circuit in all modes to make sure you've fixed the entire problem. If the problem was a blown fuse, be sure to test all of the circuits on that fuse. Make sure no new problems turn up and the original problem does not recur. Service and Repair Dome Lamp Bulb: Service and Repair Removal 1. Disconnect the battery ground cable. 2. Remove the lens (2). 3. Remove the bulb (1). - Pull out the bulb. Installation To install, follow the removal steps in the reverse order. Page 8187 To install, follow the removal steps in the reverse order, noting the following points: 1. Install the regulator handle as shown in the figure, if equipped without power windows. 2. Check to see that the window regulator operates smoothly and the glass opens and closes properly. 3. Install the waterproof sheet tightly against the door panel. Page 1255 Refrigerant Oil: Service and Repair Compressor Oil Check Compressor Oil Check The oil used to lubricate the compressor is circulating with the refrigerant. Whenever replacing any component of the system or a large amount of gas leakage occurs, add oil to maintain the original amount of oil. Oil Capacity Capacity total in system: 150 cc (5.0 fl.oz) Compressor (Service parts) charging amount: 150 cc (5.0 fl.oz) Procedures Spare Tire Carrier: Procedures Spare Tire Carrier Parts Location Removal 1. Remove the spare tire. 2. Remove the spare tire carrier by using spare tire carrier nut wrench J-34355. Installation 1. Spare tire carrier. - Tighten the carrier fixing bolts to the specified torque. Torque : 31 Nm (23 lb.ft) 2. Spare tire. - Tighten the spare tire fixing bolts to the specified torque. Torque: 118 Nm(87 lb.ft) Page 5989 and the fuses. From Fuses to Relays and Components The second half of Power Distribution shows the wiring "From Fuses to Relays and Components." This can speed your troubleshooting by showing which circuits share fuses. If Power Distribution shows that an inoperative circuit and another circuit share a fuse, check a component in the other circuit. If it works, you know the fuse is good and power is available to the inoperative circuit. Ground Distribution Schematics Locations Seat Belt Cross Bar Assembly And Associated Parts Page 3450 6. Remove the connector position assurance (CPA) clip from the APPS connector. 7. Disconnect the 10 P connector from the APPS. 8. Remove the bolts, the APPS, the spacer, and the accelerator link from the accelerator pedal assembly. 9. Separate the spacer from the APPS. Clean the grease off the spacer and the accelerator link with a clean shop towel. 10. Clean the terminals of the 10 P APPS connector (harness side) with contact cleaner. Shake the residue out of the connector, and allow the contact cleaner to evaporate for at least 3 minutes before reconnecting the connector. 11. Install a new APPS, the spacer, and the accelerator link onto the accelerator pedal assembly. Leave the mounting screws loose so the sensor can be adjusted. 12. Connect the 10 P connector to the new APPS, and lock the connector in place with the CPA. 13. Connect the PGM Tester to the data link connector (DLC), and turn the ignition switch to ON (II). Locations Transmission Position Switch/Sensor: Locations Left Side Of Automatic Transmission Page 7727 Part 2 Of 2 Page 6807 Front Door Exterior Handle: Service and Repair Removal 1. Disconnect the battery ground cable. 2. Remove the door trim panel. 3. Remove the waterproof sheet. - Taking notice of the door harness, peel the waterproof sheet off the door panel carefully. 4. Disconnect the locking links and remove the outside handle. 5. Remove the fixing clip to remove the door lock cylinder. Installation To install, follow the removal steps in the reverse order, noting the following points: 1. Be sure to install the door lock cylinder at a right angle to the outside handle. 2. Check for smooth outside handle and lock cylinder operation. 3. Tighten the outside handle fixing bolts to the specified torque. Torque 9 Nm (78 lb in) Case Adapter Oil Seal Seals and Gaskets: Service and Repair Case Adapter Oil Seal Case Adapter Oil Seal REMOVAL 1. Remove transfer case assembly from the vehicle (4x4). 2. Remove rear oil seal from transmission extension housing. INSTALLATION 1. Use J-36797 extension housing oil seal installer, and install the rear oil seal to the transmission extension housing. 2. Install the transfer case assembly to the vehicle (4x4). Diagram Information and Instructions Key Reminder Switch: Diagram Information and Instructions How to Identify Wiring Color-Coded Insulation Wire Color Wire Color Coding Page 5364 Specifications Engine Oil Pressure: Specifications Oil Pressure 392-550 kPa at 3000 rpm Page 3609 Camshaft Position Sensor: Testing and Inspection 1. Inspect the sensor O-ring for cracks or leaks. 2. Replace the O-ring if it is worn or damaged. 3. Lubricate the new O-ring with engine oil. 4. Install the lubricated O-ring. Tires - Tubless Tire Repair Information Tires: All Technical Service Bulletins Tires - Tubless Tire Repair Information 06-082 December 15, 2006 Applies To: ALL Tubeless Tire Repair Information This service bulletin provides the resource information required to repair tubeless tires on Honda automobiles and light trucks. To properly repair a tire, follow the Rubber Manufacturers Association (RMA) "Puncture Repair Procedures for Passenger and Light Truck Tires" outlined on the RMA wall poster. One wall poster has been provided to your dealership. Additional posters can be ordered through Helm, the RMA website, www.rma.org, or the tire manufacturers. Michelin(R) PAX System(TM), tires can be repaired using the same repair procedures described on the RMA poster. Whenever you repair a PAX System tire, you must inspect the support ring. Refer to the PAX System support ring section of this service bulletin for inspection procedures. WARRANTY CLAIM INFORMATION Refer to the tire manufacturer for warranty information. REQUIRED MATERIALS ^ 1/8 inch Patch-plug with lead wire ^ 1/4 inch Patch-plug with lead wire ^ 1/8 inch Plugs (stem)* ^ 1/4 inch Plugs (stem)* ^ 1/4 inch Patches* ^ 3/4 inch Patches* ^ Chemical cement ^ Liquid buffer ^ Rim-bead sealer ^ Inner liner sealer REQUIRED TOOLS ^ Tire stitcher, 1-1/2 inch wheel ^ Tire crayons ^ Tire test tank ^ Awl or probe ^ Flexible blade skiving knife ^ 1/8 inch Carbide tire tool with adapter ^ 1/4 inch Carbide tire tool with adapter ^ Low speed buffer with quick release chuck and exhaust hose ^ Carbide buffing wheel with adapter Page 2114 Camshaft Position Sensor: Service and Repair REMOVAL PROCEDURE 1. Disconnect the negative battery cable. 2. Remove the engine cover. 3. Remove the common chamber assembly. 4. Disconnect the electrical connector to the CMP sensor. 5. Remove the CMP retaining bolt from the side of left cylinder head. 6. Remove the CMP sensor from the cylinder head. INSTALLATION PROCEDURE 1. Install the CMP sensor in the cylinder head. 2. Install the CMP sensor retaining bolt. Tighten Tighten the retaining screw to 9 N.m (78 lb in.). Page 3543 2. Connect battery ground cable. Page 5212 Wire Color Abbreviations The following abbreviations are used to identify wire colors in the circuit schematics: WHT................................... White YEL................................... Yellow BLK................................... Black BLU................................... Blue GRN................................... Green RED................................... Red ORN................................... Orange PNK................................... Pink BRN................................... Brown GRY................................... Gray PUR................................... Purple LT BLU................................... Light Blue LT GRN................................... Light Green Page 3222 Page 2511 Ground - "G" Shielding Sheilding This represents RFI (Radio Frequency Interference) shielding around a wire. The shielding is always connected to ground. Splices Page 6113 The name of the component appears next to it followed by notes about its function along with any photo and connector view references. Connector "C" How to Identify Connector Terminals Cavity Numbering System The cavities (and wire terminals) in each connector are numbered starting from the upper left, looking at the male terminals from the terminal side (or looking at the female terminals from the wire side. Both views are in the same direction so the numbers are the same.) All actual cavities are numbered, even if they have no wire terminals in them. NOTE: Data Link Connector (DLC) terminals are numbered according to SAE standard J1962, not the Honda standard. The numbers of the four end terminals are molded into the corners of the connector face. Locations Intake Air Temperature Sensor: Locations 26. Left Front of Engine Left Front Of Engine Page 6533 Seat Belt Buckle: Service and Repair Rear Seat Belt Buckle Rear Center Seat Belt and Rear Bu Rear Center Seat Belt / Buckle Assembly And Associated Parts REMOVAL 1. Remove the seat lock cover (SWB). 2. Remove the rear cushion frame assembly (LWB). - Refer to Rear Seat Assembly in Seats. 3. Remove the rear seat lock assembly and rear seat belt buckle assembly. INSTALLATION To install, follow the removal steps in the reverse order, noting the following point. Tighten the rear seat lock assembly and rear seat belt buckle assembly fixing bolts to the specified torque. Torque: 39 N.m (29 lb.ft) NOTE: Removal and installation procedure of rear center seat belt assembly same as rear seat belt buckle assembly procedures. Page 652 Fuel Tank Pressure Sensor: Service and Repair REMOVAL PROCEDURE 1. Remove the fuel pump assembly. Refer to Fuel Tank. 2. Carefully pry the fuel tank pressure sensor out of the top of the fuel pump assembly. INSTALLATION PROCEDURE 1. Install the rubber grommet on the fuel pump assembly. 2. Install the fuel tank vapor pressure sensor on the fuel pump assembly. 3. Insert the sensor nipple firmly into the grommet. 4. Keep twisting and pushing the sensor until the wide portion of the nipple shows on the other side of the grommet. 5. Install the fuel pump assembly on the fuel tank. Page 3230 Steps 10 - 11 Test Description Number(s) below refer to the step number(s) on the Diagnostic Chart: 2. Relieve the fuel pressure by connecting the J 34730-1 Fuel Pressure Gauge to the fuel pressure connection on the fuel rail. CAUTION: In order to reduce the risk of fire and personal injury, wrap a shop towel around the fuel pressure connection. The towel will absorb any fuel leakage that occurs during the connection of the fuel pressure gauge. Place the towel in an approved container when the connection of the fuel pressure gauge is complete. Place the fuel pressure gauge bleed hose in an approved gasoline container. With the ignition switch "OFF," open the valve on the fuel pressure gauge. Injector Specifications 3. Record the lowest voltage displayed by the DVM after the first second of the test. (During the first second, voltage displayed by the DVM may be inaccurate due to the initial current surge.) Injector Specifications: The voltage displayed by the DVM should be within the specified range. - The voltage displayed by the DVM may increase throughout the test as the fuel injector windings warm and the resistance of the fuel injector windings changes. - An erratic voltage reading (large fluctuations in voltage that do not stabilize) indicates an intermittent connection within the fuel injector. 5. Injector Specifications: 7. The Fuel Injector Balance Test portion of this chart (Step 7 through Step 11) checks the mechanical (fuel delivery) portion of the fuel injector. An engine cool-down period of 10 minutes is necessary in order to avoid irregular fuel pressure readings due to Hot Soak" fuel boiling. Page 5916 the component if the component only has one connector, or by a capital letter (A, B, C, etc.) if the component has more than one connector. Below most connector numbers and component names are PHOTO and VIEW numbers. The PHOTO number refers to a photo in the back of the book that shows the connector's location on the car. The VIEW number refers to an illustration in the back of the book that shows the connector face, wire colors, connector cavity numbers, and other details. The connector cavity numbering sequence begins at the top left corner of the connector. Disregard any numbers molded into the connector housing. Wires Wires are identified by the abbreviated names of their colors; the second color is the color of the stripe. Wires are also identified by their location in a connector. The number "2" next to the male and female wire terminals at C416, for example, means those terminals join in cavity 2 of connector C416. Symbols A complete description of schematic symbols is given under wire color abbreviation. Power Distribution Schematics Power Distribution schematics show how power is supplied from the positive battery terminal to various circuits in the car. Refer to the Power Distribution section to get a more detailed picture of how power is supplied to the circuit you're working on. From Battery to Ignition Switch, Fuses, and Relays Individual circuit schematics begin with a fuse. The first half of Power Distribution, however, shows the wiring "upstream" between the battery SRS Operation Air Bag(s) Arming and Disarming: Description and Operation SRS Operation The SRS is a safety device which, when used in conjunction with the seat belt, is designed to help protect the driver (and front passenger) in a frontal impact exceeding a certain set limit. The system consists of the SRS unit (including safing sensor and impact sensor), the cable reel, the driver's airbag (and front passenger's airbag). Operation The main circuit in the SRS unit senses and judges the force of impact and, if necessary, ignites the inflator charge(s). If battery voltage is too low or power is disconnected due to the impact, the voltage regulator and the back-up power circuit respectively will keep voltage at a constant level. For the SRS to operate: 1. The impact sensor must activate, and send electric signals to the microprocessor. 2. The microprocessor must compute the signals, and must send signals to the airbag inflator(s). 3. The inflator(s) must ignite and deploy the airbag(s). Self-diagnosis System A self-diagnosis circuit is built into the SRS unit; when the ignition switch is turned ON (II), the SRS indicator light comes on and goes off after about six seconds if the system is operating normally. If the light does not come on, or does not go off after six seconds, or if it comes on while driving, it indicates an abnormality in the system. The system must be inspected and repaired as soon as possible. For better serviceability, the memory will store the cause of the malfunction, and the data link circuit passes on the information from the memory to the data link connector (DLC). This information can be read with the Honda PGM Tester connected to the DLC (16P). Page 7393 2. Connect the short finder across the battery terminals and the load (component) side of the fuse terminal. 3. Close all switches in the circuit you're testing. 4. Turn on the short finder. This creates a pulsing magnetic field around the wiring between the fuse box and the short. 5. Beginning at the fuse box, slowly move the short finder along the circuit wiring. The meter will read current pulses through sheet metal and body trim. As long as the meter is between the fuse and the short, the needle will move with each current pulse. Once you move the meter past the point of the short, the needle will stop moving. Check the wiring and connectors in this area to locate the cause of the short. Testing For Continuity When testing for continuity at a connector without wire seals, you do not have to separate the two halves of the connector. Instead, probe the connector from the back. Always check both sides of the connector because dirty, corroded, and bent terminals can cause problems (no electrical contact = an open). 1. Disconnect the negative cable from the car battery. If you're using a DVOM, place it in the lowest "OHMS" range. Page 2852 Air Flow Meter/Sensor: Service and Repair Mass Air Flow (MAF) Sensor REMOVAL PROCEDURE 1. Disconnect the negative battery cable. 2. Disconnect the electrical connector from the MAF sensor. 3. Loosen the clamps which secure the intake air duct and the air cleaner to the MAF sensor. 4. Remove the intake air duct from the MAF sensor. 5. Remove the MAF sensor from the air cleaner. INSTALLATION PROCEDURE Page 207 Ground - "G" Shielding Sheilding This represents RFI (Radio Frequency Interference) shielding around a wire. The shielding is always connected to ground. Splices Description and Operation Acceleration/Deceleration Sensor: Description and Operation DESCRIPTION/OPERATION The G-sensor installed inside the EHCU detects the vehicle deceleration speed and sends a signal to the EHCU. In 4WD operation, all four wheels may be decelerated in almost the same phase, since all wheels are connected mechanically. This tendency is noticeable particularly on roads with low friction coefficient, and the ABS control is adversely affected. The G-sensor judges whether the friction coefficient of road surface is low or high, and changes the EHCU's operating system to ensure ABS control. Page 6188 Heater Control Valve Cable: Technical Service Bulletins A/C - Heater Blows Cold Air, A/C Blows Warm Air SOURCE: Honda Service News TITLE: Heater Blows Cold Air, A/C Blows Warm Air APPLIES TO: all A/C-equipped Honda models that use a heater valve cable. SERVICE TIP: Got a vehicle in your shop that blows cold air from the heater or warm air from the A/C ? The problem could just be the heater valve cable has slipped off the heater valve arm. There's a real easy fix for this problem. Slip the heater valve cable back onto the heater valve arm. Then cut yourself a 10 mm length of 3.5 mm vacuum hose and slide it onto the arm. This holds the cable on the arm nice and snug so it won't slip off. Diagrams Page 5167 Check for continuity between commutator and shaft. Also, check for continuity between commutator and armature core,armature core and shaft. Replace commutator if there is continuity (i.e., internally grounded). Measure runout of armature core and commutator with a dial gauge. Repair or replace, if it exceeds the limit. Armature Standard: 0.05 mm (0.002 in) Max. Limit: 0.10 mm (0.004 in) Commutator Standard: 0.05 mm (0.002 in) Max. Limit: 0.10 mm (0.004 in) Page 7136 Sunroof / Moonroof Module: Service and Repair Removal 1. Disconnect the battery ground cable. 2. Remove the headlining (2). 3. Remove the sunroof control unit (1). - Disconnect two connectors. - Remove two screws. Installation To install, follow the removal steps in the reverse order. Page 6125 2. Connect the short finder across the battery terminals and the load (component) side of the fuse terminal. 3. Close all switches in the circuit you're testing. 4. Turn on the short finder. This creates a pulsing magnetic field around the wiring between the fuse box and the short. 5. Beginning at the fuse box, slowly move the short finder along the circuit wiring. The meter will read current pulses through sheet metal and body trim. As long as the meter is between the fuse and the short, the needle will move with each current pulse. Once you move the meter past the point of the short, the needle will stop moving. Check the wiring and connectors in this area to locate the cause of the short. Testing For Continuity When testing for continuity at a connector without wire seals, you do not have to separate the two halves of the connector. Instead, probe the connector from the back. Always check both sides of the connector because dirty, corroded, and bent terminals can cause problems (no electrical contact = an open). 1. Disconnect the negative cable from the car battery. If you're using a DVOM, place it in the lowest "OHMS" range. Page 8090 Vanity Lamp: Service and Repair Removal 1. Disconnect the battery ground cable. 2. Remove the lens (1). 3. Remove the bulb (2). - Attach some scotch tape to the bulb and pull it out. Installation To install, follow the removal steps in the reverse order. Page 1465 clearance exceeds the specified limit, the connecting rod must be replaced. Standard: 0.16 mm 0.35 mm (0.0063 inch - 0.0138 inch) Limit: 0.40 mm (0.0157 inch) 3. Measure the oil clearance between the connecting rod and the crankshaft. 1. Remove the connecting rod cap nuts and the rod caps (12). Arrange the removed rod Gaps in the cylinder number order. 2. Clean the rod bearings and the crankshaft pins. 3. Carefully check the rod bearings. If even one bearing is found to be damaged or badly worn, the entire bearing assembly must be replaced as a set. Reinstall the bearings in their original positions. Apply plastogene to the crank pin. 4. Reinstall the rod caps (12) to their original positions. Tighten the rod cap nuts. Torque: 54 Nm (40 ft. lbs.) Note: Do not allow the crankshaft to rotate. 5. Remove the rod caps. 6. Measure the width of the plastogene and determine the oil clearance. If the oil clearance exceeds the limit, replace the rod bearing as a set. Standard: 0.019 mm - 0.043 mm (0.0007 inch - 0.0017 inch) Limit: 0.08 mm (0.0031 inch) 7. Clean the plastogene from the bearings and the crankshaft pins. Con-rod Bearing Selection Select and install the new connecting rod bearings, paying close attention to the connecting rod big end diameter size mark (1). Locations Canister Purge Control Valve: Locations Top Front of Engine (Intake Duct Removed) Page 2498 Compact Disc Player (CD): Diagrams Page 3707 Wires Wire insulation can be one color, or one color with another color stripe. (The second color is the stripe.) This circuit continues on another image. (The arrow shows direction of current flow.) To follow the RED/BLK wire in this example, you would turn to "Fuel and Emissions" and look for the "A" arrow. Accelerator Pedal Assembly/Sensor - Adjustment Update Accelerator Pedal: Technical Service Bulletins Accelerator Pedal Assembly/Sensor - Adjustment Update 00-045 August 14, 2001 Applies To: 2000-02 Passport - ALL Service Manual Update: Accelerator Pedal Position Sensor (APPS) (Supersedes 00-045, dated May 23, 2000) Updated information is shown by asterisks and black bars. BACKGROUND When the accelerator pedal position sensor (APPS) or the accelerator pedal assembly is replaced for any reason, you must adjust the APPS. *This procedure is missing in the 2000 service manual and is wrong in the 2001 and 2002 service manuals. Make a note on page 6E2-539 of the 2000 Passport Fuel and Emissions manual, on page 6E2-553 of the 2001 Passport Fuel and Emissions manual, and on page 6E2-545 of the 2002 Passport Fuel and Emissions manual to refer to this bulletin.* ADJUSTMENT PROCEDURE 1. Replace the APPS or the accelerator pedal assembly, and leave the mounting screws for the APPS loose. 2. Connect the PGM Tester to the data link connector (DLC), and turn the ignition switch to ON (II). *3. While watching the APP Sensor values in the Engine Data List, adjust the APPS by turning it until the values are within the ranges shown at closed pushed all the way down), then tighten the throttle and wide open throttle (accelerator pedal mounting screws and recheck the values. ^ If all three sensors are within range, go to step 12. ^ If APP Sensor 1, APP Sensor 2, and/or APP Sensor 3 cannot be brought into range, go to step 4. 4. Troubleshoot for an open circuit or a PCM malfunction. ^ If APP Sensor 1 has a value of 0% or APP Sensor 2 and/or APP Sensor 3 have a value of 99%, an open circuit exists or the PCM is malfunctioning. Repair the circuit or replace the PCM, and repeat step 3. ^ If you don't find a problem, go to step 5. 5. Disconnect the 10P connector from the APPS. 6. View the APP Sensor values in the Engine Data List. ^ If APP Sensor 1 has a value of 0% or APP Sensor 2 and/or APP Sensor 3 have a value of 99%, go to step 7. ^ If APP Sensor 1 has a value other than 0%, or APP Sensor 2 and/or APP Sensor 3 have a value other than 99%, a short circuit exists or the PCM is malfunctioning. Repair the circuit or replace the PCM, and repeat step 3. Page 6180 Expansion Valve: Service and Repair Electronic Thermostat, Evaporator Core and/or Expansion Valve Electronic Thermostat, Evaporator Core And/Or Expansion Valve - Disassembled View Removal 1. Disconnect the battery ground cable. 2. Discharge and recover refrigerant. 3. Remove evaporator assembly. 4. Remove the electronic thermostat sensor fixing clip. Pull the sensor from the evaporator assembly. 5. Remove clip. 6. Remove attaching screw. 7. Remove upper case. Page 2948 Throttle Position Sensor: Service and Repair REMOVAL PROCEDURE 1. Disconnect the negative battery cable. 2. Disconnect the TPS electrical connector. 3. Remove the bolts and the TP sensor from the throttle body. NOTE: Do not clean the TP sensor by soaking it in solvent. The sensor will be damaged as a result. INSTALLATION PROCEDURE 1. Install the TP sensor on the throttle body with the bolts. 2. Connect the TP electrical connector. 3. Install the negative battery cable. Page 989 NOTE: Do this repair procedure if, after doing step 10 of the test-drive, the vehicle pulled in the opposite direction after you swapped the front tires. 1. Swap wheels 2 and 4 on the passenger's side of the vehicle, and test-drive again. ^ If the pull goes away, replace the tire on wheel 2, then go to step 3. ^ If the pull does not go away, put wheels 2 and 4 back to their original positions, and go to step 2. 2. Swap wheels 1 and 3 on the driver's side of the vehicle, and test-drive again. ^ If the pull goes away, replace the tire on wheel 1, then go to step 3. ^ If the pull does not go away, use a known-good tire in position 1 and continue diagnosis. 3. Use your diagnosis worksheet to fill in the following table and build your 15-digit DTC. REPAIR PROCEDURE B Page 492 The name of the component appears next to it followed by notes about its function along with any photo and connector view references. Connector "C" How to Identify Connector Terminals Cavity Numbering System The cavities (and wire terminals) in each connector are numbered starting from the upper left, looking at the male terminals from the terminal side (or looking at the female terminals from the wire side. Both views are in the same direction so the numbers are the same.) All actual cavities are numbered, even if they have no wire terminals in them. NOTE: Data Link Connector (DLC) terminals are numbered according to SAE standard J1962, not the Honda standard. The numbers of the four end terminals are molded into the corners of the connector face. Page 4322 - Remove the bushings using a remover J-39378-1 and hammer. - By using installer J-39378-2 and base J-39378-3 press fit the bushings into the bracket. REASSEMBLY 1. Install DOJ case to bracket. 2. Install oil seal and fix snap ring. 3. Install bearing and fix snap ring. 4. Install bracket to axle case. Tighten the bracket bolt to the specified torque. Torque: 116 Nm (85 Ft. lbs.) 5. Apply 150 g of the specified grease in BJ. 6. Install dust seal. 7. Apply a thin coat of grease to the shaft for smooth installation then install bellows. 8. Install band. Note the setting direction. After installation, check that the bellows is free from distortion. 9. Install another bellows and fix band. 10. Install the ball guide with the smaller diameter side ahead onto the shaft. 11. Install ball retainer. Page 3673 4WD Motor Actuator: Connector Locations Beneath Center of Vehicle, on Transfer Case (A/T) Page 8027 2. Connect the short finder across the battery terminals and the load (component) side of the fuse terminal. 3. Close all switches in the circuit you're testing. 4. Turn on the short finder. This creates a pulsing magnetic field around the wiring between the fuse box and the short. 5. Beginning at the fuse box, slowly move the short finder along the circuit wiring. The meter will read current pulses through sheet metal and body trim. As long as the meter is between the fuse and the short, the needle will move with each current pulse. Once you move the meter past the point of the short, the needle will stop moving. Check the wiring and connectors in this area to locate the cause of the short. Testing For Continuity When testing for continuity at a connector without wire seals, you do not have to separate the two halves of the connector. Instead, probe the connector from the back. Always check both sides of the connector because dirty, corroded, and bent terminals can cause problems (no electrical contact = an open). 1. Disconnect the negative cable from the car battery. If you're using a DVOM, place it in the lowest "OHMS" range. Page 5812 - Disc - Caliper - Shift on the fly system parts (Cap, Hub flange, Shim, Snap ring) - ABS sensor ring For inspection and servicing of disc caliper and related parts, refer to Brakes and Traction Control; Brakes; Disc Brake System. REASSEMBLY 1. Install wheel pin. - Place the hub on a wood workbench or a block of wood approx. 6" by 6" to protect the wheel stud ends and threads. - Insert a wheel stud using a hammer. Be sure the wheel stud is started squarely and seats completely. 2. Align scribe marks (1) and attach the hub to the disc, then tighten the bolts to the specified torque. Torque: 103 Nm (76 ft. lbs.) 3. Use installer J-36829 and grip J-8092, then install the inner bearing by driving it into the hub. Page 2120 Coolant Temperature Sensor/Switch (For Computer): Service and Repair ENGINE COOLANT TEMPERATURE (ECT) SENSOR REMOVAL PROCEDURE NOTE: Care must be taken when handling the engine coolant temperature (ECT) sensor. Damage to the ECT sensor will affect proper operation of the fuel injection system. 1. Disconnect the negative battery cable. 2. Drain the radiator coolant. Refer to Draining and Refilling Cooling System. 3. Disconnect the electrical connector. 4. Remove the ECT sensor from the coolant crossover. INSTALLATION PROCEDURE 1. Apply sealer or the equivalent to the threads of the ECT sensor. 2. Install the ECT sensor in the coolant crossover. Tighten Tighten the ECT sensor to 30 N.m (22 lb ft.). Locations Electronic Thermostat, Evaporator Core And/Or Expansion Valve - Disassembled View Front Wheel Speed Sensor: Service and Repair Front REMOVAL 1. Remove speed sensor connector. 2. Remove sensor cable fixing bolt (Upper side). 3. Remove sensor cable! fixing bolt (Lower side). 4. Remove the speed sensor cable fixing bolt. 5. Remove speed sensor. INSTALLATION 1. Install speed sensor and take care not to hit the speed sensor pole piece during installation. 2. Install speed sensor fixing bolt and tighten the fixing bolt to the specified torque. Torque: 11 Nm (95 inch lbs.) 3. Install speed sensor cable fixing bolt (Lower side) and tighten the fixing bolt to the specified torque. Torque: 24 Nm (18 ft. lbs.) 4. Install speed sensor cable fixing bolt (Upper side) and tighten the fixing bolt to the specified torque. Torque: 6 Nm (52 ft. lbs.) Page 5412 12. Test-drive your customer¡C■s vehicle on the same road you used earlier. - If the drift is now within spec, swap the tires back to the donor vehicle one at a time, and test-drive your customer¡C■s vehicle on the same road you used earlier. Do this until the drift comes back. Replace the bad tire(s), then return the vehicle to your customer. - If the drift is still out of spec using the donor vehicle tires, contact Tech Line for further action. Page 6004 2. Connect one lead of a self-powered test light or DVOM to one end of the part of the circuit you want to test. 3. Connect the other lead to the other end. 4. If the self-powered test light glows, there is continuity. If you're using a DVOM, a low reading or no reading (zero), means good continuity. Testing For Voltage When testing for voltage at a connector without wire seals, you do not have to separate the two halves of the connector. Instead, probe the connector from the back. Always check both sides of the connector because dirty, corroded, and bent terminals can cause problems (no electrical contact = an open). 1. Connect one lead of the lest light to a known good ground, or, if you're using a digital volt ohmmeter (DVOM), place it in the appropriate DC volts range, and connect its negative lead to ground. 2. Connect the other lead of the test light or DVOM to the point you want to check. 3. If the test light glows, there is voltage present. If you're using a DVOM, note the voltage reading. It should be within one volt of measured battery voltage. A loss of more than one volt indicates a problem. NOTE: Always use a DVOM on high impedance circuits. A test light may not glow (even with battery voltage present). Testing For Voltage Drop Wires, connectors, and switches are designed to conduct current with a minimum loss of voltage. A voltage drop of more than one volt indicates a problem. 1. Place the digital volt/ohmmeter (DVOM) in the appropriate DC volts range. Connect the positive lead to the end of the wire (or to the connector or switch) closest to the battery. 2. Connect the negative lead to the other end of the wire (or the other side of the connector or switch). 3. Turn on the components in the circuit. 4. The DVOM will show the difference in voltage between the two points. A difference, or drop, of more than one volt indicates a problem. Check the circuit for loose, dirty, or bent terminals. Page 7443 Wire Color Abbreviations The following abbreviations are used to identify wire colors in the circuit schematics: WHT................................... White YEL................................... Yellow BLK................................... Black BLU................................... Blue GRN................................... Green RED................................... Red ORN................................... Orange PNK................................... Pink BRN................................... Brown GRY................................... Gray PUR................................... Purple LT BLU................................... Light Blue LT GRN................................... Light Green Specifications Axle Nut: Specifications 1. Tighten the hub nut to 29 Nm (22 lb. ft.), then fully loosen the nut. 2. Tighten the hub nut to the value given below, using a spring scale on the wheel pin. New Bearing and New Oil Seal Bearing Preload: 20 N - 25 N (4.4 lb. - 5.5 lb.) Used Bearing New Oil Seal Bearing Preload: 12 N - 18 N (2.6 lb. - 4.0 lb.) If the measured bearing preload is outside the specificatoins, adjust it by loosening or tightening the bearing nut. Front Door Trim Panel Trim Panel: Service and Repair Front Door Trim Panel Removal 1. Disconnect the battery ground cable. 2. Remove the door mirror assembly. 3. Remove the regulator handle (1). - Pull the hook (2) out and remove the regulator handle. 4. Remove the power window switch (1). - Pry the power window switch out and disconnect the switch connector. 5. Remove the speaker cover. 6. Remove the front speaker. - Remove the front speaker fixing screws in order to disconnect the speaker connector. Page 1314 Page 4864 Wire Color Abbreviations The following abbreviations are used to identify wire colors in the circuit schematics: WHT................................... White YEL................................... Yellow BLK................................... Black BLU................................... Blue GRN................................... Green RED................................... Red ORN................................... Orange PNK................................... Pink BRN................................... Brown GRY................................... Gray PUR................................... Purple LT BLU................................... Light Blue LT GRN................................... Light Green Page 4995 Hydraulic Control Assembly - Antilock Brakes: Service and Repair Disassembly and Reassembly HYDRAULIC CONTROL UNIT DISASSEMBLY 1. Remove fixing bolts from EHCU. 2. Remove coil integrated module from hydraulic unit. REASSEMBLY To reassembly, follow the disassembly steps in the reverse order, noting the following points: Torque: Fixing bolts: 4.4 Nm (39 inch lbs.) Page 7551 Air Bag(s) Arming and Disarming: Description and Operation General Description General Description Restraint Devices The Supplemental Restraint System (SRS) helps supplement the protection offered by the driver and front passenger seat belts by deploying an air bag from the center of the steering wheel and from the top of the right side of the instrument panel. The air bag deploys when the vehicle is involved in a frontal crash of sufficient force up to 30 degrees off the centerline of the vehicle; To further absorb the crash energy there is a knee bolster located beneath the instrument panel for both the driver and passenger, and the steering column is collapsible. Page 5205 The name of the component appears next to it followed by notes about its function along with any photo and connector view references. Connector "C" How to Identify Connector Terminals Cavity Numbering System The cavities (and wire terminals) in each connector are numbered starting from the upper left, looking at the male terminals from the terminal side (or looking at the female terminals from the wire side. Both views are in the same direction so the numbers are the same.) All actual cavities are numbered, even if they have no wire terminals in them. NOTE: Data Link Connector (DLC) terminals are numbered according to SAE standard J1962, not the Honda standard. The numbers of the four end terminals are molded into the corners of the connector face. Specifications Axle Nut: Specifications 1. Tighten the hub nut to 29 Nm (22 lb. ft.), then fully loosen the nut. 2. Tighten the hub nut to the value given below, using a spring scale on the wheel pin. New Bearing and New Oil Seal Bearing Preload: 20 N - 25 N (4.4 lb. - 5.5 lb.) Used Bearing New Oil Seal Bearing Preload: 12 N - 18 N (2.6 lb. - 4.0 lb.) If the measured bearing preload is outside the specificatoins, adjust it by loosening or tightening the bearing nut. Page 4484 Wires Wire insulation can be one color, or one color with another color stripe. (The second color is the stripe.) This circuit continues on another image. (The arrow shows direction of current flow.) To follow the RED/BLK wire in this example, you would turn to "Fuel and Emissions" and look for the "A" arrow. Page 891 4. Remove the fuel pressure regulator from the fuel rail. 5. Remove the fuel return line from the regulator. 6. Install the new fuel pressure regulator in the reverse order of removal. 7. Use the Smart Cable to reprogram the PCM with the latest software from the June 2001 or later HONDANET CD-ROM. Refer to Service Bulletin 99-005, Updating the Passport PCM, filed under Tools. 8. Use the PGM Tester to clear any DTCs. 9. Use the PGM Tester to check the broadcast code. Make sure the broadcast code matches the one you selected from the CD-ROM. WARRANTY CLAIM INFORMATION In warranty: The normal warranty applies. Failed Part: P/N 8-17113-398-0 H/C 5504386 Defect Code: 092 Contention Code: C99 Skill Level: Repair Technician Out of warranty: Any repair performed after warranty expiration may be eligible for goodwill consideration by the District Service Manager or your Zone Office. You must request consideration, and get a decision, before starting work. REPAIR PROCEDURE - POWER STEERING SWITCH 1. Drain the power steering fluid out of the system. 2. Remove the power steering fluid reservoir. Clean the reservoir with solvent, then with soap and water. Rinse and dry it thoroughly. 3. Reinstall the reservoir. Do not connect the return hose. 4. Remove the power steering pressure switch, then clean it with brake cleaner and a scraper. Reinstall the switch, and torque it to 20 N.m (14 lb-ft). 5. Cover the unconnected end of the reservoir with your finger, then fill the reservoir with Dexron III ATF Page 1643 B. Properly apply a 4.5 mm (0.7 inch) wide bead of sealant (TB-1207C or equivalent) to mounting surface of crankcase. Sealant bead must be continuous. The crankcase must be installed within 5 minutes after sealant application to prevent premature hardening of sealant. C. Install crankcase, tighten crankcase fixing bolts to the specified torque. Torque: 10 Nm (89 inch lbs.) 2. Install oil pan A. Remove residual sealant, lubricant and moisture from mounting surface, then dry thoroughly. B. Properly apply a 4.5 mm (07 inch) wide bead of sealant (TB-1207C or equivalent) to mounting surface of oil pan. Sealant beat must be continuous. The crankcase must be installed within 5 minutes after sealant application to prevent premature hardening of sealant. C. Install oil pan, tighten oil pan fixing bolts to the specified torque. Torque: 10 Nm (89 inch lbs.) 3. Install starter and tighten fixing bolts. Torque: 40 Nm (30 ft. lbs.) Page 5301 Terminals - "T" Each "T" terminal (ring type) is numbered for reference and location. A "T" terminal is secured with a screw or bolt. Wires Page 4455 The wire insulation has one color or one color with another color stripe. The second color is the stripe. Page 188 3. Install the fuse and relay box cover. Page 6631 Ramsey, NJ 07446 800-433-9657 (Visteon offers an open line of credit. Call their 800 number to establish an account.) NOTE: ^ The manufacturer will repair the unit and ship it back within 5-7 working days, via UPS ground prepaid or 2nd Day Air (whichever you requested). Do not forget to include the shipping cost in your dealership payment. Units damaged by misuse or mishandling cannot be shipped back within the usual 5-7 days. ^ Each manufacturer's guarantee for the repair differs. To confirm the repair guarantee, contact the manufacturer using the phone number listed above. 10. To check on the status of your repair order, call the manufacturer. If your customer has any further questions or concerns, have them call Automobile Customer Service at 800-999-1009. NOTE: A damaged unit may need extra repair. If so, the manufacturer will call you with an estimate of any added charges. ^ If you accept the estimate, mail a dealership check for the additional amount to the manufacturer, authorize the increased amount to be applied to the credit card payment, or have the manufacturer ship the unit back to you, and you pay the difference upon arrival (C.O.D.). ^ If you reject the estimate, the faulty unit will be returned to you along with a refund. However, you will be charged $30.00 (C.O.D.) for diagnosis, shipping, and handling. The unit will be shipped back to you, via UPS Ground. COMPLETING THE OUT-OF-WARRANTY/NEW REPLACEMENT AUDIO SYSTEM COMPONENT REPAIR FORM Front Accessory Power Socket Auxiliary Power Outlet: Service and Repair Front Accessory Power Socket Removal 1. Disconnect the battery ground cable. 2. Remove the front console assembly. 3. Remove the front accessory socket (2). - Disconnect the connectors (1). - Pull out the front accessory socket from the socket cover (3). Installation To install, follow the removal steps in the reverse order, noting the following point: Page 3033 Vehicle Speed Sensor: Service and Repair REMOVAL CAUTION: The VSS is located on the right side of the transfer case just ahead of the rear propeller shaft and very close to the exhaust pipes for 4WD and on the extension cover for 2WD. Be sure that the exhaust pipes are cool enough to touch before trying to remove the VSS. If the pipes are hot, you could be burned. 1. Disconnect the negative battery cable. 2. Disconnect the VSS electrical connector. 3. Remove the bolt and the clamp securing the VSS in place. IMPORTANT: Have a container ready to catch any fluid that leaks out when the VSS is removed from the transfer case for 4WD and on the extension cover for 2WD. 4. Remove the VSS from the transfer case by wiggling it slightly and pulling it straight out. INSTALLATION 1. Install the VSS in the transfer case with the notch for the connector facing the rear. Page 3335 and the fuses. From Fuses to Relays and Components The second half of Power Distribution shows the wiring "From Fuses to Relays and Components." This can speed your troubleshooting by showing which circuits share fuses. If Power Distribution shows that an inoperative circuit and another circuit share a fuse, check a component in the other circuit. If it works, you know the fuse is good and power is available to the inoperative circuit. Ground Distribution Schematics Locations Manifold Pressure/Vacuum Sensor: Locations 24. Top Rear of Engine Top Rear Of Engine Page 3826 H/C 4408092 Defect Code: 017 Contention Code: C99 Skill Level: Repair Technician Out of warranty: Any repair performed after warranty expiration may be eligible for goodwill consideration by the District Service Manager or your Zone Office. You must request consideration, and get a decision, before starting work. DISCLAIMER Locations Brake Light Switch: Locations Below Left Side of Dash Engine - Connecting Rod Damage Information Connecting Rod: Technical Service Bulletins Engine - Connecting Rod Damage Information Why Do Connecting Rods Break? Curious why connecting rods break? Afier all, these are heavy-duty parts specifically designed to endure punishing forces and temperatures. Yet, every once in a while they do bend or break and wind up as cool conversation pieces for a coffee table or desk. Connecting rods break only after they've gotten bent. And they won't get bent unless the engine hydro-locks or the rod bearings fail. When troubleshooting a bent or broken connecting rod, here are some things to consider: ^ The number one culprit for connecting rod breakage is hydro-lock. This happens when liquid (water or fuel) entering the combustion chamber exceeds the chamber's volume. Since liquids don't compress, that extra volume in the chamber causes the rod to bend. You won't really notice anything wrong, until that bent rod finally gives out and breaks. This could happen if you're driving through deep, standing water and someone coming the other way splashes water over your hood. On very rare occasions, a bad ECM/PCM or fuel injector can cause too much fuel to enter a cylinder, causing hydro-lock and resulting in a bent rod. Before this happens, though, there are usually some kind of drive ability problems that crop up and remain afier the engine is fixed. A bent rod might not show any symptoms until it actually breaks. But bent rods leave a wider-than-normal carbon witness line in the cylinder because they're shorter. Typically, a healthy engine has a carbon line that's 6 mm deep. An engine that's suffering from bent rods has a second carbon line that's 9 to 12 mm deep. ^ Connecting rod bearings fail for a number of reasons. To properly determine what actually caused a rod bearing to fail, you've got to take apart all rod bearings and main bearings and compare them side by side. If all or most of the bearings and journals show similar damage (scoring, exposed copper, or heat discoloration) the likely cause is oil starvation, poor maintenance, customer abuse, or running the engine with an aftermarket power booster (nitrous oxide setup, supercharger, turbocharger). If only the bearing or journal for the failed rod looks bad but all the other ones look good (no scoring, no exposed copper or heat discoloration) and the crankshaft journals are smooth with no heat discoloration, then that particular bearing/ clearance would be suspect. Page 5402 DIAGNOSTIC WORKSHEET REPAIR PROCEDURE A Page 2779 The wire insulation has one color or one color with another color stripe. The second color is the stripe. Page 2230 Wires Wire insulation can be one color, or one color with another color stripe. (The second color is the stripe.) This circuit continues on another image. (The arrow shows direction of current flow.) To follow the RED/BLK wire in this example, you would turn to "Fuel and Emissions" and look for the "A" arrow. Page 1177 Coolant: Service Precautions Mixing green and red colored coolants is not recommended. Moonroof - Visor Sags in The Middle Sunroof / Moonroof Weatherstrip: Customer Interest Moonroof - Visor Sags in The Middle 00-061 August 22, 2000 Applies To: 1998-00 Passport - ALL Accessory Moonroof Visor Appearance PROBLEM The rear edge of the moonroof visor sags in the middle, and/or the roof seal is distorted. CORRECTIVE ACTION Replace the moonroof visor and the roof seal with a new assembly. PARTS INFORMATION Accessory Moonroof Visor Kit: P/N 08R01-ED1101, H/C 6483838 WARRANTY CLAIM INFORMATION In warranty: The normal warranty applies. Out of warranty: Any repair performed after warranty expiration may be eligible for goodwill consideration by the District Service Manager or your Zone Office. You must request consideration, and get a decision, before starting work. REPAIR PROCEDURE 1. Remove the moonroof visor, the roof seal, and all related hardware. 2. Install the new moonroof visor kit. Refer to the Accessory Installation Instructions binder for the installation instructions. Disclaimer Page 1531 - With J-24086-C Piston pin service set and a press, press fit the piston pin. Note: Heat the connecting rod small end to a suitable temperature to ensure smooth installation. 4. Install piston ring with the piston ring expander. The compression ring must be set with the T mark (1) facing up. Marked T: No.1 Compression ring Marked T2: No.2 Compression ring Install piston rings in the following sequence. 1. Oil ring Expander ring Upper side rail Lower side rail 2. 2nd compression ring 3. 1st compression ring - The compression rings must be set with the T or T2 mark facing up. Marked T: No. 1 Compression ring Marked T2: No.2 Compression ring Page 7729 Transmission Shift Position Indicator Lamp: Service and Repair Removal 1. Disconnect the battery ground cable. 2. Remove the console assembly. - Remove four screws. 3. Remove the bulb (1). - Turn the bulb socket counterclockwise. - Pull out the bulb from the socket. Installation To install, follow the removal steps in the reverse order. Service and Repair Transmission Temperature Sensor/Switch: Service and Repair REMOVAL 1. Raise the vehicle and support it on jack stands. 2. Disconnect battery ground cable. 3. Drain fluid. 4. Remove sixteen 10 mm adapter case oil pan fixing screws, adapter case oil pan, and gasket. 5. Disconnect wiring harness from shift solenoid, band apply solenoid, and 7 pin connector of main case. Pull only on connectors, not on wiring harness. 6. Remove wiring harness assembly with transmission oil temperature sensor. INSTALLATION 1. Install wiring harness from shift solenoid, band apply solenoid, and 7 pin connector of main case. 2. Install oil pan gasket, oil pan and sixteen 10 mm fixing screws. Tighten the screws to the specified torque. Torque: 11 Nm (96 Ft. lbs.) 3. Fill transmission through the overfill screw hole of oil pan, using ATF DEXRON III. 4. Connect battery ground cable. Page 1026 ^ Loosen the front subframe bolts. See the applicable service manual for more information. NOTE: The front wheels are being viewed from the rear of the vehicle. ^ Depending which way you need to shift the subframe, insert a pry bar between the subframe and body at both the front and rear positions of the subframe. NOTE: Be careful not to damage the vehicle. You could bend and damage the frame and/or body if you apply too much pressure. ^ Press on both pry bars to shift the subframe. It will move only a few millimeters. This should adjust the camber about 0.2-0.5°. ^ While holding the subframe in place, have an assistant torque the subframe bolts to their proper torque. Front Camber Adjustment, Strut Suspension ^ Raise the vehicle, and remove the front tires. ^ Loosen the damper pinch bolts and the flange nuts. ^ Adjust the camber by moving the bottom of the damper within the range of the damper pinch bolt free play. NOTE: Some vehicles have special pinch bolts that allow more adjustment. For more information, refer to the parts catalog. ^ Tighten the damper pinch bolts to the specified torque. ^ Reinstall the front wheels and lower the vehicle. Bounce the front of the vehicle several times to stabilize the suspension. Page 6644 CD Changer Troubleshooting (All except Passport) CD Player Troubleshooting (All except Passport) Radio Troubleshooting (All except Passport) Page 6604 DVD Player: Technical Service Bulletins Audio/Navigation/RES - Warr. Exchange/Non-Warr Repair 06-001 February 26, 2010 Applies To: 1998 and Later Models - ALL Audio, Navigation, and RES Unit In-Warranty Exchange and Out-of-Warranty Repair (Supersedes 06-601, dated March 4, 2009, to revise the information marked by the black bars and asterisks) *REVISION SUMMARY Under OUT-OF-WARRANTY REPAIR, the address for Pioneer Electronics Service was changed.* COVERAGE This bulletin applies to all Honda audio units, CD players/changers, cassette tape players, navigation units, and rear entertainment system (RES) units, both in warranty and out of warranty. COMPONENT REPLACEMENT POLICY Use only remanufactured components for warranty repairs on customer vehicles. Follow the warranty information and procedures given in this service bulletin. ^ Remanufactured audio, navigation, and RES units are not available for non-warranty repairs. ^ Use new components to repair new, unsold vehicles. ^ A new component may be used to repair a customer's vehicle only if the remanufactured component is currently unavailable from American Honda. ^ You must receive authorization from your District Parts and Service Manager (DPSM) before ordering a new component. WARRANTY CLAIM INFORMATION In warranty: The normal warranty applies. Operation Number: From the Flat Rate Manual Flat Rate Time: From the Flat Rate Manual Failed Part: Use the RM part number from the repair order without the RM (example: 08A06-341-110) Defect Code: From the Flat Rate Manual Symptom Code: From Audio Customer Contention Codes in the Flat Rate Manual Part used for repair: Use the RM part number from the repair order (example: 08A06-341-110RM) IN-WARRANTY DIAGNOSIS Service Advisor: Interview the customer to get as much information as possible. Information like where and when the problem occurs is vital to your diagnosis. This information also helps you to determine if the audio, navigation, or RES system is operating normally, or if a problem exists. Write the complaint on the repair order. NOTE: For CD/DVD related problems, you must verify if the customer used discs with adhesive labels. Service Technician: Diagram Information and Instructions Brake Lamp: Diagram Information and Instructions How to Identify Wiring Color-Coded Insulation Wire Color Wire Color Coding Page 5406 6. Test-drive the vehicle to make sure it no longer pulls. If the steering wheel is now off-center by more than 2 mm, go to REPAIR PROCEDURE C. 7. Use your diagnosis worksheet to fill in the following table and build your 15-digit DTC. NOTE: Enter each reading in decimal degrees. Example 30' = 0.50. REPAIR PROCEDURE C 1. Make sure the steering wheel is centered. ^ Turn the steering wheel all the way to the right until it stops. ^ Turn the steering wheel all the way to the left, and count the number of revolutions until it stops. ^ Divide the number of revolutions in half, and turn the steering wheel until it is centered. For example, if it takes four revolutions of the steering wheel to go from lock to lock, then two turns is centered. ^ If the steering wheel is off-center by a large amount (20 mm or more), it may not be centered on the steering column shaft. Reinstall the steering wheel before going to step 2. 2. Place the vehicle on a lift, turn the steering wheel until it is centered, and then raise the vehicle. 3. Adjust the tie-rods. Use your measurements from question 13 of the test-drive to make your adjustment. Component Locations Wheel Speed Sensor: Component Locations Under Rear of Vehicle (On Differential) Page 4222 This means the branch of the wire connects to another circuit. The arrow points to the name of the circuit branch where the wire continues. Page 4019 c. Remove mode switch connector with bracket from the transmission case. d. Connect multimeter (resistance mode) to terminals 1(E) and 4(H) on mode switch connector. e. Loosen two mounting screws. f. Rotate mode switch slightly in both directions to determine the range (approx. 5 degrees) of electrical contact. g. Position mode switch in middle of contact range. h. Tighten two mounting screws. i. Remove multimeter and install mode switch harness connector with bracket to the transmission case. j. Connect transmission harness connector to mode switch connector. Specifications Radiator: Specifications Radiator Tube Type Corrugated (2 Tube In Row) Radiator Front Area 0.263 m2 Radiator Dry Weight 42 N Radiator Cap Valve Opening Pressure 93.3 - 122.7 kPa Page 8020 Wires Wire insulation can be one color, or one color with another color stripe. (The second color is the stripe.) This circuit continues on another image. (The arrow shows direction of current flow.) To follow the RED/BLK wire in this example, you would turn to "Fuel and Emissions" and look for the "A" arrow. Page 3658 5. Install magnet, main case oil pan with new gasket, and sixteen 10 mm screws. Tighten the screws to the specified torque. Torque: 11 Nm (96 Inch lbs.) 6. Fill transmission through the overfill screw hole of oil pan, using ATF DEXRON-III. 7. Connect battery ground cable. Page 3350 2. Connect one lead of a self-powered test light or DVOM to one end of the part of the circuit you want to test. 3. Connect the other lead to the other end. 4. If the self-powered test light glows, there is continuity. If you're using a DVOM, a low reading or no reading (zero), means good continuity. Testing For Voltage When testing for voltage at a connector without wire seals, you do not have to separate the two halves of the connector. Instead, probe the connector from the back. Always check both sides of the connector because dirty, corroded, and bent terminals can cause problems (no electrical contact = an open). 1. Connect one lead of the lest light to a known good ground, or, if you're using a digital volt ohmmeter (DVOM), place it in the appropriate DC volts range, and connect its negative lead to ground. 2. Connect the other lead of the test light or DVOM to the point you want to check. 3. If the test light glows, there is voltage present. If you're using a DVOM, note the voltage reading. It should be within one volt of measured battery voltage. A loss of more than one volt indicates a problem. NOTE: Always use a DVOM on high impedance circuits. A test light may not glow (even with battery voltage present). Testing For Voltage Drop Wires, connectors, and switches are designed to conduct current with a minimum loss of voltage. A voltage drop of more than one volt indicates a problem. 1. Place the digital volt/ohmmeter (DVOM) in the appropriate DC volts range. Connect the positive lead to the end of the wire (or to the connector or switch) closest to the battery. 2. Connect the negative lead to the other end of the wire (or the other side of the connector or switch). 3. Turn on the components in the circuit. 4. The DVOM will show the difference in voltage between the two points. A difference, or drop, of more than one volt indicates a problem. Check the circuit for loose, dirty, or bent terminals. Page 2785 Powertrain Control Module: Connector Views Page 7845 Door Switch: Service and Repair Removal 1. Disconnect the battery ground cable. 2. Remove the door switch (2). - Remove the screw (1). - Disconnect the connector (3). Installation To install, follow the removal steps in the reverse order. Locations Blower Motor Switch: Locations Fan Control Switch Fan Control Switch Page 6279 Condenser Fan Motor Relay: Testing and Inspection 1. Disconnect relays and check for continuity and resistance between relay terminals. - For handling of these relays, refer to Heater Relay. Page 6597 1. At the iPod, make sure the iPod connector is fully engaged. Is the iPod connector fully engaged? Yes - Go to step 2. No - Properly connect the iPod connector and retest. Replace the cable if the connector is loose or damaged. 2. Disconnect the customer's iPod. 3. Connect headphones to the iPod, and listen to the sound quality. Is the sound quality normal in the headphones? Yes - Go to step 4. No - There is static from the customer's uploaded music. If the volume is weak or low, verify the iTunes sound level setting. 4. Connect a known-good iPod and retest. NOTE: Known-good test iPods are available from Tech Line. Is the sound quality normal over the speakers? Yes - The vehicle is functioning normally. Do an iPod reset on the customer's iPod and retest. If the problem does not go away, have the service advisor explain to the customer that the vehicle is operating properly and advise the customer to: ^ Install the latest iPod firmware. ^ Consult the general information at www.apple.com. This is not a comprehensive list, only a suggested starting point for the customer to troubleshoot the iPod. No - Go to step 5. 5. Disconnect the known-good iPod. 6. Do a vehicle battery cable reset: ^ Remove the negative and positive battery cables. Use a jumper wire to short the two cables together, then turn the ignition switch to ON (II) and wait 15 minutes. ^ Turn the ignition switch to LOCK (0), and remove the jumper wire. Reconnect the positive battery cable first, then reconnect the negative cable. 7. Reconnect the customer's iPod and retest. Is the sound quality normal over the speakers? Yes It is an intermittent audio unit/Music Link failure, and the system is OK at this time. No - Do the "Check mark is not shown on iPod display screen, radio will not switch to CD-C or CD4 mode" troubleshooting. Music Link has no sound, check mark is shown on iPod display screen. 1. At the Music Link interface unit, make sure both connectors are fully engaged, and the cables do not have any broken or bent pins. NOTE: To release the Music Link interface unit connectors, you must pull back on the lock sleeves. Does either cable have the connector partially disengaged, or are any pins broken or bent? Yes - Reconnect or replace the loose or damaged cable. No - Go to step 2. 2. At the audio unit, make sure the cable connectors and the connector pin fits are tight. Also check that the optional Y-bus harness (if installed) connector and connector pin fits are tight. Do the cable connections and pins fit properly? Yes - Substitute a known-good iPod and retest. If the sound is normal, do an iPod reset, and retest. A/C - Heater Blows Cold Air/A/C Blows Hot Air Heater Control Valve Cable: Technical Service Bulletins A/C - Heater Blows Cold Air/A/C Blows Hot Air Heater Blows Cold Air; A/C Blows Warm Air NOTE: This article applies to all A/C-equipped Honda models that use a heater valve cable. Got a vehicle in your shop that blows cold air from the heater or warm air from the A/C? The problem could just be the heater valve cable has slipped off the heater valve arm. There's a real easy fix for this problem. Slip the heater valve cable back onto the heater valve arm. Then cut yourself a 10 mm length of 3.5 mm vacuum hose (P/N 95005-35008-10M, H/C 2325058), and slide it onto the arm. This holds the cable on the arm nice and snug so it won't slip off. Page 714 12. Install the new cover using the accumulator cover installation tool. 13. Reinstall the snap ring. 14. 2002 only: Reconnect the cooler return line, and tighten the bracket that secures the ATF cooler line. 15. Check the transmission fluid level, and refill as necessary with Dexron III ATF. Refer to the Automatic Transmission section of the appropriate Passport Service Manual. Disclaimer Page 6302 Testing For A Short With A Self-Powered Test Light or DVOM 1. Remove the blown fuse and disconnect the battery and load. 2. Connect one lead of a self-powered test light or digital volt/ohmmeter (DVOM) (switched to the lowest "OHMS" range) to the fuse terminal on the load side. 3. Connect the other lead to a known good ground. 4. Beginning near the fuse box, wiggle the harness. Continue this at convenient points about six inches apart while watching the test light or DVOM. 5. If the self-powered test light goes on or the DVOM displays a low reading or no reading (zero), there is a short to ground in the wiring near that point. Testing for a Short with a Test Light or DVOM 1. Remove the blown fuse and disconnect the load. 2. Connect a test light or digital volt/ohmmeter (DVOM), switched to the appropriate DC volts range, across the fuse terminals to make sure voltage is present. You might have to turn the ignition switch to ON; check the schematic to see. 3. Beginning near the fuse box, wiggle the harness. Continue this at convenient points about six inches apart while watching the test light or DVOM. 4. Where the test light goes , or the DVOM voltage drops to zero, there is a short to ground in the wiring near that point. NOTE: Always use a DVOM on high impedance circuits. A test light may not glow (even with battery voltage present). Testing For A Short With A Short Circuit Locator (Short Finder) 1. Remove the blown fuse. Leave the battery connected. Page 5783 10. Remove both type A reinforcement brackets. Save the body mount studs and nuts for the final installation, and discard the original trailing link front mount mounting nuts. 11. Using a 1/2 in. drill motor and a 33/64 in. bit, drill final holes where you made the pilot holes. 12. Test fit a pop nut into each hole to be sure drilling is complete. NOTE: If a pop nut doesn't fit, don't try to enlarge the hole by pivoting the drill bit. Doing this creates an uneven seating surface for the pop nut. If the pop nut doesn't fit, your drill bit is worn out and needs to be sharpened or replaced. 13. Insert an air gun into the frame rail hole, and blow up and down the inside of the frame rails to move any rust or metal debris away from the area. 14. Attach the pop nut installer to shop air, and adjust the tool's air pressure regulator to between 72 and 87 psi. NOTE: ^ The tool's air pressure is critical: if it's too low, the pop nuts cannot be correctly installed; if it's too high, the tool will be damaged. ^ If this is your first time using the pop nut installer, or if you haven't used it in a while, practice installing one or two pop nuts onto the pop nut test plate: - Place a pop nut at the tip of installer's threaded mandrel. Make sure to keep your fingers away from the gap between the pop nut and the base of the mandrel. Squeeze the installer's trigger; the pop nut threads onto the mandrel. Page 5385 Defect Code: 07406 Symptom Code: 03602 Skill Level: Repair Technician Diagnostic Trouble Code: To create the 15-digit DTC, see the applicable repair procedure. Out of warranty: Any repair performed after warranty expiration may be eligible for goodwill consideration by the District Parts and Service Manager or your Zone Office. You must request consideration, and get a decision, before starting work. TOOL DESCRIPTIONS The holding force gauge measures the amount of pull on the vehicle. It is a bracket that counts as one weight, plus five removable weights. During the test-drive, attach the bracket and the weights to the steering wheel on the side opposite the pulling direction. For example, if the vehicle pulls to the right, attach the bracket and weights to the left side of the steering wheel. Start with the maximum amount of weight on the steering wheel, and remove the weights until the vehicle drives in a straight line. When recording the pull on the worksheet, write down the direction of the pull (lefi or right) and the number of weights required to balance the pull (one through six). For example, if you have the bracket and two weights on the steering wheel, then record this as three weights. NOTE: The bracket counts as one weight. Locations Fan Control Switch Locations Combination Switch: Locations Driver's Inflator Module Connector Page 6453 SRS Unit Locations Page 7794 Cargo Lamp: Diagnostic Aids Before Troubleshooting Before Troubleshooting See: Service Precautions/Vehicle Damage Warnings/Tips and Precautions 1. Check applicable fuses in the appropriate fuse/relay box. 2. Check the battery for damage, state of charge, and clean and tight connections. CAUTION: Do not quick-charge a battery unless the battery ground cable has been disconnected, otherwise you will damage the alternator diodes. - Do not attempt to crank the engine with the battery ground cable loosely connected or you will severely damage the wiring. While You're Working 1. Make sure connectors are clean, and have no loose terminals or receptacles. 2. Make sure that connectors without wire seals are packed with dielectric (silicone) grease. Part Number: 08798-9001. 3. When connecting a connector, push it until it "clicks" into place. CAUTION: Do not pull on the wires when disconnecting a connector. Pull only on the connector housings. - Most circuits include solid-state devices. Test the voltages in these circuits only with a 10-megaohm or higher impedance digital multi meter. Never use a test light or analog meter on circuits that contain solid-state devices. Damage to the devices may result. Five-Step Troubleshooting 1. Verify The Complaint Turn on all the components in the problem circuit to check the accuracy of the customer complaint. Note the symptoms. Do not begin disassembly or testing until you have narrowed down the problem area. 2. Analyze The Schematic Look up the schematic for the problem circuit. Determine how the circuit is supposed to work by tracing the current paths from the power source through the circuit components to ground. Also, trace circuits that share wiring with the problem circuit. The names of circuits that share the same fuse, ground, or switch, and so on, are referred to in each circuit schematic. Try to operate any shared circuits you didn't check in step 1. If the shared circuits work, the shared wiring is OK, and the cause must be in the wiring used only by the problem circuit. If several circuits fail at the same time, the fuse or ground is a likely cause. Based on the symptoms and your understanding of the circuit's operation, identify one or more possible causes. 3. Isolate The Problem By Testing The Circuit Make circuit tests to check the diagnosis you made in step 2. Keep in mind that a logical, simple procedure is the key to efficient troubleshooting. Test for the most likely cause of failure first. Try to make tests at points that are easily accessible. 4. Fix The Problem Once the specific problem is identified, make the repair. Be sure to use proper tools and safe procedures. 5. Make Sure The Circuit Works Turn on all components in the repaired circuit in all modes to make sure you've fixed the entire problem. If the problem was a blown fuse, be sure to test all of the circuits on that fuse. Make sure no new problems turn up and the original problem does not recur. Page 5420 Alignment: By Symptom Technical Service Bulletin # 06-068 Date: 090502 Steering/Suspension - Vehicle Pulls Left/Right 06-068 May 2, 2009 Applies To: ALL *Vehicle Pulls or Drifts, and/or Steering Wheel Is Off-Center (Supersedes 06-068, Vehicle Pulling or Drifting, dated October 4, 2007, to revise the information marked by asterisks) (Replaces 90-011, Steering Wheel Off-Center Adjustment at PDI)* *REVISION SUMMARY The title description was revised.* SYMPTOM While driving on a straight road, the vehicle pulls or drifts to the right or left. BACKGROUND New tools were developed to help you diagnose and correct a pulling and/or steering wheel off-center issue. There is a diagnosis worksheet included to take on your test-drive and record your findings. These values are used to build the 15-digit DTC (diagnostic trouble code) that is required for your warranty claim. The last step in each repair procedure helps you create the correct code. In the rare case that you have to repair a vehicle that pulls and has the steering wheel off-center, use REPAIR PROCEDURE B to file your warranty claim. For more information, refer to Training Module SSC 44 - Steering Drift or Pull Interactive Service Bulletin. PROBABLE CAUSES Several conditions can cause the vehicle to pull or drift: ^ Wheel alignment ^ Tires ^ Off-center steering wheel (no pulling or drifting, but a customer may believe this is the case) CORRECTIVE ACTION Diagnose the problem using the special tools and the worksheet on page 4 that guides you to one of four repair procedures. TOOL INFORMATION Centering Tape (enough to diagnose 240 vehicles): T/N O7AAJ-001A300 Steering Drift Set Level: T/N 07AAJ-00100 Steering Drift Set: T/N O7MJ-001A140 Replacement Weight for Steering Drift Set: T/N 07AAJ-001A400 WARRANTY CLAIM INFORMATION In warranty: The normal warranty applies. Page 568 Part 1 Of 3 Page 4203 3. Connect the terminals as shown in figure. Shift rod of the motor actuator moves and stops at 2WD position. 4. If 2) and 3) fail, replace with a new motor actuator. Locations Transmission Position Switch/Sensor: Locations Left Side Of Automatic Transmission Page 2794 Powertrain Control Module: Description and Operation PCM Components PCM Components The PCM is designed to maintain exhaust emission levels to government mandated standards while providing excellent driveability and fuel efficiency. The PCM monitors numerous engine and vehicle functions via electronic sensors such as the throttle position (TP) sensor, heated oxygen sensor (HO2S), and vehicle speed sensor (VSS). The PCM also controls certain engine operations through the following: - Fuel injector control - Ignition control module - ION sensing module - Automatic transmission shift functions - Cruise control - Evaporative emission (EVAP) purge - A/C clutch control Page 4916 1. Wheel stud: a. Place the hub on a wood workbench or a block of wood approx. 6" by 6" to protect the wheel stud ends and threads. b. Insert a wheel stud using a hammer. Be sure the wheel stud is started squarely and seats completely. 2. Bolt. Align scribe marks and attach the hub to the disc. Tighten the bolts to 103 Nm (76 ft. lbs.). 3. Inner Bearing Outer Race. Install the outer race: inner bearing by driving it into the hub. - Installer: J-36829. - Grip: J-8092. Page 7798 2. Connect one lead of a self-powered test light or DVOM to one end of the part of the circuit you want to test. 3. Connect the other lead to the other end. 4. If the self-powered test light glows, there is continuity. If you're using a DVOM, a low reading or no reading (zero), means good continuity. Testing For Voltage When testing for voltage at a connector without wire seals, you do not have to separate the two halves of the connector. Instead, probe the connector from the back. Always check both sides of the connector because dirty, corroded, and bent terminals can cause problems (no electrical contact = an open). 1. Connect one lead of the lest light to a known good ground, or, if you're using a digital volt ohmmeter (DVOM), place it in the appropriate DC volts range, and connect its negative lead to ground. 2. Connect the other lead of the test light or DVOM to the point you want to check. 3. If the test light glows, there is voltage present. If you're using a DVOM, note the voltage reading. It should be within one volt of measured battery voltage. A loss of more than one volt indicates a problem. NOTE: Always use a DVOM on high impedance circuits. A test light may not glow (even with battery voltage present). Testing For Voltage Drop Wires, connectors, and switches are designed to conduct current with a minimum loss of voltage. A voltage drop of more than one volt indicates a problem. 1. Place the digital volt/ohmmeter (DVOM) in the appropriate DC volts range. Connect the positive lead to the end of the wire (or to the connector or switch) closest to the battery. 2. Connect the negative lead to the other end of the wire (or the other side of the connector or switch). 3. Turn on the components in the circuit. 4. The DVOM will show the difference in voltage between the two points. A difference, or drop, of more than one volt indicates a problem. Check the circuit for loose, dirty, or bent terminals. Page 11 Alarm/Immobilizer Control Unit: Service and Repair Alarm and Relay Control Unit Removal 1. Disconnect the battery ground cable. 2. Remove the instrument panel (1). 3. Remove the alarm and relay control unit (2). Disconnect the connector. Installation To install, follow the removal steps in the reverse order. Page 875 INSTALLATION 1. Install lock cylinder assembly. 2. Install shift lock cable (for A/T). 3. Install cushion rubber. 4. Install snap ring. 5. Install Combination switch and SRS coil assembly. After installation of combination switch assembly, connect the combination switch wiring harness connector and the SRS 2-way connector located under the steering column. 6. Turn the SRS coil counterclockwise to full, return about 3 turns and align the neutral mark. CAUTION: When turning the SRS coil counterclockwise to full, stop turning if resistance is felt. Forced further turning may damage to the cable in the SRS coil. Accelerator Pedal Assembly/Sensor - Adjustment Update Accelerator Pedal Position Sensor: All Technical Service Bulletins Accelerator Pedal Assembly/Sensor - Adjustment Update 00-045 August 14, 2001 Applies To: 2000-02 Passport - ALL Service Manual Update: Accelerator Pedal Position Sensor (APPS) (Supersedes 00-045, dated May 23, 2000) Updated information is shown by asterisks and black bars. BACKGROUND When the accelerator pedal position sensor (APPS) or the accelerator pedal assembly is replaced for any reason, you must adjust the APPS. *This procedure is missing in the 2000 service manual and is wrong in the 2001 and 2002 service manuals. Make a note on page 6E2-539 of the 2000 Passport Fuel and Emissions manual, on page 6E2-553 of the 2001 Passport Fuel and Emissions manual, and on page 6E2-545 of the 2002 Passport Fuel and Emissions manual to refer to this bulletin.* ADJUSTMENT PROCEDURE 1. Replace the APPS or the accelerator pedal assembly, and leave the mounting screws for the APPS loose. 2. Connect the PGM Tester to the data link connector (DLC), and turn the ignition switch to ON (II). *3. While watching the APP Sensor values in the Engine Data List, adjust the APPS by turning it until the values are within the ranges shown at closed pushed all the way down), then tighten the throttle and wide open throttle (accelerator pedal mounting screws and recheck the values. ^ If all three sensors are within range, go to step 12. ^ If APP Sensor 1, APP Sensor 2, and/or APP Sensor 3 cannot be brought into range, go to step 4. 4. Troubleshoot for an open circuit or a PCM malfunction. ^ If APP Sensor 1 has a value of 0% or APP Sensor 2 and/or APP Sensor 3 have a value of 99%, an open circuit exists or the PCM is malfunctioning. Repair the circuit or replace the PCM, and repeat step 3. ^ If you don't find a problem, go to step 5. 5. Disconnect the 10P connector from the APPS. 6. View the APP Sensor values in the Engine Data List. ^ If APP Sensor 1 has a value of 0% or APP Sensor 2 and/or APP Sensor 3 have a value of 99%, go to step 7. ^ If APP Sensor 1 has a value other than 0%, or APP Sensor 2 and/or APP Sensor 3 have a value other than 99%, a short circuit exists or the PCM is malfunctioning. Repair the circuit or replace the PCM, and repeat step 3. A/T - Identifying Shift Solenoids Shift Solenoid: Technical Service Bulletins A/T - Identifying Shift Solenoids SOURCE: Honda Service News November 2003 TITLE: Identifying A/T Shift Solenoids APPLIES TO: 1994-02 Passport SERVICE TIP: If you've ever replaced the A/T shift solenoids in a 1994-02 Passport, you're probably aware that the S/M and parts catalog descriptions for the solenoids don't exactly match. Use this handy chart when ordering replacement solenoids: When installing these solenoids in the valve body, make sure you don't get them mixed up or install them in the wrong position. It's easy to do since these solenoids look almost identical. Fortunately, each solenoid has some of its part number engraved on its connector. Solenoid A has 593; solenoid B has 224. Page 4680 Each schematic represents one circuit. A circuit's wires and components are arranged to show current flow, from power at the top of the page, to ground, at the bottom. Shared Circuits Other circuits may share power or ground terminals or wiring with the circuit shown. A wire that connects one circuit to another, for example, is cut short and has an arrowhead at the end of it pointing in the direction of current flow. Next to the arrowhead is the name of the circuit or component which shares that wiring. To quickly check shared wiring, check the operation of a component it serves. If that component works, you know the shared wiring is OK. Connectors All in-line and junction connectors are numbered (C725, C416, etc.). Component connectors are not numbered but are identified either by the name of Page 2260 20. Using a DVOM, check the voltage between the reference voltage pin for each sensor and ground. ^ If the sensor circuits all read 5.0 volts, go to step 22. ^ If any sensor circuit is above or below 5.0 volts, go to step 21. 21. Troubleshoot for an internal short in another sensor or a PCM malfunction. ^ To find the sensor with an internal short, monitor the reference voltage, and disconnect each sensor (FTPS, EGR, MAP TPS, CKP and CMP) one at a time until the reference voltage reads 5.0 volts. Replace that sensor, and repeat step 14. ^ To find a malfunctioning PCM, replace it with a known-good PCM. If all three sensors (APP Sensor 1, APP Sensor 2, and APP Sensor 3) are within range, the original PCM is faulty; replace it and repeat step 14. 22. Using a jumper wire, connect the reference voltage of each circuit to its signal input, and view the APP Sensor values in the Engine Data List. APP Sensor 1 should have a value of 99%, and APP Sensor 2 and APP Sensor 3 should each have a value of 0%. ^ If the values are not as specified, troubleshoot for high resistance on the signal input or a PCM malfunction. Repair the circuit or replace the PCM, then repeat step 14. ^ If the values are as specified, the problem may be intermittent. Disconnect the 10 P connector from the modified APPS, and connect it to the new APPS; then repeat step 14. Wiggle the APPS wires as you go through the adjustment procedure to find the intermittent problem. 23. Install the accelerator pedal assembly, and torque the bolts to 10 N.m (7 lb-ft). Page 2292 Air Flow Meter/Sensor: Service and Repair Mass Air Flow (MAF) Sensor REMOVAL PROCEDURE 1. Disconnect the negative battery cable. 2. Disconnect the electrical connector from the MAF sensor. 3. Loosen the clamps which secure the intake air duct and the air cleaner to the MAF sensor. 4. Remove the intake air duct from the MAF sensor. 5. Remove the MAF sensor from the air cleaner. INSTALLATION PROCEDURE Page 762 Testing For A Short With A Self-Powered Test Light or DVOM 1. Remove the blown fuse and disconnect the battery and load. 2. Connect one lead of a self-powered test light or digital volt/ohmmeter (DVOM) (switched to the lowest "OHMS" range) to the fuse terminal on the load side. 3. Connect the other lead to a known good ground. 4. Beginning near the fuse box, wiggle the harness. Continue this at convenient points about six inches apart while watching the test light or DVOM. 5. If the self-powered test light goes on or the DVOM displays a low reading or no reading (zero), there is a short to ground in the wiring near that point. Testing for a Short with a Test Light or DVOM 1. Remove the blown fuse and disconnect the load. 2. Connect a test light or digital volt/ohmmeter (DVOM), switched to the appropriate DC volts range, across the fuse terminals to make sure voltage is present. You might have to turn the ignition switch to ON; check the schematic to see. 3. Beginning near the fuse box, wiggle the harness. Continue this at convenient points about six inches apart while watching the test light or DVOM. 4. Where the test light goes , or the DVOM voltage drops to zero, there is a short to ground in the wiring near that point. NOTE: Always use a DVOM on high impedance circuits. A test light may not glow (even with battery voltage present). Testing For A Short With A Short Circuit Locator (Short Finder) 1. Remove the blown fuse. Leave the battery connected. Page 4857 The name of the component appears next to it followed by notes about its function along with any photo and connector view references. Connector "C" How to Identify Connector Terminals Cavity Numbering System The cavities (and wire terminals) in each connector are numbered starting from the upper left, looking at the male terminals from the terminal side (or looking at the female terminals from the wire side. Both views are in the same direction so the numbers are the same.) All actual cavities are numbered, even if they have no wire terminals in them. NOTE: Data Link Connector (DLC) terminals are numbered according to SAE standard J1962, not the Honda standard. The numbers of the four end terminals are molded into the corners of the connector face. Page 3487 Throttle Body: Testing and Inspection NOTE: Do not use solvent of any type when you clean the gasket surfaces on the intake manifold and the throttle body assembly. The gasket surfaces and the throttle body assembly may be damaged as a result. - If the throttle body gasket needs to be replaced, remove any gasket material that may be stuck to the mating surfaces of the manifold. - Do not leave any scratches in the aluminum casting. Diagram Information and Instructions 4WD Control Unit: Diagram Information and Instructions How to Identify Wiring Color-Coded Insulation Wire Color Wire Color Coding Page 7795 Test Equipment CAUTION: Most circuits include solid-state devices. Test the voltages in these circuits only with a 10-megaohm or higher impedance digital multimeter. Never use a test light or analog meter on circuits that contain solid-state devices. Damage to the devices may result. Test Light and DVOM On circuits without solid-state devices, use a test light to check for voltage. A test light is made up of a 12 volt bulb with a pair of leads attached. After grounding one lead, touch the other lead to various points along the circuit where voltage should be present. The bulb will go on if there is voltage at the point being tested. If you need to know how much voltage is present, use a digital volt/ohmmeter (DVOM). Self-Powered Test Light and DVOM Use a self-powered test light to check for continuity. This tool is made up of a light bulb, battery, and two leads. To test it, touch the leads together: the light should go on. Use a self-powered test light only on an unpowered circuit. First, disconnect the battery, or remove the fuse that feeds the circuit you are working on. Select two points in the circuit between which you want to check continuity. Connect one lead of the self-powered test light to each point. If there is continuity, the test light's circuit will be completed, and the light will go on. If, in addition, you need to know exactly how much resistance there is between two points, use a digital volt/ohmmeter (DVOM). In the "OHMS" range, the DVOM will measure resistance between two points along a circuit. Low resistance means good continuity. Diodes and solid-state devices in a circuit can make a DVOM give a false reading. To check a reading, reverse the leads, and take a second reading. If the readings differ, the component is affecting the measurement. Jumper Wire Use a jumper wire to bypass an open circuit. A jumper wire is made up of an in-line fuse holder connected to a set of test leads. It should have a five ampere fuse. Never connect a jumper wire across a short circuit. The direct battery short will blow the fuse. Short Finder (Short Circuit Locator) Short finders are available to locate shorts to ground. The short finder creates a pulsing magnetic field in the shorted circuit which you can follow to the location of the short. To order any test equipment shown above, contact your local tool supplier. For a list of suppliers and tool numbers, refer to Honda Required Special Tools and Equipment Service Bulletin. Page 538 Door Switch: Service and Repair Removal 1. Disconnect the battery ground cable. 2. Remove the door switch (2). - Remove the screw (1). - Disconnect the connector (3). Installation To install, follow the removal steps in the reverse order. Page 7662 it is located, and what it connects to. Use the Connector Views to help locate the proper cavity when you need to probe a connector. It can be especially helpful if the connector has more than one wire of the same color. A dash symbol (-) indicates that the cavity is empty. Connector views can also be used to help diagnose multiple symptoms in separate circuits which could be caused by a single problem in a connector shared by those circuits. Here's an example: 1. Pick one of the multiple symptoms and look up the schematic for that circuit. 2. Make a list of all the in-line and fuse box connectors in that schematic , 3. Then, in the Connector Views, look up each connector on your list to see if circuits related to the other symptoms run through one of them. If they do, inspect that connector for the problem. Example: The blower, rear window defogger, and the windshield wiper don't work. List all in-line and fuse box connectors in the blower controls circuit and then check the Connector View (see the sample). You find that C324 is common to the blower controls, rear window defogger, and wiper/washer, so you inspect C324 and find the problem, bent terminals. Finding Component/Connector Locations Finding Component/Connector Locations To see where a component or connector is located on the car, look up its photo number in the "Component Location". The photo will also tell you the color of the connector, and how many cavities it has. Diagram Information and Instructions Axle Disconnect Control Control Unit: Diagram Information and Instructions How to Identify Wiring Color-Coded Insulation Wire Color Wire Color Coding Page 1390 4. Use installer J-36828 and grip J-8092 then install the outer bearing by driving it into the hub. 5. Apply grease (NLG1 No.2 or equivalent) to the lip portion, then install oil seal by using installer J-36830 and grip J-8092. 6. Install ABS sensor ring, then tighten the bolts to the specified torque. Torque: 18 Nm (13 ft. lbs.) 7. Install hub and disc assembly. - Apply grease in the hub. - Apply wheel bearing type grease NLGI No. 2 or equivalent to the outer and inner bearing. Page 4369 If the snap ring is stuck in position, remove paint from the hole in the yoke or tap around the edge of the bearing lightly with a soft drift. 2. Set the yoke in the arbor press with a piece of tube stock beneath it. Place a solid plug on the upper bearing and press it through to release the lower bearing. 3. If the bearing will not pull out by hand after pressing, tap the base of the lug near the bearing to dislodge it. 4. To remove the opposite bearing, turn the yoke over and straighten the spider in the open spider hole. Then carefully press on the end of the spider so the remaining bearing moves straight out of the bearing spider hole. If the spider or bearing are cocked, the bearing will score the walls of the spider hole and ruin it. 5. Repeat this procedure on the remaining bearing to remove the spider from the yoke. INSPECTION Page 4228 2. Connect the short finder across the battery terminals and the load (component) side of the fuse terminal. 3. Close all switches in the circuit you're testing. 4. Turn on the short finder. This creates a pulsing magnetic field around the wiring between the fuse box and the short. 5. Beginning at the fuse box, slowly move the short finder along the circuit wiring. The meter will read current pulses through sheet metal and body trim. As long as the meter is between the fuse and the short, the needle will move with each current pulse. Once you move the meter past the point of the short, the needle will stop moving. Check the wiring and connectors in this area to locate the cause of the short. Testing For Continuity When testing for continuity at a connector without wire seals, you do not have to separate the two halves of the connector. Instead, probe the connector from the back. Always check both sides of the connector because dirty, corroded, and bent terminals can cause problems (no electrical contact = an open). 1. Disconnect the negative cable from the car battery. If you're using a DVOM, place it in the lowest "OHMS" range. Page 5404 1. Place the vehicle on a commercially available, computerized, four-wheel alignment rack, and record the following measurements. Follow the equipment manufacturer's instructions. NOTE: Enter each reading in decimal degrees. Example 30' = 0.50. 2. If any measurement is out of specification, inspect the front suspension for any damage. Repair any damaged parts before continuing your diagnosis. 3. Determine how the front wheel camber is affecting the pull. Pick the combination of left- and right-front camber that best matches the vehicle you are repairing, then note the camber thrust direction for that combination: NOTE: ^ If the camber of both front wheels is negative, but one wheel is grossly more negative than the other, the camber thrust direction will be opposite the wheel with more negative camber (for example, if the left-front wheel is more negative, the camber thrust direction is right). ^ If the camber of both front wheels is positive, but one wheel is grossly more positive than the other, the camber thrust direction will be the same as the wheel with more positive camber (for example, if the left-front wheel is more positive, the camber thrust direction is left). 4. Determine how the camber needs to be adjusted. 5. Adjust the camber as needed. Front Camber Adjustment, Double Wishbone Suspension Page 5670 - Install the rubber bushing (Frame side) by using Installer J-39215. NOTE: When mounting rubber bushings, do not use grease on bushings or any other nearby parts. 3. Rubber bushing (Axle side): - Remove the rubber bushing (Axle side) by using remover J-39792. - Install the rubber bushing (Axle side) by using installer J-39792. INSTALLATION Page 7403 If there is no photo number below or beside a component name or a connector, ground, or terminal number, look up that name or number in the appropriate Connector Identification Chart. The chart lists how many cavities a connector has, where it's located, and what it connects to. The related illustration shows the connector's location on the harness, and the harness routing. NOTE: Photos listed by number are located at Locations / Components / Photograohs. See: Locations/Component Locations/Photographs Circuit Schematics Air Bag Disarming and Arming Air Bag(s) Arming and Disarming: Service and Repair Air Bag Disarming and Arming Disabling The SRS Removal Turn the ignition switch to "lock" and remove key. 1. Remove SRS fuse "METER" and "SRS", from left dash side lower fuse block or disconnect battery. 2. Disconnect yellow 2 - pin connector at the base of steering column. 3. Remove glove box assembly, Refer to "Passenger Air Bag Assembly Replacement". 4. Disconnect yellow 2 - pin connector behind the glove box assembly. CAUTION: With the "SRS" fuse removed and ignition switch "ON", "AIR BAG" warning lamp will be "ON". This is normal operation and does not indicate an SRS malfunction. Enabling The SRS Installation CAUTION: Never use the air bag assembly from another vehicle. Use only the air bag assembly. Turn ignition switch to "LOCK" and remove key. 1. Connect yellow 2 - pin connector passenger air bag assembly. 2. Install glove box assembly, refer to "Passenger Air Bag Assembly Replacement". 3. Connect yellow 2 - pin connector at the base of steering column. 4. Install "AIR BAG" fuse "METER" and "SRS" to left dash side lower fuse block or connect battery. Turn ignition switch to "ON" and verify that the "AIR BAG" warning lamp flashes seven times and then turns "OFF". If it does not operate as described, perform the "Supplemental Restraint System (SRS) Diagnostic System Check". Page 3463 Accelerator Pedal Position Sensor: Service and Repair Accelerator Position Sensor Replacement CAUTION: Remove the Accelerator (A) pedal assembly as a unit to have it services. Do not remove the Accelerator Position (AP) sensor on the A pedal. If the AP sensor is removed for emergency cause, refer to following Items as necessary. Removal Procedure 1. Disconnect the negative battery cable. 2. Disconnect the electrical harness from the AP sensor. 3. Remove the AP sensor. Installation Procedure 1. Install the accelerator position (AP) sensor to bolts with accelerator (A) pedal. 2. Connect the connector to AP sensor. 3. Install the negative battery cable. Page 3889 5. Install magnet, main case oil pan with new gasket, and sixteen 10 mm screws. Tighten the screws to the specified torque. Torque: 11 Nm (96 Inch lbs.) 6. Fill transmission through the overfill screw hole of oil pan, using ATF DEXRON-III. 7. Connect battery ground cable. Page 7956 Parking Lamp: Diagnostic Aids Before Troubleshooting Before Troubleshooting See: Service Precautions/Vehicle Damage Warnings/Tips and Precautions 1. Check applicable fuses in the appropriate fuse/relay box. 2. Check the battery for damage, state of charge, and clean and tight connections. CAUTION: Do not quick-charge a battery unless the battery ground cable has been disconnected, otherwise you will damage the alternator diodes. - Do not attempt to crank the engine with the battery ground cable loosely connected or you will severely damage the wiring. While You're Working 1. Make sure connectors are clean, and have no loose terminals or receptacles. 2. Make sure that connectors without wire seals are packed with dielectric (silicone) grease. Part Number: 08798-9001. 3. When connecting a connector, push it until it "clicks" into place. CAUTION: Do not pull on the wires when disconnecting a connector. Pull only on the connector housings. - Most circuits include solid-state devices. Test the voltages in these circuits only with a 10-megaohm or higher impedance digital multi meter. Never use a test light or analog meter on circuits that contain solid-state devices. Damage to the devices may result. Five-Step Troubleshooting 1. Verify The Complaint Turn on all the components in the problem circuit to check the accuracy of the customer complaint. Note the symptoms. Do not begin disassembly or testing until you have narrowed down the problem area. 2. Analyze The Schematic Look up the schematic for the problem circuit. Determine how the circuit is supposed to work by tracing the current paths from the power source through the circuit components to ground. Also, trace circuits that share wiring with the problem circuit. The names of circuits that share the same fuse, ground, or switch, and so on, are referred to in each circuit schematic. Try to operate any shared circuits you didn't check in step 1. If the shared circuits work, the shared wiring is OK, and the cause must be in the wiring used only by the problem circuit. If several circuits fail at the same time, the fuse or ground is a likely cause. Based on the symptoms and your understanding of the circuit's operation, identify one or more possible causes. 3. Isolate The Problem By Testing The Circuit Make circuit tests to check the diagnosis you made in step 2. Keep in mind that a logical, simple procedure is the key to efficient troubleshooting. Test for the most likely cause of failure first. Try to make tests at points that are easily accessible. 4. Fix The Problem Once the specific problem is identified, make the repair. Be sure to use proper tools and safe procedures. 5. Make Sure The Circuit Works Turn on all components in the repaired circuit in all modes to make sure you've fixed the entire problem. If the problem was a blown fuse, be sure to test all of the circuits on that fuse. Make sure no new problems turn up and the original problem does not recur. Page 7039 3. Remove the screw while pulling the inside lever toward you and then remove the inside handle. 4. Remove the speaker grille (1). - Pull out the front side of the grille. 5. Remove the speaker assembly (2). - Remove 4 screws and disconnect the speaker harness connector (3). 6. Remove the courtesy light lens. Page 505 2. Connect one lead of a self-powered test light or DVOM to one end of the part of the circuit you want to test. 3. Connect the other lead to the other end. 4. If the self-powered test light glows, there is continuity. If you're using a DVOM, a low reading or no reading (zero), means good continuity. Testing For Voltage When testing for voltage at a connector without wire seals, you do not have to separate the two halves of the connector. Instead, probe the connector from the back. Always check both sides of the connector because dirty, corroded, and bent terminals can cause problems (no electrical contact = an open). 1. Connect one lead of the lest light to a known good ground, or, if you're using a digital volt ohmmeter (DVOM), place it in the appropriate DC volts range, and connect its negative lead to ground. 2. Connect the other lead of the test light or DVOM to the point you want to check. 3. If the test light glows, there is voltage present. If you're using a DVOM, note the voltage reading. It should be within one volt of measured battery voltage. A loss of more than one volt indicates a problem. NOTE: Always use a DVOM on high impedance circuits. A test light may not glow (even with battery voltage present). Testing For Voltage Drop Wires, connectors, and switches are designed to conduct current with a minimum loss of voltage. A voltage drop of more than one volt indicates a problem. 1. Place the digital volt/ohmmeter (DVOM) in the appropriate DC volts range. Connect the positive lead to the end of the wire (or to the connector or switch) closest to the battery. 2. Connect the negative lead to the other end of the wire (or the other side of the connector or switch). 3. Turn on the components in the circuit. 4. The DVOM will show the difference in voltage between the two points. A difference, or drop, of more than one volt indicates a problem. Check the circuit for loose, dirty, or bent terminals. Page 1971 2. Connect the short finder across the battery terminals and the load (component) side of the fuse terminal. 3. Close all switches in the circuit you're testing. 4. Turn on the short finder. This creates a pulsing magnetic field around the wiring between the fuse box and the short. 5. Beginning at the fuse box, slowly move the short finder along the circuit wiring. The meter will read current pulses through sheet metal and body trim. As long as the meter is between the fuse and the short, the needle will move with each current pulse. Once you move the meter past the point of the short, the needle will stop moving. Check the wiring and connectors in this area to locate the cause of the short. Testing For Continuity When testing for continuity at a connector without wire seals, you do not have to separate the two halves of the connector. Instead, probe the connector from the back. Always check both sides of the connector because dirty, corroded, and bent terminals can cause problems (no electrical contact = an open). 1. Disconnect the negative cable from the car battery. If you're using a DVOM, place it in the lowest "OHMS" range. Page 4677 Distinct Of Circuit By Wire Base Color All wires have color-coded insulation. Wires belonging to a system's main harness will have a single color. Wires belonging to a system's sub-circuits will have a colored stripe. Striped wires use the codes found in the chart to show wire size and colors. Abbreviations are used to indicate wire color within a circuit diagram. How to Identify Connector Terminals How to Identify Connector Terminals Cavity Numbering System The cavities (and wire terminals) in each connector are numbered starting from the upper left, looking at the male terminals from the terminal side (or looking at the female terminals from the wire side. Both views are in the same direction so the numbers are the same.) All actual cavities are numbered, even if they have no wire terminals in them. NOTE: Data Link Connector (DLC) terminals are numbered according to SAE standard J1962, not the Honda standard. The numbers of the four end terminals are molded into the corners of the connector face. The connector cavity number is listed next to each terminal on the circuit schematic. The cavity / terminal shown is # 6. Using/Identifying Connector Terminal Views How to Use Connector Terminal Views To see the configuration of a connector's cavities, look up its view number in the Connector Views. Each view includes the color of the connector, where Page 2998 Transmission Position Switch/Sensor: Description and Operation Transmission Range Switch IMPORTANT: The vehicle should not be driven with the transmission range switch disconnected; idle quality will be affected. The four inputs from the transmission range switch indicate to the PCM which position is selected by the transmission selector lever. This information is used for ignition timing, EVAP canister purge, EGR operation. For more information on the transmission on the transmission range switch, refer to Transmission Control System Diagnosis. See: Transmission Control Systems/Testing and Inspection Page 2993 Throttle Position Sensor: Testing and Inspection Function Check Use a Tech 2 to check the TP sensor output voltage at closed throttle. - The voltage should be under 0.85 volt. - If the reading is greater than 0.85 volt, check the throttle shaft to see if it is binding. Page 1591 Valve Guide Replacement 1. Using Valve guide replacer: J-42899, drive out the valve guide from the combustion chamber side. 2. Apply engine oil to the outside of the valve guide. Using valve guide replacer J-42899, drive in a new valve guide from the camshaft side, and check the valve guide height. Valve guide upper end height: 13.0 mm (0.5118 inch) (Measured from the cylinder head upper face) 3. Check the clearance. If the clearance is less than the specified value, ream the inside diameter of valve guide. Using a sharp 6 mm reamer, ream the valve guide to obtain the specified clearance. Valve Seat 1. Measure the protrusion of the valve stem when a new valve is installed in the cylinder head. If the protrusion of the valve stem exceeds the limit, replace the valve seat insert or the cylinder head assembly. Protrusion of valve stem Intake Standard: 39.32 mm (1.5480 inch) Page 3376 2. Connect one lead of a self-powered test light or DVOM to one end of the part of the circuit you want to test. 3. Connect the other lead to the other end. 4. If the self-powered test light glows, there is continuity. If you're using a DVOM, a low reading or no reading (zero), means good continuity. Testing For Voltage When testing for voltage at a connector without wire seals, you do not have to separate the two halves of the connector. Instead, probe the connector from the back. Always check both sides of the connector because dirty, corroded, and bent terminals can cause problems (no electrical contact = an open). 1. Connect one lead of the lest light to a known good ground, or, if you're using a digital volt ohmmeter (DVOM), place it in the appropriate DC volts range, and connect its negative lead to ground. 2. Connect the other lead of the test light or DVOM to the point you want to check. 3. If the test light glows, there is voltage present. If you're using a DVOM, note the voltage reading. It should be within one volt of measured battery voltage. A loss of more than one volt indicates a problem. NOTE: Always use a DVOM on high impedance circuits. A test light may not glow (even with battery voltage present). Testing For Voltage Drop Wires, connectors, and switches are designed to conduct current with a minimum loss of voltage. A voltage drop of more than one volt indicates a problem. 1. Place the digital volt/ohmmeter (DVOM) in the appropriate DC volts range. Connect the positive lead to the end of the wire (or to the connector or switch) closest to the battery. 2. Connect the negative lead to the other end of the wire (or the other side of the connector or switch). 3. Turn on the components in the circuit. 4. The DVOM will show the difference in voltage between the two points. A difference, or drop, of more than one volt indicates a problem. Check the circuit for loose, dirty, or bent terminals. Page 6456 Air Bag Control Module: Vehicle Damage Warnings 1. Air bag assembly should not be subjected to temperatures above 93 °C (200 °C). 2. Air bag assembly, and Sensing and Diagnostic Module (SDM) should not be used If they have been dropped from a height of 100 centimeters (3.28 feet). 3. When a SDM is replaced, it must be oriented with the arrow on the sensor pointing toward the front of the vehicle. It is very important for the SDM to be located flat on the mounting surface, parallel to the vehicle datum line. It is important that the SDM mounting surface is free of any dirt or other foreign material. 4. Do not apply power to the SRS unless all components are connected or a diagnostic chant requests it, as this will set a diagnostic trouble code. 5. The "SRS Diagnostic System Check" must be the starting point of any SRS diagnostics. The "SRS Diagnostic System Check" will verify proper "AIR BAG" warning lamp operation and will lead you to the correct chart to diagnose any SRS malfunctions. Bypassing these procedures may result in extended diagnostic time, incorrect diagnosis, and incorrect pants replacement. Page 986 The road crown gauge measures the amount of road crown. Almost all roads have a crown to help drain water during rainstorms. Use the suction cup to attach the road crown gauge bracket to the vehicle in a vertical position. If necessary, bend the bracket until the gauge is vertical. Once you attach and align the road crown gauge, calibrate the gauge to zero. There are two ways to calibrate the gauge: ^ Park the vehicle on a level surface, such as an alignment rack, and calibrate the gauge by moving the gauge until the ball is on the zero mark. ^ If you do not have a perfectly flat surface, park the vehicle on a reasonably flat surface and note the gauge reading. Turn the vehicle 1800 and, with the tires in the same spot, note the new gauge reading. Then move the gauge half of the difference. For example, if your first reading is +3 and, after moving the vehicle, the gauge reads -1, then the difference is 4 degrees. Position the gauge to read +1. NOTE: You must calibrate the gauge with the same weight in the vehicle that you will use for the test-drive. If you plan to have an assistant help you during the test-drive, calibrate the gauge while both of you are sitting in the vehicle. Page 260 and the fuses. From Fuses to Relays and Components The second half of Power Distribution shows the wiring "From Fuses to Relays and Components." This can speed your troubleshooting by showing which circuits share fuses. If Power Distribution shows that an inoperative circuit and another circuit share a fuse, check a component in the other circuit. If it works, you know the fuse is good and power is available to the inoperative circuit. Ground Distribution Schematics Page 5747 10. Remove both type A reinforcement brackets. Save the body mount studs and nuts for the final installation, and discard the original trailing link front mount mounting nuts. 11. Using a 1/2 in. drill motor and a 33/64 in. bit, drill final holes where you made the pilot holes. 12. Test fit a pop nut into each hole to be sure drilling is complete. NOTE: If a pop nut doesn't fit, don't try to enlarge the hole by pivoting the drill bit. Doing this creates an uneven seating surface for the pop nut. If the pop nut doesn't fit, your drill bit is worn out and needs to be sharpened or replaced. 13. Insert an air gun into the frame rail hole, and blow up and down the inside of the frame rails to move any rust or metal debris away from the area. 14. Attach the pop nut installer to shop air, and adjust the tool's air pressure regulator to between 72 and 87 psi. NOTE: ^ The tool's air pressure is critical: if it's too low, the pop nuts cannot be correctly installed; if it's too high, the tool will be damaged. ^ If this is your first time using the pop nut installer, or if you haven't used it in a while, practice installing one or two pop nuts onto the pop nut test plate: - Place a pop nut at the tip of installer's threaded mandrel. Make sure to keep your fingers away from the gap between the pop nut and the base of the mandrel. Squeeze the installer's trigger; the pop nut threads onto the mandrel. Page 167 and the fuses. From Fuses to Relays and Components The second half of Power Distribution shows the wiring "From Fuses to Relays and Components." This can speed your troubleshooting by showing which circuits share fuses. If Power Distribution shows that an inoperative circuit and another circuit share a fuse, check a component in the other circuit. If it works, you know the fuse is good and power is available to the inoperative circuit. Ground Distribution Schematics Page 5204 This sample Ground Distribution schematic shows all of the components that share two ground points. Components A solid border line means the entire component is shown. A broken border line indicates that only part of the component is shown. Page 7824 Splices Splices are shown as a dot. Their location and the number of wires may vary depending on the harness manufacturer. Switches Switches These switches move together; the broken straight line between them means they are mechanically connected. Other types of switches are controlled by a coil or a solid state circuit. Unless otherwise noted, all switches are shown in their normal (rest) position, with power off. Terminal "T" Description and Operation EGR Valve Position Sensor: Description and Operation EGR Pintle Position Sensor The PCM monitors the EGR valve pintle position input to endure that the valve responds properly to commands from the PCM and to detect a fault if the pintle position sensor and control circuits are open or shorted. If the PCM detects a pintle position signal voltage outside the normal range of the pintle position sensor, or a signal voltage that is not within a tolerance considered acceptable for proper EGR system operation, the PCM will set DTC P1406. Page 4610 Part 2 Of 3 Page 1171 Clutch Fluid: Service and Repair For further information regarding this component and the system that it is a part of, please refer to Clutch, M/T; Service and Repair; Hydraulic System Bleed. Page 7791 This means the branch of the wire connects to another circuit. The arrow points to the name of the circuit branch where the wire continues. Page 2900 Manifold Pressure/Vacuum Sensor: Service and Repair MANIFOLD ABSOLUTE PRESSURE (MAP) SENSOR REMOVAL PROCEDURE 1. Disconnect the negative battery cable. 2. Disconnect the electrical connector from the MAP sensor. 3. Remove the bolt securing the MAP sensor to the mounting bracket on the common chamber. 4. Remove the MAP sensor from the mounting bracket. INSTALLATION PROCEDURE 1. Install the MAP sensor in the mounting bracket. 2. Install the mounting bracket retaining bolt on the common chamber. Page 1811 Coolant: Service Precautions Mixing green and red colored coolants is not recommended. Page 549 If there is no photo number below or beside a component name or a connector, ground, or terminal number, look up that name or number in the appropriate Connector Identification Chart. The chart lists how many cavities a connector has, where it's located, and what it connects to. The related illustration shows the connector's location on the harness, and the harness routing. NOTE: Photos listed by number are located at Locations / Components / Photograohs. See: Locations/Component Locations/Photographs Circuit Schematics Page 6499 4. Clean and dry the seat belt guide, then put a piece of teflon tape on the inside. Use the teflon tape specified in this service bulletin; other brands or types of tape may eventually peel off and restrict seat belt movement. 5. Install the seat belt guide and the door panel. 6. Test the belt for proper retraction by pulling the latch plate down to the floor of the vehicle and then releasing it. The belt should retract fully in four seconds or less. Disclaimer Page 3016 The name of the component appears next to it followed by notes about its function along with any photo and connector view references. Connector "C" How to Identify Connector Terminals Cavity Numbering System The cavities (and wire terminals) in each connector are numbered starting from the upper left, looking at the male terminals from the terminal side (or looking at the female terminals from the wire side. Both views are in the same direction so the numbers are the same.) All actual cavities are numbered, even if they have no wire terminals in them. NOTE: Data Link Connector (DLC) terminals are numbered according to SAE standard J1962, not the Honda standard. The numbers of the four end terminals are molded into the corners of the connector face. Page 1326 Supportable Point: Front - Position the chassis stands at the bottom of the frame sidemember, behind the front wheel. Lifting Point: Rear - Position the floor jack at the center of the rear axle case when lifting the vehicle. Supportable Point: Rear - Position the chassis stands at the bottom of the frame sidemember, just behind the trailing link bracket. Testing and Inspection Air Filter Element: Testing and Inspection Air Cleaner Element Check the air cleaner filter for damage or dust clogging. Replace if it is damaged, or clean if it is clogged. Page 1955 Each schematic represents one circuit. A circuit's wires and components are arranged to show current flow, from power at the top of the page, to ground, at the bottom. Shared Circuits Other circuits may share power or ground terminals or wiring with the circuit shown. A wire that connects one circuit to another, for example, is cut short and has an arrowhead at the end of it pointing in the direction of current flow. Next to the arrowhead is the name of the circuit or component which shares that wiring. To quickly check shared wiring, check the operation of a component it serves. If that component works, you know the shared wiring is OK. Connectors All in-line and junction connectors are numbered (C725, C416, etc.). Component connectors are not numbered but are identified either by the name of Page 2714 amount of oxygen present in the exhaust gas entering the three-way catalytic converter. The Bank 1 HO2S 2 and the Bank 2 HO2S 2 sensors produce an output signal which indicates the oxygen storage capacity of the catalyst. This indicates the catalyst's ability to efficiently convert exhaust gases. If the catalyst is operating efficiently, the Bank 1 HO2S 1 and the Bank 2 HO2S 1 signals will be more active than the signals produced by the Bank 1 HO2S 2 and the Bank 2 HO2S 2 sensors. The catalyst monitor sensors operate the same as the fuel control sensors. The Bank 1 HO2S 2 and the Bank 2 HO2S 2 sensors" main function is catalyst monitoring, but they also have a limited role in fuel control. If a sensor output indicates a voltage either above or below the 450 mV bias voltage for an extended period of time, the PCM will make a slight adjustment to fuel trim to ensure that fuel delivery is correct for catalyst monitoring. A problem with the Bank 1 HO2S 2 signal circuit will set DTC P0137, P0138, or P0140, depending on the specific condition. A problem with the Bank 2 HO2S 2 signal circuit will set DTC P0157, P0158, or P0160, depending on the specific condition. A fault in the heated oxygen sensor heater element or its ignition feed or ground will result in lower sensor response. This may cause incorrect catalyst monitor diagnostic results. Brakes - Revised Brake Bleeding Procedure Brake Bleeding: All Technical Service Bulletins Brakes - Revised Brake Bleeding Procedure 01-016 January 30, 2001 Applies To: 1998-01 Passport - ALL Service Manual Update: Revised Brake Bleeding Procedure BACKGROUND The brake bleeding procedure in the 1998 thru 2001 Passport Service Manuals is incomplete. Use this service bulletin to update the manuals. WARRANTY INFORMATION None. CORRECTIVE ACTION 1. In the 1998, 1999, 2000, and 2001 Passport Service Manuals, on pages 5A-21 and 5A-22, cross out the entire Tech 2 Service Bleed procedure. 2. In each manual, on page 5A-21, write this note: See page 5C-10 for the brake bleeding procedure 3. In each manual, on page 5C-10, between steps 1 and 2, write this note: For important additional information, see Service Bulletin 01-016, Service Manual Update: Revised Brake Bleeding Procedure, Filed under Brakes. SERVICE MANUAL UPDATE INFORMATION To avoid trapping air bubbles in the ABS hydraulic unit while bleeding the brakes, the hydraulic unit must be tilted forward at a 15-degree angle or greater. Before bleeding, check the angle of the ABS hydraulic unit with an angle locator level. If needed, raise the rear of the vehicle to get the proper Accelerator Pedal Assembly/Sensor - Adjustment Update Accelerator Pedal Position Sensor: All Technical Service Bulletins Accelerator Pedal Assembly/Sensor - Adjustment Update 00-045 August 14, 2001 Applies To: 2000-02 Passport - ALL Service Manual Update: Accelerator Pedal Position Sensor (APPS) (Supersedes 00-045, dated May 23, 2000) Updated information is shown by asterisks and black bars. BACKGROUND When the accelerator pedal position sensor (APPS) or the accelerator pedal assembly is replaced for any reason, you must adjust the APPS. *This procedure is missing in the 2000 service manual and is wrong in the 2001 and 2002 service manuals. Make a note on page 6E2-539 of the 2000 Passport Fuel and Emissions manual, on page 6E2-553 of the 2001 Passport Fuel and Emissions manual, and on page 6E2-545 of the 2002 Passport Fuel and Emissions manual to refer to this bulletin.* ADJUSTMENT PROCEDURE 1. Replace the APPS or the accelerator pedal assembly, and leave the mounting screws for the APPS loose. 2. Connect the PGM Tester to the data link connector (DLC), and turn the ignition switch to ON (II). *3. While watching the APP Sensor values in the Engine Data List, adjust the APPS by turning it until the values are within the ranges shown at closed pushed all the way down), then tighten the throttle and wide open throttle (accelerator pedal mounting screws and recheck the values. ^ If all three sensors are within range, go to step 12. ^ If APP Sensor 1, APP Sensor 2, and/or APP Sensor 3 cannot be brought into range, go to step 4. 4. Troubleshoot for an open circuit or a PCM malfunction. ^ If APP Sensor 1 has a value of 0% or APP Sensor 2 and/or APP Sensor 3 have a value of 99%, an open circuit exists or the PCM is malfunctioning. Repair the circuit or replace the PCM, and repeat step 3. ^ If you don't find a problem, go to step 5. 5. Disconnect the 10P connector from the APPS. 6. View the APP Sensor values in the Engine Data List. ^ If APP Sensor 1 has a value of 0% or APP Sensor 2 and/or APP Sensor 3 have a value of 99%, go to step 7. ^ If APP Sensor 1 has a value other than 0%, or APP Sensor 2 and/or APP Sensor 3 have a value other than 99%, a short circuit exists or the PCM is malfunctioning. Repair the circuit or replace the PCM, and repeat step 3. Page 4899 Honda 1-Piece Speed Mounts P/N KWY-108006000 (for most models), P/N KWY-108007500 (Odysseys, Pilots, and Ridgelines with two-piston calipers) Attaching the Power Drive System 1. Make sure the drive motor assembly on the power drive system is level with the brake disc. 2. Attach the mounting yoke to the brake disc, and secure it with one of the wheel nuts. Torque the wheel nut to the required specification (see the appropriate service manual). Page 6118 Wires Wire insulation can be one color, or one color with another color stripe. (The second color is the stripe.) This circuit continues on another image. (The arrow shows direction of current flow.) To follow the RED/BLK wire in this example, you would turn to "Fuel and Emissions" and look for the "A" arrow. Steering/Suspension - Vehicle Pulls Left/Right Alignment: Customer Interest Steering/Suspension - Vehicle Pulls Left/Right 06-068 May 2, 2009 Applies To: ALL *Vehicle Pulls or Drifts, and/or Steering Wheel Is Off-Center (Supersedes 06-068, Vehicle Pulling or Drifting, dated October 4, 2007, to revise the information marked by asterisks) (Replaces 90-011, Steering Wheel Off-Center Adjustment at PDI)* *REVISION SUMMARY The title description was revised.* SYMPTOM While driving on a straight road, the vehicle pulls or drifts to the right or left. BACKGROUND New tools were developed to help you diagnose and correct a pulling and/or steering wheel off-center issue. There is a diagnosis worksheet included to take on your test-drive and record your findings. These values are used to build the 15-digit DTC (diagnostic trouble code) that is required for your warranty claim. The last step in each repair procedure helps you create the correct code. In the rare case that you have to repair a vehicle that pulls and has the steering wheel off-center, use REPAIR PROCEDURE B to file your warranty claim. For more information, refer to Training Module SSC 44 - Steering Drift or Pull Interactive Service Bulletin. PROBABLE CAUSES Several conditions can cause the vehicle to pull or drift: ^ Wheel alignment ^ Tires ^ Off-center steering wheel (no pulling or drifting, but a customer may believe this is the case) CORRECTIVE ACTION Diagnose the problem using the special tools and the worksheet on page 4 that guides you to one of four repair procedures. TOOL INFORMATION Centering Tape (enough to diagnose 240 vehicles): T/N O7AAJ-001A300 Steering Drift Set Level: T/N 07AAJ-00100 Steering Drift Set: T/N O7MJ-001A140 Replacement Weight for Steering Drift Set: T/N 07AAJ-001A400 WARRANTY CLAIM INFORMATION In warranty: The normal warranty applies. Failed Part: P/N 53560-SDA-AO1 H/C 7139652 Page 7714 Ground - "G" Shielding Sheilding This represents RFI (Radio Frequency Interference) shielding around a wire. The shielding is always connected to ground. Splices Page 243 View A REMOVAL 1. Disconnect the battery ground cable. 2. Remove the front console assembly. 3. Disconnect the connector from the control unit. 4. Remove 4 nuts. 5. Disconnect the control unit with brackets. 6. Remove 4 screws. 7. Disconnect the control unit from brackets. INSTALLATION To install, follow the removal steps in the reverse order, noting the following points. Torque: Nut (1) 8 Nm (69 inch lbs.) Air Bag Disarming and Arming Air Bag(s) Arming and Disarming: Service and Repair Air Bag Disarming and Arming Disabling The SRS Removal Turn the ignition switch to "lock" and remove key. 1. Remove SRS fuse "METER" and "SRS", from left dash side lower fuse block or disconnect battery. 2. Disconnect yellow 2 - pin connector at the base of steering column. 3. Remove glove box assembly, Refer to "Passenger Air Bag Assembly Replacement". 4. Disconnect yellow 2 - pin connector behind the glove box assembly. CAUTION: With the "SRS" fuse removed and ignition switch "ON", "AIR BAG" warning lamp will be "ON". This is normal operation and does not indicate an SRS malfunction. Enabling The SRS Installation CAUTION: Never use the air bag assembly from another vehicle. Use only the air bag assembly. Turn ignition switch to "LOCK" and remove key. 1. Connect yellow 2 - pin connector passenger air bag assembly. 2. Install glove box assembly, refer to "Passenger Air Bag Assembly Replacement". 3. Connect yellow 2 - pin connector at the base of steering column. 4. Install "AIR BAG" fuse "METER" and "SRS" to left dash side lower fuse block or connect battery. Turn ignition switch to "ON" and verify that the "AIR BAG" warning lamp flashes seven times and then turns "OFF". If it does not operate as described, perform the "Supplemental Restraint System (SRS) Diagnostic System Check". Front Hub and Disc Front Hub And Disc (4WD) Page 232 Air Bag Control Module: Description and Operation SRS Component and Wiring Location View SDM (Sensing and Diagnostic Module) WARNING: DURING SERVICE PROCEDURES, BE VERY CAREFUL WHEN HANDLING A SDM. NEVER STRIKE OR JAR THE SDM. NEVER POWER UP THE SRS WHEN THE SDM IS NOT RIGIDLY ATTACHED TO THE VEHICLE. ALL SDM AND MOUNTING BRACKET FASTENERS MUST BE CAREFULLY TORQUED AND THE ARROW MUST BE POINTED TOWARD THE FRONT OF THE VEHICLE TO ENSURE PROPER OPERATION OF THE SRS. THE SDM COULD BE ACTIVATED WHEN POWERED WHILE NOT RIGIDLY ATTACHED TO THE VEHICLE WHICH COULD CAUSE DEPLOYMENT AND RESULT IN PERSONAL INJURY. The SDM is designed to perform the following functions in the Supplemental Restraint System (SRS). 1. Energy Reserve -The SDM maintains 24 - Volt Loop Reserve (24 VLR) energy supply to provide deployment energy when ignition voltage is lost in a frontal crash. 2. Frontal Crash Detection - The SDM monitors vehicle velocity changes to detect frontal crashes which are severe enough to warrant deployment. 3. Air Bag Deployment - When a frontal crash of sufficient force is detected, the SDM will cause enough current to flow through the air bag assembly to deploy the air bag. 4. Malfunction Detection - The SDM performs diagnostic monitoring of SRS electrical components and sets a diagnostic trouble code when a malfunction is detected. 5. Frontal Crash Recording - The SDM records information regarding SRS status during frontal crash. 6. Malfunction Diagnosis - The SDM displays SRS diagnostic trouble codes and system status information through the use of a scan tool. 7. Driver notification - The SDM warns the vehicle driver of SRS malfunctions by controlling the "Air Bag" warning lamp. Page 1478 Crankshaft: Diagrams Page 5401 The steering wheel offset gauge is a sticker that attaches to the steering wheel and the steering column cover. Place the sticker on the steering wheel when the steering wheel is straight. When you test-drive the vehicle, you can read how many millimeters the steering wheel is off-center. NOTE: If the vehicle is pulling, repairing the pull may correct the steering wheel offset. Page 6899 Liftgate Window Glass: Service and Repair Tailgate Glass (Resin Top) Tailgate Glass (Resin Top) Removal 1. Disconnect the battery ground cable. 2. Remove the spare tire. 3. Remove the rear wiper. 4. Disconnect the rear defogger connectors (LH & RH). 5. Remove the tailgate glass stays. - Remove the two seats of two tailgate trim cover fixing bolts. 6. Remove the tailgate glass assembly. - Remove the two caps each on the left and right sides, then remove the screws. - Remove the two clips from the two ends of the tailgate moulding, then lift the glass assembly up and out. - Removing and installing the glass assembly require two persons. 7. Remove the tailgate seal. Installation To install, follow the removal steps in the reverse order, noting the following points. 1. Tighten the tailgate glass stay fixing bolts to the specified torque. Torque:19 Nm (14 lb.ft) 2. Make sure the lip is properly oriented when installing the tailgate seal. Page 7778 Distinct Of Circuit By Wire Base Color All wires have color-coded insulation. Wires belonging to a system's main harness will have a single color. Wires belonging to a system's sub-circuits will have a colored stripe. Striped wires use the codes found in the chart to show wire size and colors. Abbreviations are used to indicate wire color within a circuit diagram. How to Identify Connector Terminals How to Identify Connector Terminals Cavity Numbering System The cavities (and wire terminals) in each connector are numbered starting from the upper left, looking at the male terminals from the terminal side (or looking at the female terminals from the wire side. Both views are in the same direction so the numbers are the same.) All actual cavities are numbered, even if they have no wire terminals in them. NOTE: Data Link Connector (DLC) terminals are numbered according to SAE standard J1962, not the Honda standard. The numbers of the four end terminals are molded into the corners of the connector face. The connector cavity number is listed next to each terminal on the circuit schematic. The cavity / terminal shown is # 6. Using/Identifying Connector Terminal Views How to Use Connector Terminal Views To see the configuration of a connector's cavities, look up its view number in the Connector Views. Each view includes the color of the connector, where Page 7598 The name of the component appears next to it followed by notes about its function along with any photo and connector view references. Connector "C" How to Identify Connector Terminals Cavity Numbering System The cavities (and wire terminals) in each connector are numbered starting from the upper left, looking at the male terminals from the terminal side (or looking at the female terminals from the wire side. Both views are in the same direction so the numbers are the same.) All actual cavities are numbered, even if they have no wire terminals in them. NOTE: Data Link Connector (DLC) terminals are numbered according to SAE standard J1962, not the Honda standard. The numbers of the four end terminals are molded into the corners of the connector face. Page 3705 Splices Splices are shown as a dot. Their location and the number of wires may vary depending on the harness manufacturer. Switches Switches These switches move together; the broken straight line between them means they are mechanically connected. Other types of switches are controlled by a coil or a solid state circuit. Unless otherwise noted, all switches are shown in their normal (rest) position, with power off. Terminal "T" Page 4813 Chart B-24 Wheel Speed Input Abnormality (DTC 65 (Flash Out) / C0238 (Serial Communications)) Sensor Signal Abnormality Criteria Using TECH 2 1. While driving, the speed of one or two wheels is 25% or more higher than that of the other wheels. 2. The speed of one or two wheels is 10 km/h (6 mph) or more higher than that of the other wheels. 3. During steady driving, wheel speed changes abruptly. NOTE: Even after repairing the faulty part the Warning Light (W/L) does not go out if the vehicle is at a stop. Turn the ignition switch to the ON position and drive the vehicle at 12 km/h (8 mph) or higher to make sure that the warning light goes out. It is important to verify that the correct tires are installed on vehicle. Page 3636 may be due to improper gap adjustment or to excessive wear of the electrode during use. A check of the gap size and comparison to the gap specified for the vehicle in Maintenance and Lubrication will tell if the gap is too wide. A spark plug gap that is too small may cause an unstable idle condition. Excessive gap wear can be an indication of continuous operation at high speeds or with engine loads, causing the spark to run too hot. Another possible cause is an excessively lean fuel mixture. Low or high spark plug installation torque or improper seating can result in the spark plug running too hot and can cause excessive center electrode wear. The plug and the cylinder head seats must be in good contact for proper heat transfer and spark plug cooling. Dirty or damaged threads in the head or on the spark plug can keep it from seating even though the proper torque is applied. Once spark plugs are properly seated, tighten them to the torque shown in the Specifications Table. Low torque may result in poor contact of the seats due to a loose spark plug. Overtightening may cause the spark plug shell to be stretched and will result in poor contact between the seats. In extreme cases, exhaust blow-by and damage beyond simple gap wear may occur. Cracked or broken insulators may be the result of improper installation, damage during spark plug re-gapping, or heat shock to the insulator material. Upper insulators can be broken when a poorly fitting tool is used during installation or removal, when the spark plug is hit from the outside, or is dropped on a hard surface. Cracks in the upper insulator may be inside the shell and not visible. Also, the breakage may not cause problems until oil or moisture penetrates the crack later. A broken or cracked lower insulator tip (around the center electrode) may result from damage during re-gapping or from "heat shock" (spark plug suddenly operating too hot). - Damage during re-gapping can happen if the gapping tool is pushed against the center electrode or the insulator around it, causing the insulator to crack. When re-gapping a spark plug, make the adjustment by bending only the ground side terminal, keeping the tool clear of other parts. - "Heat shock" breakage in the lower insulator tip generally occurs during several engine operating conditions (high speeds or heavy loading) and may be caused by over-advanced timing or low grade fuels. Heat shock refers to a rapid increase in the tip temperature that causes the insulator material to crack. Spark plugs with less than the recommended amount of service can sometimes be cleaned and re-gapped then returned to service. However, if there is any doubt about the serviceability of a spark plug, replace it. Spark plugs with cracked or broken insulators should always be replaced. Page 5356 2. Unfasten C123 from the side of the engine compartment using a 90-degree pick. 3. Disconnect C123, and clean the terminals on both sides of the connector with contact cleaner. Shake the residue out of the connector. Allow the contact cleaner to evaporate for at least 3 minutes, then reconnect C123. 4. Fasten C123 to the left side of the engine compartment, and reinstall the air cleaner housing cover. 5. Remove the connector position assurance (CPA) clip from the APPS connector. 6. Disconnect the lop connector from the APPS. 7. Clean the terminals of the 10P APPS connector (harness side) with contact cleaner. Shake out residue from the connector, and allow the contact cleaner to evaporate for at least 3 minutes, then reconnect it. 8. Use the Smart Cable to reprogram the PCM with the latest software from the June 2001 or later HONDANET CD-ROM. Refer to Service Bulletin 99-005, Updating the Passport PCM, filed under Tools. 9. Use the PGM Tester to clear any DTCs. Page 5742 12. Insert the Noxudol 700 spray nozzle into the frame rail side hole, pointing down, until it touches the bottom of the frame. Spray the Noxudol downward while pulling out the nozzle. Spray two times. 13. Remove the long spray nozzle from the Noxudol 700 can, and attach the regular spray valve. Spray a coat of Noxudol 700 on the outside of both lower trailing link frame brackets and frame rails in the 20-inch (500 mm) section shown below. Be careful not to overspray onto the exhaust system or body painted areas. 14. Spray a coat of Noxudol 300 on the same areas you sprayed in step 13. Be careful not to overspray onto the exhaust system or painted areas on the body. 15. Reinstall both frame rail side hole plugs. If either plug was damaged or missing, install a new one. 16. If the side steps or the running boards were removed, reinstall them. Page 2594 Steps 6 - 8 Page 6109 Each schematic represents one circuit. A circuit's wires and components are arranged to show current flow, from power at the top of the page, to ground, at the bottom. Shared Circuits Other circuits may share power or ground terminals or wiring with the circuit shown. A wire that connects one circuit to another, for example, is cut short and has an arrowhead at the end of it pointing in the direction of current flow. Next to the arrowhead is the name of the circuit or component which shares that wiring. To quickly check shared wiring, check the operation of a component it serves. If that component works, you know the shared wiring is OK. Connectors All in-line and junction connectors are numbered (C725, C416, etc.). Component connectors are not numbered but are identified either by the name of Service and Repair Transmission Temperature Sensor/Switch: Service and Repair REMOVAL 1. Raise the vehicle and support it on jack stands. 2. Disconnect battery ground cable. 3. Drain fluid. 4. Remove sixteen 10 mm adapter case oil pan fixing screws, adapter case oil pan, and gasket. 5. Disconnect wiring harness from shift solenoid, band apply solenoid, and 7 pin connector of main case. Pull only on connectors, not on wiring harness. 6. Remove wiring harness assembly with transmission oil temperature sensor. INSTALLATION 1. Install wiring harness from shift solenoid, band apply solenoid, and 7 pin connector of main case. 2. Install oil pan gasket, oil pan and sixteen 10 mm fixing screws. Tighten the screws to the specified torque. Torque: 11 Nm (96 Ft. lbs.) 3. Fill transmission through the overfill screw hole of oil pan, using ATF DEXRON III. 4. Connect battery ground cable. Page 2125 Crankshaft Position Sensor: Description and Operation Crankshaft Position (CKP) Sensor The crankshaft position (CKP) sensor provides a signal used by the powertrain control module (PCM) to calculate the ignition sequence. The CKP sensor initiates the 58X reference pulses which the PCM uses to calculate RPM and crankshaft position. Page 255 Distinct Of Circuit By Wire Base Color All wires have color-coded insulation. Wires belonging to a system's main harness will have a single color. Wires belonging to a system's sub-circuits will have a colored stripe. Striped wires use the codes found in the chart to show wire size and colors. Abbreviations are used to indicate wire color within a circuit diagram. How to Identify Connector Terminals How to Identify Connector Terminals Cavity Numbering System The cavities (and wire terminals) in each connector are numbered starting from the upper left, looking at the male terminals from the terminal side (or looking at the female terminals from the wire side. Both views are in the same direction so the numbers are the same.) All actual cavities are numbered, even if they have no wire terminals in them. NOTE: Data Link Connector (DLC) terminals are numbered according to SAE standard J1962, not the Honda standard. The numbers of the four end terminals are molded into the corners of the connector face. The connector cavity number is listed next to each terminal on the circuit schematic. The cavity / terminal shown is # 6. Using/Identifying Connector Terminal Views How to Use Connector Terminal Views To see the configuration of a connector's cavities, look up its view number in the Connector Views. Each view includes the color of the connector, where Page 4113 Valve Body: Service and Repair Unit Overhaul For further information regarding this component and the system that it is a part of, please refer to Automatic Transmission/Transaxle; Service and Repair; Unit Overhaul Page 6524 5. Remove the rear roof trim cover. - Pry the trim cover clips free from the body panel. 6. Remove the rear sill plate. 7. Remove the anchor cover and the lower anchor bolt. 8. Remove the upper and lower quarter trim cover. - Refer to Interior Trim Panel (LWB) in Exterior/Interior Trim. 9. Remove the slider plate trim assembly (2). - Remove the two fixing screws from the adjustable shoulder anchor (1). - Pull out the seat belt through the hole (3) on the slider plate trim. 10. Remove the seat belt upper anchor bolt. 11. Remove the retractor. 12. Remove the rear seat belt assembly. 13. Remove the adjustable shoulder anchor assembly. - Remove the two fixing bolts. INSTALLATION To install, follow the removal steps in the reverse order, noting the following point. 1. Tighten the adjustable shoulder anchor assembly fixing bolts to the specified torque. Torque: 39 N.m (29 lb.ft) 2. Tighten the seat belt anchor bolts (Upper & Lower) and the retractor fixing bolts to the specified torque. Torque: 39 N.m (29 lb.ft). Removable Top Page 7797 2. Connect the short finder across the battery terminals and the load (component) side of the fuse terminal. 3. Close all switches in the circuit you're testing. 4. Turn on the short finder. This creates a pulsing magnetic field around the wiring between the fuse box and the short. 5. Beginning at the fuse box, slowly move the short finder along the circuit wiring. The meter will read current pulses through sheet metal and body trim. As long as the meter is between the fuse and the short, the needle will move with each current pulse. Once you move the meter past the point of the short, the needle will stop moving. Check the wiring and connectors in this area to locate the cause of the short. Testing For Continuity When testing for continuity at a connector without wire seals, you do not have to separate the two halves of the connector. Instead, probe the connector from the back. Always check both sides of the connector because dirty, corroded, and bent terminals can cause problems (no electrical contact = an open). 1. Disconnect the negative cable from the car battery. If you're using a DVOM, place it in the lowest "OHMS" range. Page 5682 Page 3452 20. Using a DVOM, check the voltage between the reference voltage pin for each sensor and ground. ^ If the sensor circuits all read 5.0 volts, go to step 22. ^ If any sensor circuit is above or below 5.0 volts, go to step 21. 21. Troubleshoot for an internal short in another sensor or a PCM malfunction. ^ To find the sensor with an internal short, monitor the reference voltage, and disconnect each sensor (FTPS, EGR, MAP TPS, CKP and CMP) one at a time until the reference voltage reads 5.0 volts. Replace that sensor, and repeat step 14. ^ To find a malfunctioning PCM, replace it with a known-good PCM. If all three sensors (APP Sensor 1, APP Sensor 2, and APP Sensor 3) are within range, the original PCM is faulty; replace it and repeat step 14. 22. Using a jumper wire, connect the reference voltage of each circuit to its signal input, and view the APP Sensor values in the Engine Data List. APP Sensor 1 should have a value of 99%, and APP Sensor 2 and APP Sensor 3 should each have a value of 0%. ^ If the values are not as specified, troubleshoot for high resistance on the signal input or a PCM malfunction. Repair the circuit or replace the PCM, then repeat step 14. ^ If the values are as specified, the problem may be intermittent. Disconnect the 10 P connector from the modified APPS, and connect it to the new APPS; then repeat step 14. Wiggle the APPS wires as you go through the adjustment procedure to find the intermittent problem. 23. Install the accelerator pedal assembly, and torque the bolts to 10 N.m (7 lb-ft). Page 4985 Page 5564 The SRS consists of the Sensing and Diagnostic Module (SDM), the driver air bag assembly, the SRS coil assembly, the passenger air bag assembly, and the "AIR BAG" warning lamp in the instrument cluster. The SDM, SRS coil assembly (driver side only), driver air bag assembly, passenger air bag assembly and connector wire make up the deployment loops. The function of the deployment loops is to supply current through air bag assembly, which will cause deployment of the air bags in the event of a frontal crash of sufficient force, up to 30 degrees off the centerline of the vehicle. The air bag assemblies are only supplied enough current to deploy when the SDM detects vehicle velocity changes severe enough to warrant deployment. The SDM contains a sensing device which converts vehicle velocity change to an electrical signal. The electrical signal generated is processed by the SDM and then compared to a value stored in memory. When the generated signal exceeds the stored value, the SDM will cause current to flow through the air bag assembly deploying the air bags. Page 6853 - Remove the fixing screws from back side of the rear door trim panel. 8. Remove the bracket. 9. Disconnect the speaker harness connector. 10. Remove the speaker with the speaker harness connector from the door inner panel. 11. Remove the waterproof sheet (1). - Taking notice of the door harness, peel the waterproof sheet off the door panel carefully. 12. Remove the speaker bracket. - Remove the six fixing screws. 13. Remove the fixing glass. - Remove one bolt and screw as shown in the figure, then pull it upward. Page 7879 The name of the component appears next to it followed by notes about its function along with any photo and connector view references. Connector "C" How to Identify Connector Terminals Cavity Numbering System The cavities (and wire terminals) in each connector are numbered starting from the upper left, looking at the male terminals from the terminal side (or looking at the female terminals from the wire side. Both views are in the same direction so the numbers are the same.) All actual cavities are numbered, even if they have no wire terminals in them. NOTE: Data Link Connector (DLC) terminals are numbered according to SAE standard J1962, not the Honda standard. The numbers of the four end terminals are molded into the corners of the connector face. Specifications Fuel Pressure: Specifications PRESSURE PRESSURE With Regulator Vacuume Hose Disconnected 42-55 Psi. Page 5923 Terminals - "T" Each "T" terminal (ring type) is numbered for reference and location. A "T" terminal is secured with a screw or bolt. Wires Page 1813 2. If antifreeze solution is used at a mixing ratio higher than 60%, the specific heat of the coolant falls and the engine may be overheated. Moreover, antifreeze performance drop and the coolant may be frozen. The density of the solution must be adjusted as occasion calls. Antifreeze solution lower than 20% may not have sufficient anticorrosive performance, and therefore, please never fail to adjust as occasion demands within the range of 20% to 60%. Page 7569 and the fuses. From Fuses to Relays and Components The second half of Power Distribution shows the wiring "From Fuses to Relays and Components." This can speed your troubleshooting by showing which circuits share fuses. If Power Distribution shows that an inoperative circuit and another circuit share a fuse, check a component in the other circuit. If it works, you know the fuse is good and power is available to the inoperative circuit. Ground Distribution Schematics Removal and Installation Power Steering Pump: Service and Repair Removal and Installation REMOVAL 1. Remove the drive belt. 2. Place a drain pan below the pump. 3. Disconnect the suction hose. 4. Disconnect the flexible hose. 5. Remove the power steering fixing bolt and remove the pump assembly. INSTALLATION 1. Install the pump assembly to the pump brakes, tighten the fixing bolt to the specified torque. Torque to 46 Nm (34 ft. lbs.). 2. Install the flexible hose. Tighten the eye bolt to specified torque. Torque to 54 Nm (40 ft. lbs.). 3. Install the drive belt. 4. Connect the suction hose, then fill and bleed system. Page 1485 2. Diameter size mark (1). The diameter size marks are stamped on the No.1 crankshaft balancer as shown in the illustration. Page 4918 8. Hub Nut. Turn to the place where there is a chamfer in the tapped hole to the outer side, and attach the nut. Preload Adjustment: a. Tighten the hub nut to 29 Nm (22 ft. lbs.), then fully loosen the nut. - Wrench: J-36827. b. Tighten the hub nut to the value given below, using a spring scale on the wheel stud. Bearing Preload: New bearing and New oil seal 20-25 N (4.4 - 5.5 lbs.) Used bearing and New oil seal 12-18 N (2.6 4.0 lbs.) c. If the measured bearing preload is outside the specifications, adjust it by loosening or tightening the bearing nut. 9. Lock Washer and Lock Screw. Turn the side with larger diameter of the tapered bore to the vehicle outer side, and attach the washer. If the bolt holes in the lock plate are not aligned with the corresponding holes in the nut, reverse the lock plate. If the bolt holes are still out of alignment, turn in the nut just enough to obtain alignment. Screw is to be fastened tightly so its head may come lower than the surface of the washer. 10. Hub flange. Apply adhesive (LOCTITE 515 or equivalent) to both joining faces. Page 1992 Powertrain Control Module: Service and Repair Reprogramming the PCM Electrically Erasable Programmable Read Only Memory (EEPROM) The electrically erasable programmable read only memory (EEPROM) is a permanent memory chip that is physically soldered within the PCM. The EEPROM contains the program and the calibration information that the PCM needs to control powertrain operation. Unlike the PROM used in past applications, the EEPROM is not replaceable. If the PCM is replaced, the new PCM will need to be programmed. Equipment containing the correct program and calibration for the vehicle is required to program the PCM. EEPROM Programming 1. Set-up - Ensure that the following conditions have been met: - The battery is fully charged. - The ignition is "ON." - The Vehicle Interface Module cable connection at the DLC is secure. 2. Program the PCM using the latest software matching the vehicle. Refer to up-to-date Techline equipment user's instructions. 3. If the PCM fails to program, proceed as follows: - Ensure that all PCM connections are OK. - Check the Techline equipment for the latest software version. - Attempt to program the PCM. If the PCM still cannot be programmed properly, replace the PCM. The replacement PCM must be programmed. Functional Check 1. Perform the On-Board Diagnostic System Check. 2. Start the engine and run for least one minute. 3. Check for DTCs using Scan Tool. 4. If the PCM fails to program, proceed as follow: - Ensure that all PCM connections are OK. - Check the ITCS for latest version software. - Attempt to program PCM again. If PCM still cannot be programmed properly, replace PCM. The replacement PCM must be programmed. Locations Shift Interlock Solenoid: Locations Under Center Console Page 7884 Wires Wire insulation can be one color, or one color with another color stripe. (The second color is the stripe.) This circuit continues on another image. (The arrow shows direction of current flow.) To follow the RED/BLK wire in this example, you would turn to "Fuel and Emissions" and look for the "A" arrow. Page 5130 2. Check for continuity across one of the stator coils and stator core. If a continuity exists, replace the coil. Standard: More than 1 M ohms Brush Measure the brush length. If more than limit, replace the brush. Standard: 18.0 mm (0.709 in) Limit: 5.5 mm (0.217 in) Rectifier Assembly Page 4419 Gear Sensor/Switch: Testing and Inspection TRANSFER POSITION SWITCH 1. With ball being free. A-B: There is continuity. 2. With ball forced into the switch. A-B: No continuity. 3. If 1) and 2) fail, replace with a new switch. Diagram Information and Instructions Brake Warning Indicator: Diagram Information and Instructions How to Identify Wiring Color-Coded Insulation Wire Color Wire Color Coding Page 1957 and the fuses. From Fuses to Relays and Components The second half of Power Distribution shows the wiring "From Fuses to Relays and Components." This can speed your troubleshooting by showing which circuits share fuses. If Power Distribution shows that an inoperative circuit and another circuit share a fuse, check a component in the other circuit. If it works, you know the fuse is good and power is available to the inoperative circuit. Ground Distribution Schematics Page 7405 the component if the component only has one connector, or by a capital letter (A, B, C, etc.) if the component has more than one connector. Below most connector numbers and component names are PHOTO and VIEW numbers. The PHOTO number refers to a photo in the back of the book that shows the connector's location on the car. The VIEW number refers to an illustration in the back of the book that shows the connector face, wire colors, connector cavity numbers, and other details. The connector cavity numbering sequence begins at the top left corner of the connector. Disregard any numbers molded into the connector housing. Wires Wires are identified by the abbreviated names of their colors; the second color is the color of the stripe. Wires are also identified by their location in a connector. The number "2" next to the male and female wire terminals at C416, for example, means those terminals join in cavity 2 of connector C416. Symbols A complete description of schematic symbols is given under wire color abbreviation. Power Distribution Schematics Power Distribution schematics show how power is supplied from the positive battery terminal to various circuits in the car. Refer to the Power Distribution section to get a more detailed picture of how power is supplied to the circuit you're working on. From Battery to Ignition Switch, Fuses, and Relays Individual circuit schematics begin with a fuse. The first half of Power Distribution, however, shows the wiring "upstream" between the battery Page 1843 Locations Transmission Position Switch/Sensor: Locations Left Side Of Automatic Transmission Page 5736 REQUIRED MATERIALS TOOL INFORMATION Service and Repair Rear Door Window Glass Weatherstrip: Service and Repair Rear Window Regulator, Glass and Glass Run Rear Window Regulator, Glass and Glass Run Removal 1. Disconnect the battery ground cable. 2. Remove the rear corner garnish. - Pull the garnish to disconnect the retaining clip. Locations Specifications Firing Order: Specifications Firing Order Firing Order Firing Order 1-2-3-4-5-6 Page 3732 and the fuses. From Fuses to Relays and Components The second half of Power Distribution shows the wiring "From Fuses to Relays and Components." This can speed your troubleshooting by showing which circuits share fuses. If Power Distribution shows that an inoperative circuit and another circuit share a fuse, check a component in the other circuit. If it works, you know the fuse is good and power is available to the inoperative circuit. Ground Distribution Schematics Page 4556 This means the branch of the wire connects to another circuit. The arrow points to the name of the circuit branch where the wire continues. Page 5755 8. On the passenger's side of the frame, loosen the four brake line clips. 9. Loosen the ABS speed sensor harness bracket bolts and clip from both front fenderwells. 10. Loosen the EVAP canister line from the bulkhead (three clips). Page 7678 Test Equipment CAUTION: Most circuits include solid-state devices. Test the voltages in these circuits only with a 10-megaohm or higher impedance digital multimeter. Never use a test light or analog meter on circuits that contain solid-state devices. Damage to the devices may result. Test Light and DVOM On circuits without solid-state devices, use a test light to check for voltage. A test light is made up of a 12 volt bulb with a pair of leads attached. After grounding one lead, touch the other lead to various points along the circuit where voltage should be present. The bulb will go on if there is voltage at the point being tested. If you need to know how much voltage is present, use a digital volt/ohmmeter (DVOM). Self-Powered Test Light and DVOM Use a self-powered test light to check for continuity. This tool is made up of a light bulb, battery, and two leads. To test it, touch the leads together: the light should go on. Use a self-powered test light only on an unpowered circuit. First, disconnect the battery, or remove the fuse that feeds the circuit you are working on. Select two points in the circuit between which you want to check continuity. Connect one lead of the self-powered test light to each point. If there is continuity, the test light's circuit will be completed, and the light will go on. If, in addition, you need to know exactly how much resistance there is between two points, use a digital volt/ohmmeter (DVOM). In the "OHMS" range, the DVOM will measure resistance between two points along a circuit. Low resistance means good continuity. Diodes and solid-state devices in a circuit can make a DVOM give a false reading. To check a reading, reverse the leads, and take a second reading. If the readings differ, the component is affecting the measurement. Jumper Wire Use a jumper wire to bypass an open circuit. A jumper wire is made up of an in-line fuse holder connected to a set of test leads. It should have a five ampere fuse. Never connect a jumper wire across a short circuit. The direct battery short will blow the fuse. Short Finder (Short Circuit Locator) Short finders are available to locate shorts to ground. The short finder creates a pulsing magnetic field in the shorted circuit which you can follow to the location of the short. To order any test equipment shown above, contact your local tool supplier. For a list of suppliers and tool numbers, refer to Honda Required Special Tools and Equipment Service Bulletin. Page 5421 Failed Part: P/N 53560-SDA-AO1 H/C 7139652 Defect Code: 07406 Symptom Code: 03602 Skill Level: Repair Technician Diagnostic Trouble Code: To create the 15-digit DTC, see the applicable repair procedure. Out of warranty: Any repair performed after warranty expiration may be eligible for goodwill consideration by the District Parts and Service Manager or your Zone Office. You must request consideration, and get a decision, before starting work. TOOL DESCRIPTIONS The holding force gauge measures the amount of pull on the vehicle. It is a bracket that counts as one weight, plus five removable weights. During the test-drive, attach the bracket and the weights to the steering wheel on the side opposite the pulling direction. For example, if the vehicle pulls to the right, attach the bracket and weights to the left side of the steering wheel. Start with the maximum amount of weight on the steering wheel, and remove the weights until the vehicle drives in a straight line. When recording the pull on the worksheet, write down the direction of the pull (lefi or right) and the number of weights required to balance the pull (one through six). For example, if you have the bracket and two weights on the steering wheel, then record this as three weights. NOTE: The bracket counts as one weight. Page 3077 Evaporative Emissions Hose: Description and Operation Purge/Vacuum Hoses Made of rubber compounds, these hoses route the gasoline fumes from their sources to the canister and from the canister to the intake air flow. Page 3333 Each schematic represents one circuit. A circuit's wires and components are arranged to show current flow, from power at the top of the page, to ground, at the bottom. Shared Circuits Other circuits may share power or ground terminals or wiring with the circuit shown. A wire that connects one circuit to another, for example, is cut short and has an arrowhead at the end of it pointing in the direction of current flow. Next to the arrowhead is the name of the circuit or component which shares that wiring. To quickly check shared wiring, check the operation of a component it serves. If that component works, you know the shared wiring is OK. Connectors All in-line and junction connectors are numbered (C725, C416, etc.). Component connectors are not numbered but are identified either by the name of Page 4733 Part 3 Of 3 Page 6767 and the fuses. From Fuses to Relays and Components The second half of Power Distribution shows the wiring "From Fuses to Relays and Components." This can speed your troubleshooting by showing which circuits share fuses. If Power Distribution shows that an inoperative circuit and another circuit share a fuse, check a component in the other circuit. If it works, you know the fuse is good and power is available to the inoperative circuit. Ground Distribution Schematics Page 6258 Refrigerant Oil: Service and Repair Contamination of Compressor Oil Contamination of Compressor Oil Unlike engine oil, no cleaning agent is added to the compressor oil. Even if the compressor runs for a long period of time (approximately one season), the oil never becomes contaminated as long as there is nothing wrong with the compressor or its method of use. Inspect the extracted oil for any of the following conditions: - The capacity of the oil has increased. - The oil has changed to red. - Foreign substances, metal powder, etc., are present in the oil. If any of these conditions exists, the compressor oil is contaminated. Whenever contaminated compressor oil is discovered, the receiver/drier must be replaced. Page 1694 6. Place the end of the return hose in a container. Have someone start the engine, then pour ATF into the reservoir while you watch the fluid coming out of the return hose. When the fluid coming out is the same color as the new fluid, turn off the engine. 7. Reconnect the return hose to the reservoir. 8. Start the engine. Fill the power steering reservoir to the proper level with ATF then turn off the engine. 9. Use the Smart Cable to reprogram the PCM with the latest software from the June 2001 or later HONDANET CD-ROM. Refer to Service Bulletin 99-005, Updating the Passport PCM, filed under Tools. 10. Use the PGM Tester to clear any DTCs. 11. Use the PGM Tester to check the broadcast code. Make sure the broadcast code matches the one you selected from the CD-ROM. WARRANTY CLAIM INFORMATION In warranty: The normal warranty applies. Failed Part: P/N 8-97181-590-0 H/C 5698030 Defect Code: 064 Contention Code: C01 Skill Level: Repair Technician Out of warranty: Any repair performed after warranty expiration may be eligible for goodwill consideration by the District Service Manager or your Zone Office. You must request consideration, and get a decision, before starting work. REPAIR PROCEDURE - APPS GROUND 1. Unclamp the air cleaner housing cover, and move it to the side for access to connector C123 (16P BLK). Page 1683 6. Place the end of the return hose in a container. Have someone start the engine, then pour ATF into the reservoir while you watch the fluid coming out of the return hose. When the fluid coming out is the same color as the new fluid, turn off the engine. 7. Reconnect the return hose to the reservoir. 8. Start the engine. Fill the power steering reservoir to the proper level with ATF then turn off the engine. 9. Use the Smart Cable to reprogram the PCM with the latest software from the June 2001 or later HONDANET CD-ROM. Refer to Service Bulletin 99-005, Updating the Passport PCM, filed under Tools. 10. Use the PGM Tester to clear any DTCs. 11. Use the PGM Tester to check the broadcast code. Make sure the broadcast code matches the one you selected from the CD-ROM. WARRANTY CLAIM INFORMATION In warranty: The normal warranty applies. Failed Part: P/N 8-97181-590-0 H/C 5698030 Defect Code: 064 Contention Code: C01 Skill Level: Repair Technician Out of warranty: Any repair performed after warranty expiration may be eligible for goodwill consideration by the District Service Manager or your Zone Office. You must request consideration, and get a decision, before starting work. REPAIR PROCEDURE - APPS GROUND 1. Unclamp the air cleaner housing cover, and move it to the side for access to connector C123 (16P BLK). A/T - Vehicle Speed Sensor Installation Precautions Vehicle Speed Sensor: Technical Service Bulletins A/T - Vehicle Speed Sensor Installation Precautions Install VSS Properly to Avoid Reman A/T Damage We can't emphasize enough how important it is to follow, to the letter, the installation instructions that come with a reman A/T. These instructions help ensure that you avoid damaging the A/T and score a successful repair. This is particularly true when it comes to installing the vehicle speed sensor (VSS). Step 6 of the instructions tells you to make sure its gear is fully engaged and the VSS is fully seated before you tighten the retaining bolt. If you don't install the VSS properly, the speed sensor gear will get stripped and the A/T will be seriously damaged. So don't take risks with your customer's vehicle. Always follow these instructions to the letter. You can rest assured you're doing the job right. Locations Page 4816 NOTE: Confirm that a white line marked on the cable is not twisted when connecting the speed sensor cable. 5. Install speed sensor connector. Page 6513 Seat Belt: Testing and Inspection Specifications Compression Check: Specifications Compression Pressure 145 psi. kg/cm2 at 300 rpm Page 3657 Shift Solenoid: Service and Repair REMOVAL 1. Raise the vehicle and support it on jack stands. 2. Disconnect battery ground cable. 3. Drain fluid. 4. Remove sixteen 10 mm screws, main case oil pan, magnet, and gasket. 5. Remove three 13 mm screws, oil filter. 6. Disconnect wiring harness from band control solenoid and shift solenoids. Pull only on connectors, not on wiring harness. 7. Remove spring pin for shift solenoid A, shift solenoid B, and band control solenoid respectively, using suitable pliers taking care not to damage solenoids. 8. Remove shift solenoid A, shift solenoid B, band control solenoid, and gaskets from main case valve body. Do not pull on wiring harness. Remove solenoids by grasping the metal tip. INSTALLATION 1. Install shift solenoid A, shift solenoid B, band control solenoid with new gaskets to main case valve body respectively. 2. Carefully install spring pin with hammer to avoid damage to valve body, etc. 3. Connect wiring harness to solenoids. 4. Install oil filter with a new gasket and the three 13 mm screws, tighten to the specified torque. Torque: 20 Nm (15 Ft. lbs.) Page 5671 1. Install lateral rod and make sure that the lateral rod is in its correct position. NOTE: When mounting lateral rod, be sure not to use grease on bushings or any other nearby part. 2. Install bolt and nut. Tighten the bolt and nut lightly, then retighten them to the specified torque after the vehicle is at curb height. Torque to 137 Nm (101 ft. lbs.). 3. Install nut and washer. Tighten the nut lightly, then retighten the nut to the specified torque after the vehicle is at curb height. Torque to 78 Nm (58 ft. lbs.). Page 7918 2. Connect the short finder across the battery terminals and the load (component) side of the fuse terminal. 3. Close all switches in the circuit you're testing. 4. Turn on the short finder. This creates a pulsing magnetic field around the wiring between the fuse box and the short. 5. Beginning at the fuse box, slowly move the short finder along the circuit wiring. The meter will read current pulses through sheet metal and body trim. As long as the meter is between the fuse and the short, the needle will move with each current pulse. Once you move the meter past the point of the short, the needle will stop moving. Check the wiring and connectors in this area to locate the cause of the short. Testing For Continuity When testing for continuity at a connector without wire seals, you do not have to separate the two halves of the connector. Instead, probe the connector from the back. Always check both sides of the connector because dirty, corroded, and bent terminals can cause problems (no electrical contact = an open). 1. Disconnect the negative cable from the car battery. If you're using a DVOM, place it in the lowest "OHMS" range. Page 5303 This means the branch of the wire connects to another circuit. The arrow points to the name of the circuit branch where the wire continues. Engine Controls - Engine Spark Knock Or Pinging Powertrain Control Module: All Technical Service Bulletins Engine Controls - Engine Spark Knock Or Pinging 01-084 June 19, 2009 Applies To: 2000-02 Passport - ALL Engine Spark Knock (Pinging) (Supersedes 01-084, dated March 18, 2003, to revise the information marked by asterisks) *REVISION SUMMARY Under WARRANTY CLAIM INFORMATION, the failed part number, the Honda code, the defect code, and the symptom code have been updated.* SYMPTOM An engine spark knock (pinging). PROBABLE CAUSE The programmed ignition timing does not correct quickly enough in some climates. CORRECTIVE ACTION Update the PCM software with the Smart Cable. TOOL INFORMATION PGM Tester with software update release SN200P (9/1/01) or later. For the other tools and equipment you need to update the PCM software, refer to Service Bulletin 99-005, Updathg the Passport POM, filed under Tools. WARRANTY CLAIM INFORMATION In warranty: The normal warranty applies. Operation Number: 125517 Flat Rate Time: 0.3 hour *Failed Part: P/N 8-12212-079-0 H/C 6974992 Defect Code: 03214 Symptom Code: 09117* Template ID: 01-084A Skill Level: Repair Technician Out of warranty: Any repair performed after warranty expiration may be eligible for goodwill consideration by the District Parts and Service Manager or your Zone Office. You must request consideration, and get a decision, before starting work. REPAIR PROCEDURE 1. Retrieve the PCM broadcast code with the PGM Tester or the Smart Cable (refer to Service Bulletin 99-005, Updathg the Passport PCM). Page 7158 Luggage Rack: Service and Repair Roof Rail Roof Rail Removal 1. Remove the front and rear roof rail cover. - Pry the roof rail covers. 2. Remove the roof rail sub assembly. - Remove the four fixing bolts at each roof rail. Installation To install, follow the removal steps in the reverse order, noting the following points. 1. Tighten the roof rail sub assembly fixing bolts to the specified torque. Torque: 8 N.m (69 lb.in) Page 4861 Terminals - "T" Each "T" terminal (ring type) is numbered for reference and location. A "T" terminal is secured with a screw or bolt. Wires Page 3610 Camshaft Position Sensor: Service and Repair REMOVAL PROCEDURE 1. Disconnect the negative battery cable. 2. Remove the engine cover. 3. Remove the common chamber assembly. 4. Disconnect the electrical connector to the CMP sensor. 5. Remove the CMP retaining bolt from the side of left cylinder head. 6. Remove the CMP sensor from the cylinder head. INSTALLATION PROCEDURE 1. Install the CMP sensor in the cylinder head. 2. Install the CMP sensor retaining bolt. Tighten Tighten the retaining screw to 9 N.m (78 lb in.). Page 5320 Page 6155 Test Equipment CAUTION: Most circuits include solid-state devices. Test the voltages in these circuits only with a 10-megaohm or higher impedance digital multimeter. Never use a test light or analog meter on circuits that contain solid-state devices. Damage to the devices may result. Test Light and DVOM On circuits without solid-state devices, use a test light to check for voltage. A test light is made up of a 12 volt bulb with a pair of leads attached. After grounding one lead, touch the other lead to various points along the circuit where voltage should be present. The bulb will go on if there is voltage at the point being tested. If you need to know how much voltage is present, use a digital volt/ohmmeter (DVOM). Self-Powered Test Light and DVOM Use a self-powered test light to check for continuity. This tool is made up of a light bulb, battery, and two leads. To test it, touch the leads together: the light should go on. Use a self-powered test light only on an unpowered circuit. First, disconnect the battery, or remove the fuse that feeds the circuit you are working on. Select two points in the circuit between which you want to check continuity. Connect one lead of the self-powered test light to each point. If there is continuity, the test light's circuit will be completed, and the light will go on. If, in addition, you need to know exactly how much resistance there is between two points, use a digital volt/ohmmeter (DVOM). In the "OHMS" range, the DVOM will measure resistance between two points along a circuit. Low resistance means good continuity. Diodes and solid-state devices in a circuit can make a DVOM give a false reading. To check a reading, reverse the leads, and take a second reading. If the readings differ, the component is affecting the measurement. Jumper Wire Use a jumper wire to bypass an open circuit. A jumper wire is made up of an in-line fuse holder connected to a set of test leads. It should have a five ampere fuse. Never connect a jumper wire across a short circuit. The direct battery short will blow the fuse. Short Finder (Short Circuit Locator) Short finders are available to locate shorts to ground. The short finder creates a pulsing magnetic field in the shorted circuit which you can follow to the location of the short. To order any test equipment shown above, contact your local tool supplier. For a list of suppliers and tool numbers, refer to Honda Required Special Tools and Equipment Service Bulletin. Page 6122 HVAC Control Bezel: Diagnostic Aids Before Troubleshooting Before Troubleshooting See: Service Precautions/Vehicle Damage Warnings/Tips and Precautions 1. Check applicable fuses in the appropriate fuse/relay box. 2. Check the battery for damage, state of charge, and clean and tight connections. CAUTION: Do not quick-charge a battery unless the battery ground cable has been disconnected, otherwise you will damage the alternator diodes. - Do not attempt to crank the engine with the battery ground cable loosely connected or you will severely damage the wiring. While You're Working 1. Make sure connectors are clean, and have no loose terminals or receptacles. 2. Make sure that connectors without wire seals are packed with dielectric (silicone) grease. Part Number: 08798-9001. 3. When connecting a connector, push it until it "clicks" into place. CAUTION: Do not pull on the wires when disconnecting a connector. Pull only on the connector housings. - Most circuits include solid-state devices. Test the voltages in these circuits only with a 10-megaohm or higher impedance digital multi meter. Never use a test light or analog meter on circuits that contain solid-state devices. Damage to the devices may result. Five-Step Troubleshooting 1. Verify The Complaint Turn on all the components in the problem circuit to check the accuracy of the customer complaint. Note the symptoms. Do not begin disassembly or testing until you have narrowed down the problem area. 2. Analyze The Schematic Look up the schematic for the problem circuit. Determine how the circuit is supposed to work by tracing the current paths from the power source through the circuit components to ground. Also, trace circuits that share wiring with the problem circuit. The names of circuits that share the same fuse, ground, or switch, and so on, are referred to in each circuit schematic. Try to operate any shared circuits you didn't check in step 1. If the shared circuits work, the shared wiring is OK, and the cause must be in the wiring used only by the problem circuit. If several circuits fail at the same time, the fuse or ground is a likely cause. Based on the symptoms and your understanding of the circuit's operation, identify one or more possible causes. 3. Isolate The Problem By Testing The Circuit Make circuit tests to check the diagnosis you made in step 2. Keep in mind that a logical, simple procedure is the key to efficient troubleshooting. Test for the most likely cause of failure first. Try to make tests at points that are easily accessible. 4. Fix The Problem Once the specific problem is identified, make the repair. Be sure to use proper tools and safe procedures. 5. Make Sure The Circuit Works Turn on all components in the repaired circuit in all modes to make sure you've fixed the entire problem. If the problem was a blown fuse, be sure to test all of the circuits on that fuse. Make sure no new problems turn up and the original problem does not recur. Page 162 Distinct Of Circuit By Wire Base Color All wires have color-coded insulation. Wires belonging to a system's main harness will have a single color. Wires belonging to a system's sub-circuits will have a colored stripe. Striped wires use the codes found in the chart to show wire size and colors. Abbreviations are used to indicate wire color within a circuit diagram. How to Identify Connector Terminals How to Identify Connector Terminals Cavity Numbering System The cavities (and wire terminals) in each connector are numbered starting from the upper left, looking at the male terminals from the terminal side (or looking at the female terminals from the wire side. Both views are in the same direction so the numbers are the same.) All actual cavities are numbered, even if they have no wire terminals in them. NOTE: Data Link Connector (DLC) terminals are numbered according to SAE standard J1962, not the Honda standard. The numbers of the four end terminals are molded into the corners of the connector face. The connector cavity number is listed next to each terminal on the circuit schematic. The cavity / terminal shown is # 6. Using/Identifying Connector Terminal Views How to Use Connector Terminal Views To see the configuration of a connector's cavities, look up its view number in the Connector Views. Each view includes the color of the connector, where Page 7646 2. Connect one lead of a self-powered test light or DVOM to one end of the part of the circuit you want to test. 3. Connect the other lead to the other end. 4. If the self-powered test light glows, there is continuity. If you're using a DVOM, a low reading or no reading (zero), means good continuity. Testing For Voltage When testing for voltage at a connector without wire seals, you do not have to separate the two halves of the connector. Instead, probe the connector from the back. Always check both sides of the connector because dirty, corroded, and bent terminals can cause problems (no electrical contact = an open). 1. Connect one lead of the lest light to a known good ground, or, if you're using a digital volt ohmmeter (DVOM), place it in the appropriate DC volts range, and connect its negative lead to ground. 2. Connect the other lead of the test light or DVOM to the point you want to check. 3. If the test light glows, there is voltage present. If you're using a DVOM, note the voltage reading. It should be within one volt of measured battery voltage. A loss of more than one volt indicates a problem. NOTE: Always use a DVOM on high impedance circuits. A test light may not glow (even with battery voltage present). Testing For Voltage Drop Wires, connectors, and switches are designed to conduct current with a minimum loss of voltage. A voltage drop of more than one volt indicates a problem. 1. Place the digital volt/ohmmeter (DVOM) in the appropriate DC volts range. Connect the positive lead to the end of the wire (or to the connector or switch) closest to the battery. 2. Connect the negative lead to the other end of the wire (or the other side of the connector or switch). 3. Turn on the components in the circuit. 4. The DVOM will show the difference in voltage between the two points. A difference, or drop, of more than one volt indicates a problem. Check the circuit for loose, dirty, or bent terminals. Page 3810 2. Compare the retrieved code with the codes shown. ^ If the code you retrieved is not in the list, the PCM has already been updated. Troubleshoot other causes for the PCM to reset. ^ If the code you retrieved is in the list, go to step 3. 3. If not already done, load the May 2001 or later HONDANET 2000 CD onto your HONDANET 2000 master terminal. Loading instructions are included in the CD's mailing. 4. Update the PCM software with the Smart Cable and the broadcast code information on the HONDANET 2000 CD. For updating instructions, refer to Service Bulletin 99-005, Updating the Passport PCM, filed under Tools. NOTE: ^ Since the Smart Cable may need to be cleared from a previous PCM update or the Smart Cable firmware may need to be reprogrammed, always begin each vehicle's PCM software update at the HONDANET 2000 workstation. ^ Make sure you select the most recent broadcast code from the list on the HONDANET screen. (This code is not necessarily at the top of the list. The most recent code is the last one in alphabetical sequence, letter by letter.) For example, among the codes DJTF, DDNN, and DCLY the most recent code is DJTF. 5. Use the PGM Tester to clear any DTCs. 6. After you update the PCM, retrieve the PCM broadcast code with the PGM Tester. Make sure the code does not match any from the list in step 2. DISCLAIMER Engine Controls - High/Erratic Engine Idle PROM - Programmable Read Only Memory: Customer Interest Engine Controls - High/Erratic Engine Idle 01-080 August 14, 2001 Applies To: 2000-02 Passport - ALL 2000-02 Passport: High or Erratic Idle SYMPTOM The engine occasionally idles at too high a speed, or the idle speed fluctuates. PROBABLE CAUSES The symptom could be the result of any of these conditions: ^ Loose or corroded engine or body ground ^ High resistance in the APPS ground circuit ^ PSP (power steering pressure) switch is internally shorted to ground ^ Fuel pressure regulator is leaking fuel into the intake manifold CORRECTIVE ACTION Diagnose the cause of the idle condition, and select the proper REPAIR PROCEDURE. PARTS INFORMATION REQUIRED MATERIALS REQUIRED SOFTWARE Each REPAIR PROCEDURE requires you to use the Smart Cable to reprogram the PCM with the latest software. To select the latest software from the CDROM, enter the year, model, engine, transmission, and emissions type (49-state or California). This gives you a list of broadcast codes. Select the broadcast code at the top of the list. WARRANTY CLAIM INFORMATION Refer to the Warranty Claim Information for each Repair Procedure. DIAGNOSIS 1. Find out from the customer when the high or erratic idle condition occurs and what the RPM range is: ^ Within 20 minutes of a cold start ^ After braking to a stop ^ All the time ^ Intermittently, with no set pattern Page 6696 Part 2 Of 2 Page 4367 SLIP JOINT DISASSEMBLY 1. Lay the shaft horizontally on a bench and secure. 2. Indicate the original assembled position by marking the phasing of the shaft prior to disassembly. 3. Using the flat blade of a screwdriver, pry the loose end of the boot clamp upwards and away from the propeller shaft boot. Be careful not to damage the boot. 4. When boot clamps becomes loose, remove by hand. 5. Repeat for the other boot clamp. 6. Remove the slip yoke assembly from the driveshaft, by securing the boot with one hand and pulling on the slip yoke. 7. Remove the boot from the shaft assembly. Auto Light Sensor Connector Ambient Light Sensor: Locations Auto Light Sensor Connector Behind Gauge Assembly Page 1563 Limit: 39.47 mm (1.5539 inch) Exhaust Standard: 39.3 mm (1.5472 inch) Limit: 39.45 mm (1.5531 inch) 2. Measure the valve seat contact width. Make the necessary corrections if the seat contact surface is damaged or rough or if the contact width wear exceeds the limit. Valve seat contact width Standard: 1.1 mm (0.0433 inch) Limit: 1.7 mm (0.0669 inch) Contact Surface Angle on Valve Seat on Valve 1. Measure contact surface angle on valve seat. 2. If the measured value exceeds the limit, replace valve, valve guide and valve seat as a set. Valve contact surface angle: 45° Valve Seat Insert Correction 1. Remove the carbon from the valve seat insert surface. Locations Fuel Pump Relay: Locations Fuse/Relay Box (Cover Removed) Page 3572 Ion Sensing Module: Description and Operation ION Sensing Module ION Sensing Module This module has the function to energize and de-energize the primary ignition coil in response to signals from the PCM. Page 2326 Ignition Switch Lock Cylinder: Service and Repair REMOVAL 1. Turn the steering wheel so that the vehicle's wheels are pointing straight ahead. 2. Turn the ignition switch to "LOCK". 3. Disconnect the battery "-" terminal cable, and wait at least 5 minutes. 4. Disconnect the yellow 2-way SRS connector located under the steering column. CAUTION: The wheels of the vehicle must be straight ahead and the steering column in the "LOCK" position before disconnecting the steering wheel. Failure to do so will cause the coil assembly to become uncentered which will cause damage to the coil assembly. 5. Remove the engine hood opening lever and steering lower cover. 6. Remove knee bolster (reinforcement). Page 2115 3. Connect the electrical connector to the CMP sensor. 4. Install the common chamber assembly. 5. Install the engine cover. 6. Connect the negative battery cable. Page 1409 Supportable Point: Rear - Position the chassis stands at the bottom of the rear axle case. Page 7750 If there is no photo number below or beside a component name or a connector, ground, or terminal number, look up that name or number in the appropriate Connector Identification Chart. The chart lists how many cavities a connector has, where it's located, and what it connects to. The related illustration shows the connector's location on the harness, and the harness routing. NOTE: Photos listed by number are located at Locations / Components / Photograohs. See: Locations/Component Locations/Photographs Circuit Schematics Page 3816 2. Compare the retrieved code with the listed codes. ^ If the code is in the list, go to step 3. ^ If the code is not in the list, the PCM has already been updated. Troubleshoot other causes for the detonation. NOTE: Since the Smart Cable may need to be cleared from a previous PCM update or the Smart Cable firmware may need to be reprogrammed, always begin each PCM update at the iN workstation. 3. Update the PCM software with the Smart Cable. For instructions, refer to Service Bulletin 99-005. NOTE: Make sure you select the most recent broadcast code from the list on the iN screen that applies to the model year, transmission type, and emission level. This code is not necessarily at the top of the list since the most recent code is the last one in the alphabetical sequence, letter by letter. 4. Use the PGM Tester to clear any DTCs set during programming. 5. Retrieve the broadcast code. Make sure it does not match any of the codes in the list in step 2 (indicating the PCM has been updated) and that it applies to the model year, transmission type, and emission level for the vehicle. The broadcast code should match a code in the list below. Disclaimer Page 2106 Air Flow Meter/Sensor: Description and Operation Mass Air Flow (MAF) Sensor The mass air flow (MAF) sensor measures the difference between the volume and the quantity of air that enters the engine. "Volume" means the size of the space to be filled. "Quantity" means the number of air molecules that will fit into the space. This information is important to the PCM because heavier, denser air will hold more fuel than lighter, thinner air. The PCM adjusts the air/fuel ratio as needed depending on the MAF value. The Tech 2 reads the MAF value and displays it in terms of grams per second (g/sec). At idle, the Tech 2 should read between 4 - 7 g/sec on a fully warmed up engine. Values should change quickly on acceleration. Values should remain stable at any given RPM. A failure in the MAF sensor or circuit will set DTC P0101, DTC P0102, or DTC P0103. Page 6860 Page 3213 Wires Wire insulation can be one color, or one color with another color stripe. (The second color is the stripe.) This circuit continues on another image. (The arrow shows direction of current flow.) To follow the RED/BLK wire in this example, you would turn to "Fuel and Emissions" and look for the "A" arrow. Page 5241 Page 7831 Test Equipment CAUTION: Most circuits include solid-state devices. Test the voltages in these circuits only with a 10-megaohm or higher impedance digital multimeter. Never use a test light or analog meter on circuits that contain solid-state devices. Damage to the devices may result. Test Light and DVOM On circuits without solid-state devices, use a test light to check for voltage. A test light is made up of a 12 volt bulb with a pair of leads attached. After grounding one lead, touch the other lead to various points along the circuit where voltage should be present. The bulb will go on if there is voltage at the point being tested. If you need to know how much voltage is present, use a digital volt/ohmmeter (DVOM). Self-Powered Test Light and DVOM Use a self-powered test light to check for continuity. This tool is made up of a light bulb, battery, and two leads. To test it, touch the leads together: the light should go on. Use a self-powered test light only on an unpowered circuit. First, disconnect the battery, or remove the fuse that feeds the circuit you are working on. Select two points in the circuit between which you want to check continuity. Connect one lead of the self-powered test light to each point. If there is continuity, the test light's circuit will be completed, and the light will go on. If, in addition, you need to know exactly how much resistance there is between two points, use a digital volt/ohmmeter (DVOM). In the "OHMS" range, the DVOM will measure resistance between two points along a circuit. Low resistance means good continuity. Diodes and solid-state devices in a circuit can make a DVOM give a false reading. To check a reading, reverse the leads, and take a second reading. If the readings differ, the component is affecting the measurement. Jumper Wire Use a jumper wire to bypass an open circuit. A jumper wire is made up of an in-line fuse holder connected to a set of test leads. It should have a five ampere fuse. Never connect a jumper wire across a short circuit. The direct battery short will blow the fuse. Short Finder (Short Circuit Locator) Short finders are available to locate shorts to ground. The short finder creates a pulsing magnetic field in the shorted circuit which you can follow to the location of the short. To order any test equipment shown above, contact your local tool supplier. For a list of suppliers and tool numbers, refer to Honda Required Special Tools and Equipment Service Bulletin. Page 263 The connector cavity number is listed next to each terminal on the circuit schematic. The cavity / terminal shown is # 6. Diodes A rectifier diode works like a one way valve. It allows current to flow only in the direction of the arrow. A Zener diode blocks reverse current at normal voltages just like a rectifier diode. At high voltages, however, a Zener diode allows current to flow in reverse. Fuses Locations Air Flow Meter/Sensor: Locations 28. Left Side of Engine Compartment Left Side Of Engine Compartment Page 7947 The name of the component appears next to it followed by notes about its function along with any photo and connector view references. Connector "C" How to Identify Connector Terminals Cavity Numbering System The cavities (and wire terminals) in each connector are numbered starting from the upper left, looking at the male terminals from the terminal side (or looking at the female terminals from the wire side. Both views are in the same direction so the numbers are the same.) All actual cavities are numbered, even if they have no wire terminals in them. NOTE: Data Link Connector (DLC) terminals are numbered according to SAE standard J1962, not the Honda standard. The numbers of the four end terminals are molded into the corners of the connector face. Page 5699 View B REMOVAL 1. Removal 2 screws. 2. Disconnect the actuator. 3. Remove the nut. 4. Disconnect bracket. 5. Remove the nut. 6. Disconnect the washer. 7. Remove the shock absorber. INSPECTION AND REPAIR Make necessary correction or parts replacement if wear, damage, corrosion or any other abnormal condition are found through inspection. Check the following parts: Shock absorber - Rubber bushing INSTALLATION 1. Install the shock absorber. 2. Install the washer and nut (5), then tighten it to the specified torque. Torque: 37 Nm (27 ft. lbs.) 3. Install bracket and nut (3), then tighten it to the specified torque. Torque: 37 Nm (27 ft. lbs.) Page 761 Test Equipment CAUTION: Most circuits include solid-state devices. Test the voltages in these circuits only with a 10-megaohm or higher impedance digital multimeter. Never use a test light or analog meter on circuits that contain solid-state devices. Damage to the devices may result. Test Light and DVOM On circuits without solid-state devices, use a test light to check for voltage. A test light is made up of a 12 volt bulb with a pair of leads attached. After grounding one lead, touch the other lead to various points along the circuit where voltage should be present. The bulb will go on if there is voltage at the point being tested. If you need to know how much voltage is present, use a digital volt/ohmmeter (DVOM). Self-Powered Test Light and DVOM Use a self-powered test light to check for continuity. This tool is made up of a light bulb, battery, and two leads. To test it, touch the leads together: the light should go on. Use a self-powered test light only on an unpowered circuit. First, disconnect the battery, or remove the fuse that feeds the circuit you are working on. Select two points in the circuit between which you want to check continuity. Connect one lead of the self-powered test light to each point. If there is continuity, the test light's circuit will be completed, and the light will go on. If, in addition, you need to know exactly how much resistance there is between two points, use a digital volt/ohmmeter (DVOM). In the "OHMS" range, the DVOM will measure resistance between two points along a circuit. Low resistance means good continuity. Diodes and solid-state devices in a circuit can make a DVOM give a false reading. To check a reading, reverse the leads, and take a second reading. If the readings differ, the component is affecting the measurement. Jumper Wire Use a jumper wire to bypass an open circuit. A jumper wire is made up of an in-line fuse holder connected to a set of test leads. It should have a five ampere fuse. Never connect a jumper wire across a short circuit. The direct battery short will blow the fuse. Short Finder (Short Circuit Locator) Short finders are available to locate shorts to ground. The short finder creates a pulsing magnetic field in the shorted circuit which you can follow to the location of the short. To order any test equipment shown above, contact your local tool supplier. For a list of suppliers and tool numbers, refer to Honda Required Special Tools and Equipment Service Bulletin. Page 1752 Air Filter Element: Service and Repair Cleaning Method Air Cleaner Element Tap the air cleaner filter gently so as not to damage the paper filter, or clean the element by blowing with compressed air of about 490 kPa (71 psi) from the clean side if it is extremely dirty. Page 4158 Clutch Release Fork: Service and Repair For further information regarding this component and the system that it is a part of, please refer to Clutch; Service and Repair; Unit Overhaul Page 2629 The wire insulation has one color or one color with another color stripe. The second color is the stripe. Page 7010 - Remove the rear roof bracket cover (4), rear roof bracket (2) connecting with resin top (1) and rear roof trim cover (3) by removing four fixing bolts (Resin top model). 3. Remove the dome light lens 4. Remove the dome light. - Remove the fixing screws. - Disconnect the dome light connector. 5. Remove the rear roof trim cover. 6. Remove the interior trim panels. 7. Remove the sunroof glass assembly. 8. Remove the sun roof handle cover and sunroof handle plate. - Remove the screw from the cover and the three fixing nuts from the plate. 9. Remove the sunvisor. - Remove the sunvisor fixing screws and the sunvisor holder. 10. Remove the sunroof finisher. 11. Remove the headlining. Installation To install, follow the removal steps in the reverse order, noting the following point. Page 5471 10. Use the PGM Tester to check the broadcast code. Make sure the broadcast code matches the one you selected from the CD-ROM. WARRANTY CLAIM INFORMATION In warranty: The normal warranty applies. Failed Part: P/N 8-17087-655-0 H/C 4375820 Defect Code: 064 Contention Code: C01 Skill Level: Repair Technician Out of warranty: Any repair performed after warranty expiration may be eligible for goodwill consideration by the District Service Manager or your Zone Office. You must request consideration, and get a decision, before starting work. REPAIR PROCEDURE - ENGINE/BODY GROUND 1. Use the ETM for the appropriate year to locate these ground connectors: G101, G104, G105, G106 and G160. 2. Inspect each connector for corrosion or looseness. 3. Remove the bolt from any connector that is corroded or loose. Clean the terminal connector with a wire brush. File flat any solder bumps on the connector. 4. Clean the contact surface on the engine or body with a wire brush. 5. Replace the bolt if it is heavily corroded. Otherwise, clean it with a wire brush. 6. Apply lithium dielectric grease to both sides of the terminal connector. 7. Reinstall the bolt, torque it to 14 N.m (10 lb-ft). 8. Use the Smart Cable to reprogram the PCM with the latest software from the June 2001 or later HONDANET CD-ROM. Refer to Service Bulletin 99-005, Updating the Passport PCM, filed under Tools. 9. Use the PGM Tester to clear any DTCs. 10. Use the PGM Tester to check the broadcast code. Make sure the broadcast code matches the one you selected from the CD-ROM. WARRANTY CLAIM INFORMATION In warranty: The normal warranty applies. Failed Part: P/N 8-97086-823-0 Page 1567 Let the cam push down the edge of tappet by using J-42689 valve clearance adjusting tool and push out the shim with a flat blade screw driver as shown in illustrations. Page 7530 Headlamp Reminder Indicator: Diagnostic Aids Before Troubleshooting Before Troubleshooting See: Service Precautions/Vehicle Damage Warnings/Tips and Precautions 1. Check applicable fuses in the appropriate fuse/relay box. 2. Check the battery for damage, state of charge, and clean and tight connections. CAUTION: Do not quick-charge a battery unless the battery ground cable has been disconnected, otherwise you will damage the alternator diodes. - Do not attempt to crank the engine with the battery ground cable loosely connected or you will severely damage the wiring. While You're Working 1. Make sure connectors are clean, and have no loose terminals or receptacles. 2. Make sure that connectors without wire seals are packed with dielectric (silicone) grease. Part Number: 08798-9001. 3. When connecting a connector, push it until it "clicks" into place. CAUTION: Do not pull on the wires when disconnecting a connector. Pull only on the connector housings. - Most circuits include solid-state devices. Test the voltages in these circuits only with a 10-megaohm or higher impedance digital multi meter. Never use a test light or analog meter on circuits that contain solid-state devices. Damage to the devices may result. Five-Step Troubleshooting 1. Verify The Complaint Turn on all the components in the problem circuit to check the accuracy of the customer complaint. Note the symptoms. Do not begin disassembly or testing until you have narrowed down the problem area. 2. Analyze The Schematic Look up the schematic for the problem circuit. Determine how the circuit is supposed to work by tracing the current paths from the power source through the circuit components to ground. Also, trace circuits that share wiring with the problem circuit. The names of circuits that share the same fuse, ground, or switch, and so on, are referred to in each circuit schematic. Try to operate any shared circuits you didn't check in step 1. If the shared circuits work, the shared wiring is OK, and the cause must be in the wiring used only by the problem circuit. If several circuits fail at the same time, the fuse or ground is a likely cause. Based on the symptoms and your understanding of the circuit's operation, identify one or more possible causes. 3. Isolate The Problem By Testing The Circuit Make circuit tests to check the diagnosis you made in step 2. Keep in mind that a logical, simple procedure is the key to efficient troubleshooting. Test for the most likely cause of failure first. Try to make tests at points that are easily accessible. 4. Fix The Problem Once the specific problem is identified, make the repair. Be sure to use proper tools and safe procedures. 5. Make Sure The Circuit Works Turn on all components in the repaired circuit in all modes to make sure you've fixed the entire problem. If the problem was a blown fuse, be sure to test all of the circuits on that fuse. Make sure no new problems turn up and the original problem does not recur. Page 6003 2. Connect the short finder across the battery terminals and the load (component) side of the fuse terminal. 3. Close all switches in the circuit you're testing. 4. Turn on the short finder. This creates a pulsing magnetic field around the wiring between the fuse box and the short. 5. Beginning at the fuse box, slowly move the short finder along the circuit wiring. The meter will read current pulses through sheet metal and body trim. As long as the meter is between the fuse and the short, the needle will move with each current pulse. Once you move the meter past the point of the short, the needle will stop moving. Check the wiring and connectors in this area to locate the cause of the short. Testing For Continuity When testing for continuity at a connector without wire seals, you do not have to separate the two halves of the connector. Instead, probe the connector from the back. Always check both sides of the connector because dirty, corroded, and bent terminals can cause problems (no electrical contact = an open). 1. Disconnect the negative cable from the car battery. If you're using a DVOM, place it in the lowest "OHMS" range. Locations Fuse Block: Locations Page 3271 H/C 4408092 Defect Code: 017 Contention Code: C99 Skill Level: Repair Technician Out of warranty: Any repair performed after warranty expiration may be eligible for goodwill consideration by the District Service Manager or your Zone Office. You must request consideration, and get a decision, before starting work. DISCLAIMER Page 8078 Splices Splices are shown as a dot. Their location and the number of wires may vary depending on the harness manufacturer. Switches Switches These switches move together; the broken straight line between them means they are mechanically connected. Other types of switches are controlled by a coil or a solid state circuit. Unless otherwise noted, all switches are shown in their normal (rest) position, with power off. Terminal "T" Page 5518 Power Steering Pump: Service and Repair Overhaul Page 7900 it is located, and what it connects to. Use the Connector Views to help locate the proper cavity when you need to probe a connector. It can be especially helpful if the connector has more than one wire of the same color. A dash symbol (-) indicates that the cavity is empty. Connector views can also be used to help diagnose multiple symptoms in separate circuits which could be caused by a single problem in a connector shared by those circuits. Here's an example: 1. Pick one of the multiple symptoms and look up the schematic for that circuit. 2. Make a list of all the in-line and fuse box connectors in that schematic , 3. Then, in the Connector Views, look up each connector on your list to see if circuits related to the other symptoms run through one of them. If they do, inspect that connector for the problem. Example: The blower, rear window defogger, and the windshield wiper don't work. List all in-line and fuse box connectors in the blower controls circuit and then check the Connector View (see the sample). You find that C324 is common to the blower controls, rear window defogger, and wiper/washer, so you inspect C324 and find the problem, bent terminals. Finding Component/Connector Locations Finding Component/Connector Locations To see where a component or connector is located on the car, look up its photo number in the "Component Location". The photo will also tell you the color of the connector, and how many cavities it has. Page 6029 6. Use a clean shop towel or a shop vacuum to remove any debris from the inside of the blower assembly housing. 7. Install the new blower resistor. 8. Install the new blower motor assembly and gasket, and plug in the 2P connector. 9. Plug the 6P connector into the new blower resistor. 10. 2000-01 Models: Reinstall the intake actuator relay. 11. Lift up the glove box, and push it back into the stops. Return the contents to the glove box. 12. Start the engine, and run the blower to make sure it works properly. Disclaimer Page 2519 Test Equipment CAUTION: Most circuits include solid-state devices. Test the voltages in these circuits only with a 10-megaohm or higher impedance digital multimeter. Never use a test light or analog meter on circuits that contain solid-state devices. Damage to the devices may result. Test Light and DVOM On circuits without solid-state devices, use a test light to check for voltage. A test light is made up of a 12 volt bulb with a pair of leads attached. After grounding one lead, touch the other lead to various points along the circuit where voltage should be present. The bulb will go on if there is voltage at the point being tested. If you need to know how much voltage is present, use a digital volt/ohmmeter (DVOM). Self-Powered Test Light and DVOM Use a self-powered test light to check for continuity. This tool is made up of a light bulb, battery, and two leads. To test it, touch the leads together: the light should go on. Use a self-powered test light only on an unpowered circuit. First, disconnect the battery, or remove the fuse that feeds the circuit you are working on. Select two points in the circuit between which you want to check continuity. Connect one lead of the self-powered test light to each point. If there is continuity, the test light's circuit will be completed, and the light will go on. If, in addition, you need to know exactly how much resistance there is between two points, use a digital volt/ohmmeter (DVOM). In the "OHMS" range, the DVOM will measure resistance between two points along a circuit. Low resistance means good continuity. Diodes and solid-state devices in a circuit can make a DVOM give a false reading. To check a reading, reverse the leads, and take a second reading. If the readings differ, the component is affecting the measurement. Jumper Wire Use a jumper wire to bypass an open circuit. A jumper wire is made up of an in-line fuse holder connected to a set of test leads. It should have a five ampere fuse. Never connect a jumper wire across a short circuit. The direct battery short will blow the fuse. Short Finder (Short Circuit Locator) Short finders are available to locate shorts to ground. The short finder creates a pulsing magnetic field in the shorted circuit which you can follow to the location of the short. To order any test equipment shown above, contact your local tool supplier. For a list of suppliers and tool numbers, refer to Honda Required Special Tools and Equipment Service Bulletin. Page 3233 Fuel Injector: Testing and Inspection Visual Inspection 1. Inspect the O-ring for cracks or leaks. 2. Replace worn or damaged O-rings. 3. Lubricate the new O-rings with engine oil before installation. Page 3567 Test Equipment CAUTION: Most circuits include solid-state devices. Test the voltages in these circuits only with a 10-megaohm or higher impedance digital multimeter. Never use a test light or analog meter on circuits that contain solid-state devices. Damage to the devices may result. Test Light and DVOM On circuits without solid-state devices, use a test light to check for voltage. A test light is made up of a 12 volt bulb with a pair of leads attached. After grounding one lead, touch the other lead to various points along the circuit where voltage should be present. The bulb will go on if there is voltage at the point being tested. If you need to know how much voltage is present, use a digital volt/ohmmeter (DVOM). Self-Powered Test Light and DVOM Use a self-powered test light to check for continuity. This tool is made up of a light bulb, battery, and two leads. To test it, touch the leads together: the light should go on. Use a self-powered test light only on an unpowered circuit. First, disconnect the battery, or remove the fuse that feeds the circuit you are working on. Select two points in the circuit between which you want to check continuity. Connect one lead of the self-powered test light to each point. If there is continuity, the test light's circuit will be completed, and the light will go on. If, in addition, you need to know exactly how much resistance there is between two points, use a digital volt/ohmmeter (DVOM). In the "OHMS" range, the DVOM will measure resistance between two points along a circuit. Low resistance means good continuity. Diodes and solid-state devices in a circuit can make a DVOM give a false reading. To check a reading, reverse the leads, and take a second reading. If the readings differ, the component is affecting the measurement. Jumper Wire Use a jumper wire to bypass an open circuit. A jumper wire is made up of an in-line fuse holder connected to a set of test leads. It should have a five ampere fuse. Never connect a jumper wire across a short circuit. The direct battery short will blow the fuse. Short Finder (Short Circuit Locator) Short finders are available to locate shorts to ground. The short finder creates a pulsing magnetic field in the shorted circuit which you can follow to the location of the short. To order any test equipment shown above, contact your local tool supplier. For a list of suppliers and tool numbers, refer to Honda Required Special Tools and Equipment Service Bulletin. Page 1121 15. Move drive belt tensioner to loose side using wrench, then install drive belt to normal position. 16. Install radiator upper fan shroud. 17. Install air cleaner assembly. Page 6074 the component if the component only has one connector, or by a capital letter (A, B, C, etc.) if the component has more than one connector. Below most connector numbers and component names are PHOTO and VIEW numbers. The PHOTO number refers to a photo in the back of the book that shows the connector's location on the car. The VIEW number refers to an illustration in the back of the book that shows the connector face, wire colors, connector cavity numbers, and other details. The connector cavity numbering sequence begins at the top left corner of the connector. Disregard any numbers molded into the connector housing. Wires Wires are identified by the abbreviated names of their colors; the second color is the color of the stripe. Wires are also identified by their location in a connector. The number "2" next to the male and female wire terminals at C416, for example, means those terminals join in cavity 2 of connector C416. Symbols A complete description of schematic symbols is given under wire color abbreviation. Power Distribution Schematics Power Distribution schematics show how power is supplied from the positive battery terminal to various circuits in the car. Refer to the Power Distribution section to get a more detailed picture of how power is supplied to the circuit you're working on. From Battery to Ignition Switch, Fuses, and Relays Individual circuit schematics begin with a fuse. The first half of Power Distribution, however, shows the wiring "upstream" between the battery Page 2789 Powertrain Control Module: Service Precautions Electrostatic Discharge Damage Electrostatic Discharge Damage Electronic components used in the PCM are often designed to carry very low voltage. Electronic components are susceptible to damage caused by electrostatic discharge. Less than 100 volts of static electricity can cause damage to some electronic components. By comparison, it takes as much as 4000 volts for a person to feel even the zap of a static discharge. There are several ways for a person to become statically charged. The most common methods of charging are by friction and induction. - An example of charging by friction is a person sliding across a vehicle seat. - Charge by induction occurs when a person with well insulated shoes stands near a highly charged object and momentary touches ground. Charges of the same polarity are drained off leaving the person highly charged with the opposite polarity. Static charges can cause damage, therefore it is important to use care when handling and testing electronic components. NOTE: To prevent possible electrostatic discharge damage, follow these guidelines: - Do not touch the PCM connector pins or soldered components on the PCM circuit board. - Do not open the replacement part package until the part is ready to be installed. - Before removing the pan: from the package, ground the package to a known good ground on the vehicle. - If the part has been handled while sliding across the seat, while sitting down from a standing position, or while walking a distance, touch a known good ground before installing the part. Page 4239 10. Remove the lower nut (1) of the stabilizer link. 11. Remove the lower bolt and nut (2) of the shock absorber. 12. Remove the tie-rod end from the knuckle. 13. Disconnect the hose of the shift on the fly, at the hose clip portion (1). 14. Disconnect the shift switch connector (2). 15. Remove the bolts and nuts of the lower control arm (Frame side), then disconnect the lower control arm from frame. 16. Disconnect between the right side upper control arm and the knuckle, then remove the knuckle with lower control arm. CAUTION: When removing the knuckle, be careful not to damage the oil seal inside of the knuckle. Page 6523 Rear Seat Belt And Associated Parts REMOVAL 1. Disconnect the battery ground cable. 2. Remove the tailgate weather strip. 3. Remove the rear end floor trim cover. 4. Remove the luggage room light. - Remove the luggage room light lens (1) and the fixing screw. - Disconnect the luggage room light connector. Page 7101 Test Equipment CAUTION: Most circuits include solid-state devices. Test the voltages in these circuits only with a 10-megaohm or higher impedance digital multimeter. Never use a test light or analog meter on circuits that contain solid-state devices. Damage to the devices may result. Test Light and DVOM On circuits without solid-state devices, use a test light to check for voltage. A test light is made up of a 12 volt bulb with a pair of leads attached. After grounding one lead, touch the other lead to various points along the circuit where voltage should be present. The bulb will go on if there is voltage at the point being tested. If you need to know how much voltage is present, use a digital volt/ohmmeter (DVOM). Self-Powered Test Light and DVOM Use a self-powered test light to check for continuity. This tool is made up of a light bulb, battery, and two leads. To test it, touch the leads together: the light should go on. Use a self-powered test light only on an unpowered circuit. First, disconnect the battery, or remove the fuse that feeds the circuit you are working on. Select two points in the circuit between which you want to check continuity. Connect one lead of the self-powered test light to each point. If there is continuity, the test light's circuit will be completed, and the light will go on. If, in addition, you need to know exactly how much resistance there is between two points, use a digital volt/ohmmeter (DVOM). In the "OHMS" range, the DVOM will measure resistance between two points along a circuit. Low resistance means good continuity. Diodes and solid-state devices in a circuit can make a DVOM give a false reading. To check a reading, reverse the leads, and take a second reading. If the readings differ, the component is affecting the measurement. Jumper Wire Use a jumper wire to bypass an open circuit. A jumper wire is made up of an in-line fuse holder connected to a set of test leads. It should have a five ampere fuse. Never connect a jumper wire across a short circuit. The direct battery short will blow the fuse. Short Finder (Short Circuit Locator) Short finders are available to locate shorts to ground. The short finder creates a pulsing magnetic field in the shorted circuit which you can follow to the location of the short. To order any test equipment shown above, contact your local tool supplier. For a list of suppliers and tool numbers, refer to Honda Required Special Tools and Equipment Service Bulletin. Page 3205 the component if the component only has one connector, or by a capital letter (A, B, C, etc.) if the component has more than one connector. Below most connector numbers and component names are PHOTO and VIEW numbers. The PHOTO number refers to a photo in the back of the book that shows the connector's location on the car. The VIEW number refers to an illustration in the back of the book that shows the connector face, wire colors, connector cavity numbers, and other details. The connector cavity numbering sequence begins at the top left corner of the connector. Disregard any numbers molded into the connector housing. Wires Wires are identified by the abbreviated names of their colors; the second color is the color of the stripe. Wires are also identified by their location in a connector. The number "2" next to the male and female wire terminals at C416, for example, means those terminals join in cavity 2 of connector C416. Symbols A complete description of schematic symbols is given under wire color abbreviation. Power Distribution Schematics Power Distribution schematics show how power is supplied from the positive battery terminal to various circuits in the car. Refer to the Power Distribution section to get a more detailed picture of how power is supplied to the circuit you're working on. From Battery to Ignition Switch, Fuses, and Relays Individual circuit schematics begin with a fuse. The first half of Power Distribution, however, shows the wiring "upstream" between the battery Page 3728 it is located, and what it connects to. Use the Connector Views to help locate the proper cavity when you need to probe a connector. It can be especially helpful if the connector has more than one wire of the same color. A dash symbol (-) indicates that the cavity is empty. Connector views can also be used to help diagnose multiple symptoms in separate circuits which could be caused by a single problem in a connector shared by those circuits. Here's an example: 1. Pick one of the multiple symptoms and look up the schematic for that circuit. 2. Make a list of all the in-line and fuse box connectors in that schematic , 3. Then, in the Connector Views, look up each connector on your list to see if circuits related to the other symptoms run through one of them. If they do, inspect that connector for the problem. Example: The blower, rear window defogger, and the windshield wiper don't work. List all in-line and fuse box connectors in the blower controls circuit and then check the Connector View (see the sample). You find that C324 is common to the blower controls, rear window defogger, and wiper/washer, so you inspect C324 and find the problem, bent terminals. Finding Component/Connector Locations Finding Component/Connector Locations To see where a component or connector is located on the car, look up its photo number in the "Component Location". The photo will also tell you the color of the connector, and how many cavities it has. Page 1042 Alignment: Description and Operation GENERAL DESCRIPTION "Front End Alignment" refers to the angular relationship between the front wheels, the front suspension attaching parts and the ground. Proper front end alignment must be maintained in order to insure efficient steering, good directional stability and to prevent abnormal tire wear. The most important factors of front end alignment are wheel toe-in, wheel camber and axle caster. CAMBER: Camber is the vertical tilting inward or outward of the front wheels. When the wheels tilt outward at the top, the camber is positive (+). When the wheels tilt inward at the top, the camber is negative (-). The amount of tilt measured in degrees from the vertical is called the camber angle (1). If camber is extreme or unequal between the wheels, improper steering and excessive tire wear will result. Negative camber causes wear on the inside of the tire, while positive camber causes wear to the outside. CASTER: This illustration shows view from the side of the vehicle. Caster (1) is the vertical tilting of the wheel axis either forward or backward (when viewed from the side of the vehicle). A backward tilt is positive (+) and a forward tilt is negative (-). On the short and long arm type suspension you cannot see a caster angle without a special instrument, but if you look straight down from the top of the upper control arm to the ground, the ball joints do not line up (fore and aft) when a caster angle other than 0 degree is present. With a positive angle, the lower ball joint would be slightly ahead (toward the front of the vehicle) of the upper ball joint center line. Page 7860 Hazard Warning Switch: Service and Repair Removal 1. Disconnect the battery ground cable. 2. Remove the meter cluster assembly (1). 3. Remove the hazard warning switch (2). - Disconnect the switch connector. - To remove the switch, push the lock from the back side of the meter cluster assembly. Installation To install, follow the removal steps in the reverse order. Page 2305 Throttle Position Sensor: Service and Repair REMOVAL PROCEDURE 1. Disconnect the negative battery cable. 2. Disconnect the TPS electrical connector. 3. Remove the bolts and the TP sensor from the throttle body. NOTE: Do not clean the TP sensor by soaking it in solvent. The sensor will be damaged as a result. INSTALLATION PROCEDURE 1. Install the TP sensor on the throttle body with the bolts. 2. Connect the TP electrical connector. 3. Install the negative battery cable. Page 999 Defect Code: 07406 Symptom Code: 03602 Skill Level: Repair Technician Diagnostic Trouble Code: To create the 15-digit DTC, see the applicable repair procedure. Out of warranty: Any repair performed after warranty expiration may be eligible for goodwill consideration by the District Parts and Service Manager or your Zone Office. You must request consideration, and get a decision, before starting work. TOOL DESCRIPTIONS The holding force gauge measures the amount of pull on the vehicle. It is a bracket that counts as one weight, plus five removable weights. During the test-drive, attach the bracket and the weights to the steering wheel on the side opposite the pulling direction. For example, if the vehicle pulls to the right, attach the bracket and weights to the left side of the steering wheel. Start with the maximum amount of weight on the steering wheel, and remove the weights until the vehicle drives in a straight line. When recording the pull on the worksheet, write down the direction of the pull (lefi or right) and the number of weights required to balance the pull (one through six). For example, if you have the bracket and two weights on the steering wheel, then record this as three weights. NOTE: The bracket counts as one weight. Page 2197 Power Steering Pressure Switch: Locations 27. Left Side of Engine Left Side Of Engine Page 1018 12. Test-drive your customer¡C■s vehicle on the same road you used earlier. - If the drift is now within spec, swap the tires back to the donor vehicle one at a time, and test-drive your customer¡C■s vehicle on the same road you used earlier. Do this until the drift comes back. Replace the bad tire(s), then return the vehicle to your customer. - If the drift is still out of spec using the donor vehicle tires, contact Tech Line for further action. A/T - Do Not Remove Torque Converter From Mainshaft Torque Converter: Technical Service Bulletins A/T - Do Not Remove Torque Converter From Mainshaft SOURCE: Honda Service News TITLE: Keep Torque Converter on Mainshaft to Avoid Damage APPLIES TO: All models SERVICE TIP: We can't emphasize enough how important it is to keep the torque converter in place when you're handling or installing a reman A/T. If the torque converter slips off the mainshaft, and you don't put it back on the shaft exactly right, you could cut the O-ring. This could result in loss of lock-up control and ATF leakage. Paint - Industrial Fallout Paint Damage Paint: Technical Service Bulletins Paint - Industrial Fallout Paint Damage 99-062 January 15, 2007 Applies To: ALL Paint Damage From Environmental Fallout (Supersedes 99-062, dated October 12, 1999 to update the information marked by the black bars and asterisks) SYMPTOM The exterior paint surface does not feel smooth after the vehicle is washed. PROBABLE CAUSE Environmental fallout (airborne metallic particles, tree sap, paint overspray, road tar, insect residue, etc.) has adhered to the exterior paint surface. NOTE: This form of paint damage should not be confused with acid rain damage. Unlike environmental fallout damage, acid rain damage appears on the paint surface as pits or water spots-possibly black or brown in the center-which may feel smooth to the touch. PREVENTION The shipping wax/wrap guard applied to the vehicle at the factory provides the best protection for the paint finish from environmental fallout and acid rain damage. American Honda strongly recommends that you leave the shipping wax/wrap guard on the vehicle for as long as possible. Your dealership is responsible for maintaining the vehicle's finish after the shipping wax/ wrap guard is removed. CORRECTIVE ACTION Select a product line from one of the manufacturers listed in REQUIRED MATERIALS to clean the paint surface and to wax it after cleaning. Make sure you follow the manufacturer's instructions for each of the products you use. REQUIRED MATERIALS Each of the clays listed should do at least three vehicles. WARRANTY CLAIM INFORMATION Page 1427 4. Loosen adjusting nut by three turns and tighten lock nut. Then, manually operating the throttle valve, make sure that the valve lever returns up to the stopper screw. If it does not reach the stopper screw, repeat from step 1. Page 3374 Testing For A Short With A Self-Powered Test Light or DVOM 1. Remove the blown fuse and disconnect the battery and load. 2. Connect one lead of a self-powered test light or digital volt/ohmmeter (DVOM) (switched to the lowest "OHMS" range) to the fuse terminal on the load side. 3. Connect the other lead to a known good ground. 4. Beginning near the fuse box, wiggle the harness. Continue this at convenient points about six inches apart while watching the test light or DVOM. 5. If the self-powered test light goes on or the DVOM displays a low reading or no reading (zero), there is a short to ground in the wiring near that point. Testing for a Short with a Test Light or DVOM 1. Remove the blown fuse and disconnect the load. 2. Connect a test light or digital volt/ohmmeter (DVOM), switched to the appropriate DC volts range, across the fuse terminals to make sure voltage is present. You might have to turn the ignition switch to ON; check the schematic to see. 3. Beginning near the fuse box, wiggle the harness. Continue this at convenient points about six inches apart while watching the test light or DVOM. 4. Where the test light goes , or the DVOM voltage drops to zero, there is a short to ground in the wiring near that point. NOTE: Always use a DVOM on high impedance circuits. A test light may not glow (even with battery voltage present). Testing For A Short With A Short Circuit Locator (Short Finder) 1. Remove the blown fuse. Leave the battery connected. Page 720 REPAIR PROCEDURE 1. Raise the vehicle on a hoist. 2. 2002 only: Loosen the bracket that secures the ATF cooler return line, and disconnect the line from the transmission. 3. Clean the accumulator housing. 4. Using the accumulator cover installation tool and a Phillips screwdriver to hold the tool, tap on the accumulator cover to unseat the cover from the snap ring. 5. Remove the snap ring from the accumulator housing. Page 5283 V6 Engine Room Component Locations 54. Below Center of Dash (Console Removed) Page 4444 the component if the component only has one connector, or by a capital letter (A, B, C, etc.) if the component has more than one connector. Below most connector numbers and component names are PHOTO and VIEW numbers. The PHOTO number refers to a photo in the back of the book that shows the connector's location on the car. The VIEW number refers to an illustration in the back of the book that shows the connector face, wire colors, connector cavity numbers, and other details. The connector cavity numbering sequence begins at the top left corner of the connector. Disregard any numbers molded into the connector housing. Wires Wires are identified by the abbreviated names of their colors; the second color is the color of the stripe. Wires are also identified by their location in a connector. The number "2" next to the male and female wire terminals at C416, for example, means those terminals join in cavity 2 of connector C416. Symbols A complete description of schematic symbols is given under wire color abbreviation. Power Distribution Schematics Power Distribution schematics show how power is supplied from the positive battery terminal to various circuits in the car. Refer to the Power Distribution section to get a more detailed picture of how power is supplied to the circuit you're working on. From Battery to Ignition Switch, Fuses, and Relays Individual circuit schematics begin with a fuse. The first half of Power Distribution, however, shows the wiring "upstream" between the battery Page 2082 7. Modify the original APPS by cutting the connector housing off of the sensor. 8. Connect the 10P connector to the modified APPS connector housing. 9. Using a DVOM, check the voltage between the reference voltage pin for each sensor and ground. ^ If the sensor circuits all read 5.0 volts, go to step 11. ^ If any sensor circuit is above or below 5.0 volts, go to step 10. 10. Troubleshoot for an internal short in another sensor or a PCM malfunction. ^ To find the sensor with an internal short, monitor the incorrect reference voltage, and disconnect each sensor (FTPS, EGR, MAP, TPS, CKP, and CMP) one at a time until the reference voltage reads 5.0 volts. Replace that sensor, and repeat step 3. ^ To find a malfunctioning PCM, replace it with a known-good PCM. If all three sensors (APP Sensor 1, APP Sensor 2, and APP Sensor 3) are within range, the original PCM is faulty; replace it and repeat step 3. Page 4681 the component if the component only has one connector, or by a capital letter (A, B, C, etc.) if the component has more than one connector. Below most connector numbers and component names are PHOTO and VIEW numbers. The PHOTO number refers to a photo in the back of the book that shows the connector's location on the car. The VIEW number refers to an illustration in the back of the book that shows the connector face, wire colors, connector cavity numbers, and other details. The connector cavity numbering sequence begins at the top left corner of the connector. Disregard any numbers molded into the connector housing. Wires Wires are identified by the abbreviated names of their colors; the second color is the color of the stripe. Wires are also identified by their location in a connector. The number "2" next to the male and female wire terminals at C416, for example, means those terminals join in cavity 2 of connector C416. Symbols A complete description of schematic symbols is given under wire color abbreviation. Power Distribution Schematics Power Distribution schematics show how power is supplied from the positive battery terminal to various circuits in the car. Refer to the Power Distribution section to get a more detailed picture of how power is supplied to the circuit you're working on. From Battery to Ignition Switch, Fuses, and Relays Individual circuit schematics begin with a fuse. The first half of Power Distribution, however, shows the wiring "upstream" between the battery Page 35 Electronic Brake Control Module: Pinout Values and Diagnostic Parameters EHCU Connector Pin-Out Checks Part 1 of 2 Part 2 of 2 - Disconnect Electronic Hydraulic Control Module. - Perform checks with high impedance digital multimeter J-39200 or equivalent. Page 4320 1. Raise the hooked end of the band with a screwdriver or equivalent. 2. Remove band (1). 3. Pry off circlip (1) with a screwdriver or equivalent. 4. Remove drive shaft joint assembly. 5. Remove the six balls (1) with a screwdriver or equivalent. Diagrams Page 2595 Steps 9 - 12 Test Description Number(s) below refer to the step number(s) on the Diagnostic Chart: 2. Visually/physically inspect for the following throttle valve conditions. 3. Visually/physically inspect for the following acceleration pedal conditions. 5. Check the following circuits for throttle valve and DC motor. Check the following TP sensor resistance and DC motor. 7. Check the following circuits for acceleration pedal. Check the following AP sensor resistance. 9. Following DTC: Software detect Error for ETC system. 10. Following DTC: Software detect Error for ETC system. Page 6741 This means the branch of the wire connects to another circuit. The arrow points to the name of the circuit branch where the wire continues. Page 5075 INSTALLATION 1. Install speed sensor (3). 2. Tighten the sensor fixing bolt (2) to the specified torque. Torque: 11 Nm (95 inch lbs.) 3. Connect harness connector (1). Page 3164 7. Modify the original APPS by cutting the connector housing off of the sensor. 8. Connect the 10P connector to the modified APPS connector housing. 9. Using a DVOM, check the voltage between the reference voltage pin for each sensor and ground. ^ If the sensor circuits all read 5.0 volts, go to step 11. ^ If any sensor circuit is above or below 5.0 volts, go to step 10. 10. Troubleshoot for an internal short in another sensor or a PCM malfunction. ^ To find the sensor with an internal short, monitor the incorrect reference voltage, and disconnect each sensor (FTPS, EGR, MAP, TPS, CKP, and CMP) one at a time until the reference voltage reads 5.0 volts. Replace that sensor, and repeat step 3. ^ To find a malfunctioning PCM, replace it with a known-good PCM. If all three sensors (APP Sensor 1, APP Sensor 2, and APP Sensor 3) are within range, the original PCM is faulty; replace it and repeat step 3. Service and Repair Vehicle Lifting: Service and Repair CAUTION: - If a lifting device other than the original jack is used, it is most important that the device be applied only to the correct lifting points. Raising the vehicle from any other point may result in serious damage. - When jacking or lifting a vehicle at the frame side rail or other prescribed lift points, be certain that lift pads do not contact the catalytic converter, brake pipes or cables, or fuel lines. Such contact may result in damage or unsatisfactory vehicle performance. Lifting Points And Supportive Point Locations Lifting Points and Supportable Point Locations Lifting Point: Front - When using a floor jack, lift on the Convex portion of the skid plate. Page 1644 4. Install axle housing assembly and tighten fixing bolts to the specified torque (4X4). Axle case bolts Torque: 82 Nm (60 ft. lbs.) Mounting bolts Torque: 152 Nm (112 ft. lbs.) 5. Install the shift on the fly. 6. Install relay lever assembly and tighten fixing bolts. Torque: 44 Nm (32 ft. lbs.) 7. Install suspension crossmember and tighten fixing bolts to the specified torque. Torque: 78 Nm (58 ft. lbs.) 8. Install radiator under fan shroud. 9. Install under cover. 10. Install engine oil level dipstick. 11. Fill engine oil until full level on engine oil gauge dipstick. Page 5689 4. Install bolt and nut, then tighten the nut to the specified torque. Torque to 31 Nm (27 ft. lbs.). Page 4392 5. Remove the meter assembly. - Push the metal cover (6) with the screw driver (7). 6. Remove the meter rear cover. 7. Remove the meter circuit board. 8. Remove the A/T shift indicator bulb. Installation To install, follow the removal steps in the reverse order. Page 6182 - Tear off the insulator carefully. - Remove the sensor fixing clip. - Use a back-up wrench when disconnecting all refrigerant pipes. Installation To install, follow the removal steps in the reverse order, noting the following points: 1. The sensor is installed on the core with the clip. 2. The sensor must not interfere with the evaporator core. 3. When installing the new evaporator core, install the duct sensor (2) to the evaporator core (1) specified position with the clip in the illustration. 4. O-rings cannot be reused. Always replace with new ones. 5. Be sure to apply new compressor oil to the O-ring when connecting lines. 6. Be sure to install the sensor and the insulator on the place where they were before. 7. To install a new evaporator core, add 50cc (1.7 fl.oz.) of new compressor oil to the new core. 8. Tighten the refrigerant lines to the specified torque. Refer to Main Data and Specifications for Torque Specifications. 9. Apply an adhesive to the parting face of the lining when assembling the evaporator assembly. Locations Parking Brake Warning Switch: Locations Under Center Console Page 4283 Testing For A Short With A Self-Powered Test Light or DVOM 1. Remove the blown fuse and disconnect the battery and load. 2. Connect one lead of a self-powered test light or digital volt/ohmmeter (DVOM) (switched to the lowest "OHMS" range) to the fuse terminal on the load side. 3. Connect the other lead to a known good ground. 4. Beginning near the fuse box, wiggle the harness. Continue this at convenient points about six inches apart while watching the test light or DVOM. 5. If the self-powered test light goes on or the DVOM displays a low reading or no reading (zero), there is a short to ground in the wiring near that point. Testing for a Short with a Test Light or DVOM 1. Remove the blown fuse and disconnect the load. 2. Connect a test light or digital volt/ohmmeter (DVOM), switched to the appropriate DC volts range, across the fuse terminals to make sure voltage is present. You might have to turn the ignition switch to ON; check the schematic to see. 3. Beginning near the fuse box, wiggle the harness. Continue this at convenient points about six inches apart while watching the test light or DVOM. 4. Where the test light goes , or the DVOM voltage drops to zero, there is a short to ground in the wiring near that point. NOTE: Always use a DVOM on high impedance circuits. A test light may not glow (even with battery voltage present). Testing For A Short With A Short Circuit Locator (Short Finder) 1. Remove the blown fuse. Leave the battery connected. Page 1660 Caution: When assembling the engine and transmission, confirm that dowels have been mounted in the specified positions at the engine side. Take care that dowel positions are different between the manual transmission and the automatic transmission. Otherwise, the transmission may be damaged. Page 6694 Radio/Stereo: Connector Views Page 6648 ^ Handle a CD by its edges; never touch the flat surfaces. Contamination from fingerprints, liquids, felt-tip pens, and labels can cause the CD to not play properly, or possibly jam in the drive. ^ When cleaning a disc, use a clean soft cloth. Wipe across the disc from the center to the outside. Do not wipe the disc in a circular motion. ^ A new CD may be rough on the inner and outer edges. The small plastic pieces causing this roughness can flake off and fall on the recording surface of the disc, causing skipping or other problems. Remove these pieces by rubbing the inner and outer edges with the side of a pencil or pen. ^ Various accessories are available to protect CDs and improve the sound quality of CDs. These accessories increase the thickness or diameter of the discs, and should not be used in CD changers. Disclaimer Diagram Information and Instructions Control Module HVAC: Diagram Information and Instructions How to Identify Wiring Color-Coded Insulation Wire Color Wire Color Coding Audio System - CD/DVD Precautions Compact Disc Player (CD): All Technical Service Bulletins Audio System - CD/DVD Precautions Adhesive Labels or Protective Disc Covers on CDs or DVDs: A Big Taboo NOTE: This article applies to all Honda models with a factory- or dealer-installed CD/DVD player or changer. We can't emphasize this enough: Never put adhesive labels or protective disc covers on recordable CDs or DVDs to be used in automotive CD/DVD players or changers. Here's why: ^ Recordable CDs and DVDs are actually thicker than their pre-recorded brethern. Automotive players and changers use rollers to draw the disc into the unit. The added thickness of an adhesive label or a protective disc cover can cause the disc to jam when it's loaded into or ejected from the unit. ^ CD/DVD players or changers are exposed to high temperatures inside the vehicle. High temperature can cause the label adhesive to soften. This can cause the label to curl on the edges and even form bubbles. Curled edges can catch on the rollers and bubbles add thickness to the disc. Either one can cause the disc to jam. To cut down on customer-caused damage, all '05 and later 0/Ms include this notice: Do not use CDs with adhesive labels. The label can curl up and cause the CD to jam in the unit. Anytime a service customer comes in with a loading or ejecting problem for a CD/DVD player or changer, ask if he or she used any discs with adhesive labels or protective disc covers. If the answer is yes, contact your DPSM for possible goodwill assistance. If the answer is no, then replace the audio unit under normal warranty. Page 2640 Powertrain Control Module: Service Precautions Reprogramming the PCM Reprogramming the PCM Reprogramming of the PCM is done without removing it from the vehicle . This provides a flexible and cost-effective method of making changes in software calibrations. Refer to the latest Techline information on reprogramming or flashing procedures. Page 8055 11. Turn the ignition switch to "ON" while watching warning light and check the light should flash 7 times and then go off. Page 4370 - Propeller shaft for run-out (Aluminum tube type). Static run-out limit: 1.0 mm (0.04 inch) TIR full length of tubing maximum. (TIR: Total Indicator Reading) - Propeller shaft for run-out (Steel tube type). Static run-out limit: 0.13 mm (0.005 inch) TIR on the neck of the slip tube shaft (with a boot). 0.25 mm (0.010 inch) TIR on the ends of the tubing 3 inches from the welds. 0.38 mm (0.015 inch) TIR at the linear center of the tube. 0.38 mm (0.015 inch) TIR for the full length of tube with 30" or less of tubing. (TIR: Total Indicator Reading) - Play in universal joint. Limit: Less than 0.15 mm (0.006 inch) Page 5887 9. Use wrench J-36827, remove hub nut. 10. Remove hub and disc assembly. 11. Remove ABS sensor ring. 12. Remove outer bearing. 13. Remove oil seal. 14. Remove inner bearing. 15. Remove bolt, if necessary, replace the wheel pin in the following manner. - Apply a scribe mark (1) to disc to hub. - Clamp the hub and disc assembly in a vise, using protective pads. Remove the 6 disc-to-hub retaining bolts. - Place hub on a suitable work surface and remove the studs by using a hammer. INSPECTION AND REPAIR Make necessary correction or parts replacement if wear, damage, corrosion or any other abnormal condition are found through inspection. Check the following parts. Hub - Hub bearing oil seal - Knuckle spindle Page 2504 If there is no photo number below or beside a component name or a connector, ground, or terminal number, look up that name or number in the appropriate Connector Identification Chart. The chart lists how many cavities a connector has, where it's located, and what it connects to. The related illustration shows the connector's location on the harness, and the harness routing. NOTE: Photos listed by number are located at Locations / Components / Photograohs. See: Locations/Component Locations/Photographs Circuit Schematics Locations 105. Left Side of Driver's Seat Service and Repair Suspension Spring ( Coil / Leaf ): Service and Repair REMOVAL 1. Raise the vehicle and support the frame with suitable safety stands. 2. Support the rear axle case with a jack. 3. Disconnect brake hose at the crossmember. 4. Remove breather hose. 5. Remove upper link fixing bolt, nut and rubber plate on the rear axle case (left-side only). 6. Disconnect the stabilizer bar at the stabilizer link. 7. Remove the shock absorber from the axle case. 8. Remove spring insulator. 9. Remove the insulator and coil spring while lowering the rear axle case. CAUTION: Be sure not to let the brake hose, parking brake cable, and breather hose extend to their full length. INSPECTION AND REPAIR Make necessary correction or parts replacement if wear, damage, corrosion or any other abnormal condition are found through inspection. Check the following parts: Coil spring - Insulator INSTALLATION Page 7525 Terminals - "T" Each "T" terminal (ring type) is numbered for reference and location. A "T" terminal is secured with a screw or bolt. Wires Page 7899 Distinct Of Circuit By Wire Base Color All wires have color-coded insulation. Wires belonging to a system's main harness will have a single color. Wires belonging to a system's sub-circuits will have a colored stripe. Striped wires use the codes found in the chart to show wire size and colors. Abbreviations are used to indicate wire color within a circuit diagram. How to Identify Connector Terminals How to Identify Connector Terminals Cavity Numbering System The cavities (and wire terminals) in each connector are numbered starting from the upper left, looking at the male terminals from the terminal side (or looking at the female terminals from the wire side. Both views are in the same direction so the numbers are the same.) All actual cavities are numbered, even if they have no wire terminals in them. NOTE: Data Link Connector (DLC) terminals are numbered according to SAE standard J1962, not the Honda standard. The numbers of the four end terminals are molded into the corners of the connector face. The connector cavity number is listed next to each terminal on the circuit schematic. The cavity / terminal shown is # 6. Using/Identifying Connector Terminal Views How to Use Connector Terminal Views To see the configuration of a connector's cavities, look up its view number in the Connector Views. Each view includes the color of the connector, where Page 7283 Spare Tire Carrier Removal 1. Remove the spare tire. 2. Remove the spare tire carrier by using spare tire carrier nut wrench J-34355. Installation 1. Spare tire carrier. - Tighten the carrier fixing bolts to the specified torque. Torque: 31 N.m (23 lb.ft) 2. Spare tire - Tighten the spare tire fixing bolts to the specified torque. Torque: 118 N.m (87 lb.ft) Page 2152 Manifold Pressure/Vacuum Sensor: Testing and Inspection Manifold Absolute Pressure (MAP) Output Check Circuit Description The manifold absolute pressure (MAP) sensor measures the changes in the intake MAP which result from engine load (intake manifold vacuum) and engine speed changes; and converts these into a voltage output. The powertrain control module (PCM) sends a 5-volt reference voltage to the MAP sensor. As the MAP changes, the output voltage of the sensor also changes. By monitoring the the sensor output voltage, the PCM knows the MAP. A lower pressure (low voltage) output voltage will be about 1 - 2 volts at idle. Higher pressure (high voltage) output voltage will be about 4 - 4.8 volts at wide open throttle. The MAP sensor is also used, under certain conditions, to measure barometric pressure, allowing the PCM to make adjustments for different altitudes. The PCM uses the MAP sensor to diagnose proper operation of the EGR system, in addition to other functions. Airbag Deployment and Disposal Air Bag: Service and Repair Airbag Deployment and Disposal Deploying the Airbags/Tensioner (Inside Vehicle) Only deploy the airbag inside the vehicle If the vehicle is to be destroyed or salvaged for component parts. This includes, but is not limited to, the following situations. 1. The vehicle has completed its useful life. 2. The vehicle has been damaged beyond repair in a non deployment type accident. 3. The vehicle has been stripped or damaged beyond repair in a theft. 4. Vehicle will be salvaged for component parts to be used on a vehicle with a different Vehicle Identification Number (VIN) as opposed to being rebuilt as same VIN. Never use SRS components from another vehicle. WARNING: FAILURE TO FOLLOW PROPER SRS AIR BAG ASSEMBLY DISPOSAL PROCEDURES CAN RESULT IN AIR BAG DEPLOYMENT WHICH MAY CAUSE PERSONAL INJURY. UNDEPLOYED AIR BAG ASSEMBLIES MUST NOT BE DISPOSED OF THROUGH NORMAL REFUSE CHANNELS. THE UNDEPLOYED AIR BAG ASSEMBLY CONTAINS SUBSTANCES THAT CAN CAUSE SEVERE ILLNESS OR PERSONAL INJURY IF THE SEALED CONTAINER IS DAMAGED DURING DISPOSAL. DISPOSAL IN ANY MANNER INCONSISTENT WITH PROPER PROCEDURES MAY BE A VIOLATION OF FEDERAL, STATE AND/OR LOCAL LAWS. 1. Turn ignition switch to "LOCK", remove key and put on safety glasses. 2. Remove all loose objects from front seats. 3. Disconnect Supplemental Restraint System (SRS) coil assembly, yellow 2 - pin connector located at the base of the steering column. 4. Cut the SRS coil assembly yellow 2 - pin harness connector from the vehicle leaving at least 16 cm (six inches) of wire at the connector. 5. Strip 13 mm (1/2 inch) of insulation from yellow - green and yellow - lack wire lead of the connector. 6. Cut two 900 cm (30 feet) deployment wires from 0.8 sq.mm (18 gauge) or thicker multi - strand wire. These wires will be used to fabricate the driver deployment harness. 7. Strip 13 mm (112 inch) of insulation from both ends of the wires cut in the previous step. 8. Short the wires by twisting together one end from each. Deployment wires shall remain shorted and not be connected to a power source until the air bag is to be deployed. WARNING: FAILURE TO FOLLOW PROCEDURES IN THE ORDER LISTED COULD RESULT IN PERSONAL INJURY. NEVER CONNECT DEPLOYMENT WIRES TO ANY POWER SOURCE BEFORE CONNECTING DEPLOYMENT WIRES TO THE AIR BAG ASSEMBLY LEADS. DEPLOYMENT WIRES SHALL REMAIN SHORTED AND NOT BE CONNECTED TO A POWER SOURCE UNTIL THE AIR BAG IS TO BE DEPLOYED. THE AIR BAG ASSEMBLY WILL IMMEDIATELY DEPLOY THE AIR BAG WHEN A POWER SOURCE IS CONNECTED TO IT. WEAR SAFETY GLASSES THROUGHOUT THIS ENTIRE DEPLOYMENT AND DISPOSAL PROCEDURE. 9. Twist together ore connector wire lead to one deployment wire. The connection should be mechanically secure. Page 6067 Page 3633 Spark Plug: Specifications Plug Torque 13 ft lb (18 Nm) Page 1272 angle. The angle locator level (P/N SUN-YA328A) is available through the Honda Tool and Equipment Program. To order one, call 888-424-6857. DISCLAIMER Page 7986 Brake Light Switch: Service and Repair REMOVAL 1. Disconnect connector (1) 2. Remove lock nut (3). 3. Remove switch (2). INSTALLATION 1. Adjust the stop light switch to the specified clearance (between switch housing and brake pedal) by rotating the switch housing. NOTE: Do not attempt to force the push rod into position during the stop light switch installation and adjustment procedure. 2. Connect connector (1). 3. Install lock nut (3). Page 2709 Oxygen Sensor: Connector Locations 95. Right Front Exhaust Downpipe Right Front Exhaust Downpipe 93. Left Front Exhaust Downpipe Left Front Exhaust Downpipe Locations Page 218 2. Connect one lead of a self-powered test light or DVOM to one end of the part of the circuit you want to test. 3. Connect the other lead to the other end. 4. If the self-powered test light glows, there is continuity. If you're using a DVOM, a low reading or no reading (zero), means good continuity. Testing For Voltage When testing for voltage at a connector without wire seals, you do not have to separate the two halves of the connector. Instead, probe the connector from the back. Always check both sides of the connector because dirty, corroded, and bent terminals can cause problems (no electrical contact = an open). 1. Connect one lead of the lest light to a known good ground, or, if you're using a digital volt ohmmeter (DVOM), place it in the appropriate DC volts range, and connect its negative lead to ground. 2. Connect the other lead of the test light or DVOM to the point you want to check. 3. If the test light glows, there is voltage present. If you're using a DVOM, note the voltage reading. It should be within one volt of measured battery voltage. A loss of more than one volt indicates a problem. NOTE: Always use a DVOM on high impedance circuits. A test light may not glow (even with battery voltage present). Testing For Voltage Drop Wires, connectors, and switches are designed to conduct current with a minimum loss of voltage. A voltage drop of more than one volt indicates a problem. 1. Place the digital volt/ohmmeter (DVOM) in the appropriate DC volts range. Connect the positive lead to the end of the wire (or to the connector or switch) closest to the battery. 2. Connect the negative lead to the other end of the wire (or the other side of the connector or switch). 3. Turn on the components in the circuit. 4. The DVOM will show the difference in voltage between the two points. A difference, or drop, of more than one volt indicates a problem. Check the circuit for loose, dirty, or bent terminals. Page 4577 Fluid - Transfer Case: Fluid Type Specifications Transfer Case Fluid Transfer (4WD) .................................................................................................................................... ............................................................ SAE 5W-30 Shift On The Fly System: Type ..................................................................................................................................................... ...................................................... GL-5 GearLube* Viscosity: Below 50° F (10° C) Front ................................................................................................................... ............................................................................... SAE 75W-90 synthetic Rear ................................ .............................................................................................................................................................. ........... SAE 80 or 80W-90 From 0° F to 90° F (-18° C to 32° C) Front .......................................................................................... ........................................................................................................ SAE 75W-90 synthetic Rear ....... .............................................................................................................................................................. .................................... SAE 90 or 80W-90 Above 50° F (10° C) consistently Front ............................................................................................... ...................................................................................... SAE 80W-90 or SAE 80W-140 Rear ............ .............................................................................................................................................................. ............................................... SAE 140 Front Wheel Speed Sensor: Service and Repair Front REMOVAL 1. Remove speed sensor connector. 2. Remove sensor cable fixing bolt (Upper side). 3. Remove sensor cable! fixing bolt (Lower side). 4. Remove the speed sensor cable fixing bolt. 5. Remove speed sensor. INSTALLATION 1. Install speed sensor and take care not to hit the speed sensor pole piece during installation. 2. Install speed sensor fixing bolt and tighten the fixing bolt to the specified torque. Torque: 11 Nm (95 inch lbs.) 3. Install speed sensor cable fixing bolt (Lower side) and tighten the fixing bolt to the specified torque. Torque: 24 Nm (18 ft. lbs.) 4. Install speed sensor cable fixing bolt (Upper side) and tighten the fixing bolt to the specified torque. Torque: 6 Nm (52 ft. lbs.) Page 7480 the component if the component only has one connector, or by a capital letter (A, B, C, etc.) if the component has more than one connector. Below most connector numbers and component names are PHOTO and VIEW numbers. The PHOTO number refers to a photo in the back of the book that shows the connector's location on the car. The VIEW number refers to an illustration in the back of the book that shows the connector face, wire colors, connector cavity numbers, and other details. The connector cavity numbering sequence begins at the top left corner of the connector. Disregard any numbers molded into the connector housing. Wires Wires are identified by the abbreviated names of their colors; the second color is the color of the stripe. Wires are also identified by their location in a connector. The number "2" next to the male and female wire terminals at C416, for example, means those terminals join in cavity 2 of connector C416. Symbols A complete description of schematic symbols is given under wire color abbreviation. Power Distribution Schematics Power Distribution schematics show how power is supplied from the positive battery terminal to various circuits in the car. Refer to the Power Distribution section to get a more detailed picture of how power is supplied to the circuit you're working on. From Battery to Ignition Switch, Fuses, and Relays Individual circuit schematics begin with a fuse. The first half of Power Distribution, however, shows the wiring "upstream" between the battery Page 6107 it is located, and what it connects to. Use the Connector Views to help locate the proper cavity when you need to probe a connector. It can be especially helpful if the connector has more than one wire of the same color. A dash symbol (-) indicates that the cavity is empty. Connector views can also be used to help diagnose multiple symptoms in separate circuits which could be caused by a single problem in a connector shared by those circuits. Here's an example: 1. Pick one of the multiple symptoms and look up the schematic for that circuit. 2. Make a list of all the in-line and fuse box connectors in that schematic , 3. Then, in the Connector Views, look up each connector on your list to see if circuits related to the other symptoms run through one of them. If they do, inspect that connector for the problem. Example: The blower, rear window defogger, and the windshield wiper don't work. List all in-line and fuse box connectors in the blower controls circuit and then check the Connector View (see the sample). You find that C324 is common to the blower controls, rear window defogger, and wiper/washer, so you inspect C324 and find the problem, bent terminals. Finding Component/Connector Locations Finding Component/Connector Locations To see where a component or connector is located on the car, look up its photo number in the "Component Location". The photo will also tell you the color of the connector, and how many cavities it has. Page 2630 Powertrain Control Module: Diagnostic Aids Before Troubleshooting Before Troubleshooting See: Service Precautions/Vehicle Damage Warnings/Tips and Precautions 1. Check applicable fuses in the appropriate fuse/relay box. 2. Check the battery for damage, state of charge, and clean and tight connections. CAUTION: Do not quick-charge a battery unless the battery ground cable has been disconnected, otherwise you will damage the alternator diodes. - Do not attempt to crank the engine with the battery ground cable loosely connected or you will severely damage the wiring. While You're Working 1. Make sure connectors are clean, and have no loose terminals or receptacles. 2. Make sure that connectors without wire seals are packed with dielectric (silicone) grease. Part Number: 08798-9001. 3. When connecting a connector, push it until it "clicks" into place. CAUTION: Do not pull on the wires when disconnecting a connector. Pull only on the connector housings. - Most circuits include solid-state devices. Test the voltages in these circuits only with a 10-megaohm or higher impedance digital multi meter. Never use a test light or analog meter on circuits that contain solid-state devices. Damage to the devices may result. Five-Step Troubleshooting 1. Verify The Complaint Turn on all the components in the problem circuit to check the accuracy of the customer complaint. Note the symptoms. Do not begin disassembly or testing until you have narrowed down the problem area. 2. Analyze The Schematic Look up the schematic for the problem circuit. Determine how the circuit is supposed to work by tracing the current paths from the power source through the circuit components to ground. Also, trace circuits that share wiring with the problem circuit. The names of circuits that share the same fuse, ground, or switch, and so on, are referred to in each circuit schematic. Try to operate any shared circuits you didn't check in step 1. If the shared circuits work, the shared wiring is OK, and the cause must be in the wiring used only by the problem circuit. If several circuits fail at the same time, the fuse or ground is a likely cause. Based on the symptoms and your understanding of the circuit's operation, identify one or more possible causes. 3. Isolate The Problem By Testing The Circuit Make circuit tests to check the diagnosis you made in step 2. Keep in mind that a logical, simple procedure is the key to efficient troubleshooting. Test for the most likely cause of failure first. Try to make tests at points that are easily accessible. 4. Fix The Problem Once the specific problem is identified, make the repair. Be sure to use proper tools and safe procedures. 5. Make Sure The Circuit Works Turn on all components in the repaired circuit in all modes to make sure you've fixed the entire problem. If the problem was a blown fuse, be sure to test all of the circuits on that fuse. Make sure no new problems turn up and the original problem does not recur. Starting System - Unable To Key In Ignition Switch Ignition Lock: Technical Service Bulletins Starting System - Unable To Key In Ignition Switch Can't Turn Ignition Switch? Check for Locked Steering Got a service customer complaining he or she can't turn the ignition switch to start the engine? The reason could just be the steering column lock pin is engaged with the front wheels turned. Here's what typically happens: Some folks use the steering wheel to help support themselves while climbing in or out of the vehicle. This is very common among elderly or disabled drivers. Doing this turns the front wheels, which twists the tires against the ground. The twisted tires apply torque to the steering column. With the ignition switch in LOCK (0), the steering column lock pin is engaged. But the applied torque on the steering column binds the lock pin, making it tough to turn the ignition switch. The ignition switch won't turn to ON (II) if the lock pin isn't disengaged from the steering column. Tell your customer there's nothing wrong with the ignition switch itself. All he or she needs to do is turn the steering wheel from side to side while turning the switch. This usually releases the lock pin so the engine can be started. In some cases, though, your customer may need to give a good tug on the wheel. This could easily happen when parking on a hill and the wheels are turned sharply before the engine is shut off. Description and Operation Seat Belt Buckle: Description and Operation Seat Belt and Seat Belt Buckle Tensioners The seat belt and seat belt buckle tensioners are linked with the SRS airbags to further increase the effectiveness of the seat belt. In a front-end collision, the tensioners instantly retract the belt and buckle firmly to secure the occupants in their seats. Page 2960 Vehicle Speed Sensor: Locations 92. Beneath Center of Vehicle, on Transfer Case (A/T) Beneath Center of Vehicle, on Transfer Case (A/T) Page 2462 Disclaimer Repair Procedure 1. Unclamp the air cleaner housing cover, and move it to the side for access to connector C123 (16P BLK). 2. Unfasten C123 from the side of the engine compartment using a 90-degree pick. 3. Disconnect C123, and clean the terminals on both sides of the connector with contact cleaner. Shake the residue out of the connector. Allow the contact cleaner to evaporate for at least 3 minutes, then reconnect C123. 4. Fasten C123 to the left side of the engine compartment, then reinstall the air cleaner housing cover. 5. While supporting the accelerator pedal assembly, remove the two bolts that secure the assembly to the bulkhead. Carefully lower the assembly to gain access to the connector. Page 6736 The connector cavity number is listed next to each terminal on the circuit schematic. The cavity / terminal shown is # 6. Diodes A rectifier diode works like a one way valve. It allows current to flow only in the direction of the arrow. A Zener diode blocks reverse current at normal voltages just like a rectifier diode. At high voltages, however, a Zener diode allows current to flow in reverse. Fuses Page 3090 5. Control EGR Valve and check data list. - If data list changes, the EGR Control is normal. Page 6489 2. Remove the fixing bolt and child seat tether anchorage bracket. INSTALLATION To install, follow the removal steps in the reverse order, noting the following points. 1. Install the bracket such that its tether belt hook hole is facing toward the front of the vehicle. 2. Tighten the fixing bolts to the specified torque. Torque: 19 N.m (14 lb.ft) Page 5330 Description and Operation Knee Diverter: Description and Operation The knee bolsters are used to absorb energy to protect knees and control the forward movement of the vehicle's front seat occupants during a frontal crash, by limiting leg movement. Page 750 This sample Ground Distribution schematic shows all of the components that share two ground points. Components A solid border line means the entire component is shown. A broken border line indicates that only part of the component is shown. Page 1966 Wire Color Abbreviations The following abbreviations are used to identify wire colors in the circuit schematics: WHT................................... White YEL................................... Yellow BLK................................... Black BLU................................... Blue GRN................................... Green RED................................... Red ORN................................... Orange PNK................................... Pink BRN................................... Brown GRY................................... Gray PUR................................... Purple LT BLU................................... Light Blue LT GRN................................... Light Green Interior - Seat Belts Slow to Retract Seat Belt: Customer Interest Interior - Seat Belts Slow to Retract 03-062 September 16, 2003 Applies To: ALL Seat Belt Slow to Retract (Replaces 91-030, dated January 22, 1996) SYMPTOM The seat belt will not retract all the way, or retracts slowly. PROBABLE CAUSE Dirt on the seat belt webbing and guide. CORRECTIVE ACTION Clean the seat belts and guides with a mild soap and water solution, or isopropyl alcohol. This applies only to three-point active and passive seat belt systems, not to motorized systems. REQUIRED MATERIALS Required only for three-point passive seat belts. Teflon Tape (ten pieces per package): P/N 81496-SH3-505, H/C 4008041 WARRANTY CLAIM INFORMATION This repair is covered by the Lifetime Seat Belt Limited Warranty. Failed Part: P/N 818AD-SM1-A05ZB H/C 3478047 Defect Code: L11 Contention Code: B99 Skill Level: Repair Technician REPAIR PROCEDURE Three-Point Active Seat Belts 1. Use either isopropyl alcohol, or prepare a solution of 5 ounces of mild dishwashing liquid in a gallon of warm water. NOTICE Do not use strong cleaning solutions, upholstery cleaners or commercial automotive interior cleaners. They can affect the durability of the webbing. Page 2578 Testing For A Short With A Self-Powered Test Light or DVOM 1. Remove the blown fuse and disconnect the battery and load. 2. Connect one lead of a self-powered test light or digital volt/ohmmeter (DVOM) (switched to the lowest "OHMS" range) to the fuse terminal on the load side. 3. Connect the other lead to a known good ground. 4. Beginning near the fuse box, wiggle the harness. Continue this at convenient points about six inches apart while watching the test light or DVOM. 5. If the self-powered test light goes on or the DVOM displays a low reading or no reading (zero), there is a short to ground in the wiring near that point. Testing for a Short with a Test Light or DVOM 1. Remove the blown fuse and disconnect the load. 2. Connect a test light or digital volt/ohmmeter (DVOM), switched to the appropriate DC volts range, across the fuse terminals to make sure voltage is present. You might have to turn the ignition switch to ON; check the schematic to see. 3. Beginning near the fuse box, wiggle the harness. Continue this at convenient points about six inches apart while watching the test light or DVOM. 4. Where the test light goes , or the DVOM voltage drops to zero, there is a short to ground in the wiring near that point. NOTE: Always use a DVOM on high impedance circuits. A test light may not glow (even with battery voltage present). Testing For A Short With A Short Circuit Locator (Short Finder) 1. Remove the blown fuse. Leave the battery connected. Page 2088 Disclaimer Repair Procedure 1. Unclamp the air cleaner housing cover, and move it to the side for access to connector C123 (16P BLK). 2. Unfasten C123 from the side of the engine compartment using a 90-degree pick. 3. Disconnect C123, and clean the terminals on both sides of the connector with contact cleaner. Shake the residue out of the connector. Allow the contact cleaner to evaporate for at least 3 minutes, then reconnect C123. 4. Fasten C123 to the left side of the engine compartment, then reinstall the air cleaner housing cover. 5. While supporting the accelerator pedal assembly, remove the two bolts that secure the assembly to the bulkhead. Carefully lower the assembly to gain access to the connector. Page 142 Powertrain Control Module: Description and Operation PCM Components PCM Components The PCM is designed to maintain exhaust emission levels to government mandated standards while providing excellent driveability and fuel efficiency. The PCM monitors numerous engine and vehicle functions via electronic sensors such as the throttle position (TP) sensor, heated oxygen sensor (HO2S), and vehicle speed sensor (VSS). The PCM also controls certain engine operations through the following: - Fuel injector control - Ignition control module - ION sensing module - Automatic transmission shift functions - Cruise control - Evaporative emission (EVAP) purge - A/C clutch control Locations Locations Page 3667 3. Connect the terminals as shown in figure. Shift rod of the motor actuator moves and stops at 2WD position. 4. If 2) and 3) fail, replace with a new motor actuator. Page 599 6. Remove the connector position assurance (CPA) clip from the APPS connector. 7. Disconnect the 10 P connector from the APPS. 8. Remove the bolts, the APPS, the spacer, and the accelerator link from the accelerator pedal assembly. 9. Separate the spacer from the APPS. Clean the grease off the spacer and the accelerator link with a clean shop towel. 10. Clean the terminals of the 10 P APPS connector (harness side) with contact cleaner. Shake the residue out of the connector, and allow the contact cleaner to evaporate for at least 3 minutes before reconnecting the connector. 11. Install a new APPS, the spacer, and the accelerator link onto the accelerator pedal assembly. Leave the mounting screws loose so the sensor can be adjusted. 12. Connect the 10 P connector to the new APPS, and lock the connector in place with the CPA. 13. Connect the PGM Tester to the data link connector (DLC), and turn the ignition switch to ON (II). Removal and Installation Spark Plug: Service and Repair Removal and Installation Removal 1. Remove spark plugs. Installation 1. Spark plugs - Tighten spark plugs to the specified torque. Torque: 18 Nm (13 lb.ft) Page 6285 it is located, and what it connects to. Use the Connector Views to help locate the proper cavity when you need to probe a connector. It can be especially helpful if the connector has more than one wire of the same color. A dash symbol (-) indicates that the cavity is empty. Connector views can also be used to help diagnose multiple symptoms in separate circuits which could be caused by a single problem in a connector shared by those circuits. Here's an example: 1. Pick one of the multiple symptoms and look up the schematic for that circuit. 2. Make a list of all the in-line and fuse box connectors in that schematic , 3. Then, in the Connector Views, look up each connector on your list to see if circuits related to the other symptoms run through one of them. If they do, inspect that connector for the problem. Example: The blower, rear window defogger, and the windshield wiper don't work. List all in-line and fuse box connectors in the blower controls circuit and then check the Connector View (see the sample). You find that C324 is common to the blower controls, rear window defogger, and wiper/washer, so you inspect C324 and find the problem, bent terminals. Finding Component/Connector Locations Finding Component/Connector Locations To see where a component or connector is located on the car, look up its photo number in the "Component Location". The photo will also tell you the color of the connector, and how many cavities it has. Page 4034 ^ Gently pry out the cover to release the four clips, unplug the electrical connectors, and remove the cover. 3. Remove the seven mounting screws in the lower steering column cover. Remove the upper cover, but leave the lower cover in place. Page 3245 Fuel Line Coupler: Service and Repair Reuse of Fuel Tube/Quick-Connector Fittings (Delivery Pipe) - Replace the pipe and connector if scratch, dent or crack is found. - Remove mud and dust from the pipe and make sure that the end including spool is free of defects, such as scratch, rust, and dent, which may cause poor sealability. If defective, replace with a new pipe. - If the retainer removed according to the removal step above is attached to the pipe, clean and insert it straight into the quick-connector till it clicks. After it clicks, try pulling it out to make sure that it is not drawn and is securely locked. NOTE: The retainer, once removed from the pipe, cannot be reused. Just replace with a new retainer. Insert the new retainer into the connector side until it clicks, and connect the pipe as inserting it into the retainer until it clicks. (Return Pipe) - Replace the pipe and connector if scratch, dent or crack is found. - Remove mud or dust from the pipe and make sure that the end including spool is free from defects, such as scratch, rust, and dent, which may cause poor sealability. If defective, replace with a new pipe. - After cleaning the pipe, insert it straight into the connector until it clicks. After it clicks, try pulling it out to make sure that it is not drawn and is securely locked. Page 2025 5. Select F0 : Fuel Pump Relay. 6. Push "On" soft key. 7. Control Fuel Pump Relay and check data list. - If the data list changes, the Fuel Pump Relay is normal. 8. Select F1 : A/C Clutch Relay. 9. Run the Engine at idle. 10. Turn on Air Conditioning. 11. Turn "On" and "Off" A/C Switch. 12. Control A/C Clutch Relay and check data list. Page 3062 Steps 7 - 13 Steps 14 - 15 Test Description Page 4321 6. Using snap ring pliers, remove the snap ring (1) fastening the ball retainer to the center shaft. 7. Remove ball retainer, ball guide and bellows. 8. Raise the hooked end of the band with a screwdriver or equivalent. 9. Remove band (1). 10. Remove bellows. 11. Remove dust seal. 12. Remove BJ shaft assembly. 13. Remove the mounting bracket fixing bolts, and then remove DOJ case assembly from the axle case. 14. Remove snap ring and bearing. 15. Remove snap ring and oil seal. 16. Remove bracket. INSPECTION AND REPAIR Make necessary correction or parts replacement if wear, damage, corrosion or any other abnormal condition are found through inspection. Check the following parts. 1. Drive shaft joint assembly 2. DOJ case, ball, ball guide, ball retainer 3. Bellows 4. Bearing 5. Dust seal, oil seal BUSHING REPLACEMENT Capacity Specifications Coolant: Capacity Specifications Coolant Capacity Automatic Transmission 11.1 qt (US) Manual Transmission 11.2 qt (US) Page 7645 2. Connect the short finder across the battery terminals and the load (component) side of the fuse terminal. 3. Close all switches in the circuit you're testing. 4. Turn on the short finder. This creates a pulsing magnetic field around the wiring between the fuse box and the short. 5. Beginning at the fuse box, slowly move the short finder along the circuit wiring. The meter will read current pulses through sheet metal and body trim. As long as the meter is between the fuse and the short, the needle will move with each current pulse. Once you move the meter past the point of the short, the needle will stop moving. Check the wiring and connectors in this area to locate the cause of the short. Testing For Continuity When testing for continuity at a connector without wire seals, you do not have to separate the two halves of the connector. Instead, probe the connector from the back. Always check both sides of the connector because dirty, corroded, and bent terminals can cause problems (no electrical contact = an open). 1. Disconnect the negative cable from the car battery. If you're using a DVOM, place it in the lowest "OHMS" range. Page 3583 Each schematic represents one circuit. A circuit's wires and components are arranged to show current flow, from power at the top of the page, to ground, at the bottom. Shared Circuits Other circuits may share power or ground terminals or wiring with the circuit shown. A wire that connects one circuit to another, for example, is cut short and has an arrowhead at the end of it pointing in the direction of current flow. Next to the arrowhead is the name of the circuit or component which shares that wiring. To quickly check shared wiring, check the operation of a component it serves. If that component works, you know the shared wiring is OK. Connectors All in-line and junction connectors are numbered (C725, C416, etc.). Component connectors are not numbered but are identified either by the name of Page 506 Key Reminder Switch: Electrical Diagrams Seat Belt, Lights-ON and Ignition Key Reminders Part 1 Of 2 Diagram Information and Instructions Fuel Injector: Diagram Information and Instructions How to Identify Wiring Color-Coded Insulation Wire Color Wire Color Coding Capacity Specifications Refrigerant Oil: Capacity Specifications HVAC SYSTEM HVAC SYSTEM ITEM SPECIFICATION Refrigerant Oil Type Vane Rotary Type Compressor Oil Capacity Of Components Condenser 1.0 fl. oz (30 cc) Evaporator 1.7 fl. oz (50 cc) Refrigerant Line (one piece) 0.3 fl. oz (10 cc) Receiver/Dryer 1.0 fl. oz (30 cc) Compressor 5.0 fl. oz (150 cc) Page 1510 2. Measure the inside diameter of the connecting rod small end. If the fitting interference between the small end and pin does not conform to the specified value, the connecting rod must be replaced. Standard: 0.023 mm - 0.038 mm (0.0009 inch - 0.0015 inch) 3. Insert the new pin into the piston and rotate it. If the pin rotates smoothly with no backlash, the clearance is normal. If there is backlash or roughness, measure the clearance. If the clearance exceeds the specified limit, the piston must be replaced. Clearance Standard: 0.010 mm - 0.017 mm (0.0004 inch - 0.0007 inch) Limit: 0.040 mm (0.0016 inch) Connecting Rods 1. Check the connecting rod alignment. If either the bend or the twist exceeds the specified limit, the connecting rod must be replaced. Bend per 100 mm (3.937 inch) Limit: 0.15 (0.0059) Twist per 100 mm (3.937 inch) Limit: 0.20 (0.0078) 2. Measure the connecting rod thrust clearance. Use a feeler gauge to measure the thrust clearance at the large end of the connecting rod. If the Page 2645 Powertrain Control Module: Description and Operation PCM Function PCM Function The PCM supplies either 5 or 12 volts to power various sensors or switches. The power is supplied through resistances in the PCM which are so high in value that a test light will not light when connected to the circuit. In some cases, even an ordinary shop voltmeter will not give an accurate reading because its resistance is too low. Therefore, a digital voltmeter with at least 10 megohms input impedance is required to ensure accurate voltage readings. Tool J 39200 meets this requirement. The PCM controls output circuits such as the injectors, fan relays, etc., by controlling the ground or the power feed circuit through transistors or through either of the following two devices: - Output Driver Module (0DM) - Quad Driver Module (QDM) Specifications Clutch Disc: Specifications Clutch Disc Outside Diameter 260 mm Inside Diameter 170 mm Thickness Clutch Disengaged 8.6 mm Thickness Clutch Engaged 8.0 mm Page 7717 Wires Wire insulation can be one color, or one color with another color stripe. (The second color is the stripe.) This circuit continues on another image. (The arrow shows direction of current flow.) To follow the RED/BLK wire in this example, you would turn to "Fuel and Emissions" and look for the "A" arrow. Description and Operation Clutch Slave Cylinder: Description and Operation SLAVE CYLINDER X22SE engine, MUA transmission 6VD1 engine, MUA transmission The slave cylinder converts hydraulic energy into mechanical energy. Hydraulic fluid supplied by the master cylinder moves the slave cylinder piston to actuate the shift fork. The mechanical energy produced by the slave cylinder is directly proportional to the diameters of the master cylinder and the slave cylinder. Testing and Inspection Blower Motor Relay: Testing and Inspection 1. Disconnect the heater relay (X-1). - When removing the connector for relay unfasten the tank lock of the connector by using a screwdriver, then pull the relay (1) out. 2. Check for continuity between the heater relay (X-1) terminals. Page 8202 - Remove the fixing screws from back side of the rear door trim panel. 8. Remove the bracket. 9. Disconnect the speaker harness connector. 10. Remove the speaker with the speaker harness connector from the door inner panel. 11. Remove the waterproof sheet (1). - Taking notice of the door harness, peel the waterproof sheet off the door panel carefully. 12. Remove the speaker bracket. - Remove the six fixing screws. 13. Remove the fixing glass. - Remove one bolt and screw as shown in the figure, then pull it upward. Page 7519 and the fuses. From Fuses to Relays and Components The second half of Power Distribution shows the wiring "From Fuses to Relays and Components." This can speed your troubleshooting by showing which circuits share fuses. If Power Distribution shows that an inoperative circuit and another circuit share a fuse, check a component in the other circuit. If it works, you know the fuse is good and power is available to the inoperative circuit. Ground Distribution Schematics Engine Controls - High/Erratic Engine Idle Power Steering Pressure Switch: All Technical Service Bulletins Engine Controls - High/Erratic Engine Idle 01-080 August 14, 2001 Applies To: 2000-02 Passport - ALL 2000-02 Passport: High or Erratic Idle SYMPTOM The engine occasionally idles at too high a speed, or the idle speed fluctuates. PROBABLE CAUSES The symptom could be the result of any of these conditions: ^ Loose or corroded engine or body ground ^ High resistance in the APPS ground circuit ^ PSP (power steering pressure) switch is internally shorted to ground ^ Fuel pressure regulator is leaking fuel into the intake manifold CORRECTIVE ACTION Diagnose the cause of the idle condition, and select the proper REPAIR PROCEDURE. PARTS INFORMATION REQUIRED MATERIALS REQUIRED SOFTWARE Each REPAIR PROCEDURE requires you to use the Smart Cable to reprogram the PCM with the latest software. To select the latest software from the CDROM, enter the year, model, engine, transmission, and emissions type (49-state or California). This gives you a list of broadcast codes. Select the broadcast code at the top of the list. WARRANTY CLAIM INFORMATION Refer to the Warranty Claim Information for each Repair Procedure. DIAGNOSIS 1. Find out from the customer when the high or erratic idle condition occurs and what the RPM range is: ^ Within 20 minutes of a cold start ^ After braking to a stop ^ All the time ^ Intermittently, with no set pattern Page 8184 3. Remove the window regulator handle. - Remove the clip on the rear side of the regulator handle using a wire. 4. Remove the screw while pulling the inside lever toward you and then remove the inside handle. 5. Remove the 1 screw at the pull case. 6. Pull out the trim panel at the 8 clip positions. - Disconnect the power window switch connector. 7. Remove the power window switch and pull case, if equipped. Page 4298 4. Remove flange nut by using pinion flange holder J-8614-01. 5. Remove flange. 6. Remove oil seal. 7. Remove outer bearing by using remover J-39602. 8. Remove collapsible spacer. INSPECTION AND REPAIR Make necessary correction or parts replacement if wear, damage, corrosion or any other abnormal condition are found through inspection. Check the following parts. 1. Seal surface of the pinion. 2. Cage bore for burns. INSTALLATION 1. Install collapsible spacer. Discard the used collapsible spacer and install a new one. 2. Install outer bearing. NOTE: Do not drive in, but just temporarily set in the outer bearing by hand, which should be indirectly pressed in finally by tightening the flange nut. 3. Install oil seal, use oil seal installer J-24250 to install a new oil seal that has grease on seal lip. 4. Install flange. Page 4607 2. Connect one lead of a self-powered test light or DVOM to one end of the part of the circuit you want to test. 3. Connect the other lead to the other end. 4. If the self-powered test light glows, there is continuity. If you're using a DVOM, a low reading or no reading (zero), means good continuity. Testing For Voltage When testing for voltage at a connector without wire seals, you do not have to separate the two halves of the connector. Instead, probe the connector from the back. Always check both sides of the connector because dirty, corroded, and bent terminals can cause problems (no electrical contact = an open). 1. Connect one lead of the lest light to a known good ground, or, if you're using a digital volt ohmmeter (DVOM), place it in the appropriate DC volts range, and connect its negative lead to ground. 2. Connect the other lead of the test light or DVOM to the point you want to check. 3. If the test light glows, there is voltage present. If you're using a DVOM, note the voltage reading. It should be within one volt of measured battery voltage. A loss of more than one volt indicates a problem. NOTE: Always use a DVOM on high impedance circuits. A test light may not glow (even with battery voltage present). Testing For Voltage Drop Wires, connectors, and switches are designed to conduct current with a minimum loss of voltage. A voltage drop of more than one volt indicates a problem. 1. Place the digital volt/ohmmeter (DVOM) in the appropriate DC volts range. Connect the positive lead to the end of the wire (or to the connector or switch) closest to the battery. 2. Connect the negative lead to the other end of the wire (or the other side of the connector or switch). 3. Turn on the components in the circuit. 4. The DVOM will show the difference in voltage between the two points. A difference, or drop, of more than one volt indicates a problem. Check the circuit for loose, dirty, or bent terminals. Page 2731 10. Use the PGM Tester to check the broadcast code. Make sure the broadcast code matches the one you selected from the CD-ROM. WARRANTY CLAIM INFORMATION In warranty: The normal warranty applies. Failed Part: P/N 8-17087-655-0 H/C 4375820 Defect Code: 064 Contention Code: C01 Skill Level: Repair Technician Out of warranty: Any repair performed after warranty expiration may be eligible for goodwill consideration by the District Service Manager or your Zone Office. You must request consideration, and get a decision, before starting work. REPAIR PROCEDURE - ENGINE/BODY GROUND 1. Use the ETM for the appropriate year to locate these ground connectors: G101, G104, G105, G106 and G160. 2. Inspect each connector for corrosion or looseness. 3. Remove the bolt from any connector that is corroded or loose. Clean the terminal connector with a wire brush. File flat any solder bumps on the connector. 4. Clean the contact surface on the engine or body with a wire brush. 5. Replace the bolt if it is heavily corroded. Otherwise, clean it with a wire brush. 6. Apply lithium dielectric grease to both sides of the terminal connector. 7. Reinstall the bolt, torque it to 14 N.m (10 lb-ft). 8. Use the Smart Cable to reprogram the PCM with the latest software from the June 2001 or later HONDANET CD-ROM. Refer to Service Bulletin 99-005, Updating the Passport PCM, filed under Tools. 9. Use the PGM Tester to clear any DTCs. 10. Use the PGM Tester to check the broadcast code. Make sure the broadcast code matches the one you selected from the CD-ROM. WARRANTY CLAIM INFORMATION In warranty: The normal warranty applies. Failed Part: P/N 8-97086-823-0 Page 2959 Torque Specifications Page 3366 Splices Splices are shown as a dot. Their location and the number of wires may vary depending on the harness manufacturer. Switches Switches These switches move together; the broken straight line between them means they are mechanically connected. Other types of switches are controlled by a coil or a solid state circuit. Unless otherwise noted, all switches are shown in their normal (rest) position, with power off. Terminal "T" Page 4487 The wire insulation has one color or one color with another color stripe. The second color is the stripe. Page 5933 Page 4077 Torque Converter: Specifications Torque Converter Stall Speed 2100 rpm +/- 150 rpm Page 5890 Grease Amount - Hub: 35 g (1.23 oz.) - Outer bearing: 10 g (0.35 oz.) - Inner bearing: 15 g (0.53 oz.) 8. Install hub nut. Turn to the place where there is a chamfer in the tapped hole to the outer side, then attach the nut by using front hub nut wrench J-36827. PRELOAD ADJUSTMENT 1. Tighten the hub nut to 29 Nm (22 ft. lbs.), then fully loosen the nut. Page 4463 Axle Disconnect Control Control Unit: Testing and Inspection AXLE DISCONNECT CONTROLLER 1. Connect 12 V with terminal (3) and the ground with the terminal (6). 2. Send the signal to the terminal (4). 2WD - 4WD less than 2.4 V 4WD - 2WD more than 9.0 V 3. Confirm the output signal from the terminals (1) & (2) (2 seconds output). Page 5251 4. Remove the fuel pressure regulator from the fuel rail. 5. Remove the fuel return line from the regulator. 6. Install the new fuel pressure regulator in the reverse order of removal. 7. Use the Smart Cable to reprogram the PCM with the latest software from the June 2001 or later HONDANET CD-ROM. Refer to Service Bulletin 99-005, Updating the Passport PCM, filed under Tools. 8. Use the PGM Tester to clear any DTCs. 9. Use the PGM Tester to check the broadcast code. Make sure the broadcast code matches the one you selected from the CD-ROM. WARRANTY CLAIM INFORMATION In warranty: The normal warranty applies. Failed Part: P/N 8-17113-398-0 H/C 5504386 Defect Code: 092 Contention Code: C99 Skill Level: Repair Technician Out of warranty: Any repair performed after warranty expiration may be eligible for goodwill consideration by the District Service Manager or your Zone Office. You must request consideration, and get a decision, before starting work. REPAIR PROCEDURE - POWER STEERING SWITCH 1. Drain the power steering fluid out of the system. 2. Remove the power steering fluid reservoir. Clean the reservoir with solvent, then with soap and water. Rinse and dry it thoroughly. 3. Reinstall the reservoir. Do not connect the return hose. 4. Remove the power steering pressure switch, then clean it with brake cleaner and a scraper. Reinstall the switch, and torque it to 20 N.m (14 lb-ft). 5. Cover the unconnected end of the reservoir with your finger, then fill the reservoir with Dexron III ATF Page 5387 The steering wheel offset gauge is a sticker that attaches to the steering wheel and the steering column cover. Place the sticker on the steering wheel when the steering wheel is straight. When you test-drive the vehicle, you can read how many millimeters the steering wheel is off-center. NOTE: If the vehicle is pulling, repairing the pull may correct the steering wheel offset. Page 767 Vehicle Speed Sensor: Testing and Inspection 1. Inspect the electrical connector for signs of corrosion or warping. Replace the VSS if the electrical connector is corroded or warped. 2. Inspect the VSS driven gear for chips, breaks, or worn condition. Replace the VSS if the driven gear is chipped, broken or worn. 3. Inspect the O-ring for wear, nicks, tears, or looseness. Replace the O-ring if necessary. Page 2773 Ground - "G" Shielding Sheilding This represents RFI (Radio Frequency Interference) shielding around a wire. The shielding is always connected to ground. Splices Page 3367 Terminals - "T" Each "T" terminal (ring type) is numbered for reference and location. A "T" terminal is secured with a screw or bolt. Wires Page 3763 c. Remove mode switch connector with bracket from the transmission case. d. Connect multimeter (resistance mode) to terminals 1(E) and 4(H) on mode switch connector. e. Loosen two mounting screws. f. Rotate mode switch slightly in both directions to determine the range (approx. 5 degrees) of electrical contact. g. Position mode switch in middle of contact range. h. Tighten two mounting screws. i. Remove multimeter and install mode switch harness connector with bracket to the transmission case. j. Connect transmission harness connector to mode switch connector. Page 3831 2. Compare the retrieved code with the codes shown. ^ If the code you retrieved is not in the list, the PCM has already been updated. Troubleshoot other causes for the PCM to reset. ^ If the code you retrieved is in the list, go to step 3. 3. If not already done, load the May 2001 or later HONDANET 2000 CD onto your HONDANET 2000 master terminal. Loading instructions are included in the CD's mailing. 4. Update the PCM software with the Smart Cable and the broadcast code information on the HONDANET 2000 CD. For updating instructions, refer to Service Bulletin 99-005, Updating the Passport PCM, filed under Tools. NOTE: ^ Since the Smart Cable may need to be cleared from a previous PCM update or the Smart Cable firmware may need to be reprogrammed, always begin each vehicle's PCM software update at the HONDANET 2000 workstation. ^ Make sure you select the most recent broadcast code from the list on the HONDANET screen. (This code is not necessarily at the top of the list. The most recent code is the last one in alphabetical sequence, letter by letter.) For example, among the codes DJTF, DDNN, and DCLY the most recent code is DJTF. 5. Use the PGM Tester to clear any DTCs. 6. After you update the PCM, retrieve the PCM broadcast code with the PGM Tester. Make sure the code does not match any from the list in step 2. DISCLAIMER Page 965 Power Window Switch: Service and Repair Rear Passengers Window Switches Removal 1. Disconnect the battery ground cable. 2. Remove the rear door trim pad (2). - Disconnect the rear power window switch (1) connector. 3. Remove the rear power window switch (1). - Remove the switch fixing screw from the back side of the rear door trim (2). Installation To install, follow the removal steps in the reverse order. Blower Assembly Housing Assembly HVAC: Service and Repair Blower Assembly Removal 1. Disconnect the battery ground cable. 2. Discharge and recover refrigerant (with air conditioning). 3. Remove instrument panel assembly. 4. Disconnect resistor connector. 5. Remove duct. 6. Remove evaporator assembly (A/C only). 7. Disconnect blower motor connector. 8. Remove blower assembly. Installation To install, follow the removal steps in the reverse order. Page 7378 the component if the component only has one connector, or by a capital letter (A, B, C, etc.) if the component has more than one connector. Below most connector numbers and component names are PHOTO and VIEW numbers. The PHOTO number refers to a photo in the back of the book that shows the connector's location on the car. The VIEW number refers to an illustration in the back of the book that shows the connector face, wire colors, connector cavity numbers, and other details. The connector cavity numbering sequence begins at the top left corner of the connector. Disregard any numbers molded into the connector housing. Wires Wires are identified by the abbreviated names of their colors; the second color is the color of the stripe. Wires are also identified by their location in a connector. The number "2" next to the male and female wire terminals at C416, for example, means those terminals join in cavity 2 of connector C416. Symbols A complete description of schematic symbols is given under wire color abbreviation. Power Distribution Schematics Power Distribution schematics show how power is supplied from the positive battery terminal to various circuits in the car. Refer to the Power Distribution section to get a more detailed picture of how power is supplied to the circuit you're working on. From Battery to Ignition Switch, Fuses, and Relays Individual circuit schematics begin with a fuse. The first half of Power Distribution, however, shows the wiring "upstream" between the battery Service Specifications Connecting Rod: Specifications Connecting rods Bend per 100 mm Limit 0.15 mm Twist per 100 mm Limit 0.20 mm Connecting Rod Thrust Clearance Standard 0.16 - 0.35 mm Limit 0.40 mm Description and Operation Fuel Gauge: Description and Operation The fuel gauge consists of two intersecting coils wound around a permanent magnet rotor (see engine coolant temperature gauge for operation). The engine (M/T) or powertrain (A/T) control module (ECM or PCM) tracks the fuel level by monitoring the resistance in the fuel tank unit. The resistance varies from about 80 ohms with the tank full to 290 ohms with it empty. The ECM or PCM uses this information to control the fuel gauge. NOTE 1: The circuit between the PCM and the gauge can be tested with the PGM Tester. In the ENGINE\MISC TESTS\FUEL GAUGE" menu, the PGM Tester can command the PCM to move the gauge in 10% increments. Page 8119 Power Window Switch: Service and Repair Rear Passengers Window Switches Removal 1. Disconnect the battery ground cable. 2. Remove the rear door trim pad (2). - Disconnect the rear power window switch (1) connector. 3. Remove the rear power window switch (1). - Remove the switch fixing screw from the back side of the rear door trim (2). Installation To install, follow the removal steps in the reverse order. Page 1610 2. Loosen the two flange nuts holding the transmission mount to the third crossmember. 3. Use a pry bar to shift the engine assembly all the way forward. 4. Hold the prybar in place, and torque the flange nuts to 50 N.m (37 lb-ft). 5. Lower the vehicle. 6. Start the engine, and check for vibration. Make sure the chassis is not touching the lift during this check. ^ If the vibration is gone, no further action is required. ^ If the vibration is still there, go to REPAIR PROCEDURE B. REPAIR PROCEDURE B 1. Write down your customer's radio station presets and mode settings. 2. Disconnect the negative cable from the battery. 3. Raise the vehicle on a lift. 4. Remove both front wheels. 5. Models With 4WD: Remove the front skid plate (four bolts, four lock washers, four washers). Page 3347 Test Equipment CAUTION: Most circuits include solid-state devices. Test the voltages in these circuits only with a 10-megaohm or higher impedance digital multimeter. Never use a test light or analog meter on circuits that contain solid-state devices. Damage to the devices may result. Test Light and DVOM On circuits without solid-state devices, use a test light to check for voltage. A test light is made up of a 12 volt bulb with a pair of leads attached. After grounding one lead, touch the other lead to various points along the circuit where voltage should be present. The bulb will go on if there is voltage at the point being tested. If you need to know how much voltage is present, use a digital volt/ohmmeter (DVOM). Self-Powered Test Light and DVOM Use a self-powered test light to check for continuity. This tool is made up of a light bulb, battery, and two leads. To test it, touch the leads together: the light should go on. Use a self-powered test light only on an unpowered circuit. First, disconnect the battery, or remove the fuse that feeds the circuit you are working on. Select two points in the circuit between which you want to check continuity. Connect one lead of the self-powered test light to each point. If there is continuity, the test light's circuit will be completed, and the light will go on. If, in addition, you need to know exactly how much resistance there is between two points, use a digital volt/ohmmeter (DVOM). In the "OHMS" range, the DVOM will measure resistance between two points along a circuit. Low resistance means good continuity. Diodes and solid-state devices in a circuit can make a DVOM give a false reading. To check a reading, reverse the leads, and take a second reading. If the readings differ, the component is affecting the measurement. Jumper Wire Use a jumper wire to bypass an open circuit. A jumper wire is made up of an in-line fuse holder connected to a set of test leads. It should have a five ampere fuse. Never connect a jumper wire across a short circuit. The direct battery short will blow the fuse. Short Finder (Short Circuit Locator) Short finders are available to locate shorts to ground. The short finder creates a pulsing magnetic field in the shorted circuit which you can follow to the location of the short. To order any test equipment shown above, contact your local tool supplier. For a list of suppliers and tool numbers, refer to Honda Required Special Tools and Equipment Service Bulletin. Page 4197 3. Connect the terminals as shown in figure. Shift rod of the motor actuator moves and stops at 2WD position. 4. If 2) and 3) fail, replace with a new motor actuator. Page 5561 Air Bag(s) Arming and Disarming: Description and Operation Definitions Air Bag An inflatable cloth cushion designed to deploy in certain frontal crashes. It supplements the protection offered by the seat belts by distributing the impact load more evenly over the vehicle occupant's head and torso. Asynchronous Performed in a nonperiodic fashion, (i.e., no defined time or interval). (B+) Battery voltage, (B+) The voltage available at the battery at the time of the indicated measurement. With the key "ON" and the engine not running, the system voltage will likely be between 12 and 12.5 volts. At idle the voltage may be 14 to 16 volts. The voltage could be as low as 10 volts during engine cranking. Bulb Check The SDM will cause the "AIR BAG" warning lamp to flash seven times and then go "OFF" whenever the ignition switch transitions to the ON position from any other ignition switch position and no malfunctions are detected. "CONTINUOUS MONITORING" Tests performed by the SDM on the SRS every 100 milliseconds while "Ignition 1" voltage is in the normal operating voltage range at the SDM. Data Link Connector (DLC) Formerly "DLC" a connector which allows communication with an external computer, such as a scan tool. Datum Line A base line parallel to the plane of the underbody or frame from which all vertical measurements originate. Deploy To inflate the air bag. Deployment Loops The circuits which supply current to the air bag assemblies to deploy the air bag. Diagnostic Trouble Code (DTC) Formerly "Code", a numerical designator used by the SDM to indicate specific SRS malfunctions. Driver Current Source An output of the SDM which applies current into the driver air bag assembly circuit during the "Initiator Assembly Resistance Test". Driver Air Bag Assembly An assembly located in the steering wheel hub consisting of an inflatable bag, an inflator and an initiator. EEPROM Electronically Erasable Programmable Read Only Memory. Memory which retains its contents when power is removed from the SDM. Ignition Cycle The voltage at the SDM "Ignition 1" inputs, with ignition switch "ON", is within the normal operating voltage range for at least ten seconds before turning ignition switch "OFF". Ignition 1 Page 3799 10. Use the PGM Tester to check the broadcast code. Make sure the broadcast code matches the one you selected from the CD-ROM. WARRANTY CLAIM INFORMATION In warranty: The normal warranty applies. Failed Part: P/N 8-17087-655-0 H/C 4375820 Defect Code: 064 Contention Code: C01 Skill Level: Repair Technician Out of warranty: Any repair performed after warranty expiration may be eligible for goodwill consideration by the District Service Manager or your Zone Office. You must request consideration, and get a decision, before starting work. REPAIR PROCEDURE - ENGINE/BODY GROUND 1. Use the ETM for the appropriate year to locate these ground connectors: G101, G104, G105, G106 and G160. 2. Inspect each connector for corrosion or looseness. 3. Remove the bolt from any connector that is corroded or loose. Clean the terminal connector with a wire brush. File flat any solder bumps on the connector. 4. Clean the contact surface on the engine or body with a wire brush. 5. Replace the bolt if it is heavily corroded. Otherwise, clean it with a wire brush. 6. Apply lithium dielectric grease to both sides of the terminal connector. 7. Reinstall the bolt, torque it to 14 N.m (10 lb-ft). 8. Use the Smart Cable to reprogram the PCM with the latest software from the June 2001 or later HONDANET CD-ROM. Refer to Service Bulletin 99-005, Updating the Passport PCM, filed under Tools. 9. Use the PGM Tester to clear any DTCs. 10. Use the PGM Tester to check the broadcast code. Make sure the broadcast code matches the one you selected from the CD-ROM. WARRANTY CLAIM INFORMATION In warranty: The normal warranty applies. Failed Part: P/N 8-97086-823-0 Page 7816 If there is no photo number below or beside a component name or a connector, ground, or terminal number, look up that name or number in the appropriate Connector Identification Chart. The chart lists how many cavities a connector has, where it's located, and what it connects to. The related illustration shows the connector's location on the harness, and the harness routing. NOTE: Photos listed by number are located at Locations / Components / Photograohs. See: Locations/Component Locations/Photographs Circuit Schematics Page 8 Locations Timing Marks and Indicators: Locations IGNITION IS NOT ADJUSTABLE Ignition timing is done by the electronic ignition (EI) that directly fires the spark plugs from ignition coils through spark plug wires without using a distributor. A pair of ignition coils for the cylinders having different phases by 36O° (No.1 and No.4,No.2 and No.5,No.3 and No.6) are fired simultaneously. Since the cylinder on exhaust stroke requires less energy to fire its ignition plug, energy from the ignition coils can be utilized to fire the mating cylinder on compression stroke. After additional 36O° rotation, respective cylinder strokes are reversed. The EI consists of six ignition coils,ignition control module, crank angle sensor, powertrain control module (PCM) and other components. The ignition coils are connected with the PCM by means of a 32 pin connector. The ignition control module turns on/off the primary circuit of ignition coils, and also it controls the ignition timing at the engine speed below 538 rpm. A notch in the timing disc on the crankshaft activates the crank angle sensor which then sends information such as firing order and starting timing of each ignition coil to the PCM. Further, the EI employs ignition control (IC) to control similar to a distributor system. By receiving signals such as crank position,engine speed, water temperature and Manifold Absolute Pressure (MAP), the PCM controls the ignition timing. Diagram Information and Instructions Condenser Fan: Diagram Information and Instructions How to Identify Wiring Color-Coded Insulation Wire Color Wire Color Coding Page 6128 Page 1095 Spark Plug: Service and Repair Inspection and Repair Inspection and Repair The spark plug affects entire engine performance and therefore its inspection is very important. - Check electrode and insulator for presence of cracks, and replace if any. - Check electrode for wear, and replace if necessary.. - Check gasket for damage, and replace if necessary. - Measure insulation resistance with an ohmmeter, and replace if faulty. - Adjust spark plug gap to 1.0 mm (0.040 in) to 1.1 mm (0.043 in). - Check fuel and electrical systems if spark plug is extremely dirty. - Use spark plugs having low heat value (hot type plug) if fuel and electrical systems are normal. - Use spark plugs having high heat value (cold type plug) if insulator and electrode are extremely burned. Sooty Spark Plugs Much deposit of carbon or oil on the electrode and insulator of spark plug reduces the engine performance. Possible causes: - Too rich mixture - Presence of oil in combustion chamber - Incorrectly adjusted spark plug gap Burning Electrodes This fault is characterized by scorched or heavily oxidized electrode or blistered insulator nose. Possible causes: - Too lean mixture - Improper heat value Measuring Insulation Resistance - Measure insulation resistance using a 500 volt megaohm meter. - Replace spark plugs if measured value is out of standard. Insulation resistance: 50 Mohm or more. Page 6730 If there is no photo number below or beside a component name or a connector, ground, or terminal number, look up that name or number in the appropriate Connector Identification Chart. The chart lists how many cavities a connector has, where it's located, and what it connects to. The related illustration shows the connector's location on the harness, and the harness routing. NOTE: Photos listed by number are located at Locations / Components / Photograohs. See: Locations/Component Locations/Photographs Circuit Schematics Page 7788 Splices Splices are shown as a dot. Their location and the number of wires may vary depending on the harness manufacturer. Switches Switches These switches move together; the broken straight line between them means they are mechanically connected. Other types of switches are controlled by a coil or a solid state circuit. Unless otherwise noted, all switches are shown in their normal (rest) position, with power off. Terminal "T" Page 2627 This means the branch of the wire connects to another circuit. The arrow points to the name of the circuit branch where the wire continues. Page 7674 This means the branch of the wire connects to another circuit. The arrow points to the name of the circuit branch where the wire continues. Page 5114 Disassembled View Starting System - Unable To Key In Ignition Switch Ignition Switch Lock Cylinder: Technical Service Bulletins Starting System - Unable To Key In Ignition Switch Can't Turn Ignition Switch? Check for Locked Steering Got a service customer complaining he or she can't turn the ignition switch to start the engine? The reason could just be the steering column lock pin is engaged with the front wheels turned. Here's what typically happens: Some folks use the steering wheel to help support themselves while climbing in or out of the vehicle. This is very common among elderly or disabled drivers. Doing this turns the front wheels, which twists the tires against the ground. The twisted tires apply torque to the steering column. With the ignition switch in LOCK (0), the steering column lock pin is engaged. But the applied torque on the steering column binds the lock pin, making it tough to turn the ignition switch. The ignition switch won't turn to ON (II) if the lock pin isn't disengaged from the steering column. Tell your customer there's nothing wrong with the ignition switch itself. All he or she needs to do is turn the steering wheel from side to side while turning the switch. This usually releases the lock pin so the engine can be started. In some cases, though, your customer may need to give a good tug on the wheel. This could easily happen when parking on a hill and the wheels are turned sharply before the engine is shut off. Page 169 The name of the component appears next to it followed by notes about its function along with any photo and connector view references. Connector "C" How to Identify Connector Terminals Cavity Numbering System The cavities (and wire terminals) in each connector are numbered starting from the upper left, looking at the male terminals from the terminal side (or looking at the female terminals from the wire side. Both views are in the same direction so the numbers are the same.) All actual cavities are numbered, even if they have no wire terminals in them. NOTE: Data Link Connector (DLC) terminals are numbered according to SAE standard J1962, not the Honda standard. The numbers of the four end terminals are molded into the corners of the connector face. Page 2059 Page 1436 2. On the right cylinder bank, turn the camshaft pulley until its green mark is at 12 o'clock in relation to the head surface, at the center of the head. Turning the pulley brings the timing dots on the camshaft drive gear into their correct position: to the left and right of the gear's centerline. 3. On the left cylinder bank, turn the camshaft pulley until its green mark is at 12 o'clock in relation to the head surface, at the center of the head. Then turn the pulley counterclockwise until its green mark points close to the timing belt cover bolt hole. Turning the pulley brings the timing dots on the camshaft drive gear into their correct position: to the left and right of the gear's centerline. 4. Install the intake and exhaust camshafts in the right cylinder bank: - Set the camshaft marked "RI" into the intake side of the head. Make sure the single timing dot on the camshaft gear aligns with the timing dot on the camshaft drive gear. Page 5915 Each schematic represents one circuit. A circuit's wires and components are arranged to show current flow, from power at the top of the page, to ground, at the bottom. Shared Circuits Other circuits may share power or ground terminals or wiring with the circuit shown. A wire that connects one circuit to another, for example, is cut short and has an arrowhead at the end of it pointing in the direction of current flow. Next to the arrowhead is the name of the circuit or component which shares that wiring. To quickly check shared wiring, check the operation of a component it serves. If that component works, you know the shared wiring is OK. Connectors All in-line and junction connectors are numbered (C725, C416, etc.). Component connectors are not numbered but are identified either by the name of Page 2988 2. Secure the VSS in place with the clamp and the bolt. 3. Tighten the bolt to 27 Nm (20 lb ft.). 4. Connect the VSS electrical connector. 5. Check the transfer case oil level. Add fluid if necessary. 6. Connect the negative battery cable. Page 2304 Throttle Position Sensor: Testing and Inspection Function Check Use a Tech 2 to check the TP sensor output voltage at closed throttle. - The voltage should be under 0.85 volt. - If the reading is greater than 0.85 volt, check the throttle shaft to see if it is binding. Page 7712 The name of the component appears next to it followed by notes about its function along with any photo and connector view references. Connector "C" How to Identify Connector Terminals Cavity Numbering System The cavities (and wire terminals) in each connector are numbered starting from the upper left, looking at the male terminals from the terminal side (or looking at the female terminals from the wire side. Both views are in the same direction so the numbers are the same.) All actual cavities are numbered, even if they have no wire terminals in them. NOTE: Data Link Connector (DLC) terminals are numbered according to SAE standard J1962, not the Honda standard. The numbers of the four end terminals are molded into the corners of the connector face. Page 8215 7. Pull out the trim panel at the 8 clip positions. - Disconnect the power window switch connector and courtesy light connector. 8. Remove the power window switch, if equipped. 9. Remove the bracket. 10. Remove the waterproof sheet (1). - Taking notice of the door harness, peel the waterproof sheet off the door panel carefully. Locations Locations Behind Glove Box Page 5266 H/C 4408092 Defect Code: 017 Contention Code: C99 Skill Level: Repair Technician Out of warranty: Any repair performed after warranty expiration may be eligible for goodwill consideration by the District Service Manager or your Zone Office. You must request consideration, and get a decision, before starting work. DISCLAIMER Page 7769 Page 7921 Horn: Service and Repair Removal 1. Disconnect the battery ground cable. 2. Remove the radiator grille. 3. Remove the horn (1). - Disconnect the connector. - Remove the horn mounting bolt. Installation To install, follow the removal steps in the reverse order. Page 2897 Manifold Pressure/Vacuum Sensor: Testing and Inspection Manifold Absolute Pressure (MAP) Output Check Circuit Description The manifold absolute pressure (MAP) sensor measures the changes in the intake MAP which result from engine load (intake manifold vacuum) and engine speed changes; and converts these into a voltage output. The powertrain control module (PCM) sends a 5-volt reference voltage to the MAP sensor. As the MAP changes, the output voltage of the sensor also changes. By monitoring the the sensor output voltage, the PCM knows the MAP. A lower pressure (low voltage) output voltage will be about 1 - 2 volts at idle. Higher pressure (high voltage) output voltage will be about 4 - 4.8 volts at wide open throttle. The MAP sensor is also used, under certain conditions, to measure barometric pressure, allowing the PCM to make adjustments for different altitudes. The PCM uses the MAP sensor to diagnose proper operation of the EGR system, in addition to other functions. A/T - Vehicle Speed Sensor Installation Precautions Transmission Speed Sensor: Technical Service Bulletins A/T - Vehicle Speed Sensor Installation Precautions Install VSS Properly to Avoid Reman A/T Damage We can't emphasize enough how important it is to follow, to the letter, the installation instructions that come with a reman A/T. These instructions help ensure that you avoid damaging the A/T and score a successful repair. This is particularly true when it comes to installing the vehicle speed sensor (VSS). Step 6 of the instructions tells you to make sure its gear is fully engaged and the VSS is fully seated before you tighten the retaining bolt. If you don't install the VSS properly, the speed sensor gear will get stripped and the A/T will be seriously damaged. So don't take risks with your customer's vehicle. Always follow these instructions to the letter. You can rest assured you're doing the job right. Page 3706 Terminals - "T" Each "T" terminal (ring type) is numbered for reference and location. A "T" terminal is secured with a screw or bolt. Wires Page 2024 Fuel Pump Relay: Testing and Inspection Relays Test This test is conducted to check Fuel Pump Relay and A/C Clutch for proper operation. Tech 2 must be used for this test. Test Procedure: 1. Connect Tech 2 to the vehicle DLC. 2. Ignition SW is "On". 3. Select F3 : Miscellaneous Test in the Application Menu. 4. Select F1 : Relay Test in the Miscellaneous Test. Brakes - Revised Brake Bleeding Procedure Brake Bleeding: By Symptom Brakes - Revised Brake Bleeding Procedure 01-016 January 30, 2001 Applies To: 1998-01 Passport - ALL Service Manual Update: Revised Brake Bleeding Procedure BACKGROUND The brake bleeding procedure in the 1998 thru 2001 Passport Service Manuals is incomplete. Use this service bulletin to update the manuals. WARRANTY INFORMATION None. CORRECTIVE ACTION 1. In the 1998, 1999, 2000, and 2001 Passport Service Manuals, on pages 5A-21 and 5A-22, cross out the entire Tech 2 Service Bleed procedure. 2. In each manual, on page 5A-21, write this note: See page 5C-10 for the brake bleeding procedure 3. In each manual, on page 5C-10, between steps 1 and 2, write this note: For important additional information, see Service Bulletin 01-016, Service Manual Update: Revised Brake Bleeding Procedure, Filed under Brakes. SERVICE MANUAL UPDATE INFORMATION To avoid trapping air bubbles in the ABS hydraulic unit while bleeding the brakes, the hydraulic unit must be tilted forward at a 15-degree angle or greater. Before bleeding, check the angle of the ABS hydraulic unit with an angle locator level. If needed, raise the rear of the vehicle to get the proper Page 7912 This means the branch of the wire connects to another circuit. The arrow points to the name of the circuit branch where the wire continues. Page 4952 5. Insert a block of wood into the caliper and force out the piston by blowing compressed air into the caliper at the flexible hose attachment. This procedure must be done prior to removal of the dust boot. Remove piston. WARNING: Do not place your fingers in front of the piston in an attempt to catch or protect it when applying compressed air. this could result in personal injury. CAUTION: Use just enough air to ease the piston out of the bore. If the piston is blown out, it may be damaged. 6. Remove dust boot: piston. 7. Remove piston seal. 8. Remove bleeder with cap. 9. Remove caliper body. INSPECTION AND REPAIR Make necessary parts replacement, if wear, damage, corrosion or any other abnormal conditions are found through inspection. Check the following parts: Rotor - Cylinder body - Cylinder bore - Piston - Guide bolt, lock bolt - Support bracket NOTE: The piston dust seal and dust boot are to be replaced each time the caliper is overhauled. Discard these used rubber parts and replace with new ones. REASSEMBLY 1. Install caliper body. 2. Install bleeder with cap and tighten the cap to the specified torque. Torque: 8 Nm (69 ft. lbs.) 3. Install piston seal and apply special rubber grease to the piston seal and cylinder wall, then insert the piston seal into the cylinder. The special rubber grease is included in the repair kit. Page 7026 Trim Panel: Service and Repair Interior Trim Panels LWB Removal 1. Disconnect the battery ground cable. 2. Remove the sill plates (Front & Rear). 3. Remove the dash side trim cover. 4. Remove the lower center pillar trim cover. - Remove the lower anchor bolt cover and lower anchor bolt from the front seat belt. - Pry the trim cover clips free from the body panel. 5. Remove the door finishers (Front & Rear). 6. Remove the upper center pillar trim cover. - Pry the trim cover clips free from the body panel. 7. Remove the front pillar trim cover. - Ply the trim cover clips free from the body panel. 8. Remove the tailgate weather strip. 9. Remove the rear end floor trim cover. - Remove the five fixing screws. 10. Remove the luggage room light. - Remove the luggage room light lens (1) and the fixing screw. - Disconnect the luggage room light connector. 11. Remove the rear roof trim cover. - Pry the trim cover clips free from the body panel. Page 2560 Distinct Of Circuit By Wire Base Color All wires have color-coded insulation. Wires belonging to a system's main harness will have a single color. Wires belonging to a system's sub-circuits will have a colored stripe. Striped wires use the codes found in the chart to show wire size and colors. Abbreviations are used to indicate wire color within a circuit diagram. How to Identify Connector Terminals How to Identify Connector Terminals Cavity Numbering System The cavities (and wire terminals) in each connector are numbered starting from the upper left, looking at the male terminals from the terminal side (or looking at the female terminals from the wire side. Both views are in the same direction so the numbers are the same.) All actual cavities are numbered, even if they have no wire terminals in them. NOTE: Data Link Connector (DLC) terminals are numbered according to SAE standard J1962, not the Honda standard. The numbers of the four end terminals are molded into the corners of the connector face. The connector cavity number is listed next to each terminal on the circuit schematic. The cavity / terminal shown is # 6. Using/Identifying Connector Terminal Views How to Use Connector Terminal Views To see the configuration of a connector's cavities, look up its view number in the Connector Views. Each view includes the color of the connector, where Page 6236 Low ambient light conditions (a dark work area) will aid in locating the leak. NOTE: Not all UV lamps work well with all types of fluorescent dye. Use only the lamp provided in the kit to inspect for leaks. (c) Inspect the entire system. Be sure to check these locations: ^ damaged and corroded areas ^ fittings ^ hose-to-line couplings ^ refrigerant controls ^ service ports ^ brazed or welded areas ^ areas near attachment points (d) Check for evaporator leaks by illuminating the evaporator drain tube area with the UV lamp and glasses. (e) After repairing a leak, remove any fluorescent residue using the GLO-AWAY dye cleaner from the kit and hot water (follow the instructions on the bottle). Disclaimer Page 4224 The wire insulation has one color or one color with another color stripe. The second color is the stripe. Page 678 Oxygen Sensor: Testing and Inspection Heated Oxygen Sensor (HO2S) All four sensors are identical. Inspect each in the same way. 1. Inspect the pigtail and the electrical connector for grease, dirt, corrosion, and bare wires or worn insulation. 2. Inspect the lowered end of the sensor for grease, dirt, or other contaminations. Page 2505 Each schematic represents one circuit. A circuit's wires and components are arranged to show current flow, from power at the top of the page, to ground, at the bottom. Shared Circuits Other circuits may share power or ground terminals or wiring with the circuit shown. A wire that connects one circuit to another, for example, is cut short and has an arrowhead at the end of it pointing in the direction of current flow. Next to the arrowhead is the name of the circuit or component which shares that wiring. To quickly check shared wiring, check the operation of a component it serves. If that component works, you know the shared wiring is OK. Connectors All in-line and junction connectors are numbered (C725, C416, etc.). Component connectors are not numbered but are identified either by the name of A/T - Identifying Shift Solenoids Shift Solenoid: Technical Service Bulletins A/T - Identifying Shift Solenoids SOURCE: Honda Service News November 2003 TITLE: Identifying A/T Shift Solenoids APPLIES TO: 1994-02 Passport SERVICE TIP: If you've ever replaced the A/T shift solenoids in a 1994-02 Passport, you're probably aware that the S/M and parts catalog descriptions for the solenoids don't exactly match. Use this handy chart when ordering replacement solenoids: When installing these solenoids in the valve body, make sure you don't get them mixed up or install them in the wrong position. It's easy to do since these solenoids look almost identical. Fortunately, each solenoid has some of its part number engraved on its connector. Solenoid A has 593; solenoid B has 224. Page 5882 Wheels: Service and Repair REMOVAL 1. Loosen wheel lug nut by approximately 180 g (half a rotation), then raise the vehicle and remove the nuts. 2. Remove wheel and tire. NOTE: Never use heat to loosen a tight wheel lug nut. The application of heat to the hub can shorten the life of the wheel and may cause damage to wheel bearings. INSTALLATION 1. Install wheel and tire. 2. Install wheel lug nut, and lower the vehicle. Tighten the wheel lug nuts to the specified torque in numerical order. Torque to 118 Nm (87 ft. lbs.). CAUTION: Before installing wheels, remove any build-up of corrosion on the wheel mounting surface and brake disc mounting surface by scraping and wire brushing. Installing wheels without good metal-to-metal contact at mounting surfaces can cause wheel nuts to loosen, which can later allow a wheel to come off while the vehicle is moving. NOTE: Valve caps should be on the valve stems to keep dust and water out. Page 5867 2. Poor steering stability. 3. Rapid and uneven wear at center of the tread. Lower than recommended pressure can cause: 1. Tire squeal on turns. 2. Hard steering. 3. Rapid and uneven wear on the edges of the tread. 4. Tire rim bruises and rupture. 5. Tire cord breakage. 6. High tire temperatures. 7. Reduced handling. 8. Reduced fuel economy. Unequal pressure on same axle can cause: 1. Uneven braking. 2. Steering lead. 3. Reduced handling. 4. Swerve on acceleration. Radial Tire Waddle Waddle is side-to-side movement at the front and/or rear of the car. It can be caused by the steel belt not being straight within the tire, or by excessive lateral runout of the tire or wheel. It is most noticeable at low speed, about 8 to 48 km/h (5 to 30 mph). It may also cause rough ride at 80 to 113 km/h (50 to 70 mph). The car can be road tested to see which end of the car has the faulty tire. If the tire causing the waddle is on the rear, the rear end of the car will "waddle". From the driver's seat, it feels as if someone is pushing on the side of the car. If the faulty tire is on the front, the waddle is more easily seen. The front sheet metal appears to be moving back and forth. It feels as if the driver's seat is the pivot point in the car. Another more time-consuming method of determining the faulty tire is substituting tire and wheel assemblies that are known to be good. Follow these steps: 1. Drive the car to determine if the waddle is coming from the front or rear. 2. Install tire and wheel assemblies known to be good (from a similar car) in place of those on the end of the car which is waddling. If the waddle cannot be isolated to front or rear, start with the rear tires. 3. Road test again. If improvement is noted, install the original tire and wheel assemblies one at a time until the faulty tire is found. If no improvement is noted, install tires known to be good in place of all four. Then, install the originals one at a time until the faulty tire is found. Radial Tire Lead/Pull "Lead/Pull" is vehicle deviation from a straight path, on a level road with no pressure on the steering wheel. Lead is usually caused by: 1. Poorly manufactured radial tires. 2. Uneven brake adjustment. 3. Wheel alignment. The way in which a tire is built can produce lead in a car. An example of this is placement of the belt. Off-center belts on radial tires can cause the tire to develop a side force while rolling straight down the road and the tire will tend to roll like a cone. The "Radial Tire Lead/Pull Correction" chart should be used to make sure that front wheel alignment is not mistaken for tire lead. Rear tires will not cause lead/pull. Page 7482 This sample Ground Distribution schematic shows all of the components that share two ground points. Components A solid border line means the entire component is shown. A broken border line indicates that only part of the component is shown. Page 6973 Air Bag(s) Arming and Disarming: Service Precautions Airbag Handling and Storage Airbag Handling and Storage Do not disassemble an airbag. It has no serviceable parts. Once an airbag has been deployed, it cannot be repaired or reused. For temporary storage of the airbag during service, please observe the following precautions. - Store the removed airbag with the pad surface up. Never put anything on the removed airbag. - Keep free from any oil, grease, detergent, or water to prevent damage to the airbag assembly. - Store the removed airbag on a secure, flat surface away from any high heat source (exceeding 200 °F/93 °C). - Never perform electrical inspections to the airbags, such as measuring resistance. - Do not position yourself in front of the airbag assembly during removal, inspection, or replacement. Page 1392 2. Tighten the hub nut to the value given below, using a spring scale on the wheel pin. New bearing and New oil seal Bearing Preload: 20 N - 25 N (4.4 lbs. - 5.5 lbs.) Used bearing and New oil seal Bearing Preload: 12 N - 18 N (2.6 lbs. - 4.0 lbs.) If the measured bearing preload is outside the specifications, adjust it by loosening or tightening the bearing nut. 9. Install lock washer and lock screw in the following manner. - Turn the side with larger diameter of the tapered bore to the vehicle outer side, then attach the washer. - If the bolt holes in the lock plate are not aligned with the corresponding holes in the nut, reverse the lock plate. - If the bolt holes are still out of alignment, turn in the nut just enough to obtain alignment. - Screw is to be fastened tightly so its head may come lower than the surface of the washer. 10. Apply adhesive (LOCTITE 515 or equivalent) to both joining flange faces then install hub flange. 11. Install snap ring and shim. Adjust the clearance between the freewheeling hub body and the snap ring. Clearance: 0 mm - 0.3 mm (0 inch - 0.012 inch) Shims Available: 0.2 mm, 0.3 mm, 0.5 mm, 1.0 mm (0.008 inch, 0.012 inch, 0.020 inch, 0.039 inch) 12. Install hub cap. Exhaust Manifold LH Exhaust Manifold: Service and Repair Exhaust Manifold LH Removal 1. Disconnect battery ground cable. 2. Remove air cleaner duct assembly. 3. Disconnect O2 sensor connector. 4. Remove exhaust front pipe three stud nuts from exhaust side and two nuts from rear end of exhaust front pipe. 5. Remove heat protector two fixing bolts then the heat protector. 6. Remove a bolt on engine LH side for Air Conditioner (A/C) compressor bracket and loosen two bolts for A/C compressor then move A/C compressor to front side. 7. Remove exhaust manifold eight fixing nuts and remove exhaust manifold from the engine. Installation 1. Install exhaust manifold and tighten exhaust manifold fixing nuts to the specified torque with new nuts. Torque: 57 Nm (42 ft. lbs.) Page 53 it is located, and what it connects to. Use the Connector Views to help locate the proper cavity when you need to probe a connector. It can be especially helpful if the connector has more than one wire of the same color. A dash symbol (-) indicates that the cavity is empty. Connector views can also be used to help diagnose multiple symptoms in separate circuits which could be caused by a single problem in a connector shared by those circuits. Here's an example: 1. Pick one of the multiple symptoms and look up the schematic for that circuit. 2. Make a list of all the in-line and fuse box connectors in that schematic , 3. Then, in the Connector Views, look up each connector on your list to see if circuits related to the other symptoms run through one of them. If they do, inspect that connector for the problem. Example: The blower, rear window defogger, and the windshield wiper don't work. List all in-line and fuse box connectors in the blower controls circuit and then check the Connector View (see the sample). You find that C324 is common to the blower controls, rear window defogger, and wiper/washer, so you inspect C324 and find the problem, bent terminals. Finding Component/Connector Locations Finding Component/Connector Locations To see where a component or connector is located on the car, look up its photo number in the "Component Location". The photo will also tell you the color of the connector, and how many cavities it has. Page 2864 Coolant Temperature Sensor/Switch (For Computer): Description and Operation Engine Coolant Temperature (ECT) Sensor The engine coolant temperature (ECT) sensor is a thermistor (a resistor which changes value based on temperature) mounted in the engine coolant stream. Low coolant temperature produces a high resistance of 100,000 ohms at -40 °C (-40 °F). High temperature causes a low resistance of 70 ohms at 130 °C (266 °F). The PCM supplies a 5-volt signal to the ECT sensor through resistors in the PCM and measures the voltage. The signal voltage will be high when the engine is cold and low when the engine is hot. By measuring the voltage, the PCM calculates the engine coolant temperature. Engine coolant temperature affects most of the systems that the PCM controls. The Tech 2 displays engine coolant temperature in degrees. After engine start-up, the temperature should rise steadily to about 85 °C (185 °F). It then stabilizes when the thermostat opens. If the engine has not been run for several hours (overnight), the engine coolant temperature and intake air temperature displays should be close to each other. A hard fault in the engine coolant sensor circuit will set DTC P0177 or DTC P0118. An intermittent fault will set a DTC P1114 or P1115. Page 2972 Ground - "G" Shielding Sheilding This represents RFI (Radio Frequency Interference) shielding around a wire. The shielding is always connected to ground. Splices Locations Main Relay (Computer/Fuel System): Locations 9. Fuse/Relay Box (Cover Removed) Fuse/Relay Box (Cover Removed) Page 5799 If you need more labels, order them from Helm using reorder number Y0895.* Page 6168 Evaporator Core: Service and Repair Electronic Thermostat, Evaporator Core And/Or Expansion Valve - Disassembled View Electronic Thermostat, Evaporator Core and/or Expansion Valve Removal 1. Disconnect the battery ground cable. 2. Discharge and recover refrigerant. 3. Remove evaporator assembly. 4. Remove the electronic thermostat sensor fixing clip. Pull the sensor from the evaporator assembly. 5. Remove clip. 6. Remove attaching screw. 7. Remove upper case. Page 5444 TOE-IN: This illustration shows view from the top of the vehicle. Toe-in is the measured amount the front wheels are turn in. The actual amount of toe-in is normally a fraction of a degree. Toe-in is measured from the center of the tire treads or from the inside of the tires. The purpose of toe-in is to insure parallel rolling of the front wheels and to offset any small deflections of the wheel support system which occurs when the vehicle is rolling forward. Incorrect toe-in results in excessive toe-in and unstable steering. Toe-in is the last alignment to be set in the front end alignment procedure. Dual Pressure Switch Refrigerant Pressure Sensor / Switch: Testing and Inspection Dual Pressure Switch 1. Disconnect pressure switch connector and check for continuity between pressure switch side connector terminals (1) and (2). Page 6776 Wire Color Abbreviations The following abbreviations are used to identify wire colors in the circuit schematics: WHT................................... White YEL................................... Yellow BLK................................... Black BLU................................... Blue GRN................................... Green RED................................... Red ORN................................... Orange PNK................................... Pink BRN................................... Brown GRY................................... Gray PUR................................... Purple LT BLU................................... Light Blue LT GRN................................... Light Green Page 1377 Tires: Service and Repair Spare Tire Spare Tire Hanger Removal 1. Open the hatch gate and tail gate. 2. Remove the spare tire (3). - Put the spare tire handle (1) to the center of upper side of rear bumper (2) and turn counterclockwise. Put spare tire down. 3. Remove the spare tire support. - Remove the four bolts that are fixed to frame cross member. 4. Remove the spare tire hanger assembly. - Remove the two fixing bolts. Installation To install, follow the removal steps in the reverse order, noting the following points. 1. Install the spare tire firmly. 2. Tighten the spare tire support fixing bolts to the specified torque. Torque: 40 Nm (4.1 kg.m) 3. Tighten the spare tire hanger fixing bolts to the specified torque. Torque: 19 Nm (1.9 kg.m) Steering/Suspension - Vehicle Pulls Left/Right Alignment: All Technical Service Bulletins Steering/Suspension - Vehicle Pulls Left/Right 06-068 May 2, 2009 Applies To: ALL *Vehicle Pulls or Drifts, and/or Steering Wheel Is Off-Center (Supersedes 06-068, Vehicle Pulling or Drifting, dated October 4, 2007, to revise the information marked by asterisks) (Replaces 90-011, Steering Wheel Off-Center Adjustment at PDI)* *REVISION SUMMARY The title description was revised.* SYMPTOM While driving on a straight road, the vehicle pulls or drifts to the right or left. BACKGROUND New tools were developed to help you diagnose and correct a pulling and/or steering wheel off-center issue. There is a diagnosis worksheet included to take on your test-drive and record your findings. These values are used to build the 15-digit DTC (diagnostic trouble code) that is required for your warranty claim. The last step in each repair procedure helps you create the correct code. In the rare case that you have to repair a vehicle that pulls and has the steering wheel off-center, use REPAIR PROCEDURE B to file your warranty claim. For more information, refer to Training Module SSC 44 - Steering Drift or Pull Interactive Service Bulletin. PROBABLE CAUSES Several conditions can cause the vehicle to pull or drift: ^ Wheel alignment ^ Tires ^ Off-center steering wheel (no pulling or drifting, but a customer may believe this is the case) CORRECTIVE ACTION Diagnose the problem using the special tools and the worksheet on page 4 that guides you to one of four repair procedures. TOOL INFORMATION Centering Tape (enough to diagnose 240 vehicles): T/N O7AAJ-001A300 Steering Drift Set Level: T/N 07AAJ-00100 Steering Drift Set: T/N O7MJ-001A140 Replacement Weight for Steering Drift Set: T/N 07AAJ-001A400 WARRANTY CLAIM INFORMATION In warranty: The normal warranty applies. Failed Part: P/N 53560-SDA-AO1 H/C 7139652 Page 583 6. Remove the connector position assurance (CPA) clip from the APPS connector. 7. Disconnect the 10 P connector from the APPS. 8. Remove the bolts, the APPS, the spacer, and the accelerator link from the accelerator pedal assembly. 9. Separate the spacer from the APPS. Clean the grease off the spacer and the accelerator link with a clean shop towel. 10. Clean the terminals of the 10 P APPS connector (harness side) with contact cleaner. Shake the residue out of the connector, and allow the contact cleaner to evaporate for at least 3 minutes before reconnecting the connector. 11. Install a new APPS, the spacer, and the accelerator link onto the accelerator pedal assembly. Leave the mounting screws loose so the sensor can be adjusted. 12. Connect the 10 P connector to the new APPS, and lock the connector in place with the CPA. 13. Connect the PGM Tester to the data link connector (DLC), and turn the ignition switch to ON (II). Page 1788 Compression Check: Testing and Inspection Engine Compression Test Procedure 1. Start and run the engine until the engine reaches normal operating temperature. 2. Turn the engine off. 3. Remove all the spark plugs. 4. Remove ignition coil fuse (15A) and disable the ignition system. 5. Remove the fuel pump relay from the relay and fuse box. 6. Engage the starter and check that the cranking speed is approximately 300 rpm. 7. Install cylinder compression gauge into spark plug hole. 8. With the throttle valve opened fully, keep the starter engaged until the compression gage needle reaches the maximum level. Note the reading. 9. Repeat the test with each cylinder. If the compression pressure obtained falls below the limit, engine overhaul is necessary. Limit: 1000 kPa (145 psi) Page 5735 Some vehicles affected by this campaign may be in your used vehicle inventory. As a matter of federal law, these vehicles must be repaired before they are sold. Should a dealership sell an unrepaired vehicle that subsequently causes an injury or damage because of the recalled item, the dealership will be solely responsible to the damaged party, and will be required to defend and indemnify American Honda for any resulting claims. To see if a vehicle in inventory is affected by this campaign, do an iN VIN status inquiry before selling it. CORRECTIVE ACTION Inspect the lower trailing link frame brackets for corrosion (Refer to inspection procedure below) and, depending on the stage of corrosion, do one of these repairs: ^ STAGE 1 REPAIR (about 50 percent of affected vehicles): Apply Noxudol 300 anti-corrosion wax. ^ STAGE 2 REPAIR (about 40 percent of affected vehicles): Apply Noxudol 300 and Noxudol 700 anti-corrosion wax. ^ STAGE 3 REPAIR (about 8 percent of affected vehicles): Install Trailing Link Frame Bracket Kit A, and apply Noxudol 300 and Noxudol 700 anti-corrosion wax. ^ STAGE 4 REPAIR (only about 1 percent of affected vehicles): Install Trailing Link Frame Bracket Kit B, and apply Noxudol 300 and Noxudol 700 anti-corrosion wax. PARTS INFORMATION Page 259 the component if the component only has one connector, or by a capital letter (A, B, C, etc.) if the component has more than one connector. Below most connector numbers and component names are PHOTO and VIEW numbers. The PHOTO number refers to a photo in the back of the book that shows the connector's location on the car. The VIEW number refers to an illustration in the back of the book that shows the connector face, wire colors, connector cavity numbers, and other details. The connector cavity numbering sequence begins at the top left corner of the connector. Disregard any numbers molded into the connector housing. Wires Wires are identified by the abbreviated names of their colors; the second color is the color of the stripe. Wires are also identified by their location in a connector. The number "2" next to the male and female wire terminals at C416, for example, means those terminals join in cavity 2 of connector C416. Symbols A complete description of schematic symbols is given under wire color abbreviation. Power Distribution Schematics Power Distribution schematics show how power is supplied from the positive battery terminal to various circuits in the car. Refer to the Power Distribution section to get a more detailed picture of how power is supplied to the circuit you're working on. From Battery to Ignition Switch, Fuses, and Relays Individual circuit schematics begin with a fuse. The first half of Power Distribution, however, shows the wiring "upstream" between the battery Page 1917 14. Working through the right front wheelwell, remove the two upper flange bolts holding the bracket to the engine. 15. Working from under the vehicle, rotate the right engine mount, and remove the two flange nuts holding the mount and the mount cover to the bracket. 16. Remove the mount, the cover, and the bracket. Discard the cover. 17. Assemble the bracket, the new cover, and the mount in the engine compartment. Secure the assembly with the two flange nuts. Torque the flange nuts to 50 N.m (37 lb-ft). Page 3590 Splices Splices are shown as a dot. Their location and the number of wires may vary depending on the harness manufacturer. Switches Switches These switches move together; the broken straight line between them means they are mechanically connected. Other types of switches are controlled by a coil or a solid state circuit. Unless otherwise noted, all switches are shown in their normal (rest) position, with power off. Terminal "T" Page 6519 Front Seat Belt And Associated Parts REMOVAL 1. Disconnect the battery ground cable. 2. Remove the rear seat assembly. - Refer to Rear Seat Assembly in Seats. 3. Remove the soft top assembly or resin top assembly. - Refer to Soft Top Assembly or Resin Top Assembly in Sunroof/Convertible Top section. 4. Remove the luggage side trim cover. - Refer to Rear Seat Belt (SWB). 5. Remove the sill plate. 6. Remove the anchor covers and seat belt lower anchor bolts (Front & Rear). Page 7001 4. Remove the old metal detent clips. 5. Install two new metal detent clips. 6. Reinstall the ashtray/rear beverage holder assembly onto the rear console. 7. Plug in the connector (A/T), and reinstall the rear console assembly. 8. Open and close the rear beverage holder swing arm several times to make sure the detents hold. DISCLAIMER Page 7677 Key Reminder Switch: Diagnostic Aids Before Troubleshooting Before Troubleshooting See: Service Precautions/Vehicle Damage Warnings/Tips and Precautions 1. Check applicable fuses in the appropriate fuse/relay box. 2. Check the battery for damage, state of charge, and clean and tight connections. CAUTION: Do not quick-charge a battery unless the battery ground cable has been disconnected, otherwise you will damage the alternator diodes. - Do not attempt to crank the engine with the battery ground cable loosely connected or you will severely damage the wiring. While You're Working 1. Make sure connectors are clean, and have no loose terminals or receptacles. 2. Make sure that connectors without wire seals are packed with dielectric (silicone) grease. Part Number: 08798-9001. 3. When connecting a connector, push it until it "clicks" into place. CAUTION: Do not pull on the wires when disconnecting a connector. Pull only on the connector housings. - Most circuits include solid-state devices. Test the voltages in these circuits only with a 10-megaohm or higher impedance digital multi meter. Never use a test light or analog meter on circuits that contain solid-state devices. Damage to the devices may result. Five-Step Troubleshooting 1. Verify The Complaint Turn on all the components in the problem circuit to check the accuracy of the customer complaint. Note the symptoms. Do not begin disassembly or testing until you have narrowed down the problem area. 2. Analyze The Schematic Look up the schematic for the problem circuit. Determine how the circuit is supposed to work by tracing the current paths from the power source through the circuit components to ground. Also, trace circuits that share wiring with the problem circuit. The names of circuits that share the same fuse, ground, or switch, and so on, are referred to in each circuit schematic. Try to operate any shared circuits you didn't check in step 1. If the shared circuits work, the shared wiring is OK, and the cause must be in the wiring used only by the problem circuit. If several circuits fail at the same time, the fuse or ground is a likely cause. Based on the symptoms and your understanding of the circuit's operation, identify one or more possible causes. 3. Isolate The Problem By Testing The Circuit Make circuit tests to check the diagnosis you made in step 2. Keep in mind that a logical, simple procedure is the key to efficient troubleshooting. Test for the most likely cause of failure first. Try to make tests at points that are easily accessible. 4. Fix The Problem Once the specific problem is identified, make the repair. Be sure to use proper tools and safe procedures. 5. Make Sure The Circuit Works Turn on all components in the repaired circuit in all modes to make sure you've fixed the entire problem. If the problem was a blown fuse, be sure to test all of the circuits on that fuse. Make sure no new problems turn up and the original problem does not recur. Page 6691 Testing For A Short With A Self-Powered Test Light or DVOM 1. Remove the blown fuse and disconnect the battery and load. 2. Connect one lead of a self-powered test light or digital volt/ohmmeter (DVOM) (switched to the lowest "OHMS" range) to the fuse terminal on the load side. 3. Connect the other lead to a known good ground. 4. Beginning near the fuse box, wiggle the harness. Continue this at convenient points about six inches apart while watching the test light or DVOM. 5. If the self-powered test light goes on or the DVOM displays a low reading or no reading (zero), there is a short to ground in the wiring near that point. Testing for a Short with a Test Light or DVOM 1. Remove the blown fuse and disconnect the load. 2. Connect a test light or digital volt/ohmmeter (DVOM), switched to the appropriate DC volts range, across the fuse terminals to make sure voltage is present. You might have to turn the ignition switch to ON; check the schematic to see. 3. Beginning near the fuse box, wiggle the harness. Continue this at convenient points about six inches apart while watching the test light or DVOM. 4. Where the test light goes , or the DVOM voltage drops to zero, there is a short to ground in the wiring near that point. NOTE: Always use a DVOM on high impedance circuits. A test light may not glow (even with battery voltage present). Testing For A Short With A Short Circuit Locator (Short Finder) 1. Remove the blown fuse. Leave the battery connected. Locations Behind Glove Box Page 4698 Page 3699 the component if the component only has one connector, or by a capital letter (A, B, C, etc.) if the component has more than one connector. Below most connector numbers and component names are PHOTO and VIEW numbers. The PHOTO number refers to a photo in the back of the book that shows the connector's location on the car. The VIEW number refers to an illustration in the back of the book that shows the connector face, wire colors, connector cavity numbers, and other details. The connector cavity numbering sequence begins at the top left corner of the connector. Disregard any numbers molded into the connector housing. Wires Wires are identified by the abbreviated names of their colors; the second color is the color of the stripe. Wires are also identified by their location in a connector. The number "2" next to the male and female wire terminals at C416, for example, means those terminals join in cavity 2 of connector C416. Symbols A complete description of schematic symbols is given under wire color abbreviation. Power Distribution Schematics Power Distribution schematics show how power is supplied from the positive battery terminal to various circuits in the car. Refer to the Power Distribution section to get a more detailed picture of how power is supplied to the circuit you're working on. From Battery to Ignition Switch, Fuses, and Relays Individual circuit schematics begin with a fuse. The first half of Power Distribution, however, shows the wiring "upstream" between the battery Locations PCV Valve Page 2392 Valve Shim Replacement Chart Page 1561 2. Measure the valve spring squareness with a steel square and replace the valve springs if the measured value exceeds the specified limit. Limit: 2 mm (0.079 inch) 3. Using a spring tester to compress the springs to the installed height, measure the compressed spring tension, and replace the springs if the measured tension is below the specified limit. At installed height: 35.0 mm (1.38 inch) Standard: 196 N (44 lbs.) Limit: Less than 181 N (41 lbs.) Valve Guide Caution: Take care not to damage the valve seat contact surface, when removing carbon adhering to the valve head. Carefully inspect the valve stem for scratches or abnormal wear. If these conditions are present, the valve and the valve guide must be replaced as a set 1. Measure the valve stem diameter with a micrometer. If the valve stem diameter is less than the specified limit, the valve and the valve guide must be replaced as a set. Diameter of Valve Stem Intake Standard: 5.977 mm - 5.959 mm (0.2353 in 0.2346 inch) Limit: 5.90 mm (0.2323 inch) Exhaust Standard: 5.952 mm - 5.970 mm (0.2343 in 0.2350 inch) Limit: 5.90 mm (0.2323 inch) 2. Measure the inside diameter of the valve guide with a micrometer. Subtract the measured outer diameter of the valve stem from the measured inner diameter of the valve guide. If the value exceeds the specified limit, the valve and the valve guide must be replaced as a set. Inside Diameter of the Valve Guide Inlet clearance Standard: 0.023 mm - 0.056 mm (0.0009 in - 0.0002 inch) Limit: 0.20 mm (0.00787 inch) Exhaust clearance Standard: 0.030 mm - 0.063 mm (0.0012 in - 0.0025 inch) Limit: 0.20 mm (0.00787 inch) Page 2615 it is located, and what it connects to. Use the Connector Views to help locate the proper cavity when you need to probe a connector. It can be especially helpful if the connector has more than one wire of the same color. A dash symbol (-) indicates that the cavity is empty. Connector views can also be used to help diagnose multiple symptoms in separate circuits which could be caused by a single problem in a connector shared by those circuits. Here's an example: 1. Pick one of the multiple symptoms and look up the schematic for that circuit. 2. Make a list of all the in-line and fuse box connectors in that schematic , 3. Then, in the Connector Views, look up each connector on your list to see if circuits related to the other symptoms run through one of them. If they do, inspect that connector for the problem. Example: The blower, rear window defogger, and the windshield wiper don't work. List all in-line and fuse box connectors in the blower controls circuit and then check the Connector View (see the sample). You find that C324 is common to the blower controls, rear window defogger, and wiper/washer, so you inspect C324 and find the problem, bent terminals. Finding Component/Connector Locations Finding Component/Connector Locations To see where a component or connector is located on the car, look up its photo number in the "Component Location". The photo will also tell you the color of the connector, and how many cavities it has. Page 6617 NOTE: It is very important that you fill out this form fully and accurately. An accurate explanation of the problem and conditions helps the manufacturer to duplicate the problem, speeding the repair, and reducing the number of No Trouble Found" (NTF) units. Disclaimer Page 7084 Distinct Of Circuit By Wire Base Color All wires have color-coded insulation. Wires belonging to a system's main harness will have a single color. Wires belonging to a system's sub-circuits will have a colored stripe. Striped wires use the codes found in the chart to show wire size and colors. Abbreviations are used to indicate wire color within a circuit diagram. How to Identify Connector Terminals How to Identify Connector Terminals Cavity Numbering System The cavities (and wire terminals) in each connector are numbered starting from the upper left, looking at the male terminals from the terminal side (or looking at the female terminals from the wire side. Both views are in the same direction so the numbers are the same.) All actual cavities are numbered, even if they have no wire terminals in them. NOTE: Data Link Connector (DLC) terminals are numbered according to SAE standard J1962, not the Honda standard. The numbers of the four end terminals are molded into the corners of the connector face. The connector cavity number is listed next to each terminal on the circuit schematic. The cavity / terminal shown is # 6. Using/Identifying Connector Terminal Views How to Use Connector Terminal Views To see the configuration of a connector's cavities, look up its view number in the Connector Views. Each view includes the color of the connector, where Page 1176 Coolant: Fluid Type Specifications Mixture of water and good quality ethylene glycol base type antifreeze mixed 50/50. Page 6869 To install, follow the removal steps in the reverse order, noting the following points: 1. Install the regulator handle as shown in the figure, if equipped without power windows. 2. Check to see that the window regulator operates smoothly and the glass opens and closes properly. 3. Install the waterproof sheet tightly against the door panel. Page 6407 Air Bag: Service and Repair Front Passenger Airbag Spring-Loaded Lock Connector REMOVAL To remove the connector, hold the cover insulator(l) and pull it. The cover insulator slides and lock will be released. Do not hold the socket insulator(2). INSTALLATION Page 1611 6. Working from under the vehicle, unplug the 3P connector from the crankshaft position sensor. 7. Remove the crankshaft position sensor (one flange bolt). 8. Remove the crankshaft position sensor harness clamp from the engine (one flange nut). 9. Models With A/T: Remove the front and rear clamps for the ATF cooler lines. 10. Support the engine with a block of wood and a powertrain lift or commercially available jack as shown. Locations Page 5314 Auxiliary Power Outlet: Service and Repair Rear Accessory Power Socket Removal 1. Disconnect the battery ground cable. 2. Remove the quarter trim lower cover. 3. Remove the rear accessory socket (2). - Disconnect the connectors (1). - Pull out the front accessory socket from the socket cover (3). Installation To install, follow the removal steps in the reverse order, noting the following point: Page 8010 If there is no photo number below or beside a component name or a connector, ground, or terminal number, look up that name or number in the appropriate Connector Identification Chart. The chart lists how many cavities a connector has, where it's located, and what it connects to. The related illustration shows the connector's location on the harness, and the harness routing. NOTE: Photos listed by number are located at Locations / Components / Photograohs. See: Locations/Component Locations/Photographs Circuit Schematics Page 5227 Page 1087 Spark Plug: Specifications Plug Torque 13 ft lb (18 Nm) Capacity Specifications Fluid - Differential: Capacity Specifications Differential Oil Capacity ............................................................................................................................................... ...................................................................... 1.87 Qt Page 3246 Fuel Line Coupler: Service and Repair Assembling Advice Application of engine oil or light oil to the pipe facilitates connecting work. The work should be started immediately after lubrication, since dust may stick to the pipe surface to cause poor sealability if a long time passes after lubrication. Test/Inspection After Assembling 1. Reconnect the battery negative cable. 2. Turn the ignition key to the "ON" position and check pump start up sound. As the pump is actuated to raise fuel pressure, check and see fuel leak from the piping system. 3. Make sure of no fuel leakage by conducting the above fuel leak check a few times. 4. Start the engine and make sure of stable idling speed and normal vehicle run. The entry of dust during the work may sometimes affect the fuel injection system. Page 2038 Distinct Of Circuit By Wire Base Color All wires have color-coded insulation. Wires belonging to a system's main harness will have a single color. Wires belonging to a system's sub-circuits will have a colored stripe. Striped wires use the codes found in the chart to show wire size and colors. Abbreviations are used to indicate wire color within a circuit diagram. How to Identify Connector Terminals How to Identify Connector Terminals Cavity Numbering System The cavities (and wire terminals) in each connector are numbered starting from the upper left, looking at the male terminals from the terminal side (or looking at the female terminals from the wire side. Both views are in the same direction so the numbers are the same.) All actual cavities are numbered, even if they have no wire terminals in them. NOTE: Data Link Connector (DLC) terminals are numbered according to SAE standard J1962, not the Honda standard. The numbers of the four end terminals are molded into the corners of the connector face. The connector cavity number is listed next to each terminal on the circuit schematic. The cavity / terminal shown is # 6. Using/Identifying Connector Terminal Views How to Use Connector Terminal Views To see the configuration of a connector's cavities, look up its view number in the Connector Views. Each view includes the color of the connector, where Page 1483 9. Install main bearing caps, oil gallery and crank case bolts in the order shown, and tighten each bolt to the specified torque. Note: Do not apply engine oil to the crank case side bolts. Main bearing cap bolts. Torque: 39 Nm (29 ft. lbs.) Oil gallery fixing bolts. Torque: 1st step: 29 Nm (21 ft. lbs.) 2nd step: 55° - 65° Crank case side bolts Torque: 39 Nm (29 ft. lbs.) Note: Do not allow the crankshaft to rotate. 10. Remove the main bearing caps in the sequence shown in the illustration. 11. Measure the plastogene width and determine the oil clearance. If the oil clearance exceeds the specified limit, replace the main bearings as a set and/or replace the crankshaft. Standard: 0.019 mm - 0.043 mm (0.0007 inch - 0.0017 inch) Limit: 0.08 mm (0.0031 inch) 12. Clean the plastogene from the bearings and the crankshaft. Remove the crankshaft and the bearings. Crankshaft (12) Inspection Inspect the surface of the crankshaft journal and crank pins for excessive wear and damage. Inspect the oil seal fitting surfaces for excessive wear and damage. Inspect the oil ports for obstructions. Inspection and Repair Page 7078 1. When setting up links, pay attention to the position and direction of the links. 2. Apply chassis grease to the lock assembly and striker moving surface. 3. Check that the tailgate lock operates correctly after installing it. 4. Tighten the hatchgate lock assembly fixing bolts to the specified torque. Torque 7 Nm (61 lb in) Page 7907 The connector cavity number is listed next to each terminal on the circuit schematic. The cavity / terminal shown is # 6. Diodes A rectifier diode works like a one way valve. It allows current to flow only in the direction of the arrow. A Zener diode blocks reverse current at normal voltages just like a rectifier diode. At high voltages, however, a Zener diode allows current to flow in reverse. Fuses Page 4590 Each schematic represents one circuit. A circuit's wires and components are arranged to show current flow, from power at the top of the page, to ground, at the bottom. Shared Circuits Other circuits may share power or ground terminals or wiring with the circuit shown. A wire that connects one circuit to another, for example, is cut short and has an arrowhead at the end of it pointing in the direction of current flow. Next to the arrowhead is the name of the circuit or component which shares that wiring. To quickly check shared wiring, check the operation of a component it serves. If that component works, you know the shared wiring is OK. Connectors All in-line and junction connectors are numbered (C725, C416, etc.). Component connectors are not numbered but are identified either by the name of Page 7208 Service and Repair Torque Converter Clutch Solenoid: Service and Repair REMOVAL 1. Raise the vehicle and support it on jack stands. 2. Disconnect battery ground cable. 3. Drain fluid. 4. Remove twelve 10 mm adapter case oil pan fixing screws, adapter case oil pan, and gasket. NOTE: Oil pan still contains transmission fluid. Place a large drain container under the oil pan. Drain the fluid carefully. 5. Disconnect wiring harness from force motor solenoid and converter clutch solenoid. Pull only on connectors, not on wiring harness. 6. Remove seven 13 mm screws from adapter case valve body assembly, then remove transfer plate, two gaskets, and adapter case valve body. INSTALLATION 1. Inspect electrical 4 pin connector and seal of adapter case. Replace if necessary. 2. Install gasket, transfer plate, and gasket. 3. Install adapter case valve body and seven 13 mm screws. Tighten the screws to the specified torque. Torque: 20 Nm (15 Ft. lbs.) 4. Connect wiring harness assembly to converter clutch solenoid and force motor. 5. Install oil pan gasket, oil pan, and twelve 10 mm screws. Tighten the screws to the specified torque. Torque: 11 Nm (96 Ft. lbs.) 6. Fill transmission through the overfill screw hole of oil pan, using ATF DEXRON III. 7. Connect battery ground cable. Page 4700 Axle Disconnect Control Control Unit: Testing and Inspection AXLE DISCONNECT CONTROLLER 1. Connect 12 V with terminal (3) and the ground with the terminal (6). 2. Send the signal to the terminal (4). 2WD - 4WD less than 2.4 V 4WD - 2WD more than 9.0 V 3. Confirm the output signal from the terminals (1) & (2) (2 seconds output). Page 1487 - Assemble the thrust washer to the No.3 bearing journal. The oil grooves must face the crankshaft. Rear oil seal (10) - Remove the oil from the cylinder block and the retainer mounting surface. - Apply sealant (TB-1207B or equivalent) to the retainer mounting surface, following the pattern shown in the illustration. The retainer must be installed within 5 minutes after sealant application to prevent premature hardening of sealant. - Apply engine oil to the oil seal lip. - Align the cylinder block dowel pin holes with the rear retainer dowel pins. - Tighten the rear retainer fixing bolts. New bolts should be used when installing rear retainer. Torque: 18 Nm (13 ft. lbs.) Note: Be very careful not to disengage the oil seal garter spring during installation of the rear retainer. Specifications Fuel Pressure: Specifications PRESSURE PRESSURE With Regulator Vacuume Hose Disconnected 42-55 Psi. Page 4962 Brake Fluid: Service and Repair Leakage of Brake Fluid Leakage of Brake Fluid With engine idling, set shift lever in the neutral position and continue to depress brake pedal at a constant pedal application force. Should the pedal stroke become deeper gradually, a leakage from the hydraulic pressure system is possible. Make sure by visual check that there is no leak. Page 5790 ^ Disconnect the fuel tank at locations 2, 3, and 4. shown below. 6. Loosen the parking brake cable mounting brackets on both sides of the frame (four places). 7. On the driver's side of the frame, loosen the six wire harness clips. Page 4624 Locations Air Flow Meter/Sensor: Locations 28. Left Side of Engine Compartment Left Side Of Engine Compartment Page 2047 Ground - "G" Shielding Sheilding This represents RFI (Radio Frequency Interference) shielding around a wire. The shielding is always connected to ground. Splices Page 6474 Air Bag(s) Arming and Disarming: Description and Operation Definitions Air Bag An inflatable cloth cushion designed to deploy in certain frontal crashes. It supplements the protection offered by the seat belts by distributing the impact load more evenly over the vehicle occupant's head and torso. Asynchronous Performed in a nonperiodic fashion, (i.e., no defined time or interval). (B+) Battery voltage, (B+) The voltage available at the battery at the time of the indicated measurement. With the key "ON" and the engine not running, the system voltage will likely be between 12 and 12.5 volts. At idle the voltage may be 14 to 16 volts. The voltage could be as low as 10 volts during engine cranking. Bulb Check The SDM will cause the "AIR BAG" warning lamp to flash seven times and then go "OFF" whenever the ignition switch transitions to the ON position from any other ignition switch position and no malfunctions are detected. "CONTINUOUS MONITORING" Tests performed by the SDM on the SRS every 100 milliseconds while "Ignition 1" voltage is in the normal operating voltage range at the SDM. Data Link Connector (DLC) Formerly "DLC" a connector which allows communication with an external computer, such as a scan tool. Datum Line A base line parallel to the plane of the underbody or frame from which all vertical measurements originate. Deploy To inflate the air bag. Deployment Loops The circuits which supply current to the air bag assemblies to deploy the air bag. Diagnostic Trouble Code (DTC) Formerly "Code", a numerical designator used by the SDM to indicate specific SRS malfunctions. Driver Current Source An output of the SDM which applies current into the driver air bag assembly circuit during the "Initiator Assembly Resistance Test". Driver Air Bag Assembly An assembly located in the steering wheel hub consisting of an inflatable bag, an inflator and an initiator. EEPROM Electronically Erasable Programmable Read Only Memory. Memory which retains its contents when power is removed from the SDM. Ignition Cycle The voltage at the SDM "Ignition 1" inputs, with ignition switch "ON", is within the normal operating voltage range for at least ten seconds before turning ignition switch "OFF". Ignition 1 Page 1370 Localized Tread Wear 1. Once spotty wear develops in tread due to hard braking or abrupt starting, localized wear tends to be promoted. Shoulder Wear (Generally Wear Develops In Outer Shoulder): 1. Camber or toe-in incorrect. 2. Shoulder wear caused by repeated hard-cornering. Wear In Shoulders At Points Opposed To Each Other 1. Tire or wheel out of round or distorted. 2. Play in bearings or ball joint. Page 6330 Refrigerant Pressure Sensor / Switch: Testing and Inspection Triple Pressure Switch 1. Disconnect the connector and check for continuity between pressure switch side connector terminals (1) and (2). 2. Reconnect the connector to activate the A/C switch and check to see if there is continuity between the chassis side connector terminals (3) and (4) and the fan operates. Page 2303 Throttle Position Sensor: Description and Operation Throttle Position (TP) Sensor The throttle position (TP) sensor is a potentiometer connected to the throttle shaft on the throttle body. The PCM monitors the voltage on the signal line and calculates throttle position. As the throttle valve angle is changed (accelerator pedal moved), the TP sensor signal also changes. At a closed throttle position, the output of the TP1 sensor is low. As the throttle valve opens, the output increases so that at wide open throttle (WOT), the output voltage should be above 92 % (Tech 2 Display). The PCM calculates fuel delivery based on throttle valve angle (driver demand). A broken or loose TP sensor may cause intermittent bursts of fuel from an injector and unstable idle because the PCM thinks the throttle is moving. Page 6228 Page 4448 The connector cavity number is listed next to each terminal on the circuit schematic. The cavity / terminal shown is # 6. Diodes A rectifier diode works like a one way valve. It allows current to flow only in the direction of the arrow. A Zener diode blocks reverse current at normal voltages just like a rectifier diode. At high voltages, however, a Zener diode allows current to flow in reverse. Fuses Page 1466 Note: Take care not to confuse the alignment mark (2) and the size mark (1) during the installation procedure. Reassembly 1. Install connecting rod 2. Install piston 3. Install piston pin - Apply a thin coat of engine oil to the piston pin. Try to insert the piston pin into the piston pin hole with normal finger pressure. Note: When changing piston/connecting rod combinations, do not change the piston/piston pin combination and do not reuse the old piston pin. - Attach the piston to the connecting rod with the piston front mark and the connecting rod front mark on the same side. Page 3581 it is located, and what it connects to. Use the Connector Views to help locate the proper cavity when you need to probe a connector. It can be especially helpful if the connector has more than one wire of the same color. A dash symbol (-) indicates that the cavity is empty. Connector views can also be used to help diagnose multiple symptoms in separate circuits which could be caused by a single problem in a connector shared by those circuits. Here's an example: 1. Pick one of the multiple symptoms and look up the schematic for that circuit. 2. Make a list of all the in-line and fuse box connectors in that schematic , 3. Then, in the Connector Views, look up each connector on your list to see if circuits related to the other symptoms run through one of them. If they do, inspect that connector for the problem. Example: The blower, rear window defogger, and the windshield wiper don't work. List all in-line and fuse box connectors in the blower controls circuit and then check the Connector View (see the sample). You find that C324 is common to the blower controls, rear window defogger, and wiper/washer, so you inspect C324 and find the problem, bent terminals. Finding Component/Connector Locations Finding Component/Connector Locations To see where a component or connector is located on the car, look up its photo number in the "Component Location". The photo will also tell you the color of the connector, and how many cavities it has. Locations Timing Belt Removal and Engine Timing Timing Belt: Service and Repair Timing Belt Removal and Engine Timing THIS ARTICLE HAS BEEN UPDATED BY TSB 02-047 TIMING BELT REMOVAL NOTE: Left and right engine callouts are from the driver's seat. 1. Disconnect battery ground cable. 2. Remove air cleaner assembly. 3. Remove radiator upper fan shroud from radiator. 4. Move drive belt tensioner, to loose side, using wrench then remove drive belt. 5. Remove cooling fan assembly four nuts, then the cooling fan assembly. 6. Remove cooling fan drive pulley assembly. 7. Remove idle pulley assembly. 8. Remove serpentine belt tensioner assembly. 9. Remove power steering pump assembly. 10. Remove crankshaft pulley assembly using J-8614-01 crankshaft holder, hold crankshaft pulley remove center bolt, then the pulley. Description and Operation Fuel Level Sensor: Description and Operation Fuel Level Sensor The fuel level sensor is an important input to the PCM for the enhanced EVAP system diagnostic. The PCM needs fuel level information to know the volume of fuel in the tank. The fuel level affects the rate of change of air pressure in the EVAP system. Several of the enhanced EVAP system diagnostic sub-tests are dependent upon correct fuel level information. The diagnostic will not run when the tank is less than 15 % or more than 85 % full. Be sure to diagnose any Fuel Level Sensor DTCs first, as they can cause other DTCs to set. Locations Page 7012 Headliner: Removal and Replacement Headlining Headlining (LWB) Removal 1. Disconnect the battery ground cable. 2. Remove the interior trim panels. 3. Remove the dome light. - Remove the dome light lens and the fixing screws. - Disconnect the dome light connectors. Page 3744 Test Equipment CAUTION: Most circuits include solid-state devices. Test the voltages in these circuits only with a 10-megaohm or higher impedance digital multimeter. Never use a test light or analog meter on circuits that contain solid-state devices. Damage to the devices may result. Test Light and DVOM On circuits without solid-state devices, use a test light to check for voltage. A test light is made up of a 12 volt bulb with a pair of leads attached. After grounding one lead, touch the other lead to various points along the circuit where voltage should be present. The bulb will go on if there is voltage at the point being tested. If you need to know how much voltage is present, use a digital volt/ohmmeter (DVOM). Self-Powered Test Light and DVOM Use a self-powered test light to check for continuity. This tool is made up of a light bulb, battery, and two leads. To test it, touch the leads together: the light should go on. Use a self-powered test light only on an unpowered circuit. First, disconnect the battery, or remove the fuse that feeds the circuit you are working on. Select two points in the circuit between which you want to check continuity. Connect one lead of the self-powered test light to each point. If there is continuity, the test light's circuit will be completed, and the light will go on. If, in addition, you need to know exactly how much resistance there is between two points, use a digital volt/ohmmeter (DVOM). In the "OHMS" range, the DVOM will measure resistance between two points along a circuit. Low resistance means good continuity. Diodes and solid-state devices in a circuit can make a DVOM give a false reading. To check a reading, reverse the leads, and take a second reading. If the readings differ, the component is affecting the measurement. Jumper Wire Use a jumper wire to bypass an open circuit. A jumper wire is made up of an in-line fuse holder connected to a set of test leads. It should have a five ampere fuse. Never connect a jumper wire across a short circuit. The direct battery short will blow the fuse. Short Finder (Short Circuit Locator) Short finders are available to locate shorts to ground. The short finder creates a pulsing magnetic field in the shorted circuit which you can follow to the location of the short. To order any test equipment shown above, contact your local tool supplier. For a list of suppliers and tool numbers, refer to Honda Required Special Tools and Equipment Service Bulletin. Page 493 The connector cavity number is listed next to each terminal on the circuit schematic. The cavity / terminal shown is # 6. Diodes A rectifier diode works like a one way valve. It allows current to flow only in the direction of the arrow. A Zener diode blocks reverse current at normal voltages just like a rectifier diode. At high voltages, however, a Zener diode allows current to flow in reverse. Fuses Page 5995 Terminals - "T" Each "T" terminal (ring type) is numbered for reference and location. A "T" terminal is secured with a screw or bolt. Wires Locations Diagram Information and Instructions Headlamp Switch: Diagram Information and Instructions How to Identify Wiring Color-Coded Insulation Wire Color Wire Color Coding Page 2782 Testing For A Short With A Self-Powered Test Light or DVOM 1. Remove the blown fuse and disconnect the battery and load. 2. Connect one lead of a self-powered test light or digital volt/ohmmeter (DVOM) (switched to the lowest "OHMS" range) to the fuse terminal on the load side. 3. Connect the other lead to a known good ground. 4. Beginning near the fuse box, wiggle the harness. Continue this at convenient points about six inches apart while watching the test light or DVOM. 5. If the self-powered test light goes on or the DVOM displays a low reading or no reading (zero), there is a short to ground in the wiring near that point. Testing for a Short with a Test Light or DVOM 1. Remove the blown fuse and disconnect the load. 2. Connect a test light or digital volt/ohmmeter (DVOM), switched to the appropriate DC volts range, across the fuse terminals to make sure voltage is present. You might have to turn the ignition switch to ON; check the schematic to see. 3. Beginning near the fuse box, wiggle the harness. Continue this at convenient points about six inches apart while watching the test light or DVOM. 4. Where the test light goes , or the DVOM voltage drops to zero, there is a short to ground in the wiring near that point. NOTE: Always use a DVOM on high impedance circuits. A test light may not glow (even with battery voltage present). Testing For A Short With A Short Circuit Locator (Short Finder) 1. Remove the blown fuse. Leave the battery connected. Page 831 Throttle Position Sensor: Service and Repair REMOVAL PROCEDURE 1. Disconnect the negative battery cable. 2. Disconnect the TPS electrical connector. 3. Remove the bolts and the TP sensor from the throttle body. NOTE: Do not clean the TP sensor by soaking it in solvent. The sensor will be damaged as a result. INSTALLATION PROCEDURE 1. Install the TP sensor on the throttle body with the bolts. 2. Connect the TP electrical connector. 3. Install the negative battery cable. Testing and Inspection Wheel Bearing: Testing and Inspection FRONT HUB BEARING PRELOAD CHECK Check the hub bearing preload at the wheel pin. New bearing and New oil seal: 19.6 - 24.5 N (4.4 - 5.5 lbs.) Used bearing and New oil seal: 11.8 17.7 N (2.6 - 4.0 lbs.) Page 7301 4. Align the template on the mud flap. Mark the area on the mud flap that needs to be cut away with a pencil or scribe. 5. Use a utility knife to remove the marked area. 6. Repeat steps 4 and 5 on the other mud flap. 7. Reinstall the mud flaps on the vehicle. DISCLAIMER Page 2978 The wire insulation has one color or one color with another color stripe. The second color is the stripe. Page 1266 angle. The angle locator level (P/N SUN-YA328A) is available through the Honda Tool and Equipment Program. To order one, call 888-424-6857. DISCLAIMER Page 7322 1. Install the regulator handle as shown in the figure, if equipped without Dower windows. 2. Check to see that the window regulator operates smoothly and the glass opens and closes properly. 3. Install the waterproof sheet tightly against the door panel. Page 2476 5. Insert a thin stainless steel ruler or a "Slim Jim" under the magazine, about 1-1/2" from the right side of the opening. 6. Push the ruler in until it presses against the eject lever at the back of the unit. 7. Slowly remove the ruler and magazine at the same time. Two-piece door model: 1. Remove the changer from the vehicle. 2. Remove the top cover plate from the changer, and look for a jammed tray. 3. If a tray is stuck in the player, reinstall the cover and replace the changer. If all the trays are in the magazine, insert a thin stainless steel ruler or a "Slim Jim" under the magazine, about 1/2" from the right side of the opening. 4. Push the ruler in until it presses against the eject lever at the back of the unit. 5. Slowly remove the ruler and magazine at the same time. Page 1462 The size mark (1) for piston outside diameter is represented as shown in Figure. Outside Diameter Size Mark A: 93.360 mm - 93.370 mm (3.6756 inch - 3.6760 inch) Size Mark B: 93.371 mm 93.380 mm (3.6760 inch - 3.6764 inch) Size Mark C: 93.381 mm - 93.390 mm (3.6764 inch 3.6768 inch) Measure the cylinder bore inside diameter (refer to Cylinder Block). Piston Rings (8) Any worn or damaged part discovered during engine overhaul must be replaced with a new one. 1. Ring end gap measurement - Insert the piston ring into the bore. Checking/Adjusting Oil For New Compressor Refrigerant Oil: Service and Repair Checking/Adjusting Oil For New Compressor 150 cc (5.0 fl.oz.) of oil is charged in compressor (service parts). So it is necessary to drain the proper amount of oil from the new compressor. 1. Perform oil return operation. 2. Discharge and recover the refrigerant and remove the compressor. 3. Drain the compressor oil and measure the extracted oil. 4. Check the compressor oil for contamination. 5. Adjust the oil level as required. 6. Evacuate, charge and perform the oil return operation. 7. Check the system operation. Page 4858 The connector cavity number is listed next to each terminal on the circuit schematic. The cavity / terminal shown is # 6. Diodes A rectifier diode works like a one way valve. It allows current to flow only in the direction of the arrow. A Zener diode blocks reverse current at normal voltages just like a rectifier diode. At high voltages, however, a Zener diode allows current to flow in reverse. Fuses Locations Behind Glove Box Page 3223 Fuel Injector: Description and Operation Fuel Injector The sequential multiport fuel injection (SFI) fuel injector is a solenoid-operated device controlled by the PCM. The PCM energizes the solenoid, which opens a valve to allow fuel delivery. The fuel is injected under pressure in a conical spray pattern at the opening of the intake valve. Excess fuel not used by the injectors passes through the fuel pressure regulator before being returned to the fuel tank. A fuel injector which is stuck partly open will cause a loss of fuel pressure after engine shut down, causing long crank times. Procedures Windshield: Procedures Removal 1. Disconnect the battery ground cable. 2. Remove the front pillar trim cover. - Turn up the finisher and pry the trim cover clips free from the body panel. 3. Remove the sunvisors and sunvisor holders. 4. Remove the rear view mirror. - Disconnect the connector (1). - Turn the channel mount (2) 90 degrees clockwise and pull down. 5. Remove the windshield wiper arm. 6. Remove the windshield side molding. - Pull the molding out from drip rail. 7. Remove the front cowl cover. 8. Remove the windshield support. 9. Remove the upper moulding. 10. Remove the windshield. - Use a knife to cut through part of the adhesive caulking material. - Secure one end of a piece of steel piano wire (0.02 inches in diameter) to a piece of wood that can serve as a handle. - Use a pair of needle nose pliers to insert the other end of the piano wire through the adhesive caulking material at the edge of the windshield glass. - Secure the other end of the piano wire to another piece of wood. - With the aid of an assistant, carefully move the piano wire with a sawing motion to cut through the adhesive caulking material around the entire circumference of the windshield glass. Page 1797 Page 5177 10. Remove brush holder(6). 11. Raise a brush spring to detach brushes (4 pcs) from the commutator face and pull off the brush holder(12) and brush(11). 12. Remove yoke assembly(14). 13. Remove armature(15). 14. Pull OFF the yoke assembly, then remove armature, washer and center bracket.(A) (13). NOTE: In disassembling the yoke assembly, hold the armature and pull off slowly the yoke assembly. Because of strong magnetic force, avoid Page 7444 The wire insulation has one color or one color with another color stripe. The second color is the stripe. Page 6372 the component if the component only has one connector, or by a capital letter (A, B, C, etc.) if the component has more than one connector. Below most connector numbers and component names are PHOTO and VIEW numbers. The PHOTO number refers to a photo in the back of the book that shows the connector's location on the car. The VIEW number refers to an illustration in the back of the book that shows the connector face, wire colors, connector cavity numbers, and other details. The connector cavity numbering sequence begins at the top left corner of the connector. Disregard any numbers molded into the connector housing. Wires Wires are identified by the abbreviated names of their colors; the second color is the color of the stripe. Wires are also identified by their location in a connector. The number "2" next to the male and female wire terminals at C416, for example, means those terminals join in cavity 2 of connector C416. Symbols A complete description of schematic symbols is given under wire color abbreviation. Power Distribution Schematics Power Distribution schematics show how power is supplied from the positive battery terminal to various circuits in the car. Refer to the Power Distribution section to get a more detailed picture of how power is supplied to the circuit you're working on. From Battery to Ignition Switch, Fuses, and Relays Individual circuit schematics begin with a fuse. The first half of Power Distribution, however, shows the wiring "upstream" between the battery Page 2161 96. Rear of Right Catalytic Converter Rear of right catalytic converter 94. Rear of Left Catalytic Converter Rear of Left Catalytic Converter Page 6358 To install the connector, hold the socket insulator(l) and insert it. The cover insulator slides and connector will be locked. Do not hold the cover insulator(2). Page 963 Power Window Switch: Service and Repair Master Switch Replacement Removal 1. Disconnect the battery ground cable. 2. Remove the switch (1). - Pull out the switch by pushing the spring with the tip of a screwdriver. - Disconnect the connector. Installation To install, follow the removal steps in the reverse order. Page 2540 Camshaft Position Sensor: Testing and Inspection 1. Inspect the sensor O-ring for cracks or leaks. 2. Replace the O-ring if it is worn or damaged. 3. Lubricate the new O-ring with engine oil. 4. Install the lubricated O-ring. Page 2420 CD Player/Changer Troubleshooting (Passport only) Manually Removing a Jammed Magazine (All except Passport) One-piece door model: 1. Remove the changer from the vehicle. 2. Remove the rear cover plate from the changer, and look for a jammed disc. 3. If a disc is jammed between the player and the magazine, turn the loading gear until the disc returns to the player mechanism. Do not attempt to reload the disc back into the magazine. 4. After the disc is loaded into the player mechanism, turn the changer so that the front is facing you. Page 2502 Distinct Of Circuit By Wire Base Color All wires have color-coded insulation. Wires belonging to a system's main harness will have a single color. Wires belonging to a system's sub-circuits will have a colored stripe. Striped wires use the codes found in the chart to show wire size and colors. Abbreviations are used to indicate wire color within a circuit diagram. How to Identify Connector Terminals How to Identify Connector Terminals Cavity Numbering System The cavities (and wire terminals) in each connector are numbered starting from the upper left, looking at the male terminals from the terminal side (or looking at the female terminals from the wire side. Both views are in the same direction so the numbers are the same.) All actual cavities are numbered, even if they have no wire terminals in them. NOTE: Data Link Connector (DLC) terminals are numbered according to SAE standard J1962, not the Honda standard. The numbers of the four end terminals are molded into the corners of the connector face. The connector cavity number is listed next to each terminal on the circuit schematic. The cavity / terminal shown is # 6. Using/Identifying Connector Terminal Views How to Use Connector Terminal Views To see the configuration of a connector's cavities, look up its view number in the Connector Views. Each view includes the color of the connector, where Page 8011 Each schematic represents one circuit. A circuit's wires and components are arranged to show current flow, from power at the top of the page, to ground, at the bottom. Shared Circuits Other circuits may share power or ground terminals or wiring with the circuit shown. A wire that connects one circuit to another, for example, is cut short and has an arrowhead at the end of it pointing in the direction of current flow. Next to the arrowhead is the name of the circuit or component which shares that wiring. To quickly check shared wiring, check the operation of a component it serves. If that component works, you know the shared wiring is OK. Connectors All in-line and junction connectors are numbered (C725, C416, etc.). Component connectors are not numbered but are identified either by the name of Page 3762 Transmission Position Switch/Sensor: Service and Repair REMOVAL 1. Place selector lever in neutral. 2. Disconnect battery ground cable. 3. Remove mode switch cover (1). 4. Disconnect selector lever (2) from the mode switch. 5. Remove bracket with cable (3). 6. Disconnect transmission harness from the mode switch connector (4). 7. Remove bracket with mode switch connector from the transmission case. 8. Remove mode switch connector (4) from the bracket (5). 9. Remove two mode switch bolts and nut then remove mode switch (6). INSTALLATION To install, follow the removal steps in the reverse order, noting the following points; 1. Torque Mode switch bolt: 13 Nm (113 inch lbs.) Selector lever nut: 23 Nm (17 ft. lbs.) 2. Mode switch setting procedure. Perform either of the following adjustment procedures: Procedure 1 a. Place selector lever in neutral. b. Remove selector lever from the mode switch. c. Remove the mode switch cover. d. Loosen the two 10 mm screws. e. Rotate the mode switch until the slot in the mode switch housing aligns with the selector shaft bushing, and insert a 3/32 inch (2.4 mm) drill bit or punch (1) into the slot. f. Tighten the screws to 13 Nm (113 inch lbs.). g. After completing adjustment, snap the mode switch cover into place. h. Reinstall the selector lever. Procedure 2 a. Place selector lever in neutral. b. Disconnect transmission harness connector from mode switch connector. Page 7477 it is located, and what it connects to. Use the Connector Views to help locate the proper cavity when you need to probe a connector. It can be especially helpful if the connector has more than one wire of the same color. A dash symbol (-) indicates that the cavity is empty. Connector views can also be used to help diagnose multiple symptoms in separate circuits which could be caused by a single problem in a connector shared by those circuits. Here's an example: 1. Pick one of the multiple symptoms and look up the schematic for that circuit. 2. Make a list of all the in-line and fuse box connectors in that schematic , 3. Then, in the Connector Views, look up each connector on your list to see if circuits related to the other symptoms run through one of them. If they do, inspect that connector for the problem. Example: The blower, rear window defogger, and the windshield wiper don't work. List all in-line and fuse box connectors in the blower controls circuit and then check the Connector View (see the sample). You find that C324 is common to the blower controls, rear window defogger, and wiper/washer, so you inspect C324 and find the problem, bent terminals. Finding Component/Connector Locations Finding Component/Connector Locations To see where a component or connector is located on the car, look up its photo number in the "Component Location". The photo will also tell you the color of the connector, and how many cavities it has. Page 3674 Page 6609 ^ Click on Returns and Surplus. ^ Click on Audio Core Return. ^ Select the appropriate VIN to view the Update Core Return information screen. ^ Review the form, then print out a copy by clicking on the printer icon. 14. Place the printed copies of the Warranty Audio/Navigation/RES Unit Order form and the Core Return Update Acknowledgement into the core return box with the failed audio/navigation/RES unit core. NOTE: If you return a failed audio/navigation/RES core without the proper forms, your warranty claim will be debited and the core will be sent back to your dealership. 15. Ship the failed audio/navigation/RES unit core to the appropriate location by using the prepaid shipping label that came with the remanufactured audio/navigation/RES unit. NOTE: If the failed audio/navigation/RES unit core is not received at the specified address within 30 days from the order date of the remanufactured audio/navigation/RES unit, your warranty claim will be debited, and your dealership will be issued a core loss charge ranging between $800 and $2,500. If you know that you cannot return the core within 30 days, call the Remanufactured Parts Dealer Service Group, and ask for an extension. ^ If you call for an extension and the core is not received within 60 days from the order date, you will be debited the full amount of the warranty claim. ^ If you do not call for an extension, and the core is received between 31 and 60 days from the order date of the remanufactured audio/navigation/RES unit, a $250 late core charge will be assessed. WARRANTY AUDIO ORDER PROGRAM FREQUENTLY ASKED QUESTIONS Here is a list of answers to the most frequently asked questions about the warranty audio order program: Question: When do I use the warranty audio order program? Answer: Use the program when you are replacing an audio/navigation/RES unit under warranty (including goodwill) that has an internal failure. NOTE: The customer's media (CD, CD magazine, DVD, DVD-A, cassette tape, etc.) is removed by the supplier at tear down and inspection of the failed unit, and mailed to your dealership. Any failed audio/navigation/RES unit core that is returned disassembled is considered an unusable core, and your dealership will be issued a core loss charge ranging between $800 and $2,500. Remanufactured audio/navigation/RES units are not available for non-warranty repairs. New components should be used to repair new, unsold vehicles. A new component may be used to repair a customer's vehicle only if the remanufactured component is currently unavailable from American Honda. Your DPSM must authorize ordering a new component. Question: How do I order a remanufactured audio/navigation/RES unit? Answer: For a warranty replacement, use the ordering information IN WARRANTY EXCHANGE. For goodwill repair, contact your DPSM. For a non-warranty repair, see OUT-OF-WARRANTY REPAIR. Question: Who do I call for questions on the Warranty Audio Order Program? Answer: For administrative questions, call the Remanufactured Parts Dealer Service Group. A/T - Fixing Banjo Bolt Leaks Fluid Line/Hose: Technical Service Bulletins A/T - Fixing Banjo Bolt Leaks SOURCE: Honda Service News TITLE: Fixing A/T Banjo Bolt Leaks APPLIES TO: All models SERVICE TIP: Got ATF leaking from any of the A/T banjo bolts? The first thing you need to do is replace the sealing washers. Next, start threading the banjo and line bracket bolts in their holes. Finally, torque the banjo bolt to 31 Nm (22 lb-ft) and the line bracket bolt to 9.8 Nm (7.2 lb-ft.). NOTE: The banjo bolt torque spec we're recommending is slightly higher than what's listed in the S/M. This is intentional. If you torque just the banjo bolt, you won't really fix the leak. ATF leaks at the banjo bolt stem from the line bracket getting tightened before the banjo bolt. This can misalign the banjo joint, causing the banjo bolt sealing washers not to contact their mating surfaces evenly. Once the sealing washers have been used, you must replace them. A/T Main Case Oil Plug - Fluid Leaks Drain Plug: Customer Interest A/T Main Case Oil Plug - Fluid Leaks 01-078 October 16, 2001 Applies To: 1996-00 Passport - ALL with A/T A/T Main Case Oil Pan Plug Leaks SYMPTOM The main case oil pan appears to leak ATF at the drain plug, the fill plug, or both. PROBABLE CAUSE An irregular surface finish on the main case oil pan damages the 0-rings on the plugs. CORRECTIVE ACTION Check the drain plug and fill plug on the main case oil pan for signs of leakage. If either plug leaks, replace both plugs and gaskets with captive 0-ring plugs. PARTS INFORMATION WARRANTY CLAIM INFORMATION In warranty: The normal warranty applies. Operation Number: 218159 Flat Rate Time: 0.3 hour Failed Part: P/N 8-96015-481-0 H/C 5043229 Defect Code: 051 Contention Code: B06 Template ID: 01-078A Skill Level: Repair Technician Out of warranty: Any repair performed after warranty expiration may be eligible for goodwill consideration by the District Service Manager or your Zone Office. You must request consideration, and get a decision, before starting work. REPAIR PROCEDURE 1. Raise the vehicle on a lift, making sure the vehicle is level. 2. Clean the area around the drain plug and fill plug on the A/T main case oil pan. Page 256 it is located, and what it connects to. Use the Connector Views to help locate the proper cavity when you need to probe a connector. It can be especially helpful if the connector has more than one wire of the same color. A dash symbol (-) indicates that the cavity is empty. Connector views can also be used to help diagnose multiple symptoms in separate circuits which could be caused by a single problem in a connector shared by those circuits. Here's an example: 1. Pick one of the multiple symptoms and look up the schematic for that circuit. 2. Make a list of all the in-line and fuse box connectors in that schematic , 3. Then, in the Connector Views, look up each connector on your list to see if circuits related to the other symptoms run through one of them. If they do, inspect that connector for the problem. Example: The blower, rear window defogger, and the windshield wiper don't work. List all in-line and fuse box connectors in the blower controls circuit and then check the Connector View (see the sample). You find that C324 is common to the blower controls, rear window defogger, and wiper/washer, so you inspect C324 and find the problem, bent terminals. Finding Component/Connector Locations Finding Component/Connector Locations To see where a component or connector is located on the car, look up its photo number in the "Component Location". The photo will also tell you the color of the connector, and how many cavities it has. Page 5430 9. Test-drive the vehicle on the same road you used earlier. - If the drift is now within spec, swap each rear tire back to the front, one at a time, and test-drive the vehicle on the same road you used earlier. Replace the bad tire, then return the vehicle to your customer. - If the drift is still out of spec after swapping the front and rear tires, go to step 10. 10. Test-drive a known-good donor vehicle on the same road you used earlier, and check its pull. 11. Swap all four tires from the donor vehicle with the tires on your customer¡C■s vehicle. 12. Test-drive your customer¡C■s vehicle on the same road you used earlier. - If the drift is now within spec, swap the tires back to the donor vehicle one at a time, and test-drive your customer¡C■s vehicle on the same road you used earlier. Do this until the drift comes back. Replace the bad tire(s), then return the vehicle to your customer. - If the drift is still out of spec using the donor vehicle tires, contact Tech Line for further action. Technical Service Bulletin # 06-068 Date: 090502 Steering/Suspension - Vehicle Pulls Left/Right 06-068 May 2, 2009 Applies To: ALL *Vehicle Pulls or Drifts, and/or Steering Wheel Is Off-Center (Supersedes 06-068, Vehicle Pulling or Drifting, dated October 4, 2007, to revise the information marked by asterisks) (Replaces 90-011, Steering Wheel Off-Center Adjustment at PDI)* *REVISION SUMMARY The title description was revised.* SYMPTOM While driving on a straight road, the vehicle pulls or drifts to the right or left. BACKGROUND New tools were developed to help you diagnose and correct a pulling and/or steering wheel off-center issue. There is a diagnosis worksheet included to take on your test-drive and record your findings. These values are used to build the 15-digit DTC (diagnostic trouble code) that is required for your warranty claim. The last step in each repair procedure helps you create the correct code. In the rare case that you have to repair a vehicle that pulls and has the steering wheel off-center, use REPAIR PROCEDURE B to file your warranty claim. For more information, refer to Training Module SSC 44 - Steering Drift or Pull Interactive Service Bulletin. PROBABLE CAUSES Several conditions can cause the vehicle to pull or drift: ^ Wheel alignment ^ Tires ^ Off-center steering wheel (no pulling or drifting, but a customer may believe this is the case) CORRECTIVE ACTION Diagnose the problem using the special tools and the worksheet on page 4 that guides you to one of four repair procedures. Rear Hatchgate Liftgate Window Glass: Service and Repair Rear Hatchgate Rear Hatchgate Rear Hatchgate (LWB) Removal 1. Disconnect the battery ground cable. 2. Disconnect the high mount stoplight and rear defogger harness connectors. Page 65 This means the branch of the wire connects to another circuit. The arrow points to the name of the circuit branch where the wire continues. Page 6921 4. Remove the waterproof sheet (1). - Carefully remove the waterproof sheet not to brake it. 5. Remove the license plate garnish asm. - Remove the a screw on the upper side. - Remove the two fixed nuts from the inside of the tailgate and remove the three clips by pushing the tip of the clips with a screwdriver. Installation To install, follow the removal steps in the reverse order. Page 4953 4. When inserting the piston into the cylinder, use finger pressure only and do not use a mallet or other impact tool, since damage to the cylinder wall or piston seal can result. Install piston. 5. Apply special grease (approximately 1 g) to the piston and attach the dust boot to the piston and caliper Insert the dust boot ring into the dust boot. 6. Install guide bolt and lock bolt dust boot. 7. Install the dust boot on the support bracket after applying special grease (Approx. 1 g) onto the dust boot inner surface. Also apply special grease onto the lock bolt and guide bolt setting hole of the support bracket. 8. Install lock bolt and guide bolt and tighten the bolt to the specified torque. Torque: 44 Nm (32 ft. lbs.) Page 2335 Fuel Pressure: Service Precautions WARNING: Adhere to the following procedures any time the fuel system is being worked on in order to reduce the risk of fire and personal injury: - Keep a dry chemical (Class B) fire extinguisher near the work area. - Place a "CAUTION FLAMMABLE" sign in the work area. - Work in a well-ventilated area. Do not smoke, and keep sparks and open flames away. - Wear eye protection. - Use caution when working near the catalytic converter to prevent the possibility of burns or fire. (The temperatures within the converter can exceed 537 °C (1000 °F). - Relieve the fuel system pressure prior to disconnecting fuel system components. - Disconnect the negative battery cable except for tests where battery voltage is required. - Use a suitable container to store or catch fuel. - Do not replace fuel pipe with fuel hose. - Plug all disconnected fuel line fittings and hoses. - After making any fuel system repairs ALWAYS inspect for fuel leaks. Page 7281 Spare Tire Carrier: Removal and Replacement Spare Tire Hanger Spare Tire Hanger Spare Tire Hanger Special Tools Removal Page 2925 ^ If the idle speed ever exceeds 1,300 rpm 2. Remove the vacuum hose from the fuel pressure regulator, then start the engine. ^ If fuel comes out of the fuel pressure regulator vacuum hose connection, go to REPAIR PROCEDURE FUEL PRESSURE REGULATOR. ^ If no fuel comes out of the regulator, reconnect the vacuum hose and continue to step 3. 3. Connect the PGM Tester. Set it to Engine Data List. 4. Have an assistant drive the vehicle under the conditions described by the customer. 5. If the high or erratic idle condition occurs, note the values of the PSP Switch and APP Sensor 1 when it is occurring. ^ If the PSP Switch is HIGH, and you are not turning, go to REPAIR PROCEDURE POWER STEERING SWITCH. ^ If the APP Sensor 1 is greater than 15% and APP Sensor 2 and/or APP Sensor 3 are less than 85%, and the accelerator pedal is not depressed, go to REPAIR PROCEDURE APPS GROUND. ^ If the PSP Switch is reading LOW when not turning and HIGH when turning, and the APP Sensors are reading within the range shown, discontinue the test-drive and go to step 6. 6. Do these repairs: ^ REPAIR PROCEDURE APPS GROUND ^ REPAIR PROCEDURE ENGINE/BODY GROUND REPAIR PROCEDURE - FUEL PRESSURE REGULATOR 1. Relieve fuel system pressure: ^ Remove the fuel fill cap. ^ Remove the fuel pump relay. ^ Start the engine and run it until it stalls. ^ Crank the engine for 3 seconds. 2. Remove the vacuum hose from the fuel pressure regulator. 3. Remove the fuel pressure regulator shield from the common chamber (two bolts). Page 7647 Dimmer Switch: Electrical Diagrams Part 1 Of 2 Page 3701 This sample Ground Distribution schematic shows all of the components that share two ground points. Components A solid border line means the entire component is shown. A broken border line indicates that only part of the component is shown. Blower Motor - Will Not Run In One Or More Settings Blower Motor: All Technical Service Bulletins Blower Motor - Will Not Run In One Or More Settings 01-007 October 16, 2001 Applies To: 1998-01 Passport - ALL Blower Does Not Run in One or More Settings (Supersedes 01-007, dated July 3, 2001) SYMPTOM The blower does not run in one or more fan control lever positions. PROBABLE CAUSE A high current draw on the blower resistor causes it overheat and to become electrically "open." This high current draw is usually caused by high friction in the blower motor bearings and/or debris in the blower assembly housing, which jams or slows the blower motor and damages its commutator. CORRECTIVE ACTION Replace the blower resistor and the blower motor assembly. Clean out all debris from inside the blower assembly housing. PARTS INFORMATION Blower Resistor (1998-99 models): P/N 8-97078-452-1, H/C 4906202 Blower Resistor (2000-01 models): P/N 8-97260-283-0, H/C 6633390 Blower Motor Assembly (1998-99 models): P/N 8-97231-642-0, H/C 6447544 Blower Motor Assembly (2000-01 models): P/N 8-97229-613-1, H/C 6262083 WARRANTY CLAIM INFORMATION In warranty: The normal warranty applies. Operation Number: 612109 Flat Rate Time: 0.4 hour Failed Part: P/N 8-97046-497-0 H/C 4402186 Defect Code: 032 Contention Code: B01 Template ID: 01-007A (1998-99 models) 01-007B (2000-01 models) Skill Level: Repair Technician Out of warranty: Any repair performed after warranty expiration may be eligible for goodwill consideration by the District Service Manager or your Zone Office. You must request consideration, and get a decision, before starting work. REPAIR PROCEDURE Page 4334 Wheel Bearing: Service and Repair DISASSEMBLED VIEW DISASSEMBLY 1. Before disassembly, select the 2WD position with the 4WD switch. 2. Jack up the front of vehicle and support frame with jack stands. 3. Remove the disc brake caliper assembly and hang it on the frame with wires. 4. Remove bolt. 5. Remove cap. 6. Remove snap ring and shim. 7. Remove hub flange. 8. Remove lock washer and lock screw. Page 3561 Terminals - "T" Each "T" terminal (ring type) is numbered for reference and location. A "T" terminal is secured with a screw or bolt. Wires Page 1091 Spark Plug: Testing and Inspection Inspection and Repair The spark plug affects entire engine performance and therefore its inspection is very important. - Check electrode and insulator for presence of cracks, and replace if any. - Check electrode for wear, and replace if necessary.. - Check gasket for damage, and replace if necessary. - Measure insulation resistance with an ohmmeter, and replace if faulty. - Adjust spark plug gap to 1.0 mm (0.040 in) to 1.1 mm (0.043 in). - Check fuel and electrical systems if spark plug is extremely dirty. - Use spark plugs having low heat value (hot type plug) if fuel and electrical systems are normal. - Use spark plugs having high heat value (cold type plug) if insulator and electrode are extremely burned. Sooty Spark Plugs Much deposit of carbon or oil on the electrode and insulator of spark plug reduces the engine performance. Possible causes: - Too rich mixture - Presence of oil in combustion chamber - Incorrectly adjusted spark plug gap Burning Electrodes This fault is characterized by scorched or heavily oxidized electrode or blistered insulator nose. Possible causes: - Too lean mixture - Improper heat value Measuring Insulation Resistance - Measure insulation resistance using a 500 volt megaohm meter. - Replace spark plugs if measured value is out of standard. Insulation resistance: 50 Mohm or more. Page 114 If there is no photo number below or beside a component name or a connector, ground, or terminal number, look up that name or number in the appropriate Connector Identification Chart. The chart lists how many cavities a connector has, where it's located, and what it connects to. The related illustration shows the connector's location on the harness, and the harness routing. NOTE: Photos listed by number are located at Locations / Components / Photograohs. See: Locations/Component Locations/Photographs Circuit Schematics Page 4018 Transmission Position Switch/Sensor: Service and Repair REMOVAL 1. Place selector lever in neutral. 2. Disconnect battery ground cable. 3. Remove mode switch cover (1). 4. Disconnect selector lever (2) from the mode switch. 5. Remove bracket with cable (3). 6. Disconnect transmission harness from the mode switch connector (4). 7. Remove bracket with mode switch connector from the transmission case. 8. Remove mode switch connector (4) from the bracket (5). 9. Remove two mode switch bolts and nut then remove mode switch (6). INSTALLATION To install, follow the removal steps in the reverse order, noting the following points; 1. Torque Mode switch bolt: 13 Nm (113 inch lbs.) Selector lever nut: 23 Nm (17 ft. lbs.) 2. Mode switch setting procedure. Perform either of the following adjustment procedures: Procedure 1 a. Place selector lever in neutral. b. Remove selector lever from the mode switch. c. Remove the mode switch cover. d. Loosen the two 10 mm screws. e. Rotate the mode switch until the slot in the mode switch housing aligns with the selector shaft bushing, and insert a 3/32 inch (2.4 mm) drill bit or punch (1) into the slot. f. Tighten the screws to 13 Nm (113 inch lbs.). g. After completing adjustment, snap the mode switch cover into place. h. Reinstall the selector lever. Procedure 2 a. Place selector lever in neutral. b. Disconnect transmission harness connector from mode switch connector. Locations Fuel Pressure Sensor/Switch: Locations Top Rear of Fuel Tank Page 215 Test Equipment CAUTION: Most circuits include solid-state devices. Test the voltages in these circuits only with a 10-megaohm or higher impedance digital multimeter. Never use a test light or analog meter on circuits that contain solid-state devices. Damage to the devices may result. Test Light and DVOM On circuits without solid-state devices, use a test light to check for voltage. A test light is made up of a 12 volt bulb with a pair of leads attached. After grounding one lead, touch the other lead to various points along the circuit where voltage should be present. The bulb will go on if there is voltage at the point being tested. If you need to know how much voltage is present, use a digital volt/ohmmeter (DVOM). Self-Powered Test Light and DVOM Use a self-powered test light to check for continuity. This tool is made up of a light bulb, battery, and two leads. To test it, touch the leads together: the light should go on. Use a self-powered test light only on an unpowered circuit. First, disconnect the battery, or remove the fuse that feeds the circuit you are working on. Select two points in the circuit between which you want to check continuity. Connect one lead of the self-powered test light to each point. If there is continuity, the test light's circuit will be completed, and the light will go on. If, in addition, you need to know exactly how much resistance there is between two points, use a digital volt/ohmmeter (DVOM). In the "OHMS" range, the DVOM will measure resistance between two points along a circuit. Low resistance means good continuity. Diodes and solid-state devices in a circuit can make a DVOM give a false reading. To check a reading, reverse the leads, and take a second reading. If the readings differ, the component is affecting the measurement. Jumper Wire Use a jumper wire to bypass an open circuit. A jumper wire is made up of an in-line fuse holder connected to a set of test leads. It should have a five ampere fuse. Never connect a jumper wire across a short circuit. The direct battery short will blow the fuse. Short Finder (Short Circuit Locator) Short finders are available to locate shorts to ground. The short finder creates a pulsing magnetic field in the shorted circuit which you can follow to the location of the short. To order any test equipment shown above, contact your local tool supplier. For a list of suppliers and tool numbers, refer to Honda Required Special Tools and Equipment Service Bulletin. Locations Page 4778 Electronic Brake Control Module: Description and Operation The EHCU consists of ABS control circuits, fault detector, and a fail-safe. It drives the hydraulic unit according to the signal from each sensor, cancelling ABS to return to normal braking when a malfunction has occurred in the ABS. The EHCU has a self-diagnosing function which can indicate faulty circuits during diagnosis. The EHCU is mounted on the engine compartment rear right side. It consists of a Motor, Plunger Pump, Solenoid Valves. Solenoid Valves: Reduces or holds the caliper fluid pressure for each front disc brake or both rear disc brakes according to the signal sent from the EHCU. Reservoir: Temporarily holds the brake fluid that returns from the front and rear disc brake caliper so that pressure of front disc brake caliper can be reduced smoothly. Plunger Pump: Feeds the brake fluid held in the reservoir to the master cylinder. Motor: Drives the pump according to the signal from EHCU. Check Valve: Controls the brake fluid flow. Page 4368 UNIVERSAL JOINT DISASSEMBLY NOTE: Aluminum is softer than steel. Care must be taken not to remove excessive material or damage bearing holes. If the vehicle has aluminum tube type propeller shaft, flange yoke, boot kit, journal kit can be replaced. If other parts are damaged, replace propeller shaft as assembly. 1. Apply alignment marks on the yoke of the universal joint, then remove the snap ring. Description and Operation ABS Light: Description and Operation ABS Warning Light Vehicles equipped with the Anti-lock Brake System (ABS) have an amber "ABS" warning light in the instrument panel. The "ABS" warning light will illuminate if a malfunction in the Anti-lock Brake System is detected by the Electronic Hydraulic Control Unit (EHCU). In case of an electronic malfunction, the EHCU will turn "ON" the "ABS" warning light and disable the Anti-lock braking function. The "ABS" light will turn "ON" for approximately three seconds after the ignition switch is turned to the "ON" position. If the "ABS" light stays "ON" after the ignition switch is turned to the "ON" position, or comes "ON" and stays "ON" while driving, the Anti-lock Brake System should be inspected for a malfunction according to the diagnosis procedure. When Anti-lock Brake System (ABS) trouble occurs to actuate "ABS" warning light, the trouble code corresponding to the trouble is stored in the Electronic Hydraulic Control Unit (EHCU). Only ordinary brake is available with ABS being unactuated. Even when "ABS" warning light is actuated, if the starter switch is set ON after setting it OFF once, the EHCU checks up on the entire system and, if there is no abnormality, judges ABS to work currently and the warning light is lit normally even though the trouble code is stored. NOTE: Illumination of the "ABS" warning light indicates that anti-lock braking is no longer available. Power assisted braking without anti-lock control is still available. Page 6612 ^ Online, enter keyword AUDIO, NAVI, or RES, and select the appropriate removal procedure from the list. NOTE: If the customer's media (CD, CD magazine, DVD, DVD-A, cassette tape, navigation DVD, etc.) is stuck in the unit, leave it there. The manufacturer will remove and return it. 3. Obtain an Out-of-Warranty/New Replacement component repair form, and complete the Technician section.To obtain the form, do this: ^ On ISIS, click on Technical Library, then click on Job Aids. ^ Select the applicable form from the list, and print it out: - Out-of-Warranty/New Replacement Audio System Component Repair Form - Out-of-Warranty/New Replacement Navigation System Component Repair Form - Out-of-Warranty/New Replacement Rear Entertainment System Component Repair Form Parts Manager: 4. Complete the parts manager's section of the Out-of-Warranty/New Replacement component repair form. Make sure you include your name, department, and dealership phone number on the form. 5. Identify the manufacturer. Units sent to the wrong manufacturer may not be shipped back within the usual 5-7 days. ^ Look for the number code on the face of the unit. ^ If the unit has no number code on its face, check the label on the unit housing, and compare the first two or three letters of the radio reference number (or the audio unit model number) to this list: Alpine - CM, CD, MR, or MF Clarion - PH Fujitsu Ten - CE or SD Panasonic - CQ or CR Pioneer KEH or DEH 6. Contact the manufacturer (see step 9) to request an estimate for the cost of the repair plus shipping. 7. Complete the required paperwork: ^ Paying by check - Make a dealership check out to the manufacturer for the cost of repair and return shipping. Make sure to include the check number on the form. NOTE: For all Panasonic products, make your check out to Komtec Electronics. ^ Paying by credit card (Visa or Mastercard only) - When you use a credit card, fill in all of these fields on the component repair form: - Credit card number - Credit card expiration date Page 1464 2. Measure the inside diameter of the connecting rod small end. If the fitting interference between the small end and pin does not conform to the specified value, the connecting rod must be replaced. Standard: 0.023 mm - 0.038 mm (0.0009 inch - 0.0015 inch) 3. Insert the new pin into the piston and rotate it. If the pin rotates smoothly with no backlash, the clearance is normal. If there is backlash or roughness, measure the clearance. If the clearance exceeds the specified limit, the piston must be replaced. Clearance Standard: 0.010 mm - 0.017 mm (0.0004 inch - 0.0007 inch) Limit: 0.040 mm (0.0016 inch) Connecting Rods 1. Check the connecting rod alignment. If either the bend or the twist exceeds the specified limit, the connecting rod must be replaced. Bend per 100 mm (3.937 inch) Limit: 0.15 (0.0059) Twist per 100 mm (3.937 inch) Limit: 0.20 (0.0078) 2. Measure the connecting rod thrust clearance. Use a feeler gauge to measure the thrust clearance at the large end of the connecting rod. If the Page 4047 ^ If you cannot turn the switch to LOCK and the cable slider is clear of the white plastic interlock pin, troubleshoot the lock cylinder assembly. 13. Move the cable slider so it clears the interlock pin, then turn the ignition switch to LOCK. 14. Pry out the shift lock cable adjuster clip, then snap it back into place. Make sure the raised "T" on the side of the clip faces up. 15. Turn the ignition switch to ACC. Push the cable slider toward the cable until it stops. Turn the ignition switch to LOCK. ^ If you can turn the switch to LOCK, the shift lock cable is properly adjusted. Press firmly on the shift lever pushbutton, and pull down on the shift lever to make sure the lever is locked in P. Go to step 18. ^ If you cannot turn the switch to LOCK or it still feels notchy when you turn it, more adjusting is needed. Go to step 16. Page 6971 Air Bag(s) Arming and Disarming: Service Precautions Precautions For Electrical Inspections Precautions For Electrical Inspections When using electrical test equipment, insert the probe of the tester into the wire side of the connector. Do not insert the probe of the tester into the terminal side of the connector, and do not tamper with the connector. Use a U-shaped probe. Do not insert the probe forcibly. Use specified service connectors in troubleshooting. Using improper tools could cause an error in inspection due to poor metal-to-metal contact. Page 1036 ^ Loosen the front subframe bolts. See the applicable service manual for more information. NOTE: The front wheels are being viewed from the rear of the vehicle. ^ Depending which way you need to shift the subframe, insert a pry bar between the subframe and body at both the front and rear positions of the subframe. NOTE: Be careful not to damage the vehicle. You could bend and damage the frame and/or body if you apply too much pressure. ^ Press on both pry bars to shift the subframe. It will move only a few millimeters. This should adjust the camber about 0.2-0.5°. ^ While holding the subframe in place, have an assistant torque the subframe bolts to their proper torque. Front Camber Adjustment, Strut Suspension ^ Raise the vehicle, and remove the front tires. ^ Loosen the damper pinch bolts and the flange nuts. ^ Adjust the camber by moving the bottom of the damper within the range of the damper pinch bolt free play. NOTE: Some vehicles have special pinch bolts that allow more adjustment. For more information, refer to the parts catalog. ^ Tighten the damper pinch bolts to the specified torque. ^ Reinstall the front wheels and lower the vehicle. Bounce the front of the vehicle several times to stabilize the suspension. Page 3727 Distinct Of Circuit By Wire Base Color All wires have color-coded insulation. Wires belonging to a system's main harness will have a single color. Wires belonging to a system's sub-circuits will have a colored stripe. Striped wires use the codes found in the chart to show wire size and colors. Abbreviations are used to indicate wire color within a circuit diagram. How to Identify Connector Terminals How to Identify Connector Terminals Cavity Numbering System The cavities (and wire terminals) in each connector are numbered starting from the upper left, looking at the male terminals from the terminal side (or looking at the female terminals from the wire side. Both views are in the same direction so the numbers are the same.) All actual cavities are numbered, even if they have no wire terminals in them. NOTE: Data Link Connector (DLC) terminals are numbered according to SAE standard J1962, not the Honda standard. The numbers of the four end terminals are molded into the corners of the connector face. The connector cavity number is listed next to each terminal on the circuit schematic. The cavity / terminal shown is # 6. Using/Identifying Connector Terminal Views How to Use Connector Terminal Views To see the configuration of a connector's cavities, look up its view number in the Connector Views. Each view includes the color of the connector, where Page 4715 This sample Ground Distribution schematic shows all of the components that share two ground points. Components A solid border line means the entire component is shown. A broken border line indicates that only part of the component is shown. Page 5603 Steering Gear: Description and Operation GENERAL DESCRIPTION The power steering unit is rack and pinion type. The toe-in angle can be adjusted by turning the rod on each side. The steering housing cannot be disassembled. Description and Operation Fuel Rail: Description and Operation Fuel Rail The fuel rail is mounted to the top of the engine and distributes fuel to the individual injectors. Fuel is delivered to the fuel inlet tube of the fuel rail by the fuel lines. The fuel goes through the fuel rail to the fuel pressure regulator. The fuel pressure regulator maintains a constant fuel pressure at the injectors. Remaining fuel is then returned to the fuel tank. Page 5437 ^ Loosen the front subframe bolts. See the applicable service manual for more information. NOTE: The front wheels are being viewed from the rear of the vehicle. ^ Depending which way you need to shift the subframe, insert a pry bar between the subframe and body at both the front and rear positions of the subframe. NOTE: Be careful not to damage the vehicle. You could bend and damage the frame and/or body if you apply too much pressure. ^ Press on both pry bars to shift the subframe. It will move only a few millimeters. This should adjust the camber about 0.2-0.5°. ^ While holding the subframe in place, have an assistant torque the subframe bolts to their proper torque. Front Camber Adjustment, Strut Suspension ^ Raise the vehicle, and remove the front tires. ^ Loosen the damper pinch bolts and the flange nuts. ^ Adjust the camber by moving the bottom of the damper within the range of the damper pinch bolt free play. NOTE: Some vehicles have special pinch bolts that allow more adjustment. For more information, refer to the parts catalog. ^ Tighten the damper pinch bolts to the specified torque. ^ Reinstall the front wheels and lower the vehicle. Bounce the front of the vehicle several times to stabilize the suspension. Page 204 This sample Ground Distribution schematic shows all of the components that share two ground points. Components A solid border line means the entire component is shown. A broken border line indicates that only part of the component is shown. Page 4712 Each schematic represents one circuit. A circuit's wires and components are arranged to show current flow, from power at the top of the page, to ground, at the bottom. Shared Circuits Other circuits may share power or ground terminals or wiring with the circuit shown. A wire that connects one circuit to another, for example, is cut short and has an arrowhead at the end of it pointing in the direction of current flow. Next to the arrowhead is the name of the circuit or component which shares that wiring. To quickly check shared wiring, check the operation of a component it serves. If that component works, you know the shared wiring is OK. Connectors All in-line and junction connectors are numbered (C725, C416, etc.). Component connectors are not numbered but are identified either by the name of Engine Controls - High/Erratic Engine Idle Power Steering Pressure Switch: All Technical Service Bulletins Engine Controls - High/Erratic Engine Idle 01-080 August 14, 2001 Applies To: 2000-02 Passport - ALL 2000-02 Passport: High or Erratic Idle SYMPTOM The engine occasionally idles at too high a speed, or the idle speed fluctuates. PROBABLE CAUSES The symptom could be the result of any of these conditions: ^ Loose or corroded engine or body ground ^ High resistance in the APPS ground circuit ^ PSP (power steering pressure) switch is internally shorted to ground ^ Fuel pressure regulator is leaking fuel into the intake manifold CORRECTIVE ACTION Diagnose the cause of the idle condition, and select the proper REPAIR PROCEDURE. PARTS INFORMATION REQUIRED MATERIALS REQUIRED SOFTWARE Each REPAIR PROCEDURE requires you to use the Smart Cable to reprogram the PCM with the latest software. To select the latest software from the CDROM, enter the year, model, engine, transmission, and emissions type (49-state or California). This gives you a list of broadcast codes. Select the broadcast code at the top of the list. WARRANTY CLAIM INFORMATION Refer to the Warranty Claim Information for each Repair Procedure. DIAGNOSIS 1. Find out from the customer when the high or erratic idle condition occurs and what the RPM range is: ^ Within 20 minutes of a cold start ^ After braking to a stop ^ All the time ^ Intermittently, with no set pattern Page 1219 Engine Oil: Fluid Type Specifications New standard for engine oil, GF-4. See TSB SN050109 for Honda Service News 050109 for additional information. Engine Oil API Classification ............................................................................................................................................................ SJ "Energy Conserving" grade oil. Above 0°F (-20°C) ........................................................................ ............................................................................................... SAE 10W-30 is preferred. Above -20°F (-30°C) ....................................................................................................................................... ................................................... SAE 5W-30 NOTE: Additional designations of quality may also be present (SJ/CC, SJ/CD, SJ, CC etc) but SJ must be included. Page 463 This means the branch of the wire connects to another circuit. The arrow points to the name of the circuit branch where the wire continues. Page 4089 Disclaimer Page 2775 Terminals - "T" Each "T" terminal (ring type) is numbered for reference and location. A "T" terminal is secured with a screw or bolt. Wires Specifications Idle Speed: Specifications Idle speed is PCM controlled Page 7448 2. Connect the short finder across the battery terminals and the load (component) side of the fuse terminal. 3. Close all switches in the circuit you're testing. 4. Turn on the short finder. This creates a pulsing magnetic field around the wiring between the fuse box and the short. 5. Beginning at the fuse box, slowly move the short finder along the circuit wiring. The meter will read current pulses through sheet metal and body trim. As long as the meter is between the fuse and the short, the needle will move with each current pulse. Once you move the meter past the point of the short, the needle will stop moving. Check the wiring and connectors in this area to locate the cause of the short. Testing For Continuity When testing for continuity at a connector without wire seals, you do not have to separate the two halves of the connector. Instead, probe the connector from the back. Always check both sides of the connector because dirty, corroded, and bent terminals can cause problems (no electrical contact = an open). 1. Disconnect the negative cable from the car battery. If you're using a DVOM, place it in the lowest "OHMS" range. Page 307 2. Connect one lead of a self-powered test light or DVOM to one end of the part of the circuit you want to test. 3. Connect the other lead to the other end. 4. If the self-powered test light glows, there is continuity. If you're using a DVOM, a low reading or no reading (zero), means good continuity. Testing For Voltage When testing for voltage at a connector without wire seals, you do not have to separate the two halves of the connector. Instead, probe the connector from the back. Always check both sides of the connector because dirty, corroded, and bent terminals can cause problems (no electrical contact = an open). 1. Connect one lead of the lest light to a known good ground, or, if you're using a digital volt ohmmeter (DVOM), place it in the appropriate DC volts range, and connect its negative lead to ground. 2. Connect the other lead of the test light or DVOM to the point you want to check. 3. If the test light glows, there is voltage present. If you're using a DVOM, note the voltage reading. It should be within one volt of measured battery voltage. A loss of more than one volt indicates a problem. NOTE: Always use a DVOM on high impedance circuits. A test light may not glow (even with battery voltage present). Testing For Voltage Drop Wires, connectors, and switches are designed to conduct current with a minimum loss of voltage. A voltage drop of more than one volt indicates a problem. 1. Place the digital volt/ohmmeter (DVOM) in the appropriate DC volts range. Connect the positive lead to the end of the wire (or to the connector or switch) closest to the battery. 2. Connect the negative lead to the other end of the wire (or the other side of the connector or switch). 3. Turn on the components in the circuit. 4. The DVOM will show the difference in voltage between the two points. A difference, or drop, of more than one volt indicates a problem. Check the circuit for loose, dirty, or bent terminals. Page 7543 Air Bag(s) Arming and Disarming: Service Precautions Precautions For Electrical Inspections Precautions For Electrical Inspections When using electrical test equipment, insert the probe of the tester into the wire side of the connector. Do not insert the probe of the tester into the terminal side of the connector, and do not tamper with the connector. Use a U-shaped probe. Do not insert the probe forcibly. Use specified service connectors in troubleshooting. Using improper tools could cause an error in inspection due to poor metal-to-metal contact. Locations Camshaft Position Sensor Page 6143 and the fuses. From Fuses to Relays and Components The second half of Power Distribution shows the wiring "From Fuses to Relays and Components." This can speed your troubleshooting by showing which circuits share fuses. If Power Distribution shows that an inoperative circuit and another circuit share a fuse, check a component in the other circuit. If it works, you know the fuse is good and power is available to the inoperative circuit. Ground Distribution Schematics Page 1226 Power Steering Fluid: Description and Operation The power steering fluid is Dexron II-E Automatic Transmission Fluid. No other types of fluids are recommended by the manufacturer for this system. Page 712 REPAIR PROCEDURE 1. Raise the vehicle on a hoist. 2. 2002 only: Loosen the bracket that secures the ATF cooler return line, and disconnect the line from the transmission. 3. Clean the accumulator housing. 4. Using the accumulator cover installation tool and a Phillips screwdriver to hold the tool, tap on the accumulator cover to unseat the cover from the snap ring. 5. Remove the snap ring from the accumulator housing. Page 3415 Fuel Pump Relay: Description and Operation In order to control the FPAS operation, the FPAS relay is provided. When the starter switch is turned to "ON" position, the FPAS relay operates the FPAS for 2 seconds. When it is turned to "START" position, the Engine Control Module receives the reference pulse from the Ignition Control Module and it operates the relay, again causing the FPAS to feed fuel. Page 5209 Terminals - "T" Each "T" terminal (ring type) is numbered for reference and location. A "T" terminal is secured with a screw or bolt. Wires Page 3843 SMART CABLE DIAGNOSIS If the red light (# 3) on the Smart Cable came on or was flashing while updating the PCM, do this: *1. If not already done, load the May 1999 or later DOS CD onto your DOS workstation. Loading instructions were included in the CD'S mailing.* 2. Disconnect the Smart Cable from the vehicle's DLC. *3. Connect the Smart Cable to the DOS workstation (see steps 2 and 3 of REPROGRAMMING A SMART CABLE).* 4. Connect the 110 VAC/12 VAC power supply to the Smart Cable box and to 110 VAC power. *5. Log in to HONDANET 2000. 6. From the choices across the top of the HONDANET 2000 screen, click on Service Bay, and then click on Smart Cable from the drop-down menu. 7. Click on View Err at the bottom of the screen to display the problem encountered while the Smart Cable was connected to the vehicle. SMART CABLE ASSISTANCE For questions when loading the DCS CD, contact the HONDANET 2000 Support Center at 800-245-4343. For questions or problems on Smart Cable hardware and Smart Cable usage, contact American Honda Special Tools at 800-345-8327.* Disclaimer Page 6658 CD Changer Troubleshooting (All except Passport) CD Player Troubleshooting (All except Passport) Radio Troubleshooting (All except Passport) Page 2319 Crankshaft Position Sensor: Service and Repair REMOVAL 1. Disconnect the negative battery cable. 2. Disconnect the wiring connector from crankshaft position sensor. 3. Remove one bolt and remove the CKP sensor from the right side of the engine block, just behind the mount. NOTE: Use caution to avoid any hot oil that might drip out. INSTALLATION 1. Apply a small amount of engine oil to the O-ring and install the CKP sensor in the engine block. 2. Install the CKP sensor mounting bolt. 3. Tighten the mounting bolt to 10 Nm (89 lb in.). 4. Connect the wiring connector to the CKP sensor. 5. Connect the negative battery cable. Procedures Headliner: Procedures LWB Removal 1. Disconnect the battery ground cable. 2. Remove the interior trim panels. 3. Remove the dome light. - Remove the dome light lens and the fixing screws. - Disconnect the dome light connectors. 4. Remove the sunroof switch (With sunroof). - Pry the clip positions free from the sunroof switch bracket and disconnect the connector. - Disconnect the vanity mirror illumination connector. (if so equipped) 5. Remove the sunvisors. - Remove the fixing screws and pull out the sunvisor holder (1) to remove it. 6. Remove the sunroof finisher (With sunroof). 7. Remove the headlining. - Remove the headlining fixing clips. Installation To install, follow the removal steps in the reverse order, noting the following points. 1. Install the headlining so that the fixing clips will not come off. Mechanical Specifications Service and Repair Spot Lamp: Service and Repair Removal 1. Disconnect the battery ground cable. 2. Remove the lens (2). 3. Remove the bulb (1). - Pull out the bulb. Installation To install, follow the removal steps in the reverse order. Page 7574 Splices Splices are shown as a dot. Their location and the number of wires may vary depending on the harness manufacturer. Switches Switches These switches move together; the broken straight line between them means they are mechanically connected. Other types of switches are controlled by a coil or a solid state circuit. Unless otherwise noted, all switches are shown in their normal (rest) position, with power off. Terminal "T" Page 144 Powertrain Control Module: Description and Operation Circuit Operation The engine or powertrain control module (ECM or PCM) receives inputs from the engine sensors and switches, controlling the functions of the engine. It also turns on the malfunction indicator "check engine" light whenever a malfunction or abnormal engine performance is detected, and allows for diagnostic testing through the data link connector (DLC). Electrically Erasable Programmable Read Only Memory (EEPROM) Electrically Erasable Programmable Read Only Memory (EEPROM) The electrically erasable programmable read only memory (EEPROM) is a permanent memory chip that is physically soldered within the PCM. The EEPROM contains the program and the calibration information that the PCM needs to control powertrain operation. Unlike the PROM used in past applications, the EEPROM is not replaceable. If the PCM is replaced, the new PCM will need to be programmed. Equipment containing the correct program and calibration for the vehicle is required to program the PCM. PCM Components PCM Components The PCM is designed to maintain exhaust emission levels to government mandated standards while providing excellent driveability and fuel efficiency. The PCM monitors numerous engine and vehicle functions via electronic sensors such as the throttle position (TP) sensor, heated oxygen sensor (HO2S), and vehicle speed sensor (VSS). The PCM also controls certain engine operations through the following: - Fuel injector control - Ignition control module - ION sensing module - Automatic transmission shift functions - Cruise control - Evaporative emission (EVAP) purge - A/C clutch control PCM Function PCM Function The PCM supplies either 5 or 12 volts to power various sensors or switches. The power is supplied through resistances in the PCM which are so high in value that a test light will not light when connected to the circuit. In some cases, even an ordinary shop voltmeter will not give an accurate reading because its resistance is too low. Therefore, a digital voltmeter with at least 10 megohms input impedance is required to ensure accurate voltage readings. Tool J 39200 meets this requirement. The PCM controls output circuits such as the injectors, fan relays, etc., by controlling the ground or the power feed circuit through transistors or through either of the following two devices: - Output Driver Module (0DM) - Quad Driver Module (QDM) PCM Input/Outputs PCM Input/Outputs Inputs - Operating Conditions Read - Air Conditioning "ON" or "OFF" Page 1981 Powertrain Control Module: Description and Operation Electrically Erasable Programmable Read Only Memory (EEPROM) Electrically Erasable Programmable Read Only Memory (EEPROM) The electrically erasable programmable read only memory (EEPROM) is a permanent memory chip that is physically soldered within the PCM. The EEPROM contains the program and the calibration information that the PCM needs to control powertrain operation. Unlike the PROM used in past applications, the EEPROM is not replaceable. If the PCM is replaced, the new PCM will need to be programmed. Equipment containing the correct program and calibration for the vehicle is required to program the PCM. Page 451 it is located, and what it connects to. Use the Connector Views to help locate the proper cavity when you need to probe a connector. It can be especially helpful if the connector has more than one wire of the same color. A dash symbol (-) indicates that the cavity is empty. Connector views can also be used to help diagnose multiple symptoms in separate circuits which could be caused by a single problem in a connector shared by those circuits. Here's an example: 1. Pick one of the multiple symptoms and look up the schematic for that circuit. 2. Make a list of all the in-line and fuse box connectors in that schematic , 3. Then, in the Connector Views, look up each connector on your list to see if circuits related to the other symptoms run through one of them. If they do, inspect that connector for the problem. Example: The blower, rear window defogger, and the windshield wiper don't work. List all in-line and fuse box connectors in the blower controls circuit and then check the Connector View (see the sample). You find that C324 is common to the blower controls, rear window defogger, and wiper/washer, so you inspect C324 and find the problem, bent terminals. Finding Component/Connector Locations Finding Component/Connector Locations To see where a component or connector is located on the car, look up its photo number in the "Component Location". The photo will also tell you the color of the connector, and how many cavities it has. Page 8250 Windshield Washer Spray Nozzle: Service and Repair Rear Washer Nozzle Removal 1. Remove the washer nozzle (1). - Pull out the washer nozzle from the washer hose (2). Installation To install, follow the removal steps in the reverse order. Engine Controls - High/Erratic Engine Idle Power Steering Pressure Switch: Customer Interest Engine Controls - High/Erratic Engine Idle 01-080 August 14, 2001 Applies To: 2000-02 Passport - ALL 2000-02 Passport: High or Erratic Idle SYMPTOM The engine occasionally idles at too high a speed, or the idle speed fluctuates. PROBABLE CAUSES The symptom could be the result of any of these conditions: ^ Loose or corroded engine or body ground ^ High resistance in the APPS ground circuit ^ PSP (power steering pressure) switch is internally shorted to ground ^ Fuel pressure regulator is leaking fuel into the intake manifold CORRECTIVE ACTION Diagnose the cause of the idle condition, and select the proper REPAIR PROCEDURE. PARTS INFORMATION REQUIRED MATERIALS REQUIRED SOFTWARE Each REPAIR PROCEDURE requires you to use the Smart Cable to reprogram the PCM with the latest software. To select the latest software from the CDROM, enter the year, model, engine, transmission, and emissions type (49-state or California). This gives you a list of broadcast codes. Select the broadcast code at the top of the list. WARRANTY CLAIM INFORMATION Refer to the Warranty Claim Information for each Repair Procedure. DIAGNOSIS 1. Find out from the customer when the high or erratic idle condition occurs and what the RPM range is: ^ Within 20 minutes of a cold start ^ After braking to a stop ^ All the time ^ Intermittently, with no set pattern Locations Housing Assembly HVAC: Locations Page 4892 1. Install clip (2). 2. Apply special grease (approximately 0.2 g) to both contacting surfaces of the inner shims. Wipe off extruded grease after installing. Install pad assembly with shim. Page 3300 This means the branch of the wire connects to another circuit. The arrow points to the name of the circuit branch where the wire continues. Page 3795 ^ If the idle speed ever exceeds 1,300 rpm 2. Remove the vacuum hose from the fuel pressure regulator, then start the engine. ^ If fuel comes out of the fuel pressure regulator vacuum hose connection, go to REPAIR PROCEDURE FUEL PRESSURE REGULATOR. ^ If no fuel comes out of the regulator, reconnect the vacuum hose and continue to step 3. 3. Connect the PGM Tester. Set it to Engine Data List. 4. Have an assistant drive the vehicle under the conditions described by the customer. 5. If the high or erratic idle condition occurs, note the values of the PSP Switch and APP Sensor 1 when it is occurring. ^ If the PSP Switch is HIGH, and you are not turning, go to REPAIR PROCEDURE POWER STEERING SWITCH. ^ If the APP Sensor 1 is greater than 15% and APP Sensor 2 and/or APP Sensor 3 are less than 85%, and the accelerator pedal is not depressed, go to REPAIR PROCEDURE APPS GROUND. ^ If the PSP Switch is reading LOW when not turning and HIGH when turning, and the APP Sensors are reading within the range shown, discontinue the test-drive and go to step 6. 6. Do these repairs: ^ REPAIR PROCEDURE APPS GROUND ^ REPAIR PROCEDURE ENGINE/BODY GROUND REPAIR PROCEDURE - FUEL PRESSURE REGULATOR 1. Relieve fuel system pressure: ^ Remove the fuel fill cap. ^ Remove the fuel pump relay. ^ Start the engine and run it until it stalls. ^ Crank the engine for 3 seconds. 2. Remove the vacuum hose from the fuel pressure regulator. 3. Remove the fuel pressure regulator shield from the common chamber (two bolts). Diagram Information and Instructions Powertrain Control Module: Diagram Information and Instructions How to Identify Wiring Color-Coded Insulation Wire Color Wire Color Coding Page 5593 2. Connect one lead of a self-powered test light or DVOM to one end of the part of the circuit you want to test. 3. Connect the other lead to the other end. 4. If the self-powered test light glows, there is continuity. If you're using a DVOM, a low reading or no reading (zero), means good continuity. Testing For Voltage When testing for voltage at a connector without wire seals, you do not have to separate the two halves of the connector. Instead, probe the connector from the back. Always check both sides of the connector because dirty, corroded, and bent terminals can cause problems (no electrical contact = an open). 1. Connect one lead of the lest light to a known good ground, or, if you're using a digital volt ohmmeter (DVOM), place it in the appropriate DC volts range, and connect its negative lead to ground. 2. Connect the other lead of the test light or DVOM to the point you want to check. 3. If the test light glows, there is voltage present. If you're using a DVOM, note the voltage reading. It should be within one volt of measured battery voltage. A loss of more than one volt indicates a problem. NOTE: Always use a DVOM on high impedance circuits. A test light may not glow (even with battery voltage present). Testing For Voltage Drop Wires, connectors, and switches are designed to conduct current with a minimum loss of voltage. A voltage drop of more than one volt indicates a problem. 1. Place the digital volt/ohmmeter (DVOM) in the appropriate DC volts range. Connect the positive lead to the end of the wire (or to the connector or switch) closest to the battery. 2. Connect the negative lead to the other end of the wire (or the other side of the connector or switch). 3. Turn on the components in the circuit. 4. The DVOM will show the difference in voltage between the two points. A difference, or drop, of more than one volt indicates a problem. Check the circuit for loose, dirty, or bent terminals. Page 3287 Distinct Of Circuit By Wire Base Color All wires have color-coded insulation. Wires belonging to a system's main harness will have a single color. Wires belonging to a system's sub-circuits will have a colored stripe. Striped wires use the codes found in the chart to show wire size and colors. Abbreviations are used to indicate wire color within a circuit diagram. How to Identify Connector Terminals How to Identify Connector Terminals Cavity Numbering System The cavities (and wire terminals) in each connector are numbered starting from the upper left, looking at the male terminals from the terminal side (or looking at the female terminals from the wire side. Both views are in the same direction so the numbers are the same.) All actual cavities are numbered, even if they have no wire terminals in them. NOTE: Data Link Connector (DLC) terminals are numbered according to SAE standard J1962, not the Honda standard. The numbers of the four end terminals are molded into the corners of the connector face. The connector cavity number is listed next to each terminal on the circuit schematic. The cavity / terminal shown is # 6. Using/Identifying Connector Terminal Views How to Use Connector Terminal Views To see the configuration of a connector's cavities, look up its view number in the Connector Views. Each view includes the color of the connector, where Page 503 Testing For A Short With A Self-Powered Test Light or DVOM 1. Remove the blown fuse and disconnect the battery and load. 2. Connect one lead of a self-powered test light or digital volt/ohmmeter (DVOM) (switched to the lowest "OHMS" range) to the fuse terminal on the load side. 3. Connect the other lead to a known good ground. 4. Beginning near the fuse box, wiggle the harness. Continue this at convenient points about six inches apart while watching the test light or DVOM. 5. If the self-powered test light goes on or the DVOM displays a low reading or no reading (zero), there is a short to ground in the wiring near that point. Testing for a Short with a Test Light or DVOM 1. Remove the blown fuse and disconnect the load. 2. Connect a test light or digital volt/ohmmeter (DVOM), switched to the appropriate DC volts range, across the fuse terminals to make sure voltage is present. You might have to turn the ignition switch to ON; check the schematic to see. 3. Beginning near the fuse box, wiggle the harness. Continue this at convenient points about six inches apart while watching the test light or DVOM. 4. Where the test light goes , or the DVOM voltage drops to zero, there is a short to ground in the wiring near that point. NOTE: Always use a DVOM on high impedance circuits. A test light may not glow (even with battery voltage present). Testing For A Short With A Short Circuit Locator (Short Finder) 1. Remove the blown fuse. Leave the battery connected. Page 533 1. Install combination switch and SRS coil assembly. After installation of combination switch assembly, connect the combination switch wiring harness connector and the SRS 2-way connector located under the steering column. Then turn the SRS coil counterclockwise to full, return about 3 turns and align the neutral mark. CAUTION: When turning the SRS coil counterclockwise to full, stop turning if resistance is felt. Forced further turning may damage to the cable in the SRS coil. 2. When installing the steering column cover, be sure to route each wire harness as illustrated so that the harnesses do not catch on any moving parts. 3. Align the setting marks made when removing then install steering wheel. CAUTION: Never apply force to the steering wheel in direction of the shaft by using a hammer or other impact tools in an attempt to remove the steering wheel. The steering shaft is designed as an energy absorbing unit. 4. Tighten the steering wheel fixing nut to the specified torque. Torque: 34 Nm (25 ft. lbs.) 5. Support the inflator module and carefully connect the SRS connector and horn lead. NOTE: Pass the lead wire through the tabs on the plastic cover (wire protector) of inflator to prevent lead wire from being pinched. 6. Tighten bolts to specified torque. Torque: 9 Nm (78 inch lbs.) 7. Install driver knee bolster (reinforcement). 8. Install instrument panel lower cover then install the engine hood opening lever. 9. Connect the SRS connector. 10. Connect the battery "-" terminal cable. Page 4693 Axle Disconnect Control Control Unit: Diagnostic Aids Before Troubleshooting Before Troubleshooting See: Service Precautions/Vehicle Damage Warnings/Tips and Precautions 1. Check applicable fuses in the appropriate fuse/relay box. 2. Check the battery for damage, state of charge, and clean and tight connections. CAUTION: Do not quick-charge a battery unless the battery ground cable has been disconnected, otherwise you will damage the alternator diodes. - Do not attempt to crank the engine with the battery ground cable loosely connected or you will severely damage the wiring. While You're Working 1. Make sure connectors are clean, and have no loose terminals or receptacles. 2. Make sure that connectors without wire seals are packed with dielectric (silicone) grease. Part Number: 08798-9001. 3. When connecting a connector, push it until it "clicks" into place. CAUTION: Do not pull on the wires when disconnecting a connector. Pull only on the connector housings. - Most circuits include solid-state devices. Test the voltages in these circuits only with a 10-megaohm or higher impedance digital multi meter. Never use a test light or analog meter on circuits that contain solid-state devices. Damage to the devices may result. Five-Step Troubleshooting 1. Verify The Complaint Turn on all the components in the problem circuit to check the accuracy of the customer complaint. Note the symptoms. Do not begin disassembly or testing until you have narrowed down the problem area. 2. Analyze The Schematic Look up the schematic for the problem circuit. Determine how the circuit is supposed to work by tracing the current paths from the power source through the circuit components to ground. Also, trace circuits that share wiring with the problem circuit. The names of circuits that share the same fuse, ground, or switch, and so on, are referred to in each circuit schematic. Try to operate any shared circuits you didn't check in step 1. If the shared circuits work, the shared wiring is OK, and the cause must be in the wiring used only by the problem circuit. If several circuits fail at the same time, the fuse or ground is a likely cause. Based on the symptoms and your understanding of the circuit's operation, identify one or more possible causes. 3. Isolate The Problem By Testing The Circuit Make circuit tests to check the diagnosis you made in step 2. Keep in mind that a logical, simple procedure is the key to efficient troubleshooting. Test for the most likely cause of failure first. Try to make tests at points that are easily accessible. 4. Fix The Problem Once the specific problem is identified, make the repair. Be sure to use proper tools and safe procedures. 5. Make Sure The Circuit Works Turn on all components in the repaired circuit in all modes to make sure you've fixed the entire problem. If the problem was a blown fuse, be sure to test all of the circuits on that fuse. Make sure no new problems turn up and the original problem does not recur. Air Bag Disarming and Arming Air Bag(s) Arming and Disarming: Service and Repair Air Bag Disarming and Arming Disabling The SRS Removal Turn the ignition switch to "lock" and remove key. 1. Remove SRS fuse "METER" and "SRS", from left dash side lower fuse block or disconnect battery. 2. Disconnect yellow 2 - pin connector at the base of steering column. 3. Remove glove box assembly, Refer to "Passenger Air Bag Assembly Replacement". 4. Disconnect yellow 2 - pin connector behind the glove box assembly. CAUTION: With the "SRS" fuse removed and ignition switch "ON", "AIR BAG" warning lamp will be "ON". This is normal operation and does not indicate an SRS malfunction. Enabling The SRS Installation CAUTION: Never use the air bag assembly from another vehicle. Use only the air bag assembly. Turn ignition switch to "LOCK" and remove key. 1. Connect yellow 2 - pin connector passenger air bag assembly. 2. Install glove box assembly, refer to "Passenger Air Bag Assembly Replacement". 3. Connect yellow 2 - pin connector at the base of steering column. 4. Install "AIR BAG" fuse "METER" and "SRS" to left dash side lower fuse block or connect battery. Turn ignition switch to "ON" and verify that the "AIR BAG" warning lamp flashes seven times and then turns "OFF". If it does not operate as described, perform the "Supplemental Restraint System (SRS) Diagnostic System Check". Page 5714 Suspension Strut / Shock Absorber: Application and ID TYPE Front .................................................................................................................................................... .................. Hydraulic, Double Acting, Telescopic Rear ...................................................................... .................................................................................................. Hydraulic, Double Acting, Telescopic Page 7487 Terminals - "T" Each "T" terminal (ring type) is numbered for reference and location. A "T" terminal is secured with a screw or bolt. Wires Description and Operation Electric Load Sensor: Description and Operation Electrical Load Detector (ELD) Since the early ’90s, Honda vehicles have come with an electrical load detector (ELD) unit in the under-hood fuse/relay box. This unit allows the ECM/PCM to regulate the alternator (switch it between high output and low output) to provide the best combination of fuel economy and electrical system operation. The ELD sends a signal to the ECM/PCM that is proportional to the electrical demand. The ECM/PCM switches the alternator between high output and low output depending on several factors, which include electrical demand, battery charge level, and the driving cycle. When the alternator is in low output, the engine load is reduced and fuel economy improves. Page 3014 and the fuses. From Fuses to Relays and Components The second half of Power Distribution shows the wiring "From Fuses to Relays and Components." This can speed your troubleshooting by showing which circuits share fuses. If Power Distribution shows that an inoperative circuit and another circuit share a fuse, check a component in the other circuit. If it works, you know the fuse is good and power is available to the inoperative circuit. Ground Distribution Schematics Page 1540 Valve Shims (While 41 shims are available, the 10 sizes will cover most valve adjustments): Page 109 Powertrain Control Module: Locations 30. Left Side of Engine Compartment Left Side Of Engine Compartment Page 1705 Valve Guide Replacement 1. Using Valve guide replacer: J-42899, drive out the valve guide from the combustion chamber side. 2. Apply engine oil to the outside of the valve guide. Using valve guide replacer J-42899, drive in a new valve guide from the camshaft side, and check the valve guide height. Valve guide upper end height: 13.0 mm (0.5118 inch) (Measured from the cylinder head upper face) 3. Check the clearance. If the clearance is less than the specified value, ream the inside diameter of valve guide. Using a sharp 6 mm reamer, ream the valve guide to obtain the specified clearance. Valve Seat 1. Measure the protrusion of the valve stem when a new valve is installed in the cylinder head. If the protrusion of the valve stem exceeds the limit, replace the valve seat insert or the cylinder head assembly. Protrusion of valve stem Intake Standard: 39.32 mm (1.5480 inch) Page 6357 Air Bag(s) Arming and Disarming: Service and Repair Connector Disconnection / Connection REMOVAL To remove the connector, hold the cover insulator(l) and pull it. The cover insulator slides and lock will be released. Do not hold the socket insulator(2). INSTALLATION Page 6288 the component if the component only has one connector, or by a capital letter (A, B, C, etc.) if the component has more than one connector. Below most connector numbers and component names are PHOTO and VIEW numbers. The PHOTO number refers to a photo in the back of the book that shows the connector's location on the car. The VIEW number refers to an illustration in the back of the book that shows the connector face, wire colors, connector cavity numbers, and other details. The connector cavity numbering sequence begins at the top left corner of the connector. Disregard any numbers molded into the connector housing. Wires Wires are identified by the abbreviated names of their colors; the second color is the color of the stripe. Wires are also identified by their location in a connector. The number "2" next to the male and female wire terminals at C416, for example, means those terminals join in cavity 2 of connector C416. Symbols A complete description of schematic symbols is given under wire color abbreviation. Power Distribution Schematics Power Distribution schematics show how power is supplied from the positive battery terminal to various circuits in the car. Refer to the Power Distribution section to get a more detailed picture of how power is supplied to the circuit you're working on. From Battery to Ignition Switch, Fuses, and Relays Individual circuit schematics begin with a fuse. The first half of Power Distribution, however, shows the wiring "upstream" between the battery Page 5873 Tires: Service and Repair Inflation of Tires Tire pressure, in cold condition (after vehicle has set for three hours or more, and driven less than one mile) should be checked monthly or before any extended trip. Tire pressure increases approximately 15% when the tires become hot during driving. Tire pressure specification is shown on the label located on the left door lock pillar. NOTE: Check the tire pressure whenever irregular wear is found. Tire inflation greatly affects tire wear. If the alignment check does not reveal any alignment problems, check the condition of the shock absorbers and wheel/tire balance. Specifications Steering Gear: Specifications Steering Gear Lock To Lock 3.64 Turns Rack Stroke 152 mm Transfer Gear Assembly 31 Nm Bracket Nuts 116 Nm Pressure Lines 13 Nm Page 1949 Powertrain Control Module: Locations 30. Left Side of Engine Compartment Left Side Of Engine Compartment Page 5185 Brush Measure the length of brush. Replace with a new one, if it is below the limit. Standard: 16 mm (0.63 in) Limit: 11 mm (0.43 in) Brush Holder Check for continuity between brush holder (+) (4) and base (-). Replace, if there is continuity (i.e., insulation is broken). Page 1528 2. Measure the inside diameter of the connecting rod small end. If the fitting interference between the small end and pin does not conform to the specified value, the connecting rod must be replaced. Standard: 0.023 mm - 0.038 mm (0.0009 inch - 0.0015 inch) 3. Insert the new pin into the piston and rotate it. If the pin rotates smoothly with no backlash, the clearance is normal. If there is backlash or roughness, measure the clearance. If the clearance exceeds the specified limit, the piston must be replaced. Clearance Standard: 0.010 mm - 0.017 mm (0.0004 inch - 0.0007 inch) Limit: 0.040 mm (0.0016 inch) Connecting Rods 1. Check the connecting rod alignment. If either the bend or the twist exceeds the specified limit, the connecting rod must be replaced. Bend per 100 mm (3.937 inch) Limit: 0.15 (0.0059) Twist per 100 mm (3.937 inch) Limit: 0.20 (0.0078) 2. Measure the connecting rod thrust clearance. Use a feeler gauge to measure the thrust clearance at the large end of the connecting rod. If the Testing and Inspection Wheel Bearing: Testing and Inspection FRONT HUB BEARING PRELOAD CHECK Check the hub bearing preload at the wheel pin. New bearing and New oil seal: 19.6 - 24.5 N (4.4 - 5.5 lbs.) Used bearing and New oil seal: 11.8 17.7 N (2.6 - 4.0 lbs.) Page 6676 Each schematic represents one circuit. A circuit's wires and components are arranged to show current flow, from power at the top of the page, to ground, at the bottom. Shared Circuits Other circuits may share power or ground terminals or wiring with the circuit shown. A wire that connects one circuit to another, for example, is cut short and has an arrowhead at the end of it pointing in the direction of current flow. Next to the arrowhead is the name of the circuit or component which shares that wiring. To quickly check shared wiring, check the operation of a component it serves. If that component works, you know the shared wiring is OK. Connectors All in-line and junction connectors are numbered (C725, C416, etc.). Component connectors are not numbered but are identified either by the name of Page 3836 2. Compare the retrieved code with the codes shown. ^ If the code you retrieved is not in the list, the PCM has already been updated. Troubleshoot other causes for the PCM to reset. ^ If the code you retrieved is in the list, go to step 3. 3. If not already done, load the May 2001 or later HONDANET 2000 CD onto your HONDANET 2000 master terminal. Loading instructions are included in the CD's mailing. 4. Update the PCM software with the Smart Cable and the broadcast code information on the HONDANET 2000 CD. For updating instructions, refer to Service Bulletin 99-005, Updating the Passport PCM, filed under Tools. NOTE: ^ Since the Smart Cable may need to be cleared from a previous PCM update or the Smart Cable firmware may need to be reprogrammed, always begin each vehicle's PCM software update at the HONDANET 2000 workstation. ^ Make sure you select the most recent broadcast code from the list on the HONDANET screen. (This code is not necessarily at the top of the list. The most recent code is the last one in alphabetical sequence, letter by letter.) For example, among the codes DJTF, DDNN, and DCLY the most recent code is DJTF. 5. Use the PGM Tester to clear any DTCs. 6. After you update the PCM, retrieve the PCM broadcast code with the PGM Tester. Make sure the code does not match any from the list in step 2. DISCLAIMER Page 988 DIAGNOSTIC WORKSHEET REPAIR PROCEDURE A Page 5213 The wire insulation has one color or one color with another color stripe. The second color is the stripe. Page 5310 2. Connect one lead of a self-powered test light or DVOM to one end of the part of the circuit you want to test. 3. Connect the other lead to the other end. 4. If the self-powered test light glows, there is continuity. If you're using a DVOM, a low reading or no reading (zero), means good continuity. Testing For Voltage When testing for voltage at a connector without wire seals, you do not have to separate the two halves of the connector. Instead, probe the connector from the back. Always check both sides of the connector because dirty, corroded, and bent terminals can cause problems (no electrical contact = an open). 1. Connect one lead of the lest light to a known good ground, or, if you're using a digital volt ohmmeter (DVOM), place it in the appropriate DC volts range, and connect its negative lead to ground. 2. Connect the other lead of the test light or DVOM to the point you want to check. 3. If the test light glows, there is voltage present. If you're using a DVOM, note the voltage reading. It should be within one volt of measured battery voltage. A loss of more than one volt indicates a problem. NOTE: Always use a DVOM on high impedance circuits. A test light may not glow (even with battery voltage present). Testing For Voltage Drop Wires, connectors, and switches are designed to conduct current with a minimum loss of voltage. A voltage drop of more than one volt indicates a problem. 1. Place the digital volt/ohmmeter (DVOM) in the appropriate DC volts range. Connect the positive lead to the end of the wire (or to the connector or switch) closest to the battery. 2. Connect the negative lead to the other end of the wire (or the other side of the connector or switch). 3. Turn on the components in the circuit. 4. The DVOM will show the difference in voltage between the two points. A difference, or drop, of more than one volt indicates a problem. Check the circuit for loose, dirty, or bent terminals. Page 468 Testing For A Short With A Self-Powered Test Light or DVOM 1. Remove the blown fuse and disconnect the battery and load. 2. Connect one lead of a self-powered test light or digital volt/ohmmeter (DVOM) (switched to the lowest "OHMS" range) to the fuse terminal on the load side. 3. Connect the other lead to a known good ground. 4. Beginning near the fuse box, wiggle the harness. Continue this at convenient points about six inches apart while watching the test light or DVOM. 5. If the self-powered test light goes on or the DVOM displays a low reading or no reading (zero), there is a short to ground in the wiring near that point. Testing for a Short with a Test Light or DVOM 1. Remove the blown fuse and disconnect the load. 2. Connect a test light or digital volt/ohmmeter (DVOM), switched to the appropriate DC volts range, across the fuse terminals to make sure voltage is present. You might have to turn the ignition switch to ON; check the schematic to see. 3. Beginning near the fuse box, wiggle the harness. Continue this at convenient points about six inches apart while watching the test light or DVOM. 4. Where the test light goes , or the DVOM voltage drops to zero, there is a short to ground in the wiring near that point. NOTE: Always use a DVOM on high impedance circuits. A test light may not glow (even with battery voltage present). Testing For A Short With A Short Circuit Locator (Short Finder) 1. Remove the blown fuse. Leave the battery connected. Page 3696 it is located, and what it connects to. Use the Connector Views to help locate the proper cavity when you need to probe a connector. It can be especially helpful if the connector has more than one wire of the same color. A dash symbol (-) indicates that the cavity is empty. Connector views can also be used to help diagnose multiple symptoms in separate circuits which could be caused by a single problem in a connector shared by those circuits. Here's an example: 1. Pick one of the multiple symptoms and look up the schematic for that circuit. 2. Make a list of all the in-line and fuse box connectors in that schematic , 3. Then, in the Connector Views, look up each connector on your list to see if circuits related to the other symptoms run through one of them. If they do, inspect that connector for the problem. Example: The blower, rear window defogger, and the windshield wiper don't work. List all in-line and fuse box connectors in the blower controls circuit and then check the Connector View (see the sample). You find that C324 is common to the blower controls, rear window defogger, and wiper/washer, so you inspect C324 and find the problem, bent terminals. Finding Component/Connector Locations Finding Component/Connector Locations To see where a component or connector is located on the car, look up its photo number in the "Component Location". The photo will also tell you the color of the connector, and how many cavities it has. Page 5226 Page 7715 Splices Splices are shown as a dot. Their location and the number of wires may vary depending on the harness manufacturer. Switches Switches These switches move together; the broken straight line between them means they are mechanically connected. Other types of switches are controlled by a coil or a solid state circuit. Unless otherwise noted, all switches are shown in their normal (rest) position, with power off. Terminal "T" Page 7395 Page 1593 2. Use a valve cutter to minimize scratches and other rough areas. This will bring the contact width back to the standard value. Remove only the scratches and rough areas. Do not cut away too much. Take care not to cut away unblemished areas of the valve seat surface. Valve seat angle degree: 90° 3. Apply abrasive compound to the valve seat insert surface. 4. Insert the valve into the valve guide. 5. Turn the valve while lapping it to fit the valve seat insert. 6. Check that the valve contact width is correct. 7. Check that the valve seat insert surface is in contact with the entire circumference of the valve. Valve Seat Insert Replacement 1. Arc weld the rod at several points. Be careful not to damage the aluminum. 2. Allow the rod to cool for a few minutes. This will cause the valve seat to shrink. 3. Strike the rod and pull it out. 4. Carefully clean the valve seat press- fit on the cylinder head side. 5. Heat the press-fit with steam or some other means to cause expansion. Cool the valve seat with dry ice or some other means. Page 168 This sample Ground Distribution schematic shows all of the components that share two ground points. Components A solid border line means the entire component is shown. A broken border line indicates that only part of the component is shown. Page 5594 Key Reminder Switch: Electrical Diagrams Seat Belt, Lights-ON and Ignition Key Reminders Part 1 Of 2 Page 5782 9. Using a 3/8 in. drill motor, a 1/4 in. drill guide, and a 1/4 in. bit, drill three pilot holes per side into the bottom of the frame rail, through each hole in the type A reinforcement bracket. NOTE: On some 2000 models and all 2001-02 models, the driver's side requires only two holes due to the welded nut inside the frame, at the front bracket hole. Do not drill a hole in this location. PCM Service Precautions Powertrain Control Module: Service Precautions PCM Service Precautions PCM Service Precautions The PCM is designed to withstand normal current draws associated with vehicle operation. Avoid overloading any circuit. When testing for opens and shorts, do not ground or apply voltage to any of the PCM's circuits unless instructed to do so. These circuits should only be tested using digital voltmeter J 39200. The PCM should remain connected to the PCM or to a recommended breakout box. Page 5173 Measure inner diameter of bushing in the rear cover, and replace if it exceeds the limit. Standard: 12.50 mm to 12.527 mm (0.492 in to 0.4932 in) Limit: 12.60 mm (0.4961 in) Measure inner diameter of bushing in the center bracket (P), and replace if it exceeds the limit. Standard: 18.01 mm to 18.127 mm (0.7091 in to 0.7137 in) Limit: 18.15 mm (0.7146 in) Page 6576 Hood Sensor/Switch (For Alarm): Service and Repair Removal 1. Disconnect the battery ground cable. 2. Disconnect the connector. 3. Remove the engine hood switch (1). Installation To install, follow the removal steps in the reverse order. Page 4603 4WD Control Unit: Diagnostic Aids Before Troubleshooting Before Troubleshooting See: Service Precautions/Vehicle Damage Warnings/Tips and Precautions 1. Check applicable fuses in the appropriate fuse/relay box. 2. Check the battery for damage, state of charge, and clean and tight connections. CAUTION: Do not quick-charge a battery unless the battery ground cable has been disconnected, otherwise you will damage the alternator diodes. - Do not attempt to crank the engine with the battery ground cable loosely connected or you will severely damage the wiring. While You're Working 1. Make sure connectors are clean, and have no loose terminals or receptacles. 2. Make sure that connectors without wire seals are packed with dielectric (silicone) grease. Part Number: 08798-9001. 3. When connecting a connector, push it until it "clicks" into place. CAUTION: Do not pull on the wires when disconnecting a connector. Pull only on the connector housings. - Most circuits include solid-state devices. Test the voltages in these circuits only with a 10-megaohm or higher impedance digital multi meter. Never use a test light or analog meter on circuits that contain solid-state devices. Damage to the devices may result. Five-Step Troubleshooting 1. Verify The Complaint Turn on all the components in the problem circuit to check the accuracy of the customer complaint. Note the symptoms. Do not begin disassembly or testing until you have narrowed down the problem area. 2. Analyze The Schematic Look up the schematic for the problem circuit. Determine how the circuit is supposed to work by tracing the current paths from the power source through the circuit components to ground. Also, trace circuits that share wiring with the problem circuit. The names of circuits that share the same fuse, ground, or switch, and so on, are referred to in each circuit schematic. Try to operate any shared circuits you didn't check in step 1. If the shared circuits work, the shared wiring is OK, and the cause must be in the wiring used only by the problem circuit. If several circuits fail at the same time, the fuse or ground is a likely cause. Based on the symptoms and your understanding of the circuit's operation, identify one or more possible causes. 3. Isolate The Problem By Testing The Circuit Make circuit tests to check the diagnosis you made in step 2. Keep in mind that a logical, simple procedure is the key to efficient troubleshooting. Test for the most likely cause of failure first. Try to make tests at points that are easily accessible. 4. Fix The Problem Once the specific problem is identified, make the repair. Be sure to use proper tools and safe procedures. 5. Make Sure The Circuit Works Turn on all components in the repaired circuit in all modes to make sure you've fixed the entire problem. If the problem was a blown fuse, be sure to test all of the circuits on that fuse. Make sure no new problems turn up and the original problem does not recur. Page 2229 Terminals - "T" Each "T" terminal (ring type) is numbered for reference and location. A "T" terminal is secured with a screw or bolt. Wires Page 3530 Crankshaft Position Sensor: Service and Repair REMOVAL 1. Disconnect the negative battery cable. 2. Disconnect the wiring connector from crankshaft position sensor. 3. Remove one bolt and remove the CKP sensor from the right side of the engine block, just behind the mount. NOTE: Use caution to avoid any hot oil that might drip out. INSTALLATION 1. Apply a small amount of engine oil to the O-ring and install the CKP sensor in the engine block. 2. Install the CKP sensor mounting bolt. 3. Tighten the mounting bolt to 10 Nm (89 lb in.). 4. Connect the wiring connector to the CKP sensor. 5. Connect the negative battery cable. Engine Controls - Engine Spark Knock Or Pinging Powertrain Control Module: Customer Interest Engine Controls - Engine Spark Knock Or Pinging 01-084 June 19, 2009 Applies To: 2000-02 Passport - ALL Engine Spark Knock (Pinging) (Supersedes 01-084, dated March 18, 2003, to revise the information marked by asterisks) *REVISION SUMMARY Under WARRANTY CLAIM INFORMATION, the failed part number, the Honda code, the defect code, and the symptom code have been updated.* SYMPTOM An engine spark knock (pinging). PROBABLE CAUSE The programmed ignition timing does not correct quickly enough in some climates. CORRECTIVE ACTION Update the PCM software with the Smart Cable. TOOL INFORMATION PGM Tester with software update release SN200P (9/1/01) or later. For the other tools and equipment you need to update the PCM software, refer to Service Bulletin 99-005, Updathg the Passport POM, filed under Tools. WARRANTY CLAIM INFORMATION In warranty: The normal warranty applies. Operation Number: 125517 Flat Rate Time: 0.3 hour *Failed Part: P/N 8-12212-079-0 H/C 6974992 Defect Code: 03214 Symptom Code: 09117* Template ID: 01-084A Skill Level: Repair Technician Out of warranty: Any repair performed after warranty expiration may be eligible for goodwill consideration by the District Parts and Service Manager or your Zone Office. You must request consideration, and get a decision, before starting work. REPAIR PROCEDURE 1. Retrieve the PCM broadcast code with the PGM Tester or the Smart Cable (refer to Service Bulletin 99-005, Updathg the Passport PCM). Service and Repair Windshield Washer Switch: Service and Repair Rear Wiper and Washer Switch Removal 1. Disconnect the battery ground cable. 2. Remove the dash side trim panel (1). 3. Remove the lower cover assembly (2). 4. Remove the meter cluster assembly (4). 5. Remove the rear wiper & washer switch (5). - Disconnect the connector. - Push the lock from the back side of the meter cluster assembly. Installation To install, follow the removal steps in the reverse order, noting the following point: 1. Push the switch with your fingers until it locks securely. Page 2048 Splices Splices are shown as a dot. Their location and the number of wires may vary depending on the harness manufacturer. Switches Switches These switches move together; the broken straight line between them means they are mechanically connected. Other types of switches are controlled by a coil or a solid state circuit. Unless otherwise noted, all switches are shown in their normal (rest) position, with power off. Terminal "T" Page 1349 4. Align the template on the mud flap. Mark the area on the mud flap that needs to be cut away with a pencil or scribe. 5. Use a utility knife to remove the marked area. 6. Repeat steps 4 and 5 on the other mud flap. 7. Reinstall the mud flaps on the vehicle. DISCLAIMER Page 3461 129 - Below Left Side Of I/P Page 6049 2. Remove drive plate by using drive plate puller J-33944-A (2) and forcing screw J-33944-4 (1). 3. Remove shim (s). 4. Remove snap ring (1) by using snap ring pliers. 5. Remove pulley assembly by using pulley puller pilot J-38424 (2), pulley puller J-8433 (1) and pulley puller leg J-24092-2 (3). Locations Page 6508 Torque Specifications Part 2 Page 6476 Air Bag(s) Arming and Disarming: Description and Operation General Description General Description Restraint Devices The Supplemental Restraint System (SRS) helps supplement the protection offered by the driver and front passenger seat belts by deploying an air bag from the center of the steering wheel and from the top of the right side of the instrument panel. The air bag deploys when the vehicle is involved in a frontal crash of sufficient force up to 30 degrees off the centerline of the vehicle; To further absorb the crash energy there is a knee bolster located beneath the instrument panel for both the driver and passenger, and the steering column is collapsible. Locations 46 - Top Front Of 3.2L Engine (Intake Duct Removed) Page 120 The connector cavity number is listed next to each terminal on the circuit schematic. The cavity / terminal shown is # 6. Diodes A rectifier diode works like a one way valve. It allows current to flow only in the direction of the arrow. A Zener diode blocks reverse current at normal voltages just like a rectifier diode. At high voltages, however, a Zener diode allows current to flow in reverse. Fuses Page 3299 Wires Wire insulation can be one color, or one color with another color stripe. (The second color is the stripe.) This circuit continues on another image. (The arrow shows direction of current flow.) To follow the RED/BLK wire in this example, you would turn to "Fuel and Emissions" and look for the "A" arrow. Page 1336 3. Photocopy the template that is shown. Cut out the template. Service and Repair Transmission Temperature Sensor/Switch: Service and Repair REMOVAL 1. Raise the vehicle and support it on jack stands. 2. Disconnect battery ground cable. 3. Drain fluid. 4. Remove sixteen 10 mm adapter case oil pan fixing screws, adapter case oil pan, and gasket. 5. Disconnect wiring harness from shift solenoid, band apply solenoid, and 7 pin connector of main case. Pull only on connectors, not on wiring harness. 6. Remove wiring harness assembly with transmission oil temperature sensor. INSTALLATION 1. Install wiring harness from shift solenoid, band apply solenoid, and 7 pin connector of main case. 2. Install oil pan gasket, oil pan and sixteen 10 mm fixing screws. Tighten the screws to the specified torque. Torque: 11 Nm (96 Ft. lbs.) 3. Fill transmission through the overfill screw hole of oil pan, using ATF DEXRON III. 4. Connect battery ground cable. Page 5944 1. Adjust the control cable. - Temperature control cable. 1. Turn the control knob to the left ("MAX COLD" position). 2. Connect the control cable at the "COLD" position of the temperature control link of the heater unit and secure it with the clip. - Air select control cable 1. Turn the control knob to the right ("DEFROST" position). 2. Connect the control cable at the "DEFROST" position of the mode control link of the heater unit and secure it with the clip. 2. Check the control cable operation. Engine Controls - High/Erratic Engine Idle Power Steering Pressure Switch: All Technical Service Bulletins Engine Controls - High/Erratic Engine Idle 01-080 August 14, 2001 Applies To: 2000-02 Passport - ALL 2000-02 Passport: High or Erratic Idle SYMPTOM The engine occasionally idles at too high a speed, or the idle speed fluctuates. PROBABLE CAUSES The symptom could be the result of any of these conditions: ^ Loose or corroded engine or body ground ^ High resistance in the APPS ground circuit ^ PSP (power steering pressure) switch is internally shorted to ground ^ Fuel pressure regulator is leaking fuel into the intake manifold CORRECTIVE ACTION Diagnose the cause of the idle condition, and select the proper REPAIR PROCEDURE. PARTS INFORMATION REQUIRED MATERIALS REQUIRED SOFTWARE Each REPAIR PROCEDURE requires you to use the Smart Cable to reprogram the PCM with the latest software. To select the latest software from the CDROM, enter the year, model, engine, transmission, and emissions type (49-state or California). This gives you a list of broadcast codes. Select the broadcast code at the top of the list. WARRANTY CLAIM INFORMATION Refer to the Warranty Claim Information for each Repair Procedure. DIAGNOSIS 1. Find out from the customer when the high or erratic idle condition occurs and what the RPM range is: ^ Within 20 minutes of a cold start ^ After braking to a stop ^ All the time ^ Intermittently, with no set pattern Page 5780 3. Remove the lower half of body mount #4 from both sides of the vehicle. 4. Using two ratcheting straps, lash up both sides of the rear axle to remove the tension on the trailing links: ^ Attach one end of the straps to the lower trailing link rear mounting bracket on rear axle. ^ Route the strap around the rear axle, making sure not to route it over any brake lines. ^ Attach the other end of the straps to the transmission mount crossmember. ^ Ratchet the straps to apply enough forward tension on the rear axle to allow the lower trailing link front mounting bolts to be moved by hand. 5. Using a hammer, knock on the outside of the frame rail around the lower trailing link bracket area to loosen any rust on the inside of the frame. 6. Using a wire brush and a scraper, remove any loose frame coating, weld spatter, and rust from the outside frame rail and the lower trailing link frame bracket in the 20-inch (500 mm) section shown below. Page 635 Crankshaft Position Sensor: Description and Operation Crankshaft Position (CKP) Sensor The crankshaft position (CKP) sensor provides a signal used by the powertrain control module (PCM) to calculate the ignition sequence. The CKP sensor initiates the 58X reference pulses which the PCM uses to calculate RPM and crankshaft position. Page 5442 Alignment: Specifications Trim Height Trim Height .......................................................................................................................................... ................................. 119 +/- 5 mm (4.69 +/- 0.2 in.) Page 2046 The connector cavity number is listed next to each terminal on the circuit schematic. The cavity / terminal shown is # 6. Diodes A rectifier diode works like a one way valve. It allows current to flow only in the direction of the arrow. A Zener diode blocks reverse current at normal voltages just like a rectifier diode. At high voltages, however, a Zener diode allows current to flow in reverse. Fuses Page 7609 Testing For A Short With A Self-Powered Test Light or DVOM 1. Remove the blown fuse and disconnect the battery and load. 2. Connect one lead of a self-powered test light or digital volt/ohmmeter (DVOM) (switched to the lowest "OHMS" range) to the fuse terminal on the load side. 3. Connect the other lead to a known good ground. 4. Beginning near the fuse box, wiggle the harness. Continue this at convenient points about six inches apart while watching the test light or DVOM. 5. If the self-powered test light goes on or the DVOM displays a low reading or no reading (zero), there is a short to ground in the wiring near that point. Testing for a Short with a Test Light or DVOM 1. Remove the blown fuse and disconnect the load. 2. Connect a test light or digital volt/ohmmeter (DVOM), switched to the appropriate DC volts range, across the fuse terminals to make sure voltage is present. You might have to turn the ignition switch to ON; check the schematic to see. 3. Beginning near the fuse box, wiggle the harness. Continue this at convenient points about six inches apart while watching the test light or DVOM. 4. Where the test light goes , or the DVOM voltage drops to zero, there is a short to ground in the wiring near that point. NOTE: Always use a DVOM on high impedance circuits. A test light may not glow (even with battery voltage present). Testing For A Short With A Short Circuit Locator (Short Finder) 1. Remove the blown fuse. Leave the battery connected. Page 7640 Wire Color Abbreviations The following abbreviations are used to identify wire colors in the circuit schematics: WHT................................... White YEL................................... Yellow BLK................................... Black BLU................................... Blue GRN................................... Green RED................................... Red ORN................................... Orange PNK................................... Pink BRN................................... Brown GRY................................... Gray PUR................................... Purple LT BLU................................... Light Blue LT GRN................................... Light Green Page 7648 Part 2 Of 2 Page 1425 3. Tighten sub gear setting bolt. 1. Use J-42686 to turn sub gear to right direction until it aligns with the M5 bolt hole between camshaft driven gear and sub gear. 2. Tighten the M5 bolt to a suitable torque to prevent the sub gear from moving. Locations Oil Pressure Switch (For Fuel Pump): Locations Bottom Center Front of Engine Page 1952 Distinct Of Circuit By Wire Base Color All wires have color-coded insulation. Wires belonging to a system's main harness will have a single color. Wires belonging to a system's sub-circuits will have a colored stripe. Striped wires use the codes found in the chart to show wire size and colors. Abbreviations are used to indicate wire color within a circuit diagram. How to Identify Connector Terminals How to Identify Connector Terminals Cavity Numbering System The cavities (and wire terminals) in each connector are numbered starting from the upper left, looking at the male terminals from the terminal side (or looking at the female terminals from the wire side. Both views are in the same direction so the numbers are the same.) All actual cavities are numbered, even if they have no wire terminals in them. NOTE: Data Link Connector (DLC) terminals are numbered according to SAE standard J1962, not the Honda standard. The numbers of the four end terminals are molded into the corners of the connector face. The connector cavity number is listed next to each terminal on the circuit schematic. The cavity / terminal shown is # 6. Using/Identifying Connector Terminal Views How to Use Connector Terminal Views To see the configuration of a connector's cavities, look up its view number in the Connector Views. Each view includes the color of the connector, where Page 2886 Fuel Tank Pressure Sensor: Testing and Inspection 1. Inspect the vapor pressure sensor for cracks in the housing and corrosion on the electrical terminals. 2. Inspect the rubber grommet for tears and signs of rot. Page 5171 Continuity of Contacts With the plunger faced downward, push down the magnetic switch. In this state, check for continuity between terminals B and M. Replace, if there is no continuity (i.e., contacts are faulty). Pinion Check if the pinion rotates smoothly in drive direction by hand, or if it is locked when it is rotated in reverse. If not, replace the pinion. Page 4552 Ground - "G" Shielding Sheilding This represents RFI (Radio Frequency Interference) shielding around a wire. The shielding is always connected to ground. Splices Page 6093 Condenser Fan: Testing and Inspection 1. Disconnect the condenser fan connector. 2. Connect the battery positive terminal to the condenser fan side connector terminal No.C-24-1 and negative to the No.C-24-2. 3. Check that condenser fan is rotating correctly. Page 5744 3. Remove the lower half of body mount #4 from both sides of the vehicle. 4. Using two ratcheting straps, lash up both sides of the rear axle to remove the tension on the trailing links: ^ Attach one end of the straps to the lower trailing link rear mounting bracket on rear axle. ^ Route the strap around the rear axle, making sure not to route it over any brake lines. ^ Attach the other end of the straps to the transmission mount crossmember. ^ Ratchet the straps to apply enough forward tension on the rear axle to allow the lower trailing link front mounting bolts to be moved by hand. 5. Using a hammer, knock on the outside of the frame rail around the lower trailing link bracket area to loosen any rust on the inside of the frame. 6. Using a wire brush and a scraper, remove any loose frame coating, weld spatter, and rust from the outside frame rail and the lower trailing link frame bracket in the 20-inch (500 mm) section shown below. Description and Operation EGR Valve Position Sensor: Description and Operation EGR Pintle Position Sensor The PCM monitors the EGR valve pintle position input to endure that the valve responds properly to commands from the PCM and to detect a fault if the pintle position sensor and control circuits are open or shorted. If the PCM detects a pintle position signal voltage outside the normal range of the pintle position sensor, or a signal voltage that is not within a tolerance considered acceptable for proper EGR system operation, the PCM will set DTC P1406. Page 3221 2. Connect one lead of a self-powered test light or DVOM to one end of the part of the circuit you want to test. 3. Connect the other lead to the other end. 4. If the self-powered test light glows, there is continuity. If you're using a DVOM, a low reading or no reading (zero), means good continuity. Testing For Voltage When testing for voltage at a connector without wire seals, you do not have to separate the two halves of the connector. Instead, probe the connector from the back. Always check both sides of the connector because dirty, corroded, and bent terminals can cause problems (no electrical contact = an open). 1. Connect one lead of the lest light to a known good ground, or, if you're using a digital volt ohmmeter (DVOM), place it in the appropriate DC volts range, and connect its negative lead to ground. 2. Connect the other lead of the test light or DVOM to the point you want to check. 3. If the test light glows, there is voltage present. If you're using a DVOM, note the voltage reading. It should be within one volt of measured battery voltage. A loss of more than one volt indicates a problem. NOTE: Always use a DVOM on high impedance circuits. A test light may not glow (even with battery voltage present). Testing For Voltage Drop Wires, connectors, and switches are designed to conduct current with a minimum loss of voltage. A voltage drop of more than one volt indicates a problem. 1. Place the digital volt/ohmmeter (DVOM) in the appropriate DC volts range. Connect the positive lead to the end of the wire (or to the connector or switch) closest to the battery. 2. Connect the negative lead to the other end of the wire (or the other side of the connector or switch). 3. Turn on the components in the circuit. 4. The DVOM will show the difference in voltage between the two points. A difference, or drop, of more than one volt indicates a problem. Check the circuit for loose, dirty, or bent terminals. Page 6373 and the fuses. From Fuses to Relays and Components The second half of Power Distribution shows the wiring "From Fuses to Relays and Components." This can speed your troubleshooting by showing which circuits share fuses. If Power Distribution shows that an inoperative circuit and another circuit share a fuse, check a component in the other circuit. If it works, you know the fuse is good and power is available to the inoperative circuit. Ground Distribution Schematics Page 1482 2. Remove the main bearing cap fixing bolts in the sequence shown in the illustration. Arrange the removed main bearing caps in the cylinder number order. Remove the main bearings. 3. Remove the crankshaft. Remove the main bearings. 4. Clean the upper and lower bearings as well as the crankshaft main journal. 5. Check the bearings for damage or excessive wear. The bearings must be replaced as a set if damage or excessive wear is discovered during inspection. 6. Set the upper bearings and the thrust washers to their original positions. Carefully install the crankshaft. 7. Set the lower bearings to the bearing cap original position. 8. Apply plastogene to the crankshaft journal unit as shown in the illustration. Note: Do not set the plastogene on the oil hole. Component Locations 4WD Motor Actuator: Component Locations Beneath Center of Vehicle, on Transfer Case (A/T) Page 6744 Trailer Connector: Diagnostic Aids Before Troubleshooting Before Troubleshooting See: Service Precautions/Vehicle Damage Warnings/Tips and Precautions 1. Check applicable fuses in the appropriate fuse/relay box. 2. Check the battery for damage, state of charge, and clean and tight connections. CAUTION: Do not quick-charge a battery unless the battery ground cable has been disconnected, otherwise you will damage the alternator diodes. - Do not attempt to crank the engine with the battery ground cable loosely connected or you will severely damage the wiring. While You're Working 1. Make sure connectors are clean, and have no loose terminals or receptacles. 2. Make sure that connectors without wire seals are packed with dielectric (silicone) grease. Part Number: 08798-9001. 3. When connecting a connector, push it until it "clicks" into place. CAUTION: Do not pull on the wires when disconnecting a connector. Pull only on the connector housings. - Most circuits include solid-state devices. Test the voltages in these circuits only with a 10-megaohm or higher impedance digital multi meter. Never use a test light or analog meter on circuits that contain solid-state devices. Damage to the devices may result. Five-Step Troubleshooting 1. Verify The Complaint Turn on all the components in the problem circuit to check the accuracy of the customer complaint. Note the symptoms. Do not begin disassembly or testing until you have narrowed down the problem area. 2. Analyze The Schematic Look up the schematic for the problem circuit. Determine how the circuit is supposed to work by tracing the current paths from the power source through the circuit components to ground. Also, trace circuits that share wiring with the problem circuit. The names of circuits that share the same fuse, ground, or switch, and so on, are referred to in each circuit schematic. Try to operate any shared circuits you didn't check in step 1. If the shared circuits work, the shared wiring is OK, and the cause must be in the wiring used only by the problem circuit. If several circuits fail at the same time, the fuse or ground is a likely cause. Based on the symptoms and your understanding of the circuit's operation, identify one or more possible causes. 3. Isolate The Problem By Testing The Circuit Make circuit tests to check the diagnosis you made in step 2. Keep in mind that a logical, simple procedure is the key to efficient troubleshooting. Test for the most likely cause of failure first. Try to make tests at points that are easily accessible. 4. Fix The Problem Once the specific problem is identified, make the repair. Be sure to use proper tools and safe procedures. 5. Make Sure The Circuit Works Turn on all components in the repaired circuit in all modes to make sure you've fixed the entire problem. If the problem was a blown fuse, be sure to test all of the circuits on that fuse. Make sure no new problems turn up and the original problem does not recur. Page 2898 Steps 1 - 3 Steps 4 - 7 Test Description IMPORTANT: Be sure to used the same diagnostic test equipment for all measurements. The Number(s) below refer to the step number(s) on the Diagnostic Chart. 2. Applying 34 kPa (10 Hg) vacuum to the MAP sensor should cause the voltage to be 1.5 - 2.1 volts less than the voltage at step 1. Upon applying vacuum to the sensor, the change in voltage should be instantaneous. A slow voltage change indicates a faulty sensor. Page 2547 Coolant Temperature Sensor/Switch (For Computer): Service and Repair ENGINE COOLANT TEMPERATURE (ECT) SENSOR REMOVAL PROCEDURE NOTE: Care must be taken when handling the engine coolant temperature (ECT) sensor. Damage to the ECT sensor will affect proper operation of the fuel injection system. 1. Disconnect the negative battery cable. 2. Drain the radiator coolant. Refer to Draining and Refilling Cooling System. 3. Disconnect the electrical connector. 4. Remove the ECT sensor from the coolant crossover. INSTALLATION PROCEDURE 1. Apply sealer or the equivalent to the threads of the ECT sensor. 2. Install the ECT sensor in the coolant crossover. Tighten Tighten the ECT sensor to 30 N.m (22 lb ft.). Page 5984 Distinct Of Circuit By Wire Base Color All wires have color-coded insulation. Wires belonging to a system's main harness will have a single color. Wires belonging to a system's sub-circuits will have a colored stripe. Striped wires use the codes found in the chart to show wire size and colors. Abbreviations are used to indicate wire color within a circuit diagram. How to Identify Connector Terminals How to Identify Connector Terminals Cavity Numbering System The cavities (and wire terminals) in each connector are numbered starting from the upper left, looking at the male terminals from the terminal side (or looking at the female terminals from the wire side. Both views are in the same direction so the numbers are the same.) All actual cavities are numbered, even if they have no wire terminals in them. NOTE: Data Link Connector (DLC) terminals are numbered according to SAE standard J1962, not the Honda standard. The numbers of the four end terminals are molded into the corners of the connector face. The connector cavity number is listed next to each terminal on the circuit schematic. The cavity / terminal shown is # 6. Using/Identifying Connector Terminal Views How to Use Connector Terminal Views To see the configuration of a connector's cavities, look up its view number in the Connector Views. Each view includes the color of the connector, where Page 4009 Seals and Gaskets: Service and Repair Torque Converter Seal REMOVAL 1. Remove transmission assembly from the vehicle. 2. Remove torque converter from converter housing. 3. Remove three screws and oil seal ring from converter housing. INSTALLATION 1. Apply clean ATF to the new oil seal ring lip. - Install oil seal ring to converter housing, tighten to the specified torque. Torque: 3 Nm (26 inch lbs.) 2. Install torque converter to converter housing. 3. Install transmission assembly case to the vehicle. Page 2429 7. Modify the original APPS by cutting the connector housing off of the sensor. 8. Connect the 10P connector to the modified APPS connector housing. 9. Using a DVOM, check the voltage between the reference voltage pin for each sensor and ground. ^ If the sensor circuits all read 5.0 volts, go to step 11. ^ If any sensor circuit is above or below 5.0 volts, go to step 10. 10. Troubleshoot for an internal short in another sensor or a PCM malfunction. ^ To find the sensor with an internal short, monitor the incorrect reference voltage, and disconnect each sensor (FTPS, EGR, MAP, TPS, CKP, and CMP) one at a time until the reference voltage reads 5.0 volts. Replace that sensor, and repeat step 3. ^ To find a malfunctioning PCM, replace it with a known-good PCM. If all three sensors (APP Sensor 1, APP Sensor 2, and APP Sensor 3) are within range, the original PCM is faulty; replace it and repeat step 3. Page 4551 The connector cavity number is listed next to each terminal on the circuit schematic. The cavity / terminal shown is # 6. Diodes A rectifier diode works like a one way valve. It allows current to flow only in the direction of the arrow. A Zener diode blocks reverse current at normal voltages just like a rectifier diode. At high voltages, however, a Zener diode allows current to flow in reverse. Fuses Page 5962 6. Use a clean shop towel or a shop vacuum to remove any debris from the inside of the blower assembly housing. 7. Install the new blower resistor. 8. Install the new blower motor assembly and gasket, and plug in the 2P connector. 9. Plug the 6P connector into the new blower resistor. 10. 2000-01 Models: Reinstall the intake actuator relay. 11. Lift up the glove box, and push it back into the stops. Return the contents to the glove box. 12. Start the engine, and run the blower to make sure it works properly. Disclaimer Page 2946 Throttle Position Sensor: Description and Operation Throttle Position (TP) Sensor The throttle position (TP) sensor is a potentiometer connected to the throttle shaft on the throttle body. The PCM monitors the voltage on the signal line and calculates throttle position. As the throttle valve angle is changed (accelerator pedal moved), the TP sensor signal also changes. At a closed throttle position, the output of the TP1 sensor is low. As the throttle valve opens, the output increases so that at wide open throttle (WOT), the output voltage should be above 92 % (Tech 2 Display). The PCM calculates fuel delivery based on throttle valve angle (driver demand). A broken or loose TP sensor may cause intermittent bursts of fuel from an injector and unstable idle because the PCM thinks the throttle is moving. Locations Page 2566 This sample Ground Distribution schematic shows all of the components that share two ground points. Components A solid border line means the entire component is shown. A broken border line indicates that only part of the component is shown. Page 1623 14. Working through the right front wheelwell, remove the two upper flange bolts holding the bracket to the engine. 15. Working from under the vehicle, rotate the right engine mount, and remove the two flange nuts holding the mount and the mount cover to the bracket. 16. Remove the mount, the cover, and the bracket. Discard the cover. 17. Assemble the bracket, the new cover, and the mount in the engine compartment. Secure the assembly with the two flange nuts. Torque the flange nuts to 50 N.m (37 lb-ft). Page 1893 2. Install heat protector. 3. Install exhaust front pipe and tighten three stud nuts and two nuts to the specified torque. Torque: Stud nuts: 67 Nm (49 ft. lbs.) Nuts: 43 Nm (32 ft. lbs.) 4. Set A/C compressor to normal position and tighten two bolts and a bolt to the specified torque. Torque: 40 Nm (30 ft. lbs.) 5. Reconnect O2 sensor connector. 6. Install air cleaner duct assembly. Page 4035 4. Set the parking brake, and move the shift lever to L. Remove the ashtray. 5. Remove the lower cluster assembly (one screw and four clips), then unplug the connectors from the cigarette lighter. 6. Remove the rear console (two screws inside the storage area), then unplug the connectors from the POWER and WINTER switches. 7. On 4WD models, remove the knob from the transfer control lever. 8. Remove the front console (six screws), then unplug the connectors from the accessory power outlet. 9. Move the shift lever to P then turn the ignition switch to ACC. 10. Press and hold the shift lever pushbutton, then check the condition of the spring pin cover in the lock cylinder assembly. ^ If the cover is loose, out of position, or missing, disregard this service bulletin, and replace the lock cylinder assembly. See section 2A of the appropriate Passport Service Manual for the replacement procedure. Fuel Injector Coil Test / Fuel Injector Balance Test Fuel Injector: Testing and Inspection Fuel Injector Coil Test / Fuel Injector Balance Test Fuel Injector Coil Test Procedure and Fuel Injector Balance Test Procedure Page 132 2. Connect one lead of a self-powered test light or DVOM to one end of the part of the circuit you want to test. 3. Connect the other lead to the other end. 4. If the self-powered test light glows, there is continuity. If you're using a DVOM, a low reading or no reading (zero), means good continuity. Testing For Voltage When testing for voltage at a connector without wire seals, you do not have to separate the two halves of the connector. Instead, probe the connector from the back. Always check both sides of the connector because dirty, corroded, and bent terminals can cause problems (no electrical contact = an open). 1. Connect one lead of the lest light to a known good ground, or, if you're using a digital volt ohmmeter (DVOM), place it in the appropriate DC volts range, and connect its negative lead to ground. 2. Connect the other lead of the test light or DVOM to the point you want to check. 3. If the test light glows, there is voltage present. If you're using a DVOM, note the voltage reading. It should be within one volt of measured battery voltage. A loss of more than one volt indicates a problem. NOTE: Always use a DVOM on high impedance circuits. A test light may not glow (even with battery voltage present). Testing For Voltage Drop Wires, connectors, and switches are designed to conduct current with a minimum loss of voltage. A voltage drop of more than one volt indicates a problem. 1. Place the digital volt/ohmmeter (DVOM) in the appropriate DC volts range. Connect the positive lead to the end of the wire (or to the connector or switch) closest to the battery. 2. Connect the negative lead to the other end of the wire (or the other side of the connector or switch). 3. Turn on the components in the circuit. 4. The DVOM will show the difference in voltage between the two points. A difference, or drop, of more than one volt indicates a problem. Check the circuit for loose, dirty, or bent terminals. Tire Rotation Tires: Service and Repair Tire Rotation Tire rotation is recommended to equalize wear for longer life. If the following conditions are noted, rotate the tires: - Front tire wear is different from rear. - Uneven wear exists across the tread of any tire. - Left and right front tire wear is unequal. - Left and right rear tire wear is unequal. Check wheel alignment if the following conditions are noted: - Left and right front tire wear is unequal. - Wear is uneven across the tread of any front tire. - Front tire treads have a scuffed appearance with "feather" edges on one side of the tread ribs or blocks. Page 6734 This sample Ground Distribution schematic shows all of the components that share two ground points. Components A solid border line means the entire component is shown. A broken border line indicates that only part of the component is shown. Page 5214 Auxiliary Power Outlet: Diagnostic Aids Before Troubleshooting Before Troubleshooting See: Service Precautions/Vehicle Damage Warnings/Tips and Precautions 1. Check applicable fuses in the appropriate fuse/relay box. 2. Check the battery for damage, state of charge, and clean and tight connections. CAUTION: Do not quick-charge a battery unless the battery ground cable has been disconnected, otherwise you will damage the alternator diodes. - Do not attempt to crank the engine with the battery ground cable loosely connected or you will severely damage the wiring. While You're Working 1. Make sure connectors are clean, and have no loose terminals or receptacles. 2. Make sure that connectors without wire seals are packed with dielectric (silicone) grease. Part Number: 08798-9001. 3. When connecting a connector, push it until it "clicks" into place. CAUTION: Do not pull on the wires when disconnecting a connector. Pull only on the connector housings. - Most circuits include solid-state devices. Test the voltages in these circuits only with a 10-megaohm or higher impedance digital multi meter. Never use a test light or analog meter on circuits that contain solid-state devices. Damage to the devices may result. Five-Step Troubleshooting 1. Verify The Complaint Turn on all the components in the problem circuit to check the accuracy of the customer complaint. Note the symptoms. Do not begin disassembly or testing until you have narrowed down the problem area. 2. Analyze The Schematic Look up the schematic for the problem circuit. Determine how the circuit is supposed to work by tracing the current paths from the power source through the circuit components to ground. Also, trace circuits that share wiring with the problem circuit. The names of circuits that share the same fuse, ground, or switch, and so on, are referred to in each circuit schematic. Try to operate any shared circuits you didn't check in step 1. If the shared circuits work, the shared wiring is OK, and the cause must be in the wiring used only by the problem circuit. If several circuits fail at the same time, the fuse or ground is a likely cause. Based on the symptoms and your understanding of the circuit's operation, identify one or more possible causes. 3. Isolate The Problem By Testing The Circuit Make circuit tests to check the diagnosis you made in step 2. Keep in mind that a logical, simple procedure is the key to efficient troubleshooting. Test for the most likely cause of failure first. Try to make tests at points that are easily accessible. 4. Fix The Problem Once the specific problem is identified, make the repair. Be sure to use proper tools and safe procedures. 5. Make Sure The Circuit Works Turn on all components in the repaired circuit in all modes to make sure you've fixed the entire problem. If the problem was a blown fuse, be sure to test all of the circuits on that fuse. Make sure no new problems turn up and the original problem does not recur. Page 7631 and the fuses. From Fuses to Relays and Components The second half of Power Distribution shows the wiring "From Fuses to Relays and Components." This can speed your troubleshooting by showing which circuits share fuses. If Power Distribution shows that an inoperative circuit and another circuit share a fuse, check a component in the other circuit. If it works, you know the fuse is good and power is available to the inoperative circuit. Ground Distribution Schematics Page 5280 Page 4688 Terminals - "T" Each "T" terminal (ring type) is numbered for reference and location. A "T" terminal is secured with a screw or bolt. Wires Page 4460 2. Connect one lead of a self-powered test light or DVOM to one end of the part of the circuit you want to test. 3. Connect the other lead to the other end. 4. If the self-powered test light glows, there is continuity. If you're using a DVOM, a low reading or no reading (zero), means good continuity. Testing For Voltage When testing for voltage at a connector without wire seals, you do not have to separate the two halves of the connector. Instead, probe the connector from the back. Always check both sides of the connector because dirty, corroded, and bent terminals can cause problems (no electrical contact = an open). 1. Connect one lead of the lest light to a known good ground, or, if you're using a digital volt ohmmeter (DVOM), place it in the appropriate DC volts range, and connect its negative lead to ground. 2. Connect the other lead of the test light or DVOM to the point you want to check. 3. If the test light glows, there is voltage present. If you're using a DVOM, note the voltage reading. It should be within one volt of measured battery voltage. A loss of more than one volt indicates a problem. NOTE: Always use a DVOM on high impedance circuits. A test light may not glow (even with battery voltage present). Testing For Voltage Drop Wires, connectors, and switches are designed to conduct current with a minimum loss of voltage. A voltage drop of more than one volt indicates a problem. 1. Place the digital volt/ohmmeter (DVOM) in the appropriate DC volts range. Connect the positive lead to the end of the wire (or to the connector or switch) closest to the battery. 2. Connect the negative lead to the other end of the wire (or the other side of the connector or switch). 3. Turn on the components in the circuit. 4. The DVOM will show the difference in voltage between the two points. A difference, or drop, of more than one volt indicates a problem. Check the circuit for loose, dirty, or bent terminals. A/T - Identifying Shift Solenoids Shift Solenoid: Technical Service Bulletins A/T - Identifying Shift Solenoids SOURCE: Honda Service News November 2003 TITLE: Identifying A/T Shift Solenoids APPLIES TO: 1994-02 Passport SERVICE TIP: If you've ever replaced the A/T shift solenoids in a 1994-02 Passport, you're probably aware that the S/M and parts catalog descriptions for the solenoids don't exactly match. Use this handy chart when ordering replacement solenoids: When installing these solenoids in the valve body, make sure you don't get them mixed up or install them in the wrong position. It's easy to do since these solenoids look almost identical. Fortunately, each solenoid has some of its part number engraved on its connector. Solenoid A has 593; solenoid B has 224. Page 7419 Testing For A Short With A Self-Powered Test Light or DVOM 1. Remove the blown fuse and disconnect the battery and load. 2. Connect one lead of a self-powered test light or digital volt/ohmmeter (DVOM) (switched to the lowest "OHMS" range) to the fuse terminal on the load side. 3. Connect the other lead to a known good ground. 4. Beginning near the fuse box, wiggle the harness. Continue this at convenient points about six inches apart while watching the test light or DVOM. 5. If the self-powered test light goes on or the DVOM displays a low reading or no reading (zero), there is a short to ground in the wiring near that point. Testing for a Short with a Test Light or DVOM 1. Remove the blown fuse and disconnect the load. 2. Connect a test light or digital volt/ohmmeter (DVOM), switched to the appropriate DC volts range, across the fuse terminals to make sure voltage is present. You might have to turn the ignition switch to ON; check the schematic to see. 3. Beginning near the fuse box, wiggle the harness. Continue this at convenient points about six inches apart while watching the test light or DVOM. 4. Where the test light goes , or the DVOM voltage drops to zero, there is a short to ground in the wiring near that point. NOTE: Always use a DVOM on high impedance circuits. A test light may not glow (even with battery voltage present). Testing For A Short With A Short Circuit Locator (Short Finder) 1. Remove the blown fuse. Leave the battery connected. Page 7035 Door Locks: Diagrams Front Door Lock Assembly Page 3348 Testing For A Short With A Self-Powered Test Light or DVOM 1. Remove the blown fuse and disconnect the battery and load. 2. Connect one lead of a self-powered test light or digital volt/ohmmeter (DVOM) (switched to the lowest "OHMS" range) to the fuse terminal on the load side. 3. Connect the other lead to a known good ground. 4. Beginning near the fuse box, wiggle the harness. Continue this at convenient points about six inches apart while watching the test light or DVOM. 5. If the self-powered test light goes on or the DVOM displays a low reading or no reading (zero), there is a short to ground in the wiring near that point. Testing for a Short with a Test Light or DVOM 1. Remove the blown fuse and disconnect the load. 2. Connect a test light or digital volt/ohmmeter (DVOM), switched to the appropriate DC volts range, across the fuse terminals to make sure voltage is present. You might have to turn the ignition switch to ON; check the schematic to see. 3. Beginning near the fuse box, wiggle the harness. Continue this at convenient points about six inches apart while watching the test light or DVOM. 4. Where the test light goes , or the DVOM voltage drops to zero, there is a short to ground in the wiring near that point. NOTE: Always use a DVOM on high impedance circuits. A test light may not glow (even with battery voltage present). Testing For A Short With A Short Circuit Locator (Short Finder) 1. Remove the blown fuse. Leave the battery connected. Removal and Installation Air Filter Element: Service and Repair Removal and Installation Air Cleaner Element REMOVAL 1. Remove positive ventilation hose connector (1). 2. Remove intake air temperature sensor (2). 3. Remove air flow sensor (3). 4. Remove air cleaner duct assembly (4). 5. Remove air cleaner element (5). INSTALLATION 1. Install air cleaner element (5). 2. Attach the mass air cleaner duct cover to the body completely, then clamp it with the clip (4). 3. Install air flow sensor (3). 4. Install air temperature sensor (2). 5. Install positive crankcase ventilation hose connector (1). Page 1962 Splices Splices are shown as a dot. Their location and the number of wires may vary depending on the harness manufacturer. Switches Switches These switches move together; the broken straight line between them means they are mechanically connected. Other types of switches are controlled by a coil or a solid state circuit. Unless otherwise noted, all switches are shown in their normal (rest) position, with power off. Terminal "T" Specifications Fuel Pressure: Specifications PRESSURE PRESSURE With Regulator Vacuume Hose Disconnected 42-55 Psi. Locations Main Relay (Computer/Fuel System): Locations 9. Fuse/Relay Box (Cover Removed) Fuse/Relay Box (Cover Removed) Page 3028 2. Connect the short finder across the battery terminals and the load (component) side of the fuse terminal. 3. Close all switches in the circuit you're testing. 4. Turn on the short finder. This creates a pulsing magnetic field around the wiring between the fuse box and the short. 5. Beginning at the fuse box, slowly move the short finder along the circuit wiring. The meter will read current pulses through sheet metal and body trim. As long as the meter is between the fuse and the short, the needle will move with each current pulse. Once you move the meter past the point of the short, the needle will stop moving. Check the wiring and connectors in this area to locate the cause of the short. Testing For Continuity When testing for continuity at a connector without wire seals, you do not have to separate the two halves of the connector. Instead, probe the connector from the back. Always check both sides of the connector because dirty, corroded, and bent terminals can cause problems (no electrical contact = an open). 1. Disconnect the negative cable from the car battery. If you're using a DVOM, place it in the lowest "OHMS" range. Service and Repair Fuel Gauge Sender: Service and Repair Removal and Installation As for removal and installation of the Fuel Gauge Unit, refer to "Fuel Tank" as the fuel gauge unit is combined with the fuel pump and sender assembly. Diagram Information and Instructions Ion Sensing Module: Diagram Information and Instructions How to Identify Wiring Color-Coded Insulation Wire Color Wire Color Coding Page 3485 Locations ECT Sensor Page 5425 NOTE: Do this repair procedure if, after doing step 10 of the test-drive, the vehicle pulled in the opposite direction after you swapped the front tires. 1. Swap wheels 2 and 4 on the passenger's side of the vehicle, and test-drive again. ^ If the pull goes away, replace the tire on wheel 2, then go to step 3. ^ If the pull does not go away, put wheels 2 and 4 back to their original positions, and go to step 2. 2. Swap wheels 1 and 3 on the driver's side of the vehicle, and test-drive again. ^ If the pull goes away, replace the tire on wheel 1, then go to step 3. ^ If the pull does not go away, use a known-good tire in position 1 and continue diagnosis. 3. Use your diagnosis worksheet to fill in the following table and build your 15-digit DTC. REPAIR PROCEDURE B Page 7436 The name of the component appears next to it followed by notes about its function along with any photo and connector view references. Connector "C" How to Identify Connector Terminals Cavity Numbering System The cavities (and wire terminals) in each connector are numbered starting from the upper left, looking at the male terminals from the terminal side (or looking at the female terminals from the wire side. Both views are in the same direction so the numbers are the same.) All actual cavities are numbered, even if they have no wire terminals in them. NOTE: Data Link Connector (DLC) terminals are numbered according to SAE standard J1962, not the Honda standard. The numbers of the four end terminals are molded into the corners of the connector face. Page 892 6. Place the end of the return hose in a container. Have someone start the engine, then pour ATF into the reservoir while you watch the fluid coming out of the return hose. When the fluid coming out is the same color as the new fluid, turn off the engine. 7. Reconnect the return hose to the reservoir. 8. Start the engine. Fill the power steering reservoir to the proper level with ATF then turn off the engine. 9. Use the Smart Cable to reprogram the PCM with the latest software from the June 2001 or later HONDANET CD-ROM. Refer to Service Bulletin 99-005, Updating the Passport PCM, filed under Tools. 10. Use the PGM Tester to clear any DTCs. 11. Use the PGM Tester to check the broadcast code. Make sure the broadcast code matches the one you selected from the CD-ROM. WARRANTY CLAIM INFORMATION In warranty: The normal warranty applies. Failed Part: P/N 8-97181-590-0 H/C 5698030 Defect Code: 064 Contention Code: C01 Skill Level: Repair Technician Out of warranty: Any repair performed after warranty expiration may be eligible for goodwill consideration by the District Service Manager or your Zone Office. You must request consideration, and get a decision, before starting work. REPAIR PROCEDURE - APPS GROUND 1. Unclamp the air cleaner housing cover, and move it to the side for access to connector C123 (16P BLK). Page 2866 3. Connect the electrical connector. 4. Fill the radiator with coolant. Refer to Draining and Refilling Cooling System. 5. Connect the negative battery cable. Specifications Axle Nut: Specifications 1. Tighten the hub nut to 29 Nm (22 lb. ft.), then fully loosen the nut. 2. Tighten the hub nut to the value given below, using a spring scale on the wheel pin. New Bearing and New Oil Seal Bearing Preload: 20 N - 25 N (4.4 lb. - 5.5 lb.) Used Bearing New Oil Seal Bearing Preload: 12 N - 18 N (2.6 lb. - 4.0 lb.) If the measured bearing preload is outside the specificatoins, adjust it by loosening or tightening the bearing nut. Page 8246 Windshield Washer Motor: Service and Repair Rear Washer Motor Removal 1. Disconnect the battery ground cable. 2. Remove the fender inner liner (right side). 3. Disconnect the windshield washer motor connector and the rear washer motor connector. 4. Disconnect the windshield washer hose connector and the rear washer hose connector. 5. Remove the filler neck (2). - Remove the bolt. 6. Remove the washer tank (1). - Remove the three nuts. 7. Pull the windshield washer motor (4) from the washer tank. Installation To install, follow the removal steps in the reverse order. Page 7836 Part 2 Of 2 Page 552 and the fuses. From Fuses to Relays and Components The second half of Power Distribution shows the wiring "From Fuses to Relays and Components." This can speed your troubleshooting by showing which circuits share fuses. If Power Distribution shows that an inoperative circuit and another circuit share a fuse, check a component in the other circuit. If it works, you know the fuse is good and power is available to the inoperative circuit. Ground Distribution Schematics Page 7093 Ground - "G" Shielding Sheilding This represents RFI (Radio Frequency Interference) shielding around a wire. The shielding is always connected to ground. Splices Page 7823 Ground - "G" Shielding Sheilding This represents RFI (Radio Frequency Interference) shielding around a wire. The shielding is always connected to ground. Splices Page 3594 Wire Color Abbreviations The following abbreviations are used to identify wire colors in the circuit schematics: WHT................................... White YEL................................... Yellow BLK................................... Black BLU................................... Blue GRN................................... Green RED................................... Red ORN................................... Orange PNK................................... Pink BRN................................... Brown GRY................................... Gray PUR................................... Purple LT BLU................................... Light Blue LT GRN................................... Light Green Locations Trailer Connector: Locations Left Rear of Cargo Compartment Left Rear of Cargo Compartment Below Left side of Rear Bumper Page 5163 Starter Motor: Description and Operation Cranking Circuit The cranking system consists of a battery, starter, starter switch, starter relay, etc. These main components are connected. Starter The cranking system employs a magnetic type reduction starter in which the motor shaft is also used as a pinion shaft. When the starter switch is turned Page 8074 This sample Ground Distribution schematic shows all of the components that share two ground points. Components A solid border line means the entire component is shown. A broken border line indicates that only part of the component is shown. Page 487 If there is no photo number below or beside a component name or a connector, ground, or terminal number, look up that name or number in the appropriate Connector Identification Chart. The chart lists how many cavities a connector has, where it's located, and what it connects to. The related illustration shows the connector's location on the harness, and the harness routing. NOTE: Photos listed by number are located at Locations / Components / Photograohs. See: Locations/Component Locations/Photographs Circuit Schematics Page 6220 7. Remove case (Temperature control) separate two halves of core case. 8. Remove heater core (1). 9. Pull out the mode door while raising up the catch of the door lever. Installation Page 7192 Sunroof / Moonroof Motor: Service and Repair Removal 1. Disconnect the battery ground cable. 2. Remove the headlining (2). 3. Remove the sunroof motor (1). - Disconnect the connector. - Remove three nuts and two screws. Installation To install, follow the removal steps in the reverse order. Diagram Information and Instructions HVAC Control Bezel: Diagram Information and Instructions How to Identify Wiring Color-Coded Insulation Wire Color Wire Color Coding Page 1118 Timing Belt: Service and Repair Timing Belt Installation THIS ARTICLE HAS BEEN UPDATED BY TSB 02-047 NOTE: - Do not install the timing belt until you are sure the camshafts, camshaft pulleys, and crankshaft timing pulley are in their correct "timed" positions. - Left and right engine callouts are from the driver's seat. 1. With the green direction arrows on the timing belt pointing clockwise, slip the belt over the right camshaft pulley so its solid white line (the line closest to the direction arrows) aligns with the mark on the pulley. Secure the belt to the pulley with a large binder clip. 2. Wrap the timing belt around the bottom of the water pump pulley, and draw it tight. 3. Slip the timing belt over the left camshaft pulley so its other solid white line (the one farthest from the direction arrows) aligns with the mark on the pulley. Secure the belt to the pulley with a large binder clip. 4. Wrap the timing belt around the inner side of the idler pulley, then slip the belt over the crankshaft timing pulley with its dotted white line aligned to the green mark on the crankshaft timing pulley. NOTE: For correct belt stretch, the doffed line must meet the green mark on the crankshaft timing pulley at the 9 o'clock position. If there isn't enough slack to slip the belt over the pulley in the correct position, turn the crankshaft a few degrees counterclockwise, install the belt, then turn the crankshaft back to the 9 o'clock position. Page 873 7. Loosen the inflator module fixing bolt from behind the steering wheel assembly using a TORE driver or equivalent until the inflator module can be released from steering assembly. 8. Disconnect the yellow 2-way SRS connector and horn lead located behind the inflator module. 9. Apply a setting mark (1) across the steering wheel and shaft so parts can be reassembled in their original position. Page 5296 This sample Ground Distribution schematic shows all of the components that share two ground points. Components A solid border line means the entire component is shown. A broken border line indicates that only part of the component is shown. Page 7029 10. Remove the lower quarter trim cover. - Disengage the clips from the body panel by twisting them free. 11. Remove the assist grips (1) (Front & Rear). - Open the both sides of the assist grip cover (2) and remove the fixing screws. 12. Remove the door seal finisher. 13. Remove the dome light. - Remove the dome light lens (2) and the fixing screws. - Disconnect the dome light connector. 14. Remove the rear roof bracket (Resin top model) or the soft top latch (Soft top model). 15. Remove the rear roof trim cover. 16. Remove the upper quarter trim cover. 17. Remove the front pillar trim cover. Installation To install, follow the removal steps in the reverse order, noting the following point. 1. Tighten the front and rear seat belt anchor bolts to the specified torque. Torque: 39 Nm (29 lb.ft) Locations Electronic Brake Control Module: Locations Right Rear Corner Of Engine Compartment Page 7959 2. Connect the short finder across the battery terminals and the load (component) side of the fuse terminal. 3. Close all switches in the circuit you're testing. 4. Turn on the short finder. This creates a pulsing magnetic field around the wiring between the fuse box and the short. 5. Beginning at the fuse box, slowly move the short finder along the circuit wiring. The meter will read current pulses through sheet metal and body trim. As long as the meter is between the fuse and the short, the needle will move with each current pulse. Once you move the meter past the point of the short, the needle will stop moving. Check the wiring and connectors in this area to locate the cause of the short. Testing For Continuity When testing for continuity at a connector without wire seals, you do not have to separate the two halves of the connector. Instead, probe the connector from the back. Always check both sides of the connector because dirty, corroded, and bent terminals can cause problems (no electrical contact = an open). 1. Disconnect the negative cable from the car battery. If you're using a DVOM, place it in the lowest "OHMS" range. Page 5319 Page 5990 This sample Ground Distribution schematic shows all of the components that share two ground points. Components A solid border line means the entire component is shown. A broken border line indicates that only part of the component is shown. Page 2771 The name of the component appears next to it followed by notes about its function along with any photo and connector view references. Connector "C" How to Identify Connector Terminals Cavity Numbering System The cavities (and wire terminals) in each connector are numbered starting from the upper left, looking at the male terminals from the terminal side (or looking at the female terminals from the wire side. Both views are in the same direction so the numbers are the same.) All actual cavities are numbered, even if they have no wire terminals in them. NOTE: Data Link Connector (DLC) terminals are numbered according to SAE standard J1962, not the Honda standard. The numbers of the four end terminals are molded into the corners of the connector face. Page 6164 - Use a back-up wrench when disconnecting and reconnecting the refrigerant lines. - When removing the refrigerant line connected part, the connecting part should immediately be plugged or capped to prevent foreign matter from being mixed into the line. 7. Remove evaporator assembly. Installation To install, follow the removal steps in the reverse order, noting the following points: 1. To install a new evaporator assembly, add 50cc (1.7 fl.oz.) of new compressor oil to the new core. 2. Tighten the refrigerant outlet line to the specified torque. Torque: 25 Nm (18 lb.ft) 3. Tighten the refrigerant inlet line to the specified torque. Torque: 15 Nm (11 lb.ft) 4. 0-rings cannot be reused. Always replace with new ones. 5. Be sure to apply new compressor oil to the O-ring when connecting lines. Page 3031 Vehicle Speed Sensor: Description and Operation Vehicle Speed Sensor (VSS) The PCM determines the speed of the vehicle by converting a plusing voltage signal from the vehicle speed sensor (VSS) into miles per hour. The PCM uses this signal to operate the cruise control, speedometer, and the TCC and shift solenoids in the transmission. For more information on the TCC and shift solenoids, refer to 4L30-E Automatic Transmission (Transmission Control System Diagnosis). How the Circuit Works The VSS generates a signal for the speedometer. The speedometer consists of its own speed sensor, an ammeter (to move the needle), stepper motor (to turn the odometer), and a driving circuit (printed circuit board). The VSS is mounted to the transmission. The transmission pinion shaft generates four pulses per one rotation. The rate at which the pulses are generated indicates the vehicle speed. The speed sensor in the speedometer uses the pulses to control how far and fast the needle moves and to send vehicle speed information (4096 pulses per mile) to the ECM or PCM. Tires - Tubless Tire Repair Information Tires: All Technical Service Bulletins Tires - Tubless Tire Repair Information 06-082 December 15, 2006 Applies To: ALL Tubeless Tire Repair Information This service bulletin provides the resource information required to repair tubeless tires on Honda automobiles and light trucks. To properly repair a tire, follow the Rubber Manufacturers Association (RMA) "Puncture Repair Procedures for Passenger and Light Truck Tires" outlined on the RMA wall poster. One wall poster has been provided to your dealership. Additional posters can be ordered through Helm, the RMA website, www.rma.org, or the tire manufacturers. Michelin(R) PAX System(TM), tires can be repaired using the same repair procedures described on the RMA poster. Whenever you repair a PAX System tire, you must inspect the support ring. Refer to the PAX System support ring section of this service bulletin for inspection procedures. WARRANTY CLAIM INFORMATION Refer to the tire manufacturer for warranty information. REQUIRED MATERIALS ^ 1/8 inch Patch-plug with lead wire ^ 1/4 inch Patch-plug with lead wire ^ 1/8 inch Plugs (stem)* ^ 1/4 inch Plugs (stem)* ^ 1/4 inch Patches* ^ 3/4 inch Patches* ^ Chemical cement ^ Liquid buffer ^ Rim-bead sealer ^ Inner liner sealer REQUIRED TOOLS ^ Tire stitcher, 1-1/2 inch wheel ^ Tire crayons ^ Tire test tank ^ Awl or probe ^ Flexible blade skiving knife ^ 1/8 inch Carbide tire tool with adapter ^ 1/4 inch Carbide tire tool with adapter ^ Low speed buffer with quick release chuck and exhaust hose ^ Carbide buffing wheel with adapter Page 1038 ^ If the wheels are pointed to the right, shorten the driver's side tie-rod, and lengthen the passenger's side. ^ If the wheels are pointed to the left, shorten the passenger's side tie-rod, and lengthen the driver's side. ^ Each 360° turn of the tie-rod equals about 8 mm of steering wheel adjustment. For example, a steering wheel is off-center by 4 mm with the front wheels pointed right (when the steering wheel is centered). To correct the off-center, shorten the driver's side tie-rod by a half-turn, and lengthen the passenger's side tie-rod by a half-turn. 4. Use your diagnosis worksheet to fill in the following table and build your 15-digit DTC. Page 5090 10. Move the front wheels to the straight ahead position, then use steering wheel remover J-29752 to remove the steering wheel CAUTION: Never apply force to the steering wheel in direction of the shaft by using a hammer or other impact tools in an attempt to remove the steering wheel. The steering shaft is designed as an energy absorbing unit. WARNING: THE INFLATOR MODULE SHOULD ALWAYS BE CARRIED WITH THE URETHANE COVER AWAY FROM YOUR BODY AND SHOULD ALWAYS BE LAID ON A FLAT SURFACE WITH THE URETHANE SIDE UP. THIS IS NECESSARY BECAUSE A FREE SPACE IS PROVIDED TO ALLOW THE AIR CUSHION TO EXPAND IN THE UNLIKELY EVENT OF ACCIDENTAL DEPLOYMENT. OTHERWISE. PERSONAL INJURY MAY RESULT. 11. .Remove steering column cover. 12. Disconnect the wiring harness connectors located under the steering column. 13. Remove the combination switch assembly with SRS coil. NOTE: The SRS coil is a part of the combination switch assembly, which can not be replaced separately. Therefore, be sure not to remove the SRS coil from the combination switch assembly. 14. Remove snap ring. 15. Remove cushion rubber. 16. Remove shift lock cable (for A/T). 17. Disconnect the starter switch harness connector located under the steering column, then remove lock cylinder assembly. Page 5931 2. Connect the short finder across the battery terminals and the load (component) side of the fuse terminal. 3. Close all switches in the circuit you're testing. 4. Turn on the short finder. This creates a pulsing magnetic field around the wiring between the fuse box and the short. 5. Beginning at the fuse box, slowly move the short finder along the circuit wiring. The meter will read current pulses through sheet metal and body trim. As long as the meter is between the fuse and the short, the needle will move with each current pulse. Once you move the meter past the point of the short, the needle will stop moving. Check the wiring and connectors in this area to locate the cause of the short. Testing For Continuity When testing for continuity at a connector without wire seals, you do not have to separate the two halves of the connector. Instead, probe the connector from the back. Always check both sides of the connector because dirty, corroded, and bent terminals can cause problems (no electrical contact = an open). 1. Disconnect the negative cable from the car battery. If you're using a DVOM, place it in the lowest "OHMS" range. Page 129 Test Equipment CAUTION: Most circuits include solid-state devices. Test the voltages in these circuits only with a 10-megaohm or higher impedance digital multimeter. Never use a test light or analog meter on circuits that contain solid-state devices. Damage to the devices may result. Test Light and DVOM On circuits without solid-state devices, use a test light to check for voltage. A test light is made up of a 12 volt bulb with a pair of leads attached. After grounding one lead, touch the other lead to various points along the circuit where voltage should be present. The bulb will go on if there is voltage at the point being tested. If you need to know how much voltage is present, use a digital volt/ohmmeter (DVOM). Self-Powered Test Light and DVOM Use a self-powered test light to check for continuity. This tool is made up of a light bulb, battery, and two leads. To test it, touch the leads together: the light should go on. Use a self-powered test light only on an unpowered circuit. First, disconnect the battery, or remove the fuse that feeds the circuit you are working on. Select two points in the circuit between which you want to check continuity. Connect one lead of the self-powered test light to each point. If there is continuity, the test light's circuit will be completed, and the light will go on. If, in addition, you need to know exactly how much resistance there is between two points, use a digital volt/ohmmeter (DVOM). In the "OHMS" range, the DVOM will measure resistance between two points along a circuit. Low resistance means good continuity. Diodes and solid-state devices in a circuit can make a DVOM give a false reading. To check a reading, reverse the leads, and take a second reading. If the readings differ, the component is affecting the measurement. Jumper Wire Use a jumper wire to bypass an open circuit. A jumper wire is made up of an in-line fuse holder connected to a set of test leads. It should have a five ampere fuse. Never connect a jumper wire across a short circuit. The direct battery short will blow the fuse. Short Finder (Short Circuit Locator) Short finders are available to locate shorts to ground. The short finder creates a pulsing magnetic field in the shorted circuit which you can follow to the location of the short. To order any test equipment shown above, contact your local tool supplier. For a list of suppliers and tool numbers, refer to Honda Required Special Tools and Equipment Service Bulletin. Page 6126 2. Connect one lead of a self-powered test light or DVOM to one end of the part of the circuit you want to test. 3. Connect the other lead to the other end. 4. If the self-powered test light glows, there is continuity. If you're using a DVOM, a low reading or no reading (zero), means good continuity. Testing For Voltage When testing for voltage at a connector without wire seals, you do not have to separate the two halves of the connector. Instead, probe the connector from the back. Always check both sides of the connector because dirty, corroded, and bent terminals can cause problems (no electrical contact = an open). 1. Connect one lead of the lest light to a known good ground, or, if you're using a digital volt ohmmeter (DVOM), place it in the appropriate DC volts range, and connect its negative lead to ground. 2. Connect the other lead of the test light or DVOM to the point you want to check. 3. If the test light glows, there is voltage present. If you're using a DVOM, note the voltage reading. It should be within one volt of measured battery voltage. A loss of more than one volt indicates a problem. NOTE: Always use a DVOM on high impedance circuits. A test light may not glow (even with battery voltage present). Testing For Voltage Drop Wires, connectors, and switches are designed to conduct current with a minimum loss of voltage. A voltage drop of more than one volt indicates a problem. 1. Place the digital volt/ohmmeter (DVOM) in the appropriate DC volts range. Connect the positive lead to the end of the wire (or to the connector or switch) closest to the battery. 2. Connect the negative lead to the other end of the wire (or the other side of the connector or switch). 3. Turn on the components in the circuit. 4. The DVOM will show the difference in voltage between the two points. A difference, or drop, of more than one volt indicates a problem. Check the circuit for loose, dirty, or bent terminals. Page 2026 - If the data list changes, the Fuel Pump Relay is normal. Page 3751 Part 3 Of 3 Component Locations Oxygen Sensor: Component Locations 95. Right Front Exhaust Downpipe Right Front Exhaust Downpipe 93. Left Front Exhaust Downpipe Left Front Exhaust Downpipe Page 6738 Splices Splices are shown as a dot. Their location and the number of wires may vary depending on the harness manufacturer. Switches Switches These switches move together; the broken straight line between them means they are mechanically connected. Other types of switches are controlled by a coil or a solid state circuit. Unless otherwise noted, all switches are shown in their normal (rest) position, with power off. Terminal "T" Page 917 Power Steering Pressure Switch: Locations 27. Left Side of Engine Left Side Of Engine Page 2937 4. Remove the fuel pressure regulator from the fuel rail. 5. Remove the fuel return line from the regulator. 6. Install the new fuel pressure regulator in the reverse order of removal. 7. Use the Smart Cable to reprogram the PCM with the latest software from the June 2001 or later HONDANET CD-ROM. Refer to Service Bulletin 99-005, Updating the Passport PCM, filed under Tools. 8. Use the PGM Tester to clear any DTCs. 9. Use the PGM Tester to check the broadcast code. Make sure the broadcast code matches the one you selected from the CD-ROM. WARRANTY CLAIM INFORMATION In warranty: The normal warranty applies. Failed Part: P/N 8-17113-398-0 H/C 5504386 Defect Code: 092 Contention Code: C99 Skill Level: Repair Technician Out of warranty: Any repair performed after warranty expiration may be eligible for goodwill consideration by the District Service Manager or your Zone Office. You must request consideration, and get a decision, before starting work. REPAIR PROCEDURE - POWER STEERING SWITCH 1. Drain the power steering fluid out of the system. 2. Remove the power steering fluid reservoir. Clean the reservoir with solvent, then with soap and water. Rinse and dry it thoroughly. 3. Reinstall the reservoir. Do not connect the return hose. 4. Remove the power steering pressure switch, then clean it with brake cleaner and a scraper. Reinstall the switch, and torque it to 20 N.m (14 lb-ft). 5. Cover the unconnected end of the reservoir with your finger, then fill the reservoir with Dexron III ATF Locations Main Relay (Computer/Fuel System): Locations 9. Fuse/Relay Box (Cover Removed) Fuse/Relay Box (Cover Removed) Page 3070 Canister Vent Valve: Testing and Inspection EVAP Canister Vent Solenoid 1. Check for cracks or leaks. 2. Energize the solenoid and try to blow through it. The solenoid should not allow passage of air when energized. (J 35616 Connector Test Kit can be used to easily attach jumper wires from the battery to the solenoid). Page 2776 Wires Wire insulation can be one color, or one color with another color stripe. (The second color is the stripe.) This circuit continues on another image. (The arrow shows direction of current flow.) To follow the RED/BLK wire in this example, you would turn to "Fuel and Emissions" and look for the "A" arrow. Locations Shift Interlock Solenoid: Locations Under Center Console Page 8071 Each schematic represents one circuit. A circuit's wires and components are arranged to show current flow, from power at the top of the page, to ground, at the bottom. Shared Circuits Other circuits may share power or ground terminals or wiring with the circuit shown. A wire that connects one circuit to another, for example, is cut short and has an arrowhead at the end of it pointing in the direction of current flow. Next to the arrowhead is the name of the circuit or component which shares that wiring. To quickly check shared wiring, check the operation of a component it serves. If that component works, you know the shared wiring is OK. Connectors All in-line and junction connectors are numbered (C725, C416, etc.). Component connectors are not numbered but are identified either by the name of Page 7520 This sample Ground Distribution schematic shows all of the components that share two ground points. Components A solid border line means the entire component is shown. A broken border line indicates that only part of the component is shown. Locations Shift Interlock Solenoid: Locations Under Center Console Page 5037 Page 2465 20. Using a DVOM, check the voltage between the reference voltage pin for each sensor and ground. ^ If the sensor circuits all read 5.0 volts, go to step 22. ^ If any sensor circuit is above or below 5.0 volts, go to step 21. 21. Troubleshoot for an internal short in another sensor or a PCM malfunction. ^ To find the sensor with an internal short, monitor the reference voltage, and disconnect each sensor (FTPS, EGR, MAP TPS, CKP and CMP) one at a time until the reference voltage reads 5.0 volts. Replace that sensor, and repeat step 14. ^ To find a malfunctioning PCM, replace it with a known-good PCM. If all three sensors (APP Sensor 1, APP Sensor 2, and APP Sensor 3) are within range, the original PCM is faulty; replace it and repeat step 14. 22. Using a jumper wire, connect the reference voltage of each circuit to its signal input, and view the APP Sensor values in the Engine Data List. APP Sensor 1 should have a value of 99%, and APP Sensor 2 and APP Sensor 3 should each have a value of 0%. ^ If the values are not as specified, troubleshoot for high resistance on the signal input or a PCM malfunction. Repair the circuit or replace the PCM, then repeat step 14. ^ If the values are as specified, the problem may be intermittent. Disconnect the 10 P connector from the modified APPS, and connect it to the new APPS; then repeat step 14. Wiggle the APPS wires as you go through the adjustment procedure to find the intermittent problem. 23. Install the accelerator pedal assembly, and torque the bolts to 10 N.m (7 lb-ft). Page 5881 Wheels: Description and Operation Replacement wheels or tires must be equivalent to the originals in load capacity, specified dimension and mounting configuration. Improper size or type may affect bearing life, brake performance, speedometer/odometer calibration, vehicle ground clearance and tire clearance to the body and chassis. All model are equipped with metric sized tubeless steel belted radial tires. Correct tire pressures and driving habits have an important influence on tire life. Heavy cornering, excessively rapid acceleration and unnecessary sharp braking increase premature and uneven wear. Page 7782 the component if the component only has one connector, or by a capital letter (A, B, C, etc.) if the component has more than one connector. Below most connector numbers and component names are PHOTO and VIEW numbers. The PHOTO number refers to a photo in the back of the book that shows the connector's location on the car. The VIEW number refers to an illustration in the back of the book that shows the connector face, wire colors, connector cavity numbers, and other details. The connector cavity numbering sequence begins at the top left corner of the connector. Disregard any numbers molded into the connector housing. Wires Wires are identified by the abbreviated names of their colors; the second color is the color of the stripe. Wires are also identified by their location in a connector. The number "2" next to the male and female wire terminals at C416, for example, means those terminals join in cavity 2 of connector C416. Symbols A complete description of schematic symbols is given under wire color abbreviation. Power Distribution Schematics Power Distribution schematics show how power is supplied from the positive battery terminal to various circuits in the car. Refer to the Power Distribution section to get a more detailed picture of how power is supplied to the circuit you're working on. From Battery to Ignition Switch, Fuses, and Relays Individual circuit schematics begin with a fuse. The first half of Power Distribution, however, shows the wiring "upstream" between the battery Electronic Hydraulic Control Unit and Associated Parts Component Locations Page 7092 The connector cavity number is listed next to each terminal on the circuit schematic. The cavity / terminal shown is # 6. Diodes A rectifier diode works like a one way valve. It allows current to flow only in the direction of the arrow. A Zener diode blocks reverse current at normal voltages just like a rectifier diode. At high voltages, however, a Zener diode allows current to flow in reverse. Fuses Page 753 Ground - "G" Shielding Sheilding This represents RFI (Radio Frequency Interference) shielding around a wire. The shielding is always connected to ground. Splices Page 7830 Dimmer Switch: Diagnostic Aids Before Troubleshooting Before Troubleshooting See: Service Precautions/Vehicle Damage Warnings/Tips and Precautions 1. Check applicable fuses in the appropriate fuse/relay box. 2. Check the battery for damage, state of charge, and clean and tight connections. CAUTION: Do not quick-charge a battery unless the battery ground cable has been disconnected, otherwise you will damage the alternator diodes. - Do not attempt to crank the engine with the battery ground cable loosely connected or you will severely damage the wiring. While You're Working 1. Make sure connectors are clean, and have no loose terminals or receptacles. 2. Make sure that connectors without wire seals are packed with dielectric (silicone) grease. Part Number: 08798-9001. 3. When connecting a connector, push it until it "clicks" into place. CAUTION: Do not pull on the wires when disconnecting a connector. Pull only on the connector housings. - Most circuits include solid-state devices. Test the voltages in these circuits only with a 10-megaohm or higher impedance digital multi meter. Never use a test light or analog meter on circuits that contain solid-state devices. Damage to the devices may result. Five-Step Troubleshooting 1. Verify The Complaint Turn on all the components in the problem circuit to check the accuracy of the customer complaint. Note the symptoms. Do not begin disassembly or testing until you have narrowed down the problem area. 2. Analyze The Schematic Look up the schematic for the problem circuit. Determine how the circuit is supposed to work by tracing the current paths from the power source through the circuit components to ground. Also, trace circuits that share wiring with the problem circuit. The names of circuits that share the same fuse, ground, or switch, and so on, are referred to in each circuit schematic. Try to operate any shared circuits you didn't check in step 1. If the shared circuits work, the shared wiring is OK, and the cause must be in the wiring used only by the problem circuit. If several circuits fail at the same time, the fuse or ground is a likely cause. Based on the symptoms and your understanding of the circuit's operation, identify one or more possible causes. 3. Isolate The Problem By Testing The Circuit Make circuit tests to check the diagnosis you made in step 2. Keep in mind that a logical, simple procedure is the key to efficient troubleshooting. Test for the most likely cause of failure first. Try to make tests at points that are easily accessible. 4. Fix The Problem Once the specific problem is identified, make the repair. Be sure to use proper tools and safe procedures. 5. Make Sure The Circuit Works Turn on all components in the repaired circuit in all modes to make sure you've fixed the entire problem. If the problem was a blown fuse, be sure to test all of the circuits on that fuse. Make sure no new problems turn up and the original problem does not recur. Page 4142 Clutch Slave Cylinder: Service and Repair Hydraulic System Bleed For further information regarding this component and the system that it is a part of, please refer to Clutch, M/T; Service and Repair; Hydraulic System Bleed. Page 6286 If there is no photo number below or beside a component name or a connector, ground, or terminal number, look up that name or number in the appropriate Connector Identification Chart. The chart lists how many cavities a connector has, where it's located, and what it connects to. The related illustration shows the connector's location on the harness, and the harness routing. NOTE: Photos listed by number are located at Locations / Components / Photograohs. See: Locations/Component Locations/Photographs Circuit Schematics Locations Manifold Pressure/Vacuum Sensor: Locations 24. Top Rear of Engine Top Rear Of Engine Diagrams Engine Hood Latch Page 3419 Fuel Pump Relay: Service and Repair REMOVAL PROCEDURE 1. Remove the fuse and relay box cover from under the hood. 2. Consult the diagram on the cover to determine which is the correct relay. 3. Insert a small screwdriver into the catch slot on the forward side of the fuel pump relay. 4. The screwdriver blade will release the catch inside. 5. Pull the relay straight up and out of the fuse and relay box. INSTALLATION PROCEDURE 1. Insert the relay into the correct place in the fuse and relay box with the catch slot facing forward. 2. Press down until the catch engages. - An audible "click" will be heard. Page 6818 2. Remove the power window switch/regulator handle. - Pry out the power window switch and remove the connectors. - To remove the regulator handle (1), remove the clip (2) at the root of the handle by using wire with hook. 3. Remove the screw while pulling the inside lever toward you and then remove the inside handle. 4. Remove the speaker grille (3). - Pull out the front side of the grille. Page 3357 it is located, and what it connects to. Use the Connector Views to help locate the proper cavity when you need to probe a connector. It can be especially helpful if the connector has more than one wire of the same color. A dash symbol (-) indicates that the cavity is empty. Connector views can also be used to help diagnose multiple symptoms in separate circuits which could be caused by a single problem in a connector shared by those circuits. Here's an example: 1. Pick one of the multiple symptoms and look up the schematic for that circuit. 2. Make a list of all the in-line and fuse box connectors in that schematic , 3. Then, in the Connector Views, look up each connector on your list to see if circuits related to the other symptoms run through one of them. If they do, inspect that connector for the problem. Example: The blower, rear window defogger, and the windshield wiper don't work. List all in-line and fuse box connectors in the blower controls circuit and then check the Connector View (see the sample). You find that C324 is common to the blower controls, rear window defogger, and wiper/washer, so you inspect C324 and find the problem, bent terminals. Finding Component/Connector Locations Finding Component/Connector Locations To see where a component or connector is located on the car, look up its photo number in the "Component Location". The photo will also tell you the color of the connector, and how many cavities it has. Page 5926 Wire Color Abbreviations The following abbreviations are used to identify wire colors in the circuit schematics: WHT................................... White YEL................................... Yellow BLK................................... Black BLU................................... Blue GRN................................... Green RED................................... Red ORN................................... Orange PNK................................... Pink BRN................................... Brown GRY................................... Gray PUR................................... Purple LT BLU................................... Light Blue LT GRN................................... Light Green Page 3410 Fuel Pump Relay: Diagnostic Aids Before Troubleshooting Before Troubleshooting See: Service Precautions/Vehicle Damage Warnings/Tips and Precautions 1. Check applicable fuses in the appropriate fuse/relay box. 2. Check the battery for damage, state of charge, and clean and tight connections. CAUTION: Do not quick-charge a battery unless the battery ground cable has been disconnected, otherwise you will damage the alternator diodes. - Do not attempt to crank the engine with the battery ground cable loosely connected or you will severely damage the wiring. While You're Working 1. Make sure connectors are clean, and have no loose terminals or receptacles. 2. Make sure that connectors without wire seals are packed with dielectric (silicone) grease. Part Number: 08798-9001. 3. When connecting a connector, push it until it "clicks" into place. CAUTION: Do not pull on the wires when disconnecting a connector. Pull only on the connector housings. - Most circuits include solid-state devices. Test the voltages in these circuits only with a 10-megaohm or higher impedance digital multi meter. Never use a test light or analog meter on circuits that contain solid-state devices. Damage to the devices may result. Five-Step Troubleshooting 1. Verify The Complaint Turn on all the components in the problem circuit to check the accuracy of the customer complaint. Note the symptoms. Do not begin disassembly or testing until you have narrowed down the problem area. 2. Analyze The Schematic Look up the schematic for the problem circuit. Determine how the circuit is supposed to work by tracing the current paths from the power source through the circuit components to ground. Also, trace circuits that share wiring with the problem circuit. The names of circuits that share the same fuse, ground, or switch, and so on, are referred to in each circuit schematic. Try to operate any shared circuits you didn't check in step 1. If the shared circuits work, the shared wiring is OK, and the cause must be in the wiring used only by the problem circuit. If several circuits fail at the same time, the fuse or ground is a likely cause. Based on the symptoms and your understanding of the circuit's operation, identify one or more possible causes. 3. Isolate The Problem By Testing The Circuit Make circuit tests to check the diagnosis you made in step 2. Keep in mind that a logical, simple procedure is the key to efficient troubleshooting. Test for the most likely cause of failure first. Try to make tests at points that are easily accessible. 4. Fix The Problem Once the specific problem is identified, make the repair. Be sure to use proper tools and safe procedures. 5. Make Sure The Circuit Works Turn on all components in the repaired circuit in all modes to make sure you've fixed the entire problem. If the problem was a blown fuse, be sure to test all of the circuits on that fuse. Make sure no new problems turn up and the original problem does not recur. Page 6030 Page 6384 Air Bag: Diagnostic Aids Before Troubleshooting Before Troubleshooting See: Service Precautions/Vehicle Damage Warnings/Tips and Precautions 1. Check applicable fuses in the appropriate fuse/relay box. 2. Check the battery for damage, state of charge, and clean and tight connections. CAUTION: Do not quick-charge a battery unless the battery ground cable has been disconnected, otherwise you will damage the alternator diodes. - Do not attempt to crank the engine with the battery ground cable loosely connected or you will severely damage the wiring. While You're Working 1. Make sure connectors are clean, and have no loose terminals or receptacles. 2. Make sure that connectors without wire seals are packed with dielectric (silicone) grease. Part Number: 08798-9001. 3. When connecting a connector, push it until it "clicks" into place. CAUTION: Do not pull on the wires when disconnecting a connector. Pull only on the connector housings. - Most circuits include solid-state devices. Test the voltages in these circuits only with a 10-megaohm or higher impedance digital multi meter. Never use a test light or analog meter on circuits that contain solid-state devices. Damage to the devices may result. Five-Step Troubleshooting 1. Verify The Complaint Turn on all the components in the problem circuit to check the accuracy of the customer complaint. Note the symptoms. Do not begin disassembly or testing until you have narrowed down the problem area. 2. Analyze The Schematic Look up the schematic for the problem circuit. Determine how the circuit is supposed to work by tracing the current paths from the power source through the circuit components to ground. Also, trace circuits that share wiring with the problem circuit. The names of circuits that share the same fuse, ground, or switch, and so on, are referred to in each circuit schematic. Try to operate any shared circuits you didn't check in step 1. If the shared circuits work, the shared wiring is OK, and the cause must be in the wiring used only by the problem circuit. If several circuits fail at the same time, the fuse or ground is a likely cause. Based on the symptoms and your understanding of the circuit's operation, identify one or more possible causes. 3. Isolate The Problem By Testing The Circuit Make circuit tests to check the diagnosis you made in step 2. Keep in mind that a logical, simple procedure is the key to efficient troubleshooting. Test for the most likely cause of failure first. Try to make tests at points that are easily accessible. 4. Fix The Problem Once the specific problem is identified, make the repair. Be sure to use proper tools and safe procedures. 5. Make Sure The Circuit Works Turn on all components in the repaired circuit in all modes to make sure you've fixed the entire problem. If the problem was a blown fuse, be sure to test all of the circuits on that fuse. Make sure no new problems turn up and the original problem does not recur. Diagrams Power Window Switch: Diagrams Page 6132 1. Adjust the control cable. - Temperature control cable. 1. Turn the control knob to the left ("MAX COLD" position). 2. Connect the control cable at the "COLD" position of the temperature control link of the heater unit and secure it with the clip. - Air select control cable 1. Turn the control knob to the right ("DEFROST" position). 2. Connect the control cable at the "DEFROST" position of the mode control link of the heater unit and secure it with the clip. 2. Check the control cable operation. Page 2683 The wire insulation has one color or one color with another color stripe. The second color is the stripe. Page 61 Ground - "G" Shielding Sheilding This represents RFI (Radio Frequency Interference) shielding around a wire. The shielding is always connected to ground. Splices Page 3858 5. Install magnet, main case oil pan with new gasket, and sixteen 10 mm screws. Tighten the screws to the specified torque. Torque: 11 Nm (96 Inch lbs.) 6. Fill transmission through the overfill screw hole of oil pan, using ATF DEXRON-III. 7. Connect battery ground cable. Technician Safety Information Air Bag Control Module: Technician Safety Information Service Precautions WARNING: DURING SERVICE PROCEDURES, BE VERY CAREFUL WHEN HANDLING SDM. NEVER STRIKE OR JAR SDM. UNDER SOME CIRCUMSTANCES, IT COULD CAUSE DEPLOYMENT AND RESULT IN PERSONAL INJURY OR IMPROPER OPERATION OF THE SUPPLEMENTAL RESTRAINT SYSTEM (SRS). SDM MOUNTING BRACKET BOLTS MUST BE CAREFULLY TORQUED TO ASSURE PROPER OPERATION. THE SRS SHOULD ONLY BE CONNECTED TO A POWER SOURCE WHEN IT IS INSTALLED SECURELY IN THE VEHICLE. THE SDM MAY SUDDENLY DEPLOY THE AIRBAGS CAUSING PERSONAL INJURY WARNING: PROPER OPERATION OF THE SENSING AND DIAGNOSTIC MODULE (SDM) REQUIRES THE SDM TO BE SECURELY INSTALLED ON THE VEHICLE AND THE ARROW ON THE SENSOR MUST BE POINTING TOWARD THE FRONT OF THE VEHICLE. SDM is specifically calibrated and is keyed to the SDM location SRS wiring harness. Caution should be used to ensure proper location of the SDM. The keying of the SDM to its location and wiring harness connectors should never be modified in the field. Be careful not to bump or impact the SRS unit or the side impact sensors whenever the ignition switch is ON (II), or at least for three minutes after the ignition switch is turned OFF. During installation or replacement, be careful not to bump (by impact wrench, hammer, etc.) the area around the SRS unit and the side impact sensor. The airbags could accidentally deploy and cause damage or injury. After a collision in which the airbags were deployed, replace the SRS unit. After a collision in which the side airbag was deployed, replace the side impact sensor on the side where the side airbag deployed and the SRS unit. After a collision in which the airbags or the side airbags did not deploy, inspect for any damage or any deformation on the SRS unit and the side impact sensors. If there is any damage, replace the SRS unit and/or the side impact sensors. Do not disassemble the SRS unit or the side impact sensors. Turn the ignition switch OFF, disconnect the battery negative cable and wait at least three minutes before beginning installation or replacement of the SRS unit, and disconnect the connectors from the SRS unit. Be sure the SRS unit and side impact sensors are installed securely with the mounting bolts torqued to 9.8 Nm (1.0 kg.m, 7.2 lb.ft) Do not spill water or oil on the SRS unit or the side impact sensors and keep them away from dust. Store the SRS unit and the side impact sensors in a cool (less than 104°F / 40°C) and dry (less than 80% relative humidity, no moisture) area. Interior - Fabric Upholstery Wrinkle Information Seat Cover: Technical Service Bulletins Interior - Fabric Upholstery Wrinkle Information Use a Steamer to Smooth Out Fabric Upholstery A garment steamer and a stiff-bristle brush make a great team for removing those nasty wrinkles, lines, or impressions in fabric upholstery. You can buy an inexpensive, small, hand-held garment/ fabric steamer from a number of different manufacturers. Some of these units even come with a handy built-in brush. Once you've got your steamer, follow the manufacturer's instructions to get it ready for use. Then apply a generous amount of steam to the problem area. Keep the steamer moving slowly over the area until it's hot and moist. A Word of Caution: Go easy on the steam if you're cleaning the front passenger seat in a vehicle with side airbags. Moisture can adversely affect or damage the OPDS sensors in the seatback. While the area is hot and moist, use a stiff-bristle brush, or the built-in brush if your steamer has one, to work the fabric back and forth and up and down. Stubborn areas might need more steam and brushing, so be patient and stay with it. It's worth the effort. Locations Camshaft Position Sensor Page 582 Disclaimer Repair Procedure 1. Unclamp the air cleaner housing cover, and move it to the side for access to connector C123 (16P BLK). 2. Unfasten C123 from the side of the engine compartment using a 90-degree pick. 3. Disconnect C123, and clean the terminals on both sides of the connector with contact cleaner. Shake the residue out of the connector. Allow the contact cleaner to evaporate for at least 3 minutes, then reconnect C123. 4. Fasten C123 to the left side of the engine compartment, then reinstall the air cleaner housing cover. 5. While supporting the accelerator pedal assembly, remove the two bolts that secure the assembly to the bulkhead. Carefully lower the assembly to gain access to the connector. Page 5261 ^ If the idle speed ever exceeds 1,300 rpm 2. Remove the vacuum hose from the fuel pressure regulator, then start the engine. ^ If fuel comes out of the fuel pressure regulator vacuum hose connection, go to REPAIR PROCEDURE FUEL PRESSURE REGULATOR. ^ If no fuel comes out of the regulator, reconnect the vacuum hose and continue to step 3. 3. Connect the PGM Tester. Set it to Engine Data List. 4. Have an assistant drive the vehicle under the conditions described by the customer. 5. If the high or erratic idle condition occurs, note the values of the PSP Switch and APP Sensor 1 when it is occurring. ^ If the PSP Switch is HIGH, and you are not turning, go to REPAIR PROCEDURE POWER STEERING SWITCH. ^ If the APP Sensor 1 is greater than 15% and APP Sensor 2 and/or APP Sensor 3 are less than 85%, and the accelerator pedal is not depressed, go to REPAIR PROCEDURE APPS GROUND. ^ If the PSP Switch is reading LOW when not turning and HIGH when turning, and the APP Sensors are reading within the range shown, discontinue the test-drive and go to step 6. 6. Do these repairs: ^ REPAIR PROCEDURE APPS GROUND ^ REPAIR PROCEDURE ENGINE/BODY GROUND REPAIR PROCEDURE - FUEL PRESSURE REGULATOR 1. Relieve fuel system pressure: ^ Remove the fuel fill cap. ^ Remove the fuel pump relay. ^ Start the engine and run it until it stalls. ^ Crank the engine for 3 seconds. 2. Remove the vacuum hose from the fuel pressure regulator. 3. Remove the fuel pressure regulator shield from the common chamber (two bolts). Page 1438 8. Remove the bolts used to hold the preload of the camshaft subgears. 9. If not already done, inspect the camshaft thrust clearances. If any clearances are not within specification, replace the cylinder head(s). Page 2678 Splices Splices are shown as a dot. Their location and the number of wires may vary depending on the harness manufacturer. Switches Switches These switches move together; the broken straight line between them means they are mechanically connected. Other types of switches are controlled by a coil or a solid state circuit. Unless otherwise noted, all switches are shown in their normal (rest) position, with power off. Terminal "T" Page 4546 Each schematic represents one circuit. A circuit's wires and components are arranged to show current flow, from power at the top of the page, to ground, at the bottom. Shared Circuits Other circuits may share power or ground terminals or wiring with the circuit shown. A wire that connects one circuit to another, for example, is cut short and has an arrowhead at the end of it pointing in the direction of current flow. Next to the arrowhead is the name of the circuit or component which shares that wiring. To quickly check shared wiring, check the operation of a component it serves. If that component works, you know the shared wiring is OK. Connectors All in-line and junction connectors are numbered (C725, C416, etc.). Component connectors are not numbered but are identified either by the name of Page 2797 - Engine Coolant Temperature - Crankshaft Position - Exhaust Oxygen Content - Electronic Ignition - Manifold Absolute Pressure - Battery Voltage - Throttle Position - Vehicle Speed - Fuel Pump Voltage - Power Steering Pressure - Intake Air Temperature - Mass Air Flow - Engine knock - Camshaft Position Outputs - Systems Controlled - EVAP Canister Purge - Exhaust Gas Recirculation (EGR) - Ignition Control - Fuel Control - ION Sensing Module - Electric Fuel Pump - Air Conditioning - Diagnostics Malfunction Indicator Lamp - Data Link Connector (DLC) - Data Output - Transmission Control Module PCM Voltage Description PCM Voltage Description The PCM supplies a buffered voltage to various switches and sensors. It can do this because resistance in the PCM is so high in value that a test light may not illuminate when connected to the circuit. An ordinary shop voltmeter may not give an accurate reading because the voltmeter input impedance is too low. Use a 10 megohms input impedance digital voltmeter (such as J 39200) to assure accurate voltage readings. The input/output devices in the PCM include analog-to-digital converters, signal buffers, counters, and special drivers. The PCM controls most components with electronic switches which complete a ground circuit when turned "ON." These switches are arranged in groups of 4 and 7, called either a surface-mounted quad driver module (QDM), which can independently control up to 4 output terminals, or QDMs which can independently control up to 7 outputs. Not all outputs are always used. Powertrain Control Module (PCM) Powertrain Control Module (PCM) The powertrain control module (PCM) is located in the passenger compartment below the center console. The PCM controls the following: - Fuel metering system. - Transmission shifting (automatic transmission only). - Ignition timing. - On-board diagnostics for powertrain functions. The PCM constantly observes the information from various sensors. The PCM controls the systems that affect vehicle performance. The PCM performs the diagnostic function of the system. It can recognize operational problems, alert the driver through the MIL (Check Engine lamp), and store diagnostic trouble codes (DTCs). DTCs identify the problem areas to aid the technician in making repairs. 58X Reference PCM Input 58X Reference PCM Input The powertrain control module (PCM) uses this signal from the crankshaft position (CKP) sensor to calculate engine RPM and crankshaft position at all engine speeds. The PCM also uses the pulses on this circuit to initiate injector pulses. If the PCM receives no pulses on this circuit, DTC P0337 will set. The engine will not start and run without using the 58X reference signal. Page 6245 Refrigerant: Service and Repair System Charging There are various methods of charging refrigerant into the air conditioning system. These include using J-39500 (ACR(4):HFC-134a Refrigerant Recovery / Recycling / Recharging / System) or equivalent and direct charging with a weight scale charging station. Charging Procedure - ACR(4)(or equivalent) Method For the charging of refrigerant recovered by ACR(4)(or equivalent), follow the manufacturer's instruction. - Direct charging with a weight scale charging station method 1. Make sure the evacuation process is correctly completed. 2. Connect the center hose of the manifold gauge to the weight scale. 3. Connect the low pressure charging hose of the manifold gauge to the low pressure side service valve of the vehicle. Page 2220 If there is no photo number below or beside a component name or a connector, ground, or terminal number, look up that name or number in the appropriate Connector Identification Chart. The chart lists how many cavities a connector has, where it's located, and what it connects to. The related illustration shows the connector's location on the harness, and the harness routing. NOTE: Photos listed by number are located at Locations / Components / Photograohs. See: Locations/Component Locations/Photographs Circuit Schematics Page 3943 3. Start the engine, and let it warm up to normal operating temperature. 4. Move the selector lever through all shift positions, then apply the brakes, and move the lever to Park. 5. Check the drain plug and fill plug for signs of leakage. ^ If you see signs of leakage, turn off the engine. Remove and discard both plugs and gaskets. Let the oil pan drain completely, then install the new drain plug. Torque the drain plug to 38 N.m (28 lb-ft). Add DEXRON III ATF until it runs out the fill hole. Install the new fill plug hand tight. Go to step 6. ^ If you do not see signs of leakage, look for other possible causes of the leak. 6. Connect the PGM Tester to the 16P data link connector to measure ATF temperature. Start the engine. 7. Remove the fill plug, and add ATF until it runs out the fill hole. Reinstall the fill plug. 8. Move the selector lever through all shift positions, then apply the brakes, and move the lever to Park. 9. Remove the fill plug. 10. Let the engine idle until the ATF temperature is between 90° and 135° F (32° and 57° C). As the temperature increases, ATF drips out the fill hole until the correct fluid level is reached. 11. Reinstall the fill plug. Torque the fill plug to 38 N.m (28 lb-ft). 12. Turn off the engine, and disconnect the PGM Tester. Lower the vehicle. DISCLAIMER Locations Page 586 24. Verify APP Sensor 1 is between 11 and 15 percent, and APP Sensor 2 and APP Sensor 3 are between 89 and 85 percent with the pedal up (closed throttle). If not, loosen the mounting screws on the APPS sensor, and go to step 14. 25. Clear all DTCs with the PGM Tester. 26. Turn off the ignition switch, and disconnect the PGM Tester. Page 112 Distinct Of Circuit By Wire Base Color All wires have color-coded insulation. Wires belonging to a system's main harness will have a single color. Wires belonging to a system's sub-circuits will have a colored stripe. Striped wires use the codes found in the chart to show wire size and colors. Abbreviations are used to indicate wire color within a circuit diagram. How to Identify Connector Terminals How to Identify Connector Terminals Cavity Numbering System The cavities (and wire terminals) in each connector are numbered starting from the upper left, looking at the male terminals from the terminal side (or looking at the female terminals from the wire side. Both views are in the same direction so the numbers are the same.) All actual cavities are numbered, even if they have no wire terminals in them. NOTE: Data Link Connector (DLC) terminals are numbered according to SAE standard J1962, not the Honda standard. The numbers of the four end terminals are molded into the corners of the connector face. The connector cavity number is listed next to each terminal on the circuit schematic. The cavity / terminal shown is # 6. Using/Identifying Connector Terminal Views How to Use Connector Terminal Views To see the configuration of a connector's cavities, look up its view number in the Connector Views. Each view includes the color of the connector, where Page 1371 Premature Wear In Shoulders 1. Flexing of tire excessive due to under-inflation. One Sided Feather Edging 1. Wear caused by repeated hard cornering. 2. Camber or toe-in incorrect. Page 3593 This means the branch of the wire connects to another circuit. The arrow points to the name of the circuit branch where the wire continues. Technician Safety Information Brake Fluid: Technician Safety Information SAFETY PRECAUTIONS WARNING: Brake fluid may be irritating to the skin or eyes. In case of contact, take the following actions: * Eye Contact - rinse eyes thoroughly with water. * Skin Contact - wash skin with soap and water. Locations Timing Marks and Indicators: Locations IGNITION IS NOT ADJUSTABLE Ignition timing is done by the electronic ignition (EI) that directly fires the spark plugs from ignition coils through spark plug wires without using a distributor. A pair of ignition coils for the cylinders having different phases by 36O° (No.1 and No.4,No.2 and No.5,No.3 and No.6) are fired simultaneously. Since the cylinder on exhaust stroke requires less energy to fire its ignition plug, energy from the ignition coils can be utilized to fire the mating cylinder on compression stroke. After additional 36O° rotation, respective cylinder strokes are reversed. The EI consists of six ignition coils,ignition control module, crank angle sensor, powertrain control module (PCM) and other components. The ignition coils are connected with the PCM by means of a 32 pin connector. The ignition control module turns on/off the primary circuit of ignition coils, and also it controls the ignition timing at the engine speed below 538 rpm. A notch in the timing disc on the crankshaft activates the crank angle sensor which then sends information such as firing order and starting timing of each ignition coil to the PCM. Further, the EI employs ignition control (IC) to control similar to a distributor system. By receiving signals such as crank position,engine speed, water temperature and Manifold Absolute Pressure (MAP), the PCM controls the ignition timing. Page 7394 2. Connect one lead of a self-powered test light or DVOM to one end of the part of the circuit you want to test. 3. Connect the other lead to the other end. 4. If the self-powered test light glows, there is continuity. If you're using a DVOM, a low reading or no reading (zero), means good continuity. Testing For Voltage When testing for voltage at a connector without wire seals, you do not have to separate the two halves of the connector. Instead, probe the connector from the back. Always check both sides of the connector because dirty, corroded, and bent terminals can cause problems (no electrical contact = an open). 1. Connect one lead of the lest light to a known good ground, or, if you're using a digital volt ohmmeter (DVOM), place it in the appropriate DC volts range, and connect its negative lead to ground. 2. Connect the other lead of the test light or DVOM to the point you want to check. 3. If the test light glows, there is voltage present. If you're using a DVOM, note the voltage reading. It should be within one volt of measured battery voltage. A loss of more than one volt indicates a problem. NOTE: Always use a DVOM on high impedance circuits. A test light may not glow (even with battery voltage present). Testing For Voltage Drop Wires, connectors, and switches are designed to conduct current with a minimum loss of voltage. A voltage drop of more than one volt indicates a problem. 1. Place the digital volt/ohmmeter (DVOM) in the appropriate DC volts range. Connect the positive lead to the end of the wire (or to the connector or switch) closest to the battery. 2. Connect the negative lead to the other end of the wire (or the other side of the connector or switch). 3. Turn on the components in the circuit. 4. The DVOM will show the difference in voltage between the two points. A difference, or drop, of more than one volt indicates a problem. Check the circuit for loose, dirty, or bent terminals. Removal and Installation Air Filter Element: Service and Repair Removal and Installation Air Cleaner Element REMOVAL 1. Remove positive ventilation hose connector (1). 2. Remove intake air temperature sensor (2). 3. Remove air flow sensor (3). 4. Remove air cleaner duct assembly (4). 5. Remove air cleaner element (5). INSTALLATION 1. Install air cleaner element (5). 2. Attach the mass air cleaner duct cover to the body completely, then clamp it with the clip (4). 3. Install air flow sensor (3). 4. Install air temperature sensor (2). 5. Install positive crankcase ventilation hose connector (1). Page 3216 The wire insulation has one color or one color with another color stripe. The second color is the stripe. Page 1388 9. Use wrench J-36827, remove hub nut. 10. Remove hub and disc assembly. 11. Remove ABS sensor ring. 12. Remove outer bearing. 13. Remove oil seal. 14. Remove inner bearing. 15. Remove bolt, if necessary, replace the wheel pin in the following manner. - Apply a scribe mark (1) to disc to hub. - Clamp the hub and disc assembly in a vise, using protective pads. Remove the 6 disc-to-hub retaining bolts. - Place hub on a suitable work surface and remove the studs by using a hammer. INSPECTION AND REPAIR Make necessary correction or parts replacement if wear, damage, corrosion or any other abnormal condition are found through inspection. Check the following parts. Hub - Hub bearing oil seal - Knuckle spindle Brakes - Revised Brake Bleeding Procedure Brake Bleeding: By Symptom Brakes - Revised Brake Bleeding Procedure 01-016 January 30, 2001 Applies To: 1998-01 Passport - ALL Service Manual Update: Revised Brake Bleeding Procedure BACKGROUND The brake bleeding procedure in the 1998 thru 2001 Passport Service Manuals is incomplete. Use this service bulletin to update the manuals. WARRANTY INFORMATION None. CORRECTIVE ACTION 1. In the 1998, 1999, 2000, and 2001 Passport Service Manuals, on pages 5A-21 and 5A-22, cross out the entire Tech 2 Service Bleed procedure. 2. In each manual, on page 5A-21, write this note: See page 5C-10 for the brake bleeding procedure 3. In each manual, on page 5C-10, between steps 1 and 2, write this note: For important additional information, see Service Bulletin 01-016, Service Manual Update: Revised Brake Bleeding Procedure, Filed under Brakes. SERVICE MANUAL UPDATE INFORMATION To avoid trapping air bubbles in the ABS hydraulic unit while bleeding the brakes, the hydraulic unit must be tilted forward at a 15-degree angle or greater. Before bleeding, check the angle of the ABS hydraulic unit with an angle locator level. If needed, raise the rear of the vehicle to get the proper Page 3020 Terminals - "T" Each "T" terminal (ring type) is numbered for reference and location. A "T" terminal is secured with a screw or bolt. Wires Page 6400 10. Place a power source near the shorted end of the SRS deployment harness. Recommended application: 12 volts minimum, 2 amps minimum. A vehicle battery is suggested. 11. Connect the driver air bag assembly to the pigtail adapter on the Supplemental Restraint System (SRS) deployment harness. Deployment harness shall remain shorted and not be connected to a power source until the air bag is to be deployed. The driver air bag assembly will immediately deploy the air bag when a power source is connected to it. NOTE: Ensure that the pigtail adapter is firmly seated into the driver air bag assembly connector. Failure to fully seat the connectors may leave the shorting bar located in the driver air bag assembly connector functioning (shorted) and may result in non deployment of the driver air bag assembly. 12. Verify that the area around the driver air bag assembly is clear of all people and loose or flammable objects. 13. Verify that the driver air bag assembly is firmly and properly in J-41434. 14. Notify all people in the immediate area that you intend to deploy the driver air bag. The deployment will be accompanied by a substantial noise which may startle the uninformed. 15. Separate the two banana plugs on the SRS deployment harness. NOTE: When the air bag deploys, the rapid gas expansion will create a substantial noise. Notify all people in the immediate area that you intend to deploy the driver air bag. WARNING: DEPLOYMENT HARNESS SHALL REMAIN SHORTED AND NOT BE CONNECTED TO A POWER SOURCE UNTIL THE AIR BAG IS TO BE DEPLOYED. THE AIR BAG ASSEMBLY WILL IMMEDIATELY DEPLOY THE AIR BAG WHEN A POWER SOURCE IS CONNECTED TO IT. CONNECTING THE DEPLOYMENT HARNESS TO THE POWER SOURCE SHOULD ALWAYS BE THE LAST STEP IN THE AIR BAG ASSEMBLY DEPLOYMENT PROCEDURE. FAILURE TO FOLLOW PROCEDURES IN THE ORDER LISTED MAY RESULT IN PERSONAL INJURY. 16. Connect the Supplemental Restraint System (SRS) deployment harness wires to the power source to immediately deploy the driver air bag. Recommended application: 12 volts minimum, 2 amps minimum. A vehicle battery is suggested. 17. Disconnect the SRS deployment harness from the power source. 18. Short the two SRS deployment harness leads together by fully seating one banana plug into the other. 19. In the unlikely event that the driver air bag assembly did not deploy after following these procedures, proceed immediately with Steps 24 through 26. If the driver air bag assembly did deploy, proceed with Steps 20 through 23. 20. Put on a pair of shop gloves and safety glasses to protect your hands and eyes from possible irritation and heat when handling the deployed driver air bag assembly. After the air bag assembly has been deployed, the surface of the air bag may contain solid particulate. This solid particulate consists primarily of by products of the chemical reaction, Potassium Chloride and copper metal dust. Compounds of Potassium Borate, Strontium Chloride, Copper Chloride, and Ammonium Chloride may be found in amounts of about 1 % (each) of the total particulate. WARNING: SAFETY PRECAUTIONS MUST BE OBSERVED WHEN HANDING A DEPLOYED AIR BAG ASSEMBLY. AFTER DEPLOYMENT, THE METAL SURFACES OF THE AIR BAG ASSEMBLY WILL BE VERY HOT. ALLOW THE INFLATOR MODULE TO COOL BEFORE HANDLING ANY METAL PORTION OF IT. DO NOT PLACE THE DEPLOYED AIR BAG ASSEMBLY NEAR ANY FLAMMABLE OBJECTS. FAILURE TO FOLLOW PROCEDURES MAY RESULT IN FIRE OR PERSONAL INJURY. AFTER A DRIVER AIR BAG ASSEMBLY HAS BEEN DEPLOYED, THE METAL CANISTER AND Page 7873 it is located, and what it connects to. Use the Connector Views to help locate the proper cavity when you need to probe a connector. It can be especially helpful if the connector has more than one wire of the same color. A dash symbol (-) indicates that the cavity is empty. Connector views can also be used to help diagnose multiple symptoms in separate circuits which could be caused by a single problem in a connector shared by those circuits. Here's an example: 1. Pick one of the multiple symptoms and look up the schematic for that circuit. 2. Make a list of all the in-line and fuse box connectors in that schematic , 3. Then, in the Connector Views, look up each connector on your list to see if circuits related to the other symptoms run through one of them. If they do, inspect that connector for the problem. Example: The blower, rear window defogger, and the windshield wiper don't work. List all in-line and fuse box connectors in the blower controls circuit and then check the Connector View (see the sample). You find that C324 is common to the blower controls, rear window defogger, and wiper/washer, so you inspect C324 and find the problem, bent terminals. Finding Component/Connector Locations Finding Component/Connector Locations To see where a component or connector is located on the car, look up its photo number in the "Component Location". The photo will also tell you the color of the connector, and how many cavities it has. Page 265 Splices Splices are shown as a dot. Their location and the number of wires may vary depending on the harness manufacturer. Switches Switches These switches move together; the broken straight line between them means they are mechanically connected. Other types of switches are controlled by a coil or a solid state circuit. Unless otherwise noted, all switches are shown in their normal (rest) position, with power off. Terminal "T" Page 529 Page 4787 Interior - Rear Beverage Holder Swing Arm Won't Lock Drink Holders: All Technical Service Bulletins Interior - Rear Beverage Holder Swing Arm Won't Lock 02-022 April 9, 2002 Applies To: 1999-02 Passport - ALL Rear Beverage Holder Swing Arm Does Not Lock SYMPTOM The rear beverage holder swing arm does not firmly stay in an open or closed position because the detents do not hold. PROBABLE CAUSE One or both metal detent clips are out of place or missing. CORRECTIVE ACTION Replace both detent clips. PARTS INFORMATION Rear Beverage Holder Detent Clip (two required): P/N 8-97212-275-0, H/C 7084197 WARRANTY CLAIM INFORMATION In warranty: The normal warranty applies. Operation Number: 044104 Flat Rate Time: 0.3 hour Failed Part: P/N 8-97292-133-3 H/C 6193379 Defect Code: 030 Contention Code: B02 Template ID: 02-022A Skill Level: Repair Technician Out of warranty: Any repair performed after warranty expiration may be eligible for goodwill consideration by the District Service Manager or your Zone Office. You must request consideration, and get a decision, before starting work. REPAIR PROCEDURE Engine Controls - Engine Stalls After Cold Start PROM - Programmable Read Only Memory: All Technical Service Bulletins Engine Controls Engine Stalls After Cold Start 01-015 May 8, 2001 Applies To: 2000 Passport - ALL 2001 Passport - From VIN 4S6..58W.14400001 thru 4S6..58W.14409430 Engine Stalls After a Cold Start SYMPTOM After a cold start, the engine occasionally stalls when you shift from Neutral or Park to any gear. PROBABLE CAUSE The PCM software delays the idle speed changes needed during cold start conditions. CORRECTIVE ACTION Update the PCM software with the Smart Cable. TOOL INFORMATION PGM Tester loaded with SN131 (04/16/01) or later software. For other tools and equipment needed to update the PCM software, refer to Service Bulletin 99-005, Updating the Passport PCM, filed under Tools. WARRANTY CLAIM INFORMATION In warranty: The normal warranty applies. Operation Number: 122305 Flat Rate Time: 0.3 hour Failed Part: P/N 8-09392-189-0 H/C 6392971 Defect Code: 093 Contention Code: C05 Template ID: 01-015A Skill Level: Repair Technician Out of warranty: Any repair performed after warranty expiration may be eligible for goodwill consideration by the District Service Manager or your Zone Office. You must request consideration, and get a decision, before starting work. REPAIR PROCEDURE 1. Retrieve the PCM broadcast code with the PGM Tester. (From the MISC TESTS menu, select BROADCAST CODE). Page 3000 c. Remove mode switch connector with bracket from the transmission case. d. Connect multimeter (resistance mode) to terminals 1(E) and 4(H) on mode switch connector. e. Loosen two mounting screws. f. Rotate mode switch slightly in both directions to determine the range (approx. 5 degrees) of electrical contact. g. Position mode switch in middle of contact range. h. Tighten two mounting screws. i. Remove multimeter and install mode switch harness connector with bracket to the transmission case. j. Connect transmission harness connector to mode switch connector. Mechanical Specifications Page 6257 Refrigerant Oil: Service and Repair Compressor Oil Check Compressor Oil Check The oil used to lubricate the compressor is circulating with the refrigerant. Whenever replacing any component of the system or a large amount of gas leakage occurs, add oil to maintain the original amount of oil. Oil Capacity Capacity total in system: 150 cc (5.0 fl.oz) Compressor (Service parts) charging amount: 150 cc (5.0 fl.oz) Page 443 Refrigerant Pressure Sensor / Switch: Testing and Inspection Triple Pressure Switch 1. Disconnect the connector and check for continuity between pressure switch side connector terminals (1) and (2). 2. Reconnect the connector to activate the A/C switch and check to see if there is continuity between the chassis side connector terminals (3) and (4) and the fan operates. Page 116 the component if the component only has one connector, or by a capital letter (A, B, C, etc.) if the component has more than one connector. Below most connector numbers and component names are PHOTO and VIEW numbers. The PHOTO number refers to a photo in the back of the book that shows the connector's location on the car. The VIEW number refers to an illustration in the back of the book that shows the connector face, wire colors, connector cavity numbers, and other details. The connector cavity numbering sequence begins at the top left corner of the connector. Disregard any numbers molded into the connector housing. Wires Wires are identified by the abbreviated names of their colors; the second color is the color of the stripe. Wires are also identified by their location in a connector. The number "2" next to the male and female wire terminals at C416, for example, means those terminals join in cavity 2 of connector C416. Symbols A complete description of schematic symbols is given under wire color abbreviation. Power Distribution Schematics Power Distribution schematics show how power is supplied from the positive battery terminal to various circuits in the car. Refer to the Power Distribution section to get a more detailed picture of how power is supplied to the circuit you're working on. From Battery to Ignition Switch, Fuses, and Relays Individual circuit schematics begin with a fuse. The first half of Power Distribution, however, shows the wiring "upstream" between the battery Page 2772 The connector cavity number is listed next to each terminal on the circuit schematic. The cavity / terminal shown is # 6. Diodes A rectifier diode works like a one way valve. It allows current to flow only in the direction of the arrow. A Zener diode blocks reverse current at normal voltages just like a rectifier diode. At high voltages, however, a Zener diode allows current to flow in reverse. Fuses Page 5127 2. Install pulley on the rotor. Secure the pulley directly in the vise between two copper plates, and tighten nut to the specified torque. Torque: 111 Nm (82 lb.ft) Page 1871 2. Install water pump assembly and tighten bolts to the specified torque in sequence (shown in image). Torque: 25 Nm (18 ft. lbs.) Note: To prevent the oil leakage, apply the LOCTITE 262 or an equivalent, to the arrow marked fixing bolt thread. 3. Idle pulley - Install idle pulley and tighten bolt to the specified torque. Torque: 52 Nm (38 ft. lbs.) 4. Timing belt - Install timing belt. 5. Connect radiator inlet hose and replenish engine coolant. 6. Connect battery ground cable. Page 1364 Tires: Testing and Inspection Tread Wear Indicators Tread Wear Indicators The original equipment tires have built-in tread wear indicators (l) to show when tires need replacement. These indicators may appear as wide bands. When the indicators appear in two or more grooves at three locations, tire replacement is recommended. Page 7914 The wire insulation has one color or one color with another color stripe. The second color is the stripe. Antitheft & Keyless Entry Controller Alarm/Immobilizer Control Unit: Service and Repair Antitheft & Keyless Entry Controller Anti-Theft & Keyless Entry Controller Removal 1. Disconnect the battery ground cable. 2. Remove the glove box from the instrument panel assembly (1). - Refer to the Instrument Panel Assembly in Body Structure section. 3. Remove the anti-theft & keyless entry controller (2). - Disconnect the connector. Remove two fixing screws. Installation To install, follow the removal steps in the reverse order. Page 7152 Hard Top: Service and Repair Removal 1. Disconnect the battery ground cable. 2. Remove the rear sun roof glass. 3. Remove the sun roof deflector. - Remove the four fixing screws. 4. Remove the rear roof bracket covers (4) and remove the both sets of two bolts (3) on the resin top sides of the rear roof brackets (2). 5. Remove the air outlet grille assembly (LH & RH). - Remove the two screws and pull the grille assemblies off toward the rear. 6. Remove the luggage light assembly and disconnect the connector. 7. Remove the high mount stoplight assembly and disconnect the connector. 8. Disconnect the rear washer hose (Right side, inside air outlet grille assembly). Page 7913 Wire Color Abbreviations The following abbreviations are used to identify wire colors in the circuit schematics: WHT................................... White YEL................................... Yellow BLK................................... Black BLU................................... Blue GRN................................... Green RED................................... Red ORN................................... Orange PNK................................... Pink BRN................................... Brown GRY................................... Gray PUR................................... Purple LT BLU................................... Light Blue LT GRN................................... Light Green Front Seat Belt: Service and Repair Front Front Seat Belt Buckle Removal 1. Disconnect the battery ground cable. 2. Disconnect the seat belt warning connector (driver's side) and remove a clip. 3. Remove the front seat buckle assembly (1). Installation To install, follow the removal steps in the reverse order, noting the following point. 1. Tighten the buckle anchor bolt to the specified torque. Torque: 39 N.m (29 lb ft) Hard Top Engine Controls - Engine Stalls After Cold Start PROM - Programmable Read Only Memory: Customer Interest Engine Controls - Engine Stalls After Cold Start 01-015 May 8, 2001 Applies To: 2000 Passport - ALL 2001 Passport - From VIN 4S6..58W.14400001 thru 4S6..58W.14409430 Engine Stalls After a Cold Start SYMPTOM After a cold start, the engine occasionally stalls when you shift from Neutral or Park to any gear. PROBABLE CAUSE The PCM software delays the idle speed changes needed during cold start conditions. CORRECTIVE ACTION Update the PCM software with the Smart Cable. TOOL INFORMATION PGM Tester loaded with SN131 (04/16/01) or later software. For other tools and equipment needed to update the PCM software, refer to Service Bulletin 99-005, Updating the Passport PCM, filed under Tools. WARRANTY CLAIM INFORMATION In warranty: The normal warranty applies. Operation Number: 122305 Flat Rate Time: 0.3 hour Failed Part: P/N 8-09392-189-0 H/C 6392971 Defect Code: 093 Contention Code: C05 Template ID: 01-015A Skill Level: Repair Technician Out of warranty: Any repair performed after warranty expiration may be eligible for goodwill consideration by the District Service Manager or your Zone Office. You must request consideration, and get a decision, before starting work. REPAIR PROCEDURE 1. Retrieve the PCM broadcast code with the PGM Tester. (From the MISC TESTS menu, select BROADCAST CODE). Page 1089 Spark Plug: Description and Operation Spark Plug Although worn or dirty spark plugs may give satisfactory operation at idling speed, they frequency fail at higher engine speeds. Faulty spark plugs may cause poor fuel economy, power loss, loss of speed, hard starting and generally poor engine performance. Follow the scheduled maintenance service recommendations to ensure satisfactory spark plug performance. Refer to Maintenance and Lubrication. Normal spark plug operation will result in brown to grayish-tan deposits appearing on the insulator portion of the spark plug. A small amount of red-brown, yellow, and white powdery material may also be present on the insulator tip around the center electrode. These deposits are normal combustion by-products of fuels and lubricating oils with additives. Some electrode wear will also occur. Engines which are not running properly are often referred to as "misfiring." This means the ignition spark is not igniting the air/fuel mixture at the proper time. While other ignition and fuel system causes must also be considered, possible causes include ignition system conditions which allow the spark voltage to reach ground in some other manner than by jumping across the air gap at the tip of the spark plug, leaving the air/fuel mixture unburned. Refer to DTC P0300. Misfiring may also occur when the tip of the spark plug becomes overheated and ignites the mixture before the spark jumps. This is referred to as "pre-ignition." Spark plugs may also misfire due to fouling, excessive gap, or a cracked or broken insulator. If misfiring occurs before the recommended replacement interval, locate and correct the cause. Carbon fouling of the spark plug is indicated by dry, black carbon (soot) deposits on the portion of the spark plug in the cylinder. Excessive idling and slow speeds under light engine loads can keep the spark plug temperatures so low that these deposits are not burned off. Very rich fuel mixtures or poor ignition system output may also be the cause. Refer to DTC P0172. Oil fouling of the spark plug is indicated by wet oily deposits on the portion of the spark plug in the cylinder, usually with little electrode wear. This may be caused by oil during break-in of new or newly overhauled engines. Deposit fouling of the spark plug occurs when the normal red-brown, yellow or white deposits of combustion by products become sufficient to cause misfiring. In some cases, these deposits may melt and form a shiny glaze on the insulator around the center electrode. If the fouling is found in only one or two cylinders, valve stem clearances or intake valve seals may be allowing excess lubricating oil to enter the cylinder, particularly if the deposits are heavier on the side of the spark plug facing the intake valve. Excessive gap means that the air space between the center and the side electrodes at the bottom of the spark plug is too wide for consistent firing. This Page 3231 Fuel Injector: Testing and Inspection Injector Balance Test Injector Balance Test This test is conducted to make sure the appropriate electric signals are being sent to injectors Nos. 1-6. Tech 2 must be used for this test. Test Procedure: 1. Connect Tech 2 to the vehicle DLC. 2. Run the Engine at idle. 3. Select F3: Miscellaneous Test in the Application Menu. 4. Select F7: Injector Balance Test in the Miscellaneous Test. Locations Rear Outside Handle And Associated Parts Page 531 7. Loosen the inflator module fixing bolt from behind the steering wheel assembly using a TORX driver or equivalent until the inflator module can be released from steering assembly. Disconnect the yellow 2-way SRS connector and horn lead located behind the inflator module, then remove inflator module. WARNING: THE INFLATOR MODULE SHOULD ALWAYS BE CARRIED WITH THE URETHANE COVER AWAY FROM YOUR BODY AND SHOULD ALWAYS BE LAID ON A FLAT SURFACE WITH THE URETHANE SIDE UP. THIS IS NECESSARY BECAUSE A FREE SPACE IS PROVIDED TO ALLOW THE AIR CUSHION TO EXPAND IN THE UNLIKELY EVENT OF ACCIDENTAL DEPLOYMENT. OTHERWISE, PERSONAL INJURY MAY RESULT. Page 6739 Terminals - "T" Each "T" terminal (ring type) is numbered for reference and location. A "T" terminal is secured with a screw or bolt. Wires Locations Power Door Lock Actuator: Locations Page 4553 Splices Splices are shown as a dot. Their location and the number of wires may vary depending on the harness manufacturer. Switches Switches These switches move together; the broken straight line between them means they are mechanically connected. Other types of switches are controlled by a coil or a solid state circuit. Unless otherwise noted, all switches are shown in their normal (rest) position, with power off. Terminal "T" Page 7764 Brake Lamp: Diagnostic Aids Before Troubleshooting Before Troubleshooting See: Service Precautions/Vehicle Damage Warnings/Tips and Precautions 1. Check applicable fuses in the appropriate fuse/relay box. 2. Check the battery for damage, state of charge, and clean and tight connections. CAUTION: Do not quick-charge a battery unless the battery ground cable has been disconnected, otherwise you will damage the alternator diodes. - Do not attempt to crank the engine with the battery ground cable loosely connected or you will severely damage the wiring. While You're Working 1. Make sure connectors are clean, and have no loose terminals or receptacles. 2. Make sure that connectors without wire seals are packed with dielectric (silicone) grease. Part Number: 08798-9001. 3. When connecting a connector, push it until it "clicks" into place. CAUTION: Do not pull on the wires when disconnecting a connector. Pull only on the connector housings. - Most circuits include solid-state devices. Test the voltages in these circuits only with a 10-megaohm or higher impedance digital multi meter. Never use a test light or analog meter on circuits that contain solid-state devices. Damage to the devices may result. Five-Step Troubleshooting 1. Verify The Complaint Turn on all the components in the problem circuit to check the accuracy of the customer complaint. Note the symptoms. Do not begin disassembly or testing until you have narrowed down the problem area. 2. Analyze The Schematic Look up the schematic for the problem circuit. Determine how the circuit is supposed to work by tracing the current paths from the power source through the circuit components to ground. Also, trace circuits that share wiring with the problem circuit. The names of circuits that share the same fuse, ground, or switch, and so on, are referred to in each circuit schematic. Try to operate any shared circuits you didn't check in step 1. If the shared circuits work, the shared wiring is OK, and the cause must be in the wiring used only by the problem circuit. If several circuits fail at the same time, the fuse or ground is a likely cause. Based on the symptoms and your understanding of the circuit's operation, identify one or more possible causes. 3. Isolate The Problem By Testing The Circuit Make circuit tests to check the diagnosis you made in step 2. Keep in mind that a logical, simple procedure is the key to efficient troubleshooting. Test for the most likely cause of failure first. Try to make tests at points that are easily accessible. 4. Fix The Problem Once the specific problem is identified, make the repair. Be sure to use proper tools and safe procedures. 5. Make Sure The Circuit Works Turn on all components in the repaired circuit in all modes to make sure you've fixed the entire problem. If the problem was a blown fuse, be sure to test all of the circuits on that fuse. Make sure no new problems turn up and the original problem does not recur. Page 5472 H/C 4408092 Defect Code: 017 Contention Code: C99 Skill Level: Repair Technician Out of warranty: Any repair performed after warranty expiration may be eligible for goodwill consideration by the District Service Manager or your Zone Office. You must request consideration, and get a decision, before starting work. DISCLAIMER Page 6338 Page 3553 Each schematic represents one circuit. A circuit's wires and components are arranged to show current flow, from power at the top of the page, to ground, at the bottom. Shared Circuits Other circuits may share power or ground terminals or wiring with the circuit shown. A wire that connects one circuit to another, for example, is cut short and has an arrowhead at the end of it pointing in the direction of current flow. Next to the arrowhead is the name of the circuit or component which shares that wiring. To quickly check shared wiring, check the operation of a component it serves. If that component works, you know the shared wiring is OK. Connectors All in-line and junction connectors are numbered (C725, C416, etc.). Component connectors are not numbered but are identified either by the name of Page 7478 If there is no photo number below or beside a component name or a connector, ground, or terminal number, look up that name or number in the appropriate Connector Identification Chart. The chart lists how many cavities a connector has, where it's located, and what it connects to. The related illustration shows the connector's location on the harness, and the harness routing. NOTE: Photos listed by number are located at Locations / Components / Photograohs. See: Locations/Component Locations/Photographs Circuit Schematics Page 2663 Fuel Tank Pressure Sensor: Service and Repair REMOVAL PROCEDURE 1. Remove the fuel pump assembly. Refer to Fuel Tank. 2. Carefully pry the fuel tank pressure sensor out of the top of the fuel pump assembly. INSTALLATION PROCEDURE 1. Install the rubber grommet on the fuel pump assembly. 2. Install the fuel tank vapor pressure sensor on the fuel pump assembly. 3. Insert the sensor nipple firmly into the grommet. 4. Keep twisting and pushing the sensor until the wide portion of the nipple shows on the other side of the grommet. 5. Install the fuel pump assembly on the fuel tank. Page 1030 TOOL INFORMATION Centering Tape (enough to diagnose 240 vehicles): T/N O7AAJ-001A300 Steering Drift Set Level: T/N 07AAJ-00100 Steering Drift Set: T/N O7MJ-001A140 Replacement Weight for Steering Drift Set: T/N 07AAJ-001A400 WARRANTY CLAIM INFORMATION In warranty: The normal warranty applies. Failed Part: P/N 53560-SDA-AO1 H/C 7139652 Defect Code: 07406 Symptom Code: 03602 Skill Level: Repair Technician Diagnostic Trouble Code: To create the 15-digit DTC, see the applicable repair procedure. Out of warranty: Any repair performed after warranty expiration may be eligible for goodwill consideration by the District Parts and Service Manager or your Zone Office. You must request consideration, and get a decision, before starting work. TOOL DESCRIPTIONS The holding force gauge measures the amount of pull on the vehicle. It is a bracket that counts as one weight, plus five removable weights. Locations Page 1778 may be due to improper gap adjustment or to excessive wear of the electrode during use. A check of the gap size and comparison to the gap specified for the vehicle in Maintenance and Lubrication will tell if the gap is too wide. A spark plug gap that is too small may cause an unstable idle condition. Excessive gap wear can be an indication of continuous operation at high speeds or with engine loads, causing the spark to run too hot. Another possible cause is an excessively lean fuel mixture. Low or high spark plug installation torque or improper seating can result in the spark plug running too hot and can cause excessive center electrode wear. The plug and the cylinder head seats must be in good contact for proper heat transfer and spark plug cooling. Dirty or damaged threads in the head or on the spark plug can keep it from seating even though the proper torque is applied. Once spark plugs are properly seated, tighten them to the torque shown in the Specifications Table. Low torque may result in poor contact of the seats due to a loose spark plug. Overtightening may cause the spark plug shell to be stretched and will result in poor contact between the seats. In extreme cases, exhaust blow-by and damage beyond simple gap wear may occur. Cracked or broken insulators may be the result of improper installation, damage during spark plug re-gapping, or heat shock to the insulator material. Upper insulators can be broken when a poorly fitting tool is used during installation or removal, when the spark plug is hit from the outside, or is dropped on a hard surface. Cracks in the upper insulator may be inside the shell and not visible. Also, the breakage may not cause problems until oil or moisture penetrates the crack later. A broken or cracked lower insulator tip (around the center electrode) may result from damage during re-gapping or from "heat shock" (spark plug suddenly operating too hot). - Damage during re-gapping can happen if the gapping tool is pushed against the center electrode or the insulator around it, causing the insulator to crack. When re-gapping a spark plug, make the adjustment by bending only the ground side terminal, keeping the tool clear of other parts. - "Heat shock" breakage in the lower insulator tip generally occurs during several engine operating conditions (high speeds or heavy loading) and may be caused by over-advanced timing or low grade fuels. Heat shock refers to a rapid increase in the tip temperature that causes the insulator material to crack. Spark plugs with less than the recommended amount of service can sometimes be cleaned and re-gapped then returned to service. However, if there is any doubt about the serviceability of a spark plug, replace it. Spark plugs with cracked or broken insulators should always be replaced. Page 2611 Powertrain Control Module: Locations 30. Left Side of Engine Compartment Left Side Of Engine Compartment Page 1988 Powertrain Control Module: Component Tests and General Diagnostics Powertrain Control Module (PCM) Diagnosis To read and clear diagnostic trouble codes, use a Tech 2. IMPORTANT: Use of a Tech 2 is recommended to clear diagnostic trouble codes from the PCM memory. Diagnostic trouble codes can also be cleared by turning the ignition "OFF" and disconnecting the battery power from the PCM for 30 seconds. Turning off the ignition and disconnecting the battery power from the PCM will cause all diagnostic information in the PCM memory to be cleared. Therefore, all the diagnostic tests will have to be re-run. Since the PCM can have a failure which may affect only one circuit, following the diagnostic procedures will determine which circuit has a problem and where it is. If a diagnostic chart indicates that the PCM connections or the PCM is the cause of a problem, and the PCM is replaced, but this does not correct the problem, one of the following may be the reason: - There is a problem with the PCM terminal connections. The terminals may have to be removed from the connector in order to check them properly. - EEPROM program is not correct for the application. Incorrect components or reprogramming the PCM with the wrong EEPROM program may cause a malfunction and may or may not set a DTC. - The problem is intermittent. This means that the problem is not present at the time the system is being checked. In this case, refer to Symptom Diagnosis and make a careful physical inspection of all component and wiring associated with the affected system. - There is a shorted solenoid, relay coil, or harness. Solenoids and relays are turned "ON" and "OFF" by the PCM using internal electronic switches called drivers. A shorted solenoid, relay coil, or harness will not damage the PCM but will cause the solenoid or relay to be inoperative. Page 4974 Brake Hose/Line: Service and Repair Front Brake Hose REMOVAL 1. Raise the vehicle and support it with suitable safety stands. 2. Remove the wheel and tire assembly. 3. Clean dirt, grease, and other foreign material off the hose fittings at both ends. 4. Disconnect brake pipe. 5. Remove clip. 6. Remove bolt and gasket. 7. Remove hose. INSTALLATION To install, follow the removal steps in the reverse order, noting the following points. 1. Tighten the brake pipes to the specified torque Torque: 16 Nm (12 ft. lbs.) 2. Tighten the bolt to the specified torque. Torque: 35 Nm (26 ft. lbs.) NOTE: Always use new gaskets and be sure to put the hooked edge of the flexible hose end into the anti-rotation cavity. After installing the brake hoses, bleed the brakes. Page 6750 Trailer Connector: Electrical Diagrams Trailer Lighting Connector (Part 1 Of 3) Page 5920 The connector cavity number is listed next to each terminal on the circuit schematic. The cavity / terminal shown is # 6. Diodes A rectifier diode works like a one way valve. It allows current to flow only in the direction of the arrow. A Zener diode blocks reverse current at normal voltages just like a rectifier diode. At high voltages, however, a Zener diode allows current to flow in reverse. Fuses Page 4685 The connector cavity number is listed next to each terminal on the circuit schematic. The cavity / terminal shown is # 6. Diodes A rectifier diode works like a one way valve. It allows current to flow only in the direction of the arrow. A Zener diode blocks reverse current at normal voltages just like a rectifier diode. At high voltages, however, a Zener diode allows current to flow in reverse. Fuses Page 5436 1. Place the vehicle on a commercially available, computerized, four-wheel alignment rack, and record the following measurements. Follow the equipment manufacturer's instructions. NOTE: Enter each reading in decimal degrees. Example 30' = 0.50. 2. If any measurement is out of specification, inspect the front suspension for any damage. Repair any damaged parts before continuing your diagnosis. 3. Determine how the front wheel camber is affecting the pull. Pick the combination of left- and right-front camber that best matches the vehicle you are repairing, then note the camber thrust direction for that combination: NOTE: ^ If the camber of both front wheels is negative, but one wheel is grossly more negative than the other, the camber thrust direction will be opposite the wheel with more negative camber (for example, if the left-front wheel is more negative, the camber thrust direction is right). ^ If the camber of both front wheels is positive, but one wheel is grossly more positive than the other, the camber thrust direction will be the same as the wheel with more positive camber (for example, if the left-front wheel is more positive, the camber thrust direction is left). 4. Determine how the camber needs to be adjusted. 5. Adjust the camber as needed. Front Camber Adjustment, Double Wishbone Suspension Page 3212 Terminals - "T" Each "T" terminal (ring type) is numbered for reference and location. A "T" terminal is secured with a screw or bolt. Wires Page 6050 6. Loosen screw and disconnect the field coil wire connector. 7. Loosen three screws and remove the field coil. Installation 1. Install field coil. Page 7374 Distinct Of Circuit By Wire Base Color All wires have color-coded insulation. Wires belonging to a system's main harness will have a single color. Wires belonging to a system's sub-circuits will have a colored stripe. Striped wires use the codes found in the chart to show wire size and colors. Abbreviations are used to indicate wire color within a circuit diagram. How to Identify Connector Terminals How to Identify Connector Terminals Cavity Numbering System The cavities (and wire terminals) in each connector are numbered starting from the upper left, looking at the male terminals from the terminal side (or looking at the female terminals from the wire side. Both views are in the same direction so the numbers are the same.) All actual cavities are numbered, even if they have no wire terminals in them. NOTE: Data Link Connector (DLC) terminals are numbered according to SAE standard J1962, not the Honda standard. The numbers of the four end terminals are molded into the corners of the connector face. The connector cavity number is listed next to each terminal on the circuit schematic. The cavity / terminal shown is # 6. Using/Identifying Connector Terminal Views How to Use Connector Terminal Views To see the configuration of a connector's cavities, look up its view number in the Connector Views. Each view includes the color of the connector, where Page 5863 Tires: Testing and Inspection Tread Wear Indicators Tread Wear Indicators The original equipment tires have built-in tread wear indicators (l) to show when tires need replacement. These indicators may appear as wide bands. When the indicators appear in two or more grooves at three locations, tire replacement is recommended. Page 8021 This means the branch of the wire connects to another circuit. The arrow points to the name of the circuit branch where the wire continues. Page 5587 Wire Color Abbreviations The following abbreviations are used to identify wire colors in the circuit schematics: WHT................................... White YEL................................... Yellow BLK................................... Black BLU................................... Blue GRN................................... Green RED................................... Red ORN................................... Orange PNK................................... Pink BRN................................... Brown GRY................................... Gray PUR................................... Purple LT BLU................................... Light Blue LT GRN................................... Light Green Page 704 2. Unfasten C123 from the side of the engine compartment using a 90-degree pick. 3. Disconnect C123, and clean the terminals on both sides of the connector with contact cleaner. Shake the residue out of the connector. Allow the contact cleaner to evaporate for at least 3 minutes, then reconnect C123. 4. Fasten C123 to the left side of the engine compartment, and reinstall the air cleaner housing cover. 5. Remove the connector position assurance (CPA) clip from the APPS connector. 6. Disconnect the lop connector from the APPS. 7. Clean the terminals of the 10P APPS connector (harness side) with contact cleaner. Shake out residue from the connector, and allow the contact cleaner to evaporate for at least 3 minutes, then reconnect it. 8. Use the Smart Cable to reprogram the PCM with the latest software from the June 2001 or later HONDANET CD-ROM. Refer to Service Bulletin 99-005, Updating the Passport PCM, filed under Tools. 9. Use the PGM Tester to clear any DTCs. Locations Shift Interlock Solenoid: Locations Under Center Console Testing and Inspection Air Filter Element: Testing and Inspection Air Cleaner Element Check the air cleaner filter for damage or dust clogging. Replace if it is damaged, or clean if it is clogged. Page 5622 6. Disconnect the yellow 2-way SRS connector located behind the inflator module. WARNING: THE INFLATOR MODULE SHOULD ALWAYS BE CARRIED WITH THE URETHANE COVER AWAY FROM YOUR BODY AND SHOULD ALWAYS BE LAID ON A FLAT SURFACE WITH THE URETHANE SIDE UP. THIS IS NECESSARY BECAUSE A FREE SPACE IS PROVIDED TO ALLOW THE AIR CUSHION TO EXPAND IN THE UNLIKELY EVENT OF ACCIDENTAL DEPLOYMENT. OTHERWISE, PERSONAL INJURY MAY RESULT. 7. Disconnect horn lead. 8. Remove steering wheel fixing nut. 9. Apply a setting mark (1) across the steering wheel and shaft so parts can be reassembled in their original position, then remove steering wheel. 10. Move the front wheels to the straight ahead position, then use steering wheel remover J-29752 to remove the steering wheel. CAUTION: Never apply force to the steering wheel in direction of the shaft by using a hammer or other impact tools in an attempt to remove the steering wheel. The steering shaft is designed as an energy absorbing unit. INSTALLATION Page 5271 Page 300 This means the branch of the wire connects to another circuit. The arrow points to the name of the circuit branch where the wire continues. Page 6834 10. Remove the 2 screws through the access hole and pull out the glass upward. 11. Remove the window regulator. - Disconnect the window regulator motor harness connector, if equipped with power windows. 12. Remove the glass run. - Pull the glass run (6) out from the door frame groove. Installation To install, follow the removal steps in the reverse order, noting the following points: Page 1109 Page 6156 Testing For A Short With A Self-Powered Test Light or DVOM 1. Remove the blown fuse and disconnect the battery and load. 2. Connect one lead of a self-powered test light or digital volt/ohmmeter (DVOM) (switched to the lowest "OHMS" range) to the fuse terminal on the load side. 3. Connect the other lead to a known good ground. 4. Beginning near the fuse box, wiggle the harness. Continue this at convenient points about six inches apart while watching the test light or DVOM. 5. If the self-powered test light goes on or the DVOM displays a low reading or no reading (zero), there is a short to ground in the wiring near that point. Testing for a Short with a Test Light or DVOM 1. Remove the blown fuse and disconnect the load. 2. Connect a test light or digital volt/ohmmeter (DVOM), switched to the appropriate DC volts range, across the fuse terminals to make sure voltage is present. You might have to turn the ignition switch to ON; check the schematic to see. 3. Beginning near the fuse box, wiggle the harness. Continue this at convenient points about six inches apart while watching the test light or DVOM. 4. Where the test light goes , or the DVOM voltage drops to zero, there is a short to ground in the wiring near that point. NOTE: Always use a DVOM on high impedance circuits. A test light may not glow (even with battery voltage present). Testing For A Short With A Short Circuit Locator (Short Finder) 1. Remove the blown fuse. Leave the battery connected. Component Locations Page 8140 Page 2728 4. Remove the fuel pressure regulator from the fuel rail. 5. Remove the fuel return line from the regulator. 6. Install the new fuel pressure regulator in the reverse order of removal. 7. Use the Smart Cable to reprogram the PCM with the latest software from the June 2001 or later HONDANET CD-ROM. Refer to Service Bulletin 99-005, Updating the Passport PCM, filed under Tools. 8. Use the PGM Tester to clear any DTCs. 9. Use the PGM Tester to check the broadcast code. Make sure the broadcast code matches the one you selected from the CD-ROM. WARRANTY CLAIM INFORMATION In warranty: The normal warranty applies. Failed Part: P/N 8-17113-398-0 H/C 5504386 Defect Code: 092 Contention Code: C99 Skill Level: Repair Technician Out of warranty: Any repair performed after warranty expiration may be eligible for goodwill consideration by the District Service Manager or your Zone Office. You must request consideration, and get a decision, before starting work. REPAIR PROCEDURE - POWER STEERING SWITCH 1. Drain the power steering fluid out of the system. 2. Remove the power steering fluid reservoir. Clean the reservoir with solvent, then with soap and water. Rinse and dry it thoroughly. 3. Reinstall the reservoir. Do not connect the return hose. 4. Remove the power steering pressure switch, then clean it with brake cleaner and a scraper. Reinstall the switch, and torque it to 20 N.m (14 lb-ft). 5. Cover the unconnected end of the reservoir with your finger, then fill the reservoir with Dexron III ATF Page 1301 L4 Engine Room Page 7579 The wire insulation has one color or one color with another color stripe. The second color is the stripe. Page 5200 If there is no photo number below or beside a component name or a connector, ground, or terminal number, look up that name or number in the appropriate Connector Identification Chart. The chart lists how many cavities a connector has, where it's located, and what it connects to. The related illustration shows the connector's location on the harness, and the harness routing. NOTE: Photos listed by number are located at Locations / Components / Photograohs. See: Locations/Component Locations/Photographs Circuit Schematics Page 457 The name of the component appears next to it followed by notes about its function along with any photo and connector view references. Connector "C" How to Identify Connector Terminals Cavity Numbering System The cavities (and wire terminals) in each connector are numbered starting from the upper left, looking at the male terminals from the terminal side (or looking at the female terminals from the wire side. Both views are in the same direction so the numbers are the same.) All actual cavities are numbered, even if they have no wire terminals in them. NOTE: Data Link Connector (DLC) terminals are numbered according to SAE standard J1962, not the Honda standard. The numbers of the four end terminals are molded into the corners of the connector face. Page 3520 Camshaft Position Sensor: Service and Repair REMOVAL PROCEDURE 1. Disconnect the negative battery cable. 2. Remove the engine cover. 3. Remove the common chamber assembly. 4. Disconnect the electrical connector to the CMP sensor. 5. Remove the CMP retaining bolt from the side of left cylinder head. 6. Remove the CMP sensor from the cylinder head. INSTALLATION PROCEDURE 1. Install the CMP sensor in the cylinder head. 2. Install the CMP sensor retaining bolt. Tighten Tighten the retaining screw to 9 N.m (78 lb in.). Diagram Information and Instructions Axle Disconnect Control Control Unit: Diagram Information and Instructions How to Identify Wiring Color-Coded Insulation Wire Color Wire Color Coding Page 829 Throttle Position Sensor: Description and Operation Throttle Position (TP) Sensor The throttle position (TP) sensor is a potentiometer connected to the throttle shaft on the throttle body. The PCM monitors the voltage on the signal line and calculates throttle position. As the throttle valve angle is changed (accelerator pedal moved), the TP sensor signal also changes. At a closed throttle position, the output of the TP1 sensor is low. As the throttle valve opens, the output increases so that at wide open throttle (WOT), the output voltage should be above 92 % (Tech 2 Display). The PCM calculates fuel delivery based on throttle valve angle (driver demand). A broken or loose TP sensor may cause intermittent bursts of fuel from an injector and unstable idle because the PCM thinks the throttle is moving. Page 5891 2. Tighten the hub nut to the value given below, using a spring scale on the wheel pin. New bearing and New oil seal Bearing Preload: 20 N - 25 N (4.4 lbs. - 5.5 lbs.) Used bearing and New oil seal Bearing Preload: 12 N - 18 N (2.6 lbs. - 4.0 lbs.) If the measured bearing preload is outside the specifications, adjust it by loosening or tightening the bearing nut. 9. Install lock washer and lock screw in the following manner. - Turn the side with larger diameter of the tapered bore to the vehicle outer side, then attach the washer. - If the bolt holes in the lock plate are not aligned with the corresponding holes in the nut, reverse the lock plate. - If the bolt holes are still out of alignment, turn in the nut just enough to obtain alignment. - Screw is to be fastened tightly so its head may come lower than the surface of the washer. 10. Apply adhesive (LOCTITE 515 or equivalent) to both joining flange faces then install hub flange. 11. Install snap ring and shim. Adjust the clearance between the freewheeling hub body and the snap ring. Clearance: 0 mm - 0.3 mm (0 inch - 0.012 inch) Shims Available: 0.2 mm, 0.3 mm, 0.5 mm, 1.0 mm (0.008 inch, 0.012 inch, 0.020 inch, 0.039 inch) 12. Install hub cap. Page 3972 Fluid - A/T: Service and Repair ATF Replacement CHANGING TRANSMISSION FLUID There is no need to change the transmission fluid unless the transmission is used under one or more of the following heavy duty conditions. A. Repeated short trips B. Driving on rough roads C. Driving on dusty roads D. Towing a trailer If the vehicle is used under these conditions, change the fluid every 20,000 miles (32,000 km.) 1. Place a large drain pan under the oil pan. 2. Remove the transmission oil drain screw (2) and drain fluid. 3. Tighten drain screw (2). Torque: 38 Nm (28 ft. lbs.) 4. Remove the transmission overfill screw (1) and fill transmission through overfill screw opening, using DEXRON III ATF. NOTE: Add transmission fluid until it flows out over the overfill screw opening. 5. Let engine idle until a fluid temperature between 32°C (90°F) and 57°C (135°F) is reached. 6. Add transmission fluid until it flows out over the overfill screw opening, then close the overfill screw (1). Torque: 38 Nm (28 ft. lbs.) NOTE: To prevent fluid leaks, the overfill screw and oil drain screws gasket must be replaced each time these screws are removed. NOTE: Check transmission fluid temperature with scan tool. 7. Reset "Oil Life Monitor" data by using Tech 2. Page 5592 2. Connect the short finder across the battery terminals and the load (component) side of the fuse terminal. 3. Close all switches in the circuit you're testing. 4. Turn on the short finder. This creates a pulsing magnetic field around the wiring between the fuse box and the short. 5. Beginning at the fuse box, slowly move the short finder along the circuit wiring. The meter will read current pulses through sheet metal and body trim. As long as the meter is between the fuse and the short, the needle will move with each current pulse. Once you move the meter past the point of the short, the needle will stop moving. Check the wiring and connectors in this area to locate the cause of the short. Testing For Continuity When testing for continuity at a connector without wire seals, you do not have to separate the two halves of the connector. Instead, probe the connector from the back. Always check both sides of the connector because dirty, corroded, and bent terminals can cause problems (no electrical contact = an open). 1. Disconnect the negative cable from the car battery. If you're using a DVOM, place it in the lowest "OHMS" range. Page 3342 Wires Wire insulation can be one color, or one color with another color stripe. (The second color is the stripe.) This circuit continues on another image. (The arrow shows direction of current flow.) To follow the RED/BLK wire in this example, you would turn to "Fuel and Emissions" and look for the "A" arrow. Engine Controls - Engine Spark Knock Or Pinging Powertrain Control Module: Customer Interest Engine Controls - Engine Spark Knock Or Pinging 01-084 June 19, 2009 Applies To: 2000-02 Passport - ALL Engine Spark Knock (Pinging) (Supersedes 01-084, dated March 18, 2003, to revise the information marked by asterisks) *REVISION SUMMARY Under WARRANTY CLAIM INFORMATION, the failed part number, the Honda code, the defect code, and the symptom code have been updated.* SYMPTOM An engine spark knock (pinging). PROBABLE CAUSE The programmed ignition timing does not correct quickly enough in some climates. CORRECTIVE ACTION Update the PCM software with the Smart Cable. TOOL INFORMATION PGM Tester with software update release SN200P (9/1/01) or later. For the other tools and equipment you need to update the PCM software, refer to Service Bulletin 99-005, Updathg the Passport POM, filed under Tools. WARRANTY CLAIM INFORMATION In warranty: The normal warranty applies. Operation Number: 125517 Flat Rate Time: 0.3 hour *Failed Part: P/N 8-12212-079-0 H/C 6974992 Defect Code: 03214 Symptom Code: 09117* Template ID: 01-084A Skill Level: Repair Technician Out of warranty: Any repair performed after warranty expiration may be eligible for goodwill consideration by the District Parts and Service Manager or your Zone Office. You must request consideration, and get a decision, before starting work. REPAIR PROCEDURE 1. Retrieve the PCM broadcast code with the PGM Tester or the Smart Cable (refer to Service Bulletin 99-005, Updathg the Passport PCM). Page 2567 The name of the component appears next to it followed by notes about its function along with any photo and connector view references. Connector "C" How to Identify Connector Terminals Cavity Numbering System The cavities (and wire terminals) in each connector are numbered starting from the upper left, looking at the male terminals from the terminal side (or looking at the female terminals from the wire side. Both views are in the same direction so the numbers are the same.) All actual cavities are numbered, even if they have no wire terminals in them. NOTE: Data Link Connector (DLC) terminals are numbered according to SAE standard J1962, not the Honda standard. The numbers of the four end terminals are molded into the corners of the connector face. Page 3538 Left Side Of Engine Right Side Of Engine Left Side Of Engine Page 388 Part 2 of 2 B-24 Wheel Speed Input Abnormality (DTC 65/C0238) Page 7592 it is located, and what it connects to. Use the Connector Views to help locate the proper cavity when you need to probe a connector. It can be especially helpful if the connector has more than one wire of the same color. A dash symbol (-) indicates that the cavity is empty. Connector views can also be used to help diagnose multiple symptoms in separate circuits which could be caused by a single problem in a connector shared by those circuits. Here's an example: 1. Pick one of the multiple symptoms and look up the schematic for that circuit. 2. Make a list of all the in-line and fuse box connectors in that schematic , 3. Then, in the Connector Views, look up each connector on your list to see if circuits related to the other symptoms run through one of them. If they do, inspect that connector for the problem. Example: The blower, rear window defogger, and the windshield wiper don't work. List all in-line and fuse box connectors in the blower controls circuit and then check the Connector View (see the sample). You find that C324 is common to the blower controls, rear window defogger, and wiper/washer, so you inspect C324 and find the problem, bent terminals. Finding Component/Connector Locations Finding Component/Connector Locations To see where a component or connector is located on the car, look up its photo number in the "Component Location". The photo will also tell you the color of the connector, and how many cavities it has. Page 3404 Splices Splices are shown as a dot. Their location and the number of wires may vary depending on the harness manufacturer. Switches Switches These switches move together; the broken straight line between them means they are mechanically connected. Other types of switches are controlled by a coil or a solid state circuit. Unless otherwise noted, all switches are shown in their normal (rest) position, with power off. Terminal "T" Page 657 Intake Air Temperature Sensor: Service and Repair INTAKE AIR TEMPERATURE (IAT) SENSOR REMOVAL PROCEDURE 1. Disconnect the negative battery cable. 2. Remove the engine cover 3. The IAT sensor is located in the intake air duct, behind the throttle body. 4. Disconnect the electrical connector from the IAT sensor. 5. Remove the IAT sensor from the intake air duct by using a rocking motion while pulling the sensor. INSTALLATION PROCEDURE 1. Install the IAT sensor into the grommet in the intake air duct. 2. Correct the IAT electrical connector. 3. Install the engine cover. 4. Connect the negative battery cable. Page 7528 Wire Color Abbreviations The following abbreviations are used to identify wire colors in the circuit schematics: WHT................................... White YEL................................... Yellow BLK................................... Black BLU................................... Blue GRN................................... Green RED................................... Red ORN................................... Orange PNK................................... Pink BRN................................... Brown GRY................................... Gray PUR................................... Purple LT BLU................................... Light Blue LT GRN................................... Light Green Page 1793 17. Recheck the valve clearance using the Go/No-Go method (see step 4). - If the clearance is OK, repeat steps 6 thru 17 for the other valves needing adjustment. - If the clearance is still incorrect, repeat steps 6 through 17 until it is correct, then adjust the remaining valves. 18. Turn the camshaft pulleys until the single timing dot (right cylinder bank) and dual timing dots (left cylinder bank) align with the single timing dots on the camshaft drive gears. 19. Install the cylinder head covers with new gaskets. Torque the cover bolts to 9 N.m (6.5 lb-ft). Off-Vehicle Valve Adjustment 1. Make a copy of the Valve Inspection Chart. 2. Make a copy of the Valve Shim Replacement Chart, then tape the pages together, side-by-side. 3. Measure the valve clearances using the Go/No-Go method (see the note below). The clearances must be - Intake valves: 0.25 mm +0.05 mm - Exhaust valves: 0.30 mm +0.05 mm NOTE: - To measure with the Go/No-Go method, use two feeler gauges, one to measure the smallest allowable clearance, and the other to measure the largest. - If the small gauge fits and the large gauge doesn't, the valve adjustment is OK. - If the small gauge doesn't fit, or if the large gauge slides easily, the valve needs adjustment. - The feeler gauges slide through the clearance gap at a slight angle, making the drag a little more than it would be on other engines. 4. For valves with the correct clearance, draw an "X" in the appropriate circle on the Valve Inspection Chart. For valves with incorrect clearances, write down the clearance you measured in the circle. 5. Rotate the camshaft pulley until the dual timing dots (exhaust camshaft) and single timing dot (intake camshaft) align with the timing dots on the camshaft drive gear. Page 800 6. Remove the connector position assurance (CPA) clip from the APPS connector. 7. Disconnect the 10 P connector from the APPS. 8. Remove the bolts, the APPS, the spacer, and the accelerator link from the accelerator pedal assembly. 9. Separate the spacer from the APPS. Clean the grease off the spacer and the accelerator link with a clean shop towel. 10. Clean the terminals of the 10 P APPS connector (harness side) with contact cleaner. Shake the residue out of the connector, and allow the contact cleaner to evaporate for at least 3 minutes before reconnecting the connector. 11. Install a new APPS, the spacer, and the accelerator link onto the accelerator pedal assembly. Leave the mounting screws loose so the sensor can be adjusted. 12. Connect the 10 P connector to the new APPS, and lock the connector in place with the CPA. 13. Connect the PGM Tester to the data link connector (DLC), and turn the ignition switch to ON (II). Page 6387 2. Connect the short finder across the battery terminals and the load (component) side of the fuse terminal. 3. Close all switches in the circuit you're testing. 4. Turn on the short finder. This creates a pulsing magnetic field around the wiring between the fuse box and the short. 5. Beginning at the fuse box, slowly move the short finder along the circuit wiring. The meter will read current pulses through sheet metal and body trim. As long as the meter is between the fuse and the short, the needle will move with each current pulse. Once you move the meter past the point of the short, the needle will stop moving. Check the wiring and connectors in this area to locate the cause of the short. Testing For Continuity When testing for continuity at a connector without wire seals, you do not have to separate the two halves of the connector. Instead, probe the connector from the back. Always check both sides of the connector because dirty, corroded, and bent terminals can cause problems (no electrical contact = an open). 1. Disconnect the negative cable from the car battery. If you're using a DVOM, place it in the lowest "OHMS" range. Locations Page 7023 7. Remove the inside handle fixing screw. CAUTION: Take care not to apply excessive force on the inside handle link, lest this link is elongated, which could make it impossible to operate the door with the inside handle. 8. Remove the door trim panel. - Remove 5 fixing screws (1), (3) in order to take off 6 clips (2) from the door panel. - Disconnect the tweeter and courtesy light connectors to lift the door trim panel and unlock the engagement of the waist seal section. Then, pass the inside handle through the mounting hole of the trim panel, and detach the trim panel. 9. Remove the inside handle. 10. Remove the tweeter. Installation To install, follow the removal steps in the reverse order. Removal and Installation Air Filter Element: Service and Repair Removal and Installation Air Cleaner Element REMOVAL 1. Remove positive ventilation hose connector (1). 2. Remove intake air temperature sensor (2). 3. Remove air flow sensor (3). 4. Remove air cleaner duct assembly (4). 5. Remove air cleaner element (5). INSTALLATION 1. Install air cleaner element (5). 2. Attach the mass air cleaner duct cover to the body completely, then clamp it with the clip (4). 3. Install air flow sensor (3). 4. Install air temperature sensor (2). 5. Install positive crankcase ventilation hose connector (1). Service and Repair Oil Pan: Service and Repair Oil Pan and Crankcase Removal 1. Disconnect battery ground cable. 2. Lift vehicle by supporting the frame. 3. Remove under cover. 4. Drain engine oil. 5. Remove front wheels. 6. Remove oil level dipstick from level gauge tube. 7. Remove radiator under fan shroud. 8. Remove shift on the fly from axle housing. 9. Remove suspension cross member fixing bolts, 2 pcs.; each per side and remove suspension cross member. 10. Remove axle housing assembly, four fixing bolts from housing isolator side, and mounting bolts from wheel side. At this time support the axle with a garage jack and remove axle housing assembly (4X4). 11. Remove the steering unit assembly. 12. Remove starter fixing bolts. 13. Remove oil pan fixing bolts. 14. Remove oil pan, using J-37228 sealer cutter, remove oil pan. 15. Remove crankcase fixing bolts. 16. Remove crankcase, using J-37228 sealer cutter, remove crankcase. Note: Do not deform or damage the flange of oil pan and crankcase. Replace the oil pan and/or crankcase if deformed or damaged. Installation 1. Install crankcase. A. Remove residual sealant, lubricant and moisture from mounting surface, then dry thoroughly. Page 7439 Splices Splices are shown as a dot. Their location and the number of wires may vary depending on the harness manufacturer. Switches Switches These switches move together; the broken straight line between them means they are mechanically connected. Other types of switches are controlled by a coil or a solid state circuit. Unless otherwise noted, all switches are shown in their normal (rest) position, with power off. Terminal "T" Page 3910 REPAIR PROCEDURE 1. Raise the vehicle on a hoist. 2. 2002 only: Loosen the bracket that secures the ATF cooler return line, and disconnect the line from the transmission. 3. Clean the accumulator housing. 4. Using the accumulator cover installation tool and a Phillips screwdriver to hold the tool, tap on the accumulator cover to unseat the cover from the snap ring. 5. Remove the snap ring from the accumulator housing. Diagrams Testing and Inspection Mechanical Diagnosis Page 2781 Test Equipment CAUTION: Most circuits include solid-state devices. Test the voltages in these circuits only with a 10-megaohm or higher impedance digital multimeter. Never use a test light or analog meter on circuits that contain solid-state devices. Damage to the devices may result. Test Light and DVOM On circuits without solid-state devices, use a test light to check for voltage. A test light is made up of a 12 volt bulb with a pair of leads attached. After grounding one lead, touch the other lead to various points along the circuit where voltage should be present. The bulb will go on if there is voltage at the point being tested. If you need to know how much voltage is present, use a digital volt/ohmmeter (DVOM). Self-Powered Test Light and DVOM Use a self-powered test light to check for continuity. This tool is made up of a light bulb, battery, and two leads. To test it, touch the leads together: the light should go on. Use a self-powered test light only on an unpowered circuit. First, disconnect the battery, or remove the fuse that feeds the circuit you are working on. Select two points in the circuit between which you want to check continuity. Connect one lead of the self-powered test light to each point. If there is continuity, the test light's circuit will be completed, and the light will go on. If, in addition, you need to know exactly how much resistance there is between two points, use a digital volt/ohmmeter (DVOM). In the "OHMS" range, the DVOM will measure resistance between two points along a circuit. Low resistance means good continuity. Diodes and solid-state devices in a circuit can make a DVOM give a false reading. To check a reading, reverse the leads, and take a second reading. If the readings differ, the component is affecting the measurement. Jumper Wire Use a jumper wire to bypass an open circuit. A jumper wire is made up of an in-line fuse holder connected to a set of test leads. It should have a five ampere fuse. Never connect a jumper wire across a short circuit. The direct battery short will blow the fuse. Short Finder (Short Circuit Locator) Short finders are available to locate shorts to ground. The short finder creates a pulsing magnetic field in the shorted circuit which you can follow to the location of the short. To order any test equipment shown above, contact your local tool supplier. For a list of suppliers and tool numbers, refer to Honda Required Special Tools and Equipment Service Bulletin. A/T - Vehicle Speed Sensor Installation Precautions Vehicle Speed Sensor: Technical Service Bulletins A/T - Vehicle Speed Sensor Installation Precautions Install VSS Properly to Avoid Reman A/T Damage We can't emphasize enough how important it is to follow, to the letter, the installation instructions that come with a reman A/T. These instructions help ensure that you avoid damaging the A/T and score a successful repair. This is particularly true when it comes to installing the vehicle speed sensor (VSS). Step 6 of the instructions tells you to make sure its gear is fully engaged and the VSS is fully seated before you tighten the retaining bolt. If you don't install the VSS properly, the speed sensor gear will get stripped and the A/T will be seriously damaged. So don't take risks with your customer's vehicle. Always follow these instructions to the letter. You can rest assured you're doing the job right. Page 5129 4. Check for continuity between slip ring and rotor core. In case of continuity, replace the rotor assembly. Stator Coil 1. Check for continuity across the stator coils. If no continuity exists, replace the coils. Resistance value at 20°C. Standard: Approx. 0.07 ohms Page 6882 Hood Latch: Service and Repair Engine Hood Lock Engine Hood Latch Removal 1. Remove the hood lock control lever. 2. Remove the inner liner. 3. Remove the radiator grille. 4. Remove the engine hood lock assembly. - Apply setting marks(1) to the hood lock assembly and the body prior to removal. 5. Remove the control cable. - Remove the cable fixing clips from the engine hood lock. Installation Locations ECT Sensor Page 20 Keyless Entry Module: Service and Repair Anti-Theft & Keyless Entry Controller Removal 1. Disconnect the battery ground cable. 2. Remove the glove box from the instrument panel assembly (1). - Refer to the Instrument Panel Assembly in Body Structure section. 3. Remove the anti-theft & keyless entry controller (2). - Disconnect the connector. Remove two fixing screws. Installation To install, follow the removal steps in the reverse order. Page 2113 Camshaft Position Sensor: Testing and Inspection 1. Inspect the sensor O-ring for cracks or leaks. 2. Replace the O-ring if it is worn or damaged. 3. Lubricate the new O-ring with engine oil. 4. Install the lubricated O-ring. Page 4506 Transmission Position Switch/Sensor: Description and Operation Transmission Range Switch IMPORTANT: The vehicle should not be driven with the transmission range switch disconnected; idle quality will be affected. The four inputs from the transmission range switch indicate to the PCM which position is selected by the transmission selector lever. This information is used for ignition timing, EVAP canister purge, EGR operation. For more information on the transmission on the transmission range switch, refer to Transmission Control System Diagnosis. See: Transmission Control Systems/Testing and Inspection Page 4474 If there is no photo number below or beside a component name or a connector, ground, or terminal number, look up that name or number in the appropriate Connector Identification Chart. The chart lists how many cavities a connector has, where it's located, and what it connects to. The related illustration shows the connector's location on the harness, and the harness routing. NOTE: Photos listed by number are located at Locations / Components / Photograohs. See: Locations/Component Locations/Photographs Circuit Schematics Page 3882 4WD Motor Actuator: Connector Locations Beneath Center of Vehicle, on Transfer Case (A/T) Page 839 3. Connect the electrical connector to the CMP sensor. 4. Install the common chamber assembly. 5. Install the engine cover. 6. Connect the negative battery cable. Page 2214 Torque Specifications Page 235 12. Remove the three SDM fixing bolts (4) and remove SDM (3). Installation 1. Install the SDM (1) on bracket and fixing bolts (4) and tighten the fixing bolts to the specified torque. Torque: 10 ± 3 N.m (1.0 ± 0.3 kg.m / 87 ± 26 lb.in) 2. Connect the SDM harness connector (3) and after that, put CPA into connector (2). 3. Install air conditioning duct for rear seat to normal position. 4. Return carpet normal position. 5. Install right side stay between instrument panel and floor, tighten to the specified torque. Torque: 10 ± 3 N.m (1.0 ± 0.3 kg.m / 87 ± 26 lb.in) 6. Install PCM with bracket and tighten to the specified torque. (Y22SE 2.2L Engine only) Torque: 10 ± 3 N.m (1.0 ± 0.3 kg.m / 87 ± 26 lb.in) Page 4482 Splices Splices are shown as a dot. Their location and the number of wires may vary depending on the harness manufacturer. Switches Switches These switches move together; the broken straight line between them means they are mechanically connected. Other types of switches are controlled by a coil or a solid state circuit. Unless otherwise noted, all switches are shown in their normal (rest) position, with power off. Terminal "T" Page 6852 3. Remove the window regulator handle. - Remove the clip on the rear side of the regulator handle using a wire. 4. Remove the screw while pulling the inside lever toward you and then remove the inside handle. 5. Remove the 1 screw at the pull case. 6. Pull out the trim panel at the 8 clip positions. - Disconnect the power window switch connector. 7. Remove the power window switch and pull case, if equipped. Page 7100 Heated Element: Diagnostic Aids Before Troubleshooting Before Troubleshooting See: Service Precautions/Vehicle Damage Warnings/Tips and Precautions 1. Check applicable fuses in the appropriate fuse/relay box. 2. Check the battery for damage, state of charge, and clean and tight connections. CAUTION: Do not quick-charge a battery unless the battery ground cable has been disconnected, otherwise you will damage the alternator diodes. - Do not attempt to crank the engine with the battery ground cable loosely connected or you will severely damage the wiring. While You're Working 1. Make sure connectors are clean, and have no loose terminals or receptacles. 2. Make sure that connectors without wire seals are packed with dielectric (silicone) grease. Part Number: 08798-9001. 3. When connecting a connector, push it until it "clicks" into place. CAUTION: Do not pull on the wires when disconnecting a connector. Pull only on the connector housings. - Most circuits include solid-state devices. Test the voltages in these circuits only with a 10-megaohm or higher impedance digital multi meter. Never use a test light or analog meter on circuits that contain solid-state devices. Damage to the devices may result. Five-Step Troubleshooting 1. Verify The Complaint Turn on all the components in the problem circuit to check the accuracy of the customer complaint. Note the symptoms. Do not begin disassembly or testing until you have narrowed down the problem area. 2. Analyze The Schematic Look up the schematic for the problem circuit. Determine how the circuit is supposed to work by tracing the current paths from the power source through the circuit components to ground. Also, trace circuits that share wiring with the problem circuit. The names of circuits that share the same fuse, ground, or switch, and so on, are referred to in each circuit schematic. Try to operate any shared circuits you didn't check in step 1. If the shared circuits work, the shared wiring is OK, and the cause must be in the wiring used only by the problem circuit. If several circuits fail at the same time, the fuse or ground is a likely cause. Based on the symptoms and your understanding of the circuit's operation, identify one or more possible causes. 3. Isolate The Problem By Testing The Circuit Make circuit tests to check the diagnosis you made in step 2. Keep in mind that a logical, simple procedure is the key to efficient troubleshooting. Test for the most likely cause of failure first. Try to make tests at points that are easily accessible. 4. Fix The Problem Once the specific problem is identified, make the repair. Be sure to use proper tools and safe procedures. 5. Make Sure The Circuit Works Turn on all components in the repaired circuit in all modes to make sure you've fixed the entire problem. If the problem was a blown fuse, be sure to test all of the circuits on that fuse. Make sure no new problems turn up and the original problem does not recur. Page 2520 Testing For A Short With A Self-Powered Test Light or DVOM 1. Remove the blown fuse and disconnect the battery and load. 2. Connect one lead of a self-powered test light or digital volt/ohmmeter (DVOM) (switched to the lowest "OHMS" range) to the fuse terminal on the load side. 3. Connect the other lead to a known good ground. 4. Beginning near the fuse box, wiggle the harness. Continue this at convenient points about six inches apart while watching the test light or DVOM. 5. If the self-powered test light goes on or the DVOM displays a low reading or no reading (zero), there is a short to ground in the wiring near that point. Testing for a Short with a Test Light or DVOM 1. Remove the blown fuse and disconnect the load. 2. Connect a test light or digital volt/ohmmeter (DVOM), switched to the appropriate DC volts range, across the fuse terminals to make sure voltage is present. You might have to turn the ignition switch to ON; check the schematic to see. 3. Beginning near the fuse box, wiggle the harness. Continue this at convenient points about six inches apart while watching the test light or DVOM. 4. Where the test light goes , or the DVOM voltage drops to zero, there is a short to ground in the wiring near that point. NOTE: Always use a DVOM on high impedance circuits. A test light may not glow (even with battery voltage present). Testing For A Short With A Short Circuit Locator (Short Finder) 1. Remove the blown fuse. Leave the battery connected. Diagram Information and Instructions Dimmer Switch: Diagram Information and Instructions How to Identify Wiring Color-Coded Insulation Wire Color Wire Color Coding Page 369 Brake Fluid Level Sensor/Switch: Description and Operation The brake system warning light goes on to alert the driver that the parking brake is applied or that the brake fluid is low. It also lights as a bulb test when the engine is cranked. With the ignition switch in ON or START, battery voltage is applied to fuse 11 and to the brake system warning light. If the brake fluid is low, the brake fluid level switch closes and provides a ground for the light. The brake system warning light comes on to warn the driver of low brake fluid level in the brake master cylinder. (Note: Check brake pad wear before adding fluid). Locations Transmission Position Switch/Sensor: Locations Left Side Of Automatic Transmission Page 8029 Part 1 Of 3 Page 5886 Wheel Bearing: Service and Repair DISASSEMBLED VIEW DISASSEMBLY 1. Before disassembly, select the 2WD position with the 4WD switch. 2. Jack up the front of vehicle and support frame with jack stands. 3. Remove the disc brake caliper assembly and hang it on the frame with wires. 4. Remove bolt. 5. Remove cap. 6. Remove snap ring and shim. 7. Remove hub flange. 8. Remove lock washer and lock screw. Page 4307 6. Break retainer ring with hammer and chisel. 7. Break bearing cage with hammer and chisel. 8. Remove oil seal, retainer, and emergency brake assembly. 9. Remove inner race from shaft with OTC-1126 bearing splitter and press. INSPECTION - Shaft for spalling or grooves from seal wear. - Retainer - bent or damaged. - Replace items if required. INSTALLATION 1. Emergency brake assembly. Page 6404 Air Bag: Service and Repair Driver Airbag Spring-Loaded Lock Connector REMOVAL To remove the connector, hold the cover insulator(l) and pull it. The cover insulator slides and lock will be released. Do not hold the socket insulator(2). INSTALLATION Timing Belt Removal and Engine Timing Timing Belt: Service and Repair Timing Belt Removal and Engine Timing THIS ARTICLE HAS BEEN UPDATED BY TSB 02-047 TIMING BELT REMOVAL NOTE: Left and right engine callouts are from the driver's seat. 1. Disconnect battery ground cable. 2. Remove air cleaner assembly. 3. Remove radiator upper fan shroud from radiator. 4. Move drive belt tensioner, to loose side, using wrench then remove drive belt. 5. Remove cooling fan assembly four nuts, then the cooling fan assembly. 6. Remove cooling fan drive pulley assembly. 7. Remove idle pulley assembly. 8. Remove serpentine belt tensioner assembly. 9. Remove power steering pump assembly. 10. Remove crankshaft pulley assembly using J-8614-01 crankshaft holder, hold crankshaft pulley remove center bolt, then the pulley. Page 6568 Alarm/Immobilizer Control Unit: Diagrams Service Precautions Evaporative Emissions Hose: Service Precautions Aftermarket Electrical and Vacuum Equipment Aftermarket (add-on) electrical and vacuum equipment is defined as any equipment which connects to the vehicle's electrical or vacuum systems that is installed on a vehicle after it leaves the factory. No allowances have been made in the vehicle design for this type of equipment. NOTE: No add-on vacuum equipment should be added to this vehicle. NOTE: Add-on electrical equipment must only be connected to the vehicle's electrical system at the battery (power and ground). Add-on electrical equipment, even when installed to these guidelines, may still cause the powertrain system to malfunction. This may also include equipment not connected to the vehicle electrical system such as portable telephones and radios. Therefore, the first step in diagnosing any powertrain problem is to eliminate all aftermarket electrical equipment from the vehicle. After this is done, if the problem still exists, it may be diagnosed in the normal manner. Page 1532 - After installation, apply engine oil to the entire circumference of the piston rings. Check to see that all the rings rotate smoothly. 5. Install piston and connecting rod assembly. - Insert the bearings into the connecting rods and caps. Apply new engine oil to the bearing faces and nuts. - Tighten the connecting rod cap nuts Torque: 54 Nm (40 ft. lbs.) Note: Do not apply engine oil to the bearing back faces. 6. Oil gallery, refer to Crankshaft and Main Bearing. 7. Oil strainer and O-ring. 8. Oil pipe and O-ring. 9. Install crankcase with oil pan. 10. Install cylinder head gasket. 11. Install cylinder head assembly. - Refer to Cylinder Head. Page 1581 Let the cam push down the edge of tappet by using J-42689 valve clearance adjusting tool and push out the shim with a flat blade screw driver as shown in illustrations. Page 7886 Wire Color Abbreviations The following abbreviations are used to identify wire colors in the circuit schematics: WHT................................... White YEL................................... Yellow BLK................................... Black BLU................................... Blue GRN................................... Green RED................................... Red ORN................................... Orange PNK................................... Pink BRN................................... Brown GRY................................... Gray PUR................................... Purple LT BLU................................... Light Blue LT GRN................................... Light Green Page 5308 Testing For A Short With A Self-Powered Test Light or DVOM 1. Remove the blown fuse and disconnect the battery and load. 2. Connect one lead of a self-powered test light or digital volt/ohmmeter (DVOM) (switched to the lowest "OHMS" range) to the fuse terminal on the load side. 3. Connect the other lead to a known good ground. 4. Beginning near the fuse box, wiggle the harness. Continue this at convenient points about six inches apart while watching the test light or DVOM. 5. If the self-powered test light goes on or the DVOM displays a low reading or no reading (zero), there is a short to ground in the wiring near that point. Testing for a Short with a Test Light or DVOM 1. Remove the blown fuse and disconnect the load. 2. Connect a test light or digital volt/ohmmeter (DVOM), switched to the appropriate DC volts range, across the fuse terminals to make sure voltage is present. You might have to turn the ignition switch to ON; check the schematic to see. 3. Beginning near the fuse box, wiggle the harness. Continue this at convenient points about six inches apart while watching the test light or DVOM. 4. Where the test light goes , or the DVOM voltage drops to zero, there is a short to ground in the wiring near that point. NOTE: Always use a DVOM on high impedance circuits. A test light may not glow (even with battery voltage present). Testing For A Short With A Short Circuit Locator (Short Finder) 1. Remove the blown fuse. Leave the battery connected. Engine Controls - High/Erratic Engine Idle Grounding Point: Customer Interest Engine Controls - High/Erratic Engine Idle 01-080 August 14, 2001 Applies To: 2000-02 Passport - ALL 2000-02 Passport: High or Erratic Idle SYMPTOM The engine occasionally idles at too high a speed, or the idle speed fluctuates. PROBABLE CAUSES The symptom could be the result of any of these conditions: ^ Loose or corroded engine or body ground ^ High resistance in the APPS ground circuit ^ PSP (power steering pressure) switch is internally shorted to ground ^ Fuel pressure regulator is leaking fuel into the intake manifold CORRECTIVE ACTION Diagnose the cause of the idle condition, and select the proper REPAIR PROCEDURE. PARTS INFORMATION REQUIRED MATERIALS REQUIRED SOFTWARE Each REPAIR PROCEDURE requires you to use the Smart Cable to reprogram the PCM with the latest software. To select the latest software from the CDROM, enter the year, model, engine, transmission, and emissions type (49-state or California). This gives you a list of broadcast codes. Select the broadcast code at the top of the list. WARRANTY CLAIM INFORMATION Refer to the Warranty Claim Information for each Repair Procedure. DIAGNOSIS 1. Find out from the customer when the high or erratic idle condition occurs and what the RPM range is: ^ Within 20 minutes of a cold start ^ After braking to a stop ^ All the time ^ Intermittently, with no set pattern Page 5762 42. Reinstall both lower trailing links with new front mounting nuts and bolts. Hand-tighten the nuts. 43. Remove the ratcheting straps. 44. Lower the vehicle to the ground. 45. Carefully raise the rear of the body off the frame using the method you chose earlier in the repair, then remove the wood blocks. 46. With the body still raised off the frame, reinstall the No. 5 body mounts, and torque the bolts to 50 Nm (37 Ib-ft). 47. Spray some Noxudol 300 around the No. 4 body mount locations. 48. Carefully lower the body onto the frame, then torque the body mount nuts and bolts to 50 Nm (37 Ib-ft). 49. Torque the lower trailing link front mounting bolts to 165-180 Nm (122-133 Ib-ft). 50. Raise the vehicle, then reattach the EVAP canister line to the bulkhead (three clips). 51. Loosen the bracket bolts and clip from both front fenderwells. Reattach the ABS speed sensor harness clips in the front fenderwells, then torque the ABS speed sensor harness bracket bolts to 11 Nm (8 Ib-ft). Reconnect the ABS speed sensor harnesses. 52. Reattach the brake lines to the passenger's side of the frame using the four new clips from the kit. 53. Reattach the wire harness along the driver's side of the frame using the six new clips from the kit. 54. Reinstall the parking brake cable mounting brackets on both sides of the frame using the four new bolts from the kit. Torque the bolts to 7 Nm (5 Ib-ft). 55. Reinstall the fuel tank assembly using the new mounting bolts, the nut, and the clips from the kit. Torque the mounting bolts and the nut to 68 Nm (50 Ib-ft). 56. Reinstall the exhaust silencer (muffler) with a new gasket and new nuts. Torque the silencer nuts to 43 Nm (32 Ib-ft). Torque the silencer bracket mounting nuts to 15 Nm (11 lb-ft). 57. Reinstall the rear bumper assembly. Torque the bumper mounting bolts to 147 Nm (108 Ib-ft) 58. Reinstall the linear EGR valve with a new gasket. Torque the bolts to 25 Nm (18 Ib-ft). 59. Reinstall the radiator grille. 60. If the side steps or the running boards were removed, reinstall them. 61. Fill out the information on a campaign completion label. Stick this label to the back edge of the driver's door, just below the door latch. *NOTE: Page 7572 The connector cavity number is listed next to each terminal on the circuit schematic. The cavity / terminal shown is # 6. Diodes A rectifier diode works like a one way valve. It allows current to flow only in the direction of the arrow. A Zener diode blocks reverse current at normal voltages just like a rectifier diode. At high voltages, however, a Zener diode allows current to flow in reverse. Fuses Page 1035 1. Place the vehicle on a commercially available, computerized, four-wheel alignment rack, and record the following measurements. Follow the equipment manufacturer's instructions. NOTE: Enter each reading in decimal degrees. Example 30' = 0.50. 2. If any measurement is out of specification, inspect the front suspension for any damage. Repair any damaged parts before continuing your diagnosis. 3. Determine how the front wheel camber is affecting the pull. Pick the combination of left- and right-front camber that best matches the vehicle you are repairing, then note the camber thrust direction for that combination: NOTE: ^ If the camber of both front wheels is negative, but one wheel is grossly more negative than the other, the camber thrust direction will be opposite the wheel with more negative camber (for example, if the left-front wheel is more negative, the camber thrust direction is right). ^ If the camber of both front wheels is positive, but one wheel is grossly more positive than the other, the camber thrust direction will be the same as the wheel with more positive camber (for example, if the left-front wheel is more positive, the camber thrust direction is left). 4. Determine how the camber needs to be adjusted. 5. Adjust the camber as needed. Front Camber Adjustment, Double Wishbone Suspension Front Tires - Rub On Mud Flap On Sharp Turns Tires: All Technical Service Bulletins Front Tires - Rub On Mud Flap On Sharp Turns 01-088 September 11, 2001 Applies To: 1998-01 Passport - ALL Front Tire Rubs Against the Mud Flap PROBLEM The front tire rubs against the mud flap when the wheel is turned to full lock. CORRECTIVE ACTION Trim away part of the mud flap. WARRANTY CLAIM INFORMATION In warranty: The normal warranty applies. Operation Number: 031005 Flat Rate Time: 0.3 hour Failed Part: P/N 8-97261-990-0 H/C 6633416 Defect Code: 042 Contention Code: B07 Template ID: 01-088A Skill Level: Repair Technician Out of warranty: Any repair performed after warranty expiration may be eligible for goodwill consideration by the District Service Manager or your Zone Office. You must request consideration, and get a decision, before starting work. REPAIR PROCEDURE 1. Remove the mud flaps from the front fenders (four screws each). 2. Wipe off the mud flaps. Page 2927 6. Place the end of the return hose in a container. Have someone start the engine, then pour ATF into the reservoir while you watch the fluid coming out of the return hose. When the fluid coming out is the same color as the new fluid, turn off the engine. 7. Reconnect the return hose to the reservoir. 8. Start the engine. Fill the power steering reservoir to the proper level with ATF then turn off the engine. 9. Use the Smart Cable to reprogram the PCM with the latest software from the June 2001 or later HONDANET CD-ROM. Refer to Service Bulletin 99-005, Updating the Passport PCM, filed under Tools. 10. Use the PGM Tester to clear any DTCs. 11. Use the PGM Tester to check the broadcast code. Make sure the broadcast code matches the one you selected from the CD-ROM. WARRANTY CLAIM INFORMATION In warranty: The normal warranty applies. Failed Part: P/N 8-97181-590-0 H/C 5698030 Defect Code: 064 Contention Code: C01 Skill Level: Repair Technician Out of warranty: Any repair performed after warranty expiration may be eligible for goodwill consideration by the District Service Manager or your Zone Office. You must request consideration, and get a decision, before starting work. REPAIR PROCEDURE - APPS GROUND 1. Unclamp the air cleaner housing cover, and move it to the side for access to connector C123 (16P BLK). Page 6826 Front Suspension Strut / Shock Absorber: Service and Repair Front REMOVAL 1. Raise the vehicle and support it with suitable safety stands. 2. Remove wheel and tire assembly. 3. Remove bolt and nut. 4. Remove nut. 5. Remove rubber bushing and washer. 6. Remove shock absorber. 7. Remove rubber bushing and washer. INSPECTION AND REPAIR Make necessary correction or parts replacement if wear, damage, corrosion or any other abnormal condition are found through inspection. Check the following parts: Shock absorber - Rubber bushing INSTALLATION 1. Install rubber bushing and washer. 2. Install shock absorber. 3. Install rubber bushing and washer. 4. Install nut, then tighten it to the specified torque. Torque to 20 Nm (14 ft. lbs.). 5. Install bolt and nut, then tighten to the specified torque. Torque to 93 Nm (69 ft. lbs.). Page 266 Terminals - "T" Each "T" terminal (ring type) is numbered for reference and location. A "T" terminal is secured with a screw or bolt. Wires Mechanical Specifications Thermostat: Mechanical Specifications Thermostat Wax Pellet Type With Air Hole Valve Opening Temperature 74.5 - 78.5 C Page 6786 Trailer Lighting Connector (Part 3 Of 3) Page 3634 Spark Plug: Application and ID Plug Types: K16PR-P11 RC10PYPP4 PK16PR11 Page 6145 The name of the component appears next to it followed by notes about its function along with any photo and connector view references. Connector "C" How to Identify Connector Terminals Cavity Numbering System The cavities (and wire terminals) in each connector are numbered starting from the upper left, looking at the male terminals from the terminal side (or looking at the female terminals from the wire side. Both views are in the same direction so the numbers are the same.) All actual cavities are numbered, even if they have no wire terminals in them. NOTE: Data Link Connector (DLC) terminals are numbered according to SAE standard J1962, not the Honda standard. The numbers of the four end terminals are molded into the corners of the connector face. Page 2870 Crankshaft Position Sensor: Description and Operation Crankshaft Position (CKP) Sensor The crankshaft position (CKP) sensor provides a signal used by the powertrain control module (PCM) to calculate the ignition sequence. The CKP sensor initiates the 58X reference pulses which the PCM uses to calculate RPM and crankshaft position. Page 7994 1. Install combination switch and SRS coil assembly. After installation of combination switch assembly, connect the combination switch wiring harness connector and the SRS 2-way connector located under the steering column. Then turn the SRS coil counterclockwise to full, return about 3 turns and align the neutral mark. CAUTION: When turning the SRS coil counterclockwise to full, stop turning if resistance is felt. Forced further turning may damage to the cable in the SRS coil. 2. When installing the steering column cover, be sure to route each wire harness as illustrated so that the harnesses do not catch on any moving parts. 3. Align the setting marks made when removing then install steering wheel. CAUTION: Never apply force to the steering wheel in direction of the shaft by using a hammer or other impact tools in an attempt to remove the steering wheel. The steering shaft is designed as an energy absorbing unit. 4. Tighten the steering wheel fixing nut to the specified torque. Torque: 34 Nm (25 ft. lbs.) 5. Support the inflator module and carefully connect the SRS connector and horn lead. NOTE: Pass the lead wire through the tabs on the plastic cover (wire protector) of inflator to prevent lead wire from being pinched. 6. Tighten bolts to specified torque. Torque: 9 Nm (78 inch lbs.) 7. Install driver knee bolster (reinforcement). 8. Install instrument panel lower cover then install the engine hood opening lever. 9. Connect the SRS connector. 10. Connect the battery "-" terminal cable. Page 1905 Exhaust Pipe: Service and Repair Three Way Catalytic Converter (RH) Three Way Catalytic Converter RH and Forked Exhaust Pipe Removal 1. Disconnect battery ground cable. 2. Lift up the vehicle and support with suitable safety stands. 3. Disconnect O2 sensor harness connectors (2) (6). 4. Remove the forked exhaust pipe fixing bolts and nuts (5) (8) (10) and the exhaust silencer fixing nuts (9), then remove the forked exhaust pipe (7) and the mass damper. 5. Remove the three way catalytic converter fixing nuts (1) and the mounting rubber (4), then remove the three way catalytic converter (3). Installation 1. Install the three way catalytic converter (3) and the mounting rubber (4), and tighten the fixing nuts (1) to the specified torque. Torque Nuts: 67 Nm (49 ft. lbs.) 2. Install the forked exhaust pipe (7) and tighten the fixing bolts (5) & nuts (8) (9) to the specified torque. Torque Bolts & Nuts: 43 Nm (32 ft. lbs.) Nuts: 43 Nm (32 ft. lbs.) 3. Connect the O2 sensor connectors (2) (6). Diagrams Page 2821 24. Verify APP Sensor 1 is between 11 and 15 percent, and APP Sensor 2 and APP Sensor 3 are between 89 and 85 percent with the pedal up (closed throttle). If not, loosen the mounting screws on the APPS sensor, and go to step 14. 25. Clear all DTCs with the PGM Tester. 26. Turn off the ignition switch, and disconnect the PGM Tester. Page 1004 1. Place the vehicle on a commercially available, computerized, four-wheel alignment rack, and record the following measurements. Follow the equipment manufacturer's instructions. NOTE: Enter each reading in decimal degrees. Example 30' = 0.50. 2. If any measurement is out of specification, inspect the front suspension for any damage. Repair any damaged parts before continuing your diagnosis. 3. Determine how the front wheel camber is affecting the pull. Pick the combination of left- and right-front camber that best matches the vehicle you are repairing, then note the camber thrust direction for that combination: NOTE: ^ If the camber of both front wheels is negative, but one wheel is grossly more negative than the other, the camber thrust direction will be opposite the wheel with more negative camber (for example, if the left-front wheel is more negative, the camber thrust direction is right). ^ If the camber of both front wheels is positive, but one wheel is grossly more positive than the other, the camber thrust direction will be the same as the wheel with more positive camber (for example, if the left-front wheel is more positive, the camber thrust direction is left). 4. Determine how the camber needs to be adjusted. 5. Adjust the camber as needed. Front Camber Adjustment, Double Wishbone Suspension Procedures Power Mirror Switch: Procedures Removal 1. Disconnect the battery ground cable. 2. Remove the instrument panel lower cover (2). 3. Remove the door mirror switch (1). Removal and Installation Air Filter Element: Service and Repair Removal and Installation Air Cleaner Element REMOVAL 1. Remove positive ventilation hose connector (1). 2. Remove intake air temperature sensor (2). 3. Remove air flow sensor (3). 4. Remove air cleaner duct assembly (4). 5. Remove air cleaner element (5). INSTALLATION 1. Install air cleaner element (5). 2. Attach the mass air cleaner duct cover to the body completely, then clamp it with the clip (4). 3. Install air flow sensor (3). 4. Install air temperature sensor (2). 5. Install positive crankcase ventilation hose connector (1). Page 5448 The caster angle can be adjusted by means of the caster shims (1) installed between the chassis frame (2) and fulcrum pins. Caster angle: 2°30' ± 1° CAUTION: Left and right side must be equal within 30'. NOTE: Difference of the caster shim front/rear thickness should be 3.6 mm (0.142 inch) or less. Overall thickness of caster shim and camber shim should be 10.3 mm (0.425 inch) or less. Tighten the fulcrum pin bolt to the specified torque. Torque to 152 Nm (112 ft. lbs.) CAMBER The camber angle can be adjusted by means of the camber shims (2) installed in position between the chassis frame (1) and fulcrum pins. Camber angle: 0° ± 30'. King pin inclination: 12°30' ± 30'. Suspension - Drifting & Pulling At Highway Speeds Alignment: All Technical Service Bulletins Suspension - Drifting & Pulling At Highway Speeds SOURCE: Honda Service News September 2003 TITLE: Drifting and Pulling at Highway Speeds APPLIES TO: All Models SERVICE TIP: Got a customer complaining that the vehicle drifts or pulls when driving at highway speeds? Use this handy procedure to diagnose and repair the problem. NOTE: Before doing the procedure in this article, check ISIS for related S/Bs and other S/N articles for the model you're working on. 1. Check if your customer has original equipment wheels and tires and that the ride height hasn't been modified. - If the wheels, tires, and ride height are OK, go to step 2. - If the wheels or tires aren't original equipment or the ride height was modified, stop here. Aftermarket wheels or tires or a ride height that's been modified pose challenges that this article doesn't cover. Resolve these issues with your customer before going further. 2. Set the tire pressures to the recommended cold inflation values listed on the doorjamb sticker. 3. Find a straight stretch of 4-lane road where you can safely (and legally) go 60 mph for several minutes. Ideally, you want a road that's perfectly flat, but most roads have a crown that¡C■s anywhere from 1.5° to 1.75° so they can drain. Flat Road - While driving at 60 mph, use a stopwatch to time how long it takes to drift one full lane from center to center. Record the time. Repeat this, driving in the opposite direction to cancel the effects of wind, then average the two times you recorded. If the vehicle drifts one full lane from center to center in less than 6 seconds, go to step 4. If not, return the vehicle to your customer. Crowned Road - While driving at 60 mph, check if the vehicle climbs the crown. Do this for both a left- and right-crowned road. A drift to the right on a right-crowned road and a drift to the left on left-crowned road are considered normal. If the vehicle climbs the crown or it drifts to the right on a left crowned road, go to step 4. 4. Record the original toe, camber, and caster readings. On Passports, set the ride height to spec if needed. Refer to Ride Height Adjustment in S/B 99-043, Steering Wheel Shimmy or Chassis Vibration. 5. Loosen the subframe mounting bolts, and move the rear beam (it¡C■s the entire front subframe on some models) to get the maximum amount of caster and equal side-to-side camber. (As little as 0.4° of camber stagger can cause the vehicle to pull.) 6. Make sure the steering wheel is centered, then set the front and rear toe to the maximum toe-in spec. (Toe-in improves vehicle stability and reduces the tendency to drift or pull.) 7. Test-drive the vehicle on the same road you used earlier. - If the drift is now within spec, return the vehicle to your customer. - If the drift is still out of spec, go to step 8. 8. Swap the front and rear tires on each side of the vehicle, then adjust the tire pressures to the recommended cold inflation values listed on the doorjamb sticker. 9. Test-drive the vehicle on the same road you used earlier. - If the drift is now within spec, swap each rear tire back to the front, one at a time, and test-drive the vehicle on the same road you used earlier. Replace the bad tire, then return the vehicle to your customer. - If the drift is still out of spec after swapping the front and rear tires, go to step 10. 10. Test-drive a known-good donor vehicle on the same road you used earlier, and check its pull. 11. Swap all four tires from the donor vehicle with the tires on your customer¡C■s vehicle. Page 7449 2. Connect one lead of a self-powered test light or DVOM to one end of the part of the circuit you want to test. 3. Connect the other lead to the other end. 4. If the self-powered test light glows, there is continuity. If you're using a DVOM, a low reading or no reading (zero), means good continuity. Testing For Voltage When testing for voltage at a connector without wire seals, you do not have to separate the two halves of the connector. Instead, probe the connector from the back. Always check both sides of the connector because dirty, corroded, and bent terminals can cause problems (no electrical contact = an open). 1. Connect one lead of the lest light to a known good ground, or, if you're using a digital volt ohmmeter (DVOM), place it in the appropriate DC volts range, and connect its negative lead to ground. 2. Connect the other lead of the test light or DVOM to the point you want to check. 3. If the test light glows, there is voltage present. If you're using a DVOM, note the voltage reading. It should be within one volt of measured battery voltage. A loss of more than one volt indicates a problem. NOTE: Always use a DVOM on high impedance circuits. A test light may not glow (even with battery voltage present). Testing For Voltage Drop Wires, connectors, and switches are designed to conduct current with a minimum loss of voltage. A voltage drop of more than one volt indicates a problem. 1. Place the digital volt/ohmmeter (DVOM) in the appropriate DC volts range. Connect the positive lead to the end of the wire (or to the connector or switch) closest to the battery. 2. Connect the negative lead to the other end of the wire (or the other side of the connector or switch). 3. Turn on the components in the circuit. 4. The DVOM will show the difference in voltage between the two points. A difference, or drop, of more than one volt indicates a problem. Check the circuit for loose, dirty, or bent terminals. Diagram Information and Instructions Idle Speed/Throttle Actuator - Electronic: Diagram Information and Instructions How to Identify Wiring Color-Coded Insulation Wire Color Wire Color Coding Page 3555 and the fuses. From Fuses to Relays and Components The second half of Power Distribution shows the wiring "From Fuses to Relays and Components." This can speed your troubleshooting by showing which circuits share fuses. If Power Distribution shows that an inoperative circuit and another circuit share a fuse, check a component in the other circuit. If it works, you know the fuse is good and power is available to the inoperative circuit. Ground Distribution Schematics Page 672 Oxygen Sensor: Connector Locations 95. Right Front Exhaust Downpipe Right Front Exhaust Downpipe 93. Left Front Exhaust Downpipe Left Front Exhaust Downpipe Locations Main Relay (Computer/Fuel System): Locations 9. Fuse/Relay Box (Cover Removed) Fuse/Relay Box (Cover Removed) Page 564 Test Equipment CAUTION: Most circuits include solid-state devices. Test the voltages in these circuits only with a 10-megaohm or higher impedance digital multimeter. Never use a test light or analog meter on circuits that contain solid-state devices. Damage to the devices may result. Test Light and DVOM On circuits without solid-state devices, use a test light to check for voltage. A test light is made up of a 12 volt bulb with a pair of leads attached. After grounding one lead, touch the other lead to various points along the circuit where voltage should be present. The bulb will go on if there is voltage at the point being tested. If you need to know how much voltage is present, use a digital volt/ohmmeter (DVOM). Self-Powered Test Light and DVOM Use a self-powered test light to check for continuity. This tool is made up of a light bulb, battery, and two leads. To test it, touch the leads together: the light should go on. Use a self-powered test light only on an unpowered circuit. First, disconnect the battery, or remove the fuse that feeds the circuit you are working on. Select two points in the circuit between which you want to check continuity. Connect one lead of the self-powered test light to each point. If there is continuity, the test light's circuit will be completed, and the light will go on. If, in addition, you need to know exactly how much resistance there is between two points, use a digital volt/ohmmeter (DVOM). In the "OHMS" range, the DVOM will measure resistance between two points along a circuit. Low resistance means good continuity. Diodes and solid-state devices in a circuit can make a DVOM give a false reading. To check a reading, reverse the leads, and take a second reading. If the readings differ, the component is affecting the measurement. Jumper Wire Use a jumper wire to bypass an open circuit. A jumper wire is made up of an in-line fuse holder connected to a set of test leads. It should have a five ampere fuse. Never connect a jumper wire across a short circuit. The direct battery short will blow the fuse. Short Finder (Short Circuit Locator) Short finders are available to locate shorts to ground. The short finder creates a pulsing magnetic field in the shorted circuit which you can follow to the location of the short. To order any test equipment shown above, contact your local tool supplier. For a list of suppliers and tool numbers, refer to Honda Required Special Tools and Equipment Service Bulletin. Page 5029 Vacuum Brake Booster: Service and Repair Vacuum Booster Assembly Removal 1. Before removing the vacuum booster assembly, disconnect and remove the brake pipes. 2. Remove master cylinder. CAUTION: When removing the master cylinder from the vacuum booster, be sure to get rid of the internal negative pressure of the vacuum booster (by, for instance, disconnecting the vacuum hose) in advance. - If any negative pressure remains in the vacuum booster, the piston may possibly come out when the master cylinder is being removed, letting the brake fluid run out. - Do not hold the piston while removing the master cylinder, the piston can be easily pulled out. - Outside surface of the piston is the surface on which seals are to slide. Care should be taken to keep the surface free of cuts and dents. 3. Remove vacuum hose 4. Disconnect the yoke clevis from the brake pedal 5. Remove vacuum booster fixing nut 6. Remove vacuum booster Inspection and Repair Vacuum Hose (The built in check valve) 1. Inspect the check valve (2), which is installed inside the vacuum hose. 2. Air should pass freely from the vacuum booster (3) to the engine (1). 3. Air should not pass from the engine (1) to the vacuum booster (3). If it does, the check valve is inoperative and the vacuum hose built in the check valve must be replaced. Description and Operation Fuel Filler Cap: Description and Operation Fuel filler cap includes vacuum valve. In case any high vacuum happen in tank, the valve works to adjust the pressure to prevent the tank from being damaged. Locations Page 4064 Shifter A/T: Service and Repair REMOVAL 1. Disconnect battery ground cable. 2. Set ignition Key in "LOCK" position and selector lever in "P" position. 3. Remove transfer control lever knob (4x4). 4. Remove lower cluster assembly. 5. Remove rear console. 6. Remove center console. Page 3408 Wire Color Abbreviations The following abbreviations are used to identify wire colors in the circuit schematics: WHT................................... White YEL................................... Yellow BLK................................... Black BLU................................... Blue GRN................................... Green RED................................... Red ORN................................... Orange PNK................................... Pink BRN................................... Brown GRY................................... Gray PUR................................... Purple LT BLU................................... Light Blue LT GRN................................... Light Green Engine Controls - High/Erratic Engine Idle Grounding Point: All Technical Service Bulletins Engine Controls - High/Erratic Engine Idle 01-080 August 14, 2001 Applies To: 2000-02 Passport - ALL 2000-02 Passport: High or Erratic Idle SYMPTOM The engine occasionally idles at too high a speed, or the idle speed fluctuates. PROBABLE CAUSES The symptom could be the result of any of these conditions: ^ Loose or corroded engine or body ground ^ High resistance in the APPS ground circuit ^ PSP (power steering pressure) switch is internally shorted to ground ^ Fuel pressure regulator is leaking fuel into the intake manifold CORRECTIVE ACTION Diagnose the cause of the idle condition, and select the proper REPAIR PROCEDURE. PARTS INFORMATION REQUIRED MATERIALS REQUIRED SOFTWARE Each REPAIR PROCEDURE requires you to use the Smart Cable to reprogram the PCM with the latest software. To select the latest software from the CDROM, enter the year, model, engine, transmission, and emissions type (49-state or California). This gives you a list of broadcast codes. Select the broadcast code at the top of the list. WARRANTY CLAIM INFORMATION Refer to the Warranty Claim Information for each Repair Procedure. DIAGNOSIS 1. Find out from the customer when the high or erratic idle condition occurs and what the RPM range is: ^ Within 20 minutes of a cold start ^ After braking to a stop ^ All the time ^ Intermittently, with no set pattern Page 436 - Tear off the insulator carefully. - Remove the sensor fixing clip. - Use a back-up wrench when disconnecting all refrigerant pipes. Installation To install, follow the removal steps in the reverse order, noting the following points: 1. The sensor is installed on the core with the clip. 2. The sensor must not interfere with the evaporator core. 3. When installing the new evaporator core, install the duct sensor (2) to the evaporator core (1) specified position with the clip in the illustration. 4. O-rings cannot be reused. Always replace with new ones. 5. Be sure to apply new compressor oil to the O-ring when connecting lines. 6. Be sure to install the sensor and the insulator on the place where they were before. 7. To install a new evaporator core, add 50cc (1.7 fl.oz.) of new compressor oil to the new core. 8. Tighten the refrigerant lines to the specified torque. Refer to Main Data and Specifications for Torque Specifications. 9. Apply an adhesive to the parting face of the lining when assembling the evaporator assembly. Page 5764 Page 5760 ^ If this is your first time using the pop nut installer, or if you haven't used it in a while, practice installing one or two pop nuts onto the pop nut test plate: - Place a pop nut at the tip of installer's threaded mandrel. Make sure to keep your fingers away from the gap between the pop nut and the base of the mandrel. Squeeze the installer's trigger; the pop nut threads onto the mandrel. - Insert the pop nut into a hole on the pop nut test plate. Make sure the pop nut is seated against the plate. - Squeeze and hold the installer's trigger until the mandrel reverses and unthreads the pop nut. - Measure the diameter of the expanded (crush) section of the installed pop nut; it should be at least 15 mm. If you need more practice, install another pop nut on the test plate. 34. Install a pop nut in each of the 32 holes you drilled on the frame rails (16 per bracket). Make sure each pop nut is seated against the frame before you pull the trigger. Continue holding the trigger until the mandrel reverses direction. Once reversed, pull back slightly, and the mandrel unthreads the pop nut. Recall - Potential Rear Trailing Link Bracket Corrosion Technical Service Bulletin # 10-079 Date: 110217 Recall - Potential Rear Trailing Link Bracket Corrosion 10-079 February 17, 2011 Applies To: 1998-02 Passport - ALL Safety Recall: Corrosion On Lower Trailing Link Front Brackets (Supersedes 10-079, dated February 11, 2011, to revise the information marked by the black bars/shown with asterisks) REVISION SUMMARY BACKGROUND Over time, in areas that use road salt, excessive corrosion can develop on or near the brackets attaching the lower trailing links to the frame. If the corrosion reaches a heavy stage, a clunking noise may be heard during acceleration and braking. In rare cases of severe corrosion, a trailing link could separate from the frame. If this happens, vehicle handling could be affected, increasing the risk of a crash. Road salt is commonly used in an area known as the salt belt." As shown in the shaded area of the map, the salt belt includes these states: Connecticut, Delaware, Illinois, Indiana, Iowa, Kentucky, Maine, Maryland, Massachusetts, Michigan, Minnesota Missouri, New Hampshire, New Jersey, New York, Ohio, Pennsylvania, Rhode Island, Vermont, West Virginia, Wisconsin, and Washington D.C. CUSTOMER NOTIFICATION All owners of affected vehicles that were originally purchased or currently registered in a salt belt state will be sent a notification of this campaign. Two different notifications are being sent: one for vehicles less than 10 years old (as of September 22, 2010), and another for vehicles more than 10 years old (as of September 22, 2010). Examples of both customer notifications are at the end of this service bulletin. Before beginning work on a vehicle, verify its eligibility by checking at least one of these items: ^ The customer has a notification letter. ^ The vehicle is shown as eligible on an iN VIN status inquiry. In addition, check for a campaign completion label on the back edge of the driver's door, just below the door latch. This label indicates that the campaign has already been completed. Complete the recall repair on an eligible vehicle even if the vehicle is now located in a non-salt belt state. Page 7707 If there is no photo number below or beside a component name or a connector, ground, or terminal number, look up that name or number in the appropriate Connector Identification Chart. The chart lists how many cavities a connector has, where it's located, and what it connects to. The related illustration shows the connector's location on the harness, and the harness routing. NOTE: Photos listed by number are located at Locations / Components / Photograohs. See: Locations/Component Locations/Photographs Circuit Schematics Page 702 4. Remove the fuel pressure regulator from the fuel rail. 5. Remove the fuel return line from the regulator. 6. Install the new fuel pressure regulator in the reverse order of removal. 7. Use the Smart Cable to reprogram the PCM with the latest software from the June 2001 or later HONDANET CD-ROM. Refer to Service Bulletin 99-005, Updating the Passport PCM, filed under Tools. 8. Use the PGM Tester to clear any DTCs. 9. Use the PGM Tester to check the broadcast code. Make sure the broadcast code matches the one you selected from the CD-ROM. WARRANTY CLAIM INFORMATION In warranty: The normal warranty applies. Failed Part: P/N 8-17113-398-0 H/C 5504386 Defect Code: 092 Contention Code: C99 Skill Level: Repair Technician Out of warranty: Any repair performed after warranty expiration may be eligible for goodwill consideration by the District Service Manager or your Zone Office. You must request consideration, and get a decision, before starting work. REPAIR PROCEDURE - POWER STEERING SWITCH 1. Drain the power steering fluid out of the system. 2. Remove the power steering fluid reservoir. Clean the reservoir with solvent, then with soap and water. Rinse and dry it thoroughly. 3. Reinstall the reservoir. Do not connect the return hose. 4. Remove the power steering pressure switch, then clean it with brake cleaner and a scraper. Reinstall the switch, and torque it to 20 N.m (14 lb-ft). 5. Cover the unconnected end of the reservoir with your finger, then fill the reservoir with Dexron III ATF Page 679 Oxygen Sensor: Service and Repair HEATED OXYGEN SENSOR (HO2S) REMOVAL PROCEDURE 1. Disconnect the negative battery cable. 2. Locate the four oxygen sensors. - Bank 1 sensor 1 is mounted on the exhaust pipe ahead of the right-hand catalytic converter. - Bank 1 sensor 2 is mounted behind the right-hand catalytic converter. Page 7000 1. Remove the rear console assembly. 2. Remove the ashtray/rear beverage holder assembly from the rear console. 3. Open the beverage holder lid, and move the beverage holder swing arm to a position halfway between open and closed. Page 5419 4. Remove the old metal detent clips. 5. Install two new metal detent clips. 6. Reinstall the ashtray/rear beverage holder assembly onto the rear console. 7. Plug in the connector (A/T), and reinstall the rear console assembly. 8. Open and close the rear beverage holder swing arm several times to make sure the detents hold. DISCLAIMER Page 2012 Splices Splices are shown as a dot. Their location and the number of wires may vary depending on the harness manufacturer. Switches Switches These switches move together; the broken straight line between them means they are mechanically connected. Other types of switches are controlled by a coil or a solid state circuit. Unless otherwise noted, all switches are shown in their normal (rest) position, with power off. Terminal "T" Description and Operation EGR Valve Position Sensor: Description and Operation EGR Pintle Position Sensor The PCM monitors the EGR valve pintle position input to endure that the valve responds properly to commands from the PCM and to detect a fault if the pintle position sensor and control circuits are open or shorted. If the PCM detects a pintle position signal voltage outside the normal range of the pintle position sensor, or a signal voltage that is not within a tolerance considered acceptable for proper EGR system operation, the PCM will set DTC P1406. Page 1238 Refrigerant: Fluid Type Specifications Refrigerant Type HFC-134a (R-134a) Front Brake Pad: Testing and Inspection Front Check the outer pad by looking at each caliper from above. Check the thickness on the inner pad by looking down through the inspection hole in the top of the caliper. Whenever the pad is worn to about the thickness of the pad base, the pad should be removed for further measurements. The pad should be replaced anytime the pad thickness (1) is worn to within 1.00 mm (0.039 inch) of the pad itself. The disc pads have a wear indicator that makes a noise when the pad wears to where the replacement is required. Minimum limit (1): 1.0 mm (0.039 inch) Page 5677 View A REMOVAL 1. Disconnect the battery ground cable. 2. Remove the front console assembly. 3. Disconnect the connector from the control unit. 4. Remove 4 nuts. 5. Disconnect the control unit with brackets. 6. Remove 4 screws. 7. Disconnect the control unit from brackets. INSTALLATION To install, follow the removal steps in the reverse order, noting the following points. Torque: Nut (1) 8 Nm (69 inch lbs.) Page 4202 Actuator: Testing and Inspection MOTOR ACTUATOR ASSEMBLY Inspect the function of the motor actuator assembly as follows: 1. Disassemble the motor actuator from transfer rear case. 2. Connect the terminals as shown in figure. Shift rod of the motor actuator moves and stops at 4WD position. Page 269 Wire Color Abbreviations The following abbreviations are used to identify wire colors in the circuit schematics: WHT................................... White YEL................................... Yellow BLK................................... Black BLU................................... Blue GRN................................... Green RED................................... Red ORN................................... Orange PNK................................... Pink BRN................................... Brown GRY................................... Gray PUR................................... Purple LT BLU................................... Light Blue LT GRN................................... Light Green Page 6854 14. Remove the glass. - First, align the height of regulator to the access hole. Remove 2 screws attaching bottom channel and regulator, then remove the glass. - Remove the window glass by tilting it as necessary. 15. Remove the window regulator. - Remove the window regulator fixing bolts and pull the regulator out from the lower hole of the door panel. 16. Remove the glass run. - Pull the glass run out from the door frame. Installation Page 4750 Transmission Speed Sensor: Locations Top Of Transfer Case Page 7382 The connector cavity number is listed next to each terminal on the circuit schematic. The cavity / terminal shown is # 6. Diodes A rectifier diode works like a one way valve. It allows current to flow only in the direction of the arrow. A Zener diode blocks reverse current at normal voltages just like a rectifier diode. At high voltages, however, a Zener diode allows current to flow in reverse. Fuses Page 5307 Test Equipment CAUTION: Most circuits include solid-state devices. Test the voltages in these circuits only with a 10-megaohm or higher impedance digital multimeter. Never use a test light or analog meter on circuits that contain solid-state devices. Damage to the devices may result. Test Light and DVOM On circuits without solid-state devices, use a test light to check for voltage. A test light is made up of a 12 volt bulb with a pair of leads attached. After grounding one lead, touch the other lead to various points along the circuit where voltage should be present. The bulb will go on if there is voltage at the point being tested. If you need to know how much voltage is present, use a digital volt/ohmmeter (DVOM). Self-Powered Test Light and DVOM Use a self-powered test light to check for continuity. This tool is made up of a light bulb, battery, and two leads. To test it, touch the leads together: the light should go on. Use a self-powered test light only on an unpowered circuit. First, disconnect the battery, or remove the fuse that feeds the circuit you are working on. Select two points in the circuit between which you want to check continuity. Connect one lead of the self-powered test light to each point. If there is continuity, the test light's circuit will be completed, and the light will go on. If, in addition, you need to know exactly how much resistance there is between two points, use a digital volt/ohmmeter (DVOM). In the "OHMS" range, the DVOM will measure resistance between two points along a circuit. Low resistance means good continuity. Diodes and solid-state devices in a circuit can make a DVOM give a false reading. To check a reading, reverse the leads, and take a second reading. If the readings differ, the component is affecting the measurement. Jumper Wire Use a jumper wire to bypass an open circuit. A jumper wire is made up of an in-line fuse holder connected to a set of test leads. It should have a five ampere fuse. Never connect a jumper wire across a short circuit. The direct battery short will blow the fuse. Short Finder (Short Circuit Locator) Short finders are available to locate shorts to ground. The short finder creates a pulsing magnetic field in the shorted circuit which you can follow to the location of the short. To order any test equipment shown above, contact your local tool supplier. For a list of suppliers and tool numbers, refer to Honda Required Special Tools and Equipment Service Bulletin. Page 5763 If you need more labels, order them from Helm using reorder number Y0895.* Page 5972 1. Make sure the ignition key is not in the ignition switch. 2. Open the glove box, and empty out its contents. Gently squeeze the sides of the glove box together to release the stops, then lower it all the way. 3. 2000-01 Models: Slide the intake actuator relay off its mounting bracket, and move it out of the way. 4. Unplug the 6P connector from the blower resistor, then remove and discard the resistor (two screws). 5. Unplug the 2P connector from the blower motor, then remove and discard the blower motor assembly (four screws). Page 1033 DIAGNOSTIC WORKSHEET REPAIR PROCEDURE A Page 4639 Shift Solenoid: Service and Repair REMOVAL 1. Raise the vehicle and support it on jack stands. 2. Disconnect battery ground cable. 3. Drain fluid. 4. Remove sixteen 10 mm screws, main case oil pan, magnet, and gasket. 5. Remove three 13 mm screws, oil filter. 6. Disconnect wiring harness from band control solenoid and shift solenoids. Pull only on connectors, not on wiring harness. 7. Remove spring pin for shift solenoid A, shift solenoid B, and band control solenoid respectively, using suitable pliers taking care not to damage solenoids. 8. Remove shift solenoid A, shift solenoid B, band control solenoid, and gaskets from main case valve body. Do not pull on wiring harness. Remove solenoids by grasping the metal tip. INSTALLATION 1. Install shift solenoid A, shift solenoid B, band control solenoid with new gaskets to main case valve body respectively. 2. Carefully install spring pin with hammer to avoid damage to valve body, etc. 3. Connect wiring harness to solenoids. 4. Install oil filter with a new gasket and the three 13 mm screws, tighten to the specified torque. Torque: 20 Nm (15 Ft. lbs.) Diagram Information and Instructions Radio/Stereo: Diagram Information and Instructions How to Identify Wiring Color-Coded Insulation Wire Color Wire Color Coding Page 502 Test Equipment CAUTION: Most circuits include solid-state devices. Test the voltages in these circuits only with a 10-megaohm or higher impedance digital multimeter. Never use a test light or analog meter on circuits that contain solid-state devices. Damage to the devices may result. Test Light and DVOM On circuits without solid-state devices, use a test light to check for voltage. A test light is made up of a 12 volt bulb with a pair of leads attached. After grounding one lead, touch the other lead to various points along the circuit where voltage should be present. The bulb will go on if there is voltage at the point being tested. If you need to know how much voltage is present, use a digital volt/ohmmeter (DVOM). Self-Powered Test Light and DVOM Use a self-powered test light to check for continuity. This tool is made up of a light bulb, battery, and two leads. To test it, touch the leads together: the light should go on. Use a self-powered test light only on an unpowered circuit. First, disconnect the battery, or remove the fuse that feeds the circuit you are working on. Select two points in the circuit between which you want to check continuity. Connect one lead of the self-powered test light to each point. If there is continuity, the test light's circuit will be completed, and the light will go on. If, in addition, you need to know exactly how much resistance there is between two points, use a digital volt/ohmmeter (DVOM). In the "OHMS" range, the DVOM will measure resistance between two points along a circuit. Low resistance means good continuity. Diodes and solid-state devices in a circuit can make a DVOM give a false reading. To check a reading, reverse the leads, and take a second reading. If the readings differ, the component is affecting the measurement. Jumper Wire Use a jumper wire to bypass an open circuit. A jumper wire is made up of an in-line fuse holder connected to a set of test leads. It should have a five ampere fuse. Never connect a jumper wire across a short circuit. The direct battery short will blow the fuse. Short Finder (Short Circuit Locator) Short finders are available to locate shorts to ground. The short finder creates a pulsing magnetic field in the shorted circuit which you can follow to the location of the short. To order any test equipment shown above, contact your local tool supplier. For a list of suppliers and tool numbers, refer to Honda Required Special Tools and Equipment Service Bulletin. Page 1440 6. Remove twenty fixing bolts from inlet and exhaust camshaft bracket on one side bank, then camshaft brackets. 7. Remove camshaft assembly. 8. Remove fixing bolt for camshaft drive gear pulley. 9. Remove three fixing bolts from camshaft drive gear retainer, then camshaft drive gear assembly. Installation 1. Install camshaft drive gear assembly and tighten three bolts to the specified torque. Torque: 10 Nm (89 inch lbs.) 2. Tighten bolt for camshaft drive gear assembly pulley to the specified torque. Torque: 98 Nm (72 ft. lbs.) 3. Tighten sub gear setting bolt. 4. Use J-42686 to turn sub gear to right direction until it aligns with the M5 bolt hole between camshaft driven gear and sub gear. 5. Tighten the M5 bolt to a suitable torque to prevent the sub gear from moving. 6. Install camshaft assembly and camshaft brackets, tighten twenty bolts on one side bank to the specified torque. 7. Apply engine oil to camshaft journal and bearing surface of camshaft bracket. Page 3321 INSTALLATION PROCEDURE 1. If the fuel injectors were removed, install them. 2. If the fuel pressure regulator was removed, install it. 3. Install the common chamber. 4. Connect the vacuum hose on Canister VSV and positive crankcase ventilation hose. 5. Connect the connectors to manifold absolute pressure sensor, solenoid valve, electric vacuum sensing valve. 6. Connect the throttle position sensor electrical connector to throttle body. 7. Install the engine cover. 8. Connect the negative battery cable. 9. Crank the engine until it starts. Cranking the engine may take longer than usual due to trapped air in the fuel rail and in the injectors. Page 1003 NOTE: Do this repair procedure if, after doing step 10 of the test-drive, the vehicle pulled in the opposite direction after you swapped the front tires. 1. Swap wheels 2 and 4 on the passenger's side of the vehicle, and test-drive again. ^ If the pull goes away, replace the tire on wheel 2, then go to step 3. ^ If the pull does not go away, put wheels 2 and 4 back to their original positions, and go to step 2. 2. Swap wheels 1 and 3 on the driver's side of the vehicle, and test-drive again. ^ If the pull goes away, replace the tire on wheel 1, then go to step 3. ^ If the pull does not go away, use a known-good tire in position 1 and continue diagnosis. 3. Use your diagnosis worksheet to fill in the following table and build your 15-digit DTC. REPAIR PROCEDURE B Locations Page 5066 Part 1 of 2 Part 2 of 2 B-22 Rear Speed Sensor Missing (DTC 63/C0237) Chart B-22 Rear Speed Sensor Missing (DTC 63 (Flash Out) / C0236, C0237 (Serial Communications)) Page 6022 6. Use a clean shop towel or a shop vacuum to remove any debris from the inside of the blower assembly housing. 7. Install the new blower resistor. 8. Install the new blower motor assembly and gasket, and plug in the 2P connector. 9. Plug the 6P connector into the new blower resistor. 10. 2000-01 Models: Reinstall the intake actuator relay. 11. Lift up the glove box, and push it back into the stops. Return the contents to the glove box. 12. Start the engine, and run the blower to make sure it works properly. Disclaimer Page 4216 The name of the component appears next to it followed by notes about its function along with any photo and connector view references. Connector "C" How to Identify Connector Terminals Cavity Numbering System The cavities (and wire terminals) in each connector are numbered starting from the upper left, looking at the male terminals from the terminal side (or looking at the female terminals from the wire side. Both views are in the same direction so the numbers are the same.) All actual cavities are numbered, even if they have no wire terminals in them. NOTE: Data Link Connector (DLC) terminals are numbered according to SAE standard J1962, not the Honda standard. The numbers of the four end terminals are molded into the corners of the connector face. Page 991 ^ Loosen the front subframe bolts. See the applicable service manual for more information. NOTE: The front wheels are being viewed from the rear of the vehicle. ^ Depending which way you need to shift the subframe, insert a pry bar between the subframe and body at both the front and rear positions of the subframe. NOTE: Be careful not to damage the vehicle. You could bend and damage the frame and/or body if you apply too much pressure. ^ Press on both pry bars to shift the subframe. It will move only a few millimeters. This should adjust the camber about 0.2-0.5°. ^ While holding the subframe in place, have an assistant torque the subframe bolts to their proper torque. Front Camber Adjustment, Strut Suspension ^ Raise the vehicle, and remove the front tires. ^ Loosen the damper pinch bolts and the flange nuts. ^ Adjust the camber by moving the bottom of the damper within the range of the damper pinch bolt free play. NOTE: Some vehicles have special pinch bolts that allow more adjustment. For more information, refer to the parts catalog. ^ Tighten the damper pinch bolts to the specified torque. ^ Reinstall the front wheels and lower the vehicle. Bounce the front of the vehicle several times to stabilize the suspension. Page 6690 Test Equipment CAUTION: Most circuits include solid-state devices. Test the voltages in these circuits only with a 10-megaohm or higher impedance digital multimeter. Never use a test light or analog meter on circuits that contain solid-state devices. Damage to the devices may result. Test Light and DVOM On circuits without solid-state devices, use a test light to check for voltage. A test light is made up of a 12 volt bulb with a pair of leads attached. After grounding one lead, touch the other lead to various points along the circuit where voltage should be present. The bulb will go on if there is voltage at the point being tested. If you need to know how much voltage is present, use a digital volt/ohmmeter (DVOM). Self-Powered Test Light and DVOM Use a self-powered test light to check for continuity. This tool is made up of a light bulb, battery, and two leads. To test it, touch the leads together: the light should go on. Use a self-powered test light only on an unpowered circuit. First, disconnect the battery, or remove the fuse that feeds the circuit you are working on. Select two points in the circuit between which you want to check continuity. Connect one lead of the self-powered test light to each point. If there is continuity, the test light's circuit will be completed, and the light will go on. If, in addition, you need to know exactly how much resistance there is between two points, use a digital volt/ohmmeter (DVOM). In the "OHMS" range, the DVOM will measure resistance between two points along a circuit. Low resistance means good continuity. Diodes and solid-state devices in a circuit can make a DVOM give a false reading. To check a reading, reverse the leads, and take a second reading. If the readings differ, the component is affecting the measurement. Jumper Wire Use a jumper wire to bypass an open circuit. A jumper wire is made up of an in-line fuse holder connected to a set of test leads. It should have a five ampere fuse. Never connect a jumper wire across a short circuit. The direct battery short will blow the fuse. Short Finder (Short Circuit Locator) Short finders are available to locate shorts to ground. The short finder creates a pulsing magnetic field in the shorted circuit which you can follow to the location of the short. To order any test equipment shown above, contact your local tool supplier. For a list of suppliers and tool numbers, refer to Honda Required Special Tools and Equipment Service Bulletin. Page 6401 SURROUNDING AREAS OF THE DRIVER AIR BAG ASSEMBLY WILL BE VERY HOT. DO NOT TOUCH THE METAL AREAS OF THE DRIVER AIR BAG ASSEMBLY FOR ABOUT TEN MINUTES AFTER DEPLOYMENT. IF THE DEPLOYED DRIVER AIR BAG ASSEMBLY MUST BE MOVED BEFORE IT IS COOL, WEAR GLOVES AND HANDLE BY THE AIR BAG OR TRIM COVER. 21. Disconnect the pigtail adapter from the driver airbag assembly immediately after deployment. This will prevent damage to the pigtail adapter or SRS deployment harness due to possible contact with the hot driver air bag assembly canister. The pigtail adapter can be reused. They should, however, be inspected for damage after each deployment and replaced If necessary. 22. Dispose of the deployed driver air bag assembly through normal refuse channels after it has cooled for at least 30 minutes. 23. Wash your hands with mild soap and water afterward. NOTE: The remaining steps are to be followed in the unlikely event that the driver air bag assembly did not deploy after following these procedures. 24. Ensure that the SRS deployment harness has been disconnected from the power source and that its two banana plugs have been shorted together by fully seating one banana plug into the other. 25. Disconnect the pigtail adapter from the driver air bag assembly. WARNING: WHEN STORING A LIVE AIR BAG ASSEMBLY OR WHEN LEAVING A LIVE INFLATOR MODULE UNATTENDED ON A BENCH OR OTHER SURFACE, ALWAYS FACE THE BAG AND TRIM COVER UP AND AWAY FROM THE SURFACE. THIS IS NECESSARY SO THAT A FREE SPACE IS PROVIDED TO ALLOW THE AIR BAG TO EXPAND IN THE UNLIKELY EVENT OF ACCIDENTAL DEPLOYMENT. FAILURE TO FOLLOW PROCEDURES MAY RESULT IN PERSONAL INJURY. 26. Temporarily store the driver air bag assembly with its trim cover facing up. Deployment Tool Check Procedure Deployment Tool Check 1. Connect the yellow clips to both switch protector handles on the tool; connect the tool to a battery. 2. Push the operation switch: green means the tool is OK; red means the tool is faulty. 3. Disconnect the battery and the yellow clips. Disposal of Damaged Components Disposal of Damaged Components 1. If installed in a vehicle, follow the removal procedure for the driver's airbag, front passenger's airbag, side airbag, seat belt tensioner, and seat belt buckle tensioner. 2. In all cases, make a short circuit by cutting, stripping, and twisting together the two inflator wires. NOTE: The driver's and passenger's airbag each have four wires: twist each pair of like-colored wires together 3. Package the component in the same packaging that the new replacement part came in. 4. Mark the outside of the box "DAMAGED AIRBAG NOT DEPLOYED", "DAMAGED SIDE AIRBAG NOT DEPLOYED", "DAMAGED SEAT BELT TENSIONER NOT DEPLOYED" or "DAMAGED SEAT BELT BUCKLE TENSIONER NOT DEPLOYED" so it does not get confused with your parts stock. 5. Contact your Honda District Service Manager for how and where to return it for disposal. Page 735 c. Remove mode switch connector with bracket from the transmission case. d. Connect multimeter (resistance mode) to terminals 1(E) and 4(H) on mode switch connector. e. Loosen two mounting screws. f. Rotate mode switch slightly in both directions to determine the range (approx. 5 degrees) of electrical contact. g. Position mode switch in middle of contact range. h. Tighten two mounting screws. i. Remove multimeter and install mode switch harness connector with bracket to the transmission case. j. Connect transmission harness connector to mode switch connector. Page 3796 4. Remove the fuel pressure regulator from the fuel rail. 5. Remove the fuel return line from the regulator. 6. Install the new fuel pressure regulator in the reverse order of removal. 7. Use the Smart Cable to reprogram the PCM with the latest software from the June 2001 or later HONDANET CD-ROM. Refer to Service Bulletin 99-005, Updating the Passport PCM, filed under Tools. 8. Use the PGM Tester to clear any DTCs. 9. Use the PGM Tester to check the broadcast code. Make sure the broadcast code matches the one you selected from the CD-ROM. WARRANTY CLAIM INFORMATION In warranty: The normal warranty applies. Failed Part: P/N 8-17113-398-0 H/C 5504386 Defect Code: 092 Contention Code: C99 Skill Level: Repair Technician Out of warranty: Any repair performed after warranty expiration may be eligible for goodwill consideration by the District Service Manager or your Zone Office. You must request consideration, and get a decision, before starting work. REPAIR PROCEDURE - POWER STEERING SWITCH 1. Drain the power steering fluid out of the system. 2. Remove the power steering fluid reservoir. Clean the reservoir with solvent, then with soap and water. Rinse and dry it thoroughly. 3. Reinstall the reservoir. Do not connect the return hose. 4. Remove the power steering pressure switch, then clean it with brake cleaner and a scraper. Reinstall the switch, and torque it to 20 N.m (14 lb-ft). 5. Cover the unconnected end of the reservoir with your finger, then fill the reservoir with Dexron III ATF Procedures Power Mirror Switch: Procedures Removal 1. Disconnect the battery ground cable. 2. Remove the instrument panel lower cover (2). 3. Remove the door mirror switch (1). Page 5467 ^ If the idle speed ever exceeds 1,300 rpm 2. Remove the vacuum hose from the fuel pressure regulator, then start the engine. ^ If fuel comes out of the fuel pressure regulator vacuum hose connection, go to REPAIR PROCEDURE FUEL PRESSURE REGULATOR. ^ If no fuel comes out of the regulator, reconnect the vacuum hose and continue to step 3. 3. Connect the PGM Tester. Set it to Engine Data List. 4. Have an assistant drive the vehicle under the conditions described by the customer. 5. If the high or erratic idle condition occurs, note the values of the PSP Switch and APP Sensor 1 when it is occurring. ^ If the PSP Switch is HIGH, and you are not turning, go to REPAIR PROCEDURE POWER STEERING SWITCH. ^ If the APP Sensor 1 is greater than 15% and APP Sensor 2 and/or APP Sensor 3 are less than 85%, and the accelerator pedal is not depressed, go to REPAIR PROCEDURE APPS GROUND. ^ If the PSP Switch is reading LOW when not turning and HIGH when turning, and the APP Sensors are reading within the range shown, discontinue the test-drive and go to step 6. 6. Do these repairs: ^ REPAIR PROCEDURE APPS GROUND ^ REPAIR PROCEDURE ENGINE/BODY GROUND REPAIR PROCEDURE - FUEL PRESSURE REGULATOR 1. Relieve fuel system pressure: ^ Remove the fuel fill cap. ^ Remove the fuel pump relay. ^ Start the engine and run it until it stalls. ^ Crank the engine for 3 seconds. 2. Remove the vacuum hose from the fuel pressure regulator. 3. Remove the fuel pressure regulator shield from the common chamber (two bolts). A/T - Avoiding Fluid Contamination Fluid - A/T: Technical Service Bulletins A/T - Avoiding Fluid Contamination SOURCE: Honda Service News TITLE: Avoiding Comebacks From A/T Contamination APPLIES TO: All models SERVICE TIP: Installing a reman A/T? Here are some important tips to keep in mind to ensure a first-time fix and to avoid any come-backs: - If the vehicle has an ATF cooler, make sure you clean the cooler with the ATF Cooler Cleaner (P/N GHTTTCF6H). See S/B 89-022, ATF Cooler Cleaner, for details. - If the reman A/T kit includes an in-line filter, don't forget to install it. If the vehicle already has an in-line filter from an earlier A/T replacement, then remove the existing filter, and install the new one. - Spray the driveshaft splines with solvent and compressed air before installing them in the reman A/T. If the failed A/T had a speed sensor, make sure it's clean before you install it. Debris from the failed A/T can catch in the driveshaft splines or on the speed sensor and contaminate the reman A/T. - If the reman A/T comes with a heater/cooler, make sure you install the reman A/T with that heater/cooler. Never install the heater/cooler from the failed A/T; you could contaminate the reman A/T. Page 4351 Drive/Propeller Shaft: Specifications Front Propeller Shaft FRONT PROPELLER SHAFT General Specifications Torque Specifications Page 6108 If there is no photo number below or beside a component name or a connector, ground, or terminal number, look up that name or number in the appropriate Connector Identification Chart. The chart lists how many cavities a connector has, where it's located, and what it connects to. The related illustration shows the connector's location on the harness, and the harness routing. NOTE: Photos listed by number are located at Locations / Components / Photograohs. See: Locations/Component Locations/Photographs Circuit Schematics Audio System - CD/DVD Precautions Compact Disc Player (CD): All Technical Service Bulletins Audio System - CD/DVD Precautions Adhesive Labels or Protective Disc Covers on CDs or DVDs: A Big Taboo NOTE: This article applies to all Honda models with a factory- or dealer-installed CD/DVD player or changer. We can't emphasize this enough: Never put adhesive labels or protective disc covers on recordable CDs or DVDs to be used in automotive CD/DVD players or changers. Here's why: ^ Recordable CDs and DVDs are actually thicker than their pre-recorded brethern. Automotive players and changers use rollers to draw the disc into the unit. The added thickness of an adhesive label or a protective disc cover can cause the disc to jam when it's loaded into or ejected from the unit. ^ CD/DVD players or changers are exposed to high temperatures inside the vehicle. High temperature can cause the label adhesive to soften. This can cause the label to curl on the edges and even form bubbles. Curled edges can catch on the rollers and bubbles add thickness to the disc. Either one can cause the disc to jam. To cut down on customer-caused damage, all '05 and later 0/Ms include this notice: Do not use CDs with adhesive labels. The label can curl up and cause the CD to jam in the unit. Anytime a service customer comes in with a loading or ejecting problem for a CD/DVD player or changer, ask if he or she used any discs with adhesive labels or protective disc covers. If the answer is yes, contact your DPSM for possible goodwill assistance. If the answer is no, then replace the audio unit under normal warranty. Removal and Installation Air Filter Element: Service and Repair Removal and Installation Air Cleaner Element REMOVAL 1. Remove positive ventilation hose connector (1). 2. Remove intake air temperature sensor (2). 3. Remove air flow sensor (3). 4. Remove air cleaner duct assembly (4). 5. Remove air cleaner element (5). INSTALLATION 1. Install air cleaner element (5). 2. Attach the mass air cleaner duct cover to the body completely, then clamp it with the clip (4). 3. Install air flow sensor (3). 4. Install air temperature sensor (2). 5. Install positive crankcase ventilation hose connector (1). Page 5148 7. Loosen the inflator module fixing bolt from behind the steering wheel assembly using a TORE driver or equivalent until the inflator module can be released from steering assembly. 8. Disconnect the yellow 2-way SRS connector and horn lead located behind the inflator module. 9. Apply a setting mark (1) across the steering wheel and shaft so parts can be reassembled in their original position. Page 2443 24. Verify APP Sensor 1 is between 11 and 15 percent, and APP Sensor 2 and APP Sensor 3 are between 89 and 85 percent with the pedal up (closed throttle). If not, loosen the mounting screws on the APPS sensor, and go to step 14. 25. Clear all DTCs with the PGM Tester. 26. Turn off the ignition switch, and disconnect the PGM Tester. Page 6771 Ground - "G" Shielding Sheilding This represents RFI (Radio Frequency Interference) shielding around a wire. The shielding is always connected to ground. Splices Page 665 Manifold Pressure/Vacuum Sensor: Service and Repair MANIFOLD ABSOLUTE PRESSURE (MAP) SENSOR REMOVAL PROCEDURE 1. Disconnect the negative battery cable. 2. Disconnect the electrical connector from the MAP sensor. 3. Remove the bolt securing the MAP sensor to the mounting bracket on the common chamber. 4. Remove the MAP sensor from the mounting bracket. INSTALLATION PROCEDURE 1. Install the MAP sensor in the mounting bracket. 2. Install the mounting bracket retaining bolt on the common chamber. Engine Controls - Engine Spark Knock Or Pinging PROM - Programmable Read Only Memory: All Technical Service Bulletins Engine Controls Engine Spark Knock Or Pinging 01-084 June 19, 2009 Applies To: 2000-02 Passport - ALL Engine Spark Knock (Pinging) (Supersedes 01-084, dated March 18, 2003, to revise the information marked by asterisks) *REVISION SUMMARY Under WARRANTY CLAIM INFORMATION, the failed part number, the Honda code, the defect code, and the symptom code have been updated.* SYMPTOM An engine spark knock (pinging). PROBABLE CAUSE The programmed ignition timing does not correct quickly enough in some climates. CORRECTIVE ACTION Update the PCM software with the Smart Cable. TOOL INFORMATION PGM Tester with software update release SN200P (9/1/01) or later. For the other tools and equipment you need to update the PCM software, refer to Service Bulletin 99-005, Updathg the Passport POM, filed under Tools. WARRANTY CLAIM INFORMATION In warranty: The normal warranty applies. Operation Number: 125517 Flat Rate Time: 0.3 hour *Failed Part: P/N 8-12212-079-0 H/C 6974992 Defect Code: 03214 Symptom Code: 09117* Template ID: 01-084A Skill Level: Repair Technician Out of warranty: Any repair performed after warranty expiration may be eligible for goodwill consideration by the District Parts and Service Manager or your Zone Office. You must request consideration, and get a decision, before starting work. REPAIR PROCEDURE 1. Retrieve the PCM broadcast code with the PGM Tester or the Smart Cable (refer to Service Bulletin 99-005, Updathg the Passport PCM). Page 7406 and the fuses. From Fuses to Relays and Components The second half of Power Distribution shows the wiring "From Fuses to Relays and Components." This can speed your troubleshooting by showing which circuits share fuses. If Power Distribution shows that an inoperative circuit and another circuit share a fuse, check a component in the other circuit. If it works, you know the fuse is good and power is available to the inoperative circuit. Ground Distribution Schematics Page 6304 2. Connect one lead of a self-powered test light or DVOM to one end of the part of the circuit you want to test. 3. Connect the other lead to the other end. 4. If the self-powered test light glows, there is continuity. If you're using a DVOM, a low reading or no reading (zero), means good continuity. Testing For Voltage When testing for voltage at a connector without wire seals, you do not have to separate the two halves of the connector. Instead, probe the connector from the back. Always check both sides of the connector because dirty, corroded, and bent terminals can cause problems (no electrical contact = an open). 1. Connect one lead of the lest light to a known good ground, or, if you're using a digital volt ohmmeter (DVOM), place it in the appropriate DC volts range, and connect its negative lead to ground. 2. Connect the other lead of the test light or DVOM to the point you want to check. 3. If the test light glows, there is voltage present. If you're using a DVOM, note the voltage reading. It should be within one volt of measured battery voltage. A loss of more than one volt indicates a problem. NOTE: Always use a DVOM on high impedance circuits. A test light may not glow (even with battery voltage present). Testing For Voltage Drop Wires, connectors, and switches are designed to conduct current with a minimum loss of voltage. A voltage drop of more than one volt indicates a problem. 1. Place the digital volt/ohmmeter (DVOM) in the appropriate DC volts range. Connect the positive lead to the end of the wire (or to the connector or switch) closest to the battery. 2. Connect the negative lead to the other end of the wire (or the other side of the connector or switch). 3. Turn on the components in the circuit. 4. The DVOM will show the difference in voltage between the two points. A difference, or drop, of more than one volt indicates a problem. Check the circuit for loose, dirty, or bent terminals. Page 4289 4. If the trouble occurs after the above test, charge the Axle Disconnect controller to the new one. Page 3026 Test Equipment CAUTION: Most circuits include solid-state devices. Test the voltages in these circuits only with a 10-megaohm or higher impedance digital multimeter. Never use a test light or analog meter on circuits that contain solid-state devices. Damage to the devices may result. Test Light and DVOM On circuits without solid-state devices, use a test light to check for voltage. A test light is made up of a 12 volt bulb with a pair of leads attached. After grounding one lead, touch the other lead to various points along the circuit where voltage should be present. The bulb will go on if there is voltage at the point being tested. If you need to know how much voltage is present, use a digital volt/ohmmeter (DVOM). Self-Powered Test Light and DVOM Use a self-powered test light to check for continuity. This tool is made up of a light bulb, battery, and two leads. To test it, touch the leads together: the light should go on. Use a self-powered test light only on an unpowered circuit. First, disconnect the battery, or remove the fuse that feeds the circuit you are working on. Select two points in the circuit between which you want to check continuity. Connect one lead of the self-powered test light to each point. If there is continuity, the test light's circuit will be completed, and the light will go on. If, in addition, you need to know exactly how much resistance there is between two points, use a digital volt/ohmmeter (DVOM). In the "OHMS" range, the DVOM will measure resistance between two points along a circuit. Low resistance means good continuity. Diodes and solid-state devices in a circuit can make a DVOM give a false reading. To check a reading, reverse the leads, and take a second reading. If the readings differ, the component is affecting the measurement. Jumper Wire Use a jumper wire to bypass an open circuit. A jumper wire is made up of an in-line fuse holder connected to a set of test leads. It should have a five ampere fuse. Never connect a jumper wire across a short circuit. The direct battery short will blow the fuse. Short Finder (Short Circuit Locator) Short finders are available to locate shorts to ground. The short finder creates a pulsing magnetic field in the shorted circuit which you can follow to the location of the short. To order any test equipment shown above, contact your local tool supplier. For a list of suppliers and tool numbers, refer to Honda Required Special Tools and Equipment Service Bulletin. Page 56 the component if the component only has one connector, or by a capital letter (A, B, C, etc.) if the component has more than one connector. Below most connector numbers and component names are PHOTO and VIEW numbers. The PHOTO number refers to a photo in the back of the book that shows the connector's location on the car. The VIEW number refers to an illustration in the back of the book that shows the connector face, wire colors, connector cavity numbers, and other details. The connector cavity numbering sequence begins at the top left corner of the connector. Disregard any numbers molded into the connector housing. Wires Wires are identified by the abbreviated names of their colors; the second color is the color of the stripe. Wires are also identified by their location in a connector. The number "2" next to the male and female wire terminals at C416, for example, means those terminals join in cavity 2 of connector C416. Symbols A complete description of schematic symbols is given under wire color abbreviation. Power Distribution Schematics Power Distribution schematics show how power is supplied from the positive battery terminal to various circuits in the car. Refer to the Power Distribution section to get a more detailed picture of how power is supplied to the circuit you're working on. From Battery to Ignition Switch, Fuses, and Relays Individual circuit schematics begin with a fuse. The first half of Power Distribution, however, shows the wiring "upstream" between the battery Locations Page 7409 The connector cavity number is listed next to each terminal on the circuit schematic. The cavity / terminal shown is # 6. Diodes A rectifier diode works like a one way valve. It allows current to flow only in the direction of the arrow. A Zener diode blocks reverse current at normal voltages just like a rectifier diode. At high voltages, however, a Zener diode allows current to flow in reverse. Fuses Page 6351 Air Bag(s) Arming and Disarming: Description and Operation Definitions Air Bag An inflatable cloth cushion designed to deploy in certain frontal crashes. It supplements the protection offered by the seat belts by distributing the impact load more evenly over the vehicle occupant's head and torso. Asynchronous Performed in a nonperiodic fashion, (i.e., no defined time or interval). (B+) Battery voltage, (B+) The voltage available at the battery at the time of the indicated measurement. With the key "ON" and the engine not running, the system voltage will likely be between 12 and 12.5 volts. At idle the voltage may be 14 to 16 volts. The voltage could be as low as 10 volts during engine cranking. Bulb Check The SDM will cause the "AIR BAG" warning lamp to flash seven times and then go "OFF" whenever the ignition switch transitions to the ON position from any other ignition switch position and no malfunctions are detected. "CONTINUOUS MONITORING" Tests performed by the SDM on the SRS every 100 milliseconds while "Ignition 1" voltage is in the normal operating voltage range at the SDM. Data Link Connector (DLC) Formerly "DLC" a connector which allows communication with an external computer, such as a scan tool. Datum Line A base line parallel to the plane of the underbody or frame from which all vertical measurements originate. Deploy To inflate the air bag. Deployment Loops The circuits which supply current to the air bag assemblies to deploy the air bag. Diagnostic Trouble Code (DTC) Formerly "Code", a numerical designator used by the SDM to indicate specific SRS malfunctions. Driver Current Source An output of the SDM which applies current into the driver air bag assembly circuit during the "Initiator Assembly Resistance Test". Driver Air Bag Assembly An assembly located in the steering wheel hub consisting of an inflatable bag, an inflator and an initiator. EEPROM Electronically Erasable Programmable Read Only Memory. Memory which retains its contents when power is removed from the SDM. Ignition Cycle The voltage at the SDM "Ignition 1" inputs, with ignition switch "ON", is within the normal operating voltage range for at least ten seconds before turning ignition switch "OFF". Ignition 1 Page 6682 Ground - "G" Shielding Sheilding This represents RFI (Radio Frequency Interference) shielding around a wire. The shielding is always connected to ground. Splices Page 4547 the component if the component only has one connector, or by a capital letter (A, B, C, etc.) if the component has more than one connector. Below most connector numbers and component names are PHOTO and VIEW numbers. The PHOTO number refers to a photo in the back of the book that shows the connector's location on the car. The VIEW number refers to an illustration in the back of the book that shows the connector face, wire colors, connector cavity numbers, and other details. The connector cavity numbering sequence begins at the top left corner of the connector. Disregard any numbers molded into the connector housing. Wires Wires are identified by the abbreviated names of their colors; the second color is the color of the stripe. Wires are also identified by their location in a connector. The number "2" next to the male and female wire terminals at C416, for example, means those terminals join in cavity 2 of connector C416. Symbols A complete description of schematic symbols is given under wire color abbreviation. Power Distribution Schematics Power Distribution schematics show how power is supplied from the positive battery terminal to various circuits in the car. Refer to the Power Distribution section to get a more detailed picture of how power is supplied to the circuit you're working on. From Battery to Ignition Switch, Fuses, and Relays Individual circuit schematics begin with a fuse. The first half of Power Distribution, however, shows the wiring "upstream" between the battery Page 2014 Wires Wire insulation can be one color, or one color with another color stripe. (The second color is the stripe.) This circuit continues on another image. (The arrow shows direction of current flow.) To follow the RED/BLK wire in this example, you would turn to "Fuel and Emissions" and look for the "A" arrow. Service Precautions Suspension Control Module: Service Precautions The Intelligent Suspension System interfaces directly with the Control Unit which is a control computer that is similar in some regards to the Powertrain Control Module. These modules are designed to withstand normal current draws associated with vehicle operation. However, care must be taken to avoid overloading any of the Control Unit circuits. In testing for opens or shorts, do not ground or apply voltage to any of the circuits unless instructed to do so by the appropriate diagnostic procedure. These circuits should only be tested with a high impedance multimeter (J-39200) or special tools. Power should never be removed or applied to any control module with the ignition in the "ON" position. Before removing or connecting battery cables, fuses or connectors, always turn the ignition switch to the "OFF" position. Page 6709 Page 6645 CD Player/Changer Troubleshooting (Passport only) Manually Removing a Jammed Magazine (All except Passport) One-piece door model: 1. Remove the changer from the vehicle. 2. Remove the rear cover plate from the changer, and look for a jammed disc. 3. If a disc is jammed between the player and the magazine, turn the loading gear until the disc returns to the player mechanism. Do not attempt to reload the disc back into the magazine. 4. After the disc is loaded into the player mechanism, turn the changer so that the front is facing you. Page 7094 Splices Splices are shown as a dot. Their location and the number of wires may vary depending on the harness manufacturer. Switches Switches These switches move together; the broken straight line between them means they are mechanically connected. Other types of switches are controlled by a coil or a solid state circuit. Unless otherwise noted, all switches are shown in their normal (rest) position, with power off. Terminal "T" Page 5996 Wires Wire insulation can be one color, or one color with another color stripe. (The second color is the stripe.) This circuit continues on another image. (The arrow shows direction of current flow.) To follow the RED/BLK wire in this example, you would turn to "Fuel and Emissions" and look for the "A" arrow. Page 8208 Rear Window Regulator, Glass And Glass Run Locations Tailgate Lock Cylinder: Locations Tailgate Lock, Hatchgate (LWB) Lock And Associated Parts Page 15 Keyless Entry Module: Service and Repair Anti-Theft & Keyless Entry Controller Removal 1. Disconnect the battery ground cable. 2. Remove the glove box from the instrument panel assembly (1). - Refer to the Instrument Panel Assembly in Body Structure section. 3. Remove the anti-theft & keyless entry controller (2). - Disconnect the connector. Remove two fixing screws. Installation To install, follow the removal steps in the reverse order. Page 565 Testing For A Short With A Self-Powered Test Light or DVOM 1. Remove the blown fuse and disconnect the battery and load. 2. Connect one lead of a self-powered test light or digital volt/ohmmeter (DVOM) (switched to the lowest "OHMS" range) to the fuse terminal on the load side. 3. Connect the other lead to a known good ground. 4. Beginning near the fuse box, wiggle the harness. Continue this at convenient points about six inches apart while watching the test light or DVOM. 5. If the self-powered test light goes on or the DVOM displays a low reading or no reading (zero), there is a short to ground in the wiring near that point. Testing for a Short with a Test Light or DVOM 1. Remove the blown fuse and disconnect the load. 2. Connect a test light or digital volt/ohmmeter (DVOM), switched to the appropriate DC volts range, across the fuse terminals to make sure voltage is present. You might have to turn the ignition switch to ON; check the schematic to see. 3. Beginning near the fuse box, wiggle the harness. Continue this at convenient points about six inches apart while watching the test light or DVOM. 4. Where the test light goes , or the DVOM voltage drops to zero, there is a short to ground in the wiring near that point. NOTE: Always use a DVOM on high impedance circuits. A test light may not glow (even with battery voltage present). Testing For A Short With A Short Circuit Locator (Short Finder) 1. Remove the blown fuse. Leave the battery connected. Page 5504 Power Steering Fluid: Description and Operation The power steering fluid is Dexron II-E Automatic Transmission Fluid. No other types of fluids are recommended by the manufacturer for this system. Page 2061 Ion Sensing Module: Service and Repair ION Sensing Module REMOVAL PROCEDURE 1. Disconnect the negative battery cable. 2. Disconnect the ION sensing module connector. 3. Remove the bolts and the ION sensing module from the common chamber. INSTALLATION PROCEDURE 1. Install the ION sensing module on the common chamber with the bolts. Tighten Tighten the ION sensing module to 4 N.m (35 lb in.). 2. Connect the ION sensing module connectors as shown in the illustration. Page 5422 The road crown gauge measures the amount of road crown. Almost all roads have a crown to help drain water during rainstorms. Use the suction cup to attach the road crown gauge bracket to the vehicle in a vertical position. If necessary, bend the bracket until the gauge is vertical. Once you attach and align the road crown gauge, calibrate the gauge to zero. There are two ways to calibrate the gauge: ^ Park the vehicle on a level surface, such as an alignment rack, and calibrate the gauge by moving the gauge until the ball is on the zero mark. ^ If you do not have a perfectly flat surface, park the vehicle on a reasonably flat surface and note the gauge reading. Turn the vehicle 1800 and, with the tires in the same spot, note the new gauge reading. Then move the gauge half of the difference. For example, if your first reading is +3 and, after moving the vehicle, the gauge reads -1, then the difference is 4 degrees. Position the gauge to read +1. NOTE: You must calibrate the gauge with the same weight in the vehicle that you will use for the test-drive. If you plan to have an assistant help you during the test-drive, calibrate the gauge while both of you are sitting in the vehicle. Description and Operation Transmission Mode Indicator - A/T: Description and Operation With the ignition switch in ON or START battery voltage is applied to the A/T gear position switch through fuse 14. The A/T gear position switch sends a signal to the PCM which communicates this information to the multiplex control unit which in turn controls the A/T gear position indicator corresponding to the gear selected. The multiplex control unit applies voltage to the appropriate A/T gear position indicator light in the meter assembly, causing it to come on. Page 2675 The name of the component appears next to it followed by notes about its function along with any photo and connector view references. Connector "C" How to Identify Connector Terminals Cavity Numbering System The cavities (and wire terminals) in each connector are numbered starting from the upper left, looking at the male terminals from the terminal side (or looking at the female terminals from the wire side. Both views are in the same direction so the numbers are the same.) All actual cavities are numbered, even if they have no wire terminals in them. NOTE: Data Link Connector (DLC) terminals are numbered according to SAE standard J1962, not the Honda standard. The numbers of the four end terminals are molded into the corners of the connector face. Page 3449 Disclaimer Repair Procedure 1. Unclamp the air cleaner housing cover, and move it to the side for access to connector C123 (16P BLK). 2. Unfasten C123 from the side of the engine compartment using a 90-degree pick. 3. Disconnect C123, and clean the terminals on both sides of the connector with contact cleaner. Shake the residue out of the connector. Allow the contact cleaner to evaporate for at least 3 minutes, then reconnect C123. 4. Fasten C123 to the left side of the engine compartment, then reinstall the air cleaner housing cover. 5. While supporting the accelerator pedal assembly, remove the two bolts that secure the assembly to the bulkhead. Carefully lower the assembly to gain access to the connector. Engine Controls - Engine Spark Knock Or Pinging Powertrain Control Module: All Technical Service Bulletins Engine Controls - Engine Spark Knock Or Pinging 01-084 June 19, 2009 Applies To: 2000-02 Passport - ALL Engine Spark Knock (Pinging) (Supersedes 01-084, dated March 18, 2003, to revise the information marked by asterisks) *REVISION SUMMARY Under WARRANTY CLAIM INFORMATION, the failed part number, the Honda code, the defect code, and the symptom code have been updated.* SYMPTOM An engine spark knock (pinging). PROBABLE CAUSE The programmed ignition timing does not correct quickly enough in some climates. CORRECTIVE ACTION Update the PCM software with the Smart Cable. TOOL INFORMATION PGM Tester with software update release SN200P (9/1/01) or later. For the other tools and equipment you need to update the PCM software, refer to Service Bulletin 99-005, Updathg the Passport POM, filed under Tools. WARRANTY CLAIM INFORMATION In warranty: The normal warranty applies. Operation Number: 125517 Flat Rate Time: 0.3 hour *Failed Part: P/N 8-12212-079-0 H/C 6974992 Defect Code: 03214 Symptom Code: 09117* Template ID: 01-084A Skill Level: Repair Technician Out of warranty: Any repair performed after warranty expiration may be eligible for goodwill consideration by the District Parts and Service Manager or your Zone Office. You must request consideration, and get a decision, before starting work. REPAIR PROCEDURE 1. Retrieve the PCM broadcast code with the PGM Tester or the Smart Cable (refer to Service Bulletin 99-005, Updathg the Passport PCM). Page 4473 it is located, and what it connects to. Use the Connector Views to help locate the proper cavity when you need to probe a connector. It can be especially helpful if the connector has more than one wire of the same color. A dash symbol (-) indicates that the cavity is empty. Connector views can also be used to help diagnose multiple symptoms in separate circuits which could be caused by a single problem in a connector shared by those circuits. Here's an example: 1. Pick one of the multiple symptoms and look up the schematic for that circuit. 2. Make a list of all the in-line and fuse box connectors in that schematic , 3. Then, in the Connector Views, look up each connector on your list to see if circuits related to the other symptoms run through one of them. If they do, inspect that connector for the problem. Example: The blower, rear window defogger, and the windshield wiper don't work. List all in-line and fuse box connectors in the blower controls circuit and then check the Connector View (see the sample). You find that C324 is common to the blower controls, rear window defogger, and wiper/washer, so you inspect C324 and find the problem, bent terminals. Finding Component/Connector Locations Finding Component/Connector Locations To see where a component or connector is located on the car, look up its photo number in the "Component Location". The photo will also tell you the color of the connector, and how many cavities it has. Locations Door Locks: Locations Front Door Lock Assembly Page 2708 96. Rear of Right Catalytic Converter Rear of right catalytic converter 94. Rear of Left Catalytic Converter Rear of Left Catalytic Converter Page 7835 Dimmer Switch: Electrical Diagrams Part 1 Of 2 Page 2028 3. Install the fuse and relay box cover. Page 4272 The name of the component appears next to it followed by notes about its function along with any photo and connector view references. Connector "C" How to Identify Connector Terminals Cavity Numbering System The cavities (and wire terminals) in each connector are numbered starting from the upper left, looking at the male terminals from the terminal side (or looking at the female terminals from the wire side. Both views are in the same direction so the numbers are the same.) All actual cavities are numbered, even if they have no wire terminals in them. NOTE: Data Link Connector (DLC) terminals are numbered according to SAE standard J1962, not the Honda standard. The numbers of the four end terminals are molded into the corners of the connector face. Page 636 Crankshaft Position Sensor: Testing and Inspection 1. Inspect the sensor O-ring for cracks or leaks. 2. Replace the O-ring if it is worn or damaged. 3. Lubricate the new O-ring with engine oil. 4. Install the lubricated O-ring. Page 2491 Manually Removing a Jammed Magazine (Passport only) One-piece door model: 1. Open the changer door. 2. Check to see if all the trays are in the magazine. ^ If a tray is stuck in the changer, replace the changer. ^ If all the trays are in the magazine, place the changer in a horizontal position, and insert a thin stainless steel ruler or a "Slim Jim" under the magazine, about 1/2" from the right side of the opening. 3. Push the ruler in until it presses against the eject lever at the back of the unit. 4. Slowly remove the ruler and magazine at the same time. Two-piece door model: 1. Remove the changer from the vehicle. 2. Remove the top cover plate from the changer, and inspect for a jammed tray. ^ If a tray is stuck in the changer, replace the changer. ^ If all the trays are in the magazine, place the changer in a horizontal position, and insert a thin stainless steel ruler or a "Slim Jim" under the magazine, about 1/2" from the right side of the opening. 3. Push the ruler in until it presses against the eject lever at the back of the unit. 4. Slowly remove the ruler and magazine at the same time. Handling and Inspecting Compact Discs Page 6009 Blower Motor: Service and Repair Blower Motor Removal 1. Disconnect the battery ground cable. 2. Remove blower motor connector. 3. Remove attaching screw. 4. Remove blower motor assembly. 5. Remove clip. 6. Remove fan. 7. Remove blower motor. Installation To install, follow the removal steps in the reverse order. Page 7668 The name of the component appears next to it followed by notes about its function along with any photo and connector view references. Connector "C" How to Identify Connector Terminals Cavity Numbering System The cavities (and wire terminals) in each connector are numbered starting from the upper left, looking at the male terminals from the terminal side (or looking at the female terminals from the wire side. Both views are in the same direction so the numbers are the same.) All actual cavities are numbered, even if they have no wire terminals in them. NOTE: Data Link Connector (DLC) terminals are numbered according to SAE standard J1962, not the Honda standard. The numbers of the four end terminals are molded into the corners of the connector face. Page 3597 Test Equipment CAUTION: Most circuits include solid-state devices. Test the voltages in these circuits only with a 10-megaohm or higher impedance digital multimeter. Never use a test light or analog meter on circuits that contain solid-state devices. Damage to the devices may result. Test Light and DVOM On circuits without solid-state devices, use a test light to check for voltage. A test light is made up of a 12 volt bulb with a pair of leads attached. After grounding one lead, touch the other lead to various points along the circuit where voltage should be present. The bulb will go on if there is voltage at the point being tested. If you need to know how much voltage is present, use a digital volt/ohmmeter (DVOM). Self-Powered Test Light and DVOM Use a self-powered test light to check for continuity. This tool is made up of a light bulb, battery, and two leads. To test it, touch the leads together: the light should go on. Use a self-powered test light only on an unpowered circuit. First, disconnect the battery, or remove the fuse that feeds the circuit you are working on. Select two points in the circuit between which you want to check continuity. Connect one lead of the self-powered test light to each point. If there is continuity, the test light's circuit will be completed, and the light will go on. If, in addition, you need to know exactly how much resistance there is between two points, use a digital volt/ohmmeter (DVOM). In the "OHMS" range, the DVOM will measure resistance between two points along a circuit. Low resistance means good continuity. Diodes and solid-state devices in a circuit can make a DVOM give a false reading. To check a reading, reverse the leads, and take a second reading. If the readings differ, the component is affecting the measurement. Jumper Wire Use a jumper wire to bypass an open circuit. A jumper wire is made up of an in-line fuse holder connected to a set of test leads. It should have a five ampere fuse. Never connect a jumper wire across a short circuit. The direct battery short will blow the fuse. Short Finder (Short Circuit Locator) Short finders are available to locate shorts to ground. The short finder creates a pulsing magnetic field in the shorted circuit which you can follow to the location of the short. To order any test equipment shown above, contact your local tool supplier. For a list of suppliers and tool numbers, refer to Honda Required Special Tools and Equipment Service Bulletin. Page 7672 Terminals - "T" Each "T" terminal (ring type) is numbered for reference and location. A "T" terminal is secured with a screw or bolt. Wires Page 559 Wires Wire insulation can be one color, or one color with another color stripe. (The second color is the stripe.) This circuit continues on another image. (The arrow shows direction of current flow.) To follow the RED/BLK wire in this example, you would turn to "Fuel and Emissions" and look for the "A" arrow. Page 295 The connector cavity number is listed next to each terminal on the circuit schematic. The cavity / terminal shown is # 6. Diodes A rectifier diode works like a one way valve. It allows current to flow only in the direction of the arrow. A Zener diode blocks reverse current at normal voltages just like a rectifier diode. At high voltages, however, a Zener diode allows current to flow in reverse. Fuses Page 3092 3. Secure the EGR valve and the gasket with the bolts. Torque: 25 N.m (18 lb ft) NOTE: It is possible to install the EGR valve rotated 180 ° from the correct position. Make sure that the base of the valve is placed so that it aligns with the mounting flange. 4. Connect the electrical connector at the EGR valve. 5. Connect the negative battery cable. Description and Operation Transmission Mode Indicator - A/T: Description and Operation With the ignition switch in ON or START battery voltage is applied to the A/T gear position switch through fuse 14. The A/T gear position switch sends a signal to the PCM which communicates this information to the multiplex control unit which in turn controls the A/T gear position indicator corresponding to the gear selected. The multiplex control unit applies voltage to the appropriate A/T gear position indicator light in the meter assembly, causing it to come on. Page 5424 DIAGNOSTIC WORKSHEET REPAIR PROCEDURE A Service and Repair Power Steering Bleeding: Service and Repair POWER STEERING SYSTEM BLEEDING When a power steering pump or unit has been installed, or an oil line has been disconnected, the are that has entered the system must be bled out before the vehicle is operated. If air is allowed to remain in the power steering fluid system, noisy and unsatisfactory operation of the system may result. When bleeding the system, and any time fluid is added to the power steering system, be sure to use only power steering fluid as specified. 1. Fill the pump fluid reservoir to the proper level and let the fluid settle for at least two minutes. 2. Start the engine and let it run for a few seconds. Do not turn the steering wheel. Then turn the engine off. 3. Add fluid if necessary. 4. Repeat the above procedure until the fluid level remains constant after running the engine. 5. Raise and support the front end of the vehicle so that the wheels are off the ground. 6. Start the engine. Slowly turn the steering wheel right and left, lightly contacting the wheel stops. 7. Add power steering fluid if necessary. 8. Lower the vehicle, set the steering wheel at the straight forward position after turning it to its full steer positions 2 or 3 times, and stop the engine. 9. Check the fluid level and refill as required. 10. If the fluid is extremely foamy, allow the vehicle to set a few minutes, then repeat the above procedure. Page 2516 Wire Color Abbreviations The following abbreviations are used to identify wire colors in the circuit schematics: WHT................................... White YEL................................... Yellow BLK................................... Black BLU................................... Blue GRN................................... Green RED................................... Red ORN................................... Orange PNK................................... Pink BRN................................... Brown GRY................................... Gray PUR................................... Purple LT BLU................................... Light Blue LT GRN................................... Light Green Page 1461 10. Remove the piston pin (9) using J-24086-C piston pin service set and piston support with a press. Note: Keep the parts removed from each cylinder separate. All parts must be reinstalled in their original positions. Heating the connecting rod will permit easy removal of the piston pin. 11. Piston (10) 12. Connecting rod (11) Inspection and Repair Pistons (10) Carefully clean away all the carbon adhering to the piston head and the piston ring grooves. Note: Never use a wire brush to clean the pistons. Damage will result Visually check each piston for cracking, scoring, and other signs of excessive wear. If any of the above conditions are found, the piston must be replaced. Piston Diameter 1. Measure the piston outside diameter with micrometer at the piston grading position and a right angle to the piston pin. Piston grading position (from piston head) Piston grading position: 43.0 mm (1.6929 inch) Page 7410 Ground - "G" Shielding Sheilding This represents RFI (Radio Frequency Interference) shielding around a wire. The shielding is always connected to ground. Splices Page 2102 Accelerator Pedal Position Sensor: Service and Repair Accelerator Position Sensor Replacement CAUTION: Remove the Accelerator (A) pedal assembly as a unit to have it services. Do not remove the Accelerator Position (AP) sensor on the A pedal. If the AP sensor is removed for emergency cause, refer to following Items as necessary. Removal Procedure 1. Disconnect the negative battery cable. 2. Disconnect the electrical harness from the AP sensor. 3. Remove the AP sensor. Installation Procedure 1. Install the accelerator position (AP) sensor to bolts with accelerator (A) pedal. 2. Connect the connector to AP sensor. 3. Install the negative battery cable. Page 5771 Some vehicles affected by this campaign may be in your used vehicle inventory. As a matter of federal law, these vehicles must be repaired before they are sold. Should a dealership sell an unrepaired vehicle that subsequently causes an injury or damage because of the recalled item, the dealership will be solely responsible to the damaged party, and will be required to defend and indemnify American Honda for any resulting claims. To see if a vehicle in inventory is affected by this campaign, do an iN VIN status inquiry before selling it. CORRECTIVE ACTION Inspect the lower trailing link frame brackets for corrosion (Refer to inspection procedure below) and, depending on the stage of corrosion, do one of these repairs: ^ STAGE 1 REPAIR (about 50 percent of affected vehicles): Apply Noxudol 300 anti-corrosion wax. ^ STAGE 2 REPAIR (about 40 percent of affected vehicles): Apply Noxudol 300 and Noxudol 700 anti-corrosion wax. ^ STAGE 3 REPAIR (about 8 percent of affected vehicles): Install Trailing Link Frame Bracket Kit A, and apply Noxudol 300 and Noxudol 700 anti-corrosion wax. ^ STAGE 4 REPAIR (only about 1 percent of affected vehicles): Install Trailing Link Frame Bracket Kit B, and apply Noxudol 300 and Noxudol 700 anti-corrosion wax. PARTS INFORMATION Page 2311 Camshaft Position Sensor: Testing and Inspection 1. Inspect the sensor O-ring for cracks or leaks. 2. Replace the O-ring if it is worn or damaged. 3. Lubricate the new O-ring with engine oil. 4. Install the lubricated O-ring. Moonroof - Visor Sags in The Middle Sunroof / Moonroof Weatherstrip: Customer Interest Moonroof - Visor Sags in The Middle 00-061 August 22, 2000 Applies To: 1998-00 Passport - ALL Accessory Moonroof Visor Appearance PROBLEM The rear edge of the moonroof visor sags in the middle, and/or the roof seal is distorted. CORRECTIVE ACTION Replace the moonroof visor and the roof seal with a new assembly. PARTS INFORMATION Accessory Moonroof Visor Kit: P/N 08R01-ED1101, H/C 6483838 WARRANTY CLAIM INFORMATION In warranty: The normal warranty applies. Out of warranty: Any repair performed after warranty expiration may be eligible for goodwill consideration by the District Service Manager or your Zone Office. You must request consideration, and get a decision, before starting work. REPAIR PROCEDURE 1. Remove the moonroof visor, the roof seal, and all related hardware. 2. Install the new moonroof visor kit. Refer to the Accessory Installation Instructions binder for the installation instructions. Disclaimer Page 1845 Adapter: J-33984-A Check the condition of the vacuum valve in the center of the valve seat side of the cap. If considerable rust or dirt is found, or if the valve seat cannot be moved by hand, clean or replace the cap. Valve opening vacuum kPa (psi) 0 - 6.9 (0 - 1.0) Radiator Core 1. A bent fin may result in reduced ventilation and overheating may occur. All bent fins must be straightened. Pay close attention to the base of the fin when it is being straightened. 2. Remove all dust, bugs and other foreign material. Flushing the Radiator Thoroughly wash the inside of the radiator and the engine coolant passages with cold water and mild detergent. Remove all signs of scale and rust. Cooling System Leakage Check Use a radiator cap tester to force air into the radiator through the filler neck at the specified pressure of 196 kPa (28.5 psi) with a cap tester: Leakage from the radiator - Leakage from the coolant pump - Leakage from the water hoses - Check the rubber hoses for swelling. Cap tester: J-24460-01 Adapter: J-33984-A Installation 1. Install rubber cushions on both sides of radiator bottom. 2. Install radiator assembly with hose, taking care not to damage the radiator core with a fan blade. 3. Connect reserve tank hose (4). Service and Repair Headlamp Bulb: Service and Repair Removal 1. Disconnect the battery ground cable. 2. Remove the headlight bulb (3). - Disconnect the connector. - Remove the bulb cover (1). - Release the retaining ring (2). CAUTION: The halogen light bulb produces heat and temperature rises high, therefore, if the glass surface is contaminated, it will be burnt by heat leaving stains which will not come out. This may reduce the illuminating power or damage the bulb due to thermal deformation during evaporation. In order to prevent this problem, do not touch the glass surface with your fingers. Installation To install, follow the removal steps in the reverse order. Page 3044 Catalytic Converter: Diagrams LH TWC and Forked Exhaust Pipe and Associated Parts TWC LH and Forked Exhaust Pipe and Associated Parts Locations Safing Sensor: Locations The safing sensor is located inside the SRS Unit, refer to SRS Unit / Service and Repair. Locations 4WD Control Unit: Locations Under Center Console Page 2574 Wire Color Abbreviations The following abbreviations are used to identify wire colors in the circuit schematics: WHT................................... White YEL................................... Yellow BLK................................... Black BLU................................... Blue GRN................................... Green RED................................... Red ORN................................... Orange PNK................................... Pink BRN................................... Brown GRY................................... Gray PUR................................... Purple LT BLU................................... Light Blue LT GRN................................... Light Green Page 6941 To install, follow the removal steps in the reverse order, noting the following points. 1. Install the radiator grille clips remaining on the body side in the radiator grille, and then install the radiator grille on the body. Page 6162 Evaporator Assembly Page 1612 11. Working through the right front wheelwell, remove the two flange bolts holding the engine mount to the chassis. Repeat this on the left side. 12. Working from under the vehicle, remove the two lower flange bolts holding the right engine bracket to the engine. 13. Use the powertrain lift to raise the engine until both engine mounts clear the chassis. Page 2457 11. Using a jumper wire, connect the reference voltage of each circuit to its signal input and view the APP Sensor values in the Engine Data List. APP Sensor 1 should have a value of 99%, and APP Sensor 2 and APP Sensor 3 should each have a value of 0%. ^ If the values are not as specified, troubleshoot for high resistance on the signal input or a PCM malfunction. Repair the circuit or replace the PCM, then repeat step 3. ^ If the values are as specified, the problem may be intermittent. Disconnect the 10P connector from the modified APPS, and connect it to the new APPS; then repeat step 3. Wiggle the APPS wires as you go through the adjustment procedure to find the intermittent problem. 12. Turn off the ignition switch, and disconnect the PGM Tester.* DISCLAIMER A/T - Vehicle Speed Sensor Installation Precautions Transmission Speed Sensor: Technical Service Bulletins A/T - Vehicle Speed Sensor Installation Precautions Install VSS Properly to Avoid Reman A/T Damage We can't emphasize enough how important it is to follow, to the letter, the installation instructions that come with a reman A/T. These instructions help ensure that you avoid damaging the A/T and score a successful repair. This is particularly true when it comes to installing the vehicle speed sensor (VSS). Step 6 of the instructions tells you to make sure its gear is fully engaged and the VSS is fully seated before you tighten the retaining bolt. If you don't install the VSS properly, the speed sensor gear will get stripped and the A/T will be seriously damaged. So don't take risks with your customer's vehicle. Always follow these instructions to the letter. You can rest assured you're doing the job right. Page 6428 Clockspring Assembly / Spiral Cable: Adjustments Cable Reel Alignment - Misalignment of the cable reel could cause an open in the wiring making the SRS system and the horns inoperative. Center the cable reel whenever the following is performed. Installation of the steering wheel - Installation of the cable reel - Installation of the steering column - Other steering-related adjustment or installation - Do not disassemble the cable reel. - Do not apply grease on the cable reel. - If the cable reel shows any signs of damage (for example, it does not rotate smoothly) replace it with a new one. Page 1193 Fluid - A/T: Service and Repair ATF Replacement CHANGING TRANSMISSION FLUID There is no need to change the transmission fluid unless the transmission is used under one or more of the following heavy duty conditions. A. Repeated short trips B. Driving on rough roads C. Driving on dusty roads D. Towing a trailer If the vehicle is used under these conditions, change the fluid every 20,000 miles (32,000 km.) 1. Place a large drain pan under the oil pan. 2. Remove the transmission oil drain screw (2) and drain fluid. 3. Tighten drain screw (2). Torque: 38 Nm (28 ft. lbs.) 4. Remove the transmission overfill screw (1) and fill transmission through overfill screw opening, using DEXRON III ATF. NOTE: Add transmission fluid until it flows out over the overfill screw opening. 5. Let engine idle until a fluid temperature between 32°C (90°F) and 57°C (135°F) is reached. 6. Add transmission fluid until it flows out over the overfill screw opening, then close the overfill screw (1). Torque: 38 Nm (28 ft. lbs.) NOTE: To prevent fluid leaks, the overfill screw and oil drain screws gasket must be replaced each time these screws are removed. NOTE: Check transmission fluid temperature with scan tool. 7. Reset "Oil Life Monitor" data by using Tech 2. Page 3211 Splices Splices are shown as a dot. Their location and the number of wires may vary depending on the harness manufacturer. Switches Switches These switches move together; the broken straight line between them means they are mechanically connected. Other types of switches are controlled by a coil or a solid state circuit. Unless otherwise noted, all switches are shown in their normal (rest) position, with power off. Terminal "T" Locations Page 661 Manifold Pressure/Vacuum Sensor: Description and Operation Manifold Absolute Pressure (MAP) Sensor The manifold absolute pressure (MAP) sensor responds to changes in intake manifold pressure (vacuum). The MAP sensor signal voltage to the PCM varies from below 2 volts at idle (high vacuum) to above 4 volts with the ignition ON, engine not running or at wide-open throttle (low vacuum). The MAP sensor is used to determine the following: - Manifold pressure changes while the linear EGR flow test diagnostic is being run. Refer to DTC P0401. - Barometric pressure (BARO). If the PCM detects a voltage that is lower than the possible range of the MAP sensor, DTC P0107 will be set. A signal voltage higher than the possible range of the sensor will set DTC P0108. An intermittent low or high voltage will set DTC P1107, respectively. The PCM can detect a shifted MAP sensor. The PCM compares the MAP sensor signal to a calculated MAP based on throttle position and various engine load factors. If the PCM detects a MAP signal that varies excessively above or below the calculated value, DTC P0106 will set. Page 1538 17. Recheck the valve clearance using the Go/No-Go method (see step 4). - If the clearance is OK, repeat steps 6 thru 17 for the other valves needing adjustment. - If the clearance is still incorrect, repeat steps 6 through 17 until it is correct, then adjust the remaining valves. 18. Turn the camshaft pulleys until the single timing dot (right cylinder bank) and dual timing dots (left cylinder bank) align with the single timing dots on the camshaft drive gears. 19. Install the cylinder head covers with new gaskets. Torque the cover bolts to 9 N.m (6.5 lb-ft). Off-Vehicle Valve Adjustment 1. Make a copy of the Valve Inspection Chart. 2. Make a copy of the Valve Shim Replacement Chart, then tape the pages together, side-by-side. 3. Measure the valve clearances using the Go/No-Go method (see the note below). The clearances must be - Intake valves: 0.25 mm +0.05 mm - Exhaust valves: 0.30 mm +0.05 mm NOTE: - To measure with the Go/No-Go method, use two feeler gauges, one to measure the smallest allowable clearance, and the other to measure the largest. - If the small gauge fits and the large gauge doesn't, the valve adjustment is OK. - If the small gauge doesn't fit, or if the large gauge slides easily, the valve needs adjustment. - The feeler gauges slide through the clearance gap at a slight angle, making the drag a little more than it would be on other engines. 4. For valves with the correct clearance, draw an "X" in the appropriate circle on the Valve Inspection Chart. For valves with incorrect clearances, write down the clearance you measured in the circle. 5. Rotate the camshaft pulley until the dual timing dots (exhaust camshaft) and single timing dot (intake camshaft) align with the timing dots on the camshaft drive gear. Page 3749 4WD Control Unit: Electrical Diagrams Part 1 Of 3 Page 534 11. Turn the ignition switch to "ON" while watching warning light and check the light should flash 7 times and then go off. Irregular and Premature Wear Tires: Testing and Inspection Irregular and Premature Wear Irregular and/or premature wear has many causes. Some of them are incorrect inflation pressures, lack of tire rotation, poor driving habits or improper wheel alignment. Incorrect inflation is common cause of tire premature wear. NOTE: Due to their design, radial tires tend to wear faster in the shoulder area, particularly on the front tires. This makes regular rotation especially necessary. After rotation, be sure to check wheel nut torque, and set tire pressures. Page 7724 2. Connect the short finder across the battery terminals and the load (component) side of the fuse terminal. 3. Close all switches in the circuit you're testing. 4. Turn on the short finder. This creates a pulsing magnetic field around the wiring between the fuse box and the short. 5. Beginning at the fuse box, slowly move the short finder along the circuit wiring. The meter will read current pulses through sheet metal and body trim. As long as the meter is between the fuse and the short, the needle will move with each current pulse. Once you move the meter past the point of the short, the needle will stop moving. Check the wiring and connectors in this area to locate the cause of the short. Testing For Continuity When testing for continuity at a connector without wire seals, you do not have to separate the two halves of the connector. Instead, probe the connector from the back. Always check both sides of the connector because dirty, corroded, and bent terminals can cause problems (no electrical contact = an open). 1. Disconnect the negative cable from the car battery. If you're using a DVOM, place it in the lowest "OHMS" range. Page 382 Wheel Speed Sensor: Testing and Inspection Related Diagnostic Procedures B-19 Rear Speed Sensor Open or Shorted (DTC 53/C0235) Chart B-19 Rear Speed Sensor Open Or Shorted (DTC 53 (Flash Out) / C0235 (Serial Communications)) Page 768 Vehicle Speed Sensor: Service and Repair REMOVAL CAUTION: The VSS is located on the right side of the transfer case just ahead of the rear propeller shaft and very close to the exhaust pipes for 4WD and on the extension cover for 2WD. Be sure that the exhaust pipes are cool enough to touch before trying to remove the VSS. If the pipes are hot, you could be burned. 1. Disconnect the negative battery cable. 2. Disconnect the VSS electrical connector. 3. Remove the bolt and the clamp securing the VSS in place. IMPORTANT: Have a container ready to catch any fluid that leaks out when the VSS is removed from the transfer case for 4WD and on the extension cover for 2WD. 4. Remove the VSS from the transfer case by wiggling it slightly and pulling it straight out. INSTALLATION 1. Install the VSS in the transfer case with the notch for the connector facing the rear. Page 7726 Transmission Shift Position Indicator Lamp: Electrical Diagrams Part 1 Of 2 Page 5418 1. Remove the rear console assembly. 2. Remove the ashtray/rear beverage holder assembly from the rear console. 3. Open the beverage holder lid, and move the beverage holder swing arm to a position halfway between open and closed. Page 5198 Distinct Of Circuit By Wire Base Color All wires have color-coded insulation. Wires belonging to a system's main harness will have a single color. Wires belonging to a system's sub-circuits will have a colored stripe. Striped wires use the codes found in the chart to show wire size and colors. Abbreviations are used to indicate wire color within a circuit diagram. How to Identify Connector Terminals How to Identify Connector Terminals Cavity Numbering System The cavities (and wire terminals) in each connector are numbered starting from the upper left, looking at the male terminals from the terminal side (or looking at the female terminals from the wire side. Both views are in the same direction so the numbers are the same.) All actual cavities are numbered, even if they have no wire terminals in them. NOTE: Data Link Connector (DLC) terminals are numbered according to SAE standard J1962, not the Honda standard. The numbers of the four end terminals are molded into the corners of the connector face. The connector cavity number is listed next to each terminal on the circuit schematic. The cavity / terminal shown is # 6. Using/Identifying Connector Terminal Views How to Use Connector Terminal Views To see the configuration of a connector's cavities, look up its view number in the Connector Views. Each view includes the color of the connector, where Locations Behind Glove Box Page 2575 The wire insulation has one color or one color with another color stripe. The second color is the stripe. Page 7887 The wire insulation has one color or one color with another color stripe. The second color is the stripe. Page 7940 Distinct Of Circuit By Wire Base Color All wires have color-coded insulation. Wires belonging to a system's main harness will have a single color. Wires belonging to a system's sub-circuits will have a colored stripe. Striped wires use the codes found in the chart to show wire size and colors. Abbreviations are used to indicate wire color within a circuit diagram. How to Identify Connector Terminals How to Identify Connector Terminals Cavity Numbering System The cavities (and wire terminals) in each connector are numbered starting from the upper left, looking at the male terminals from the terminal side (or looking at the female terminals from the wire side. Both views are in the same direction so the numbers are the same.) All actual cavities are numbered, even if they have no wire terminals in them. NOTE: Data Link Connector (DLC) terminals are numbered according to SAE standard J1962, not the Honda standard. The numbers of the four end terminals are molded into the corners of the connector face. The connector cavity number is listed next to each terminal on the circuit schematic. The cavity / terminal shown is # 6. Using/Identifying Connector Terminal Views How to Use Connector Terminal Views To see the configuration of a connector's cavities, look up its view number in the Connector Views. Each view includes the color of the connector, where Page 3488 Throttle Body: Service and Repair REMOVAL PROCEDURE 1. Disconnect the negative battery cable. 2. Drain the cooling system. 3. Disconnect the electrical connectors: - Throttle position (TP) sensor. - Intake air temperature (IAT) sensor. 4. Disconnect the vacuum hose below the air horn. 5. Remove the intake air duct clamp. 6. Disconnect the intake air duct. 7. Disconnect the coolant lines from the throttle body. 8. Remove the bolts from the common chamber. 9. Remove the throttle body from the common chamber. 10. Remove the gasket from the common chamber. 11. Remove the TP sensor. INSTALLATION PROCEDURE 1. Install the TP sensor. 2. Install the gasket on the common chamber. 3. Install the throttle body on the common chamber. 4. Secure the gasket and the throttle body with the four bolts. Page 598 Disclaimer Repair Procedure 1. Unclamp the air cleaner housing cover, and move it to the side for access to connector C123 (16P BLK). 2. Unfasten C123 from the side of the engine compartment using a 90-degree pick. 3. Disconnect C123, and clean the terminals on both sides of the connector with contact cleaner. Shake the residue out of the connector. Allow the contact cleaner to evaporate for at least 3 minutes, then reconnect C123. 4. Fasten C123 to the left side of the engine compartment, then reinstall the air cleaner housing cover. 5. While supporting the accelerator pedal assembly, remove the two bolts that secure the assembly to the bulkhead. Carefully lower the assembly to gain access to the connector. Page 1730 Timing Belt: Service and Repair Camshaft Subgear Preloading, Gear Timing & Camshaft Install. THIS ARTICLE HAS BEEN UPDATED BY TSB 02-047 CAMSHAFT SUBGEAR PRELOADING, GEAR TIMING, AND CAMSHAFT INSTALLATION NOTE: - The V6 engine has a "non-interference" design. This means the valves never contact the pistons, even when the valves or camshafts are not correctly timed, or even if a valve is fully open and its piston is at top dead center (TDC). - The ratio between the camshaft drive gear and the camshaft gears is 1.33 to 1. This means the timing dots on a correctly timed camshaft will only align with the dots on the camshaft drive gears every 4th turn of the camshaft pulley. - The left and right intake camshafts are different. On the cam lobe side of the camshaft gear, the left intake camshaft is marked "LI," and it has dual timing dots; the right intake camshaft is marked "RI," and it has a single timing dot. - The left and right exhaust camshafts are the same. On the cam lobe side of the camshaft gear, both camshafts are marked "LE" and "RE and both have dual timing dots and a single dot. 1. Before you install the camshafts, preload the subgears (preloading must be done whenever you remove the bearing caps from a camshaft): - Make sure the spring is installed between the camshaft gear and the subgear. - With the camshaft held in a soft-jawed vise, attach the gear spring lever (T/N J-42656) to the subgear, then turn the subgear until its threaded hole lines up with the hole in the camshaft gear. - Lock the subgear to the camshaft gear with a 5 x 0.5 mm bolt through either side of the gear hole. - Preload the subgears on the other camshafts. Page 5219 Page 4991 B-16 Rear Dump Solenoid Valve Failure (DTC 46/C0252, C0254) Chart B-16 Rear Dump Solenoid Coil Failure (DTC 46 (Flash Out) / C0252, C0254 (Serial Communications)) Part 1 of 2 Part 2 of 2 Page 5013 Parking Brake Lever: Service and Repair REMOVAL 1. Remove rear console (1). 2. Disconnect switch connector (2). 3. Remove bolt (3). 4. Remove adjust nut and lock nut (4). 5. Pull out equalizer (6) from trunnion pin (5). 6. Disconnect trunnion pin (5) from Parking brake lever (8) 7. Disconnect parking brake rear cable (7). INSTALLATION 1. Apply grease (BESCO L-2 or equivalent) to the connecting portion of the rear cable (7) and equalizer (6). 2. Connect parking brake rear cable (7) to equalizer 3. Install trunnion pin (5) to parking brake lever (8). 4. Insert equalizer (6) into trunnion pin (5) and tighten adjust nut and lock nut (4). Lock Nut Torque: 13 Nm (113 inch lbs.) 5. Tighten the parking brake lever fixing bolt (3) to the specified torque. Torque: 15 Nm (11 ft. lbs.) 6. Connect switch connector (2). 7. Install rear console (1). Page 5606 5. Disconnect the feed line and return line from steering unit. Remove the clips on the crossmember and frame. Wire the power steering line to frame. NOTE: Take care to prevent foreign matter from entry when disconnect the power steering line. 6. Remove the torsion bar. 7. Remove the lower control arm bolt (Frame side). 8. Apply a setting mark across the crossmember and frame so parts can be reassembled in their original position. 9. Remove the crossmember fixing bolt. 10. Remove the power steering unit with the crossmember. 11. Remove the power steering unit. INSTALLATION 1. Install power steering unit to crossmember. Tighten fixing bolt to specified torque. Torque to 116 Nm (85 ft. lbs.). 2. Install power steering unit with crossmember to frame by aligning the setting marks made when removing. Tighten crossmember mounting bolt to specified torque. Torque to 190 Nm (140 ft. lbs.). 3. Install lower control arm bolt. 4. Install torsion bar. 5. Connect the feed line and return line. Torque to 25 Nm (18 ft. lbs.) 6. Install tie-rod end assembly to knuckle. Torque to 118 Nm (87 ft. lbs.) 7. Install transfer gear assembly. Align the setting marks made at removal. Torque to 31 Nm (23 ft. lbs.) 8. Install the stone guard. 9. Bleed the system. Page 5835 3. Photocopy the template that is shown. Cut out the template. Page 6661 Manually Removing a Jammed Magazine (Passport only) One-piece door model: 1. Open the changer door. 2. Check to see if all the trays are in the magazine. ^ If a tray is stuck in the changer, replace the changer. ^ If all the trays are in the magazine, place the changer in a horizontal position, and insert a thin stainless steel ruler or a "Slim Jim" under the magazine, about 1/2" from the right side of the opening. 3. Push the ruler in until it presses against the eject lever at the back of the unit. 4. Slowly remove the ruler and magazine at the same time. Two-piece door model: 1. Remove the changer from the vehicle. 2. Remove the top cover plate from the changer, and inspect for a jammed tray. ^ If a tray is stuck in the changer, replace the changer. ^ If all the trays are in the magazine, place the changer in a horizontal position, and insert a thin stainless steel ruler or a "Slim Jim" under the magazine, about 1/2" from the right side of the opening. 3. Push the ruler in until it presses against the eject lever at the back of the unit. 4. Slowly remove the ruler and magazine at the same time. Handling and Inspecting Compact Discs Page 7148 1. After securely covering the zippers (3) with the flaps (1), smooth out the fastener tape (2) with your hands so that there are no folds or turned up portions of the flaps. Page 2871 Crankshaft Position Sensor: Testing and Inspection 1. Inspect the sensor O-ring for cracks or leaks. 2. Replace the O-ring if it is worn or damaged. 3. Lubricate the new O-ring with engine oil. 4. Install the lubricated O-ring. Page 7503 Door Switch: Service and Repair Removal 1. Disconnect the battery ground cable. 2. Remove the door switch (2). - Remove the screw (1). - Disconnect the connector (3). Installation To install, follow the removal steps in the reverse order. Page 6766 the component if the component only has one connector, or by a capital letter (A, B, C, etc.) if the component has more than one connector. Below most connector numbers and component names are PHOTO and VIEW numbers. The PHOTO number refers to a photo in the back of the book that shows the connector's location on the car. The VIEW number refers to an illustration in the back of the book that shows the connector face, wire colors, connector cavity numbers, and other details. The connector cavity numbering sequence begins at the top left corner of the connector. Disregard any numbers molded into the connector housing. Wires Wires are identified by the abbreviated names of their colors; the second color is the color of the stripe. Wires are also identified by their location in a connector. The number "2" next to the male and female wire terminals at C416, for example, means those terminals join in cavity 2 of connector C416. Symbols A complete description of schematic symbols is given under wire color abbreviation. Power Distribution Schematics Power Distribution schematics show how power is supplied from the positive battery terminal to various circuits in the car. Refer to the Power Distribution section to get a more detailed picture of how power is supplied to the circuit you're working on. From Battery to Ignition Switch, Fuses, and Relays Individual circuit schematics begin with a fuse. The first half of Power Distribution, however, shows the wiring "upstream" between the battery Page 1122 Timing Belt: Service and Repair Camshaft Subgear Preloading, Gear Timing & Camshaft Install. THIS ARTICLE HAS BEEN UPDATED BY TSB 02-047 CAMSHAFT SUBGEAR PRELOADING, GEAR TIMING, AND CAMSHAFT INSTALLATION NOTE: - The V6 engine has a "non-interference" design. This means the valves never contact the pistons, even when the valves or camshafts are not correctly timed, or even if a valve is fully open and its piston is at top dead center (TDC). - The ratio between the camshaft drive gear and the camshaft gears is 1.33 to 1. This means the timing dots on a correctly timed camshaft will only align with the dots on the camshaft drive gears every 4th turn of the camshaft pulley. - The left and right intake camshafts are different. On the cam lobe side of the camshaft gear, the left intake camshaft is marked "LI," and it has dual timing dots; the right intake camshaft is marked "RI," and it has a single timing dot. - The left and right exhaust camshafts are the same. On the cam lobe side of the camshaft gear, both camshafts are marked "LE" and "RE and both have dual timing dots and a single dot. 1. Before you install the camshafts, preload the subgears (preloading must be done whenever you remove the bearing caps from a camshaft): - Make sure the spring is installed between the camshaft gear and the subgear. - With the camshaft held in a soft-jawed vise, attach the gear spring lever (T/N J-42656) to the subgear, then turn the subgear until its threaded hole lines up with the hole in the camshaft gear. - Lock the subgear to the camshaft gear with a 5 x 0.5 mm bolt through either side of the gear hole. - Preload the subgears on the other camshafts. Engine - Oil Recommendation GF-4 Standard Engine Oil: Technical Service Bulletins Engine - Oil Recommendation GF-4 Standard SOURCE: Honda Service News TITLE: Use ONLY New GF-4 Standard Engine Oil APPLIES TO: All Models SERVICE TIP: There's a new performance standard for engine oil: GF-4. It was jointly developed by automotive and oil experts, and it represents a significant performance upgrade and improvement in fuel economy. GF-4 engine oils must pass grueling tests totaling over 500 hours. On top of this, Honda Genuine engine oils are also tested to ensure specific compatibility with Honda vehicles. GF-4 engine oil is compatible with all current and earlier model year Honda cars and trucks. It also provides these added benefits: - Improved oxidation resistance (reduced thickening of the oil) - Improved deposit protection and better wear protection - Better low-temperature performance over the life of the oil - Environmental protection by extending the life of emissions systems While Honda has upgraded its engine oil to GF-4, other brands may not yet be at this new standard. Keep in mind you must use Honda Genuine engine oil for all warranty repairs. If you use some other brand of oil for non-warranty repairs, make sure that oil meets the GF-4 standard. We recommend you stop using non-GF-4 engine oils and check with your supplier that you're purchasing GF-4 oil. Engine oil produced after April 1, 2005, that meets the GF-4 standard, must post this starburst certification mark on the container. Always look for this mark; some oil container labels won't specifically refer to GF-4. Page 2592 Steps 2 - 3 Page 4449 Ground - "G" Shielding Sheilding This represents RFI (Radio Frequency Interference) shielding around a wire. The shielding is always connected to ground. Splices Page 2180 ^ If the idle speed ever exceeds 1,300 rpm 2. Remove the vacuum hose from the fuel pressure regulator, then start the engine. ^ If fuel comes out of the fuel pressure regulator vacuum hose connection, go to REPAIR PROCEDURE FUEL PRESSURE REGULATOR. ^ If no fuel comes out of the regulator, reconnect the vacuum hose and continue to step 3. 3. Connect the PGM Tester. Set it to Engine Data List. 4. Have an assistant drive the vehicle under the conditions described by the customer. 5. If the high or erratic idle condition occurs, note the values of the PSP Switch and APP Sensor 1 when it is occurring. ^ If the PSP Switch is HIGH, and you are not turning, go to REPAIR PROCEDURE POWER STEERING SWITCH. ^ If the APP Sensor 1 is greater than 15% and APP Sensor 2 and/or APP Sensor 3 are less than 85%, and the accelerator pedal is not depressed, go to REPAIR PROCEDURE APPS GROUND. ^ If the PSP Switch is reading LOW when not turning and HIGH when turning, and the APP Sensors are reading within the range shown, discontinue the test-drive and go to step 6. 6. Do these repairs: ^ REPAIR PROCEDURE APPS GROUND ^ REPAIR PROCEDURE ENGINE/BODY GROUND REPAIR PROCEDURE - FUEL PRESSURE REGULATOR 1. Relieve fuel system pressure: ^ Remove the fuel fill cap. ^ Remove the fuel pump relay. ^ Start the engine and run it until it stalls. ^ Crank the engine for 3 seconds. 2. Remove the vacuum hose from the fuel pressure regulator. 3. Remove the fuel pressure regulator shield from the common chamber (two bolts). Page 2207 Transmission Position Switch/Sensor: Description and Operation Transmission Range Switch IMPORTANT: The vehicle should not be driven with the transmission range switch disconnected; idle quality will be affected. The four inputs from the transmission range switch indicate to the PCM which position is selected by the transmission selector lever. This information is used for ignition timing, EVAP canister purge, EGR operation. For more information on the transmission on the transmission range switch, refer to Transmission Control System Diagnosis. See: Transmission Control Systems/Testing and Inspection Page 1818 Coolant Temperature Sensor/Switch (For Computer): Description and Operation Engine Coolant Temperature (ECT) Sensor The engine coolant temperature (ECT) sensor is a thermistor (a resistor which changes value based on temperature) mounted in the engine coolant stream. Low coolant temperature produces a high resistance of 100,000 ohms at -40 °C (-40 °F). High temperature causes a low resistance of 70 ohms at 130 °C (266 °F). The PCM supplies a 5-volt signal to the ECT sensor through resistors in the PCM and measures the voltage. The signal voltage will be high when the engine is cold and low when the engine is hot. By measuring the voltage, the PCM calculates the engine coolant temperature. Engine coolant temperature affects most of the systems that the PCM controls. The Tech 2 displays engine coolant temperature in degrees. After engine start-up, the temperature should rise steadily to about 85 °C (185 °F). It then stabilizes when the thermostat opens. If the engine has not been run for several hours (overnight), the engine coolant temperature and intake air temperature displays should be close to each other. A hard fault in the engine coolant sensor circuit will set DTC P0177 or DTC P0118. An intermittent fault will set a DTC P1114 or P1115. Page 2057 2. Connect the short finder across the battery terminals and the load (component) side of the fuse terminal. 3. Close all switches in the circuit you're testing. 4. Turn on the short finder. This creates a pulsing magnetic field around the wiring between the fuse box and the short. 5. Beginning at the fuse box, slowly move the short finder along the circuit wiring. The meter will read current pulses through sheet metal and body trim. As long as the meter is between the fuse and the short, the needle will move with each current pulse. Once you move the meter past the point of the short, the needle will stop moving. Check the wiring and connectors in this area to locate the cause of the short. Testing For Continuity When testing for continuity at a connector without wire seals, you do not have to separate the two halves of the connector. Instead, probe the connector from the back. Always check both sides of the connector because dirty, corroded, and bent terminals can cause problems (no electrical contact = an open). 1. Disconnect the negative cable from the car battery. If you're using a DVOM, place it in the lowest "OHMS" range. Capacity Specifications Refrigerant Oil: Capacity Specifications HVAC SYSTEM HVAC SYSTEM ITEM SPECIFICATION Refrigerant Oil Type Vane Rotary Type Compressor Oil Capacity Of Components Condenser 1.0 fl. oz (30 cc) Evaporator 1.7 fl. oz (50 cc) Refrigerant Line (one piece) 0.3 fl. oz (10 cc) Receiver/Dryer 1.0 fl. oz (30 cc) Compressor 5.0 fl. oz (150 cc) Page 5435 NOTE: Do this repair procedure if, after doing step 10 of the test-drive, the vehicle pulled in the opposite direction after you swapped the front tires. 1. Swap wheels 2 and 4 on the passenger's side of the vehicle, and test-drive again. ^ If the pull goes away, replace the tire on wheel 2, then go to step 3. ^ If the pull does not go away, put wheels 2 and 4 back to their original positions, and go to step 2. 2. Swap wheels 1 and 3 on the driver's side of the vehicle, and test-drive again. ^ If the pull goes away, replace the tire on wheel 1, then go to step 3. ^ If the pull does not go away, use a known-good tire in position 1 and continue diagnosis. 3. Use your diagnosis worksheet to fill in the following table and build your 15-digit DTC. REPAIR PROCEDURE B Locations Air Flow Meter/Sensor: Locations 28. Left Side of Engine Compartment Left Side Of Engine Compartment Interior - Seat Belts Slow to Retract Seat Belt: All Technical Service Bulletins Interior - Seat Belts Slow to Retract 03-062 September 16, 2003 Applies To: ALL Seat Belt Slow to Retract (Replaces 91-030, dated January 22, 1996) SYMPTOM The seat belt will not retract all the way, or retracts slowly. PROBABLE CAUSE Dirt on the seat belt webbing and guide. CORRECTIVE ACTION Clean the seat belts and guides with a mild soap and water solution, or isopropyl alcohol. This applies only to three-point active and passive seat belt systems, not to motorized systems. REQUIRED MATERIALS Required only for three-point passive seat belts. Teflon Tape (ten pieces per package): P/N 81496-SH3-505, H/C 4008041 WARRANTY CLAIM INFORMATION This repair is covered by the Lifetime Seat Belt Limited Warranty. Failed Part: P/N 818AD-SM1-A05ZB H/C 3478047 Defect Code: L11 Contention Code: B99 Skill Level: Repair Technician REPAIR PROCEDURE Three-Point Active Seat Belts 1. Use either isopropyl alcohol, or prepare a solution of 5 ounces of mild dishwashing liquid in a gallon of warm water. NOTICE Do not use strong cleaning solutions, upholstery cleaners or commercial automotive interior cleaners. They can affect the durability of the webbing. Page 3180 Air Flow Meter/Sensor: Service and Repair Mass Air Flow (MAF) Sensor REMOVAL PROCEDURE 1. Disconnect the negative battery cable. 2. Disconnect the electrical connector from the MAF sensor. 3. Loosen the clamps which secure the intake air duct and the air cleaner to the MAF sensor. 4. Remove the intake air duct from the MAF sensor. 5. Remove the MAF sensor from the air cleaner. INSTALLATION PROCEDURE Page 178 Fuel Pump Relay: Diagnostic Aids Before Troubleshooting Before Troubleshooting See: Service Precautions/Vehicle Damage Warnings/Tips and Precautions 1. Check applicable fuses in the appropriate fuse/relay box. 2. Check the battery for damage, state of charge, and clean and tight connections. CAUTION: Do not quick-charge a battery unless the battery ground cable has been disconnected, otherwise you will damage the alternator diodes. - Do not attempt to crank the engine with the battery ground cable loosely connected or you will severely damage the wiring. While You're Working 1. Make sure connectors are clean, and have no loose terminals or receptacles. 2. Make sure that connectors without wire seals are packed with dielectric (silicone) grease. Part Number: 08798-9001. 3. When connecting a connector, push it until it "clicks" into place. CAUTION: Do not pull on the wires when disconnecting a connector. Pull only on the connector housings. - Most circuits include solid-state devices. Test the voltages in these circuits only with a 10-megaohm or higher impedance digital multi meter. Never use a test light or analog meter on circuits that contain solid-state devices. Damage to the devices may result. Five-Step Troubleshooting 1. Verify The Complaint Turn on all the components in the problem circuit to check the accuracy of the customer complaint. Note the symptoms. Do not begin disassembly or testing until you have narrowed down the problem area. 2. Analyze The Schematic Look up the schematic for the problem circuit. Determine how the circuit is supposed to work by tracing the current paths from the power source through the circuit components to ground. Also, trace circuits that share wiring with the problem circuit. The names of circuits that share the same fuse, ground, or switch, and so on, are referred to in each circuit schematic. Try to operate any shared circuits you didn't check in step 1. If the shared circuits work, the shared wiring is OK, and the cause must be in the wiring used only by the problem circuit. If several circuits fail at the same time, the fuse or ground is a likely cause. Based on the symptoms and your understanding of the circuit's operation, identify one or more possible causes. 3. Isolate The Problem By Testing The Circuit Make circuit tests to check the diagnosis you made in step 2. Keep in mind that a logical, simple procedure is the key to efficient troubleshooting. Test for the most likely cause of failure first. Try to make tests at points that are easily accessible. 4. Fix The Problem Once the specific problem is identified, make the repair. Be sure to use proper tools and safe procedures. 5. Make Sure The Circuit Works Turn on all components in the repaired circuit in all modes to make sure you've fixed the entire problem. If the problem was a blown fuse, be sure to test all of the circuits on that fuse. Make sure no new problems turn up and the original problem does not recur. Locations Locations 4WD Control Unit: Locations Under Center Console Page 6743 The wire insulation has one color or one color with another color stripe. The second color is the stripe. Page 1565 6. Insert the press-fit into the valve seat horizontally. 7. Standard fitting interference: 0.14 mm 0.09 mm (0.0055 inch - 0.0035 inch) 8. After insertion, use a seat grinder to grind finish the seating face. Carefully note the seating angle, the contact width, and the depression. 9. Lap the valve and the seat. Reassembly 1. Install valve guide (1) to cylinder head. Apply engine oil to the outside of the valve guide. Using valve guide replacer J-42899, drive in a new valve guide from the camshaft side. 2. Install oil controller (3) and spring lower seat (2). Using oil controller replacer J-37281, drive in a new oil controller. 3. Install valve to valve guide. Before install valve guide apply engine oil to the outside of the valve stem. 4. Install valve spring to cylinder head. Attach the valve spring to the lower spring seat. The painted area of the valve spring should be facing downward. 5. Install lower valve spring seat, valve spring and upper valve spring seat then put split collars on the upper spring seat, using the J-8062 valve Page 444 Refrigerant Pressure Sensor / Switch: Service and Repair Removal 1. Disconnect the battery ground cable. 2. Discharge and recover refrigerant. 3. Remove radiator grille. 4. Disconnect pressure switch connector. 5. Disconnect pressure switch. - When removing the switch connected part, the connecting part should immediately be plugged or capped to prevent foreign matter from being mixed into the line. Installation To install, follow the removal steps in the reverse order, noting the following point: 1. O-ring cannot be reused. Always replace with a new one. 2. Be sure to apply new compressor oil to the O-ring when connecting pressure switch. 3. Tighten the pressure switch to the specified torque. Torque: 13 Nm (113 lb in) Specifications Timing Belt Tensioner: Specifications Timing Belt Tensioner 42 Nm Timing Belt Tensioner Pusher 25 Nm Page 1636 Engine Oil: Fluid Type Specifications New standard for engine oil, GF-4. See TSB SN050109 for Honda Service News 050109 for additional information. Engine Oil API Classification ............................................................................................................................................................ SJ "Energy Conserving" grade oil. Above 0°F (-20°C) ........................................................................ ............................................................................................... SAE 10W-30 is preferred. Above -20°F (-30°C) ....................................................................................................................................... ................................................... SAE 5W-30 NOTE: Additional designations of quality may also be present (SJ/CC, SJ/CD, SJ, CC etc) but SJ must be included. Description and Operation Solenoid Valve Page 1227 Power Steering Fluid: Testing and Inspection LEVEL CHECK 1. Run the engine until the power steering fluid reaches normal operating temperature, about 55°C (130°F) then shut the engine off. 2. Check the level of fluid in the reservoir. 3. If the fluid level is low, add power steering fluid to the proper level and install the receiver cap. 4. When checking the fluid level after the steering system has been serviced, air must be bled from the system. Page 6569 Diagram Information and Instructions Horn: Diagram Information and Instructions How to Identify Wiring Color-Coded Insulation Wire Color Wire Color Coding Locations Camshaft Position Sensor Page 2101 Accelerator Pedal Position Sensor: Adjustments Accelerator Position Sensor Adjustment AP sensor is controlled three multiple control system, and adjust the idle position and WOT position are between A and B for AP sensor 1, AP sensor 2, and AP sensor 3. Refer to "How to adjust for AP sensor". How To Adjust For AP Sensor 1. Connect the Tech 2 to DLC on vehicle. 2. Ignition "ON," engine "OFF". 3. Display the APS date list. Check the following item for AP position (%). 4. If the problem was found, adjust as necessary. Page 2819 14. While watching the APP Sensor values in the Engine Data List, adjust the APPS by turning it until the values are within the ranges shown at closed throttle and wide open throttle (accelerator pedal pushed all the way down), then tighten the mounting screws and recheck the values. ^ If all three sensors are within range, go to step 23. ^ If APP Sensor 1 APP Sensor 2, and/or APP Sensor 3 cannot be brought into range, go to step 15. 15. Troubleshoot for an open circuit or a PCM malfunction. ^ If APP Sensor 1 has a value of 0% or APP Sensor 2 and/or APP Sensor 3 have a value of 99%, an open circuit exists or the PCM is malfunctioning. Repair the circuit or replace the PCM, and repeat step 14. ^ If you don't find a problem, go to step 16. 16. Disconnect the 10 P connector from the APPS. 17. View the APP Sensor values in the Engine Data List. ^ If APP Sensor 1 has a value of 0% or APP Sensor 2 and/or APP Sensor 3 have a value of 99%, go to step 18. ^ If APP Sensor 1 has a value other than 0%, or APP Sensor 2 and/or APP Sensor 3 have a value other than 99%, a short circuit exists or the PCM is malfunctioning. Repair the circuit or replace the PCM, and repeat step 14. 18. Modify the original APPS by cutting the connector housing off of the sensor. 19. Connect the 10 P connector to the modified APPS connector housing. Page 384 Part 1 of 2 Part 2 of 2 B-21 FR Speed Sensor Missing (DTC 62/C0222, C0223) Chart B-21 FR Speed Sensor Missing (DTC 62 (Flash Out) / C0222, C0223 (Serial Communications)) Page 64 Wires Wire insulation can be one color, or one color with another color stripe. (The second color is the stripe.) This circuit continues on another image. (The arrow shows direction of current flow.) To follow the RED/BLK wire in this example, you would turn to "Fuel and Emissions" and look for the "A" arrow. Page 7177 Sunshade (LWB) - Disassembled View Page 2406 6. Remove the connector position assurance (CPA) clip from the APPS connector. 7. Disconnect the 10 P connector from the APPS. 8. Remove the bolts, the APPS, the spacer, and the accelerator link from the accelerator pedal assembly. 9. Separate the spacer from the APPS. Clean the grease off the spacer and the accelerator link with a clean shop towel. 10. Clean the terminals of the 10 P APPS connector (harness side) with contact cleaner. Shake the residue out of the connector, and allow the contact cleaner to evaporate for at least 3 minutes before reconnecting the connector. 11. Install a new APPS, the spacer, and the accelerator link onto the accelerator pedal assembly. Leave the mounting screws loose so the sensor can be adjusted. 12. Connect the 10 P connector to the new APPS, and lock the connector in place with the CPA. 13. Connect the PGM Tester to the data link connector (DLC), and turn the ignition switch to ON (II). Page 5986 If there is no photo number below or beside a component name or a connector, ground, or terminal number, look up that name or number in the appropriate Connector Identification Chart. The chart lists how many cavities a connector has, where it's located, and what it connects to. The related illustration shows the connector's location on the harness, and the harness routing. NOTE: Photos listed by number are located at Locations / Components / Photograohs. See: Locations/Component Locations/Photographs Circuit Schematics Specifications Idle Speed: Specifications Idle speed is PCM controlled Page 5168 Polish the commutator surface with sandpaper #500 to #600 if it is rough. Measure the depth of insulator in commutator. Repair,if it is below the limit. Standard: 0.5 mm to 0.8 mm (0.02 in to 0.03 in) Limit: 0.2 mm (0.008 in) Page 6630 - The name as it appears on the credit card - Signature (authorized card holder) - Phone number - Authorized charge amount NOTE: If you send in a faulty unit without a check or complete credit card information, the manufacturer may send it back to you unrepaired, or they may repair it and send it back to you C.O.D. ^ Print two copies of the completed Out-of-Warranty/New Replacement component repair form. Keep one copy with the repair order, and include the other copy with the faulty unit when you send it to the manufacturer. 8. Carefully pack the faulty unit and the paperwork in a suitable box, and label the box clearly. You are responsible for lost or damaged units; keep all shipping documents and insurance receipts. 9. Ship the faulty unit to the appropriate manufacturer via UPS. Alpine Electronics of America c/o Standard Radio Engineering Corp. 2012 Abalone Ave., Unit D Torrance, CA 90501 800-421-2284, Ext. 860304 Bose Corporation Automotive Systems Division-Service Framingham, MA 01701-9168 800-231-2673 S3 Clarion Factory Service Center 241 Beaver Rd. Walton, KY 41094 800-347-8667 (You must get authorization from Clarion before shipping units) Fujitsu Ten 19600 5. Vermont Ave. Torrance, CA 90502 800-237-5413 FTH Group Inc. (Kenwood Accessory Parts) 16685 E. Johnson Dr. City of Industry, CA 91745 626-333-2435 (You must get an RMA authorization number from www.fthgroupinc.com; from the home page, select Consumer Products) Komtec Electronics (Panasonic) 6590 Darin Way Cypress, CA 90630 714-903-3300 (Make sure your check is made out to Komtec) * Pioneer Electronics Service, Inc. 1925 E. Dominguez St. Long Beach, CA 90801 800-553-3756* Visteon c/o Model Electronics 615 E. Crescent Ave. Page 3556 This sample Ground Distribution schematic shows all of the components that share two ground points. Components A solid border line means the entire component is shown. A broken border line indicates that only part of the component is shown. Page 5027 Installation 1. Install plate and seal assembly. 2. Install retainer. 3. Install 2 gaskets and spacer. 4. Install filter. 5. Install silencer. 6. Install valve body guard. 7. Install retainer. 8. Install lock nut and yoke clevis and tighten to the specified torque. Torque: 20 Nm (15 ft. lbs.) 9. Install vacuum booster. 10. Install master cylinder and after installation, perform brake pedal check and adjustment. Page 2023 Fuel Pump Relay: Description and Operation In order to control the FPAS operation, the FPAS relay is provided. When the starter switch is turned to "ON" position, the FPAS relay operates the FPAS for 2 seconds. When it is turned to "START" position, the Engine Control Module receives the reference pulse from the Ignition Control Module and it operates the relay, again causing the FPAS to feed fuel. Page 5595 Seat Belt, Lights-ON and Ignition Key Reminders Part 2 Of 2 A/T - Do Not Remove Torque Converter From Mainshaft Torque Converter: Technical Service Bulletins A/T - Do Not Remove Torque Converter From Mainshaft SOURCE: Honda Service News TITLE: Keep Torque Converter on Mainshaft to Avoid Damage APPLIES TO: All models SERVICE TIP: We can't emphasize enough how important it is to keep the torque converter in place when you're handling or installing a reman A/T. If the torque converter slips off the mainshaft, and you don't put it back on the shaft exactly right, you could cut the O-ring. This could result in loss of lock-up control and ATF leakage. Page 4701 4. If the trouble occurs after the above test, charge the Axle Disconnect controller to the new one. Page 2195 10. Use the PGM Tester to check the broadcast code. Make sure the broadcast code matches the one you selected from the CD-ROM. WARRANTY CLAIM INFORMATION In warranty: The normal warranty applies. Failed Part: P/N 8-17087-655-0 H/C 4375820 Defect Code: 064 Contention Code: C01 Skill Level: Repair Technician Out of warranty: Any repair performed after warranty expiration may be eligible for goodwill consideration by the District Service Manager or your Zone Office. You must request consideration, and get a decision, before starting work. REPAIR PROCEDURE - ENGINE/BODY GROUND 1. Use the ETM for the appropriate year to locate these ground connectors: G101, G104, G105, G106 and G160. 2. Inspect each connector for corrosion or looseness. 3. Remove the bolt from any connector that is corroded or loose. Clean the terminal connector with a wire brush. File flat any solder bumps on the connector. 4. Clean the contact surface on the engine or body with a wire brush. 5. Replace the bolt if it is heavily corroded. Otherwise, clean it with a wire brush. 6. Apply lithium dielectric grease to both sides of the terminal connector. 7. Reinstall the bolt, torque it to 14 N.m (10 lb-ft). 8. Use the Smart Cable to reprogram the PCM with the latest software from the June 2001 or later HONDANET CD-ROM. Refer to Service Bulletin 99-005, Updating the Passport PCM, filed under Tools. 9. Use the PGM Tester to clear any DTCs. 10. Use the PGM Tester to check the broadcast code. Make sure the broadcast code matches the one you selected from the CD-ROM. WARRANTY CLAIM INFORMATION In warranty: The normal warranty applies. Failed Part: P/N 8-97086-823-0 Antitheft & Keyless Entry Controller Alarm/Immobilizer Control Unit: Service and Repair Antitheft & Keyless Entry Controller Anti-Theft & Keyless Entry Controller Removal 1. Disconnect the battery ground cable. 2. Remove the glove box from the instrument panel assembly (1). - Refer to the Instrument Panel Assembly in Body Structure section. 3. Remove the anti-theft & keyless entry controller (2). - Disconnect the connector. Remove two fixing screws. Installation To install, follow the removal steps in the reverse order. Diagram Information and Instructions Ion Sensing Module: Diagram Information and Instructions How to Identify Wiring Color-Coded Insulation Wire Color Wire Color Coding Page 4381 Universal Joint: Specifications Front Propeller Shaft FRONT PROPELLER SHAFT General Specifications Torque Specifications Page 5149 10. Move the front wheels to the straight ahead position, then use steering wheel remover J-29752 to remove the steering wheel CAUTION: Never apply force to the steering wheel in direction of the shaft by using a hammer or other impact tools in an attempt to remove the steering wheel. The steering shaft is designed as an energy absorbing unit. WARNING: THE INFLATOR MODULE SHOULD ALWAYS BE CARRIED WITH THE URETHANE COVER AWAY FROM YOUR BODY AND SHOULD ALWAYS BE LAID ON A FLAT SURFACE WITH THE URETHANE SIDE UP. THIS IS NECESSARY BECAUSE A FREE SPACE IS PROVIDED TO ALLOW THE AIR CUSHION TO EXPAND IN THE UNLIKELY EVENT OF ACCIDENTAL DEPLOYMENT. OTHERWISE. PERSONAL INJURY MAY RESULT. 11. .Remove steering column cover. 12. Disconnect the wiring harness connectors located under the steering column. 13. Remove the combination switch assembly with SRS coil. NOTE: The SRS coil is a part of the combination switch assembly, which can not be replaced separately. Therefore, be sure not to remove the SRS coil from the combination switch assembly. 14. Remove snap ring. 15. Remove cushion rubber. 16. Remove shift lock cable (for A/T). 17. Disconnect the starter switch harness connector located under the steering column, then remove lock cylinder assembly. Description and Operation Transmission Mode Indicator - A/T: Description and Operation With the ignition switch in ON or START battery voltage is applied to the A/T gear position switch through fuse 14. The A/T gear position switch sends a signal to the PCM which communicates this information to the multiplex control unit which in turn controls the A/T gear position indicator corresponding to the gear selected. The multiplex control unit applies voltage to the appropriate A/T gear position indicator light in the meter assembly, causing it to come on. Page 6284 Distinct Of Circuit By Wire Base Color All wires have color-coded insulation. Wires belonging to a system's main harness will have a single color. Wires belonging to a system's sub-circuits will have a colored stripe. Striped wires use the codes found in the chart to show wire size and colors. Abbreviations are used to indicate wire color within a circuit diagram. How to Identify Connector Terminals How to Identify Connector Terminals Cavity Numbering System The cavities (and wire terminals) in each connector are numbered starting from the upper left, looking at the male terminals from the terminal side (or looking at the female terminals from the wire side. Both views are in the same direction so the numbers are the same.) All actual cavities are numbered, even if they have no wire terminals in them. NOTE: Data Link Connector (DLC) terminals are numbered according to SAE standard J1962, not the Honda standard. The numbers of the four end terminals are molded into the corners of the connector face. The connector cavity number is listed next to each terminal on the circuit schematic. The cavity / terminal shown is # 6. Using/Identifying Connector Terminal Views How to Use Connector Terminal Views To see the configuration of a connector's cavities, look up its view number in the Connector Views. Each view includes the color of the connector, where Locations Shift Interlock Relay: Locations Under Center Console Page 6080 Splices Splices are shown as a dot. Their location and the number of wires may vary depending on the harness manufacturer. Switches Switches These switches move together; the broken straight line between them means they are mechanically connected. Other types of switches are controlled by a coil or a solid state circuit. Unless otherwise noted, all switches are shown in their normal (rest) position, with power off. Terminal "T" Page 3234 Fuel Injector: Service and Repair REMOVAL PROCEDURE NOTE: If the fuel injectors are leaking, the engine oil may be contaminated with fuel. Check the oil for signs of contamination and change the oil and the filter if necessary. NOTE: Use care in removing the fuel injectors in order to prevent damage to the fuel injector electrical connector pins or the fuel injector nozzles. The fuel injector is an electrical component and should not be immersed in any type of cleaner as this may damage the fuel injector. IMPORTANT: Fuel injectors are serviced as a complete assembly only. 1. Disconnect the negative battery cable. 2. Remove the common chamber. 3. Remove the fuel rail. 4. Remove the injector retainer clip. 5. Remove the fuel injector assembly. 6. Remove the O-ring from the fuel injector. 7. Remove the O-ring backup from the fuel injector. INSTALLATION PROCEDURE 1. Install the O-ring backup on the fuel injector. 2. Install the new O-ring on the fuel injector. Page 4554 Terminals - "T" Each "T" terminal (ring type) is numbered for reference and location. A "T" terminal is secured with a screw or bolt. Wires Page 801 14. While watching the APP Sensor values in the Engine Data List, adjust the APPS by turning it until the values are within the ranges shown at closed throttle and wide open throttle (accelerator pedal pushed all the way down), then tighten the mounting screws and recheck the values. ^ If all three sensors are within range, go to step 23. ^ If APP Sensor 1 APP Sensor 2, and/or APP Sensor 3 cannot be brought into range, go to step 15. 15. Troubleshoot for an open circuit or a PCM malfunction. ^ If APP Sensor 1 has a value of 0% or APP Sensor 2 and/or APP Sensor 3 have a value of 99%, an open circuit exists or the PCM is malfunctioning. Repair the circuit or replace the PCM, and repeat step 14. ^ If you don't find a problem, go to step 16. 16. Disconnect the 10 P connector from the APPS. 17. View the APP Sensor values in the Engine Data List. ^ If APP Sensor 1 has a value of 0% or APP Sensor 2 and/or APP Sensor 3 have a value of 99%, go to step 18. ^ If APP Sensor 1 has a value other than 0%, or APP Sensor 2 and/or APP Sensor 3 have a value other than 99%, a short circuit exists or the PCM is malfunctioning. Repair the circuit or replace the PCM, and repeat step 14. 18. Modify the original APPS by cutting the connector housing off of the sensor. 19. Connect the 10 P connector to the modified APPS connector housing. Page 2534 Intake Air Temperature Sensor: Description and Operation Intake Air Temperature (IAT) Sensor The intake air temperature (IAT) sensor is a thermistor which changes its resistance based on the temperature of air entering the engine. Low temperature produces a high resistance of 100,000 ohms at -40 °C (-40 °F). High temperature causes low resistance of 70 ohms at 130 °C (266 °F). The PCM supplies a 5-volt signal to the sensor through a resistor in the PCM and monitors the signal voltage. The voltage will be high when the incoming air is cold. The voltage will be low when the incoming air is hot. By measuring the voltage, the PCM calculates the incoming air temperature. The IAT sensor signal is used to adjust spark timing according to the incoming air density. The Tech 2 displays the temperature of the air entering the engine. The temperature should read close to the ambient air temperature when the engine is cold and rise as underhood temperature increases. If the engine has not been run for several hours (overnight), the IAT sensor temperature and engine coolant temperature should read close to each other. A fault in the IAT sensor circuit will set DTC P0112 or DTC P0113. Removal and Installation Brake Caliper: Service and Repair Removal and Installation REMOVAL 1. Raise the vehicle and support with suitable safety stands. 2. Remove wheel and tire assembly. 3. Remove the bolt and gaskets, then disconnect the flexible hose from the caliper and after disconnecting the flexible hose (1), cap or tape the openings to prevent entry of foreign material. 4. Since the brake fluid flows out from the connecting coupler, place a drain pan under the vehicle. 5. Remove lock bolt (3). Page 1895 1. Install exhaust manifold and tighten bolts to the specified torque. Torque: 57 Nm (42 ft. lbs.) 2. Install the EGR pipe, tighten bolt and nut on exhaust manifold to specified torque. Torque: 28 Nm (21 ft. lbs.) Tighten nut to EGR valve to the specified torque. Torque: 44 Nm (33 ft. lbs.) Tighten the bolt for EGR pipe bracket to specified torque. Torque: 25 Nm (18 ft. lbs.) 3. Install heat protector 4. Install exhaust front pipe and tighten three stud nuts and two nuts to the specified torque. Torque: Stud nuts: 67 Nm (49 ft. lbs.) Nuts: 43 Nm (32 ft. lbs.) 5. Install the torsion bar and readjust the vehicle height. Page 5331 Page 1110 Valve Shim Replacement Chart Page 4380 Universal Joint: Specifications Shift on the Fly System SHIFT ON THE FLY SYSTEM General Specifications Right Front Drive Shaft And Shift On The Fly Assembly Torque Specifications Page 3615 Crankshaft Position Sensor: Description and Operation Crankshaft Position (CKP) Sensor The crankshaft position (CKP) sensor provides a signal used by the powertrain control module (PCM) to calculate the ignition sequence. The CKP sensor initiates the 58X reference pulses which the PCM uses to calculate RPM and crankshaft position. Page 8052 7. Loosen the inflator module fixing bolt from behind the steering wheel assembly using a TORX driver or equivalent until the inflator module can be released from steering assembly. Disconnect the yellow 2-way SRS connector and horn lead located behind the inflator module, then remove inflator module. WARNING: THE INFLATOR MODULE SHOULD ALWAYS BE CARRIED WITH THE URETHANE COVER AWAY FROM YOUR BODY AND SHOULD ALWAYS BE LAID ON A FLAT SURFACE WITH THE URETHANE SIDE UP. THIS IS NECESSARY BECAUSE A FREE SPACE IS PROVIDED TO ALLOW THE AIR CUSHION TO EXPAND IN THE UNLIKELY EVENT OF ACCIDENTAL DEPLOYMENT. OTHERWISE, PERSONAL INJURY MAY RESULT. Page 8285 Wiper Motor Linkage: Service and Repair Removal 1. Disconnect the battery ground cable. 2. Remove the windshield wiper arm/blade. 3. Remove the vent cowl cover. 4. Remove the windshield wiper motor. 5. Remove the pivot assembly mounting nuts, fixing screws. 6. Take out the windshield wiper linkage assembly from the opening of the cowl. Installation To install, follow the removal steps in the reverse order. Audio System - CD/DVD Precautions DVD Player: Technical Service Bulletins Audio System - CD/DVD Precautions Adhesive Labels or Protective Disc Covers on CDs or DVDs: A Big Taboo NOTE: This article applies to all Honda models with a factory- or dealer-installed CD/DVD player or changer. We can't emphasize this enough: Never put adhesive labels or protective disc covers on recordable CDs or DVDs to be used in automotive CD/DVD players or changers. Here's why: ^ Recordable CDs and DVDs are actually thicker than their pre-recorded brethern. Automotive players and changers use rollers to draw the disc into the unit. The added thickness of an adhesive label or a protective disc cover can cause the disc to jam when it's loaded into or ejected from the unit. ^ CD/DVD players or changers are exposed to high temperatures inside the vehicle. High temperature can cause the label adhesive to soften. This can cause the label to curl on the edges and even form bubbles. Curled edges can catch on the rollers and bubbles add thickness to the disc. Either one can cause the disc to jam. To cut down on customer-caused damage, all '05 and later 0/Ms include this notice: Do not use CDs with adhesive labels. The label can curl up and cause the CD to jam in the unit. Anytime a service customer comes in with a loading or ejecting problem for a CD/DVD player or changer, ask if he or she used any discs with adhesive labels or protective disc covers. If the answer is yes, contact your DPSM for possible goodwill assistance. If the answer is no, then replace the audio unit under normal warranty. Page 4789 Exhaust System - Catalytic Converter Noise Catalytic Converter: Technical Service Bulletins Exhaust System - Catalytic Converter Noise SOURCE: Honda Service News TITLE: Catalytic Converter Noise? Check the Heat Shield APPLIES TO: All models SERVICE TIP: Got a vehicle in your shop that buzzes or rattles, and you suspect the catalytic converter is the culprit? Before you start replacing the converter, first check the heat shield area. If there any stones or debris trapped inside, they can cause buzzing or rattling. Page 454 the component if the component only has one connector, or by a capital letter (A, B, C, etc.) if the component has more than one connector. Below most connector numbers and component names are PHOTO and VIEW numbers. The PHOTO number refers to a photo in the back of the book that shows the connector's location on the car. The VIEW number refers to an illustration in the back of the book that shows the connector face, wire colors, connector cavity numbers, and other details. The connector cavity numbering sequence begins at the top left corner of the connector. Disregard any numbers molded into the connector housing. Wires Wires are identified by the abbreviated names of their colors; the second color is the color of the stripe. Wires are also identified by their location in a connector. The number "2" next to the male and female wire terminals at C416, for example, means those terminals join in cavity 2 of connector C416. Symbols A complete description of schematic symbols is given under wire color abbreviation. Power Distribution Schematics Power Distribution schematics show how power is supplied from the positive battery terminal to various circuits in the car. Refer to the Power Distribution section to get a more detailed picture of how power is supplied to the circuit you're working on. From Battery to Ignition Switch, Fuses, and Relays Individual circuit schematics begin with a fuse. The first half of Power Distribution, however, shows the wiring "upstream" between the battery Page 2685 Test Equipment CAUTION: Most circuits include solid-state devices. Test the voltages in these circuits only with a 10-megaohm or higher impedance digital multimeter. Never use a test light or analog meter on circuits that contain solid-state devices. Damage to the devices may result. Test Light and DVOM On circuits without solid-state devices, use a test light to check for voltage. A test light is made up of a 12 volt bulb with a pair of leads attached. After grounding one lead, touch the other lead to various points along the circuit where voltage should be present. The bulb will go on if there is voltage at the point being tested. If you need to know how much voltage is present, use a digital volt/ohmmeter (DVOM). Self-Powered Test Light and DVOM Use a self-powered test light to check for continuity. This tool is made up of a light bulb, battery, and two leads. To test it, touch the leads together: the light should go on. Use a self-powered test light only on an unpowered circuit. First, disconnect the battery, or remove the fuse that feeds the circuit you are working on. Select two points in the circuit between which you want to check continuity. Connect one lead of the self-powered test light to each point. If there is continuity, the test light's circuit will be completed, and the light will go on. If, in addition, you need to know exactly how much resistance there is between two points, use a digital volt/ohmmeter (DVOM). In the "OHMS" range, the DVOM will measure resistance between two points along a circuit. Low resistance means good continuity. Diodes and solid-state devices in a circuit can make a DVOM give a false reading. To check a reading, reverse the leads, and take a second reading. If the readings differ, the component is affecting the measurement. Jumper Wire Use a jumper wire to bypass an open circuit. A jumper wire is made up of an in-line fuse holder connected to a set of test leads. It should have a five ampere fuse. Never connect a jumper wire across a short circuit. The direct battery short will blow the fuse. Short Finder (Short Circuit Locator) Short finders are available to locate shorts to ground. The short finder creates a pulsing magnetic field in the shorted circuit which you can follow to the location of the short. To order any test equipment shown above, contact your local tool supplier. For a list of suppliers and tool numbers, refer to Honda Required Special Tools and Equipment Service Bulletin. Page 563 Headlamp Switch: Diagnostic Aids Before Troubleshooting Before Troubleshooting See: Service Precautions/Vehicle Damage Warnings/Tips and Precautions 1. Check applicable fuses in the appropriate fuse/relay box. 2. Check the battery for damage, state of charge, and clean and tight connections. CAUTION: Do not quick-charge a battery unless the battery ground cable has been disconnected, otherwise you will damage the alternator diodes. - Do not attempt to crank the engine with the battery ground cable loosely connected or you will severely damage the wiring. While You're Working 1. Make sure connectors are clean, and have no loose terminals or receptacles. 2. Make sure that connectors without wire seals are packed with dielectric (silicone) grease. Part Number: 08798-9001. 3. When connecting a connector, push it until it "clicks" into place. CAUTION: Do not pull on the wires when disconnecting a connector. Pull only on the connector housings. - Most circuits include solid-state devices. Test the voltages in these circuits only with a 10-megaohm or higher impedance digital multi meter. Never use a test light or analog meter on circuits that contain solid-state devices. Damage to the devices may result. Five-Step Troubleshooting 1. Verify The Complaint Turn on all the components in the problem circuit to check the accuracy of the customer complaint. Note the symptoms. Do not begin disassembly or testing until you have narrowed down the problem area. 2. Analyze The Schematic Look up the schematic for the problem circuit. Determine how the circuit is supposed to work by tracing the current paths from the power source through the circuit components to ground. Also, trace circuits that share wiring with the problem circuit. The names of circuits that share the same fuse, ground, or switch, and so on, are referred to in each circuit schematic. Try to operate any shared circuits you didn't check in step 1. If the shared circuits work, the shared wiring is OK, and the cause must be in the wiring used only by the problem circuit. If several circuits fail at the same time, the fuse or ground is a likely cause. Based on the symptoms and your understanding of the circuit's operation, identify one or more possible causes. 3. Isolate The Problem By Testing The Circuit Make circuit tests to check the diagnosis you made in step 2. Keep in mind that a logical, simple procedure is the key to efficient troubleshooting. Test for the most likely cause of failure first. Try to make tests at points that are easily accessible. 4. Fix The Problem Once the specific problem is identified, make the repair. Be sure to use proper tools and safe procedures. 5. Make Sure The Circuit Works Turn on all components in the repaired circuit in all modes to make sure you've fixed the entire problem. If the problem was a blown fuse, be sure to test all of the circuits on that fuse. Make sure no new problems turn up and the original problem does not recur. Audio Unit with CD Player/Changer - Error Codes Compact Disc Player (CD): Customer Interest Audio Unit with CD Player/Changer - Error Codes 00-015 March 14, 2000 Applies To: All with CD Player/Changer Audio Unit Error Codes (Replaces 91-007, dated October 6, 1997) *If the audio unit displays an error code, use the troubleshooting tables in this service bulletin to troubleshoot the problem. Refer to service bulletin 98-019 for CD Player/Changer exchange information.* Page 1702 Valve Guide Seal: Service and Repair Disassembly, Inspection and Assembly Valve Spring, Oil Controller, Valve, Valve Guide Disassembly 1. Remove camshaft bracket fixing bolts (1). 2. Remove camshaft assembly (intake). 3. Remove camshaft assembly (Exhaust side). 4. Remove shim (4) and tappet (5). Page 6512 Seat Belt: Description and Operation Seat Belt and Seat Belt Buckle Tensioners The seat belt and seat belt buckle tensioners are linked with the SRS airbags to further increase the effectiveness of the seat belt. In a front-end collision, the tensioners instantly retract the belt and buckle firmly to secure the occupants in their seats. Locations Page 2243 2. Secure the VSS in place with the clamp and the bolt. 3. Tighten the bolt to 27 Nm (20 lb ft.). 4. Connect the VSS electrical connector. 5. Check the transfer case oil level. Add fluid if necessary. 6. Connect the negative battery cable. Page 5925 This means the branch of the wire connects to another circuit. The arrow points to the name of the circuit branch where the wire continues. Component Locations 4WD Motor Actuator: Component Locations Beneath Center of Vehicle, on Transfer Case (A/T) Page 5281 Relay Box: Diagrams Instrument Panel Page 6383 The wire insulation has one color or one color with another color stripe. The second color is the stripe. General Precautions Air Bag(s) Arming and Disarming: Service Precautions General Precautions General Precautions Please read the following precautions carefully before performing the airbag system service. Observe the instructions described or the airbags could accidentally deploy and cause damage or injuries. Except when performing electrical inspections, always turn the ignition switch OFF and disconnect the negative cable from the battery, and wait at least three minutes before beginning work. NOTE: The contents in the memory is not erased even if the ignition switch is turned OFF or the battery cables are disconnected from the battery. Use the replacement parts which are manufactured to the same standards as the original parts and quality. Do not install used SRS parts from another vehicle. Use only new parts when making SRS repairs. Carefully inspect any SRS part before you install it. Do not install any part that shows signs of being dropped or improperly handled, such as dents, cracks or deformation. Before removing any of the SRS parts (including the disconnection of the connectors), always disconnect the SRS connector. Use only a digital multimeter to check the system. If it is not a Honda multimeter, make sure its output is 10 mA (0.01 A) or less when switched to the lowest value in the ohmmeter range. A tester with a higher output could cause accidental deployment and possible injury. Do not put objects on the front passenger's airbag. The original radio has a coded theft protection circuit. Be sure to get the customer's radio code before disconnecting the battery cable. Page 6486 Child Seat Tether Attachment Page 8176 - Attach the molding to the body with sealant. - Cure the bonding at a temperature of 20 °C - 30 °C (68 °F - 86 °F) for 24 hours. - Check the rear quarter glass for any signs of water leak. 2. Install the rear quarter trim panel. Page 6170 - Tear off the insulator carefully. - Remove the sensor fixing clip. - Use a back-up wrench when disconnecting all refrigerant pipes. Installation To install, follow the removal steps in the reverse order, noting the following points: 1. The sensor is installed on the core with the clip. 2. The sensor must not interfere with the evaporator core. 3. When installing the new evaporator core, install the duct sensor (2) to the evaporator core (1) specified position with the clip in the illustration. 4. O-rings cannot be reused. Always replace with new ones. 5. Be sure to apply new compressor oil to the O-ring when connecting lines. 6. Be sure to install the sensor and the insulator on the place where they were before. 7. To install a new evaporator core, add 50cc (1.7 fl.oz.) of new compressor oil to the new core. 8. Tighten the refrigerant lines to the specified torque. Refer to Main Data and Specifications for Torque Specifications. 9. Apply an adhesive to the parting face of the lining when assembling the evaporator assembly. Page 3017 The connector cavity number is listed next to each terminal on the circuit schematic. The cavity / terminal shown is # 6. Diodes A rectifier diode works like a one way valve. It allows current to flow only in the direction of the arrow. A Zener diode blocks reverse current at normal voltages just like a rectifier diode. At high voltages, however, a Zener diode allows current to flow in reverse. Fuses Electrode Gap Spark Plug: Specifications Plug Gap Standard Service Limit 0.039-0.043 in (1.0-1.1 mm) 0.050 in (1.3 mm) Page 3139 6. Remove the connector position assurance (CPA) clip from the APPS connector. 7. Disconnect the 10 P connector from the APPS. 8. Remove the bolts, the APPS, the spacer, and the accelerator link from the accelerator pedal assembly. 9. Separate the spacer from the APPS. Clean the grease off the spacer and the accelerator link with a clean shop towel. 10. Clean the terminals of the 10 P APPS connector (harness side) with contact cleaner. Shake the residue out of the connector, and allow the contact cleaner to evaporate for at least 3 minutes before reconnecting the connector. 11. Install a new APPS, the spacer, and the accelerator link onto the accelerator pedal assembly. Leave the mounting screws loose so the sensor can be adjusted. 12. Connect the 10 P connector to the new APPS, and lock the connector in place with the CPA. 13. Connect the PGM Tester to the data link connector (DLC), and turn the ignition switch to ON (II). Page 5694 Front Drive Shaft Drive/Propeller Shaft: Testing and Inspection Front Drive Shaft DIAGNOSIS OF PROPELLER SHAFT AND UNIVERSAL JOINT Part 1 of 2 Part 2 of 2 Page 5870 Premature Wear In Shoulders 1. Flexing of tire excessive due to under-inflation. One Sided Feather Edging 1. Wear caused by repeated hard cornering. 2. Camber or toe-in incorrect. Page 4549 This sample Ground Distribution schematic shows all of the components that share two ground points. Components A solid border line means the entire component is shown. A broken border line indicates that only part of the component is shown. Page 4999 Brake Master Cylinder: Description and Operation Master Cylinder Assembly The master cylinder contains two pistons that supply the hydraulic pressure for a dual-circuit braking system. The primary piston provides the fluid pressure to the front brakes, while the secondary piston provides the fluid pressure to the rear brakes. If the pressure is lost from either system, the remaining system will function to stop the vehicle. CAUTION: 1. The master cylinder is not repairable. If found defective, it must be replaced as a complete assembly. 2. If any hydraulic component is removed or disconnected, it may be necessary to bleed all or part of the brake system. 3. The torque values specified are for dry, unlubricated fasteners. 4. Perform service operations on a clean bench free from all mineral oil materials. Page 4543 Distinct Of Circuit By Wire Base Color All wires have color-coded insulation. Wires belonging to a system's main harness will have a single color. Wires belonging to a system's sub-circuits will have a colored stripe. Striped wires use the codes found in the chart to show wire size and colors. Abbreviations are used to indicate wire color within a circuit diagram. How to Identify Connector Terminals How to Identify Connector Terminals Cavity Numbering System The cavities (and wire terminals) in each connector are numbered starting from the upper left, looking at the male terminals from the terminal side (or looking at the female terminals from the wire side. Both views are in the same direction so the numbers are the same.) All actual cavities are numbered, even if they have no wire terminals in them. NOTE: Data Link Connector (DLC) terminals are numbered according to SAE standard J1962, not the Honda standard. The numbers of the four end terminals are molded into the corners of the connector face. The connector cavity number is listed next to each terminal on the circuit schematic. The cavity / terminal shown is # 6. Using/Identifying Connector Terminal Views How to Use Connector Terminal Views To see the configuration of a connector's cavities, look up its view number in the Connector Views. Each view includes the color of the connector, where Fuel Control Heated Oxygen Sensors Oxygen Sensor: Description and Operation Fuel Control Heated Oxygen Sensors Fuel Control Heated Oxygen Sensors The fuel control heated oxygen sensors (Bank 1 HO2S 1 and Bank 2 HO2S 1) are mounted in the exhaust stream where they can monitor the oxygen content of the exhaust gas. The oxygen present in the exhaust gas reacts with the sensor to produce a voltage output. This voltage should constantly fluctuate from approximately 100 mV to 900 mV. The heated oxygen sensor voltage can be monitored with a Tech 2. By monitoring the voltage output of the oxygen sensor, the PCM calculates the pulse width command for the injectors to produce the proper combustion chamber mixture. - Low HO2S voltage is a lean mixture which will result in a rich command to compensate. - High HO2S voltage is a rich mixture which will result in a lean command to compensate. An open Bank 1 HO2S 1 signal circuit will set a DTC P0134 and the Tech 2 will display a constant voltage between 400 - 500 mV. A constant voltage below 300 mV in the sensor circuit (circuit grounded) will set DTC P0131. A constant voltage above 800 mV in the circuit will set DTC P0132. Faults in the Bank 2 HO2S 1 signal circuit will cause DTC 0154 (open circuit), DTC P0151 (grounded circuit), or DTC P0152 (signal voltage high) to set. A Fault in the Bank 1 HO2S 1 heater circuit will cause DTC P0135 to set. A fault in the Bank 2 HO2S 1 heater circuit will cause DTC P0155 to set. The PCM can also detect HO2S response problems. If the response time of an HO2S is determined to be too slow, the PCM will store a DTC that indicates degraded HO2S performance. Disconnecting Airbag and Seat Belt Tensioner Connectors Seat Belt Tensioner: Service and Repair Disconnecting Airbag and Seat Belt Tensioner Connectors Before removing the airbag or SRS related devices (the SRS unit, the cable reel and the seat belt tensioner connector), disconnecting connectors from related devices, or removing the dashboard or the steering column, disconnect the airbag connectors and seat belt tensioner connectors to prevent accidental deployment. WARNING: Turn the ignition switch OFF and disconnect the negative cable from the battery, and wait at least 3 minutes before beginning the following procedures. Before disconnecting the SRS main harness from the SRS unit, disconnect both airbags (C, D) and both seat belt tensioners (F, H). Before disconnecting the cable reel 2P connector (B), disconnect the driver's airbag connector (C). Before disconnecting the left side wire harness 2P connector (E), disconnect the driver's seat belt tensioner 2P connector (F). Before disconnecting the right side wire harness 2P connector (G), disconnect the front passenger's seat belt tensioner 2P connector (H). 1. Disconnect the battery negative cable, then disconnect the positive cable from the battery, and wait at least 3 minutes. 2. Disconnect the airbag and tensioner connectors. Driver's Airbag: Remove the access panel from the steering wheel, then disconnect the 2P connector between the driver's airbag and cable reel. When disconnected, the airbag connector is automatically shorted. Page 6297 This means the branch of the wire connects to another circuit. The arrow points to the name of the circuit branch where the wire continues. Locations Combination Switch: Locations Driver's Inflator Module Connector Component Locations Wheel Speed Sensor: Component Locations Under Rear of Vehicle (On Differential) Page 6605 1. Print out the appropriate system worksheet from an Interactive Network (iN) workstation. ^ From the iN main menu, click on SERVICE. ^ Click on (ISIS) Service Publications. ^ Click on SEARCH BY PUBLICATION. ^ Click on Job Aids. ^ Click on Audio System Worksheet, Navigation System Worksheet, or Rear Entertainment System Worksheet. 2. Duplicate and confirm the problem using the customer information written on the repair order or have the customer demonstrate the problem, then write down the results on the worksheet. Using the SYMPTOM TROUBLESHOOTING INDEX or the DTC INDEX (if applicable) in the applicable service manual, find the symptom that matches the customers complaint, and follow the diagnostic procedure: ^ Refer to the appropriate section in the service manual, or ^ From the iN main menu: - Click on SERVICE. - Click on ISIS (Service Publications). - Click on SEARCH BY VEHICLE. - Enter the model and the model year. - Enter a keyword: AUDIO, NAVIGATION, or RES, and the DTC (if applicable) - Select the appropriate Service Bulletin, ServiceNews article, or Symptom Troubleshooting from the list. 3. Repair the vehicle according to your diagnosis, then confirm the repair by trying to duplicate the customer's original complaint, or check to see if the DTC returns: ^ If the problem is gone, return the vehicle to the customer. ^ If the problem is still there, go to step 4. 4. Replace the audio/navigation/RES unit with a remanufactured unit: Page 7767 2. Connect the short finder across the battery terminals and the load (component) side of the fuse terminal. 3. Close all switches in the circuit you're testing. 4. Turn on the short finder. This creates a pulsing magnetic field around the wiring between the fuse box and the short. 5. Beginning at the fuse box, slowly move the short finder along the circuit wiring. The meter will read current pulses through sheet metal and body trim. As long as the meter is between the fuse and the short, the needle will move with each current pulse. Once you move the meter past the point of the short, the needle will stop moving. Check the wiring and connectors in this area to locate the cause of the short. Testing For Continuity When testing for continuity at a connector without wire seals, you do not have to separate the two halves of the connector. Instead, probe the connector from the back. Always check both sides of the connector because dirty, corroded, and bent terminals can cause problems (no electrical contact = an open). 1. Disconnect the negative cable from the car battery. If you're using a DVOM, place it in the lowest "OHMS" range. Page 6149 Terminals - "T" Each "T" terminal (ring type) is numbered for reference and location. A "T" terminal is secured with a screw or bolt. Wires Page 4595 The connector cavity number is listed next to each terminal on the circuit schematic. The cavity / terminal shown is # 6. Diodes A rectifier diode works like a one way valve. It allows current to flow only in the direction of the arrow. A Zener diode blocks reverse current at normal voltages just like a rectifier diode. At high voltages, however, a Zener diode allows current to flow in reverse. Fuses Page 747 Each schematic represents one circuit. A circuit's wires and components are arranged to show current flow, from power at the top of the page, to ground, at the bottom. Shared Circuits Other circuits may share power or ground terminals or wiring with the circuit shown. A wire that connects one circuit to another, for example, is cut short and has an arrowhead at the end of it pointing in the direction of current flow. Next to the arrowhead is the name of the circuit or component which shares that wiring. To quickly check shared wiring, check the operation of a component it serves. If that component works, you know the shared wiring is OK. Connectors All in-line and junction connectors are numbered (C725, C416, etc.). Component connectors are not numbered but are identified either by the name of Power Window Switch Driver Seat Side Power Window Switch: Service and Repair Power Window Switch Driver Seat Side Power Window Switch Driver Seat Side Removal 1. Disconnect the battery ground cable. 2. Remove the switch (1). - Pull out the switch by pushing the spring with the tip of a screwdriver. - Disconnect the connector. Installation To install, follow the removal steps in the reverse order. Front Passenger Seat Side Removal 1. Disconnect the battery ground cable. 2. Remove the switch (1). - Pull out the switch by pushing the spring with the tip of a screwdriver. - Disconnect the connector. Installation Page 7236 Torque: 39 N.m (29 lb.ft) 2. Tighten the side hinge fixing nuts to the specified torque Torque: 29 N.m (22 lb.ft) 3. Tighten the side lock striker fixing bolts to the specified torque. Torque: 19 N.m (14 lb.ft) Page 212 Wire Color Abbreviations The following abbreviations are used to identify wire colors in the circuit schematics: WHT................................... White YEL................................... Yellow BLK................................... Black BLU................................... Blue GRN................................... Green RED................................... Red ORN................................... Orange PNK................................... Pink BRN................................... Brown GRY................................... Gray PUR................................... Purple LT BLU................................... Light Blue LT GRN................................... Light Green Page 8227 Windshield: Removal and Replacement Windshield Windshield Removal 1. Disconnect the battery ground cable. 2. Remove the front pillar trim cover. - Turn up the finisher and pry the trim cover clips free from the body panel. 3. Remove the sunvisors and sunvisor holders. Page 2512 Splices Splices are shown as a dot. Their location and the number of wires may vary depending on the harness manufacturer. Switches Switches These switches move together; the broken straight line between them means they are mechanically connected. Other types of switches are controlled by a coil or a solid state circuit. Unless otherwise noted, all switches are shown in their normal (rest) position, with power off. Terminal "T" Page 4383 Universal Joint: Service and Repair For further information regarding this component and the system that it is a part of, please refer to Drive/Propeller Shaft; Service and Repair; Front Drive Shaft. Page 7643 Test Equipment CAUTION: Most circuits include solid-state devices. Test the voltages in these circuits only with a 10-megaohm or higher impedance digital multimeter. Never use a test light or analog meter on circuits that contain solid-state devices. Damage to the devices may result. Test Light and DVOM On circuits without solid-state devices, use a test light to check for voltage. A test light is made up of a 12 volt bulb with a pair of leads attached. After grounding one lead, touch the other lead to various points along the circuit where voltage should be present. The bulb will go on if there is voltage at the point being tested. If you need to know how much voltage is present, use a digital volt/ohmmeter (DVOM). Self-Powered Test Light and DVOM Use a self-powered test light to check for continuity. This tool is made up of a light bulb, battery, and two leads. To test it, touch the leads together: the light should go on. Use a self-powered test light only on an unpowered circuit. First, disconnect the battery, or remove the fuse that feeds the circuit you are working on. Select two points in the circuit between which you want to check continuity. Connect one lead of the self-powered test light to each point. If there is continuity, the test light's circuit will be completed, and the light will go on. If, in addition, you need to know exactly how much resistance there is between two points, use a digital volt/ohmmeter (DVOM). In the "OHMS" range, the DVOM will measure resistance between two points along a circuit. Low resistance means good continuity. Diodes and solid-state devices in a circuit can make a DVOM give a false reading. To check a reading, reverse the leads, and take a second reading. If the readings differ, the component is affecting the measurement. Jumper Wire Use a jumper wire to bypass an open circuit. A jumper wire is made up of an in-line fuse holder connected to a set of test leads. It should have a five ampere fuse. Never connect a jumper wire across a short circuit. The direct battery short will blow the fuse. Short Finder (Short Circuit Locator) Short finders are available to locate shorts to ground. The short finder creates a pulsing magnetic field in the shorted circuit which you can follow to the location of the short. To order any test equipment shown above, contact your local tool supplier. For a list of suppliers and tool numbers, refer to Honda Required Special Tools and Equipment Service Bulletin. A/T - Vehicle Speed Sensor Installation Precautions Transmission Speed Sensor: Technical Service Bulletins A/T - Vehicle Speed Sensor Installation Precautions Install VSS Properly to Avoid Reman A/T Damage We can't emphasize enough how important it is to follow, to the letter, the installation instructions that come with a reman A/T. These instructions help ensure that you avoid damaging the A/T and score a successful repair. This is particularly true when it comes to installing the vehicle speed sensor (VSS). Step 6 of the instructions tells you to make sure its gear is fully engaged and the VSS is fully seated before you tighten the retaining bolt. If you don't install the VSS properly, the speed sensor gear will get stripped and the A/T will be seriously damaged. So don't take risks with your customer's vehicle. Always follow these instructions to the letter. You can rest assured you're doing the job right. Page 4232 Axle Disconnect Control Control Unit: Testing and Inspection AXLE DISCONNECT CONTROLLER 1. Connect 12 V with terminal (3) and the ground with the terminal (6). 2. Send the signal to the terminal (4). 2WD - 4WD less than 2.4 V 4WD - 2WD more than 9.0 V 3. Confirm the output signal from the terminals (1) & (2) (2 seconds output). Page 3418 - If the data list changes, the Fuel Pump Relay is normal. Front Brake Rotor/Disc: Specifications Disc Type Ventilated Disc Thickness 26 mm Disc Effective Diameter 222 mm Page 6964 Console: Removal and Replacement Consoles Consoles Removal 1. Disconnect the battery ground cable. 2. Remove the shift knob (M/T) / transfer knob (4x4). 3. Remove the rear console assembly. - Open the rear console lid and remove two screws. - Disconnect the switch connector. 4. Remove the front console assembly. - Remove six fixing screws and disconnect the accessory socket connectors. Installation To install, follow the removal steps in the reverse order. Page 2786 Page 4882 4. When inserting the piston into the cylinder, use finger pressure only and do not use a mallet or other impact tool, since damage to the cylinder wall or piston seal can result. Install piston. 5. Apply special grease (approximately 1 g) to the piston and attach the dust boot to the piston and caliper Insert the dust boot ring into the dust boot. 6. Install guide bolt and lock bolt dust boot. 7. Install the dust boot on the support bracket after applying special grease (Approx. 1 g) onto the dust boot inner surface. Also apply special grease onto the lock bolt and guide bolt setting hole of the support bracket. 8. Install lock bolt and guide bolt and tighten the bolt to the specified torque. Torque: 44 Nm (32 ft. lbs.) Page 5187 Continuity of Contacts With the plunger faced downward, push down the magnetic switch. In this state, check for continuity between terminals B and M. Replace, if there is no continuity (i.e., contacts are faulty). Pinion Check if the pinion rotates smoothly in drive direction by hand, or if it is locked when it is rotated in reverse. If not, replace the pinion. Page 3528 Crankshaft Position Sensor: Description and Operation Crankshaft Position (CKP) Sensor The crankshaft position (CKP) sensor provides a signal used by the powertrain control module (PCM) to calculate the ignition sequence. The CKP sensor initiates the 58X reference pulses which the PCM uses to calculate RPM and crankshaft position. Page 4497 4WD Control Unit: Service and Repair 4WD CONTROL UNIT ASSOCIATED PARTS REMOVAL 1. Remove center console assembly. 2. Remove two screws and harness connector (1) from 4WD control unit. INSTALLATION 1. Connect harness connector, then install 4WD control unit. 2. Install center console assembly. Page 6379 Terminals - "T" Each "T" terminal (ring type) is numbered for reference and location. A "T" terminal is secured with a screw or bolt. Wires Page 5125 4. Remove screws with bearing retainer from front cover and remove bearing. 5. Remove the mounting nuts holding the "B" terminal, the diode, and the brush holder. 6. Separate the rear cover from the stator. 7. Remove bolts which secure stator terminal to rectifier terminal, and remove stator. Page 4211 If there is no photo number below or beside a component name or a connector, ground, or terminal number, look up that name or number in the appropriate Connector Identification Chart. The chart lists how many cavities a connector has, where it's located, and what it connects to. The related illustration shows the connector's location on the harness, and the harness routing. NOTE: Photos listed by number are located at Locations / Components / Photograohs. See: Locations/Component Locations/Photographs Circuit Schematics Capacity Specifications Power Steering Fluid: Capacity Specifications Power Steering Fluid Capacity 1.0 L Removal and Installation Powertrain Control Module: Service and Repair Removal and Installation REMOVAL 1. Disconnect the negative battery cable. 2. Remove the two screws from the PCM electrical connectors. 3. Disconnect the PCM electrical connectors. 4. After removing the clip which fixes the PCM to the bracket, remove PCM. INSTALLATION 1. Install the PCM to bracket and fix with the clip. Interior - Rear Beverage Holder Swing Arm Won't Lock Drink Holders: Customer Interest Interior - Rear Beverage Holder Swing Arm Won't Lock 02-022 April 9, 2002 Applies To: 1999-02 Passport - ALL Rear Beverage Holder Swing Arm Does Not Lock SYMPTOM The rear beverage holder swing arm does not firmly stay in an open or closed position because the detents do not hold. PROBABLE CAUSE One or both metal detent clips are out of place or missing. CORRECTIVE ACTION Replace both detent clips. PARTS INFORMATION Rear Beverage Holder Detent Clip (two required): P/N 8-97212-275-0, H/C 7084197 WARRANTY CLAIM INFORMATION In warranty: The normal warranty applies. Operation Number: 044104 Flat Rate Time: 0.3 hour Failed Part: P/N 8-97292-133-3 H/C 6193379 Defect Code: 030 Contention Code: B02 Template ID: 02-022A Skill Level: Repair Technician Out of warranty: Any repair performed after warranty expiration may be eligible for goodwill consideration by the District Service Manager or your Zone Office. You must request consideration, and get a decision, before starting work. REPAIR PROCEDURE Page 2688 2. Connect one lead of a self-powered test light or DVOM to one end of the part of the circuit you want to test. 3. Connect the other lead to the other end. 4. If the self-powered test light glows, there is continuity. If you're using a DVOM, a low reading or no reading (zero), means good continuity. Testing For Voltage When testing for voltage at a connector without wire seals, you do not have to separate the two halves of the connector. Instead, probe the connector from the back. Always check both sides of the connector because dirty, corroded, and bent terminals can cause problems (no electrical contact = an open). 1. Connect one lead of the lest light to a known good ground, or, if you're using a digital volt ohmmeter (DVOM), place it in the appropriate DC volts range, and connect its negative lead to ground. 2. Connect the other lead of the test light or DVOM to the point you want to check. 3. If the test light glows, there is voltage present. If you're using a DVOM, note the voltage reading. It should be within one volt of measured battery voltage. A loss of more than one volt indicates a problem. NOTE: Always use a DVOM on high impedance circuits. A test light may not glow (even with battery voltage present). Testing For Voltage Drop Wires, connectors, and switches are designed to conduct current with a minimum loss of voltage. A voltage drop of more than one volt indicates a problem. 1. Place the digital volt/ohmmeter (DVOM) in the appropriate DC volts range. Connect the positive lead to the end of the wire (or to the connector or switch) closest to the battery. 2. Connect the negative lead to the other end of the wire (or the other side of the connector or switch). 3. Turn on the components in the circuit. 4. The DVOM will show the difference in voltage between the two points. A difference, or drop, of more than one volt indicates a problem. Check the circuit for loose, dirty, or bent terminals. Page 7199 Sunroof/Moonroof Windguard: Service and Repair Sunroof Deflector / LWB Removal 1. Open the sunroof. - Let a 5 mm drill go through two blind rivets (2) to disengage riveted portions 2. Remove the sunroof deflector (1). Installation To install, follow the removal steps in the reverse order. Sunroof Deflector / SWB Removal 1. Disconnect the battery ground cable. 2. Remove the sunroof glass 3. Remove the headlining (Front roof side). 4. Remove the sunroof deflector. - Remove the fixing screws. Installation To install, follow the removal steps in the reverse order. Page 5292 If there is no photo number below or beside a component name or a connector, ground, or terminal number, look up that name or number in the appropriate Connector Identification Chart. The chart lists how many cavities a connector has, where it's located, and what it connects to. The related illustration shows the connector's location on the harness, and the harness routing. NOTE: Photos listed by number are located at Locations / Components / Photograohs. See: Locations/Component Locations/Photographs Circuit Schematics Page 1681 ^ If the idle speed ever exceeds 1,300 rpm 2. Remove the vacuum hose from the fuel pressure regulator, then start the engine. ^ If fuel comes out of the fuel pressure regulator vacuum hose connection, go to REPAIR PROCEDURE FUEL PRESSURE REGULATOR. ^ If no fuel comes out of the regulator, reconnect the vacuum hose and continue to step 3. 3. Connect the PGM Tester. Set it to Engine Data List. 4. Have an assistant drive the vehicle under the conditions described by the customer. 5. If the high or erratic idle condition occurs, note the values of the PSP Switch and APP Sensor 1 when it is occurring. ^ If the PSP Switch is HIGH, and you are not turning, go to REPAIR PROCEDURE POWER STEERING SWITCH. ^ If the APP Sensor 1 is greater than 15% and APP Sensor 2 and/or APP Sensor 3 are less than 85%, and the accelerator pedal is not depressed, go to REPAIR PROCEDURE APPS GROUND. ^ If the PSP Switch is reading LOW when not turning and HIGH when turning, and the APP Sensors are reading within the range shown, discontinue the test-drive and go to step 6. 6. Do these repairs: ^ REPAIR PROCEDURE APPS GROUND ^ REPAIR PROCEDURE ENGINE/BODY GROUND REPAIR PROCEDURE - FUEL PRESSURE REGULATOR 1. Relieve fuel system pressure: ^ Remove the fuel fill cap. ^ Remove the fuel pump relay. ^ Start the engine and run it until it stalls. ^ Crank the engine for 3 seconds. 2. Remove the vacuum hose from the fuel pressure regulator. 3. Remove the fuel pressure regulator shield from the common chamber (two bolts). Page 3267 4. Remove the fuel pressure regulator from the fuel rail. 5. Remove the fuel return line from the regulator. 6. Install the new fuel pressure regulator in the reverse order of removal. 7. Use the Smart Cable to reprogram the PCM with the latest software from the June 2001 or later HONDANET CD-ROM. Refer to Service Bulletin 99-005, Updating the Passport PCM, filed under Tools. 8. Use the PGM Tester to clear any DTCs. 9. Use the PGM Tester to check the broadcast code. Make sure the broadcast code matches the one you selected from the CD-ROM. WARRANTY CLAIM INFORMATION In warranty: The normal warranty applies. Failed Part: P/N 8-17113-398-0 H/C 5504386 Defect Code: 092 Contention Code: C99 Skill Level: Repair Technician Out of warranty: Any repair performed after warranty expiration may be eligible for goodwill consideration by the District Service Manager or your Zone Office. You must request consideration, and get a decision, before starting work. REPAIR PROCEDURE - POWER STEERING SWITCH 1. Drain the power steering fluid out of the system. 2. Remove the power steering fluid reservoir. Clean the reservoir with solvent, then with soap and water. Rinse and dry it thoroughly. 3. Reinstall the reservoir. Do not connect the return hose. 4. Remove the power steering pressure switch, then clean it with brake cleaner and a scraper. Reinstall the switch, and torque it to 20 N.m (14 lb-ft). 5. Cover the unconnected end of the reservoir with your finger, then fill the reservoir with Dexron III ATF Page 7634 The connector cavity number is listed next to each terminal on the circuit schematic. The cavity / terminal shown is # 6. Diodes A rectifier diode works like a one way valve. It allows current to flow only in the direction of the arrow. A Zener diode blocks reverse current at normal voltages just like a rectifier diode. At high voltages, however, a Zener diode allows current to flow in reverse. Fuses Page 5785 16. Cover all six holes with the 3/4 in. round labels from the kit. This will prevent the Noxudol anti-corrosion wax from contaminating the pop nut threads and the weld nut threads (if applicable). Also, use masking tape to cover the other areas shown below. This will prevent the Noxudol from contaminating the bracket mounting surfaces. 17. Apply Noxudol 700 and Noxudol 300 anti-corrosion waxes (see steps 5 thru 13 of STAGE 2 REPAIR). 18. Remove the round labels and the masking tape. 19. Remove the passenger's side lower trailing link front mounting bolt. NOTE: On 2000-02 Passports, interference from the exhaust silencer (muffler) prevents removal of the front mounting bolt. On these vehicles, use a reciprocating saw to cut off the bolt head, then slide the rest of the bolt through the other side of the mount. Page 2851 Air Flow Meter/Sensor: Description and Operation Mass Air Flow (MAF) Sensor The mass air flow (MAF) sensor measures the difference between the volume and the quantity of air that enters the engine. "Volume" means the size of the space to be filled. "Quantity" means the number of air molecules that will fit into the space. This information is important to the PCM because heavier, denser air will hold more fuel than lighter, thinner air. The PCM adjusts the air/fuel ratio as needed depending on the MAF value. The Tech 2 reads the MAF value and displays it in terms of grams per second (g/sec). At idle, the Tech 2 should read between 4 - 7 g/sec on a fully warmed up engine. Values should change quickly on acceleration. Values should remain stable at any given RPM. A failure in the MAF sensor or circuit will set DTC P0101, DTC P0102, or DTC P0103. Upper Arm Control Arm: Service and Repair Upper Arm Without Torque Specifications REMOVAL 1. Raise the vehicle and support the frame with suitable safety stands. 2. Remove wheel and tire assembly. 3. Remove the brake caliper and disconnect brake pipe. 4. Support lower control arm with a jack. 5. Remove speed sensor cable. Locations Acceleration Sensor: Locations Below Left Side of Dash Page 6152 Wire Color Abbreviations The following abbreviations are used to identify wire colors in the circuit schematics: WHT................................... White YEL................................... Yellow BLK................................... Black BLU................................... Blue GRN................................... Green RED................................... Red ORN................................... Orange PNK................................... Pink BRN................................... Brown GRY................................... Gray PUR................................... Purple LT BLU................................... Light Blue LT GRN................................... Light Green Testing and Inspection Variable Induction Control Solenoid: Testing and Inspection Variable Intake Manifold Solenoid Test This test is conducted check VIM Solenoid for proper operation. Tech 2 must be used for this test. Test Procedure: 1. Connect Tech 2 to the vehicle DLC. 2. Ignition SW is "On". 3. Select F3: Miscellaneous Test in the Application Menu. Page 7112 Power Mirror Switch: Removal and Replacement Door Mirror Switch Removal 1. Disconnect the battery ground cable. 2. Remove the instrument panel lower cover (2). 3. Remove the door mirror switch (1). Locations Door Switch: Locations Page 1826 Heater Control Valve Cable: Technical Service Bulletins A/C - Heater Blows Cold Air, A/C Blows Warm Air SOURCE: Honda Service News TITLE: Heater Blows Cold Air, A/C Blows Warm Air APPLIES TO: all A/C-equipped Honda models that use a heater valve cable. SERVICE TIP: Got a vehicle in your shop that blows cold air from the heater or warm air from the A/C ? The problem could just be the heater valve cable has slipped off the heater valve arm. There's a real easy fix for this problem. Slip the heater valve cable back onto the heater valve arm. Then cut yourself a 10 mm length of 3.5 mm vacuum hose and slide it onto the arm. This holds the cable on the arm nice and snug so it won't slip off. Page 2939 2. Unfasten C123 from the side of the engine compartment using a 90-degree pick. 3. Disconnect C123, and clean the terminals on both sides of the connector with contact cleaner. Shake the residue out of the connector. Allow the contact cleaner to evaporate for at least 3 minutes, then reconnect C123. 4. Fasten C123 to the left side of the engine compartment, and reinstall the air cleaner housing cover. 5. Remove the connector position assurance (CPA) clip from the APPS connector. 6. Disconnect the lop connector from the APPS. 7. Clean the terminals of the 10P APPS connector (harness side) with contact cleaner. Shake out residue from the connector, and allow the contact cleaner to evaporate for at least 3 minutes, then reconnect it. 8. Use the Smart Cable to reprogram the PCM with the latest software from the June 2001 or later HONDANET CD-ROM. Refer to Service Bulletin 99-005, Updating the Passport PCM, filed under Tools. 9. Use the PGM Tester to clear any DTCs. Page 3010 it is located, and what it connects to. Use the Connector Views to help locate the proper cavity when you need to probe a connector. It can be especially helpful if the connector has more than one wire of the same color. A dash symbol (-) indicates that the cavity is empty. Connector views can also be used to help diagnose multiple symptoms in separate circuits which could be caused by a single problem in a connector shared by those circuits. Here's an example: 1. Pick one of the multiple symptoms and look up the schematic for that circuit. 2. Make a list of all the in-line and fuse box connectors in that schematic , 3. Then, in the Connector Views, look up each connector on your list to see if circuits related to the other symptoms run through one of them. If they do, inspect that connector for the problem. Example: The blower, rear window defogger, and the windshield wiper don't work. List all in-line and fuse box connectors in the blower controls circuit and then check the Connector View (see the sample). You find that C324 is common to the blower controls, rear window defogger, and wiper/washer, so you inspect C324 and find the problem, bent terminals. Finding Component/Connector Locations Finding Component/Connector Locations To see where a component or connector is located on the car, look up its photo number in the "Component Location". The photo will also tell you the color of the connector, and how many cavities it has. Page 7796 Testing For A Short With A Self-Powered Test Light or DVOM 1. Remove the blown fuse and disconnect the battery and load. 2. Connect one lead of a self-powered test light or digital volt/ohmmeter (DVOM) (switched to the lowest "OHMS" range) to the fuse terminal on the load side. 3. Connect the other lead to a known good ground. 4. Beginning near the fuse box, wiggle the harness. Continue this at convenient points about six inches apart while watching the test light or DVOM. 5. If the self-powered test light goes on or the DVOM displays a low reading or no reading (zero), there is a short to ground in the wiring near that point. Testing for a Short with a Test Light or DVOM 1. Remove the blown fuse and disconnect the load. 2. Connect a test light or digital volt/ohmmeter (DVOM), switched to the appropriate DC volts range, across the fuse terminals to make sure voltage is present. You might have to turn the ignition switch to ON; check the schematic to see. 3. Beginning near the fuse box, wiggle the harness. Continue this at convenient points about six inches apart while watching the test light or DVOM. 4. Where the test light goes , or the DVOM voltage drops to zero, there is a short to ground in the wiring near that point. NOTE: Always use a DVOM on high impedance circuits. A test light may not glow (even with battery voltage present). Testing For A Short With A Short Circuit Locator (Short Finder) 1. Remove the blown fuse. Leave the battery connected. Page 6240 Refrigerant: Fluid Type Specifications Refrigerant Type HFC-134a (R-134a) Page 4560 Test Equipment CAUTION: Most circuits include solid-state devices. Test the voltages in these circuits only with a 10-megaohm or higher impedance digital multimeter. Never use a test light or analog meter on circuits that contain solid-state devices. Damage to the devices may result. Test Light and DVOM On circuits without solid-state devices, use a test light to check for voltage. A test light is made up of a 12 volt bulb with a pair of leads attached. After grounding one lead, touch the other lead to various points along the circuit where voltage should be present. The bulb will go on if there is voltage at the point being tested. If you need to know how much voltage is present, use a digital volt/ohmmeter (DVOM). Self-Powered Test Light and DVOM Use a self-powered test light to check for continuity. This tool is made up of a light bulb, battery, and two leads. To test it, touch the leads together: the light should go on. Use a self-powered test light only on an unpowered circuit. First, disconnect the battery, or remove the fuse that feeds the circuit you are working on. Select two points in the circuit between which you want to check continuity. Connect one lead of the self-powered test light to each point. If there is continuity, the test light's circuit will be completed, and the light will go on. If, in addition, you need to know exactly how much resistance there is between two points, use a digital volt/ohmmeter (DVOM). In the "OHMS" range, the DVOM will measure resistance between two points along a circuit. Low resistance means good continuity. Diodes and solid-state devices in a circuit can make a DVOM give a false reading. To check a reading, reverse the leads, and take a second reading. If the readings differ, the component is affecting the measurement. Jumper Wire Use a jumper wire to bypass an open circuit. A jumper wire is made up of an in-line fuse holder connected to a set of test leads. It should have a five ampere fuse. Never connect a jumper wire across a short circuit. The direct battery short will blow the fuse. Short Finder (Short Circuit Locator) Short finders are available to locate shorts to ground. The short finder creates a pulsing magnetic field in the shorted circuit which you can follow to the location of the short. To order any test equipment shown above, contact your local tool supplier. For a list of suppliers and tool numbers, refer to Honda Required Special Tools and Equipment Service Bulletin. Component Locations Oxygen Sensor: Component Locations 95. Right Front Exhaust Downpipe Right Front Exhaust Downpipe 93. Left Front Exhaust Downpipe Left Front Exhaust Downpipe Page 6668 Compact Disc Player (CD): Diagrams Page 3303 Fuel Pump Relay: Diagnostic Aids Before Troubleshooting Before Troubleshooting See: Service Precautions/Vehicle Damage Warnings/Tips and Precautions 1. Check applicable fuses in the appropriate fuse/relay box. 2. Check the battery for damage, state of charge, and clean and tight connections. CAUTION: Do not quick-charge a battery unless the battery ground cable has been disconnected, otherwise you will damage the alternator diodes. - Do not attempt to crank the engine with the battery ground cable loosely connected or you will severely damage the wiring. While You're Working 1. Make sure connectors are clean, and have no loose terminals or receptacles. 2. Make sure that connectors without wire seals are packed with dielectric (silicone) grease. Part Number: 08798-9001. 3. When connecting a connector, push it until it "clicks" into place. CAUTION: Do not pull on the wires when disconnecting a connector. Pull only on the connector housings. - Most circuits include solid-state devices. Test the voltages in these circuits only with a 10-megaohm or higher impedance digital multi meter. Never use a test light or analog meter on circuits that contain solid-state devices. Damage to the devices may result. Five-Step Troubleshooting 1. Verify The Complaint Turn on all the components in the problem circuit to check the accuracy of the customer complaint. Note the symptoms. Do not begin disassembly or testing until you have narrowed down the problem area. 2. Analyze The Schematic Look up the schematic for the problem circuit. Determine how the circuit is supposed to work by tracing the current paths from the power source through the circuit components to ground. Also, trace circuits that share wiring with the problem circuit. The names of circuits that share the same fuse, ground, or switch, and so on, are referred to in each circuit schematic. Try to operate any shared circuits you didn't check in step 1. If the shared circuits work, the shared wiring is OK, and the cause must be in the wiring used only by the problem circuit. If several circuits fail at the same time, the fuse or ground is a likely cause. Based on the symptoms and your understanding of the circuit's operation, identify one or more possible causes. 3. Isolate The Problem By Testing The Circuit Make circuit tests to check the diagnosis you made in step 2. Keep in mind that a logical, simple procedure is the key to efficient troubleshooting. Test for the most likely cause of failure first. Try to make tests at points that are easily accessible. 4. Fix The Problem Once the specific problem is identified, make the repair. Be sure to use proper tools and safe procedures. 5. Make Sure The Circuit Works Turn on all components in the repaired circuit in all modes to make sure you've fixed the entire problem. If the problem was a blown fuse, be sure to test all of the circuits on that fuse. Make sure no new problems turn up and the original problem does not recur. Page 430 Blower Motor Switch: Testing and Inspection Fan Control Knob (Fan Switch) 1. Check for continuity between the fan switch and the A/C switch side connector terminals. Page 6634 NOTE: It is very important that you fill out this form fully and accurately. An accurate explanation of the problem and conditions helps the manufacturer to duplicate the problem, speeding the repair, and reducing the number of No Trouble Found" (NTF) units. Disclaimer Page 4365 REASSEMBLY 1. Apply grease evenly to both the female and male splines. 2. Apply a small amount of grease by finger to the outer lips of the boot. 3. Slide the boot onto the yoke shaft being careful not to damage the spline coating or boot. 4. Insert the yoke shaft spline into the sleeve being careful to maintain proper phasing. The spider holes should be in line and as per originally marked prior to disassembly. 5. Position boot onto sleeve and yoke shaft in final position over boot grooves. 6. Attach boot clamps and secure using pliers. 7. Be sure clamp is properly seated and secure. Page 7628 If there is no photo number below or beside a component name or a connector, ground, or terminal number, look up that name or number in the appropriate Connector Identification Chart. The chart lists how many cavities a connector has, where it's located, and what it connects to. The related illustration shows the connector's location on the harness, and the harness routing. NOTE: Photos listed by number are located at Locations / Components / Photograohs. See: Locations/Component Locations/Photographs Circuit Schematics Page 6291 The name of the component appears next to it followed by notes about its function along with any photo and connector view references. Connector "C" How to Identify Connector Terminals Cavity Numbering System The cavities (and wire terminals) in each connector are numbered starting from the upper left, looking at the male terminals from the terminal side (or looking at the female terminals from the wire side. Both views are in the same direction so the numbers are the same.) All actual cavities are numbered, even if they have no wire terminals in them. NOTE: Data Link Connector (DLC) terminals are numbered according to SAE standard J1962, not the Honda standard. The numbers of the four end terminals are molded into the corners of the connector face. Page 1686 H/C 4408092 Defect Code: 017 Contention Code: C99 Skill Level: Repair Technician Out of warranty: Any repair performed after warranty expiration may be eligible for goodwill consideration by the District Service Manager or your Zone Office. You must request consideration, and get a decision, before starting work. DISCLAIMER Page 7800 Part 2 Of 2 Page 4589 If there is no photo number below or beside a component name or a connector, ground, or terminal number, look up that name or number in the appropriate Connector Identification Chart. The chart lists how many cavities a connector has, where it's located, and what it connects to. The related illustration shows the connector's location on the harness, and the harness routing. NOTE: Photos listed by number are located at Locations / Components / Photograohs. See: Locations/Component Locations/Photographs Circuit Schematics Accelerator Pedal Assembly/Sensor - Adjustment Update Accelerator Pedal Position Sensor: All Technical Service Bulletins Accelerator Pedal Assembly/Sensor - Adjustment Update 00-045 August 14, 2001 Applies To: 2000-02 Passport - ALL Service Manual Update: Accelerator Pedal Position Sensor (APPS) (Supersedes 00-045, dated May 23, 2000) Updated information is shown by asterisks and black bars. BACKGROUND When the accelerator pedal position sensor (APPS) or the accelerator pedal assembly is replaced for any reason, you must adjust the APPS. *This procedure is missing in the 2000 service manual and is wrong in the 2001 and 2002 service manuals. Make a note on page 6E2-539 of the 2000 Passport Fuel and Emissions manual, on page 6E2-553 of the 2001 Passport Fuel and Emissions manual, and on page 6E2-545 of the 2002 Passport Fuel and Emissions manual to refer to this bulletin.* ADJUSTMENT PROCEDURE 1. Replace the APPS or the accelerator pedal assembly, and leave the mounting screws for the APPS loose. 2. Connect the PGM Tester to the data link connector (DLC), and turn the ignition switch to ON (II). *3. While watching the APP Sensor values in the Engine Data List, adjust the APPS by turning it until the values are within the ranges shown at closed pushed all the way down), then tighten the throttle and wide open throttle (accelerator pedal mounting screws and recheck the values. ^ If all three sensors are within range, go to step 12. ^ If APP Sensor 1, APP Sensor 2, and/or APP Sensor 3 cannot be brought into range, go to step 4. 4. Troubleshoot for an open circuit or a PCM malfunction. ^ If APP Sensor 1 has a value of 0% or APP Sensor 2 and/or APP Sensor 3 have a value of 99%, an open circuit exists or the PCM is malfunctioning. Repair the circuit or replace the PCM, and repeat step 3. ^ If you don't find a problem, go to step 5. 5. Disconnect the 10P connector from the APPS. 6. View the APP Sensor values in the Engine Data List. ^ If APP Sensor 1 has a value of 0% or APP Sensor 2 and/or APP Sensor 3 have a value of 99%, go to step 7. ^ If APP Sensor 1 has a value other than 0%, or APP Sensor 2 and/or APP Sensor 3 have a value other than 99%, a short circuit exists or the PCM is malfunctioning. Repair the circuit or replace the PCM, and repeat step 3. Locations Behind Glove Box Page 4219 Splices Splices are shown as a dot. Their location and the number of wires may vary depending on the harness manufacturer. Switches Switches These switches move together; the broken straight line between them means they are mechanically connected. Other types of switches are controlled by a coil or a solid state circuit. Unless otherwise noted, all switches are shown in their normal (rest) position, with power off. Terminal "T" Page 8192 Front Door Window Regulator: Service and Repair Front Window Regulator, Glass and Glass Run Front Window Regulator, Glass And Glass Run Removal 1. Disconnect the battery ground cable. Page 3565 The wire insulation has one color or one color with another color stripe. The second color is the stripe. Page 7735 Page 2056 Testing For A Short With A Self-Powered Test Light or DVOM 1. Remove the blown fuse and disconnect the battery and load. 2. Connect one lead of a self-powered test light or digital volt/ohmmeter (DVOM) (switched to the lowest "OHMS" range) to the fuse terminal on the load side. 3. Connect the other lead to a known good ground. 4. Beginning near the fuse box, wiggle the harness. Continue this at convenient points about six inches apart while watching the test light or DVOM. 5. If the self-powered test light goes on or the DVOM displays a low reading or no reading (zero), there is a short to ground in the wiring near that point. Testing for a Short with a Test Light or DVOM 1. Remove the blown fuse and disconnect the load. 2. Connect a test light or digital volt/ohmmeter (DVOM), switched to the appropriate DC volts range, across the fuse terminals to make sure voltage is present. You might have to turn the ignition switch to ON; check the schematic to see. 3. Beginning near the fuse box, wiggle the harness. Continue this at convenient points about six inches apart while watching the test light or DVOM. 4. Where the test light goes , or the DVOM voltage drops to zero, there is a short to ground in the wiring near that point. NOTE: Always use a DVOM on high impedance circuits. A test light may not glow (even with battery voltage present). Testing For A Short With A Short Circuit Locator (Short Finder) 1. Remove the blown fuse. Leave the battery connected. Page 70 Testing For A Short With A Self-Powered Test Light or DVOM 1. Remove the blown fuse and disconnect the battery and load. 2. Connect one lead of a self-powered test light or digital volt/ohmmeter (DVOM) (switched to the lowest "OHMS" range) to the fuse terminal on the load side. 3. Connect the other lead to a known good ground. 4. Beginning near the fuse box, wiggle the harness. Continue this at convenient points about six inches apart while watching the test light or DVOM. 5. If the self-powered test light goes on or the DVOM displays a low reading or no reading (zero), there is a short to ground in the wiring near that point. Testing for a Short with a Test Light or DVOM 1. Remove the blown fuse and disconnect the load. 2. Connect a test light or digital volt/ohmmeter (DVOM), switched to the appropriate DC volts range, across the fuse terminals to make sure voltage is present. You might have to turn the ignition switch to ON; check the schematic to see. 3. Beginning near the fuse box, wiggle the harness. Continue this at convenient points about six inches apart while watching the test light or DVOM. 4. Where the test light goes , or the DVOM voltage drops to zero, there is a short to ground in the wiring near that point. NOTE: Always use a DVOM on high impedance circuits. A test light may not glow (even with battery voltage present). Testing For A Short With A Short Circuit Locator (Short Finder) 1. Remove the blown fuse. Leave the battery connected. Specifications Compression Check: Specifications Compression Pressure 145 psi. kg/cm2 at 300 rpm Page 7889 Test Equipment CAUTION: Most circuits include solid-state devices. Test the voltages in these circuits only with a 10-megaohm or higher impedance digital multimeter. Never use a test light or analog meter on circuits that contain solid-state devices. Damage to the devices may result. Test Light and DVOM On circuits without solid-state devices, use a test light to check for voltage. A test light is made up of a 12 volt bulb with a pair of leads attached. After grounding one lead, touch the other lead to various points along the circuit where voltage should be present. The bulb will go on if there is voltage at the point being tested. If you need to know how much voltage is present, use a digital volt/ohmmeter (DVOM). Self-Powered Test Light and DVOM Use a self-powered test light to check for continuity. This tool is made up of a light bulb, battery, and two leads. To test it, touch the leads together: the light should go on. Use a self-powered test light only on an unpowered circuit. First, disconnect the battery, or remove the fuse that feeds the circuit you are working on. Select two points in the circuit between which you want to check continuity. Connect one lead of the self-powered test light to each point. If there is continuity, the test light's circuit will be completed, and the light will go on. If, in addition, you need to know exactly how much resistance there is between two points, use a digital volt/ohmmeter (DVOM). In the "OHMS" range, the DVOM will measure resistance between two points along a circuit. Low resistance means good continuity. Diodes and solid-state devices in a circuit can make a DVOM give a false reading. To check a reading, reverse the leads, and take a second reading. If the readings differ, the component is affecting the measurement. Jumper Wire Use a jumper wire to bypass an open circuit. A jumper wire is made up of an in-line fuse holder connected to a set of test leads. It should have a five ampere fuse. Never connect a jumper wire across a short circuit. The direct battery short will blow the fuse. Short Finder (Short Circuit Locator) Short finders are available to locate shorts to ground. The short finder creates a pulsing magnetic field in the shorted circuit which you can follow to the location of the short. To order any test equipment shown above, contact your local tool supplier. For a list of suppliers and tool numbers, refer to Honda Required Special Tools and Equipment Service Bulletin. Page 4564 Locations Oil Pressure Switch (For Fuel Pump): Locations Bottom Center Front of Engine Diagram Information and Instructions Vehicle Speed Sensor: Diagram Information and Instructions How to Identify Wiring Color-Coded Insulation Wire Color Wire Color Coding Page 2521 2. Connect the short finder across the battery terminals and the load (component) side of the fuse terminal. 3. Close all switches in the circuit you're testing. 4. Turn on the short finder. This creates a pulsing magnetic field around the wiring between the fuse box and the short. 5. Beginning at the fuse box, slowly move the short finder along the circuit wiring. The meter will read current pulses through sheet metal and body trim. As long as the meter is between the fuse and the short, the needle will move with each current pulse. Once you move the meter past the point of the short, the needle will stop moving. Check the wiring and connectors in this area to locate the cause of the short. Testing For Continuity When testing for continuity at a connector without wire seals, you do not have to separate the two halves of the connector. Instead, probe the connector from the back. Always check both sides of the connector because dirty, corroded, and bent terminals can cause problems (no electrical contact = an open). 1. Disconnect the negative cable from the car battery. If you're using a DVOM, place it in the lowest "OHMS" range. Page 4288 Axle Disconnect Control Control Unit: Testing and Inspection AXLE DISCONNECT CONTROLLER 1. Connect 12 V with terminal (3) and the ground with the terminal (6). 2. Send the signal to the terminal (4). 2WD - 4WD less than 2.4 V 4WD - 2WD more than 9.0 V 3. Confirm the output signal from the terminals (1) & (2) (2 seconds output). Capacity Specifications Power Steering Fluid: Capacity Specifications Power Steering Fluid Capacity 1.0 L Page 7386 Wires Wire insulation can be one color, or one color with another color stripe. (The second color is the stripe.) This circuit continues on another image. (The arrow shows direction of current flow.) To follow the RED/BLK wire in this example, you would turn to "Fuel and Emissions" and look for the "A" arrow. Page 1283 Air Bag(s) Arming and Disarming: Service Precautions Wiring Precautions Wiring Precautions SRS wiring can be identified by special yellow outer covering (except the SRS indicator light circuit). Never attempt to modify, splice, or repair SRS wiring. If there is an open or damage in SRS wiring, replace the harness. Be sure to install the harness wires so that they are not pinched, or interfere with other parts. Make sure all SRS ground locations are clean, and grounds are securely fastened for optimum metal-to-metal contact. Poor grounding can cause intermittent problems that are difficult to diagnose. Page 8018 Splices Splices are shown as a dot. Their location and the number of wires may vary depending on the harness manufacturer. Switches Switches These switches move together; the broken straight line between them means they are mechanically connected. Other types of switches are controlled by a coil or a solid state circuit. Unless otherwise noted, all switches are shown in their normal (rest) position, with power off. Terminal "T" Page 6685 Wires Wire insulation can be one color, or one color with another color stripe. (The second color is the stripe.) This circuit continues on another image. (The arrow shows direction of current flow.) To follow the RED/BLK wire in this example, you would turn to "Fuel and Emissions" and look for the "A" arrow. Tires - Tubless Tire Repair Information Tires: All Technical Service Bulletins Tires - Tubless Tire Repair Information 06-082 December 15, 2006 Applies To: ALL Tubeless Tire Repair Information This service bulletin provides the resource information required to repair tubeless tires on Honda automobiles and light trucks. To properly repair a tire, follow the Rubber Manufacturers Association (RMA) "Puncture Repair Procedures for Passenger and Light Truck Tires" outlined on the RMA wall poster. One wall poster has been provided to your dealership. Additional posters can be ordered through Helm, the RMA website, www.rma.org, or the tire manufacturers. Michelin(R) PAX System(TM), tires can be repaired using the same repair procedures described on the RMA poster. Whenever you repair a PAX System tire, you must inspect the support ring. Refer to the PAX System support ring section of this service bulletin for inspection procedures. WARRANTY CLAIM INFORMATION Refer to the tire manufacturer for warranty information. REQUIRED MATERIALS ^ 1/8 inch Patch-plug with lead wire ^ 1/4 inch Patch-plug with lead wire ^ 1/8 inch Plugs (stem)* ^ 1/4 inch Plugs (stem)* ^ 1/4 inch Patches* ^ 3/4 inch Patches* ^ Chemical cement ^ Liquid buffer ^ Rim-bead sealer ^ Inner liner sealer REQUIRED TOOLS ^ Tire stitcher, 1-1/2 inch wheel ^ Tire crayons ^ Tire test tank ^ Awl or probe ^ Flexible blade skiving knife ^ 1/8 inch Carbide tire tool with adapter ^ 1/4 inch Carbide tire tool with adapter ^ Low speed buffer with quick release chuck and exhaust hose ^ Carbide buffing wheel with adapter Page 3539 Ignition Coil: Description and Operation Ignition Coils A separate coil-at-plug module is located at each spark plug. The coil-at-plug module is attached to the engine with two screws. It is installed directly to the spark plug by an electrical contact inside a rubber boot. A three-way connector provides 12-volt primary supply from the 15-amp ignition fuse, a ground-switching trigger line from the PCM, and a ground. Page 7995 11. Turn the ignition switch to "ON" while watching warning light and check the light should flash 7 times and then go off. Page 4649 3. Connect the terminals as shown in figure. Shift rod of the motor actuator moves and stops at 2WD position. 4. If 2) and 3) fail, replace with a new motor actuator. Page 4459 2. Connect the short finder across the battery terminals and the load (component) side of the fuse terminal. 3. Close all switches in the circuit you're testing. 4. Turn on the short finder. This creates a pulsing magnetic field around the wiring between the fuse box and the short. 5. Beginning at the fuse box, slowly move the short finder along the circuit wiring. The meter will read current pulses through sheet metal and body trim. As long as the meter is between the fuse and the short, the needle will move with each current pulse. Once you move the meter past the point of the short, the needle will stop moving. Check the wiring and connectors in this area to locate the cause of the short. Testing For Continuity When testing for continuity at a connector without wire seals, you do not have to separate the two halves of the connector. Instead, probe the connector from the back. Always check both sides of the connector because dirty, corroded, and bent terminals can cause problems (no electrical contact = an open). 1. Disconnect the negative cable from the car battery. If you're using a DVOM, place it in the lowest "OHMS" range. Page 5297 The name of the component appears next to it followed by notes about its function along with any photo and connector view references. Connector "C" How to Identify Connector Terminals Cavity Numbering System The cavities (and wire terminals) in each connector are numbered starting from the upper left, looking at the male terminals from the terminal side (or looking at the female terminals from the wire side. Both views are in the same direction so the numbers are the same.) All actual cavities are numbered, even if they have no wire terminals in them. NOTE: Data Link Connector (DLC) terminals are numbered according to SAE standard J1962, not the Honda standard. The numbers of the four end terminals are molded into the corners of the connector face. Page 3589 Ground - "G" Shielding Sheilding This represents RFI (Radio Frequency Interference) shielding around a wire. The shielding is always connected to ground. Splices Diagram Information and Instructions 4WD Control Unit: Diagram Information and Instructions How to Identify Wiring Color-Coded Insulation Wire Color Wire Color Coding Page 231 Air Bag Control Module: Vehicle Damage Warnings 1. Air bag assembly should not be subjected to temperatures above 93 °C (200 °C). 2. Air bag assembly, and Sensing and Diagnostic Module (SDM) should not be used If they have been dropped from a height of 100 centimeters (3.28 feet). 3. When a SDM is replaced, it must be oriented with the arrow on the sensor pointing toward the front of the vehicle. It is very important for the SDM to be located flat on the mounting surface, parallel to the vehicle datum line. It is important that the SDM mounting surface is free of any dirt or other foreign material. 4. Do not apply power to the SRS unless all components are connected or a diagnostic chant requests it, as this will set a diagnostic trouble code. 5. The "SRS Diagnostic System Check" must be the starting point of any SRS diagnostics. The "SRS Diagnostic System Check" will verify proper "AIR BAG" warning lamp operation and will lead you to the correct chart to diagnose any SRS malfunctions. Bypassing these procedures may result in extended diagnostic time, incorrect diagnosis, and incorrect pants replacement. Page 7718 This means the branch of the wire connects to another circuit. The arrow points to the name of the circuit branch where the wire continues. Page 893 2. Unfasten C123 from the side of the engine compartment using a 90-degree pick. 3. Disconnect C123, and clean the terminals on both sides of the connector with contact cleaner. Shake the residue out of the connector. Allow the contact cleaner to evaporate for at least 3 minutes, then reconnect C123. 4. Fasten C123 to the left side of the engine compartment, and reinstall the air cleaner housing cover. 5. Remove the connector position assurance (CPA) clip from the APPS connector. 6. Disconnect the lop connector from the APPS. 7. Clean the terminals of the 10P APPS connector (harness side) with contact cleaner. Shake out residue from the connector, and allow the contact cleaner to evaporate for at least 3 minutes, then reconnect it. 8. Use the Smart Cable to reprogram the PCM with the latest software from the June 2001 or later HONDANET CD-ROM. Refer to Service Bulletin 99-005, Updating the Passport PCM, filed under Tools. 9. Use the PGM Tester to clear any DTCs. Page 2112 Camshaft Position Sensor: Description and Operation Camshaft Position (CMP) Sensor and Signal The camshaft position (CMP) sensor sends a CMP signal to the PCM. The PCM uses this signal as a "sync pulse" to trigger the injectors in the proper sequence. The PCM uses the CMP signal to indicate the position of the #1 piston during its power stroke. This allows the PCM to calculate true sequential fuel injection (SFI) mode of operation. If the PCM detects an incorrect CMP signal while the engine is running, DTC P0341 will set. If the CMP signal is lost while the engine is running, the fuel injection system will shift to a calculated sequential fuel injection mode based on the last fuel injection pulse, and the engine will continue to run. As long as the fault is present, the engine can be restarted. It will run in the calculated sequential mode with a 1-in-6 chance of the injector sequence being correct. Refer to DTC P0341 for further information. CMP Signal The PCM uses this signal to determine the position of the number 1 piston during its power stroke, allowing the PCM to calculate true sequential multiport fuel injection (SFI). Loss of this signal will set a DTC P0341. If the CMP signal is lost while the engine is running, the fuel injection system will shift to a calculated sequential fuel injection based on the last fuel injection pulse, and the engine will continue to run. The engine can be restarted and will run in the calculated sequential mode as long as the fault is present, with a 1-in-6 chance of being correct. Service and Repair Crankshaft Main Bearing Seal: Service and Repair Rear Oil Seal Removal 1. Remove transmission assembly. 2. Remove flywheel. 3. Remove rear oil seal using a seal remover. Note: Take care not to damage the crankshaft or oil seat retainer when removing oil seal. Installation 1. Apply engine oil to oil seal lip and install oil seal using J-39201. 2. Install flywheel. - Clean tapped holes in the crankshaft. - Remove oil on the crankshaft and flywheel mounting surface. - Tighten fixing bolts to the specified torque. Note: Do not reuse the bolts and do not apply oil or thread lock to the bolts. Torque: 54 Nm (40 ft. lbs.) 3. Install transmission. Page 7412 Terminals - "T" Each "T" terminal (ring type) is numbered for reference and location. A "T" terminal is secured with a screw or bolt. Wires Component Tests and General Diagnostics Electronic Brake Control Module: Component Tests and General Diagnostics Page 7801 Cargo Lamp: Service and Repair Removal 1. Disconnect the battery ground cable. 2. Remove the lens (2). 3. Remove the bulb (1). - Pull out the bulb. Installation To install, follow the removal steps in the reverse order. Page 7882 Splices Splices are shown as a dot. Their location and the number of wires may vary depending on the harness manufacturer. Switches Switches These switches move together; the broken straight line between them means they are mechanically connected. Other types of switches are controlled by a coil or a solid state circuit. Unless otherwise noted, all switches are shown in their normal (rest) position, with power off. Terminal "T" Page 1961 Ground - "G" Shielding Sheilding This represents RFI (Radio Frequency Interference) shielding around a wire. The shielding is always connected to ground. Splices Page 8014 This sample Ground Distribution schematic shows all of the components that share two ground points. Components A solid border line means the entire component is shown. A broken border line indicates that only part of the component is shown. Page 2325 Ignition Switch Lock Cylinder: Testing and Inspection TESTING AND INSPECTION Turn the ignition switch to "ON" while watching warning light. The light should flash 7 times and then go off. Page 5784 - Insert the pop nut into a hole on the pop nut test plate. Make sure the pop nut is seated against the plate. - Squeeze and hold the installer's trigger until the mandrel reverses and unthreads the pop nut. - Measure the diameter of the expanded (crush) section of the installed pop nut; it should be at least 15 mm. If you need more practice, install another pop nut on the test plate. 15. Install pop nuts in the holes you drilled on the frame (six holes for all 1998-99 models and some 2000 models, five holes for some 2000 models and all 2001-02 models). Make sure each pop nut is seated against the frame before you pull the trigger. Continue holding the trigger until the mandrel reverses direction. Once reversed, pull back slightly, and the mandrel unthreads the pop-nut. Page 894 10. Use the PGM Tester to check the broadcast code. Make sure the broadcast code matches the one you selected from the CD-ROM. WARRANTY CLAIM INFORMATION In warranty: The normal warranty applies. Failed Part: P/N 8-17087-655-0 H/C 4375820 Defect Code: 064 Contention Code: C01 Skill Level: Repair Technician Out of warranty: Any repair performed after warranty expiration may be eligible for goodwill consideration by the District Service Manager or your Zone Office. You must request consideration, and get a decision, before starting work. REPAIR PROCEDURE - ENGINE/BODY GROUND 1. Use the ETM for the appropriate year to locate these ground connectors: G101, G104, G105, G106 and G160. 2. Inspect each connector for corrosion or looseness. 3. Remove the bolt from any connector that is corroded or loose. Clean the terminal connector with a wire brush. File flat any solder bumps on the connector. 4. Clean the contact surface on the engine or body with a wire brush. 5. Replace the bolt if it is heavily corroded. Otherwise, clean it with a wire brush. 6. Apply lithium dielectric grease to both sides of the terminal connector. 7. Reinstall the bolt, torque it to 14 N.m (10 lb-ft). 8. Use the Smart Cable to reprogram the PCM with the latest software from the June 2001 or later HONDANET CD-ROM. Refer to Service Bulletin 99-005, Updating the Passport PCM, filed under Tools. 9. Use the PGM Tester to clear any DTCs. 10. Use the PGM Tester to check the broadcast code. Make sure the broadcast code matches the one you selected from the CD-ROM. WARRANTY CLAIM INFORMATION In warranty: The normal warranty applies. Failed Part: P/N 8-97086-823-0 Page 6077 The name of the component appears next to it followed by notes about its function along with any photo and connector view references. Connector "C" How to Identify Connector Terminals Cavity Numbering System The cavities (and wire terminals) in each connector are numbered starting from the upper left, looking at the male terminals from the terminal side (or looking at the female terminals from the wire side. Both views are in the same direction so the numbers are the same.) All actual cavities are numbered, even if they have no wire terminals in them. NOTE: Data Link Connector (DLC) terminals are numbered according to SAE standard J1962, not the Honda standard. The numbers of the four end terminals are molded into the corners of the connector face. Specifications Suspension Strut / Shock Absorber: Specifications Shock Absorber Front Upper Nut 20 Nm Lower Bolt 93 Nm Rear Upper Nut 20 Nm Lower Nut 78 Nm Page 6731 Each schematic represents one circuit. A circuit's wires and components are arranged to show current flow, from power at the top of the page, to ground, at the bottom. Shared Circuits Other circuits may share power or ground terminals or wiring with the circuit shown. A wire that connects one circuit to another, for example, is cut short and has an arrowhead at the end of it pointing in the direction of current flow. Next to the arrowhead is the name of the circuit or component which shares that wiring. To quickly check shared wiring, check the operation of a component it serves. If that component works, you know the shared wiring is OK. Connectors All in-line and junction connectors are numbered (C725, C416, etc.). Component connectors are not numbered but are identified either by the name of Recall - Potential Rear Trailing Link Bracket Corrosion Technical Service Bulletin # 10-079 Date: 110217 Recall - Potential Rear Trailing Link Bracket Corrosion 10-079 February 17, 2011 Applies To: 1998-02 Passport - ALL Safety Recall: Corrosion On Lower Trailing Link Front Brackets (Supersedes 10-079, dated February 11, 2011, to revise the information marked by the black bars/shown with asterisks) REVISION SUMMARY BACKGROUND Over time, in areas that use road salt, excessive corrosion can develop on or near the brackets attaching the lower trailing links to the frame. If the corrosion reaches a heavy stage, a clunking noise may be heard during acceleration and braking. In rare cases of severe corrosion, a trailing link could separate from the frame. If this happens, vehicle handling could be affected, increasing the risk of a crash. Road salt is commonly used in an area known as the salt belt." As shown in the shaded area of the map, the salt belt includes these states: Connecticut, Delaware, Illinois, Indiana, Iowa, Kentucky, Maine, Maryland, Massachusetts, Michigan, Minnesota Missouri, New Hampshire, New Jersey, New York, Ohio, Pennsylvania, Rhode Island, Vermont, West Virginia, Wisconsin, and Washington D.C. CUSTOMER NOTIFICATION All owners of affected vehicles that were originally purchased or currently registered in a salt belt state will be sent a notification of this campaign. Two different notifications are being sent: one for vehicles less than 10 years old (as of September 22, 2010), and another for vehicles more than 10 years old (as of September 22, 2010). Examples of both customer notifications are at the end of this service bulletin. Before beginning work on a vehicle, verify its eligibility by checking at least one of these items: ^ The customer has a notification letter. ^ The vehicle is shown as eligible on an iN VIN status inquiry. In addition, check for a campaign completion label on the back edge of the driver's door, just below the door latch. This label indicates that the campaign has already been completed. Complete the recall repair on an eligible vehicle even if the vehicle is now located in a non-salt belt state. Page 3301 Wire Color Abbreviations The following abbreviations are used to identify wire colors in the circuit schematics: WHT................................... White YEL................................... Yellow BLK................................... Black BLU................................... Blue GRN................................... Green RED................................... Red ORN................................... Orange PNK................................... Pink BRN................................... Brown GRY................................... Gray PUR................................... Purple LT BLU................................... Light Blue LT GRN................................... Light Green Page 2981 Testing For A Short With A Self-Powered Test Light or DVOM 1. Remove the blown fuse and disconnect the battery and load. 2. Connect one lead of a self-powered test light or digital volt/ohmmeter (DVOM) (switched to the lowest "OHMS" range) to the fuse terminal on the load side. 3. Connect the other lead to a known good ground. 4. Beginning near the fuse box, wiggle the harness. Continue this at convenient points about six inches apart while watching the test light or DVOM. 5. If the self-powered test light goes on or the DVOM displays a low reading or no reading (zero), there is a short to ground in the wiring near that point. Testing for a Short with a Test Light or DVOM 1. Remove the blown fuse and disconnect the load. 2. Connect a test light or digital volt/ohmmeter (DVOM), switched to the appropriate DC volts range, across the fuse terminals to make sure voltage is present. You might have to turn the ignition switch to ON; check the schematic to see. 3. Beginning near the fuse box, wiggle the harness. Continue this at convenient points about six inches apart while watching the test light or DVOM. 4. Where the test light goes , or the DVOM voltage drops to zero, there is a short to ground in the wiring near that point. NOTE: Always use a DVOM on high impedance circuits. A test light may not glow (even with battery voltage present). Testing For A Short With A Short Circuit Locator (Short Finder) 1. Remove the blown fuse. Leave the battery connected. Engine Controls - High/Erratic Engine Idle Power Steering Pressure Switch: Customer Interest Engine Controls - High/Erratic Engine Idle 01-080 August 14, 2001 Applies To: 2000-02 Passport - ALL 2000-02 Passport: High or Erratic Idle SYMPTOM The engine occasionally idles at too high a speed, or the idle speed fluctuates. PROBABLE CAUSES The symptom could be the result of any of these conditions: ^ Loose or corroded engine or body ground ^ High resistance in the APPS ground circuit ^ PSP (power steering pressure) switch is internally shorted to ground ^ Fuel pressure regulator is leaking fuel into the intake manifold CORRECTIVE ACTION Diagnose the cause of the idle condition, and select the proper REPAIR PROCEDURE. PARTS INFORMATION REQUIRED MATERIALS REQUIRED SOFTWARE Each REPAIR PROCEDURE requires you to use the Smart Cable to reprogram the PCM with the latest software. To select the latest software from the CDROM, enter the year, model, engine, transmission, and emissions type (49-state or California). This gives you a list of broadcast codes. Select the broadcast code at the top of the list. WARRANTY CLAIM INFORMATION Refer to the Warranty Claim Information for each Repair Procedure. DIAGNOSIS 1. Find out from the customer when the high or erratic idle condition occurs and what the RPM range is: ^ Within 20 minutes of a cold start ^ After braking to a stop ^ All the time ^ Intermittently, with no set pattern Page 6206 Hose/Line HVAC: Service and Repair Repair Of Refrigerant Leaks Repair Of Refrigerant Leaks Install new O-ring, if required. When disconnecting or connecting lines, use two wrenches to prevent the connecting portion from twisting or becoming damaged. When connecting the refrigerant line at a block joint, securely insert the projecting portion of the joint portion into the connecting hole on the unit side and secure with a bolt. Apply the specified compressor oil to the O-ring prior to connecting. CAUTION: Compressor (PAG) oil to be used varies according to the compressor model. Be sure to apply oil specified for the model of compressor. Procedures Grille: Procedures Removal 1. Open the hood 2. Support the hood. 3. Remove radiator grille. - Raise the clips on the radiator grille and remove screw. 4. Pull out the radiator grille rubber from fender panel front lower side. Installation To install, follow the removal steps in the reverse order, noting the following points. 1. Install the radiator grille clips remaining on the body side in the radiator grille, and then install the radiator grille on the body. Page 561 Wire Color Abbreviations The following abbreviations are used to identify wire colors in the circuit schematics: WHT................................... White YEL................................... Yellow BLK................................... Black BLU................................... Blue GRN................................... Green RED................................... Red ORN................................... Orange PNK................................... Pink BRN................................... Brown GRY................................... Gray PUR................................... Purple LT BLU................................... Light Blue LT GRN................................... Light Green Page 345 Power Mirror Switch: Removal and Replacement Door Mirror Switch Removal 1. Disconnect the battery ground cable. 2. Remove the instrument panel lower cover (2). 3. Remove the door mirror switch (1). Page 2083 11. Using a jumper wire, connect the reference voltage of each circuit to its signal input and view the APP Sensor values in the Engine Data List. APP Sensor 1 should have a value of 99%, and APP Sensor 2 and APP Sensor 3 should each have a value of 0%. ^ If the values are not as specified, troubleshoot for high resistance on the signal input or a PCM malfunction. Repair the circuit or replace the PCM, then repeat step 3. ^ If the values are as specified, the problem may be intermittent. Disconnect the 10P connector from the modified APPS, and connect it to the new APPS; then repeat step 3. Wiggle the APPS wires as you go through the adjustment procedure to find the intermittent problem. 12. Turn off the ignition switch, and disconnect the PGM Tester.* DISCLAIMER Page 3029 2. Connect one lead of a self-powered test light or DVOM to one end of the part of the circuit you want to test. 3. Connect the other lead to the other end. 4. If the self-powered test light glows, there is continuity. If you're using a DVOM, a low reading or no reading (zero), means good continuity. Testing For Voltage When testing for voltage at a connector without wire seals, you do not have to separate the two halves of the connector. Instead, probe the connector from the back. Always check both sides of the connector because dirty, corroded, and bent terminals can cause problems (no electrical contact = an open). 1. Connect one lead of the lest light to a known good ground, or, if you're using a digital volt ohmmeter (DVOM), place it in the appropriate DC volts range, and connect its negative lead to ground. 2. Connect the other lead of the test light or DVOM to the point you want to check. 3. If the test light glows, there is voltage present. If you're using a DVOM, note the voltage reading. It should be within one volt of measured battery voltage. A loss of more than one volt indicates a problem. NOTE: Always use a DVOM on high impedance circuits. A test light may not glow (even with battery voltage present). Testing For Voltage Drop Wires, connectors, and switches are designed to conduct current with a minimum loss of voltage. A voltage drop of more than one volt indicates a problem. 1. Place the digital volt/ohmmeter (DVOM) in the appropriate DC volts range. Connect the positive lead to the end of the wire (or to the connector or switch) closest to the battery. 2. Connect the negative lead to the other end of the wire (or the other side of the connector or switch). 3. Turn on the components in the circuit. 4. The DVOM will show the difference in voltage between the two points. A difference, or drop, of more than one volt indicates a problem. Check the circuit for loose, dirty, or bent terminals. Page 7319 2. Remove the power window switch/regulator handle. - Pry out the power window switch and remove the connectors. - To remove the regulator handle (1), remove the clip (2) at the root of the handle by using wire with hook. 3. Remove the screw while pulling the inside lever toward you and then remove the inside handle. 4. Remove the speaker grille (3). - Pull out the front side of the grille. Page 137 Powertrain Control Module: Service Precautions Electrostatic Discharge Damage Electrostatic Discharge Damage Electronic components used in the PCM are often designed to carry very low voltage. Electronic components are susceptible to damage caused by electrostatic discharge. Less than 100 volts of static electricity can cause damage to some electronic components. By comparison, it takes as much as 4000 volts for a person to feel even the zap of a static discharge. There are several ways for a person to become statically charged. The most common methods of charging are by friction and induction. - An example of charging by friction is a person sliding across a vehicle seat. - Charge by induction occurs when a person with well insulated shoes stands near a highly charged object and momentary touches ground. Charges of the same polarity are drained off leaving the person highly charged with the opposite polarity. Static charges can cause damage, therefore it is important to use care when handling and testing electronic components. NOTE: To prevent possible electrostatic discharge damage, follow these guidelines: - Do not touch the PCM connector pins or soldered components on the PCM circuit board. - Do not open the replacement part package until the part is ready to be installed. - Before removing the pan: from the package, ground the package to a known good ground on the vehicle. - If the part has been handled while sliding across the seat, while sitting down from a standing position, or while walking a distance, touch a known good ground before installing the part. Page 6677 the component if the component only has one connector, or by a capital letter (A, B, C, etc.) if the component has more than one connector. Below most connector numbers and component names are PHOTO and VIEW numbers. The PHOTO number refers to a photo in the back of the book that shows the connector's location on the car. The VIEW number refers to an illustration in the back of the book that shows the connector face, wire colors, connector cavity numbers, and other details. The connector cavity numbering sequence begins at the top left corner of the connector. Disregard any numbers molded into the connector housing. Wires Wires are identified by the abbreviated names of their colors; the second color is the color of the stripe. Wires are also identified by their location in a connector. The number "2" next to the male and female wire terminals at C416, for example, means those terminals join in cavity 2 of connector C416. Symbols A complete description of schematic symbols is given under wire color abbreviation. Power Distribution Schematics Power Distribution schematics show how power is supplied from the positive battery terminal to various circuits in the car. Refer to the Power Distribution section to get a more detailed picture of how power is supplied to the circuit you're working on. From Battery to Ignition Switch, Fuses, and Relays Individual circuit schematics begin with a fuse. The first half of Power Distribution, however, shows the wiring "upstream" between the battery Page 6192 Specifications Tie Rod End: Specifications Tie Rod End Lock Nut 98 N.m (72 lb-ft) Nm Page 993 ^ If the wheels are pointed to the right, shorten the driver's side tie-rod, and lengthen the passenger's side. ^ If the wheels are pointed to the left, shorten the passenger's side tie-rod, and lengthen the driver's side. ^ Each 360° turn of the tie-rod equals about 8 mm of steering wheel adjustment. For example, a steering wheel is off-center by 4 mm with the front wheels pointed right (when the steering wheel is centered). To correct the off-center, shorten the driver's side tie-rod by a half-turn, and lengthen the passenger's side tie-rod by a half-turn. 4. Use your diagnosis worksheet to fill in the following table and build your 15-digit DTC. Page 1877 Catalytic Converter: Technical Service Bulletins Catalytic Converter - Rotten Egg Smell SOURCE: Honda Service News July 2003 TITLE: Rotten Egg Smell? Could Be the Catalytic Converter APPLIES TO: All Models SERVICE TIP: Are customers complaining of a rotten egg smell, but you can't find anything wrong with their vehicles to account for it [there's no DTC(s) set, no driveability problems reported, nothing damaged or broken]? Then it could well be coming from the catalytic converter. That smell is a release of built up hydrogen sulfide (H2S) from the reaction of organic sulfur compounds in the gasoline with the catalyst in the converter. Almost all gasoline contains some amount of organic sulfur compounds, and that amount varies by region. The more sulfur there is in the gasoline, the more H2S is built up and released by the catalytic converter, so the stronger the smell. In California, where low-sulfur gasoline is actually required by state law, sulfur smell complaints are few and far between. The folks at the Environmental Protection Agency have issued a requirement for the phasing-in of low-sulfur gasoline nationwide between 2004 and 2006. This low-sulfur gasoline should go a long way toward making complaints of rotten egg smell a thing of the past. Locations Starting System - Unable To Key In Ignition Switch Ignition Switch Lock Cylinder: Technical Service Bulletins Starting System - Unable To Key In Ignition Switch Can't Turn Ignition Switch? Check for Locked Steering Got a service customer complaining he or she can't turn the ignition switch to start the engine? The reason could just be the steering column lock pin is engaged with the front wheels turned. Here's what typically happens: Some folks use the steering wheel to help support themselves while climbing in or out of the vehicle. This is very common among elderly or disabled drivers. Doing this turns the front wheels, which twists the tires against the ground. The twisted tires apply torque to the steering column. With the ignition switch in LOCK (0), the steering column lock pin is engaged. But the applied torque on the steering column binds the lock pin, making it tough to turn the ignition switch. The ignition switch won't turn to ON (II) if the lock pin isn't disengaged from the steering column. Tell your customer there's nothing wrong with the ignition switch itself. All he or she needs to do is turn the steering wheel from side to side while turning the switch. This usually releases the lock pin so the engine can be started. In some cases, though, your customer may need to give a good tug on the wheel. This could easily happen when parking on a hill and the wheels are turned sharply before the engine is shut off. Page 7451 Clock: Service and Repair Removal 1. Disconnect the battery ground cable. 2. Remove the dash side trim panel-LH (1). Refer to Instrument Panel Assembly in Body Structure. 3. Remove the lower cover assembly (2). Refer to instrument Panel Assembly in Body Structure. 4. Remove the meter cluster assembly (4). Refer to Instrument Panel Assembly in Body Structure. 5. Remove the digital clock (3). - Remove the fixing screw. - Disconnect the connector. Installation To install, follow the removal steps in the reverse order. Page 2686 Testing For A Short With A Self-Powered Test Light or DVOM 1. Remove the blown fuse and disconnect the battery and load. 2. Connect one lead of a self-powered test light or digital volt/ohmmeter (DVOM) (switched to the lowest "OHMS" range) to the fuse terminal on the load side. 3. Connect the other lead to a known good ground. 4. Beginning near the fuse box, wiggle the harness. Continue this at convenient points about six inches apart while watching the test light or DVOM. 5. If the self-powered test light goes on or the DVOM displays a low reading or no reading (zero), there is a short to ground in the wiring near that point. Testing for a Short with a Test Light or DVOM 1. Remove the blown fuse and disconnect the load. 2. Connect a test light or digital volt/ohmmeter (DVOM), switched to the appropriate DC volts range, across the fuse terminals to make sure voltage is present. You might have to turn the ignition switch to ON; check the schematic to see. 3. Beginning near the fuse box, wiggle the harness. Continue this at convenient points about six inches apart while watching the test light or DVOM. 4. Where the test light goes , or the DVOM voltage drops to zero, there is a short to ground in the wiring near that point. NOTE: Always use a DVOM on high impedance circuits. A test light may not glow (even with battery voltage present). Testing For A Short With A Short Circuit Locator (Short Finder) 1. Remove the blown fuse. Leave the battery connected. Page 4100 Transmission Position Switch/Sensor: Description and Operation Transmission Range Switch IMPORTANT: The vehicle should not be driven with the transmission range switch disconnected; idle quality will be affected. The four inputs from the transmission range switch indicate to the PCM which position is selected by the transmission selector lever. This information is used for ignition timing, EVAP canister purge, EGR operation. For more information on the transmission on the transmission range switch, refer to Transmission Control System Diagnosis. See: Transmission Control Systems/Testing and Inspection Page 7828 Wire Color Abbreviations The following abbreviations are used to identify wire colors in the circuit schematics: WHT................................... White YEL................................... Yellow BLK................................... Black BLU................................... Blue GRN................................... Green RED................................... Red ORN................................... Orange PNK................................... Pink BRN................................... Brown GRY................................... Gray PUR................................... Purple LT BLU................................... Light Blue LT GRN................................... Light Green Page 5875 Tires: Service and Repair General Balance Procedure Deposits of mud, etc. must be cleaned from the inside of the rim. The tire should be inspected for the following: match mount paint marks, bent rims, bulges, irregular tire wear, proper wheel size and inflation pressure. Then balance according to the equipment manufacturer's recommendations. There are two types of wheel and tire balance. Static balance is the equal distribution of weight around the wheel. Assemblies that are statically unbalanced cause a bouncing action called tramp. This condition will eventually cause uneven tire wear. Dynamic balance is the equal distribution of weight on each side of the wheel center-line so that when the tire spins there is no tendency for the assembly to move from side to side. Assemblies that are dynamically unbalanced may cause shimmy. WARNING: Stones should be removed from the tread to avoid operator injury during spin balancing and to obtain a good balance. Page 8069 it is located, and what it connects to. Use the Connector Views to help locate the proper cavity when you need to probe a connector. It can be especially helpful if the connector has more than one wire of the same color. A dash symbol (-) indicates that the cavity is empty. Connector views can also be used to help diagnose multiple symptoms in separate circuits which could be caused by a single problem in a connector shared by those circuits. Here's an example: 1. Pick one of the multiple symptoms and look up the schematic for that circuit. 2. Make a list of all the in-line and fuse box connectors in that schematic , 3. Then, in the Connector Views, look up each connector on your list to see if circuits related to the other symptoms run through one of them. If they do, inspect that connector for the problem. Example: The blower, rear window defogger, and the windshield wiper don't work. List all in-line and fuse box connectors in the blower controls circuit and then check the Connector View (see the sample). You find that C324 is common to the blower controls, rear window defogger, and wiper/washer, so you inspect C324 and find the problem, bent terminals. Finding Component/Connector Locations Finding Component/Connector Locations To see where a component or connector is located on the car, look up its photo number in the "Component Location". The photo will also tell you the color of the connector, and how many cavities it has. Page 6994 4. Remove the old metal detent clips. 5. Install two new metal detent clips. 6. Reinstall the ashtray/rear beverage holder assembly onto the rear console. 7. Plug in the connector (A/T), and reinstall the rear console assembly. 8. Open and close the rear beverage holder swing arm several times to make sure the detents hold. DISCLAIMER Page 3717 Part 3 Of 3 Page 378 Wheel Speed Sensor: Connector Locations Front Wheel Sensor Connector Behind Left Front Wheel (Right Wheel Similar) Rear Wheel Sensor Connector Under Rear of Vehicle (On Differential) Page 5991 The name of the component appears next to it followed by notes about its function along with any photo and connector view references. Connector "C" How to Identify Connector Terminals Cavity Numbering System The cavities (and wire terminals) in each connector are numbered starting from the upper left, looking at the male terminals from the terminal side (or looking at the female terminals from the wire side. Both views are in the same direction so the numbers are the same.) All actual cavities are numbered, even if they have no wire terminals in them. NOTE: Data Link Connector (DLC) terminals are numbered according to SAE standard J1962, not the Honda standard. The numbers of the four end terminals are molded into the corners of the connector face. Page 4608 Page 69 Test Equipment CAUTION: Most circuits include solid-state devices. Test the voltages in these circuits only with a 10-megaohm or higher impedance digital multimeter. Never use a test light or analog meter on circuits that contain solid-state devices. Damage to the devices may result. Test Light and DVOM On circuits without solid-state devices, use a test light to check for voltage. A test light is made up of a 12 volt bulb with a pair of leads attached. After grounding one lead, touch the other lead to various points along the circuit where voltage should be present. The bulb will go on if there is voltage at the point being tested. If you need to know how much voltage is present, use a digital volt/ohmmeter (DVOM). Self-Powered Test Light and DVOM Use a self-powered test light to check for continuity. This tool is made up of a light bulb, battery, and two leads. To test it, touch the leads together: the light should go on. Use a self-powered test light only on an unpowered circuit. First, disconnect the battery, or remove the fuse that feeds the circuit you are working on. Select two points in the circuit between which you want to check continuity. Connect one lead of the self-powered test light to each point. If there is continuity, the test light's circuit will be completed, and the light will go on. If, in addition, you need to know exactly how much resistance there is between two points, use a digital volt/ohmmeter (DVOM). In the "OHMS" range, the DVOM will measure resistance between two points along a circuit. Low resistance means good continuity. Diodes and solid-state devices in a circuit can make a DVOM give a false reading. To check a reading, reverse the leads, and take a second reading. If the readings differ, the component is affecting the measurement. Jumper Wire Use a jumper wire to bypass an open circuit. A jumper wire is made up of an in-line fuse holder connected to a set of test leads. It should have a five ampere fuse. Never connect a jumper wire across a short circuit. The direct battery short will blow the fuse. Short Finder (Short Circuit Locator) Short finders are available to locate shorts to ground. The short finder creates a pulsing magnetic field in the shorted circuit which you can follow to the location of the short. To order any test equipment shown above, contact your local tool supplier. For a list of suppliers and tool numbers, refer to Honda Required Special Tools and Equipment Service Bulletin. Page 6897 3. Remove the hatchgate ball stud (LH and RH). - Remove gas stay fixing screw and pull up the gas stay assembly (3) from the ball stud by spreading the retainer (2) holding the ball stud at the end of the gas stay with screwdriver (1), etc. 4. Remove the hatchgate hinge nuts from body side. 5. Remove the hatchgate glass. - When pulling down the hatchgate glass, exercise special care so as not to damage it. Hatchgate glass assembly is heavy and removal operation requires two people. 6. Remove the two screws to remove hatchgate striker and fastener. 7. Remove the outside handle. 8. Remove the hinges. 9. Remove the high mount stoplight. 10. Remove the hatchgate finisher. Installation To install, follow the removal steps in the reverse order, noting the following points. 1. Attach the upper seal (1) to the hatchgate glass (2) indicated portion (3) so that the end of the glass contacts the bottom of the upper seal. Page 1285 - Refer to the scrapping procedures for disposal of the damaged airbag. Description and Operation Acceleration/Deceleration Sensor: Description and Operation DESCRIPTION/OPERATION The G-sensor installed inside the EHCU detects the vehicle deceleration speed and sends a signal to the EHCU. In 4WD operation, all four wheels may be decelerated in almost the same phase, since all wheels are connected mechanically. This tendency is noticeable particularly on roads with low friction coefficient, and the ABS control is adversely affected. The G-sensor judges whether the friction coefficient of road surface is low or high, and changes the EHCU's operating system to ensure ABS control. Accelerator Pedal Assembly/Sensor - Adjustment Update Accelerator Pedal Position Sensor: All Technical Service Bulletins Accelerator Pedal Assembly/Sensor - Adjustment Update 00-045 August 14, 2001 Applies To: 2000-02 Passport - ALL Service Manual Update: Accelerator Pedal Position Sensor (APPS) (Supersedes 00-045, dated May 23, 2000) Updated information is shown by asterisks and black bars. BACKGROUND When the accelerator pedal position sensor (APPS) or the accelerator pedal assembly is replaced for any reason, you must adjust the APPS. *This procedure is missing in the 2000 service manual and is wrong in the 2001 and 2002 service manuals. Make a note on page 6E2-539 of the 2000 Passport Fuel and Emissions manual, on page 6E2-553 of the 2001 Passport Fuel and Emissions manual, and on page 6E2-545 of the 2002 Passport Fuel and Emissions manual to refer to this bulletin.* ADJUSTMENT PROCEDURE 1. Replace the APPS or the accelerator pedal assembly, and leave the mounting screws for the APPS loose. 2. Connect the PGM Tester to the data link connector (DLC), and turn the ignition switch to ON (II). *3. While watching the APP Sensor values in the Engine Data List, adjust the APPS by turning it until the values are within the ranges shown at closed pushed all the way down), then tighten the throttle and wide open throttle (accelerator pedal mounting screws and recheck the values. ^ If all three sensors are within range, go to step 12. ^ If APP Sensor 1, APP Sensor 2, and/or APP Sensor 3 cannot be brought into range, go to step 4. 4. Troubleshoot for an open circuit or a PCM malfunction. ^ If APP Sensor 1 has a value of 0% or APP Sensor 2 and/or APP Sensor 3 have a value of 99%, an open circuit exists or the PCM is malfunctioning. Repair the circuit or replace the PCM, and repeat step 3. ^ If you don't find a problem, go to step 5. 5. Disconnect the 10P connector from the APPS. 6. View the APP Sensor values in the Engine Data List. ^ If APP Sensor 1 has a value of 0% or APP Sensor 2 and/or APP Sensor 3 have a value of 99%, go to step 7. ^ If APP Sensor 1 has a value other than 0%, or APP Sensor 2 and/or APP Sensor 3 have a value other than 99%, a short circuit exists or the PCM is malfunctioning. Repair the circuit or replace the PCM, and repeat step 3. Page 4818 INSTALLATION 1. Install speed sensor (3). 2. Tighten the sensor fixing bolt (2) to the specified torque. Torque: 11 Nm (95 inch lbs.) 3. Connect harness connector (1). Page 180 Testing For A Short With A Self-Powered Test Light or DVOM 1. Remove the blown fuse and disconnect the battery and load. 2. Connect one lead of a self-powered test light or digital volt/ohmmeter (DVOM) (switched to the lowest "OHMS" range) to the fuse terminal on the load side. 3. Connect the other lead to a known good ground. 4. Beginning near the fuse box, wiggle the harness. Continue this at convenient points about six inches apart while watching the test light or DVOM. 5. If the self-powered test light goes on or the DVOM displays a low reading or no reading (zero), there is a short to ground in the wiring near that point. Testing for a Short with a Test Light or DVOM 1. Remove the blown fuse and disconnect the load. 2. Connect a test light or digital volt/ohmmeter (DVOM), switched to the appropriate DC volts range, across the fuse terminals to make sure voltage is present. You might have to turn the ignition switch to ON; check the schematic to see. 3. Beginning near the fuse box, wiggle the harness. Continue this at convenient points about six inches apart while watching the test light or DVOM. 4. Where the test light goes , or the DVOM voltage drops to zero, there is a short to ground in the wiring near that point. NOTE: Always use a DVOM on high impedance circuits. A test light may not glow (even with battery voltage present). Testing For A Short With A Short Circuit Locator (Short Finder) 1. Remove the blown fuse. Leave the battery connected. Page 7817 Each schematic represents one circuit. A circuit's wires and components are arranged to show current flow, from power at the top of the page, to ground, at the bottom. Shared Circuits Other circuits may share power or ground terminals or wiring with the circuit shown. A wire that connects one circuit to another, for example, is cut short and has an arrowhead at the end of it pointing in the direction of current flow. Next to the arrowhead is the name of the circuit or component which shares that wiring. To quickly check shared wiring, check the operation of a component it serves. If that component works, you know the shared wiring is OK. Connectors All in-line and junction connectors are numbered (C725, C416, etc.). Component connectors are not numbered but are identified either by the name of Page 1624 18. Reinstall the bracket on the engine. Torque the flange bolts to 50 N.m (37 lb-ft). Be careful not to pinch the crankshaft position sensor harness, and on A/T models, the ATF cooler lines. 19. Lower the engine into position. Do it slowly to avoid wedging it between the mounts; if you lower it too fast, you will compress the mounts. If you compress the mounts, they will not be able to isolate noise and absorb vibration. 20. Reinstall the engine mounts on the chassis. Torque the flange bolts to 41 N.m (30 lb-ft). 21. Reinstall the crankshaft position sensor. Torque the bolt to 9 N.m (7 lb-ft). 22. Plug the 3P connector into the crankshaft position sensor. 23. Reinstall the crankshaft position sensor harness clamp. 24. Models With A/T: Reinstall the front and rear clamps for the A/T cooler lines. 25. Models With 4WD: Reinstall the front skid plate. 26. Reinstall the front wheels. Torque the lug nuts to 118 N.m (87 lb-ft). 27. Lower the vehicle. 28. Reconnect the negative cable to the battery. 29. Enter your customer's radio station presets and mode settings. Set the clock. Disclaimer Service and Repair Rear Door Window Glass Weatherstrip: Service and Repair Rear Window Regulator, Glass and Glass Run Rear Window Regulator, Glass and Glass Run Removal 1. Disconnect the battery ground cable. 2. Remove the rear corner garnish. - Pull the garnish to disconnect the retaining clip. Page 2364 Ignition Cable: Testing and Inspection Spark Plug Cables NOTE: Never puncture the spark plug cable's insulation with a needle or the pointed end of a probe into the cable. An increase in resistance would be created which would cause the cable to become defective. 1. If the cable has broken or cracked insulation, it must be replaced. 2. If the terminals are corroded or loose, the cable must be replaced. 3. Check that the cable resistance does not exceed 10 kOHM per foot. Page 5311 Page 7580 Key Reminder Switch: Diagnostic Aids Before Troubleshooting Before Troubleshooting See: Service Precautions/Vehicle Damage Warnings/Tips and Precautions 1. Check applicable fuses in the appropriate fuse/relay box. 2. Check the battery for damage, state of charge, and clean and tight connections. CAUTION: Do not quick-charge a battery unless the battery ground cable has been disconnected, otherwise you will damage the alternator diodes. - Do not attempt to crank the engine with the battery ground cable loosely connected or you will severely damage the wiring. While You're Working 1. Make sure connectors are clean, and have no loose terminals or receptacles. 2. Make sure that connectors without wire seals are packed with dielectric (silicone) grease. Part Number: 08798-9001. 3. When connecting a connector, push it until it "clicks" into place. CAUTION: Do not pull on the wires when disconnecting a connector. Pull only on the connector housings. - Most circuits include solid-state devices. Test the voltages in these circuits only with a 10-megaohm or higher impedance digital multi meter. Never use a test light or analog meter on circuits that contain solid-state devices. Damage to the devices may result. Five-Step Troubleshooting 1. Verify The Complaint Turn on all the components in the problem circuit to check the accuracy of the customer complaint. Note the symptoms. Do not begin disassembly or testing until you have narrowed down the problem area. 2. Analyze The Schematic Look up the schematic for the problem circuit. Determine how the circuit is supposed to work by tracing the current paths from the power source through the circuit components to ground. Also, trace circuits that share wiring with the problem circuit. The names of circuits that share the same fuse, ground, or switch, and so on, are referred to in each circuit schematic. Try to operate any shared circuits you didn't check in step 1. If the shared circuits work, the shared wiring is OK, and the cause must be in the wiring used only by the problem circuit. If several circuits fail at the same time, the fuse or ground is a likely cause. Based on the symptoms and your understanding of the circuit's operation, identify one or more possible causes. 3. Isolate The Problem By Testing The Circuit Make circuit tests to check the diagnosis you made in step 2. Keep in mind that a logical, simple procedure is the key to efficient troubleshooting. Test for the most likely cause of failure first. Try to make tests at points that are easily accessible. 4. Fix The Problem Once the specific problem is identified, make the repair. Be sure to use proper tools and safe procedures. 5. Make Sure The Circuit Works Turn on all components in the repaired circuit in all modes to make sure you've fixed the entire problem. If the problem was a blown fuse, be sure to test all of the circuits on that fuse. Make sure no new problems turn up and the original problem does not recur. A/T Main Case Oil Plug - Fluid Leaks Fill Plug: Customer Interest A/T Main Case Oil Plug - Fluid Leaks 01-078 October 16, 2001 Applies To: 1996-00 Passport - ALL with A/T A/T Main Case Oil Pan Plug Leaks SYMPTOM The main case oil pan appears to leak ATF at the drain plug, the fill plug, or both. PROBABLE CAUSE An irregular surface finish on the main case oil pan damages the 0-rings on the plugs. CORRECTIVE ACTION Check the drain plug and fill plug on the main case oil pan for signs of leakage. If either plug leaks, replace both plugs and gaskets with captive 0-ring plugs. PARTS INFORMATION WARRANTY CLAIM INFORMATION In warranty: The normal warranty applies. Operation Number: 218159 Flat Rate Time: 0.3 hour Failed Part: P/N 8-96015-481-0 H/C 5043229 Defect Code: 051 Contention Code: B06 Template ID: 01-078A Skill Level: Repair Technician Out of warranty: Any repair performed after warranty expiration may be eligible for goodwill consideration by the District Service Manager or your Zone Office. You must request consideration, and get a decision, before starting work. REPAIR PROCEDURE 1. Raise the vehicle on a lift, making sure the vehicle is level. 2. Clean the area around the drain plug and fill plug on the A/T main case oil pan. Page 124 Wires Wire insulation can be one color, or one color with another color stripe. (The second color is the stripe.) This circuit continues on another image. (The arrow shows direction of current flow.) To follow the RED/BLK wire in this example, you would turn to "Fuel and Emissions" and look for the "A" arrow. Page 6235 3. Connect the universal connect set and the Tracer- Stick dye capsule: (a) Be sure the quick coupler and control valves on the set are closed. (b) Remove the low-side service port sealing cap, and connect the set to the low-side service port using the quick coupler. (c) Hold a new dye capsule so that the embossed arrow is pointing up. Remove the black end cap, and carefully attach the capsule to the control valve fitting. NOTE: The capsule must be held with the embossed arrow pointing up or the dye will leak out of the capsule. (d) Turn the capsule so the embossed arrow is pointing down. Remove the orange end cap, and carefully attach the service valve fitting provided in the kit (finger tight). NOTE: The capsule must be held with the embossed arrow pointing down or the dye will leak out. 4. Connect the NC service equipment: With the universal connect set and dye capsule attached to the vehicle's low-side service port, connect the A/C refrigerant recovery and charging station's low-side hose quick coupler to the service valve fitting. Open the blue hand-wheel valves on both quick couplers. Leave the control valve (black knob) on the universal connect set closed. NOTE: * ^ If you have recovered refrigerant to weigh it as part of your diagnostics, or if there is a low charge, it is more efficient to recharge the system using normal procedures before installing the universal connect set. Dye can then be added using approximately 0.05 lb (0.02 kg) of refrigerant.* ^ You do not need to connect the service equipment's high-side hose to the vehicle to install the dye. If the high-side hose is connected, make sure its coupler valve is closed before proceeding. ^ Do not use the A/C recovery and charging station to recover or evacuate the A/C system when a full dye capsule is attached. The dye will be drawn into the service equipment instead of being added to the vehicle's A/C system. 5. Inspect the A/C system for leaks: (a) Run the A/C system for at least 15 minutes to circulate the dye through the system. Large leaks will be seen immediately as a fluorescent yellow glow. Smaller leaks may require at least 24 hours of vehicle operation before they become visible. Operate the A/C system as much as possible during this time to keep the dye circulating. (b) Stop the vehicle's engine and inspect the system for leaks using the ultraviolet (UV) lamp and fluorescence-enhancing glasses from the kit. Page 4843 Brake Pedal Assy: Testing and Inspection Checking Pedal Travel Checking Pedal Travel 1. Pedal height must be measured after starting the engine and rowing it several times to apply vacuum to the vacuum booster fully. NOTE: Pedal height must be 95 mm (3.7 inch) or more when about 50 kg (110.25 lbs.) of stepping force is applied. 2. If the measured value is lower than the above range, air may still be present in the hydraulic system Perform the bleeding procedure. Page 7756 The connector cavity number is listed next to each terminal on the circuit schematic. The cavity / terminal shown is # 6. Diodes A rectifier diode works like a one way valve. It allows current to flow only in the direction of the arrow. A Zener diode blocks reverse current at normal voltages just like a rectifier diode. At high voltages, however, a Zener diode allows current to flow in reverse. Fuses Page 7028 16. Remove the front pillar assist grip (1) (Front & Rear). - Open the both sides of the assist grip cover (2) and remove the fixing screws and the front pillar assist grip. Installation To install, follow the removal steps in the reverse order, noting the following point: 1. Tighten the seat belt anchor bolt to the specified torque. Torque: 39 Nm (29 lb.ft) SWB Removal 1. Disconnect the battery ground cable. 2. Remove the soft top assembly or resin top assembly. 3. Remove the rear seat assembly. 4. Remove the weather strip. 5. Remove the luggage side trim cover. 6. Remove the sill plate. 7. Remove the dash side trim cover. 8. Remove the rear speaker assembly. - Disengage the front portion of the speaker grille (1) and pull it forward and off. - Remove the three fixing screws securing the speaker (2) in place and disconnect the connector (3). 9. Remove the front and rear seat belt lower anchor bolts. Page 7669 The connector cavity number is listed next to each terminal on the circuit schematic. The cavity / terminal shown is # 6. Diodes A rectifier diode works like a one way valve. It allows current to flow only in the direction of the arrow. A Zener diode blocks reverse current at normal voltages just like a rectifier diode. At high voltages, however, a Zener diode allows current to flow in reverse. Fuses Specifications Clutch Fluid: Specifications Dot 3 Hydraulic Brake Fluid Removal and Installation Spark Plug: Service and Repair Removal and Installation Removal 1. Remove spark plugs. Installation 1. Spark plugs - Tighten spark plugs to the specified torque. Torque: 18 Nm (13 lb.ft) Page 2796 Powertrain Control Module: Description and Operation Circuit Operation The engine or powertrain control module (ECM or PCM) receives inputs from the engine sensors and switches, controlling the functions of the engine. It also turns on the malfunction indicator "check engine" light whenever a malfunction or abnormal engine performance is detected, and allows for diagnostic testing through the data link connector (DLC). Electrically Erasable Programmable Read Only Memory (EEPROM) Electrically Erasable Programmable Read Only Memory (EEPROM) The electrically erasable programmable read only memory (EEPROM) is a permanent memory chip that is physically soldered within the PCM. The EEPROM contains the program and the calibration information that the PCM needs to control powertrain operation. Unlike the PROM used in past applications, the EEPROM is not replaceable. If the PCM is replaced, the new PCM will need to be programmed. Equipment containing the correct program and calibration for the vehicle is required to program the PCM. PCM Components PCM Components The PCM is designed to maintain exhaust emission levels to government mandated standards while providing excellent driveability and fuel efficiency. The PCM monitors numerous engine and vehicle functions via electronic sensors such as the throttle position (TP) sensor, heated oxygen sensor (HO2S), and vehicle speed sensor (VSS). The PCM also controls certain engine operations through the following: - Fuel injector control - Ignition control module - ION sensing module - Automatic transmission shift functions - Cruise control - Evaporative emission (EVAP) purge - A/C clutch control PCM Function PCM Function The PCM supplies either 5 or 12 volts to power various sensors or switches. The power is supplied through resistances in the PCM which are so high in value that a test light will not light when connected to the circuit. In some cases, even an ordinary shop voltmeter will not give an accurate reading because its resistance is too low. Therefore, a digital voltmeter with at least 10 megohms input impedance is required to ensure accurate voltage readings. Tool J 39200 meets this requirement. The PCM controls output circuits such as the injectors, fan relays, etc., by controlling the ground or the power feed circuit through transistors or through either of the following two devices: - Output Driver Module (0DM) - Quad Driver Module (QDM) PCM Input/Outputs PCM Input/Outputs Inputs - Operating Conditions Read - Air Conditioning "ON" or "OFF" Page 287 Distinct Of Circuit By Wire Base Color All wires have color-coded insulation. Wires belonging to a system's main harness will have a single color. Wires belonging to a system's sub-circuits will have a colored stripe. Striped wires use the codes found in the chart to show wire size and colors. Abbreviations are used to indicate wire color within a circuit diagram. How to Identify Connector Terminals How to Identify Connector Terminals Cavity Numbering System The cavities (and wire terminals) in each connector are numbered starting from the upper left, looking at the male terminals from the terminal side (or looking at the female terminals from the wire side. Both views are in the same direction so the numbers are the same.) All actual cavities are numbered, even if they have no wire terminals in them. NOTE: Data Link Connector (DLC) terminals are numbered according to SAE standard J1962, not the Honda standard. The numbers of the four end terminals are molded into the corners of the connector face. The connector cavity number is listed next to each terminal on the circuit schematic. The cavity / terminal shown is # 6. Using/Identifying Connector Terminal Views How to Use Connector Terminal Views To see the configuration of a connector's cavities, look up its view number in the Connector Views. Each view includes the color of the connector, where Page 7308 3. Remove the waterproof sheet. - Remove the waterproof sheet, taking special care so as not to break it. 4. Remove the hatchgate lock. - Disconnect the lock link and connector and remove the 3 fixing bolts. 5. Remove the key cylinder. - Disconnect the lock links. - Remove the key cylinder retaining clip with screw driver to remove the key cylinder. 6. Remove the hatchgate lock actuator assembly. - Disconnect the actuator harness connector. - Remove the 2 bolts holding hatchgate lock actuator assembly from inside. 7. Remove the outside handle. - Remove the 2 bolts holding the outside handle from inside. 8. Remove the tailgate lock assembly. - Remove the 3 screws holding the lock assembly. Installation To install, follow the removal steps in the reverse order, noting the following points: Page 6418 Air Bag Control Module: Vehicle Damage Warnings 1. Air bag assembly should not be subjected to temperatures above 93 °C (200 °C). 2. Air bag assembly, and Sensing and Diagnostic Module (SDM) should not be used If they have been dropped from a height of 100 centimeters (3.28 feet). 3. When a SDM is replaced, it must be oriented with the arrow on the sensor pointing toward the front of the vehicle. It is very important for the SDM to be located flat on the mounting surface, parallel to the vehicle datum line. It is important that the SDM mounting surface is free of any dirt or other foreign material. 4. Do not apply power to the SRS unless all components are connected or a diagnostic chant requests it, as this will set a diagnostic trouble code. 5. The "SRS Diagnostic System Check" must be the starting point of any SRS diagnostics. The "SRS Diagnostic System Check" will verify proper "AIR BAG" warning lamp operation and will lead you to the correct chart to diagnose any SRS malfunctions. Bypassing these procedures may result in extended diagnostic time, incorrect diagnosis, and incorrect pants replacement. Electrical Specifications Alternator: Electrical Specifications Measurement Standard Service Limit Battery Voltage 12 Volts Output Amperage 90 Amps Pulley Rotation Clockwise Rated Rotation Speed 5000 rpm Maximum Speed 18,000 rpm Page 2992 Throttle Position Sensor: Description and Operation Throttle Position (TP) Sensor The throttle position (TP) sensor is a potentiometer connected to the throttle shaft on the throttle body. The PCM monitors the voltage on the signal line and calculates throttle position. As the throttle valve angle is changed (accelerator pedal moved), the TP sensor signal also changes. At a closed throttle position, the output of the TP1 sensor is low. As the throttle valve opens, the output increases so that at wide open throttle (WOT), the output voltage should be above 92 % (Tech 2 Display). The PCM calculates fuel delivery based on throttle valve angle (driver demand). A broken or loose TP sensor may cause intermittent bursts of fuel from an injector and unstable idle because the PCM thinks the throttle is moving. Page 6121 The wire insulation has one color or one color with another color stripe. The second color is the stripe. Page 1984 Powertrain Control Module: Description and Operation Circuit Operation The engine or powertrain control module (ECM or PCM) receives inputs from the engine sensors and switches, controlling the functions of the engine. It also turns on the malfunction indicator "check engine" light whenever a malfunction or abnormal engine performance is detected, and allows for diagnostic testing through the data link connector (DLC). Electrically Erasable Programmable Read Only Memory (EEPROM) Electrically Erasable Programmable Read Only Memory (EEPROM) The electrically erasable programmable read only memory (EEPROM) is a permanent memory chip that is physically soldered within the PCM. The EEPROM contains the program and the calibration information that the PCM needs to control powertrain operation. Unlike the PROM used in past applications, the EEPROM is not replaceable. If the PCM is replaced, the new PCM will need to be programmed. Equipment containing the correct program and calibration for the vehicle is required to program the PCM. PCM Components PCM Components The PCM is designed to maintain exhaust emission levels to government mandated standards while providing excellent driveability and fuel efficiency. The PCM monitors numerous engine and vehicle functions via electronic sensors such as the throttle position (TP) sensor, heated oxygen sensor (HO2S), and vehicle speed sensor (VSS). The PCM also controls certain engine operations through the following: - Fuel injector control - Ignition control module - ION sensing module - Automatic transmission shift functions - Cruise control - Evaporative emission (EVAP) purge - A/C clutch control PCM Function PCM Function The PCM supplies either 5 or 12 volts to power various sensors or switches. The power is supplied through resistances in the PCM which are so high in value that a test light will not light when connected to the circuit. In some cases, even an ordinary shop voltmeter will not give an accurate reading because its resistance is too low. Therefore, a digital voltmeter with at least 10 megohms input impedance is required to ensure accurate voltage readings. Tool J 39200 meets this requirement. The PCM controls output circuits such as the injectors, fan relays, etc., by controlling the ground or the power feed circuit through transistors or through either of the following two devices: - Output Driver Module (0DM) - Quad Driver Module (QDM) PCM Input/Outputs PCM Input/Outputs Inputs - Operating Conditions Read - Air Conditioning "ON" or "OFF" Page 2492 ^ Handle a CD by its edges; never touch the flat surfaces. Contamination from fingerprints, liquids, felt-tip pens, and labels can cause the CD to not play properly, or possibly jam in the drive. ^ When cleaning a disc, use a clean soft cloth. Wipe across the disc from the center to the outside. Do not wipe the disc in a circular motion. ^ A new CD may be rough on the inner and outer edges. The small plastic pieces causing this roughness can flake off and fall on the recording surface of the disc, causing skipping or other problems. Remove these pieces by rubbing the inner and outer edges with the side of a pencil or pen. ^ Various accessories are available to protect CDs and improve the sound quality of CDs. These accessories increase the thickness or diameter of the discs, and should not be used in CD changers. Disclaimer SRS Operation Air Bag(s) Arming and Disarming: Description and Operation SRS Operation The SRS is a safety device which, when used in conjunction with the seat belt, is designed to help protect the driver (and front passenger) in a frontal impact exceeding a certain set limit. The system consists of the SRS unit (including safing sensor and impact sensor), the cable reel, the driver's airbag (and front passenger's airbag). Operation The main circuit in the SRS unit senses and judges the force of impact and, if necessary, ignites the inflator charge(s). If battery voltage is too low or power is disconnected due to the impact, the voltage regulator and the back-up power circuit respectively will keep voltage at a constant level. For the SRS to operate: 1. The impact sensor must activate, and send electric signals to the microprocessor. 2. The microprocessor must compute the signals, and must send signals to the airbag inflator(s). 3. The inflator(s) must ignite and deploy the airbag(s). Self-diagnosis System A self-diagnosis circuit is built into the SRS unit; when the ignition switch is turned ON (II), the SRS indicator light comes on and goes off after about six seconds if the system is operating normally. If the light does not come on, or does not go off after six seconds, or if it comes on while driving, it indicates an abnormality in the system. The system must be inspected and repaired as soon as possible. For better serviceability, the memory will store the cause of the malfunction, and the data link circuit passes on the information from the memory to the data link connector (DLC). This information can be read with the Honda PGM Tester connected to the DLC (16P). Page 7521 The name of the component appears next to it followed by notes about its function along with any photo and connector view references. Connector "C" How to Identify Connector Terminals Cavity Numbering System The cavities (and wire terminals) in each connector are numbered starting from the upper left, looking at the male terminals from the terminal side (or looking at the female terminals from the wire side. Both views are in the same direction so the numbers are the same.) All actual cavities are numbered, even if they have no wire terminals in them. NOTE: Data Link Connector (DLC) terminals are numbered according to SAE standard J1962, not the Honda standard. The numbers of the four end terminals are molded into the corners of the connector face. Page 4483 Terminals - "T" Each "T" terminal (ring type) is numbered for reference and location. A "T" terminal is secured with a screw or bolt. Wires Page 3228 Steps 6 - 8 Page 7077 3. Remove the waterproof sheet. - Remove the waterproof sheet, taking special care so as not to break it. 4. Remove the hatchgate lock. - Disconnect the lock link and connector and remove the 3 fixing bolts. 5. Remove the key cylinder. - Disconnect the lock links. - Remove the key cylinder retaining clip with screw driver to remove the key cylinder. 6. Remove the hatchgate lock actuator assembly. - Disconnect the actuator harness connector. - Remove the 2 bolts holding hatchgate lock actuator assembly from inside. 7. Remove the outside handle. - Remove the 2 bolts holding the outside handle from inside. 8. Remove the tailgate lock assembly. - Remove the 3 screws holding the lock assembly. Installation To install, follow the removal steps in the reverse order, noting the following points: Specifications Pressure Plate: Specifications Pressure Plate Outside Diameter 332 mm Clamping Force 7208 N Spring Finger Height 49.9 - 51.9 mm Attaching Bolts 18 Nm Page 1437 - Set the camshaft marked "RE" and "LE into the exhaust side of the cylinder bank, with "RE" at the 12 o'clock position. Make sure the single timing dot on the camshaft gear aligns with the timing dot on the camshaft drive gear. 5. Install the left cylinder bank intake and exhaust camshafts: - Set the camshaft marked "LI" into the intake side of the head. Make sure the dual timing dots on the camshaft gear align with the timing dot on the camshaft drive gear. - Set the camshaft marked "LE" and "RE," into the exhaust side of the cylinder bank, with "LE" at the 12 o'clock position. Make sure the dual timing dots on the camshaft gear align with the timing dot on the camshaft drive gear. 6. Install the camshaft bearing caps in the same locations and directions they were before you removed them. NOTE: On the right cylinder bank, the directional arrows on the bearing caps should point towards the front of the engine. On the left bank, the arrows should point towards the rear of the engine. 7. Install the bearing cap bolts, then torque them to 10 N.m (7 lb-ft) in the sequence shown below. Page 4563 2. Connect one lead of a self-powered test light or DVOM to one end of the part of the circuit you want to test. 3. Connect the other lead to the other end. 4. If the self-powered test light glows, there is continuity. If you're using a DVOM, a low reading or no reading (zero), means good continuity. Testing For Voltage When testing for voltage at a connector without wire seals, you do not have to separate the two halves of the connector. Instead, probe the connector from the back. Always check both sides of the connector because dirty, corroded, and bent terminals can cause problems (no electrical contact = an open). 1. Connect one lead of the lest light to a known good ground, or, if you're using a digital volt ohmmeter (DVOM), place it in the appropriate DC volts range, and connect its negative lead to ground. 2. Connect the other lead of the test light or DVOM to the point you want to check. 3. If the test light glows, there is voltage present. If you're using a DVOM, note the voltage reading. It should be within one volt of measured battery voltage. A loss of more than one volt indicates a problem. NOTE: Always use a DVOM on high impedance circuits. A test light may not glow (even with battery voltage present). Testing For Voltage Drop Wires, connectors, and switches are designed to conduct current with a minimum loss of voltage. A voltage drop of more than one volt indicates a problem. 1. Place the digital volt/ohmmeter (DVOM) in the appropriate DC volts range. Connect the positive lead to the end of the wire (or to the connector or switch) closest to the battery. 2. Connect the negative lead to the other end of the wire (or the other side of the connector or switch). 3. Turn on the components in the circuit. 4. The DVOM will show the difference in voltage between the two points. A difference, or drop, of more than one volt indicates a problem. Check the circuit for loose, dirty, or bent terminals. Page 5182 Starter Motor: Service and Repair Inspection and Repair Repair or replace necessary parts if extreme wear or damage is found during inspection. Armature Measure the outer diameter of commutator, and replace with a new one if it is out of the limit. Standard: 33.0 mm (1.30 in) Limit: 32.0 mm (1.26 in) Check for continuity between commutator and segment. Replace commutator if there is no continuity (i.e., disconnected). Page 5574 it is located, and what it connects to. Use the Connector Views to help locate the proper cavity when you need to probe a connector. It can be especially helpful if the connector has more than one wire of the same color. A dash symbol (-) indicates that the cavity is empty. Connector views can also be used to help diagnose multiple symptoms in separate circuits which could be caused by a single problem in a connector shared by those circuits. Here's an example: 1. Pick one of the multiple symptoms and look up the schematic for that circuit. 2. Make a list of all the in-line and fuse box connectors in that schematic , 3. Then, in the Connector Views, look up each connector on your list to see if circuits related to the other symptoms run through one of them. If they do, inspect that connector for the problem. Example: The blower, rear window defogger, and the windshield wiper don't work. List all in-line and fuse box connectors in the blower controls circuit and then check the Connector View (see the sample). You find that C324 is common to the blower controls, rear window defogger, and wiper/washer, so you inspect C324 and find the problem, bent terminals. Finding Component/Connector Locations Finding Component/Connector Locations To see where a component or connector is located on the car, look up its photo number in the "Component Location". The photo will also tell you the color of the connector, and how many cavities it has. Page 7517 Each schematic represents one circuit. A circuit's wires and components are arranged to show current flow, from power at the top of the page, to ground, at the bottom. Shared Circuits Other circuits may share power or ground terminals or wiring with the circuit shown. A wire that connects one circuit to another, for example, is cut short and has an arrowhead at the end of it pointing in the direction of current flow. Next to the arrowhead is the name of the circuit or component which shares that wiring. To quickly check shared wiring, check the operation of a component it serves. If that component works, you know the shared wiring is OK. Connectors All in-line and junction connectors are numbered (C725, C416, etc.). Component connectors are not numbered but are identified either by the name of Page 8164 2. When installing the hatchgate glass, first attach the hinge to the hatchgate glass. Align the stud of the hinge to the hole at body while supporting the hatchgate glass with two people at indicated positions (1), and then partially tighten the hinge to body nut (2). After adjustment (refer to Adjustment) is completed, fully tighten the nut, hinge to body nut. Hatchgate hinge assembly for left and right sides from each other. 3. When installing gas stay assembly (1), first install the gas stay onto the rear quarter panel with fixing screw (2) and fastener (3) and then attach the gas stay upper end to the ball stud by spreading the retainer with screwdriver, etc. Gas stay assemblies for left and right sides differ from each other (The letter (4) L(LH) or R(RH) is embossed on the gas stay assembly.) 4. When installing hatchgate striker assembly, first partially tighten the fixing screw and close the hatchgate and tailgate. Then fully tighten the fixing screw with the condition that the striker fits the hatchgate lock assembly at the tailgate. Make sure that clearance exists between hatchgate striker and lock assembly. After installation, again make sure that the striker fits the lock assembly properly. 5. Tighten the nuts; hinge to body (LH and RH) Torque: 6 N.m (52 lb.in) 6. Tighten the screws: glass and hinge fix (LH and RH) Torque: 6 N.m (52 lb.in) NOTE: When installing the hinge to the body, exercise special care not to damage the body paint surface. 7. Tighten the hatchgate striker fixing screws. Torque: 6 N.m (52 lb.in) Vibration When Idling Engine Mount: Customer Interest Vibration When Idling 00-040 April 11, 2000 Applies To: 1998-99 Passport - ALL 2000 Passport-From VIN 4S6..58W.Y4400001 thru 4S6..58W.Y4400051 Vibration When Idling SYMPTOM Harsh vibration comes from the body, the steering wheel, the seats, or the floor when the transmission is in Drive with the engine idling. The vibration is worse when the engine is cold. Sometimes, you can hear banging while starting the engine. PROBABLE CAUSE The right engine mount cover hits the chassis side of the engine mount. CORRECTIVE ACTION Shift the engine assembly slightly forward using REPAIR PROCEDURE A. If the vibration is still there, replace the right engine mount cover using REPAIR PROCEDURE B. PARTS INFORMATION Engine Mount Cover: P/N 8-97241-056-0, H/C 6362701 WARRANTY CLAIM INFORMATION In warranty: The normal warranty applies. REPAIR PROCEDURE A Operation Number: 112010 Flat Rate Time: 0.2 hour Failed Part: P/N 8-97125-561-7 H/C 6360812 Detect Code: 045 Contention Code: B99 Template ID: 00-040A Skill Level: Repair Technician REPAIR PROCEDURE B Operation Number: 112125 Flat Rate Time: 1.5 hours Failed Part: P/N 8-97125-306-0 H/C 5508981 Defect Code: 045 Contention Code: B99 Template ID: 00-040B Skill Level: Repair Technician Out of warranty: Any repair performed after warranty expiration may be eligible for goodwill consideration by the District Service Manager or your Zone Office. You must request consideration, and get a decision, before starting work. REPAIR PROCEDURE A 1. Raise the vehicle on a lift. Page 1542 Page 3407 This means the branch of the wire connects to another circuit. The arrow points to the name of the circuit branch where the wire continues. Page 7522 The connector cavity number is listed next to each terminal on the circuit schematic. The cavity / terminal shown is # 6. Diodes A rectifier diode works like a one way valve. It allows current to flow only in the direction of the arrow. A Zener diode blocks reverse current at normal voltages just like a rectifier diode. At high voltages, however, a Zener diode allows current to flow in reverse. Fuses Page 5656 6. Remove nut and cotter pin then use remover J-36831. CAUTION: Be careful not to damage the ball joint boot. 7. Remove upper ball joint. 8. Remove bolt and plate. 9. Remove nut assembly. 10. Remove camber shims and note the positions and number of shims. 11. Remove caster shims and note the positions and number of shims. 12. Remove upper control arm assembly. 13. Remove nut. 14. Remove plate. 15. Remove bushing by using remover J-29755. 16. Remove fulcrum pin. INSPECTION AND REPAIR Make necessary parts replacement if wear, damage, corrosion or any other abnormal conditions are found through inspection. Check the following Page 6894 Liftgate Window Glass: Adjustments Rear Hatchgate Adjustment - Hatchgate alignment is obtained by moving hatchgate hinges. Page 3443 7. Modify the original APPS by cutting the connector housing off of the sensor. 8. Connect the 10P connector to the modified APPS connector housing. 9. Using a DVOM, check the voltage between the reference voltage pin for each sensor and ground. ^ If the sensor circuits all read 5.0 volts, go to step 11. ^ If any sensor circuit is above or below 5.0 volts, go to step 10. 10. Troubleshoot for an internal short in another sensor or a PCM malfunction. ^ To find the sensor with an internal short, monitor the incorrect reference voltage, and disconnect each sensor (FTPS, EGR, MAP, TPS, CKP, and CMP) one at a time until the reference voltage reads 5.0 volts. Replace that sensor, and repeat step 3. ^ To find a malfunctioning PCM, replace it with a known-good PCM. If all three sensors (APP Sensor 1, APP Sensor 2, and APP Sensor 3) are within range, the original PCM is faulty; replace it and repeat step 3. Page 5987 Each schematic represents one circuit. A circuit's wires and components are arranged to show current flow, from power at the top of the page, to ground, at the bottom. Shared Circuits Other circuits may share power or ground terminals or wiring with the circuit shown. A wire that connects one circuit to another, for example, is cut short and has an arrowhead at the end of it pointing in the direction of current flow. Next to the arrowhead is the name of the circuit or component which shares that wiring. To quickly check shared wiring, check the operation of a component it serves. If that component works, you know the shared wiring is OK. Connectors All in-line and junction connectors are numbered (C725, C416, etc.). Component connectors are not numbered but are identified either by the name of Page 4796 Hydraulic Control Assembly - Antilock Brakes: Service and Repair Removal and Installation HYDRAULIC CONTROL UNIT REMOVAL 1. Remove brake pipes. - After disconnecting brake pipe, cap or tape the openings of the brake pipe to prevent the entry of foreign matter. 2. Remove three brake fixing bolts. 3. Disconnect red clip from harness connector. 4. Remove harness connector. 5. Remove EHCU ASM. 6. Remove EHCU. INSTALLATION To install, follow the removal steps in the reverse order, noting the following points: Torque: Hydraulic unit fixing nuts: 22 Nm (16 ft. lbs.) Ground cable: 14 Nm (10 ft. lbs.) Brake pipe (joint bolts): 16 Nm (12 ft. lbs.) - After installing the hydraulic unit, bleed brakes completely. Page 5028 Vacuum Brake Booster: Service and Repair Vacuum Booster Overhaul Vacuum Booster The vacuum booster cannot be disassembled for repair. Replace a defective vacuum booster with a new one. Page 1317 V6 Engine Room Steering/Suspension - Vehicle Pulls Left/Right Alignment: Customer Interest Steering/Suspension - Vehicle Pulls Left/Right 06-068 May 2, 2009 Applies To: ALL *Vehicle Pulls or Drifts, and/or Steering Wheel Is Off-Center (Supersedes 06-068, Vehicle Pulling or Drifting, dated October 4, 2007, to revise the information marked by asterisks) (Replaces 90-011, Steering Wheel Off-Center Adjustment at PDI)* *REVISION SUMMARY The title description was revised.* SYMPTOM While driving on a straight road, the vehicle pulls or drifts to the right or left. BACKGROUND New tools were developed to help you diagnose and correct a pulling and/or steering wheel off-center issue. There is a diagnosis worksheet included to take on your test-drive and record your findings. These values are used to build the 15-digit DTC (diagnostic trouble code) that is required for your warranty claim. The last step in each repair procedure helps you create the correct code. In the rare case that you have to repair a vehicle that pulls and has the steering wheel off-center, use REPAIR PROCEDURE B to file your warranty claim. For more information, refer to Training Module SSC 44 - Steering Drift or Pull Interactive Service Bulletin. PROBABLE CAUSES Several conditions can cause the vehicle to pull or drift: ^ Wheel alignment ^ Tires ^ Off-center steering wheel (no pulling or drifting, but a customer may believe this is the case) CORRECTIVE ACTION Diagnose the problem using the special tools and the worksheet on page 4 that guides you to one of four repair procedures. TOOL INFORMATION Centering Tape (enough to diagnose 240 vehicles): T/N O7AAJ-001A300 Steering Drift Set Level: T/N 07AAJ-00100 Steering Drift Set: T/N O7MJ-001A140 Replacement Weight for Steering Drift Set: T/N 07AAJ-001A400 WARRANTY CLAIM INFORMATION In warranty: The normal warranty applies. Failed Part: P/N 53560-SDA-AO1 H/C 7139652 Page 4353 Drive/Propeller Shaft: Description and Operation GENERAL DESCRIPTION PROPELLER SHAFT Torque is transmitted from the transmission to the front axle through one propeller shaft and universal joint assembles. All propeller shafts are the balanced tubular type. A splined slip joint is provided in some drivelines. Since the propeller shaft is total balanced carefully, welding or any other modification are not permitted. - Alignment marks should be applied to each propeller shaft before removal. - Be sure vehicle is stopped, engine is not running, brake is secured and vehicle is secured to prevent injury. - Be careful not to grip the propeller shaft tube too tightly in the vise as this will be cause deformation. PHASING The propeller shaft is designed and built with the yoke lugs (ears) in line with each other. This design produces the smoothest running shaft possible, called phasing. Vibration can be caused by an out-of-phase propeller shaft. The propeller shaft will absorb vibrations from speeding up and slowing down each time the universal joint goes around. This vibration would be the same as a person snapping rope and watching the "wave" reaction flow to the end. A propeller shaft working in phase would be similar to two persons snapping a rope at the same time, and watching the "waves" meet and Page 6937 Radiator Grille Front Door Window Track: Service and Repair Front Door Front Window Regulator, Glass and Glass Run Removal 1. Disconnect the battery ground cable. 2. Remove the power window switch/regulator handle. - Pry out the power window switch and remove the connectors - To remove the regulator handle (1), remove the clip (2) at the root of the handle by using wire with hook. Page 7153 9. Disconnect the harness connector for the resin top (Left side, behind the luggage side trim). - Remove the canopy cover (1), the luggage side lid (2) and luggage side upper cover (3). Then pull out the harness and disconnect the connector. 10. Remove the resin top assembly. - Remove the two fixing bolts each and nut each from the left and right sides, then lift the resin top up and off. Installation To install, follow the removal steps in the reverse order, noting the following points. 1. Removing and mounting the resin top should always be performed by two persons. 2. Tighten the resin top fixing bolts and nuts to the specified torque. Torque: 15 Nm (11 lb.ft) Page 6354 The SRS consists of the Sensing and Diagnostic Module (SDM), the driver air bag assembly, the SRS coil assembly, the passenger air bag assembly, and the "AIR BAG" warning lamp in the instrument cluster. The SDM, SRS coil assembly (driver side only), driver air bag assembly, passenger air bag assembly and connector wire make up the deployment loops. The function of the deployment loops is to supply current through air bag assembly, which will cause deployment of the air bags in the event of a frontal crash of sufficient force, up to 30 degrees off the centerline of the vehicle. The air bag assemblies are only supplied enough current to deploy when the SDM detects vehicle velocity changes severe enough to warrant deployment. The SDM contains a sensing device which converts vehicle velocity change to an electrical signal. The electrical signal generated is processed by the SDM and then compared to a value stored in memory. When the generated signal exceeds the stored value, the SDM will cause current to flow through the air bag assembly deploying the air bags. Page 6732 the component if the component only has one connector, or by a capital letter (A, B, C, etc.) if the component has more than one connector. Below most connector numbers and component names are PHOTO and VIEW numbers. The PHOTO number refers to a photo in the back of the book that shows the connector's location on the car. The VIEW number refers to an illustration in the back of the book that shows the connector face, wire colors, connector cavity numbers, and other details. The connector cavity numbering sequence begins at the top left corner of the connector. Disregard any numbers molded into the connector housing. Wires Wires are identified by the abbreviated names of their colors; the second color is the color of the stripe. Wires are also identified by their location in a connector. The number "2" next to the male and female wire terminals at C416, for example, means those terminals join in cavity 2 of connector C416. Symbols A complete description of schematic symbols is given under wire color abbreviation. Power Distribution Schematics Power Distribution schematics show how power is supplied from the positive battery terminal to various circuits in the car. Refer to the Power Distribution section to get a more detailed picture of how power is supplied to the circuit you're working on. From Battery to Ignition Switch, Fuses, and Relays Individual circuit schematics begin with a fuse. The first half of Power Distribution, however, shows the wiring "upstream" between the battery Page 7253 Power Door Lock Switch: Diagrams Page 5069 Part 2 of 2 B-24 Wheel Speed Input Abnormality (DTC 65/C0238) Page 6883 To install, follow the removal steps in the reverse order noting the following points: 1. Set the position of installing the engine hood lock assembly(4). - Install the buffers (3) to the body. - Adjust the buffers as the position of the engine hood (1) is 2 mm (0.08 in) to the fender panel (2). 2. Fix the engine hood lock assembly. - Tighten the hood lock assembly fixing bolts under condition 1 to the specified torque. Torque: 10 N.m (87 lb.in) 3. Adjust the appearance quality. (Engine hood and fender panel) - By buffers, adjust the difference of the height of engine hood is 0 ± 0.5 mm (0 ± 0.02 in) to the fender. (Turn the buffers approx. one revolution and move the position of buffers upward.) 4. Reroute the control cable to its original position, and check and see if the lock assembly and control lever work normally. Page 1954 If there is no photo number below or beside a component name or a connector, ground, or terminal number, look up that name or number in the appropriate Connector Identification Chart. The chart lists how many cavities a connector has, where it's located, and what it connects to. The related illustration shows the connector's location on the harness, and the harness routing. NOTE: Photos listed by number are located at Locations / Components / Photograohs. See: Locations/Component Locations/Photographs Circuit Schematics Page 1915 6. Working from under the vehicle, unplug the 3P connector from the crankshaft position sensor. 7. Remove the crankshaft position sensor (one flange bolt). 8. Remove the crankshaft position sensor harness clamp from the engine (one flange nut). 9. Models With A/T: Remove the front and rear clamps for the ATF cooler lines. 10. Support the engine with a block of wood and a powertrain lift or commercially available jack as shown. Page 745 it is located, and what it connects to. Use the Connector Views to help locate the proper cavity when you need to probe a connector. It can be especially helpful if the connector has more than one wire of the same color. A dash symbol (-) indicates that the cavity is empty. Connector views can also be used to help diagnose multiple symptoms in separate circuits which could be caused by a single problem in a connector shared by those circuits. Here's an example: 1. Pick one of the multiple symptoms and look up the schematic for that circuit. 2. Make a list of all the in-line and fuse box connectors in that schematic , 3. Then, in the Connector Views, look up each connector on your list to see if circuits related to the other symptoms run through one of them. If they do, inspect that connector for the problem. Example: The blower, rear window defogger, and the windshield wiper don't work. List all in-line and fuse box connectors in the blower controls circuit and then check the Connector View (see the sample). You find that C324 is common to the blower controls, rear window defogger, and wiper/washer, so you inspect C324 and find the problem, bent terminals. Finding Component/Connector Locations Finding Component/Connector Locations To see where a component or connector is located on the car, look up its photo number in the "Component Location". The photo will also tell you the color of the connector, and how many cavities it has. Page 2672 the component if the component only has one connector, or by a capital letter (A, B, C, etc.) if the component has more than one connector. Below most connector numbers and component names are PHOTO and VIEW numbers. The PHOTO number refers to a photo in the back of the book that shows the connector's location on the car. The VIEW number refers to an illustration in the back of the book that shows the connector face, wire colors, connector cavity numbers, and other details. The connector cavity numbering sequence begins at the top left corner of the connector. Disregard any numbers molded into the connector housing. Wires Wires are identified by the abbreviated names of their colors; the second color is the color of the stripe. Wires are also identified by their location in a connector. The number "2" next to the male and female wire terminals at C416, for example, means those terminals join in cavity 2 of connector C416. Symbols A complete description of schematic symbols is given under wire color abbreviation. Power Distribution Schematics Power Distribution schematics show how power is supplied from the positive battery terminal to various circuits in the car. Refer to the Power Distribution section to get a more detailed picture of how power is supplied to the circuit you're working on. From Battery to Ignition Switch, Fuses, and Relays Individual circuit schematics begin with a fuse. The first half of Power Distribution, however, shows the wiring "upstream" between the battery Page 6147 Ground - "G" Shielding Sheilding This represents RFI (Radio Frequency Interference) shielding around a wire. The shielding is always connected to ground. Splices Page 6633 Page 6353 Air Bag(s) Arming and Disarming: Description and Operation General Description General Description Restraint Devices The Supplemental Restraint System (SRS) helps supplement the protection offered by the driver and front passenger seat belts by deploying an air bag from the center of the steering wheel and from the top of the right side of the instrument panel. The air bag deploys when the vehicle is involved in a frontal crash of sufficient force up to 30 degrees off the centerline of the vehicle; To further absorb the crash energy there is a knee bolster located beneath the instrument panel for both the driver and passenger, and the steering column is collapsible. Page 2644 Powertrain Control Module: Description and Operation PCM Components PCM Components The PCM is designed to maintain exhaust emission levels to government mandated standards while providing excellent driveability and fuel efficiency. The PCM monitors numerous engine and vehicle functions via electronic sensors such as the throttle position (TP) sensor, heated oxygen sensor (HO2S), and vehicle speed sensor (VSS). The PCM also controls certain engine operations through the following: - Fuel injector control - Ignition control module - ION sensing module - Automatic transmission shift functions - Cruise control - Evaporative emission (EVAP) purge - A/C clutch control Page 8022 Wire Color Abbreviations The following abbreviations are used to identify wire colors in the circuit schematics: WHT................................... White YEL................................... Yellow BLK................................... Black BLU................................... Blue GRN................................... Green RED................................... Red ORN................................... Orange PNK................................... Pink BRN................................... Brown GRY................................... Gray PUR................................... Purple LT BLU................................... Light Blue LT GRN................................... Light Green Page 2853 1. Install the MAF sensor on the air cleaner with the clamp. 2. Install the intake air duct and the clamp on the MAF sensor. 3. Tighten the clamps to secure the MAF sensor to the intake air duct and the air cleaner. 4. Connect the MAF electrical connector. 5. Connect the negative battery cable. Page 6374 This sample Ground Distribution schematic shows all of the components that share two ground points. Components A solid border line means the entire component is shown. A broken border line indicates that only part of the component is shown. Page 1770 Ignition Cable: Testing and Inspection Spark Plug Cables NOTE: Never puncture the spark plug cable's insulation with a needle or the pointed end of a probe into the cable. An increase in resistance would be created which would cause the cable to become defective. 1. If the cable has broken or cracked insulation, it must be replaced. 2. If the terminals are corroded or loose, the cable must be replaced. 3. Check that the cable resistance does not exceed 10 kOHM per foot. Page 179 Test Equipment CAUTION: Most circuits include solid-state devices. Test the voltages in these circuits only with a 10-megaohm or higher impedance digital multimeter. Never use a test light or analog meter on circuits that contain solid-state devices. Damage to the devices may result. Test Light and DVOM On circuits without solid-state devices, use a test light to check for voltage. A test light is made up of a 12 volt bulb with a pair of leads attached. After grounding one lead, touch the other lead to various points along the circuit where voltage should be present. The bulb will go on if there is voltage at the point being tested. If you need to know how much voltage is present, use a digital volt/ohmmeter (DVOM). Self-Powered Test Light and DVOM Use a self-powered test light to check for continuity. This tool is made up of a light bulb, battery, and two leads. To test it, touch the leads together: the light should go on. Use a self-powered test light only on an unpowered circuit. First, disconnect the battery, or remove the fuse that feeds the circuit you are working on. Select two points in the circuit between which you want to check continuity. Connect one lead of the self-powered test light to each point. If there is continuity, the test light's circuit will be completed, and the light will go on. If, in addition, you need to know exactly how much resistance there is between two points, use a digital volt/ohmmeter (DVOM). In the "OHMS" range, the DVOM will measure resistance between two points along a circuit. Low resistance means good continuity. Diodes and solid-state devices in a circuit can make a DVOM give a false reading. To check a reading, reverse the leads, and take a second reading. If the readings differ, the component is affecting the measurement. Jumper Wire Use a jumper wire to bypass an open circuit. A jumper wire is made up of an in-line fuse holder connected to a set of test leads. It should have a five ampere fuse. Never connect a jumper wire across a short circuit. The direct battery short will blow the fuse. Short Finder (Short Circuit Locator) Short finders are available to locate shorts to ground. The short finder creates a pulsing magnetic field in the shorted circuit which you can follow to the location of the short. To order any test equipment shown above, contact your local tool supplier. For a list of suppliers and tool numbers, refer to Honda Required Special Tools and Equipment Service Bulletin. Page 1381 Specifications Brake Fluid: Specifications Fluid Type DOT 3 or 4 Page 299 Wires Wire insulation can be one color, or one color with another color stripe. (The second color is the stripe.) This circuit continues on another image. (The arrow shows direction of current flow.) To follow the RED/BLK wire in this example, you would turn to "Fuel and Emissions" and look for the "A" arrow. Page 5928 Air Door Actuator / Motor: Diagnostic Aids Before Troubleshooting Before Troubleshooting See: Service Precautions/Vehicle Damage Warnings/Tips and Precautions 1. Check applicable fuses in the appropriate fuse/relay box. 2. Check the battery for damage, state of charge, and clean and tight connections. CAUTION: Do not quick-charge a battery unless the battery ground cable has been disconnected, otherwise you will damage the alternator diodes. - Do not attempt to crank the engine with the battery ground cable loosely connected or you will severely damage the wiring. While You're Working 1. Make sure connectors are clean, and have no loose terminals or receptacles. 2. Make sure that connectors without wire seals are packed with dielectric (silicone) grease. Part Number: 08798-9001. 3. When connecting a connector, push it until it "clicks" into place. CAUTION: Do not pull on the wires when disconnecting a connector. Pull only on the connector housings. - Most circuits include solid-state devices. Test the voltages in these circuits only with a 10-megaohm or higher impedance digital multi meter. Never use a test light or analog meter on circuits that contain solid-state devices. Damage to the devices may result. Five-Step Troubleshooting 1. Verify The Complaint Turn on all the components in the problem circuit to check the accuracy of the customer complaint. Note the symptoms. Do not begin disassembly or testing until you have narrowed down the problem area. 2. Analyze The Schematic Look up the schematic for the problem circuit. Determine how the circuit is supposed to work by tracing the current paths from the power source through the circuit components to ground. Also, trace circuits that share wiring with the problem circuit. The names of circuits that share the same fuse, ground, or switch, and so on, are referred to in each circuit schematic. Try to operate any shared circuits you didn't check in step 1. If the shared circuits work, the shared wiring is OK, and the cause must be in the wiring used only by the problem circuit. If several circuits fail at the same time, the fuse or ground is a likely cause. Based on the symptoms and your understanding of the circuit's operation, identify one or more possible causes. 3. Isolate The Problem By Testing The Circuit Make circuit tests to check the diagnosis you made in step 2. Keep in mind that a logical, simple procedure is the key to efficient troubleshooting. Test for the most likely cause of failure first. Try to make tests at points that are easily accessible. 4. Fix The Problem Once the specific problem is identified, make the repair. Be sure to use proper tools and safe procedures. 5. Make Sure The Circuit Works Turn on all components in the repaired circuit in all modes to make sure you've fixed the entire problem. If the problem was a blown fuse, be sure to test all of the circuits on that fuse. Make sure no new problems turn up and the original problem does not recur. Page 1509 - Push the ring by the piston, at a right angle to the wall, into the point at which the cylinder bore diameter is the smallest. - Measure the ring end gap. - Positioning mark (1) is painted as shown in the illustration. Marked T: No.1 Compression ring Marked T2: No.2 Compression ring 2. Measure the clearance between the piston ring groove and the piston ring with a feeler gauge. If the piston ring groove/piston ring clearance exceeds the specified limit, the piston must be replaced. Compression Ring Clearance Standard: 0.025 mm - 0.065 mm (0.0006 inch - 0.0015 inch) Limit: 0.1mm (0.0059 inch) Piston Pin Note: Do not reuse the old piston pin. 1. Use a micrometer to measure the new piston pin outside diameter in both directions at three different positions. Page 1865 Gradually increase the water temperature. Stir the water so that the entire water is same temperature. Confirm the temperature when the valve first begins to open. Valve opening temperature 74.5 ° C - 78.5° C (166.1° F - 173.3° F) Confirm the temperature when the valve is fully opened. Valve full open temperature and lift more than 8.5 mm (0.33 inch) at 90° C (194° F) Make necessary repair and parts replacement if extreme wear or damage is found during inspection. Installation 1. Install thermostat into the outlet pipe (4) making sure that the air hole is in the up position. 2. Install thermostat housing and tighten bolts to the specified torque. Torque: 25 Nm (18 ft. lbs.) 3. Installation rubber hose. 4. Replenish Engine Coolant (EC). 5. Start engine and check for coolant leakage. Page 8073 and the fuses. From Fuses to Relays and Components The second half of Power Distribution shows the wiring "From Fuses to Relays and Components." This can speed your troubleshooting by showing which circuits share fuses. If Power Distribution shows that an inoperative circuit and another circuit share a fuse, check a component in the other circuit. If it works, you know the fuse is good and power is available to the inoperative circuit. Ground Distribution Schematics Page 5858 Spare Tire Hanger - Parts Locations Locations Page 4284 2. Connect the short finder across the battery terminals and the load (component) side of the fuse terminal. 3. Close all switches in the circuit you're testing. 4. Turn on the short finder. This creates a pulsing magnetic field around the wiring between the fuse box and the short. 5. Beginning at the fuse box, slowly move the short finder along the circuit wiring. The meter will read current pulses through sheet metal and body trim. As long as the meter is between the fuse and the short, the needle will move with each current pulse. Once you move the meter past the point of the short, the needle will stop moving. Check the wiring and connectors in this area to locate the cause of the short. Testing For Continuity When testing for continuity at a connector without wire seals, you do not have to separate the two halves of the connector. Instead, probe the connector from the back. Always check both sides of the connector because dirty, corroded, and bent terminals can cause problems (no electrical contact = an open). 1. Disconnect the negative cable from the car battery. If you're using a DVOM, place it in the lowest "OHMS" range. Page 3582 If there is no photo number below or beside a component name or a connector, ground, or terminal number, look up that name or number in the appropriate Connector Identification Chart. The chart lists how many cavities a connector has, where it's located, and what it connects to. The related illustration shows the connector's location on the harness, and the harness routing. NOTE: Photos listed by number are located at Locations / Components / Photograohs. See: Locations/Component Locations/Photographs Circuit Schematics Page 2226 The connector cavity number is listed next to each terminal on the circuit schematic. The cavity / terminal shown is # 6. Diodes A rectifier diode works like a one way valve. It allows current to flow only in the direction of the arrow. A Zener diode blocks reverse current at normal voltages just like a rectifier diode. At high voltages, however, a Zener diode allows current to flow in reverse. Fuses Page 6779 Test Equipment CAUTION: Most circuits include solid-state devices. Test the voltages in these circuits only with a 10-megaohm or higher impedance digital multimeter. Never use a test light or analog meter on circuits that contain solid-state devices. Damage to the devices may result. Test Light and DVOM On circuits without solid-state devices, use a test light to check for voltage. A test light is made up of a 12 volt bulb with a pair of leads attached. After grounding one lead, touch the other lead to various points along the circuit where voltage should be present. The bulb will go on if there is voltage at the point being tested. If you need to know how much voltage is present, use a digital volt/ohmmeter (DVOM). Self-Powered Test Light and DVOM Use a self-powered test light to check for continuity. This tool is made up of a light bulb, battery, and two leads. To test it, touch the leads together: the light should go on. Use a self-powered test light only on an unpowered circuit. First, disconnect the battery, or remove the fuse that feeds the circuit you are working on. Select two points in the circuit between which you want to check continuity. Connect one lead of the self-powered test light to each point. If there is continuity, the test light's circuit will be completed, and the light will go on. If, in addition, you need to know exactly how much resistance there is between two points, use a digital volt/ohmmeter (DVOM). In the "OHMS" range, the DVOM will measure resistance between two points along a circuit. Low resistance means good continuity. Diodes and solid-state devices in a circuit can make a DVOM give a false reading. To check a reading, reverse the leads, and take a second reading. If the readings differ, the component is affecting the measurement. Jumper Wire Use a jumper wire to bypass an open circuit. A jumper wire is made up of an in-line fuse holder connected to a set of test leads. It should have a five ampere fuse. Never connect a jumper wire across a short circuit. The direct battery short will blow the fuse. Short Finder (Short Circuit Locator) Short finders are available to locate shorts to ground. The short finder creates a pulsing magnetic field in the shorted circuit which you can follow to the location of the short. To order any test equipment shown above, contact your local tool supplier. For a list of suppliers and tool numbers, refer to Honda Required Special Tools and Equipment Service Bulletin. Page 1212 Fluid - Transfer Case: Fluid Type Specifications Transfer Case Fluid Transfer (4WD) .................................................................................................................................... ............................................................ SAE 5W-30 Shift On The Fly System: Type ..................................................................................................................................................... ...................................................... GL-5 GearLube* Viscosity: Below 50° F (10° C) Front ................................................................................................................... ............................................................................... SAE 75W-90 synthetic Rear ................................ .............................................................................................................................................................. ........... SAE 80 or 80W-90 From 0° F to 90° F (-18° C to 32° C) Front .......................................................................................... ........................................................................................................ SAE 75W-90 synthetic Rear ....... .............................................................................................................................................................. .................................... SAE 90 or 80W-90 Above 50° F (10° C) consistently Front ............................................................................................... ...................................................................................... SAE 80W-90 or SAE 80W-140 Rear ............ .............................................................................................................................................................. ............................................... SAE 140 Safety Stop Switch Sunroof/Moonroof Limit Switch: Service and Repair Safety Stop Switch Removal 1. Disconnect the battery ground cable. 2. Remove the sunroof drive unit assembly (1) to remove the safety stop switch (2). Installation To install, follow the removal steps in the reverse order Page 757 This means the branch of the wire connects to another circuit. The arrow points to the name of the circuit branch where the wire continues. Page 5032 Service and Repair Case: Service and Repair For further information regarding this component and the system that it is a part of, please refer to Transfer Case; Service and Repair; Unit Overhaul Page 5773 WARRANTY CLAIM INFORMATION INSPECTION PROCEDURE NOTE: Do this inspection on both sides of the vehicle. 1. Raise the vehicle on a lift. To allow enough clearance for the inspection, make sure the rear lifting points are at least 12 inches (300 mm) ahead of the rear trailing link front mounting brackets. 2. Visually inspect the lower trailing link front bracket area at the red circle in the photo below: ^ If the vehicle's bracket area is rusted to a similar or lesser degree than that in the photo, go to STAGE 1 REPAIR. ^ If the vehicle's bracket area is rusted to a greater degree than that in the photo, go to the next step. ^ * If the vehicle had a prior repair resulting in a modification to the lower trailing link front brackets, stop the inspection, call Tech Line to open a case, then take photos of the area, and send them to Tech Line.* 3. If the vehicle has side steps or running boards, remove them. 4. Use a 3/16 in. x 9 in. flat punch and a 12-16-oz. hammer to strike the frame areas marked X in the illustration below. Swing the hammer with a 10 to 12 inch stroke to be sure enough force is applied to the punch. Fan Control Lever (Fan Switch) Blower Motor Switch: Testing and Inspection Fan Control Lever (Fan Switch) 1. Check for continuity between the terminals of the fan switch. Engine - Oil Recommendation GF-4 Standard Engine Oil: Technical Service Bulletins Engine - Oil Recommendation GF-4 Standard SOURCE: Honda Service News TITLE: Use ONLY New GF-4 Standard Engine Oil APPLIES TO: All Models SERVICE TIP: There's a new performance standard for engine oil: GF-4. It was jointly developed by automotive and oil experts, and it represents a significant performance upgrade and improvement in fuel economy. GF-4 engine oils must pass grueling tests totaling over 500 hours. On top of this, Honda Genuine engine oils are also tested to ensure specific compatibility with Honda vehicles. GF-4 engine oil is compatible with all current and earlier model year Honda cars and trucks. It also provides these added benefits: - Improved oxidation resistance (reduced thickening of the oil) - Improved deposit protection and better wear protection - Better low-temperature performance over the life of the oil - Environmental protection by extending the life of emissions systems While Honda has upgraded its engine oil to GF-4, other brands may not yet be at this new standard. Keep in mind you must use Honda Genuine engine oil for all warranty repairs. If you use some other brand of oil for non-warranty repairs, make sure that oil meets the GF-4 standard. We recommend you stop using non-GF-4 engine oils and check with your supplier that you're purchasing GF-4 oil. Engine oil produced after April 1, 2005, that meets the GF-4 standard, must post this starburst certification mark on the container. Always look for this mark; some oil container labels won't specifically refer to GF-4. Page 8068 Distinct Of Circuit By Wire Base Color All wires have color-coded insulation. Wires belonging to a system's main harness will have a single color. Wires belonging to a system's sub-circuits will have a colored stripe. Striped wires use the codes found in the chart to show wire size and colors. Abbreviations are used to indicate wire color within a circuit diagram. How to Identify Connector Terminals How to Identify Connector Terminals Cavity Numbering System The cavities (and wire terminals) in each connector are numbered starting from the upper left, looking at the male terminals from the terminal side (or looking at the female terminals from the wire side. Both views are in the same direction so the numbers are the same.) All actual cavities are numbered, even if they have no wire terminals in them. NOTE: Data Link Connector (DLC) terminals are numbered according to SAE standard J1962, not the Honda standard. The numbers of the four end terminals are molded into the corners of the connector face. The connector cavity number is listed next to each terminal on the circuit schematic. The cavity / terminal shown is # 6. Using/Identifying Connector Terminal Views How to Use Connector Terminal Views To see the configuration of a connector's cavities, look up its view number in the Connector Views. Each view includes the color of the connector, where Page 4566 Part 2 Of 3 Page 1119 5. Place the tensioner pusher in a soft-jawed vise, then slowly compress the tensioner pusher pin until it lines up with the two small holes in the tensioner pusher housing. 6. Insert a straightened heavy duty paper clip through the holes in the housing. This will hold the pin in its compressed position. NOTE: A new tensioner pusher comes with its pin held compressed by a special wire. If you install a new tensioner pusher, save the wire for future use. 7. Install the tensioner pusher: - Install the lower bolt loosely. - Push the tensioner pusher up against the tensioner pulley, then install the upper bolt, and torque it to 25 N.m (15 lb-ft). - Torque the lower bolt to 25 N.m (15 lb-ft). 8. Remove the wire or paper clip from the tensioner pusher, and remove the binder clips from the camshaft pulleys. 9. Verify the timing belt is correctly installed: - Rotate the crankshaft three complete turns. - Align the crankshaft timing pulley notch with the mark on the oil pump housing. - Check the green marks on both camshaft pulleys; they should line up with the valve cover timing marks. Page 4743 Transmission Position Switch/Sensor: Description and Operation Transmission Range Switch IMPORTANT: The vehicle should not be driven with the transmission range switch disconnected; idle quality will be affected. The four inputs from the transmission range switch indicate to the PCM which position is selected by the transmission selector lever. This information is used for ignition timing, EVAP canister purge, EGR operation. For more information on the transmission on the transmission range switch, refer to Transmission Control System Diagnosis. See: Testing and Inspection Page 205 The name of the component appears next to it followed by notes about its function along with any photo and connector view references. Connector "C" How to Identify Connector Terminals Cavity Numbering System The cavities (and wire terminals) in each connector are numbered starting from the upper left, looking at the male terminals from the terminal side (or looking at the female terminals from the wire side. Both views are in the same direction so the numbers are the same.) All actual cavities are numbered, even if they have no wire terminals in them. NOTE: Data Link Connector (DLC) terminals are numbered according to SAE standard J1962, not the Honda standard. The numbers of the four end terminals are molded into the corners of the connector face. Page 5992 The connector cavity number is listed next to each terminal on the circuit schematic. The cavity / terminal shown is # 6. Diodes A rectifier diode works like a one way valve. It allows current to flow only in the direction of the arrow. A Zener diode blocks reverse current at normal voltages just like a rectifier diode. At high voltages, however, a Zener diode allows current to flow in reverse. Fuses Page 5753 inspection of the entire underside of the vehicle must be completed and any damage and/or modifications to the frame must be noted to determine if the campaign service remedy can or should be completed. ^ Contact Tech Line to open a case: - Inform them of any relevant information that may affect the completion of the repair. - Provide photos of the lower trailing link bracket area Via e-mail to Tech Line. (Include the VIN and the Tech Line reference number in the subject title of the e-mail.) - Based on your information, Tech Line will determine the vehicle's eligibility for completing a STAGE 4 repair or, if the a vehicle had a modification to the lower trailing link bracket area, determine the repair level needed. If any issues preventing completion of the repair, or any new evidence is learned during the repair that will prevent completion, contact Tech Line to report your findings. ^ Type B reinforcement brackets used in a STAGE 4 REPAIR require holes to be drilled in specific areas of the frame (inboard and outboard sides). Prior to receiving the brackets for a repair, match the locations of these holes to the frame in the illustrations below; this will help you to determine if the brackets can be installed. Photos of the inboard and outboard frame areas will show the feasibility of the installation and must be provided to Tech Line.* ^ This repair includes removing and reinstalling the fuel tank assembly, fuel lines, and vent lines. Take normal precautions during removal, storage, and reinstallation of these parts. Make sure to do this repair in a well vented area, away from any ignition sources. ^ This repair involves raising the body off the frame and cutting the original rear trailing link front mounting brackets off the frame rails. To avoid permanent frame damage that would make the vehicle unrepaired, carefully follow all of the steps. If you are unfamiliar with this type of repair, sublet it to a qualified body/frame repair shop. ^ If needed, refer to the appropriate Passport Service Manual for any steps not fully detailed. ^ Do this repair on both sides of the vehicle. 1. Remove the radiator grille. 2. Remove the linear EGR valve. 3. Remove the rear bumper assembly. 4. Remove the exhaust silencer (muffler). 5. Remove the fuel tank assembly: ^ Disconnect the fuel line at the fuel filter and the fuel return hoses. Page 7834 2. Connect one lead of a self-powered test light or DVOM to one end of the part of the circuit you want to test. 3. Connect the other lead to the other end. 4. If the self-powered test light glows, there is continuity. If you're using a DVOM, a low reading or no reading (zero), means good continuity. Testing For Voltage When testing for voltage at a connector without wire seals, you do not have to separate the two halves of the connector. Instead, probe the connector from the back. Always check both sides of the connector because dirty, corroded, and bent terminals can cause problems (no electrical contact = an open). 1. Connect one lead of the lest light to a known good ground, or, if you're using a digital volt ohmmeter (DVOM), place it in the appropriate DC volts range, and connect its negative lead to ground. 2. Connect the other lead of the test light or DVOM to the point you want to check. 3. If the test light glows, there is voltage present. If you're using a DVOM, note the voltage reading. It should be within one volt of measured battery voltage. A loss of more than one volt indicates a problem. NOTE: Always use a DVOM on high impedance circuits. A test light may not glow (even with battery voltage present). Testing For Voltage Drop Wires, connectors, and switches are designed to conduct current with a minimum loss of voltage. A voltage drop of more than one volt indicates a problem. 1. Place the digital volt/ohmmeter (DVOM) in the appropriate DC volts range. Connect the positive lead to the end of the wire (or to the connector or switch) closest to the battery. 2. Connect the negative lead to the other end of the wire (or the other side of the connector or switch). 3. Turn on the components in the circuit. 4. The DVOM will show the difference in voltage between the two points. A difference, or drop, of more than one volt indicates a problem. Check the circuit for loose, dirty, or bent terminals. Service and Repair Transmission Temperature Sensor/Switch: Service and Repair REMOVAL 1. Raise the vehicle and support it on jack stands. 2. Disconnect battery ground cable. 3. Drain fluid. 4. Remove sixteen 10 mm adapter case oil pan fixing screws, adapter case oil pan, and gasket. 5. Disconnect wiring harness from shift solenoid, band apply solenoid, and 7 pin connector of main case. Pull only on connectors, not on wiring harness. 6. Remove wiring harness assembly with transmission oil temperature sensor. INSTALLATION 1. Install wiring harness from shift solenoid, band apply solenoid, and 7 pin connector of main case. 2. Install oil pan gasket, oil pan and sixteen 10 mm fixing screws. Tighten the screws to the specified torque. Torque: 11 Nm (96 Ft. lbs.) 3. Fill transmission through the overfill screw hole of oil pan, using ATF DEXRON III. 4. Connect battery ground cable. Locations Manifold Pressure/Vacuum Sensor: Locations 24. Top Rear of Engine Top Rear Of Engine Page 6821 1. Install the regulator handle as shown in the figure, if equipped without Dower windows. 2. Check to see that the window regulator operates smoothly and the glass opens and closes properly. 3. Install the waterproof sheet tightly against the door panel. Page 5304 Wire Color Abbreviations The following abbreviations are used to identify wire colors in the circuit schematics: WHT................................... White YEL................................... Yellow BLK................................... Black BLU................................... Blue GRN................................... Green RED................................... Red ORN................................... Orange PNK................................... Pink BRN................................... Brown GRY................................... Gray PUR................................... Purple LT BLU................................... Light Blue LT GRN................................... Light Green Page 91 V6 Engine Room Page 922 Page 7680 2. Connect the short finder across the battery terminals and the load (component) side of the fuse terminal. 3. Close all switches in the circuit you're testing. 4. Turn on the short finder. This creates a pulsing magnetic field around the wiring between the fuse box and the short. 5. Beginning at the fuse box, slowly move the short finder along the circuit wiring. The meter will read current pulses through sheet metal and body trim. As long as the meter is between the fuse and the short, the needle will move with each current pulse. Once you move the meter past the point of the short, the needle will stop moving. Check the wiring and connectors in this area to locate the cause of the short. Testing For Continuity When testing for continuity at a connector without wire seals, you do not have to separate the two halves of the connector. Instead, probe the connector from the back. Always check both sides of the connector because dirty, corroded, and bent terminals can cause problems (no electrical contact = an open). 1. Disconnect the negative cable from the car battery. If you're using a DVOM, place it in the lowest "OHMS" range. Page 7752 the component if the component only has one connector, or by a capital letter (A, B, C, etc.) if the component has more than one connector. Below most connector numbers and component names are PHOTO and VIEW numbers. The PHOTO number refers to a photo in the back of the book that shows the connector's location on the car. The VIEW number refers to an illustration in the back of the book that shows the connector face, wire colors, connector cavity numbers, and other details. The connector cavity numbering sequence begins at the top left corner of the connector. Disregard any numbers molded into the connector housing. Wires Wires are identified by the abbreviated names of their colors; the second color is the color of the stripe. Wires are also identified by their location in a connector. The number "2" next to the male and female wire terminals at C416, for example, means those terminals join in cavity 2 of connector C416. Symbols A complete description of schematic symbols is given under wire color abbreviation. Power Distribution Schematics Power Distribution schematics show how power is supplied from the positive battery terminal to various circuits in the car. Refer to the Power Distribution section to get a more detailed picture of how power is supplied to the circuit you're working on. From Battery to Ignition Switch, Fuses, and Relays Individual circuit schematics begin with a fuse. The first half of Power Distribution, however, shows the wiring "upstream" between the battery Page 7036 Rear Door Lock Assembly Page 5985 it is located, and what it connects to. Use the Connector Views to help locate the proper cavity when you need to probe a connector. It can be especially helpful if the connector has more than one wire of the same color. A dash symbol (-) indicates that the cavity is empty. Connector views can also be used to help diagnose multiple symptoms in separate circuits which could be caused by a single problem in a connector shared by those circuits. Here's an example: 1. Pick one of the multiple symptoms and look up the schematic for that circuit. 2. Make a list of all the in-line and fuse box connectors in that schematic , 3. Then, in the Connector Views, look up each connector on your list to see if circuits related to the other symptoms run through one of them. If they do, inspect that connector for the problem. Example: The blower, rear window defogger, and the windshield wiper don't work. List all in-line and fuse box connectors in the blower controls circuit and then check the Connector View (see the sample). You find that C324 is common to the blower controls, rear window defogger, and wiper/washer, so you inspect C324 and find the problem, bent terminals. Finding Component/Connector Locations Finding Component/Connector Locations To see where a component or connector is located on the car, look up its photo number in the "Component Location". The photo will also tell you the color of the connector, and how many cavities it has. Page 7018 Front Door Trim Panel And Associated Parts Removal and Installation Hose/Line HVAC: Service and Repair Removal and Installation Removal 1. Disconnect the battery ground cable. 2. Discharge and recover refrigerant. 3. Remove radiator grille. 4. Remove clip and clamp. 5. Disconnect liquid line (High-pressure pipe). 6. Disconnect suction line (Low-pressure pipe) using a back-up wrench. 7. Disconnect suction line (Low-pressure hose) using a back-up wrench. 8. Disconnect discharge line (High-pressure hose) using a back-up wrench. - Use a backup wrench when disconnecting and reconnecting the refrigerant lines. - When removing the refrigerant line connecting part, the connecting part should immediately be plugged or capped to prevent foreign matter from being mixed into the line. Installation To install, follow the removal steps in the reverse order, noting the following point: 1. O-rings cannot be reused. Always replace with new ones. 2. Be sure to apply new compressor oil to the O-ring when connecting lines. 3. Tighten the refrigerant line to the specified torque. Refer to Main Data and Specifications for Torque Specifications. Page 5178 placing a metallic part near armature. 15. Remove dust cover(17). 16. Remove a dust cover and shift lever(16) from the gear case. 17. Remove ball bearing(19). 18. Remove bearing cover(20). 19. Remove a ball bearing and bearing cover from the gear case(18). 20. Internal gear(21). A/T - Avoiding Fluid Contamination Fluid - CVT: Technical Service Bulletins A/T - Avoiding Fluid Contamination SOURCE: Honda Service News TITLE: Avoiding Comebacks From A/T Contamination APPLIES TO: All models SERVICE TIP: Installing a reman A/T? Here are some important tips to keep in mind to ensure a first-time fix and to avoid any come-backs: - If the vehicle has an ATF cooler, make sure you clean the cooler with the ATF Cooler Cleaner (P/N GHTTTCF6H). See S/B 89-022, ATF Cooler Cleaner, for details. - If the reman A/T kit includes an in-line filter, don't forget to install it. If the vehicle already has an in-line filter from an earlier A/T replacement, then remove the existing filter, and install the new one. - Spray the driveshaft splines with solvent and compressed air before installing them in the reman A/T. If the failed A/T had a speed sensor, make sure it's clean before you install it. Debris from the failed A/T can catch in the driveshaft splines or on the speed sensor and contaminate the reman A/T. - If the reman A/T comes with a heater/cooler, make sure you install the reman A/T with that heater/cooler. Never install the heater/cooler from the failed A/T; you could contaminate the reman A/T. Locations Page 5354 4. Remove the fuel pressure regulator from the fuel rail. 5. Remove the fuel return line from the regulator. 6. Install the new fuel pressure regulator in the reverse order of removal. 7. Use the Smart Cable to reprogram the PCM with the latest software from the June 2001 or later HONDANET CD-ROM. Refer to Service Bulletin 99-005, Updating the Passport PCM, filed under Tools. 8. Use the PGM Tester to clear any DTCs. 9. Use the PGM Tester to check the broadcast code. Make sure the broadcast code matches the one you selected from the CD-ROM. WARRANTY CLAIM INFORMATION In warranty: The normal warranty applies. Failed Part: P/N 8-17113-398-0 H/C 5504386 Defect Code: 092 Contention Code: C99 Skill Level: Repair Technician Out of warranty: Any repair performed after warranty expiration may be eligible for goodwill consideration by the District Service Manager or your Zone Office. You must request consideration, and get a decision, before starting work. REPAIR PROCEDURE - POWER STEERING SWITCH 1. Drain the power steering fluid out of the system. 2. Remove the power steering fluid reservoir. Clean the reservoir with solvent, then with soap and water. Rinse and dry it thoroughly. 3. Reinstall the reservoir. Do not connect the return hose. 4. Remove the power steering pressure switch, then clean it with brake cleaner and a scraper. Reinstall the switch, and torque it to 20 N.m (14 lb-ft). 5. Cover the unconnected end of the reservoir with your finger, then fill the reservoir with Dexron III ATF Page 7644 Testing For A Short With A Self-Powered Test Light or DVOM 1. Remove the blown fuse and disconnect the battery and load. 2. Connect one lead of a self-powered test light or digital volt/ohmmeter (DVOM) (switched to the lowest "OHMS" range) to the fuse terminal on the load side. 3. Connect the other lead to a known good ground. 4. Beginning near the fuse box, wiggle the harness. Continue this at convenient points about six inches apart while watching the test light or DVOM. 5. If the self-powered test light goes on or the DVOM displays a low reading or no reading (zero), there is a short to ground in the wiring near that point. Testing for a Short with a Test Light or DVOM 1. Remove the blown fuse and disconnect the load. 2. Connect a test light or digital volt/ohmmeter (DVOM), switched to the appropriate DC volts range, across the fuse terminals to make sure voltage is present. You might have to turn the ignition switch to ON; check the schematic to see. 3. Beginning near the fuse box, wiggle the harness. Continue this at convenient points about six inches apart while watching the test light or DVOM. 4. Where the test light goes , or the DVOM voltage drops to zero, there is a short to ground in the wiring near that point. NOTE: Always use a DVOM on high impedance circuits. A test light may not glow (even with battery voltage present). Testing For A Short With A Short Circuit Locator (Short Finder) 1. Remove the blown fuse. Leave the battery connected. Page 1727 5. Place the tensioner pusher in a soft-jawed vise, then slowly compress the tensioner pusher pin until it lines up with the two small holes in the tensioner pusher housing. 6. Insert a straightened heavy duty paper clip through the holes in the housing. This will hold the pin in its compressed position. NOTE: A new tensioner pusher comes with its pin held compressed by a special wire. If you install a new tensioner pusher, save the wire for future use. 7. Install the tensioner pusher: - Install the lower bolt loosely. - Push the tensioner pusher up against the tensioner pulley, then install the upper bolt, and torque it to 25 N.m (15 lb-ft). - Torque the lower bolt to 25 N.m (15 lb-ft). 8. Remove the wire or paper clip from the tensioner pusher, and remove the binder clips from the camshaft pulleys. 9. Verify the timing belt is correctly installed: - Rotate the crankshaft three complete turns. - Align the crankshaft timing pulley notch with the mark on the oil pump housing. - Check the green marks on both camshaft pulleys; they should line up with the valve cover timing marks. Page 7667 This sample Ground Distribution schematic shows all of the components that share two ground points. Components A solid border line means the entire component is shown. A broken border line indicates that only part of the component is shown. Page 5765 Page 7595 the component if the component only has one connector, or by a capital letter (A, B, C, etc.) if the component has more than one connector. Below most connector numbers and component names are PHOTO and VIEW numbers. The PHOTO number refers to a photo in the back of the book that shows the connector's location on the car. The VIEW number refers to an illustration in the back of the book that shows the connector face, wire colors, connector cavity numbers, and other details. The connector cavity numbering sequence begins at the top left corner of the connector. Disregard any numbers molded into the connector housing. Wires Wires are identified by the abbreviated names of their colors; the second color is the color of the stripe. Wires are also identified by their location in a connector. The number "2" next to the male and female wire terminals at C416, for example, means those terminals join in cavity 2 of connector C416. Symbols A complete description of schematic symbols is given under wire color abbreviation. Power Distribution Schematics Power Distribution schematics show how power is supplied from the positive battery terminal to various circuits in the car. Refer to the Power Distribution section to get a more detailed picture of how power is supplied to the circuit you're working on. From Battery to Ignition Switch, Fuses, and Relays Individual circuit schematics begin with a fuse. The first half of Power Distribution, however, shows the wiring "upstream" between the battery Page 2994 Throttle Position Sensor: Service and Repair REMOVAL PROCEDURE 1. Disconnect the negative battery cable. 2. Disconnect the TPS electrical connector. 3. Remove the bolts and the TP sensor from the throttle body. NOTE: Do not clean the TP sensor by soaking it in solvent. The sensor will be damaged as a result. INSTALLATION PROCEDURE 1. Install the TP sensor on the throttle body with the bolts. 2. Connect the TP electrical connector. 3. Install the negative battery cable. Engine Controls - High/Erratic Engine Idle Power Steering Pressure Switch: Customer Interest Engine Controls - High/Erratic Engine Idle 01-080 August 14, 2001 Applies To: 2000-02 Passport - ALL 2000-02 Passport: High or Erratic Idle SYMPTOM The engine occasionally idles at too high a speed, or the idle speed fluctuates. PROBABLE CAUSES The symptom could be the result of any of these conditions: ^ Loose or corroded engine or body ground ^ High resistance in the APPS ground circuit ^ PSP (power steering pressure) switch is internally shorted to ground ^ Fuel pressure regulator is leaking fuel into the intake manifold CORRECTIVE ACTION Diagnose the cause of the idle condition, and select the proper REPAIR PROCEDURE. PARTS INFORMATION REQUIRED MATERIALS REQUIRED SOFTWARE Each REPAIR PROCEDURE requires you to use the Smart Cable to reprogram the PCM with the latest software. To select the latest software from the CDROM, enter the year, model, engine, transmission, and emissions type (49-state or California). This gives you a list of broadcast codes. Select the broadcast code at the top of the list. WARRANTY CLAIM INFORMATION Refer to the Warranty Claim Information for each Repair Procedure. DIAGNOSIS 1. Find out from the customer when the high or erratic idle condition occurs and what the RPM range is: ^ Within 20 minutes of a cold start ^ After braking to a stop ^ All the time ^ Intermittently, with no set pattern Page 3883 Engine Controls - Engine Spark Knock Or Pinging Powertrain Control Module: All Technical Service Bulletins Engine Controls - Engine Spark Knock Or Pinging 01-084 June 19, 2009 Applies To: 2000-02 Passport - ALL Engine Spark Knock (Pinging) (Supersedes 01-084, dated March 18, 2003, to revise the information marked by asterisks) *REVISION SUMMARY Under WARRANTY CLAIM INFORMATION, the failed part number, the Honda code, the defect code, and the symptom code have been updated.* SYMPTOM An engine spark knock (pinging). PROBABLE CAUSE The programmed ignition timing does not correct quickly enough in some climates. CORRECTIVE ACTION Update the PCM software with the Smart Cable. TOOL INFORMATION PGM Tester with software update release SN200P (9/1/01) or later. For the other tools and equipment you need to update the PCM software, refer to Service Bulletin 99-005, Updathg the Passport POM, filed under Tools. WARRANTY CLAIM INFORMATION In warranty: The normal warranty applies. Operation Number: 125517 Flat Rate Time: 0.3 hour *Failed Part: P/N 8-12212-079-0 H/C 6974992 Defect Code: 03214 Symptom Code: 09117* Template ID: 01-084A Skill Level: Repair Technician Out of warranty: Any repair performed after warranty expiration may be eligible for goodwill consideration by the District Parts and Service Manager or your Zone Office. You must request consideration, and get a decision, before starting work. REPAIR PROCEDURE 1. Retrieve the PCM broadcast code with the PGM Tester or the Smart Cable (refer to Service Bulletin 99-005, Updathg the Passport PCM). Page 4209 Distinct Of Circuit By Wire Base Color All wires have color-coded insulation. Wires belonging to a system's main harness will have a single color. Wires belonging to a system's sub-circuits will have a colored stripe. Striped wires use the codes found in the chart to show wire size and colors. Abbreviations are used to indicate wire color within a circuit diagram. How to Identify Connector Terminals How to Identify Connector Terminals Cavity Numbering System The cavities (and wire terminals) in each connector are numbered starting from the upper left, looking at the male terminals from the terminal side (or looking at the female terminals from the wire side. Both views are in the same direction so the numbers are the same.) All actual cavities are numbered, even if they have no wire terminals in them. NOTE: Data Link Connector (DLC) terminals are numbered according to SAE standard J1962, not the Honda standard. The numbers of the four end terminals are molded into the corners of the connector face. The connector cavity number is listed next to each terminal on the circuit schematic. The cavity / terminal shown is # 6. Using/Identifying Connector Terminal Views How to Use Connector Terminal Views To see the configuration of a connector's cavities, look up its view number in the Connector Views. Each view includes the color of the connector, where Page 3778 Gear Sensor/Switch: Testing and Inspection TRANSFER POSITION SWITCH 1. With ball being free. A-B: There is continuity. 2. With ball forced into the switch. A-B: No continuity. 3. If 1) and 2) fail, replace with a new switch. Page 6703 Speaker: Service and Repair Rear Speaker Removal 1. Disconnect the battery ground cable. 2. Remove the roof rear lining (1). - Release the locks and clips. 3. Remove the speaker (2). - Remove the four screws. - Disconnect the connector (3). Installation To install, follow the removal steps in the reverse order, noting the following point: Locations Shift Interlock Relay: Locations Under Center Console Page 4107 Transmission Speed Sensor: Locations Top Of Transfer Case Page 5623 1. Install steering wheel by aligning the setting marks made when removing. CAUTION: Never apply force to the steering wheel in direction of the shaft by using a hammer or other impact tools in an attempt to remove the steering wheel. The steering shaft is designed as an energy absorbing unit. 2. Tighten the steering wheel fixing nut to the specified torque. Torque: 34 Nm (25 ft. lbs.) 3. Connect horn lead. 4. Support the module and carefully connect the SRS connector. NOTE: Pass the lead wire through the tabs on the plastic cover (wire protector) of inflator to prevent lead wire from being pinched. 5. Tighten bolts to specified torque. Torque: 9 Nm (78 inch lbs.) 6. Connect the yellow 2-way SRS connector located under the steering column. 7. Connect the battery "-" terminal cable. 8. Turn the ignition switch to "ON" while watching warning light. Light should flash 7 times and then go off. Page 1430 Uneven wear: 0.05 mm (0.0020 inch) 3. Place the camshaft on V-blocks. Slowly rotate the camshaft and measure the runout with a dial indicator. Replace the camshaft if the runout exceeds the specified limit. Run out Limit: 0.1 mm (0.0039 inch) 4. Measure the camshaft journal oil clearance. 1. Measure the camshaft bracket housing inside diameter. NOTE: Tighten camshaft bracket (2) to specified torque before measuring the camshaft bracket inside diameter. Torque: 10 Nm (89 inch lbs.) 2. Subtract the camshaft outside diameter from the camshaft bracket housing inside diameter. Oil Clearance Standard: 0.027 mm - 0.078 mm (0.0011 inch - 0.0031 inch) Page 7594 Each schematic represents one circuit. A circuit's wires and components are arranged to show current flow, from power at the top of the page, to ground, at the bottom. Shared Circuits Other circuits may share power or ground terminals or wiring with the circuit shown. A wire that connects one circuit to another, for example, is cut short and has an arrowhead at the end of it pointing in the direction of current flow. Next to the arrowhead is the name of the circuit or component which shares that wiring. To quickly check shared wiring, check the operation of a component it serves. If that component works, you know the shared wiring is OK. Connectors All in-line and junction connectors are numbered (C725, C416, etc.). Component connectors are not numbered but are identified either by the name of Locations Crankshaft Position Sensor: Locations CKP Sensor 36. Bottom Right Side of Engine Bottom Right Side of Engine Page 6581 Keyless Entry Module: Service and Repair Anti-Theft & Keyless Entry Controller Removal 1. Disconnect the battery ground cable. 2. Remove the glove box from the instrument panel assembly (1). - Refer to the Instrument Panel Assembly in Body Structure section. 3. Remove the anti-theft & keyless entry controller (2). - Disconnect the connector. Remove two fixing screws. Installation To install, follow the removal steps in the reverse order. Locations Main Relay (Computer/Fuel System): Locations 9. Fuse/Relay Box (Cover Removed) Fuse/Relay Box (Cover Removed) Diagram Information and Instructions Vehicle Speed Sensor: Diagram Information and Instructions How to Identify Wiring Color-Coded Insulation Wire Color Wire Color Coding Page 7420 2. Connect the short finder across the battery terminals and the load (component) side of the fuse terminal. 3. Close all switches in the circuit you're testing. 4. Turn on the short finder. This creates a pulsing magnetic field around the wiring between the fuse box and the short. 5. Beginning at the fuse box, slowly move the short finder along the circuit wiring. The meter will read current pulses through sheet metal and body trim. As long as the meter is between the fuse and the short, the needle will move with each current pulse. Once you move the meter past the point of the short, the needle will stop moving. Check the wiring and connectors in this area to locate the cause of the short. Testing For Continuity When testing for continuity at a connector without wire seals, you do not have to separate the two halves of the connector. Instead, probe the connector from the back. Always check both sides of the connector because dirty, corroded, and bent terminals can cause problems (no electrical contact = an open). 1. Disconnect the negative cable from the car battery. If you're using a DVOM, place it in the lowest "OHMS" range. Page 5188 Yoke Assembly Check a magnet inside the yoke. Replace the yoke assembly if it is broken. Ball Bearing Clamp the inner race of the ball bearing with your finger, and check for sticking or play when rotating the outer race. Replace, if abnormality is found. Diagrams Camshaft: Diagrams Camshaft and Associated Parts Page 3167 Accelerator Pedal Position Sensor: Adjustments Accelerator Position Sensor Adjustment AP sensor is controlled three multiple control system, and adjust the idle position and WOT position are between A and B for AP sensor 1, AP sensor 2, and AP sensor 3. Refer to "How to adjust for AP sensor". How To Adjust For AP Sensor 1. Connect the Tech 2 to DLC on vehicle. 2. Ignition "ON," engine "OFF". 3. Display the APS date list. Check the following item for AP position (%). 4. If the problem was found, adjust as necessary. Page 3557 The name of the component appears next to it followed by notes about its function along with any photo and connector view references. Connector "C" How to Identify Connector Terminals Cavity Numbering System The cavities (and wire terminals) in each connector are numbered starting from the upper left, looking at the male terminals from the terminal side (or looking at the female terminals from the wire side. Both views are in the same direction so the numbers are the same.) All actual cavities are numbered, even if they have no wire terminals in them. NOTE: Data Link Connector (DLC) terminals are numbered according to SAE standard J1962, not the Honda standard. The numbers of the four end terminals are molded into the corners of the connector face. Page 7391 Test Equipment CAUTION: Most circuits include solid-state devices. Test the voltages in these circuits only with a 10-megaohm or higher impedance digital multimeter. Never use a test light or analog meter on circuits that contain solid-state devices. Damage to the devices may result. Test Light and DVOM On circuits without solid-state devices, use a test light to check for voltage. A test light is made up of a 12 volt bulb with a pair of leads attached. After grounding one lead, touch the other lead to various points along the circuit where voltage should be present. The bulb will go on if there is voltage at the point being tested. If you need to know how much voltage is present, use a digital volt/ohmmeter (DVOM). Self-Powered Test Light and DVOM Use a self-powered test light to check for continuity. This tool is made up of a light bulb, battery, and two leads. To test it, touch the leads together: the light should go on. Use a self-powered test light only on an unpowered circuit. First, disconnect the battery, or remove the fuse that feeds the circuit you are working on. Select two points in the circuit between which you want to check continuity. Connect one lead of the self-powered test light to each point. If there is continuity, the test light's circuit will be completed, and the light will go on. If, in addition, you need to know exactly how much resistance there is between two points, use a digital volt/ohmmeter (DVOM). In the "OHMS" range, the DVOM will measure resistance between two points along a circuit. Low resistance means good continuity. Diodes and solid-state devices in a circuit can make a DVOM give a false reading. To check a reading, reverse the leads, and take a second reading. If the readings differ, the component is affecting the measurement. Jumper Wire Use a jumper wire to bypass an open circuit. A jumper wire is made up of an in-line fuse holder connected to a set of test leads. It should have a five ampere fuse. Never connect a jumper wire across a short circuit. The direct battery short will blow the fuse. Short Finder (Short Circuit Locator) Short finders are available to locate shorts to ground. The short finder creates a pulsing magnetic field in the shorted circuit which you can follow to the location of the short. To order any test equipment shown above, contact your local tool supplier. For a list of suppliers and tool numbers, refer to Honda Required Special Tools and Equipment Service Bulletin. Page 5147 Ignition Switch Lock Cylinder: Service and Repair REMOVAL 1. Turn the steering wheel so that the vehicle's wheels are pointing straight ahead. 2. Turn the ignition switch to "LOCK". 3. Disconnect the battery "-" terminal cable, and wait at least 5 minutes. 4. Disconnect the yellow 2-way SRS connector located under the steering column. CAUTION: The wheels of the vehicle must be straight ahead and the steering column in the "LOCK" position before disconnecting the steering wheel. Failure to do so will cause the coil assembly to become uncentered which will cause damage to the coil assembly. 5. Remove the engine hood opening lever and steering lower cover. 6. Remove knee bolster (reinforcement). Page 47 Condenser Fan Motor Relay: Testing and Inspection 1. Disconnect relays and check for continuity and resistance between relay terminals. - For handling of these relays, refer to Heater Relay. Page 962 To install, follow the removal steps in the reverse order. Rear-Left and Right Sides Removal 1. Disconnect the battery ground cable. 2. Remove the rear door trim pad (2). - Disconnect the rear power window switch (1) connector. 3. Remove the rear power window switch (1). - Remove the switch fixing screw from the back side of the rear door trim (2). Installation To install, follow the removal steps in the reverse order. Page 3058 Canister Purge Solenoid: Description and Operation EVAP Canister Purge Solenoid Normally closed, the purge solenoid opens upon the PCM's signal to allow engine vacuum to purge gasoline fumes from the canister. Mounted on the water pipe to front of the engine assembly. Page 6127 Locations Page 2563 Each schematic represents one circuit. A circuit's wires and components are arranged to show current flow, from power at the top of the page, to ground, at the bottom. Shared Circuits Other circuits may share power or ground terminals or wiring with the circuit shown. A wire that connects one circuit to another, for example, is cut short and has an arrowhead at the end of it pointing in the direction of current flow. Next to the arrowhead is the name of the circuit or component which shares that wiring. To quickly check shared wiring, check the operation of a component it serves. If that component works, you know the shared wiring is OK. Connectors All in-line and junction connectors are numbered (C725, C416, etc.). Component connectors are not numbered but are identified either by the name of Page 485 Distinct Of Circuit By Wire Base Color All wires have color-coded insulation. Wires belonging to a system's main harness will have a single color. Wires belonging to a system's sub-circuits will have a colored stripe. Striped wires use the codes found in the chart to show wire size and colors. Abbreviations are used to indicate wire color within a circuit diagram. How to Identify Connector Terminals How to Identify Connector Terminals Cavity Numbering System The cavities (and wire terminals) in each connector are numbered starting from the upper left, looking at the male terminals from the terminal side (or looking at the female terminals from the wire side. Both views are in the same direction so the numbers are the same.) All actual cavities are numbered, even if they have no wire terminals in them. NOTE: Data Link Connector (DLC) terminals are numbered according to SAE standard J1962, not the Honda standard. The numbers of the four end terminals are molded into the corners of the connector face. The connector cavity number is listed next to each terminal on the circuit schematic. The cavity / terminal shown is # 6. Using/Identifying Connector Terminal Views How to Use Connector Terminal Views To see the configuration of a connector's cavities, look up its view number in the Connector Views. Each view includes the color of the connector, where Page 4850 Distinct Of Circuit By Wire Base Color All wires have color-coded insulation. Wires belonging to a system's main harness will have a single color. Wires belonging to a system's sub-circuits will have a colored stripe. Striped wires use the codes found in the chart to show wire size and colors. Abbreviations are used to indicate wire color within a circuit diagram. How to Identify Connector Terminals How to Identify Connector Terminals Cavity Numbering System The cavities (and wire terminals) in each connector are numbered starting from the upper left, looking at the male terminals from the terminal side (or looking at the female terminals from the wire side. Both views are in the same direction so the numbers are the same.) All actual cavities are numbered, even if they have no wire terminals in them. NOTE: Data Link Connector (DLC) terminals are numbered according to SAE standard J1962, not the Honda standard. The numbers of the four end terminals are molded into the corners of the connector face. The connector cavity number is listed next to each terminal on the circuit schematic. The cavity / terminal shown is # 6. Using/Identifying Connector Terminal Views How to Use Connector Terminal Views To see the configuration of a connector's cavities, look up its view number in the Connector Views. Each view includes the color of the connector, where Page 4550 The name of the component appears next to it followed by notes about its function along with any photo and connector view references. Connector "C" How to Identify Connector Terminals Cavity Numbering System The cavities (and wire terminals) in each connector are numbered starting from the upper left, looking at the male terminals from the terminal side (or looking at the female terminals from the wire side. Both views are in the same direction so the numbers are the same.) All actual cavities are numbered, even if they have no wire terminals in them. NOTE: Data Link Connector (DLC) terminals are numbered according to SAE standard J1962, not the Honda standard. The numbers of the four end terminals are molded into the corners of the connector face. Specifications Water Pump: Specifications Water Pump Bolts 25 Nm Engine Coolant Pump Centrifugal Impeller Type Page 5704 Suspension Control Module: Service and Repair Page 3402 The connector cavity number is listed next to each terminal on the circuit schematic. The cavity / terminal shown is # 6. Diodes A rectifier diode works like a one way valve. It allows current to flow only in the direction of the arrow. A Zener diode blocks reverse current at normal voltages just like a rectifier diode. At high voltages, however, a Zener diode allows current to flow in reverse. Fuses Page 3373 Test Equipment CAUTION: Most circuits include solid-state devices. Test the voltages in these circuits only with a 10-megaohm or higher impedance digital multimeter. Never use a test light or analog meter on circuits that contain solid-state devices. Damage to the devices may result. Test Light and DVOM On circuits without solid-state devices, use a test light to check for voltage. A test light is made up of a 12 volt bulb with a pair of leads attached. After grounding one lead, touch the other lead to various points along the circuit where voltage should be present. The bulb will go on if there is voltage at the point being tested. If you need to know how much voltage is present, use a digital volt/ohmmeter (DVOM). Self-Powered Test Light and DVOM Use a self-powered test light to check for continuity. This tool is made up of a light bulb, battery, and two leads. To test it, touch the leads together: the light should go on. Use a self-powered test light only on an unpowered circuit. First, disconnect the battery, or remove the fuse that feeds the circuit you are working on. Select two points in the circuit between which you want to check continuity. Connect one lead of the self-powered test light to each point. If there is continuity, the test light's circuit will be completed, and the light will go on. If, in addition, you need to know exactly how much resistance there is between two points, use a digital volt/ohmmeter (DVOM). In the "OHMS" range, the DVOM will measure resistance between two points along a circuit. Low resistance means good continuity. Diodes and solid-state devices in a circuit can make a DVOM give a false reading. To check a reading, reverse the leads, and take a second reading. If the readings differ, the component is affecting the measurement. Jumper Wire Use a jumper wire to bypass an open circuit. A jumper wire is made up of an in-line fuse holder connected to a set of test leads. It should have a five ampere fuse. Never connect a jumper wire across a short circuit. The direct battery short will blow the fuse. Short Finder (Short Circuit Locator) Short finders are available to locate shorts to ground. The short finder creates a pulsing magnetic field in the shorted circuit which you can follow to the location of the short. To order any test equipment shown above, contact your local tool supplier. For a list of suppliers and tool numbers, refer to Honda Required Special Tools and Equipment Service Bulletin. Page 7118 In warranty: American Honda will reimburse for this repair only under these conditions: ^ It is done during PDI ^ No more than 30 days have elapsed since the vehicle was received at the dealership (according to the date noted on the motor carrier's bill of lading) Operation number: 812355 Flat rate time: 1.0 hour Failed P/N: PDI-PAINT, H/C 3173994 *Defect code: 08103 Symptom code 08811* Skill level: Repair Technician *NOTE: When submitting the claim, make sure you enter the vehicle's date of receipt in the customer contention comment section. The claim will be rejected without this information.* REPAIR PROCEDURE 1. Wash and dry the vehicle out of direct sunlight. 2. Tear off a piece of clay. Shape the piece with your hands into a flat disk about 3 inches in diameter. 3. Spray a 2-to 3-square-foot area of the affected panel with the manufacturer's lubricant. 4. Clean a 1-square-foot section of the sprayed area by rubbing it with the clay. Page 2682 Wire Color Abbreviations The following abbreviations are used to identify wire colors in the circuit schematics: WHT................................... White YEL................................... Yellow BLK................................... Black BLU................................... Blue GRN................................... Green RED................................... Red ORN................................... Orange PNK................................... Pink BRN................................... Brown GRY................................... Gray PUR................................... Purple LT BLU................................... Light Blue LT GRN................................... Light Green Specifications Service and Repair Torque Converter Clutch Solenoid: Service and Repair REMOVAL 1. Raise the vehicle and support it on jack stands. 2. Disconnect battery ground cable. 3. Drain fluid. 4. Remove twelve 10 mm adapter case oil pan fixing screws, adapter case oil pan, and gasket. NOTE: Oil pan still contains transmission fluid. Place a large drain container under the oil pan. Drain the fluid carefully. 5. Disconnect wiring harness from force motor solenoid and converter clutch solenoid. Pull only on connectors, not on wiring harness. 6. Remove seven 13 mm screws from adapter case valve body assembly, then remove transfer plate, two gaskets, and adapter case valve body. INSTALLATION 1. Inspect electrical 4 pin connector and seal of adapter case. Replace if necessary. 2. Install gasket, transfer plate, and gasket. 3. Install adapter case valve body and seven 13 mm screws. Tighten the screws to the specified torque. Torque: 20 Nm (15 Ft. lbs.) 4. Connect wiring harness assembly to converter clutch solenoid and force motor. 5. Install oil pan gasket, oil pan, and twelve 10 mm screws. Tighten the screws to the specified torque. Torque: 11 Nm (96 Ft. lbs.) 6. Fill transmission through the overfill screw hole of oil pan, using ATF DEXRON III. 7. Connect battery ground cable. Page 600 14. While watching the APP Sensor values in the Engine Data List, adjust the APPS by turning it until the values are within the ranges shown at closed throttle and wide open throttle (accelerator pedal pushed all the way down), then tighten the mounting screws and recheck the values. ^ If all three sensors are within range, go to step 23. ^ If APP Sensor 1 APP Sensor 2, and/or APP Sensor 3 cannot be brought into range, go to step 15. 15. Troubleshoot for an open circuit or a PCM malfunction. ^ If APP Sensor 1 has a value of 0% or APP Sensor 2 and/or APP Sensor 3 have a value of 99%, an open circuit exists or the PCM is malfunctioning. Repair the circuit or replace the PCM, and repeat step 14. ^ If you don't find a problem, go to step 16. 16. Disconnect the 10 P connector from the APPS. 17. View the APP Sensor values in the Engine Data List. ^ If APP Sensor 1 has a value of 0% or APP Sensor 2 and/or APP Sensor 3 have a value of 99%, go to step 18. ^ If APP Sensor 1 has a value other than 0%, or APP Sensor 2 and/or APP Sensor 3 have a value other than 99%, a short circuit exists or the PCM is malfunctioning. Repair the circuit or replace the PCM, and repeat step 14. 18. Modify the original APPS by cutting the connector housing off of the sensor. 19. Connect the 10 P connector to the modified APPS connector housing. Page 206 The connector cavity number is listed next to each terminal on the circuit schematic. The cavity / terminal shown is # 6. Diodes A rectifier diode works like a one way valve. It allows current to flow only in the direction of the arrow. A Zener diode blocks reverse current at normal voltages just like a rectifier diode. At high voltages, however, a Zener diode allows current to flow in reverse. Fuses Page 236 7. Reconnect three connector to Powertrain Control Module (PCM). (Y22SE 2.2L Engine only) 8. Install the center console. 9. Install the transfer shift lever knob. 10. Install the dressing panel around the radio and reconnect cigar lighter harness. 11. Enable the SRS. Specifications Receiver Dryer: Specifications Main Data And Specifications Main Data And Specifications RECEIVER/DRIER Type Assembly includes sight glass with dual (triple) pressure switch (V6) or pressure sensor (L4) Internal volume 300 cc (10 fl.oz.) Page 8242 Wiper Switch: Service and Repair Rear Wiper and Washer Switch Removal 1. Disconnect the battery ground cable. 2. Remove the dash side trim panel (1). 3. Remove the lower cover assembly (2). 4. Remove the meter cluster assembly (4). 5. Remove the rear wiper & washer switch (5). - Disconnect the connector. - Push the lock from the back side of the meter cluster assembly. Installation To install, follow the removal steps in the reverse order, noting the following point: 1. Push the switch with your fingers until it locks securely. Page 141 Powertrain Control Module: Description and Operation Electrically Erasable Programmable Read Only Memory (EEPROM) Electrically Erasable Programmable Read Only Memory (EEPROM) The electrically erasable programmable read only memory (EEPROM) is a permanent memory chip that is physically soldered within the PCM. The EEPROM contains the program and the calibration information that the PCM needs to control powertrain operation. Unlike the PROM used in past applications, the EEPROM is not replaceable. If the PCM is replaced, the new PCM will need to be programmed. Equipment containing the correct program and calibration for the vehicle is required to program the PCM. Diagram Information and Instructions Low Fuel Lamp/Indicator: Diagram Information and Instructions How to Identify Wiring Color-Coded Insulation Wire Color Wire Color Coding Page 8175 Quarter Window Glass: Service and Repair Rear Quarter Glass (LWB) Rear Quarter Glass Rear Quarter Glass (LWB) Removal 1. Disconnect the battery ground cable. 2. Remove the rear quarter trim panel. 3. Remove the rear quarter glass. Installation 1. Rear quarter glass. - Clean the bonding surfaces of both the glass and the body panel. - Be absolutely sure to apply glass primer to the side glass. - Be absolutely sure to apply body primer fully to the body. NOTE: Immediately wipe off the primer left on the body or extruded sealant. - Attach the fastener to the indicated position of body with sealant as shown in the figure. - Apply the sealant to the circumference of glass as shown in the figure. - Insert the location pins on glass into the panel, push the glass against the panel, and bond them. Page 89 Relay Box: Diagrams Instrument Panel Page 4690 This means the branch of the wire connects to another circuit. The arrow points to the name of the circuit branch where the wire continues. Page 4024 Transmission Speed Sensor: Locations Top Of Transfer Case Page 2528 Air Flow Meter/Sensor: Description and Operation Mass Air Flow (MAF) Sensor The mass air flow (MAF) sensor measures the difference between the volume and the quantity of air that enters the engine. "Volume" means the size of the space to be filled. "Quantity" means the number of air molecules that will fit into the space. This information is important to the PCM because heavier, denser air will hold more fuel than lighter, thinner air. The PCM adjusts the air/fuel ratio as needed depending on the MAF value. The Tech 2 reads the MAF value and displays it in terms of grams per second (g/sec). At idle, the Tech 2 should read between 4 - 7 g/sec on a fully warmed up engine. Values should change quickly on acceleration. Values should remain stable at any given RPM. A failure in the MAF sensor or circuit will set DTC P0101, DTC P0102, or DTC P0103. Page 5854 ^ Reversible drill motor (800 RPM MAX) ^ Tire spreader ^ Inspection lamp * For repairable injuries that exceed 25 degrees TIRE REPAIR GUIDELINES Never repair tires worn below 2/32 inch of tread. Never repair a tire without removing the tire from the wheel for internal inspection. Never repair a tire with a tread injury larger than 1/4 inch (6 mm). Never use only a plug (stem) or a patch only to repair a tire injury. NOTE: If the angle of the tire injury exceeds 25 degrees, you must use the two-piece repair system as recommended by the RMA. MICHELIN PAX SYSTEM SUPPORT RING INSPECTION PAX System support rings are not repairable, under any circumstances, but they can be reused if no damage is found during a thorough inspection. If a PAX System tire ran flat or underinflated, dismount the tire from the wheel and inspect the wheel, tire, and support ring for damage. Refer to the Michelin PAX Support Rings Technical Bulletin in ISIS. Enter SEARCH BY PUBLICATION, select Job Aids, then select Michelin PAX Support Rings Technical Bulletin from the list. Disclaimer Page 6423 7. Reconnect three connector to Powertrain Control Module (PCM). (Y22SE 2.2L Engine only) 8. Install the center console. 9. Install the transfer shift lever knob. 10. Install the dressing panel around the radio and reconnect cigar lighter harness. 11. Enable the SRS. Page 985 Defect Code: 07406 Symptom Code: 03602 Skill Level: Repair Technician Diagnostic Trouble Code: To create the 15-digit DTC, see the applicable repair procedure. Out of warranty: Any repair performed after warranty expiration may be eligible for goodwill consideration by the District Parts and Service Manager or your Zone Office. You must request consideration, and get a decision, before starting work. TOOL DESCRIPTIONS The holding force gauge measures the amount of pull on the vehicle. It is a bracket that counts as one weight, plus five removable weights. During the test-drive, attach the bracket and the weights to the steering wheel on the side opposite the pulling direction. For example, if the vehicle pulls to the right, attach the bracket and weights to the left side of the steering wheel. Start with the maximum amount of weight on the steering wheel, and remove the weights until the vehicle drives in a straight line. When recording the pull on the worksheet, write down the direction of the pull (lefi or right) and the number of weights required to balance the pull (one through six). For example, if you have the bracket and two weights on the steering wheel, then record this as three weights. NOTE: The bracket counts as one weight. Page 5126 8. Remove Bolts which secure regulator, rectifier and brush-holder, and separate these pans. NOTE: Do not apply a shock or load to regulator, rectifier and brush holder. Reassembly To reassemble, follow the disassembly steps in the reverse order, noting the following points: NOTE: - Never make battery connections with polarities reversed, or battery will be shorted via the diodes. This will cause damage to the diodes. - Do not connect generator B terminal to ground- it is connected directly to the battery. This cable will burn if it is connected to ground. - Make sure to disconnect the positive (+) terminal of the battery when quick-charging battery. Diodes may be damaged due to abnormal pulse voltage generated bye the quick charger. - When reassembling the front section to rear section, insert a stiff wire into hole in the rear face of the rear cover from the outboard side to support the brush in raised position, then insert the front section to which rotor is assembled. - Reassemble parts carefully to be sure they fit into their original position, paying attention to the insulated portions. - Wipe insulating tubes, washers and plates clean and install them in position carefully to avoid getting oil or grease on them. 1. Using a press with a socket wrench attached, reassemble rotor and rear end cover assembly in the front cover. Diagrams Valve Spring: Diagrams Valve Spring, Oil Controller, Valve, Valve Guide and Associated Parts Page 3715 2. Connect one lead of a self-powered test light or DVOM to one end of the part of the circuit you want to test. 3. Connect the other lead to the other end. 4. If the self-powered test light glows, there is continuity. If you're using a DVOM, a low reading or no reading (zero), means good continuity. Testing For Voltage When testing for voltage at a connector without wire seals, you do not have to separate the two halves of the connector. Instead, probe the connector from the back. Always check both sides of the connector because dirty, corroded, and bent terminals can cause problems (no electrical contact = an open). 1. Connect one lead of the lest light to a known good ground, or, if you're using a digital volt ohmmeter (DVOM), place it in the appropriate DC volts range, and connect its negative lead to ground. 2. Connect the other lead of the test light or DVOM to the point you want to check. 3. If the test light glows, there is voltage present. If you're using a DVOM, note the voltage reading. It should be within one volt of measured battery voltage. A loss of more than one volt indicates a problem. NOTE: Always use a DVOM on high impedance circuits. A test light may not glow (even with battery voltage present). Testing For Voltage Drop Wires, connectors, and switches are designed to conduct current with a minimum loss of voltage. A voltage drop of more than one volt indicates a problem. 1. Place the digital volt/ohmmeter (DVOM) in the appropriate DC volts range. Connect the positive lead to the end of the wire (or to the connector or switch) closest to the battery. 2. Connect the negative lead to the other end of the wire (or the other side of the connector or switch). 3. Turn on the components in the circuit. 4. The DVOM will show the difference in voltage between the two points. A difference, or drop, of more than one volt indicates a problem. Check the circuit for loose, dirty, or bent terminals. Page 59 The name of the component appears next to it followed by notes about its function along with any photo and connector view references. Connector "C" How to Identify Connector Terminals Cavity Numbering System The cavities (and wire terminals) in each connector are numbered starting from the upper left, looking at the male terminals from the terminal side (or looking at the female terminals from the wire side. Both views are in the same direction so the numbers are the same.) All actual cavities are numbered, even if they have no wire terminals in them. NOTE: Data Link Connector (DLC) terminals are numbered according to SAE standard J1962, not the Honda standard. The numbers of the four end terminals are molded into the corners of the connector face. Page 4561 Testing For A Short With A Self-Powered Test Light or DVOM 1. Remove the blown fuse and disconnect the battery and load. 2. Connect one lead of a self-powered test light or digital volt/ohmmeter (DVOM) (switched to the lowest "OHMS" range) to the fuse terminal on the load side. 3. Connect the other lead to a known good ground. 4. Beginning near the fuse box, wiggle the harness. Continue this at convenient points about six inches apart while watching the test light or DVOM. 5. If the self-powered test light goes on or the DVOM displays a low reading or no reading (zero), there is a short to ground in the wiring near that point. Testing for a Short with a Test Light or DVOM 1. Remove the blown fuse and disconnect the load. 2. Connect a test light or digital volt/ohmmeter (DVOM), switched to the appropriate DC volts range, across the fuse terminals to make sure voltage is present. You might have to turn the ignition switch to ON; check the schematic to see. 3. Beginning near the fuse box, wiggle the harness. Continue this at convenient points about six inches apart while watching the test light or DVOM. 4. Where the test light goes , or the DVOM voltage drops to zero, there is a short to ground in the wiring near that point. NOTE: Always use a DVOM on high impedance circuits. A test light may not glow (even with battery voltage present). Testing For A Short With A Short Circuit Locator (Short Finder) 1. Remove the blown fuse. Leave the battery connected. Page 4727 Testing For A Short With A Self-Powered Test Light or DVOM 1. Remove the blown fuse and disconnect the battery and load. 2. Connect one lead of a self-powered test light or digital volt/ohmmeter (DVOM) (switched to the lowest "OHMS" range) to the fuse terminal on the load side. 3. Connect the other lead to a known good ground. 4. Beginning near the fuse box, wiggle the harness. Continue this at convenient points about six inches apart while watching the test light or DVOM. 5. If the self-powered test light goes on or the DVOM displays a low reading or no reading (zero), there is a short to ground in the wiring near that point. Testing for a Short with a Test Light or DVOM 1. Remove the blown fuse and disconnect the load. 2. Connect a test light or digital volt/ohmmeter (DVOM), switched to the appropriate DC volts range, across the fuse terminals to make sure voltage is present. You might have to turn the ignition switch to ON; check the schematic to see. 3. Beginning near the fuse box, wiggle the harness. Continue this at convenient points about six inches apart while watching the test light or DVOM. 4. Where the test light goes , or the DVOM voltage drops to zero, there is a short to ground in the wiring near that point. NOTE: Always use a DVOM on high impedance circuits. A test light may not glow (even with battery voltage present). Testing For A Short With A Short Circuit Locator (Short Finder) 1. Remove the blown fuse. Leave the battery connected. Page 8153 5. Remove the speaker assembly (2). - Remove the 4 screws and disconnect the speaker harness connector (1). 6. Remove the door mirror cover. 7. Remove the grip cover. 8. Remove the 5 screws (1), (3) and pull out the trim panel at the 6 clip positions (2). 9. Remove the waterproof sheet. Page 7991 Combination Switch: Service and Repair REMOVAL 1. Turn the steering wheel so that the vehicle's wheels are pointing straight ahead. 2. Turn the ignition switch to "LOCK". 3. Disconnect the battery "-" terminal cable, and wait at least 5 minutes. 4. Disconnect the yellow 2-way SRS connector located under the steering column. CAUTION: The wheels of the vehicle must be straight ahead and the steering column in the "LOCK" position before disconnecting the steering wheel. Failure to do so will cause the coil assembly to become uncentered which will cause damage to the coil assembly. 5. Remove the engine hood opening lever, then remove instrument panel lower cover. 6. Remove the driver knee bolster (reinforcement). Page 765 Page 3188 Fuel Filler Cap: Testing and Inspection Inspection Check the seal ring in the filler cap for presence of any abnormality and for seal condition. Replace the filler cap, if abnormal. CAUTION: The fuel filler cap valve has characteristics. A defective valve, no valve at all or a valve with the wrong characteristics will do a lot of harm to engine operating characteristics; be sure to use the same fuel filler cap as installed in this vehicle. Page 7955 The wire insulation has one color or one color with another color stripe. The second color is the stripe. Page 7585 Key Reminder Switch: Electrical Diagrams Seat Belt, Lights-ON and Ignition Key Reminders Part 1 Of 2 Page 6181 8. Remove lower case. - Slit the case parting face with a knife since the lining is separated when removing the evaporator. - Lift to remove the upper case. 9. Remove evaporator core. 10. Remove expansion valve. Specifications Crankshaft: Specifications Thrust Clearance Standard 0.06 - 0.24 mm Limit 0.30 mm Main Journal Diameter 63.918 - 63.933 mm Crank Pin Diameter 53.922 - 53.937 mm Page 5586 This means the branch of the wire connects to another circuit. The arrow points to the name of the circuit branch where the wire continues. Page 2405 Disclaimer Repair Procedure 1. Unclamp the air cleaner housing cover, and move it to the side for access to connector C123 (16P BLK). 2. Unfasten C123 from the side of the engine compartment using a 90-degree pick. 3. Disconnect C123, and clean the terminals on both sides of the connector with contact cleaner. Shake the residue out of the connector. Allow the contact cleaner to evaporate for at least 3 minutes, then reconnect C123. 4. Fasten C123 to the left side of the engine compartment, then reinstall the air cleaner housing cover. 5. While supporting the accelerator pedal assembly, remove the two bolts that secure the assembly to the bulkhead. Carefully lower the assembly to gain access to the connector. Page 5520 be reused after lapping the face. Relief Valve The sliding face of the valve must be free from burrs and damage. The parts with minor scores may be reused after smoothing with emery cloth (#800 or finer). Shaft Oil seal sliding faces must be free from a step wear which can be felt by the finger nail. Needle bearing fitting face must be free from damage and wear. O-ring, Oil Seal, Retaining Ring Be sure to discard used parts, and always use new parts for installation. Prior to installation, lubricate all seals and rings with power steering fluid. Pressure Switch Check the switch operation as follows: With engine idling and A/C on, turn the steering wheel fully to the left; compressor should interrupt and engine idle speed will increase. Shut off A/C and again turn steering fully to the left; engine idle will increase. If system fails to function properly, disconnect connector at the pressure switch and repeat system check while testing continuity across disconnected SW connector. REASSEMBLY 1. Install oil seal to front housing. Be sure to discard used oil seal, and always use new parts for installation. CAUTION: When installing the oil seal, be careful not to damage the oil seal contacting surface of the housing. 2. Install shaft assembly. 3. Install the vanes to rotor with curved face in contact with the inner wall of cam. Page 4776 Page 5482 10. Use the PGM Tester to check the broadcast code. Make sure the broadcast code matches the one you selected from the CD-ROM. WARRANTY CLAIM INFORMATION In warranty: The normal warranty applies. Failed Part: P/N 8-17087-655-0 H/C 4375820 Defect Code: 064 Contention Code: C01 Skill Level: Repair Technician Out of warranty: Any repair performed after warranty expiration may be eligible for goodwill consideration by the District Service Manager or your Zone Office. You must request consideration, and get a decision, before starting work. REPAIR PROCEDURE - ENGINE/BODY GROUND 1. Use the ETM for the appropriate year to locate these ground connectors: G101, G104, G105, G106 and G160. 2. Inspect each connector for corrosion or looseness. 3. Remove the bolt from any connector that is corroded or loose. Clean the terminal connector with a wire brush. File flat any solder bumps on the connector. 4. Clean the contact surface on the engine or body with a wire brush. 5. Replace the bolt if it is heavily corroded. Otherwise, clean it with a wire brush. 6. Apply lithium dielectric grease to both sides of the terminal connector. 7. Reinstall the bolt, torque it to 14 N.m (10 lb-ft). 8. Use the Smart Cable to reprogram the PCM with the latest software from the June 2001 or later HONDANET CD-ROM. Refer to Service Bulletin 99-005, Updating the Passport PCM, filed under Tools. 9. Use the PGM Tester to clear any DTCs. 10. Use the PGM Tester to check the broadcast code. Make sure the broadcast code matches the one you selected from the CD-ROM. WARRANTY CLAIM INFORMATION In warranty: The normal warranty applies. Failed Part: P/N 8-97086-823-0 Specifications Connecting Rod Bearing: Specifications Oil Clearance - Standard: 0.019 mm - 0.043 mm (0.0007 inch - 0.0017 inch) - Limit: 0.08 mm (0.0031 inch) Page 6090 2. Connect one lead of a self-powered test light or DVOM to one end of the part of the circuit you want to test. 3. Connect the other lead to the other end. 4. If the self-powered test light glows, there is continuity. If you're using a DVOM, a low reading or no reading (zero), means good continuity. Testing For Voltage When testing for voltage at a connector without wire seals, you do not have to separate the two halves of the connector. Instead, probe the connector from the back. Always check both sides of the connector because dirty, corroded, and bent terminals can cause problems (no electrical contact = an open). 1. Connect one lead of the lest light to a known good ground, or, if you're using a digital volt ohmmeter (DVOM), place it in the appropriate DC volts range, and connect its negative lead to ground. 2. Connect the other lead of the test light or DVOM to the point you want to check. 3. If the test light glows, there is voltage present. If you're using a DVOM, note the voltage reading. It should be within one volt of measured battery voltage. A loss of more than one volt indicates a problem. NOTE: Always use a DVOM on high impedance circuits. A test light may not glow (even with battery voltage present). Testing For Voltage Drop Wires, connectors, and switches are designed to conduct current with a minimum loss of voltage. A voltage drop of more than one volt indicates a problem. 1. Place the digital volt/ohmmeter (DVOM) in the appropriate DC volts range. Connect the positive lead to the end of the wire (or to the connector or switch) closest to the battery. 2. Connect the negative lead to the other end of the wire (or the other side of the connector or switch). 3. Turn on the components in the circuit. 4. The DVOM will show the difference in voltage between the two points. A difference, or drop, of more than one volt indicates a problem. Check the circuit for loose, dirty, or bent terminals. Service and Repair Input Shaft: Service and Repair For further information regarding this component and the system that it is a part of, please refer to Automatic Transmission/Transaxle; Service and Repair; Unit Overhaul Page 2509 The name of the component appears next to it followed by notes about its function along with any photo and connector view references. Connector "C" How to Identify Connector Terminals Cavity Numbering System The cavities (and wire terminals) in each connector are numbered starting from the upper left, looking at the male terminals from the terminal side (or looking at the female terminals from the wire side. Both views are in the same direction so the numbers are the same.) All actual cavities are numbered, even if they have no wire terminals in them. NOTE: Data Link Connector (DLC) terminals are numbered according to SAE standard J1962, not the Honda standard. The numbers of the four end terminals are molded into the corners of the connector face. Page 3489 5. The vacuum lines must be properly routed under the throttle body before tightening the mounting bolts. Tighten Tighten the throttle body mounting bolts to 10 N.m (87 lb in). 6. Install the coolant lines. 7. Connect all the vacuum lines. 8. Install the intake air duct. 9. Tighten the intake air duct clamp. 10. Connect all the electrical connectors: - Throttle position (TP) sensor. - Intake air temperature (IAT) sensor. 11. Install the accelerator cable assembly. 12. Fill the cooling system. 13. Install the negative battery cable. Page 242 Suspension Control Module: Service and Repair Page 6660 5. Insert a thin stainless steel ruler or a "Slim Jim" under the magazine, about 1-1/2" from the right side of the opening. 6. Push the ruler in until it presses against the eject lever at the back of the unit. 7. Slowly remove the ruler and magazine at the same time. Two-piece door model: 1. Remove the changer from the vehicle. 2. Remove the top cover plate from the changer, and look for a jammed tray. 3. If a tray is stuck in the player, reinstall the cover and replace the changer. If all the trays are in the magazine, insert a thin stainless steel ruler or a "Slim Jim" under the magazine, about 1/2" from the right side of the opening. 4. Push the ruler in until it presses against the eject lever at the back of the unit. 5. Slowly remove the ruler and magazine at the same time. Page 5164 on, the contacts of magnetic switch are closed, and the armature rotates. At the same time, the plunger is attracted, and the pinion is pushed forward by the shift lever to mesh with the ring gear. Then, the ring gear runs to start the engine. When the engine starts and the starter switch is turned off, the plunger returns, the pinion is disengaged from the ring gear, and the armature stops rotation. When the engine speed is higher than the pinion, the pinion idles, so that the armature is not driven. Capacity Specifications Fluid - Transfer Case: Capacity Specifications Transfer Case Fluid Capacity ............................................................................................................................................... .......................................................... 1.45 L (1.5 Qt) Page 853 7. Loosen the inflator module fixing bolt from behind the steering wheel assembly using a TORE driver or equivalent until the inflator module can be released from steering assembly. 8. Disconnect the yellow 2-way SRS connector and horn lead located behind the inflator module. 9. Apply a setting mark (1) across the steering wheel and shaft so parts can be reassembled in their original position. Specifications Service and Repair Windshield Washer Switch: Service and Repair Rear Wiper and Washer Switch Removal 1. Disconnect the battery ground cable. 2. Remove the dash side trim panel (1). 3. Remove the lower cover assembly (2). 4. Remove the meter cluster assembly (4). 5. Remove the rear wiper & washer switch (5). - Disconnect the connector. - Push the lock from the back side of the meter cluster assembly. Installation To install, follow the removal steps in the reverse order, noting the following point: 1. Push the switch with your fingers until it locks securely. Page 1580 spring compressor and J42898 valve spring compressor adapter to install the split collars. 6. Install tappet with shim. 7. Install camshaft assembly. - Refer to installation procedure for Camshaft. Valve Clearance Adjustments Note: To adjust valve clearance, apply engine oil to the cam as well as to the adjusting shim (2) with the cylinder head built on the cylinder block, give a few turns to the camshaft by means of timing pulley tightening bolt, and measure valve clearance when the nose of cam is just opposite to maximum cam lift (1) as shown in illustration. Valve Clearance Standard Value (cold) Intake: 0.23 mm - 0.33 mm (0.0091 inch - 0.01 30 inch) Exhaust: 0.25 mm-0.35 mm (0.0098 in-0.0138 inch) Selection of Adjusting Shim Shim to be selected = (Thickness of removed shim) + (Valve clearance measurement - Standard value) Based on the above formula, the best suited shim should be selected from 41 sorts of shim (differently thick at 0.02 mm (0.0008 inch) intervals from 2.40 mm (0.0945 inch) through 3.2 mm (0.1260 inch) thick). Install the shim and check valve clearance. Replacement of Shim Page 2530 1. Install the MAF sensor on the air cleaner with the clamp. 2. Install the intake air duct and the clamp on the MAF sensor. 3. Tighten the clamps to secure the MAF sensor to the intake air duct and the air cleaner. 4. Connect the MAF electrical connector. 5. Connect the negative battery cable. Page 4456 Axle Disconnect Control Control Unit: Diagnostic Aids Before Troubleshooting Before Troubleshooting See: Service Precautions/Vehicle Damage Warnings/Tips and Precautions 1. Check applicable fuses in the appropriate fuse/relay box. 2. Check the battery for damage, state of charge, and clean and tight connections. CAUTION: Do not quick-charge a battery unless the battery ground cable has been disconnected, otherwise you will damage the alternator diodes. - Do not attempt to crank the engine with the battery ground cable loosely connected or you will severely damage the wiring. While You're Working 1. Make sure connectors are clean, and have no loose terminals or receptacles. 2. Make sure that connectors without wire seals are packed with dielectric (silicone) grease. Part Number: 08798-9001. 3. When connecting a connector, push it until it "clicks" into place. CAUTION: Do not pull on the wires when disconnecting a connector. Pull only on the connector housings. - Most circuits include solid-state devices. Test the voltages in these circuits only with a 10-megaohm or higher impedance digital multi meter. Never use a test light or analog meter on circuits that contain solid-state devices. Damage to the devices may result. Five-Step Troubleshooting 1. Verify The Complaint Turn on all the components in the problem circuit to check the accuracy of the customer complaint. Note the symptoms. Do not begin disassembly or testing until you have narrowed down the problem area. 2. Analyze The Schematic Look up the schematic for the problem circuit. Determine how the circuit is supposed to work by tracing the current paths from the power source through the circuit components to ground. Also, trace circuits that share wiring with the problem circuit. The names of circuits that share the same fuse, ground, or switch, and so on, are referred to in each circuit schematic. Try to operate any shared circuits you didn't check in step 1. If the shared circuits work, the shared wiring is OK, and the cause must be in the wiring used only by the problem circuit. If several circuits fail at the same time, the fuse or ground is a likely cause. Based on the symptoms and your understanding of the circuit's operation, identify one or more possible causes. 3. Isolate The Problem By Testing The Circuit Make circuit tests to check the diagnosis you made in step 2. Keep in mind that a logical, simple procedure is the key to efficient troubleshooting. Test for the most likely cause of failure first. Try to make tests at points that are easily accessible. 4. Fix The Problem Once the specific problem is identified, make the repair. Be sure to use proper tools and safe procedures. 5. Make Sure The Circuit Works Turn on all components in the repaired circuit in all modes to make sure you've fixed the entire problem. If the problem was a blown fuse, be sure to test all of the circuits on that fuse. Make sure no new problems turn up and the original problem does not recur. Page 2218 Distinct Of Circuit By Wire Base Color All wires have color-coded insulation. Wires belonging to a system's main harness will have a single color. Wires belonging to a system's sub-circuits will have a colored stripe. Striped wires use the codes found in the chart to show wire size and colors. Abbreviations are used to indicate wire color within a circuit diagram. How to Identify Connector Terminals How to Identify Connector Terminals Cavity Numbering System The cavities (and wire terminals) in each connector are numbered starting from the upper left, looking at the male terminals from the terminal side (or looking at the female terminals from the wire side. Both views are in the same direction so the numbers are the same.) All actual cavities are numbered, even if they have no wire terminals in them. NOTE: Data Link Connector (DLC) terminals are numbered according to SAE standard J1962, not the Honda standard. The numbers of the four end terminals are molded into the corners of the connector face. The connector cavity number is listed next to each terminal on the circuit schematic. The cavity / terminal shown is # 6. Using/Identifying Connector Terminal Views How to Use Connector Terminal Views To see the configuration of a connector's cavities, look up its view number in the Connector Views. Each view includes the color of the connector, where Page 2892 Intake Air Temperature Sensor: Service and Repair INTAKE AIR TEMPERATURE (IAT) SENSOR REMOVAL PROCEDURE 1. Disconnect the negative battery cable. 2. Remove the engine cover 3. The IAT sensor is located in the intake air duct, behind the throttle body. 4. Disconnect the electrical connector from the IAT sensor. 5. Remove the IAT sensor from the intake air duct by using a rocking motion while pulling the sensor. INSTALLATION PROCEDURE 1. Install the IAT sensor into the grommet in the intake air duct. 2. Correct the IAT electrical connector. 3. Install the engine cover. 4. Connect the negative battery cable. Page 6763 it is located, and what it connects to. Use the Connector Views to help locate the proper cavity when you need to probe a connector. It can be especially helpful if the connector has more than one wire of the same color. A dash symbol (-) indicates that the cavity is empty. Connector views can also be used to help diagnose multiple symptoms in separate circuits which could be caused by a single problem in a connector shared by those circuits. Here's an example: 1. Pick one of the multiple symptoms and look up the schematic for that circuit. 2. Make a list of all the in-line and fuse box connectors in that schematic , 3. Then, in the Connector Views, look up each connector on your list to see if circuits related to the other symptoms run through one of them. If they do, inspect that connector for the problem. Example: The blower, rear window defogger, and the windshield wiper don't work. List all in-line and fuse box connectors in the blower controls circuit and then check the Connector View (see the sample). You find that C324 is common to the blower controls, rear window defogger, and wiper/washer, so you inspect C324 and find the problem, bent terminals. Finding Component/Connector Locations Finding Component/Connector Locations To see where a component or connector is located on the car, look up its photo number in the "Component Location". The photo will also tell you the color of the connector, and how many cavities it has. Page 1953 it is located, and what it connects to. Use the Connector Views to help locate the proper cavity when you need to probe a connector. It can be especially helpful if the connector has more than one wire of the same color. A dash symbol (-) indicates that the cavity is empty. Connector views can also be used to help diagnose multiple symptoms in separate circuits which could be caused by a single problem in a connector shared by those circuits. Here's an example: 1. Pick one of the multiple symptoms and look up the schematic for that circuit. 2. Make a list of all the in-line and fuse box connectors in that schematic , 3. Then, in the Connector Views, look up each connector on your list to see if circuits related to the other symptoms run through one of them. If they do, inspect that connector for the problem. Example: The blower, rear window defogger, and the windshield wiper don't work. List all in-line and fuse box connectors in the blower controls circuit and then check the Connector View (see the sample). You find that C324 is common to the blower controls, rear window defogger, and wiper/washer, so you inspect C324 and find the problem, bent terminals. Finding Component/Connector Locations Finding Component/Connector Locations To see where a component or connector is located on the car, look up its photo number in the "Component Location". The photo will also tell you the color of the connector, and how many cavities it has. Page 2020 Testing For A Short With A Self-Powered Test Light or DVOM 1. Remove the blown fuse and disconnect the battery and load. 2. Connect one lead of a self-powered test light or digital volt/ohmmeter (DVOM) (switched to the lowest "OHMS" range) to the fuse terminal on the load side. 3. Connect the other lead to a known good ground. 4. Beginning near the fuse box, wiggle the harness. Continue this at convenient points about six inches apart while watching the test light or DVOM. 5. If the self-powered test light goes on or the DVOM displays a low reading or no reading (zero), there is a short to ground in the wiring near that point. Testing for a Short with a Test Light or DVOM 1. Remove the blown fuse and disconnect the load. 2. Connect a test light or digital volt/ohmmeter (DVOM), switched to the appropriate DC volts range, across the fuse terminals to make sure voltage is present. You might have to turn the ignition switch to ON; check the schematic to see. 3. Beginning near the fuse box, wiggle the harness. Continue this at convenient points about six inches apart while watching the test light or DVOM. 4. Where the test light goes , or the DVOM voltage drops to zero, there is a short to ground in the wiring near that point. NOTE: Always use a DVOM on high impedance circuits. A test light may not glow (even with battery voltage present). Testing For A Short With A Short Circuit Locator (Short Finder) 1. Remove the blown fuse. Leave the battery connected. Page 499 Wire Color Abbreviations The following abbreviations are used to identify wire colors in the circuit schematics: WHT................................... White YEL................................... Yellow BLK................................... Black BLU................................... Blue GRN................................... Green RED................................... Red ORN................................... Orange PNK................................... Pink BRN................................... Brown GRY................................... Gray PUR................................... Purple LT BLU................................... Light Blue LT GRN................................... Light Green