Chevrolet - Wiring Diagram - Workshop Manual - 2001 - 2003

Page 4616 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 2865 Fuel Meter Body: Description and Operation Fuel Metering System Modes Acceleration Mode Acceleration Mode The PCM provides extra fuel when it detects a rapid increase in the throttle position and the air flow. Battery Voltage Correction Mode Battery Voltage Correction Mode When battery voltage is low, the PCM will compensate for the weak spark by increasing the following: - The amount of fuel delivered. - The idle RPM. - Ignition dwell time. Clear Flood Mode Clear Flood Mode Clear a flooded engine by pushing the accelerator pedal down all the way. The PCM then de-energizes the fuel injectors. The PCM holds the fuel injectors de-energized as long as the throttle remains above 80 % and the engine speed is below 800 RPM. If the throttle position becomes less than 80 %, the PCM again begins to pulse the injectors "ON" and "OFF," allowing fuel into the cylinders. Deceleration Mode Deceleration Mode The PCM reduces the amount of fuel injected when it detects a decrease in the throttle position and the air flow. When deceleration is very fast, the PCM may cut off fuel completely for short periods. Engine Speed/Vehicle Speed/Fuel Disable Mode Engine Speed/Vehicle Speed/Fuel Disable Mode The PCM monitors engine speed. It turns off the fuel injectors when the engine speed increase above 6400 RPM. The fuel injectors are turned back on when engine speed decreases below 6150 RPM. Fuel Cutoff Mode Fuel Cutoff Mode No fuel is delivered by the fuel injectors when the ignition is "OFF." This prevents engine run-on. In addition, the PCM suspends fuel delivery if no reference pulses are detected (engine not running) to prevent engine flooding. Run Mode Run Mode The run mode has the following two conditions: - Open loop - Closed loop When the engine is first started the system is in "open loop" operation. In "open loop," the PCM ignores the signal from the heated oxygen sensor (HO2S). It calculates the air/fuel ratio based on inputs from the TP ECT, and MAF sensors. The system remains in "open loop" until the following conditions are met: - The HO2S has a varying voltage output showing that it is hot enough to operate properly (this depends on temperature). - The ECT has reached a specified temperature. - A specific amount of time has elapsed since starting the engine. - Engine speed has been greater than a specified RPM since start-up. The specific values for the above conditions vary with different engines and are stored in the programmable read only memory (PROM). When these conditions are met, the system enters "closed loop" operation. In "closed loop," the PCM calculates the air/fuel ratio (injector on-time) based on the signal from the HO2S. This allows the air/fuel ratio to stay very close to 14.7:1. Starting Mode Page 3098 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 2245 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 6194 Alarm And Relay Controls Image 70-2 Page 4210 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) Page 3774 ^ 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 runout (Steel tube type). Static runout 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) ^ Play in universal joint. Limit: Less than 0.15 mm (0.006 inch) ^ 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 49 N (0 to 11.0 lb). Joints should rotate smoothly and freely and should exhibit no rough or ratchety movement. ^ Inspect splines of slip joint 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 indication 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 Page 3745 11. Install snap ring and shim. - Adjust the clearance between the free wheeling hub body and the snap ring. Clearance: 0 mm 0.3 mm (0 in - 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. 13. Tighten the bolts to the specified torque. Torque: 59 Nm (43 ft. lbs.) Page 1216 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 5888 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 5853 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. Specifications Compressor Clutch: Specifications Pulley-to-Pressure Plate Clearance 0.015 +/- 0.005 in Page 7195 Steps 10 - 18 Steps 19 - 20 Page 4684 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. 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/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. Engine Driveability and Emissions System Fuel Filler Cap: Description and Operation Engine Driveability and Emissions System The fuel filler cap includes a vacuum valve and a pressure valve. If high vacuum or high pressure occurs in the fuel tank, each valve works to adjust the pressure in order to prevent damage of the tank. Page 5594 Each schematic represents one circuit. A circuit's wires and components are arranged to show current flow, from power at the top 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 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. Page 6623 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). 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 1612 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 2589 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 4612 7. Right Side of Engine Compartment 38. Left Side of Dash 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. Procedures Front Bumper Bracket: Procedures 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. Page 5738 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 3503 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 5450 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 3492 ^ 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 2096 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 MOhms or more Page 667 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) (V6). 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 Specifications Steering Wheel: Specifications Steering wheel Rotational play measured at outside edge With engine running ............................................................................................................................................................ 0 - 30 mm (0 - 1.18 inch) Service and Repair Fog/Driving Lamp Bulb: Service and Repair Fog Light Bulb Removal 1. Disconnect the battery ground cable. 2. Remove the fog light bulb (2). - 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 399 Air Conditioning Switch: Testing and Inspection Check for continuity between the fan switch and the A/C switch side connector terminals. Page 7334 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 1118 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 694 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: 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 4134 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 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 7217 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 66 Ground - "G" Shielding Sheilding This represents RFI (Radio Frequency Interference) shielding around a wire. The shielding is always connected to ground. Splices Page 6502 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. Locations 39. Dash Fuse Box Page 6847 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 6430 ^ 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 6976 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. 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 1312 Tires: Service and Repair Spare Tire Spare Tire Hanger - Parts Locations Spare Tire Hanger Removal 1. Open the hatch gate and tail gate. 2. Remove the spare tire (3). 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 N.m (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 4580 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 5427 Blower Motor: Locations 65. Behind Glove Box Blower Assembly And Associated Parts Page 5031 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. 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 6991 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. 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 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: 20 Nm (14 ft. lbs.) 5. Install bolt and nut, then tighten to the specified torque. Torque: 93 Nm (69 ft. lbs.) Page 7392 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 144 Fuse To Component Index (Fuse No. 1 - 20) Image 6-3 Page 5040 Key Reminder Switch: Electrical Diagrams Seat Belt, Lights-on, And Ignition Key Reminders Image 73-0 Page 6291 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 2331 1. Install the MAP sensor in the mounting bracket. 2. Install the mounting bracket retaining bolt on the common chamber. Tighten Tighten the bolt to 20 N.m (12 lb.ft.). 3. Connect the MAP electrical connector. 4. Connect the negative battery cable. Service and Repair Shift Cable: Service and Repair 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. (4x4) 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. Page 6559 Each schematic represents one circuit. A circuit's wires and components are arranged to show current flow, from power at the top 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 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. Page 4468 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 935 DIAGNOSTIC WORKSHEET REPAIR PROCEDURE A Page 7579 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 1974 3. Connect the VSS electrical connector. 4. Check the transfer case oil level. Add fluid if necessary. 5. Connect the negative battery cable. Page 6877 The wire insulation has one color or one color with another color stripe. The second color is the stripe. Page 3712 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 2168 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 2651 Vehicle Speed Sensor: Testing and Inspection Inspection Procedure 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 3387 4WD Motor Actuator Page 7336 The wire insulation has one color or one color with another color stripe. The second color is the stripe. Page 6421 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 6893 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 4915 Alignment: Service and Repair Front End Alignment Inspection Before making any adjustments affecting caster, camber or toe-in, the 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 915 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 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 3769 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 5531 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 875 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 6435 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 7458 Hazard Warning Switch: Service and Repair Hazard Warning Light Switch 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 5579 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 4452 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 1421 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 5241 ^ 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 7087 Above 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 begins in Wire Color Abbreviations. 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 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 Page 4767 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 6222 Above 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 begins in Wire Color Abbreviations. 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 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 Page 5647 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 2480 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 1. Install the MAF sensor on the air cleaner with the clamp. Page 4473 Starter And Generator (V6) Description and Operation Knee Diverter: Description and Operation Knee Bolster The knee bolsters are used to absorb energy to protec knees and control the forward movement of the vehicle's front seat occupants during a frontal crash, by limiting leg movement. Locations Air Flow Meter/Sensor: Locations 28. Left Side of Engine Compartment MAF Sensor Locations 18. Right Side of Engine Page 689 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 5922 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 2965 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 7199 14. Push "On" of soft key. 15. Make sure Lamp illuminates. 16. If Lamp illuminates, the Lamp is operating correctly. 17. Select F3: Reduced Power Lamp 18. Push "On" of soft key. 19. Make sure Lamp illuminates. 20. If Lamp illuminates, the Lamp is operating correctly. 21. Select F5: Cruise Control Lamp 22. Push "On" of soft key. 23. Make sure Lamp illuminates. 24. It Lamp illuminates, the Lamp is operating correctly. Page 187 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 965 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 4832 Relay Box: Diagrams Relay/Fuse Box (Instrument Panel) Page 2403 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 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 4727 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 680 Above 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 begins in Wire Color Abbreviations. 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 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 Page 2876 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 3976 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 4419 Ignition Switch Lock Cylinder: Testing and Inspection System Inspection Turn the ignition switch to the "ON" position and observe the warning lamp. The lamp should flash 7 times. If the lamp does not operate correctly, refer to "Restraints". Page 5947 Child Seat Tether Attachment Page 6821 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 7523 Trailer Lamps: 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 503 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 2258 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. Three Way Catalytic Converter RH & Forked Exhaust Pipe Catalytic Converter: Diagrams Three Way Catalytic Converter RH & Forked Exhaust Pipe Three Way Catalytic Converter RH and Forked Exhaust Pipe and Associated Parts Locations 67. Behind Glove Box Page 5232 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 6992 - Refer to the scrapping procedures for disposal of the damaged airbag. Page 6909 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 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 4302 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. 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. Trim Height Adjustment Alignment: Service and Repair Trim Height Adjustment Trim Height Adjustment 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 Adjustment Locations 55. Right Side of Gear Selector Page 4177 Page 575 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. Component Locations Control Lever Assembly, Control Cable And Associated Parts Page 7254 Individual circuit schematics begin with a fuse. The first half of Power Distribution, however, shows the wiring "upstream" between the battery 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 Capacity Specifications Fluid - A/T: Capacity Specifications A/T Fluid Capacity ............................................................................................................................................... ........................................................................... 8.6L Page 4456 Individual circuit schematics begin with a fuse. The first half of Power Distribution, however, shows the wiring "upstream" between the battery 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 Front Page 6011 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 4049 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 Thermostat: 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 4579 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 4648 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 5539 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 3547 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 7405 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 1310 Tires: Service and Repair Tire Replacement Tire Replacement When replacement is necessary, the original metric tire 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 capon 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): Page 3784 Flex Plate: Specifications Driven Plate Outside Diameter x Inside Diameter 260 x 170 mm Thickness Clutch Disengaged 8.6 mm Clutch Engaged 8.0 mm Total Friction Area 304 x 2 cm2 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 3063 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 2634 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 6602 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 520 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 182 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 Powertrain Control Module: Diagram Information and Instructions How to Identify Wiring Color-Coded Insulation Wire Color Wire Color Coding Page 4557 Measure runout of the commutator with a dial gauge. Repair or replace, if it exceeds the limit. Polish the commutator surface with sandpaper #500 to #600 if it is rough. Measure the depth of insulator in commutator. Replace, if it is below the limit. Locations 14. Right Rear of Engine Compartment Page 2240 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 7410 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 6904 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 3631 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. Locations Page 6977 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 1482 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 (87 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 (0.7 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 (87 inch lbs.) 3. Install starter and tighten fixing bolts. Torque: 40 Nm (30 ft. lbs.) Page 1393 Connecting Rod: Service and Repair For further information regarding this component and the system that it is a part of, please refer to Cylinder Block Assembly; Service and Repair. Page 6572 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 4467 Alternator: 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. Description and Operation Brake Proportioning/Combination Valve: Description and Operation P & B (Proportioning and Bypass) Valve 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 4055 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 3414 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 5200 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 6121 ^ 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. Page 3421 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 5441 Ground - "G" Shielding Sheilding This represents RFI (Radio Frequency Interference) shielding around a wire. The shielding is always connected to ground. Splices Page 7526 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 4819 Grounding Point: 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 3183 Ignition Control Module: Service and Repair 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. 3. Connect the negative battery cable. Page 5526 Each schematic represents one circuit. A circuit's wires and components are arranged to show current flow, from power at the top 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 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. Page 5602 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 and Installation Powertrain Control Module: Service and Repair Removal and Installation Removal Procedure 1. Disconnect the negative battery cable. 2. Block the wheels. 3. Remove the two screws from the PCM electrical connectors. 4. Disconnect the PCM electrical connectors. 5. After removing the clip which fixes the PCM to the bracket, remove PCM. Installation Procedure Page 6650 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. Locations Locations 89. Left Side of Manual Transmission (M/T) Page 4457 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 1028 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. Stabilizer Bar Stabilizer Bar: Service and Repair Stabilizer Bar 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 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: 25 Nm (18 ft. lbs.) 4. Install link. 5. Install nut, then tighten it to the specified torque. Torque: 50 Nm (37 ft. lbs.) Rear Locations 90. Left Side of Automatic Transmission (A/T) Page 4478 Brush Measure the brush length. Replace the brush if it exceeds the limit. Rectifier Assembly 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 12 V 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 "V1" 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 measured voltage should be within the specified (14.4 ± 0.3 volts) limits. If it is not, the regulator must be replaced. Page 4765 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 6967 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 1768 Each schematic represents one circuit. A circuit's wires and components are arranged to show current flow, from power at the top 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 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. Specifications Fuel Pressure: Specifications PRESSURE PRESSURE With Regulator Vacuume Hose Disconnected 42-55 Psi. Page 6516 Door Locks: Service and Repair Rear Door Lock Rear Door Lock Assembly And Associated Parts Removal 1. Disconnect the battery ground cable. 2. Remove the rear corner garnish. - Pull the corner garnish to disconnect the retaining clip. 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. Page 1812 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 1884 Manifold Absolute Pressure 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 7568 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 2236 Each schematic represents one circuit. A circuit's wires and components are arranged to show current flow, from power at the top 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 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. Locations Electronic Thermostat, Evaporator Core And/Or Expansion Valve - Disassembled View Page 5440 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 Crankshaft Main Bearing: Specifications Main Bearing Cap Bolts 39 Nm Oil Gallery Fixing Bolts 29 Nm Crank Case Side Bolts 39 Nm Page 254 Ignition Control Module: Service and Repair 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. 3. Connect the negative battery cable. Page 6224 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 5383 Intake Actuator Page 2736 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 3557 Transmission Range Switch Page 7504 Trailer Lamps: Connector Locations 79. Left Rear of Cargo Compartment 82. Left Rear of Cargo Comp. Page 3505 ^ 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. 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 7736 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. Page 7567 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 1925 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. 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 assembly. Installation 1. Use J-36797 extension assembly oil seal installer, and install the rear oil seal to the transmission extension assembly. Install the transfer case assembly to the vehicle (4x4). Page 4740 Relay/Fuse Box Location Locations 55. Right Side of Gear Selector 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 5249 ^ 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 1412 Piston: Service and Repair For further information regarding this component and the system that it is a part of, please refer to Cylinder Block Assembly; Service and Repair. Page 5634 Expansion Valve: 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 6272 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 7465 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 2394 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 Dual Pressure Switch Refrigerant Pressure Sensor / Switch: Testing and Inspection Dual Pressure Switch Disconnect pressure switch connector and check for continuity between pressure switch side connector terminals (1) and (2). Page 6882 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 5369 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 6479 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 1163 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. Locations 18. Right Side of Engine Component Locations 54. Below Center of Dash (Console Removed) Page 7043 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. Electrode Gap Spark Plug: Specifications Electrode Gap 0.040 in (1.05 mm) Page 6854 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 1573 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 1.05 mm (0.04 in). NOTE: Do not adjust the spark plugs gap without new spark plugs. - Do not damage to tip of spark plugs. - Do not cleaning the spark plugs. If require the cleaning it due to heavy dirt, it is allowed only 20 seconds to be used spark plug cleaner. - 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 Page 7647 Liftgate Window Glass: Adjustments Rear Hatchgate Adjustment - Hatchgate alignment is obtained by moving hatchgate hinges. Locations 9. Fuse/Relay Box (Cover Removed) Page 6067 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 6185 The wire insulation has one color or one color with another color stripe. The second color is the stripe. Page 5536 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. Description and Operation Clutch Disc: Description and Operation Driven Plate Assembly 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 6458 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 2455 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. Initial Inspection and Diagnostic Overview Powertrain Control Module: Initial Inspection and Diagnostic Overview Functional Check 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 7262 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 4702 Relay Box: Diagrams Relay/Fuse Box (Instrument Panel) Page 1914 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 6639 Sun Shade: Service and Repair Sunshade - Disassembled View (LWB) Sunshade (LWB) Removal 1. Tilt the sunroof. 2. Disconnect the battery ground cable. 3. Remove the sunroof glass. 4. Pull the sight shield upward using screwdriver. Page 6125 - 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 716 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 4196 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 6376 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 6271 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 4750 7. Right Side of Engine Compartment 38. Left Side of Dash Locations Sunroof Frame Complete Assembly And Associated Parts (LWB) Safety Stop Switch Sunroof/Moonroof Limit Switch: Service and Repair Safety Stop Switch 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 7620 Rear Door Window Motor: Connector Locations 76. Left Rear Door (Right Similar) 107. Left Rear Door (Right Similar) Page 795 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 ground 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 driver knee bolster (reinforcement). 7. 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. 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 2465 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 6836 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 4331 Parking Brake Warning Switch: Description and Operation Parking Brake Switch 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 6278 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 7339 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 Blower Assembly And Associated Parts 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 knee bolster bracket. 6. Remove duct. 7. Remove evaporator assembly (A/C only). 8. Disconnect blower motor connector. 9. Remove blower assembly. Installation To install, follow the removal steps in the reverse order. Page 4266 Brake Caliper: Service and Repair Bleeding For further information regarding this component and the system that it is a part of, please refer to Brake Bleeding; Service and Repair. Page 4803 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 1620 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 615 1. Install the MAP sensor in the mounting bracket. 2. Install the mounting bracket retaining bolt on the common chamber. Tighten Tighten the bolt to 20 N.m (12 lb.ft.). 3. Connect the MAP electrical connector. 4. Connect the negative battery cable. Page 6912 Clock: Electrical Diagrams Clock Image 154 Page 4537 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 4525 Individual circuit schematics begin with a fuse. The first half of Power Distribution, however, shows the wiring "upstream" between the battery 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 6864 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 1894 Oxygen Sensor: Connector Locations 93. Left Front Exhaust Downpipe 94. Rear of Left Catalytic Converter Front Brake Rotor/Disc: Description and Operation Front 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. 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 29 mm (1.14 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 runout: 0.010 mm (0.0004 inch) Page 102 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 63. Top of Left "A" Pillar (Right Similar) Page 5578 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 7675 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 1939 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) (V6). 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 Page 4136 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 1236 Fuse Block: Electrical Diagrams Fuse Block Circuit-1 Page 1370 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 4731 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 147 Relay/Fuse Box (Engine Room) Page 4630 The wire insulation has one color or one color with another color stripe. The second color is the stripe. Page 4371 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 Tailgate Lock, Hatchgate Lock And Associated Parts (LWB) Page 5858 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 1950 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 5541 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 5967 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 6527 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 5192 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 2306 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 4132 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 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 4310 Page 1765 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 6452 - Refer to the scrapping procedures for disposal of the damaged airbag. Page 652 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 2933 5. Select F0:Fuel Pump Relay. 6. Push "On" soft key. 7. Control Fuel Pump Relay and check data list. 8. If the data list changes, the Fuel Pump Relay is normal. 9. Select F1 A/C Clutch Relay. 10. Run the Engine at idle. 11. Turn on Air Conditioning. 12. Turn "On" and "Off" A/C Switch. Page 4184 3. Carefully use adjustable pliers to bottom the piston into the caliper bore. Do not pull or twist the flexible hose or damage will occur. Install caliper assembly. Set caliber assembly in place. 4. Install lock bolt (5) and tighten the bolt to the specified torque. Torque: 74 Nm (54 ft. lbs.) 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 7710 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 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 5742 Individual circuit schematics begin with a fuse. The first half of Power Distribution, however, shows the wiring "upstream" between the battery 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 5601 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 6393 Radiator Grille Page 816 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 4211 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 5780 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-ring can not 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 (17 fl.oz.) of new compressor oil to the new core. 8. Tighten the refrigerant lines to the specified torque. 9. Apply an adhesive to the parting face of the lining when assembling the evaporator assembly. Page 2223 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 Relay Box: Locations Fuse To Component view, Image 6-2 Page 5622 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 - 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. Page 4282 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. Service and Repair 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 To install, follow the removal steps in the reverse order, noting the following points. Torque: Nut (1) 8 Nm (69 inch lbs.) 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. Specifications Water Pump: Specifications Water Pump Bolts 25 Nm Engine Coolant Pump Centrifugal Impeller Type Page 2463 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. Service and Repair License Plate Bracket: Service and Repair License Plate Garnish - Parts Location 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 4879 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. Description and Operation Temperature Gauge: Description and Operation The 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 1730 The wire insulation has one color or one color with another color stripe. The second color is the stripe. Page 7479 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 4446 General Specifications Page 4560 1. Check for continuity between the end of the field coil and yoke body. Replace the field coil, if there is continuity. 2. Check continuity between the lead wire of terminal C and brush. Replace the yoke assembly, if there is no continuity. Overrunning Clutch 1. Visual check for excessive wear or damage. 2. Test the pinion rotation, it must rotate smoothly when rotated clockwise and it shouldn't rotate when turned counterclockwise. Page 2424 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 megaohms 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 (ODM) - Quad Driver Module (QDM) PCM Input/Outputs PCM Input/Outputs Page 121 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. 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 2998 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 5843 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 4859 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 5547 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. 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 bracket, tighten the fixing bolt to the specified torque. Torque: 46 Nm (34 ft. lbs.) 2. Install the flexible hose. Tighten the eye bolt to specified torque. Torque: 54 Nm (40 ft. lbs.) 3. Install the drive belt. 4. Connect the suction hose, then fill and bleed system. 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. 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. 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: Page 3570 5. Install 8.5 mm connector of ground wire under the head of this valve body bolt and reinstall it. Tighten the bolt to the specified torque (HEC). Torque: 20 Nm (15 ft. lbs.) 6. Remove two guide pins from main case. 7. Install servo cover gasket, cover, and four 13 mm screws. Tighten the screws to the specified torque. Torque: 25 Nm (18 ft. lbs.) 8. Connect wiring harness to band control and shift solenoids. 9. 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.) 10. Install oil filter and three 13 mm screws. Tighten to the specified torque. Torque: 20 Nm (15 ft. lbs.) 11. 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.) 12. Fill transmission through overfill screw hole of oil pan, using ATF DEXRON III. 13. Connect battery ground cable. Page 3014 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 58. Under Center Console Service and Repair Shift Indicator: Service and Repair A/T Shift Indicator Light Bulb Removal 1. Disconnect the battery ground cable. 2. Pry up the bended portions (2) of the metal cover (1). 3. Remove the meter lense (3) from the meter visor (4). 4. Remove the meter visor from the meter case (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. Removal and Installation 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 bracket fixing bolts. 3. Disconnect red clip from harness connector. 4. Remove harness connector. 5. Remove Electronic Hydraulic Control Unit (EHCU) ASM. 6. Remove EHCU. Installation To install, follow the removal steps in the reverse order, noting the following points: Torque: Locations Fuse And Relay Panel (Underhood Electrical Center) Page 4961 Page 2677 Canister Purge Solenoid: Testing and Inspection EVAP Canister Purge Solenoid and EVAP Vacuum Switch A continuous purge condition with no purge commanded by the PCM will set a DTC P1441. Refer to the DTC charts for further information. 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 2302 The wire insulation has one color or one color with another color stripe. The second color is the stripe. Page 7090 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 12 Each schematic represents one circuit. A circuit's wires and components are arranged to show current flow, from power at the top 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 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. Page 6201 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 1878 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 5523 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 4939 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). Capacity Specifications Fluid - Differential: Capacity Specifications Front Differential Differential Oil Front Differential ........................................................................................................................................... ......................................................... 1.25L (1.32 Qt) Actuator Housing: Shift on the fly ..................... ........................................................................................................................................... 0.12L (0.13 Qt) Rear Differential Differential Oil Capacity ............................................................................................................................................... ......................................................... 1.77L (1.87 Qt) Page 5993 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 2980 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 4609 Fuse To Component Index (Fuse 11 - 23) Image 6-1 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 3533 10. About following installation steps, refer to Shift Lever. Page 2758 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 2293 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 569 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 2934 13. Control A/C Clutch Relay and check data list. 14. If the data list changes, the Fuel Pump Relay is normal. Page 5779 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 - 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. Page 5581 Control Lever Assembly, Control Cable And Associated Parts Page 2304 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 25. Left Side of Engine Page 7694 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 5716 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 5209 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 918 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 6051 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 447 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 870 Front Passenger's Power Window And Door Lock Switch Driver's Power Window And Door Lock Switch Page 6884 Audio, Clock, Cigarette Lighter And ACC Socket Diagram Information and Instructions Cigarette Lighter: Diagram Information and Instructions How to Identify Wiring Color-Coded Insulation Wire Color Wire Color Coding Page 4359 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 Band Control Solenoid Valve: Service and Repair For further information regarding this component and the system that it is a part of, please refer to Shift Solenoid; Service and Repair. Page 505 Each schematic represents one circuit. A circuit's wires and components are arranged to show current flow, from power at the top 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 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. Page 924 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 1133 Power Steering Fluid: Service and Repair Fluid Level 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 as specified in General Information 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. 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 2188 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 4806 Each schematic represents one circuit. A circuit's wires and components are arranged to show current flow, from power at the top 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 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. Page 6122 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 7593 Heated Glass Element Relay: Service and Repair Rear Defogger Switch 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 6935 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. 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 6126 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 4270 Brake Fluid: Service Precautions 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 403 Fan Control Switch Page 4929 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 3051 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 6070 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 1577 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 1.05 mm (0.04 in). NOTE: Do not adjust the spark plugs gap without new spark plugs. - Do not damage to tip of spark plugs. - Do not cleaning the spark plugs. If require the cleaning it due to heavy dirt, it is allowed only 20 seconds to be used spark plug cleaner. - 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 Page 5524 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 Wheel Fastener: Specifications Wheel Fastener 118 Nm Page 1693 Exhaust Pipe: Service and Repair 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.) Page 1196 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 5378 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 4053 The wire insulation has one color or one color with another color stripe. The second color is the stripe. Page 2518 Manifold Absolute Pressure 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 958 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 10.8 mm (0.425 inch) or less. Tighten the fulcrum pin bolt to the specified torque. Torque: 152 Nm 112 ( ft. lbs.) Camber Adjustment 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' CAUTION: Left and right side must be equal within 30'. Locations Page 62 Individual circuit schematics begin with a fuse. The first half of Power Distribution, however, shows the wiring "upstream" between the battery 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 10. Fuse/Relay Box (Cover Removed) Page 6156 Radio/Stereo: Service and Repair Radio Removal 1. Disconnect the battery ground cable. 2. Remove the lower cluster assembly (1). 3. Remove the radio (2). - Remove the two fixing screws. - Disconnect the connector (4) and the antenna cable (3). Installation To install, follow the removal steps in the reverse order. Page 1106 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. Page 2834 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 Steering Gear: Specifications Power Steering Unit Type Rack and Pinion Rack Stroke 152 mm Lock to Lock 3.64 Page 639 ^ 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 1. Behind Right Side of Grille Page 5315 Tires: Testing and Inspection Irregular and Premature Wear 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 Diagnosis List If the 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 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. Page 2927 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 3872 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 5798 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 7023 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 6990 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 6947 Door 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. Specifications Water Pump: Specifications Water Pump Bolts 25 Nm Engine Coolant Pump Centrifugal Impeller Type Page 3644 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 3475 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 4L30-E Automatic Transmission (Transmission Control System Diagnosis). Page 6001 Each schematic represents one circuit. A circuit's wires and components are arranged to show current flow, from power at the top 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 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. Page 549 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 Front Window Regulator, Glass And Glass Run - Parts Location Page 7020 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 7227 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 7481 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 5377 The wire insulation has one color or one color with another color stripe. The second color is the stripe. Specifications Idle Speed: Specifications Idle speed is PCM controlled Service and Repair Fuel Pressure Release: Service and Repair Fuel Pressure Relief Procedure CAUTION: To reduce the risk of fire and personal injury, there are necessary to relieve the fuel system pressure before filler and gauge unit 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 disconnect 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 Air Flow Meter/Sensor: Locations 28. Left Side of Engine Compartment MAF Sensor Specifications Starter Motor: Specifications General Specifications Torque Specifications (Part 1) Page 5694 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 5537 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 7132 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 1659 Thermostat: Description and Operation Thermostat The thermostat is a wax pellet type with a air hole (1) and is installed in the thermostat housing. Specifications Flywheel: Specifications Flywheel Fixing Bolts 54 Nm -- Do not reuse the bolts. Do not apply oil or thread lock to the bolts. Page 7051 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 80 Part 3 of 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. 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 5355 Air Conditioning Switch: Testing and Inspection Check for continuity between the fan switch and the A/C switch side connector terminals. Page 3422 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. Removal and Installation Compressor Clutch: Service and Repair Removal and Installation Magnetic Clutch Assembly (DKV-14G Type) - Parts Location View Magnetic Clutch Assembly (DKV-14G Type) Removal 1. Using drive plate holder J-33939 (1) to prevent the drive plate from rotating, then remove the drive plate bolt. 2. Remove drive plate by using drive plate puller J-33944-A (2) and forcing screw J-33944-4 (1). Page 5552 Condenser Fan Motor Relay: Testing and Inspection Heater (X-1), Thermostat (X-8), Condenser Fan (X-11) And Compressor (X-2) Relay 1. Disconnect relays and check for continuity and resistance between relay terminals. - For handling of these relays, refer to Heater Relay. Page 120 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 88. Left Side of Front Axle Page 6808 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 7018 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 53. Above Center of Dash (Console Removed) Page 586 Crankshaft Position Sensor: Testing and Inspection Inspection Procedure 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 7332 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 1317 Page 28 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 58 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 1922 ^ 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 876 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 7086 Each schematic represents one circuit. A circuit's wires and components are arranged to show current flow, from power at the top 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 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. 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 4719 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 1552 Air Filter Element: Service and Repair Cleaning Method 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 6003 Individual circuit schematics begin with a fuse. The first half of Power Distribution, however, shows the wiring "upstream" between the battery 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 7177 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 3235 Actuator: Testing and Inspection Axle Shaft Connection and Disconnection Actuator Assembly Page 1127 Engine Oil: Service and Repair Oil Service REPLACEMENT: CAUTION: Remove the drain bolt carefully while the engine is hot; the hot oil may cause scalding. 1. Warm up the engine. 2. Drain the engine oil. 3. Reinstall the drain plug with a new washer, and refill with the recommended oil. NOTE: Under normal conditions, the oil filter should be replaced at every other oil change. Under severe conditions, the oil filter should be replaced at each oil change. The numbers in the middle of the API Service label tell you the oil's SAE viscosity or weight. Select the oil for your vehicle according to this chart: Page 23 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 5205 ^ 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 717 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 6617 Soft Top Assembly And Associated Parts 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 50 Sunroof / Moonroof Module: Service and Repair Sunroof Control Unit 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. Locations 48. Below Left Side of Dash Page 2517 Manifold Absolute Pressure 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 3013 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 865 Transmission Temperature Sensor/Switch: Service and Repair Transmission Oil Temperature Sensor (Main Case) (V6) Removal 1. Raise the vehicle and support it on jack stands. 2. Disconnect battery ground cable. 3. Drain fluid. 4. Remove sixteen 10 mm main case oil pan fixing screws, main case oil pan, and gasket. 5. Disconnect wiring harness from shift solenoids, band apply solenoid, and 7 way 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 assembly with transmission oil temperature sensor to band apply solenoid, shift solenoids, and 7 way 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 inch lbs.) 3. Fill transmission through the overfill screw hole of oil pan, using ATF DEXRON III. 4. Connect battery ground cable. Page 5498 Steps 21 - 31 Page 5155 Acceleration Position Sensor Assembly Page 3806 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 770 Crankshaft Position Sensor: Service and Repair Removal 1. Disconnect battery ground cable 2. Wiring connector from crankshaft position sensor. 3. Remove crankshaft position sensor from cylinder block. Installation 1. Install crankshaft position sensor into the cylinder block. Before installation,apply small amount of engine oil to the O-ring. Torque: 10 N.m (87 lb.in) 2. Reconnect wiring connector to crankshaft position sensor. Page 2856 NOTE: Do not use tools of any kind. Only use bare hands when disconnecting the connector. Use a lubricant (light oil) and/or push and pull the connector until the pipe is disconnected. Cover the connectors that was removed with a plastic bag, to prevent dust or rain water from entering. Reuse of Quick-Connector - Replace the port and connector if scratch, dent or crack is found. - Remove any dirt build up on the port when installing the connector. Replace the connector, if there is any forms of rust, dent, scratch. - After cleaning the port, 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. 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 4280 Brake Hose/Line: Diagrams Rear Rear Axle Brake Hose and Associated Parts Replacement w/ Related Components Page 4105 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 4142 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 1846 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 1. Install the MAF sensor on the air cleaner with the clamp. 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). Minimum limit: 1.0 mm (0.039 inch) Page 6226 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 7480 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 6084 Alarm/Immobilizer Control Unit: Service and Repair Alarm and Relay Control Unit Alarm and Relay Control Unit Removal 1. Disconnect the battery ground cable. 2. Remove the grove box (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 3937 4WD Motor Actuator Page 5194 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 7264 The wire insulation has one color or one color with another color stripe. The second color is the stripe. Page 2487 2. Install the ECT sensor in the coolant crossover. Tighten Tighten the ECT sensor to 30 N.m (22 lb.ft.). 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 3139 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 7137 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 Key Reminder Switch: Diagram Information and Instructions How to Identify Wiring Color-Coded Insulation Wire Color Wire Color Coding Page 4647 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 4902 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 Testing and Inspection Parking Brake Drum: Testing and Inspection For further information regarding this component and the system that it is a part of, please refer to Brake Rotor/Disc; Testing and Inspection; Procedures. Page 2824 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 6171 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 933 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. Diagram Information and Instructions Fuel Pump Relay: Diagram Information and Instructions How to Identify Wiring Color-Coded Insulation Wire Color Wire Color Coding Page 4249 Brake Caliper: Specifications Type Floating, Pin Slide Adjusting Method Self-Adjusting Piston Diameter 41.3 mm Page 5069 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 pinches. 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 the "ON" position and observe the warning lamp. The lamp should flash 7 times. Page 2982 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 5338 Wheel Bearing: Service and Repair 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. 9. Use wrench J-36827, remove hub nut. 10. Remove hub and disc assembly. Page 4469 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 2042 Crankshaft Position Sensor: Service and Repair Removal 1. Disconnect battery ground cable 2. Wiring connector from crankshaft position sensor. 3. Remove crankshaft position sensor from cylinder block. Installation 1. Install crankshaft position sensor into the cylinder block. Before installation,apply small amount of engine oil to the O-ring. Torque: 10 N.m (87 lb.in) 2. Reconnect wiring connector to crankshaft position sensor. Page 7641 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 6068 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 1438 Torque: 4 Nm (35 inch lbs.) 4. Connect ventilation hose to cylinder head. 5. Install engine cover mating with the dowels. Page 7327 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 2818 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 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 7397 Individual circuit schematics begin with a fuse. The first half of Power Distribution, however, shows the wiring "upstream" between the battery 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 1966 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 6982 Seat Belt, Lights-on, And Ignition Key Reminders Image 73-1 Page 1306 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. 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 7745 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 Refer to Rear Wiper Motor. Removal 1. Remove the arm nut (2). 2. Remove the wiper arm/blade (1). Installation Refer to Rear Wiper Motor. See: Wiper Motor Page 4402 Wheel Speed Sensor: Description and Operation Wheel Speed Sensor 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 front sensor rotor is attached to the each brake rotor by bolts. The rear rotor is press-fit in the differential case. The magnetic 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 16 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 5754 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 762 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 TP1 about 0.4 V, TP2 about 4.6 V and TP3 about 4.6 V. - If the reading is abnormal value, check the throttle shaft to see if it is binding. Page 7394 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 5591 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 2244 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 7695 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 946 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 4194 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. Diagrams Power Window Switch: Diagrams Left Rear Power Window Switch Right Rear Power Window Switch Page 486 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 ground 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). Diagrams Power/Winter Switch Page 1815 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 3924 Control Module: Service and Repair 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 6420 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 2846 5. Select injector number and push "injector off" soft key. 6. Make sure of engine speed change. 7. 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. Page 2545 ^ 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 1195 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 7735 Rear Washer Spray Pattern (Resin Top Model) Page 3050 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 699 Vehicle Speed Sensor: Testing and Inspection Inspection Procedure 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 6744 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 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 4726 The wire insulation has one color or one color with another color stripe. The second color is the stripe. Page 5609 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 1320 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: 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. 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 6938 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 Locations 105. Left Side of Driver's Seat Page 6384 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 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. Three Way Catalytic Converter RH & Forked Exhaust Pipe Catalytic Converter: Service and Repair Three Way Catalytic Converter RH & 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 front exhaust pipe assembly 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). Page 1949 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 4070 Hydraulic Control Assembly - Antilock Brakes: Service Precautions 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. The following are general precautions which should be observed when servicing and diagnosing the Anti-lock Brake System and/or other vehicle systems. Failure to observe these precautions may result in Anti-lock Brake System damage. If welding work is to be performed on the vehicle using an electric arc welder, the EHCU and valve block connectors should be disconnected before the welding operation begins. - The EHCU and valve block connectors should never be connected or disconnected with the ignition "ON". - If only rear wheels are rotated using jacks or drum tester, the system will diagnose a speed sensor malfunction and the "ABS" warning light will illuminate. But actually no trouble exists. After inspection stop the engine once and re-start it, then make sure that the "ABS" warning light does not illuminate. If the battery has been discharged The engine may stall if the battery has been completely discharged and the engine is started via jumper cables. This is because the Anti-lock Brake System (ABS) requires a large quantity of electricity. In this case, wait until the battery is recharged, or set the ABS to a non-operative state by removing the fuse for the ABS (60A). After the battery has been recharged, stop the engine and install the ABS fuse. Start the engine again, and confirm that the ABS warning light does not light. Page 5062 Page 6933 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 1539 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 4065 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. 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). 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. Locations 59. Under Center Console Page 4602 Relay/Fuse Box Location Page 4520 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 4978 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 6483 Headlining (LWB) Page 1605 Coolant: Fluid Type Specifications Mixture of water and good quality ethylene glycol base type antifreeze mixed 50/50. Page 4048 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 5362 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 7606 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. 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 4867 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 3065 Fuel Pump Relay: Testing and Inspection Relays Test This testis 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 78. Left "C" Pillar (Right Similar) 77. Left "B" Pillar (Right Similar) Page 7721 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. Diagram Information and Instructions Seat Belt Reminder Lamp: Diagram Information and Instructions How to Identify Wiring Color-Coded Insulation Wire Color Wire Color Coding Component Locations 76. Left Rear Door (Right Similar) Page 5298 3. Photocopy the template that is shown. Cut out the template. Front Wipers (In Combination Switch) Combination Light Switch Connectors A And B Locations 29. Left Side of Engine Compartment Page 1954 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 2170 2. Install the ECT sensor in the coolant crossover. Tighten Tighten the ECT sensor to 30 N.m (22 lb.ft.). 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 5950 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) Locations 39. Dash Fuse Box Page 458 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 7470 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 4024 Transmission Temperature Sensor/Switch: Service and Repair Transmission Oil Temperature Sensor (Main Case) (V6) Removal 1. Raise the vehicle and support it on jack stands. 2. Disconnect battery ground cable. 3. Drain fluid. 4. Remove sixteen 10 mm main case oil pan fixing screws, main case oil pan, and gasket. 5. Disconnect wiring harness from shift solenoids, band apply solenoid, and 7 way 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 assembly with transmission oil temperature sensor to band apply solenoid, shift solenoids, and 7 way 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 inch lbs.) 3. Fill transmission through the overfill screw hole of oil pan, using ATF DEXRON III. 4. Connect battery ground cable. 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 3717 Page 4795 ^ 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 441 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 2400 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 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 3236 Axle Disconnect Controller 1. Connect 12V with terminal (3) and the ground with the terminal (6). 2. Send the signal to the terminal (4) 2WD -> 4WD less than 2.4V 4WD -> 2WD more than 9.0V 3. Confirm the output signal from the terminals (1) & (2) (2 seconds output) 4. If the trouble occurs after test, charge the Axle Disconnect Controller to the new one. Motor Actuator Assembly (Transfer) Inspect the function of the motor actuator assembly as follows: 1. Disassemble the motor actuator from transfer rear case. 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 6885 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. Page 7648 Liftgate Window Glass: Service and Repair Rear Hatchgate Rear Hatchgate (LWB) Removal 1. Disconnect the battery ground cable. 2. Disconnect the high mount stoplight and rear defogger harness connectors. Page 1837 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 7183 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 7466 Each schematic represents one circuit. A circuit's wires and components are arranged to show current flow, from power at the top 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 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. Page 2672 Steps 1 - 7 Page 5004 - Refer to the scrapping procedures for disposal of the damaged airbag. Page 2464 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 5971 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 7110 Dimmer Switch: Service and Repair Illumination Controller 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 7514 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 4554 6. Remove the armature. 7. Remove the housing. 8. Remove the overrunning clutch from the housing. 9. Remove the return spring from the magnetic switch. 10. Remove the steel ball from the overrunning clutch. Page 7581 Vanity Mirror Lights Image 114-6 Page 2954 Page 2301 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 5199 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 1586 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 115 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. 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 7757 - Check if the convex part (3) of wiper blade is installed in the groove of the wiper rubber. Component Locations 92. Beneath Center of Vehicle, on Transfer Case (A/T) Page 3739 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: 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 7701 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 1913 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 1858 Crankshaft Position Sensor: Testing and Inspection Inspection Procedure 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. Locations 59. Under Center Console Page 4408 Wheel Speed Sensor: Service and Repair Rear Removal 1. Disconnect harness connector (1). 2. Remove sensor fixing bolt (2). 3. Remove speed sensor (3). Installation 1. Install speed sensor (3). 2. Tighten the sensor fixing bolt (2) to the specified torque. Torque: 24 Nm (17 ft. lbs.) 3. Connect harness connector (1). Diagram Information and Instructions Electronic Brake Control Module: Diagram Information and Instructions How to Identify Wiring Color-Coded Insulation Wire Color Wire Color Coding Page 2536 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 7244 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. Clearance: 0.0 - 0.2 mm (0.0 - 0.08 inch) 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 5698 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. 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 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). Specifications Compression Check: Specifications Compression Pressure Limit 1,000 kPa Compression Ratio 9.1 : 1 Copmression Pressure At 300 rpm 145 psi. Page 2213 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. Steps 1 - 5 Page 4538 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 4114 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 5225 REQUIRED MATERIALS TOOL INFORMATION Page 684 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 826 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. 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 493 Door 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 1436 3. Connect ignition coil connector and ignition coil, then tighten bolt to the specified torque. Torque: 4 Nm (35 inch lbs.) 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. 4. Connect ground cable and tighten bolts to the specified torque. Torque: 9 Nm (78 inch lbs.) 5. Install positive crankcase ventilation hose. 6. Install engine cover mating with the dowels. Page 7468 Individual circuit schematics begin with a fuse. The first half of Power Distribution, however, shows the wiring "upstream" between the battery 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 5453 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 6397 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 2778 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 5202 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 1886 Manifold Absolute Pressure 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 Page 5254 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 5666 Blower Link Unit And/or Mode Door - Disassembled View Symptom Diagnosis Malfunction Indicator Lamp: Testing and Inspection Symptom Diagnosis Malfunction Indicator Lamp The instrument panel "CHECK ENGINE" Malfunction Indicator Lamp (MIL) illuminates by self diagnostic system when the system checks the starting of engine, or senses malfunctions. Page 3558 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 4L30-E Automatic Transmission (Transmission Control System Diagnosis). Page 5880 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 4593 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 Constant Velocity Joint: Service and Repair Front Axle Drive Shaft and Associated Parts Disassembly NOTE: For the left side, follow the same steps as right side. Page 4193 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 513 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 7104 Seat Belt Reminder Lamp: Electrical Diagrams Seat Belt, Lights-on, And Ignition Key Reminders Image 73-0 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 2825 Ground - "G" Shielding Sheilding This represents RFI (Radio Frequency Interference) shielding around a wire. The shielding is always connected to ground. Splices Page 4686 Grounding Point: Electrical Diagrams Earth Location (Engine Room) Page 3936 92. Beneath Center of Vehicle, on Transfer Case (A/T) Page 2735 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 2493 Crankshaft Position Sensor: Service and Repair Removal 1. Disconnect battery ground cable 2. Wiring connector from crankshaft position sensor. 3. Remove crankshaft position sensor from cylinder block. Installation 1. Install crankshaft position sensor into the cylinder block. Before installation,apply small amount of engine oil to the O-ring. Torque: 10 N.m (87 lb.in) 2. Reconnect wiring connector to crankshaft position sensor. Page 5580 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 7219 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 53. Above Center of Dash (Console Removed) Page 4298 Hydraulic Control Assembly - Antilock Brakes: Service and Repair Disassembly and Reassembly HYDRAULIC CONTROL UNIT Disassembly 1. Remove fixing bolts from Electronic Hydraulic Control Unit (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 7601 Front Passenger's Power Window And Door Lock Switch Driver's Power Window And Door Lock Switch Page 4169 Brake Caliper: Service and Repair Bleeding For further information regarding this component and the system that it is a part of, please refer to Brake Bleeding; Service and Repair. Locations Evaporator Temperature Sensor / Switch: Locations 65. Behind Glove Box Electronic Thermostat, Evaporator Core And/Or Expansion Valve - Disassembled View Page 1245 Relay/Fuse Box (Engine Room) 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 6590 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 18 Ground - "G" Shielding Sheilding This represents RFI (Radio Frequency Interference) shielding around a wire. The shielding is always connected to ground. Splices Page 2234 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 1766 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 1219 Above 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 begins in Wire Color Abbreviations. 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 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 Page 6456 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". 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 6960 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 Diagram Information and Instructions Fuse Block: Diagram Information and Instructions How to Identify Wiring Color-Coded Insulation Wire Color Wire Color Coding Page 6239 Trailer Lighting Connector Page 6843 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 4209 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 7197 Upshift Indicator: Testing and Inspection Lamps Test Lamps Test This test is conducted to check MIL, Up Shift Lamp, Low Fuel Lamp, Reduced Power Lamp and Cruise Control Lamp for its working. 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 F0: Lamps Test in the Miscellaneous Test. Page 7223 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 2254 Powertrain Control Module: Connector Views ECM (M/T) Or PCM (A/T) Connector A Component Locations 92. Beneath Center of Vehicle, on Transfer Case (A/T) Page 6594 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 200 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 megaohms 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 (ODM) - Quad Driver Module (QDM) Page 1311 Tires: Service and Repair General Balance Procedure 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 5960 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 17 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 5435 Each schematic represents one circuit. A circuit's wires and components are arranged to show current flow, from power at the top 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 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. Page 190 Powertrain Control Module: Connector Views ECM (M/T) Or PCM (A/T) Connector A Page 1666 Water Pump: Service and Repair 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 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. 2. Install water pump assembly and tighten bolts to the specified torque. Torque: 25 Nm (18 ft. lbs.) Tightening order The tightening order are in the illustration. NOTE: To prevent the oil leakage, apply the LOCTITE 262 or an equivalent, to the arrow marked fixing bolt thread. 3. Idle pulley Page 4771 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 7338 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 3117 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 1. Install the MAF sensor on the air cleaner with the clamp. Page 3102 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 690 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 1898 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 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. Procedures Grille: Procedures Radiator Grille - Parts Locations 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 tender 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 897 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 7406 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 Brake Pad: Specifications Pad Dimension 55 cm2 Diagram Information and Instructions Auxiliary Power Outlet: Diagram Information and Instructions How to Identify Wiring Color-Coded Insulation Wire Color Wire Color Coding Page 4458 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 6857 Brake Warning Indicator: Description and Operation How the Circuit Works 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. Parking Brake Switch 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. Brake Fluid Level Switch 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.) Bulb Check 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 6845 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 6855 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 1381 2. Align timing mark on intake camshaft (one dot for right bank, two dot for left bank) and exhaust camshaft (one dots 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. Torque: 10 Nm (87 inch lbs.) 5. Install cylinder head cover RH. 6. Install cylinder head cover LH. 7. Install timing belt. 8. Install crankshaft pulley. Page 5265 4. Use installer J-36828 and grip J-8092 then install the outer bearing by driving it into the hub. 5. Apply grease (NLGI 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. Grease Amount Hub: 35 g (1.23 oz) Outer bearing: 10 g (0.35 oz) Inner bearing: 15 g (0.53 oz) Page 5140 Stabilizer Bar: Specifications Stabilizer Bar Diameter 18 mm Page 2932 Fuel Pump Relay: Testing and Inspection Relays Test This testis 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 4674 Ground - "G" Shielding Sheilding This represents RFI (Radio Frequency Interference) shielding around a wire. The shielding is always connected to ground. Splices Page 1740 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 2474 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 3053 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 1223 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 73. Rear of Driver's Door (Frt. Pass. Similar) Page 5831 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 4563 3. Reconnect the connectors to terminals "50" (2) tighten terminals "30" (1) to specified torque. Torque: 9 N.m (78 lb in) 4. Install exhaust front left pipe (2) and tighten bolts and nuts to specified torque. Stud Nuts Torque: 67 N.m (49 lb.ft) Bolts Torque: 43 N.m (32 lb.ft) 5. Connect two Heated O2 Sensor connector (1). 6. Reconnect the battery ground cable. Page 2853 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. Piping that has been splattered with battery electrolyte or battery electrolyte soaked cloth that was wiped on the piping cannot be used. Page 4464 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 2620 a. Place selector lever in neutral. b. Disconnect transmission harness connector from mode switch connector. 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 (approximately 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 479 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. Clearance: 0.0 - 0.2 mm (0.0 - 0.08 inch) 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 420 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 5318 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. Premature wear in shoulders. Upper Arm Control Arm: Service and Repair Upper Arm 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. 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. Page 5217 Page 6127 Front Page 2201 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 78 Electronic Brake Control Module: Connector Views Part 1 of 3 Page 5562 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 4455 Above 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 begins in Wire Color Abbreviations. 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 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 Component Locations 92. Beneath Center of Vehicle, on Transfer Case (A/T) 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 4405 Wheel Speed Sensor: Testing and Inspection 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 3022 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 488 CAUTION: Never apply force to the steering wheel shaft 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. INSTALLATION 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 counter clockwise to full, return about 3 turns and align the neutral mark. CAUTION: Turn the SRS coil counter clockwise until some resistance is felt, or damage may occur to the SRS coil. Page 1220 Individual circuit schematics begin with a fuse. The first half of Power Distribution, however, shows the wiring "upstream" between the battery 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 1799 Ion Sensing Module Connectors A - C Page 2678 Canister Purge Solenoid: Service and Repair EVAP Canister Purge Solenoid Removal Procedure 1. Disconnect the negative battery cable. 2. Disconnect the electrical connector from the EVAP canister purge solenoid. 3. Disconnect the vacuum hoses from the EVAP canister purge solenoid. 4. Remove the EVAP canister purge solenoid retaining bolt from the common chamber. 5. 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.). 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 556 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 2875 ^ 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 7356 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 5449 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 7321 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 Shift Indicator: Service and Repair A/T Shift Indicator Light Bulb Removal 1. Disconnect the battery ground cable. 2. Pry up the bended portions (2) of the metal cover (1). 3. Remove the meter lense (3) from the meter visor (4). 4. Remove the meter visor from the meter case (5). Page 7325 Above 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 begins in Wire Color Abbreviations. 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 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 Page 7485 Headlight Switch Image 100-1 Page 4212 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.). Diagrams Axle Shaft: Diagrams Disc Brake Model Drum Brake Model 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 7127 Each schematic represents one circuit. A circuit's wires and components are arranged to show current flow, from power at the top 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 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. Page 4817 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 1746 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 megaohms 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 (ODM) - Quad Driver Module (QDM) Page 4621 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 5231 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 5391 Air Door Cable: Service and Repair Control Assembly / Control Cable Control Lever Assembly, Control Cable And Associated Parts 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. 6. Pull the control lever assembly out and disconnect the fan switch and air conditioning switch connectors. Page 4168 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 (Approximately 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 4400 Wheel Speed Sensor: Connector Locations 3. Behind Left Front Wheel (Right Wheel Similar) 99. Under Rear of Vehicle (On Differential) Page 732 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 6503 Trim Panel: Service and Repair Interior Trim Panels Interior Trim Panels And Associated Parts (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. Page 1728 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. 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 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 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 4657 ^ 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 4634 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 1244 Relay/Fuse Box (Engine Room) Page 1973 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 Procedure 1. Install the VSS in the transfer case with the notch for the connector facing the rear. 2. Secure the VSS in place with the clamp and the bolt. Tighten Tighten the bolt to 16 N.m (12 lb.ft.). Specifications Fuel Pressure: Specifications PRESSURE PRESSURE With Regulator Vacuume Hose Disconnected 42-55 Psi. Page 1938 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 4L30-E Automatic Transmission (Transmission Control System Diagnosis). Locations 102. Below Left Side of Rear Bumper (Honda Acc.) Page 7091 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 2787 Air Filter Element: Service and Repair Cleaning Method 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. Locations Ignition Control Module: Locations 24. Top Rear of Engine ION Sensing Module Front Wipers (In Combination Switch) Combination Light Switch Connectors A And B Page 7515 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 1182 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. Locations 40. Dash Fuse Box Locations Ignition Control Module: Locations 24. Top Rear of Engine ION Sensing Module Page 6624 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) Locations Door Switch: Locations 78. Left "C" Pillar (Right Similar) 77. Left "B" Pillar (Right Similar) Page 6768 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 5324 Tires: Service and Repair General Balance Procedure 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 5243 ^ 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 6560 Above 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 begins in Wire Color Abbreviations. 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 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 Page 4485 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. 3. Check resistance between slip rings, and replace if there is no continuity. 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. Page 5868 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 304 Hood Sensor/Switch (For Alarm): Service and Repair Engine Hood Switch 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 7341 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 5674 To install follow the removal steps in the reverse order noting the following point; 1. Check that each mode door operates properly. Page 2910 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 3855 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 4L30-E Automatic Transmission (Transmission Control System Diagnosis). Page 5237 - 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 587 Crankshaft Position Sensor: Service and Repair Removal 1. Disconnect battery ground cable 2. Wiring connector from crankshaft position sensor. 3. Remove crankshaft position sensor from cylinder block. Installation 1. Install crankshaft position sensor into the cylinder block. Before installation,apply small amount of engine oil to the O-ring. Torque: 10 N.m (87 lb.in) 2. Reconnect wiring connector to crankshaft position sensor. Page 6186 Alarm/Immobilizer 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 1148 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 1887 1. Install the MAP sensor in the mounting bracket. 2. Install the mounting bracket retaining bolt on the common chamber. Tighten Tighten the bolt to 20 N.m (12 lb.ft.). 3. Connect the MAP electrical connector. 4. Connect the negative battery cable. Page 4074 Hydraulic Control Assembly - Antilock Brakes: Service and Repair Disassembly and Reassembly HYDRAULIC CONTROL UNIT Disassembly 1. Remove fixing bolts from Electronic Hydraulic Control Unit (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 7440 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. Clearance: 0.0 - 0.2 mm (0.0 - 0.08 inch) 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 4581 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 1928 27. Left Side of Engine Specifications Fuel Pressure: Specifications PRESSURE PRESSURE With Regulator Vacuume Hose Disconnected 42-55 Psi. Page 1735 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 1733 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 557 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. Locations Relay Box: Locations Fuse To Component view, Image 6-2 Page 6110 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 6939 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 5832 Each schematic represents one circuit. A circuit's wires and components are arranged to show current flow, from power at the top 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 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. Page 2603 VSS Image 33-0 Page 5565 Individual circuit schematics begin with a fuse. The first half of Power Distribution, however, shows the wiring "upstream" between the battery 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 2604 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 5213 ^ 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 1959 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 6240 Trailer Lamps: Electrical Diagrams Trailer Lighting Connector Image 118-0 Page 3206 Spark Plug: Application and ID NGK Platinum: NGK 2647 Bosch Platinum +4: BSA 4417 Bosch Platinum +2: BSA 4303 Bosch Platinum: BSA 4202 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, M/T; Service and Repair. Page 7169 Above 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 begins in Wire Color Abbreviations. 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 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 Page 2242 Ground - "G" Shielding Sheilding This represents RFI (Radio Frequency Interference) shielding around a wire. The shielding is always connected to ground. Splices Locations 90. Left Side of Automatic Transmission (A/T) Page 2297 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 Transmission Temperature Sensor/Switch: Description and Operation Transmission Fluid Temperature (TFT) Sensor The transmission fluid temperature sensor is a thermistor which changes its resistance based on the temperature of the transmission fluid. For a complete description of the TFT sensor, refer to 4L30-E Automatic Transmission Diagnosis (Transmission Control System Diagnosis). A failure in the TFT sensor or associated wiring will cause DTC P0712 or DTC P0713 to set. In this case, engine coolant temperature will be substituted for the TFT sensor value and the transmission will operate normally. Page 3519 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. Page 7057 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. Description and Operation 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 5530 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 7578 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 1371 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 264 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 6457 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 6995 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 5850 SRS-Air Bag Page 7015 Individual circuit schematics begin with a fuse. The first half of Power Distribution, however, shows the wiring "upstream" between the battery 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 6093 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 5635 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 - 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. Page 5190 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 5022 Each schematic represents one circuit. A circuit's wires and components are arranged to show current flow, from power at the top 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 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. Locations 90. Left Side of Automatic Transmission (A/T) Locations Page 5363 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 Grounding Point: Diagram Information and Instructions How to Identify Wiring Color-Coded Insulation Wire Color Wire Color Coding Page 6433 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 3112 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. Locations 8. Fuse/Relay Box (Cover Removed) Page 2396 Above 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 begins in Wire Color Abbreviations. 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 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 Page 2197 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 6919 14. Push "On" of soft key. 15. Make sure Lamp illuminates. 16. If Lamp illuminates, the Lamp is operating correctly. 17. Select F3: Reduced Power Lamp 18. Push "On" of soft key. 19. Make sure Lamp illuminates. 20. If Lamp illuminates, the Lamp is operating correctly. 21. Select F5: Cruise Control Lamp 22. Push "On" of soft key. 23. Make sure Lamp illuminates. 24. It Lamp illuminates, the Lamp is operating correctly. Locations Power Door Lock Actuator: Locations 75. Left Rear Door (Right Similar) 73. Rear of Driver's Door (Frt. Pass. Similar) Page 3048 Individual circuit schematics begin with a fuse. The first half of Power Distribution, however, shows the wiring "upstream" between the battery 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 Specifications Harmonic Balancer - Crankshaft Pulley: Specifications Crankshaft Pulley 167 Nm Locations Relay Box: Locations Fuse To Component view, Image 6-2 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 Page 6242 Trailer Lighting Connector Image 118-2 Page 1540 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 365 Wheel Speed Sensor: Description and Operation Wheel Speed Sensor 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 front sensor rotor is attached to the each brake rotor by bolts. The rear rotor is press-fit in the differential case. The magnetic 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. Application and ID Valve Spring Shim: Application and ID Selection of Adjusting Shim Shim to be selected = (Thickness of removed shim) + (Valve clearance measurement - Standard value) Based on the formula, the best suited shim should be selected from 41 types 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 Part 1 of 3 Part 2 of 3 Part 3 of 3 Let the cam push down the edge of tappet by using J-2689 valve clearance adjusting tool and push out the shim with a flat blade screw driver. Page 7042 Individual circuit schematics begin with a fuse. The first half of Power Distribution, however, shows the wiring "upstream" between the battery 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 5475 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 4909 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: This illustration shows view from the front of the vehicle. 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. Toe-in: Page 5366 Above 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 begins in Wire Color Abbreviations. 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 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 Page 6063 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 2633 Individual circuit schematics begin with a fuse. The first half of Power Distribution, however, shows the wiring "upstream" between the battery 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 4677 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 7399 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 5851 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 6353 Liftgate Window Glass: Adjustments Rear Hatchgate Adjustment - Hatchgate alignment is obtained by moving hatchgate hinges. Locations 10. Fuse/Relay Box (Cover Removed) Page 6570 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 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. Refer to Maintenance and Lubrication in General Information for maintenance information and servicing interval. 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 NO T 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. Fluid Condition Page 5240 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 2109 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 5848 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 5778 Evaporator Temperature Sensor / Switch: 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 4701 7. Right Side of Engine Compartment Locations 85. Lower Rear of Tailgate Page 1522 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 2292 Individual circuit schematics begin with a fuse. The first half of Power Distribution, however, shows the wiring "upstream" between the battery 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 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. 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 Service and Repair Clutch: 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. Page 834 Acceleration Position Sensor Assembly Page 2832 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. Page 943 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 2491 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. Refer to Electronic Ignition System for additional information. Page 7221 Above 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 begins in Wire Color Abbreviations. 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 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 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. Page 524 Headlight Switch Image 100-1 Page 7544 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 ground 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 7713 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 Testing and Inspection Air Filter Element: Testing and Inspection Check the air cleaner filter for damage or dust clogging. Replace if it is damaged, or clean if it is clogged. Page 4180 Brake Pad: Testing and Inspection Rear 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. Wear indicators are installed on disc brake pads, disc brake pads need replacement when the wear indicator is heard. Minimum limit (1): 1.0 mm (0.039 inch) Page 5365 Each schematic represents one circuit. A circuit's wires and components are arranged to show current flow, from power at the top 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 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. Page 504 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 2548 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. Service and Repair 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. 1. Lift up carefully on the fuel injectors. Do not separate the fuel injectors from the fuel rail. 2. If an injector becomes separated from the fuel rail, the injector O-ring seals and the retainer clip must be replaced. 3. Drain residual fuel into an approved container. 8. If removal of the fuel pressure regulator is necessary, refer to Fuel Pressure Regulator. 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) 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 448 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 3009 Each schematic represents one circuit. A circuit's wires and components are arranged to show current flow, from power at the top 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 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. Page 6963 Each schematic represents one circuit. A circuit's wires and components are arranged to show current flow, from power at the top 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 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. Page 2599 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 6816 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 2785 3. Install the air cleaner lid on the MAF sensor and the air cleaner housing. 4. Tighten the clamp and secure the four latches between the lid and the air cleaner housing. Induction System 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). Page 746 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 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 Service and Repair Crankshaft Main Bearing Seal: Service and Repair 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 seal 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. CAUTION: When assembling the engine and transmission, confirm that dowels have been mounted in the specified positions at the engine side. Page 1990 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 7350 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 1300 Tires: Testing and Inspection Diagnosis List Diagnosis List If the 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 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. Locations 74. Rear of Driver's Door (Frt. Pass. Similar) Page 3069 2. Press down until the catch engages. - An audible "click" will be heard. 3. Install the fuse and relay box cover. Page 7340 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 1998 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 4459 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 4005 a. Place selector lever in neutral. b. Disconnect transmission harness connector from mode switch connector. 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 (approximately 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. Testing and Inspection Blower Motor Relay: Testing and Inspection Heater Relay 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 6079 Alarm/Immobilizer Control Unit: Electrical Diagrams Alarm And Relay Controls Image 70-0 Page 3754 Torque Specifications FRONT PROPELLER SHAFT General Specifications Torque Specifications REAR PROPELLER SHAFT Page 5595 Above 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 begins in Wire Color Abbreviations. 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 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 Page 5229 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 5065 Steering Wheel: Vehicle Damage Warnings CAUTION: Once the steering column is removed from the vehicle, the column is extremely susceptible to damage. Dropping the column assembly on its end could collapse the steering shaft or loosen the slide block, which maintains column rigidity. Leaning on the column assembly could cause the jacket to bend or deform. Any of the above damage could impair the column's collapsible design. If it is necessary to remove the steering wheel, use only the specified steering wheel puller. Under no conditions should the end of the shaft be hammered upon, as hammering could loosen the slide block, which maintains column rigidity. 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 2253 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 6234 Trailer Lamps: 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 5889 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 4533 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 6703 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 1592 Valve Shim Replacement Chart 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 2163 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. Exploded Views Page 4584 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 5068 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 shaft 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 steering wheel by aligning the setting marks made when removing. CAUTION: Never apply force to the steering wheel shaft 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.) Page 4888 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 5568 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 7532 Trailer Lamps: Description and Operation Trailer Lighting Connector How the Circuit Works Early Production only 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 6238 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 1786 Fuel Pump Relay: Description and Operation In order to control the FPS operation, the FPS relay is provided. When the starter switch is turned to "ON" position, the FPS relay operates the FPS for 2 seconds. When the key 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 FPS to feed fuel. Page 5835 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 7542 Combination Switch: Connector Locations 45. Below Left Side of Dash 46. Below Left Side of Dash 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. Windshield Wiper Blade: Service and Repair Windshield Windshield Wiper Arm/Blade Windshield Wiper Arm/Blade Removal 1. Dry 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 N.m (17 lb.ft) Windshield Wiper Blade Rubber Removal Page 4243 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/sec), 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 7634 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 5677 Housing Assembly HVAC: Service and Repair Heater Temperature Control Link Unit Heater Temperature Control Link Unit Heater Temperature Control Link Unit - Disassembled View 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 it the link unit operates correctly. Page 751 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 1. Install the MAF sensor on the air cleaner with the clamp. Page 1589 Valve Shims (While 41 shims are available, the 10 sizes will cover most valve adjustments): Page 103 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 1828 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 5034 The wire insulation has one color or one color with another color stripe. The second color is the stripe. Page 4869 DIAGNOSTIC WORKSHEET REPAIR PROCEDURE A Page 4039 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. 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". 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 2854 Fuel Line Coupler: Testing and Inspection Fuel Tube/Quick - Connector Fittings Assembling Advice By applying engine oil or light oil to the pipe, port makes pipe assembly easier. The pipe assembly should take place immediately after applying oil (to prevent dust from sticking to the pipe surface which may decrease sealing ability). Test/Inspection After Assembling 1. Reconnect the battery negative cable. 2. Turn the ignition key to the "ON" position and listen for pump start-up sound. Inspect for leaks, the fuel pressure will increase as the fuel pump is actuated. 3. Perform leak inspection (step 2) several times. 4. Start the engine and observe the engine idle speed. The presence of dirt in the fuel system may affect the fuel injection system. Page 521 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. Alignment Alignment: Specifications Alignment Locations 59. Under Center Console Locations 14. Right Rear of Engine Compartment Page 1736 Powertrain Control Module: Connector Views ECM (M/T) Or PCM (A/T) Connector A Page 1188 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 1781 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 4831 7. Right Side of Engine Compartment Locations Rear Quarter Glass (LWB) - Parts Locations Page 5865 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 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 6294 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 5766 Air Conditioning Switch: Testing and Inspection Check for continuity between the fan switch and the A/C switch side connector terminals. Page 6838 Each schematic represents one circuit. A circuit's wires and components are arranged to show current flow, from power at the top 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 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. 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 219 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 9. Fuse/Relay Box (Cover Removed) Page 4662 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 653 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. Component Locations 101. Beneath Vehicle, Behind Left Rear Wheel Page 512 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 2092 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 MOhms or more Page 6241 Trailer Lighting Connector Image 118-1 Page 1839 129 - Below Left Side Of I/P Specifications Camshaft Gear/Sprocket: Specifications Camshaft Drive Gear Assembly Bolts (3) 10 Nm Camshaft Drive Gear Assembly Pulley Bolt 98 Nm Page 2777 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 6970 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 5596 Individual circuit schematics begin with a fuse. The first half of Power Distribution, however, shows the wiring "upstream" between the battery 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 1026 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 3378 Axle Disconnect Controller 1. Connect 12V with terminal (3) and the ground with the terminal (6). 2. Send the signal to the terminal (4) 2WD -> 4WD less than 2.4V 4WD -> 2WD more than 9.0V 3. Confirm the output signal from the terminals (1) & (2) (2 seconds output) 4. If the trouble occurs after test, charge the Axle Disconnect Controller to the new one. Motor Actuator Assembly (Transfer) Inspect the function of the motor actuator assembly as follows: 1. Disassemble the motor actuator from transfer rear case. Locations 59. Under Center Console Page 2281 Fuel Tank Pressure Sensor: Testing and Inspection Inspection Procedure 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 4982 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 7330 Ground - "G" Shielding Sheilding This represents RFI (Radio Frequency Interference) shielding around a wire. The shielding is always connected to ground. Splices Page 5642 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 6971 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 5009 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 2951 1. Disconnect the fuel hose assembly from the fuel lines (quick disconnect fittings). 2. Remove the O2 harness sensor clip. 3. Remove the two transmission mounting nuts. 4. Lower the vehicle. 5. Open the hood. Remove the fuel pump relay from the underhood fuse/relay box. Remove the plastic engine cover. If any of the engine cover mounting grommets stayed on the engine, remove them and install them back in the engine cover. 6. Place a floor jack cushioned by a block of wood under the transfer case (4WD) or the transmission pan (2WD). Jack up the transmission until it bottoms against the body and the vehicle starts to lift on the suspension. Do not lift the wheels off the floor. Fan Control Lever (Fan Switch) Blower Motor Switch: Testing and Inspection Fan Control Lever (Fan Switch) Check for continuity between the terminals of the fan switch. Gas Tank - Fuel Pump/Sending Unit Installation Tip Fuel Gauge Sender: Technical Service Bulletins Gas Tank - Fuel Pump/Sending Unit Installation Tip SOURCE: Honda Service News March 2003 TITLE: Installing an In-Tank Fuel Pump/Sending Unit? Don't Forget a New Base Gasket, Locknut, and Fuel Line Retainers APPLIES TO: See Models Listed In Illustration SERVICE TIP: Whenever you install an in-tank fuel pump/sending unit into a plastic fuel tank, the S/M tells you to install a new base gasket. But did you know you also need to replace the locknut and the fuel line retainers as well? Make a note in the Fuel Supply System subsection of the appropriate S/Ms to also replace the locknut and the fuel line retainers. Then follow this handy chart to order the appropriate parts. Install the new gasket on the fuel tank side, not on the fuel pump/sending unit side; this ensures that the gasket doesn't get pinched or rolled. If you don't install the fuel pump/sending unit correctly, the MIL could come on with an EVAP control system leakage DTC set. The gasket and the locknut are currently available in Honda parts stock under separate part numbers. But soon, they'll be packaged under a single part number. The fuel sending unit, gasket, and locknut will also be packaged together under a single part number. The gasket and the locknut will then be discontinued as separate part numbers. Locations 13. Right Rear Corner of Engine Compartment Page 5697 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 5700 - 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 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 adapter case oil pan twelve fixing 10 mm screws, adapter case oil pan, and gasket. NOTE: Oil pan still contains transmission fluid. Place a large drain container under the oil pan and 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 11 mm bolt and converter clutch solenoid with two O-rings. 7. Remove 11 mm bolt, retainer, and force motor solenoid. Installation 1. Install force motor solenoid, retainer, and 11 mm bolt to adapter case valve body. Tighten the bolt to the specified torque. Torque: 10 Nm (87 inch lbs.) 2. Install converter clutch solenoid with two O-rings, and 11 mm bolt to adapter case valve body. Tighten the bolt to the specified torque. Torque: 10 Nm (87 inch lbs.) 3. Connect wiring harness assembly to solenoids. 4. Install adapter case oil pan, new gasket, and twelve 10 mm screws. Tighten the screws to the specified torque. Torque: 11 Nm (96 inch lbs.) 5. Fill transmission through overfill screw hole oil pan, using ATF DEXRON III. 6. Connect battery ground cable. Page 5150 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: 137 Nm (101 ft. lbs.) 3. Install speed sensor cable. 4. Install fuel tank. Page 4576 Each schematic represents one circuit. A circuit's wires and components are arranged to show current flow, from power at the top 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 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. Locations 105. Left Side of Driver's Seat Page 3163 Crankshaft Position Sensor: Testing and Inspection Inspection Procedure 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 6962 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 4754 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 7001 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 945 DIAGNOSTIC WORKSHEET REPAIR PROCEDURE A Page 1285 3. Photocopy the template that is shown. Cut out the template. Page 2866 Starting Mode When the ignition is first turned "ON," the PCM energizes the fuel pump relay for two seconds to allow the fuel pump to build up pressure. The PCM then checks the engine coolant temperature (ECT) sensor and the throttle position (TP) sensor to determine the proper air/fuel ratio for starting. The PCM controls the amount of fuel delivered in the starting mode by adjusting how long the fuel injectors are energized by pulsing the injectors for very short times. Page 489 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 shaft 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. 11. Turn the ignition switch to the "ON" position and observe the warning lamp. Page 4650 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 7530 Trailer Lighting Connector Image 118-1 Blower Assembly Housing Assembly HVAC: Service and Repair Blower Assembly Blower Assembly And Associated Parts 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 knee bolster bracket. 6. Remove duct. 7. Remove evaporator assembly (A/C only). 8. Disconnect blower motor connector. 9. Remove blower assembly. Installation To install, follow the removal steps in the reverse order. Page 6177 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 5480 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 6817 Ground - "G" Shielding Sheilding This represents RFI (Radio Frequency Interference) shielding around a wire. The shielding is always connected to ground. Splices Page 7413 Parking Lamp: Electrical Diagrams Parking, Tail, And Licence Lights Image 110-0 Locations Ignition Coil: Locations 19. Right Side of Engine 22. Left Side of Engine Page 1015 Valve Shims (While 41 shims are available, the 10 sizes will cover most valve adjustments): Page 2233 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 7727 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. Diagram Information and Instructions Heated Element: Diagram Information and Instructions How to Identify Wiring Color-Coded Insulation Wire Color Wire Color Coding Tire Rotation Tires: Service and Repair Tire Rotation Tire Rotation Tire rotation is recommended to equalize wear for longer tire life. If the 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 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 7447 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 ground 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). Specifications Timing Belt Tensioner: Specifications Timing Belt Tensioner 42 Nm Timing Belt Tensioner Pusher 25 Nm Page 7218 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 911 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 18. Right Side of Engine Page 3821 Transmission Temperature Sensor/Switch: Service and Repair Transmission Oil Temperature Sensor (Main Case) (V6) Removal 1. Raise the vehicle and support it on jack stands. 2. Disconnect battery ground cable. 3. Drain fluid. 4. Remove sixteen 10 mm main case oil pan fixing screws, main case oil pan, and gasket. 5. Disconnect wiring harness from shift solenoids, band apply solenoid, and 7 way 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 assembly with transmission oil temperature sensor to band apply solenoid, shift solenoids, and 7 way 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 inch lbs.) 3. Fill transmission through the overfill screw hole of oil pan, using ATF DEXRON III. 4. 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. Page 2558 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 7565 Individual circuit schematics begin with a fuse. The first half of Power Distribution, however, shows the wiring "upstream" between the battery 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 Transmission Shift Position Indicator Lamp: Diagram Information and Instructions How to Identify Wiring Color-Coded Insulation Wire Color Wire Color Coding Page 6490 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 4522 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 1529 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 Crankshaft Position Sensor: Locations 36. Bottom Right Side of Engine CKP Sensor Page 4363 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 58. Under Center Console Page 7674 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. Component Locations 101. Beneath Vehicle, Behind Left Rear Wheel Page 3770 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 (spline yoke type only). INSTALLATION NOTE: Never install the shaft assembly backwards. Never insert bar between yoke lugs when tightening or re-moving 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.) SLIP JOINT DISASSEMBLY Diagrams Hazard Warning Switch Page 612 Manifold Absolute Pressure 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. 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 947 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 3083 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 6326 - 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 1989 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 18. Right Side of Engine Page 3188 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. Refer to Electronic Ignition System for additional information. Page 497 Hazard Warning Switch: Service and Repair Hazard Warning Light Switch 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. Locations Light and Bulb Specifications (LWB) - 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 (17 ft. lbs.) 4. Install speed sensor cable fixing bolt (Upper side) and tighten the fixing bolt to the specified torque. Torque: 6 Nm (52 inch lbs.) NOTE: Confirm that a white line marked on the cable is not twisted when connecting the speed sensor cable. 5. Install speed sensor connector. Locations Heater Core: Locations Heater Core And/or Mode Door - Disassembled View Locations Specifications Vacuum Brake Booster: Specifications Vacuum Booster Diaphragm Diameter Front 205 mm Rear 230 mm Push Rod Stroke More Than 32.0 mm Plunger Diameter 10.25 mm Push Rod Diameter 27.4 mm 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 N.m (13 lb.ft) Page 2887 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 231 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 Maintenance Required Lamp/Indicator: Service and Repair The OEM does not equip this model with a Maintenace Required Indicator. Page 1777 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 7570 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 6145 Page 4591 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 3061 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 69 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 36. Bottom Right Side of Engine CKP Sensor Page 6980 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 4003 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 4L30-E Automatic Transmission (Transmission Control System Diagnosis). Diagrams Mirror Control Switch Service and Repair System Relay: Service and Repair Air Conditioning Thermo Relay 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. - The screwdriver blade will release the catch inside. 4. Pull the relay straight up and out of the fuse and relay box. Page 4461 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 379 2. Install the ECT sensor in the coolant crossover. Tighten Tighten the ECT sensor to 30 N.m (22 lb.ft.). 3. Connect the electrical connector. 4. Fill the radiator with coolant. Refer to Draining and Refilling Cooling System. 5. Connect the negative battery cable. Replacement Page 7024 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 931 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 3044 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 4928 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). 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 7484 Headlamp Switch: Electrical Diagrams Headlight Switch Image 100-0 Page 21 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 7141 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 4047 Ground - "G" Shielding Sheilding This represents RFI (Radio Frequency Interference) shielding around a wire. The shielding is always connected to ground. Splices Page 2767 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 5364 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 Rear Wiper/Washer Switch Service and Repair Main 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. Page 2294 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 Door Switch: Locations 78. Left "C" Pillar (Right Similar) 77. Left "B" Pillar (Right Similar) Page 1162 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 5373 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 1932 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 TP1 about 0.4 V, TP2 about 4.6 V and TP3 about 4.6 V. - If the reading is abnormal value, check the throttle shaft to see if it is binding. Page 4955 Power Steering Fluid: Service and Repair Fluid Level 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 as specified in General Information 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 656 27. Left Side of Engine Page 5256 Trailing Arm: Service and Repair 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. - Install the rubber bushing by using installer J-39214. 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 5053 5. Install band and clip. 6. Install tie-rod end and tighten lock nut. Torque: 98 Nm (72 ft. lbs.) Page 6129 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 Component Locations Locations 98. Top Rear of Fuel Tank Page 5529 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 4893 ^ 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 4205 Brake Rotor/Disc: Testing and Inspection Rear Disc Brake Rotor 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. Checking Lateral Runout 1. Adjust the wheel bearing correctly. 2. Attach the dial indicator accordingly so that the stem contacts the rotor surface to approximately 29 mm (1.14 inch) from the rotor edge. 3. Rotate the rotor one complete turn and inspect for signs of lateral runout. Lateral runout should not exceed 0.13 mm (0.005 inch). 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 1047 Air Filter Element: Service and Repair Cleaning Method 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. Diagrams Windshield Wiper Linkage and Associated Parts Page 5710 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 1101 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 4798 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 1210 Fuse To Component view, Image 6-2 Page 5322 Tires: Service and Repair Inflation of Tires 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 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 3424 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. Page 3728 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 3546 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 2684 Canister Vent Valve: Testing and Inspection EVAP Canister Vent Solenoid Inspection Procedure 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 5376 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 7230 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 2928 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. 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. Locations 9. Fuse/Relay Box (Cover Removed) Page 6328 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 3211 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 1.05 mm (0.04 in). NOTE: Do not adjust the spark plugs gap without new spark plugs. - Do not damage to tip of spark plugs. - Do not cleaning the spark plugs. If require the cleaning it due to heavy dirt, it is allowed only 20 seconds to be used spark plug cleaner. - 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 Page 7650 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 5293 ^ 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 3507 Shift Interlock Cable: Service and Repair Removal 1. Set ignition key in "LOCK" position and selector lever in "P" position. 2. Remove transfer control lever knob (4x4), lower cluster assembly, rear console, center console. Selector lever knob and cover. 3. Disconnect inner cable from selector lever assembly then push claw and disconnect cable assembly. 4. Disconnect lock adjust. 5. Remove instrument panel lower cover and steering column cover. 6. Remove spring pin and disconnect inner cable. ^ Disconnect outer cable from bracket. Installation 1. Set ignition key in "LOCK" position and selector lever in "P" position. 2. Connect outer cable to bracket near steering lock. Connect inner cable to steering lock and install spring pin. 3. Install steering column cover and instrument lower cover. Page 7450 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 shaft 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. 11. Turn the ignition switch to the "ON" position and observe the warning lamp. Page 4942 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 1893 95. Right Front Exhaust Downpipe Page 5623 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-ring can not 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 (17 fl.oz.) of new compressor oil to the new core. 8. Tighten the refrigerant lines to the specified torque. 9. Apply an adhesive to the parting face of the lining when assembling the evaporator assembly. Page 2642 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 539 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 6903 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 4617 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 7048 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 7404 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 3755 General Specifications Torque Specifications Page 5569 Ground - "G" Shielding Sheilding This represents RFI (Radio Frequency Interference) shielding around a wire. The shielding is always connected to ground. Splices Locations 83. Top of Tailgate (Trim Removed) Page 2993 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 7351 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 6891 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 2290 Each schematic represents one circuit. A circuit's wires and components are arranged to show current flow, from power at the top 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 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. Locations 59. Under Center Console Page 4718 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 2123 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 5557 52. Behind Center of Dash Service and Repair Shift Indicator: Service and Repair A/T Shift Indicator Light Bulb Removal 1. Disconnect the battery ground cable. 2. Pry up the bended portions (2) of the metal cover (1). 3. Remove the meter lense (3) from the meter visor (4). 4. Remove the meter visor from the meter case (5). Page 2791 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 (gm/s). At idle, the Tech 2 should read between 4 - 7 gm/s 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 1829 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 6455 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 Diagram Information and Instructions Auxiliary Power Outlet: Diagram Information and Instructions How to Identify Wiring Color-Coded Insulation Wire Color Wire Color Coding Page 4379 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 6827 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. Specifications Timing Belt: Specifications Replace Timing Belt every 75,000 miles (120,000 km) Page 3668 Actuator: Testing and Inspection Axle Shaft Connection and Disconnection Actuator Assembly 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 7041 Above 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 begins in Wire Color Abbreviations. 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 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 Locations 2. Behind Left Side of Front Grille Page 7467 Above 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 begins in Wire Color Abbreviations. 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 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 Page 1852 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. Locations Crankshaft Position Sensor: Locations 36. Bottom Right Side of Engine CKP Sensor Page 5525 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 7576 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 4631 Fuse Block: 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 3494 ^ 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 1305 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. Premature wear in shoulders. Page 3133 Throttle Body: Service and Repair Removal Procedure 1. Disconnect the negative battery cable. 2. Drain the cooling system. Refer to Cooling System. 3. Disconnect the electrical connectors: - Throttle position (TP) sensor. - Intake air temperature (IAT) sensor. Refer to Intake Air Temperature 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. Refer to Throttle Position (TP) Sensor. Installation Procedure 1. Install the TP sensor. Refer to Throttle Position (TP) Sensor. 2. Install the gasket on the common chamber. 3. Install the throttle body on the common chamber. Page 6913 Audio, Clock, Cigarette Lighter And ACC Socket Page 7517 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 7263 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 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. Page 1144 Refrigerant: Fluid Type Specifications Refrigerant Type HFC-134a (R-134a) Front Page 5319 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. Diagram Information and Instructions Trailer Lamps: Diagram Information and Instructions How to Identify Wiring Color-Coded Insulation Wire Color Wire Color Coding Main Case Valve Body Valve Body: Service and Repair Main Case Valve Body 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. Disconnect ground wire from the main case valve body (HEC). 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 way (V6) or 4 way (HEC) 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. 4. Install seven 13 mm screws, and tighten them to the specified torque. Torque: 20 Nm (15 ft. lbs.) Page 3059 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 5276 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 3508 4. Install adjust body of cable assembly to bracket in selector lever assembly. Install inner cable to lever, pulling inner cable with outer cable. 5. Check that cable moves smoothly, lightly pulling outer cable rearward. 6. Connect lock adjust, aligning "T" mark in the "Up" position. 7. About following installation steps, refer to Selector Lever. 8. Check the shift lock operation: a. Selector lever should not be moved out of "P" position with ignition key in "Lock" position. b. Selector lever can be moved out of "P" position with ignition key in "ON" position only when brake pedal is depressed. c. ignition key can be turned to "LOCK" position only when selector lever is in "P" position (key can be pulled out). 9. If a. and c. fail, readjust cable. If b. fails, readjust connector wiring and brake pedal switch. Page 3862 57. Top of Transfer Case Page 4786 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 2647 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. Procedures Windshield: Procedures Windshield - Parts Locations 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). Page 2357 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 5129 - Remove the rubber bushing (Axle side) by using remover J-39792. - Install the rubber bushing (Axle side) by using installer J-39792. INSTALLATION 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. Page 7029 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. 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 2574 a. Place selector lever in neutral. b. Disconnect transmission harness connector from mode switch connector. 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 (approximately 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 118 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. Locations Door Switch: Locations 78. Left "C" Pillar (Right Similar) 77. Left "B" Pillar (Right Similar) Page 4620 Individual circuit schematics begin with a fuse. The first half of Power Distribution, however, shows the wiring "upstream" between the battery 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 4577 Above 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 begins in Wire Color Abbreviations. 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 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 Page 2643 The wire insulation has one color or one color with another color stripe. The second color is the stripe. 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 Diode: Locations 8. Fuse/Relay Box (Cover Removed) 40. Dash Fuse Box Page 2703 5. Control EGR Valve and check data list. 6. If data list changes, the EGR Control is normal. Page 681 Individual circuit schematics begin with a fuse. The first half of Power Distribution, however, shows the wiring "upstream" between the battery 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 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 7088 Individual circuit schematics begin with a fuse. The first half of Power Distribution, however, shows the wiring "upstream" between the battery 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 1376 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. 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 7463 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 5250 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 1712 30. Left Side of Engine Compartment Recall - Fuel Return Hose Inspection/Replacement Technical Service Bulletin # 00-077 Date: 001017 Recall - Fuel Return Hose Inspection/Replacement 00-077 October 17, 2000 Applies To: 2001 Passport - See VEHICLES AFFECTED Safety Recall: Passport Fuel Return Hose BACKGROUND Some fuel return hoses were not properly treated for ozone protection during manufacture. The outer surface can deteriorate from contact with ozone in the atmosphere, and the hose can eventually crack and leak fuel. VEHICLES AFFECTED 2001 Passport: From VIN 4S6..58W.14400001 thru 4S6..58W.14401765 Not every vehicle in the above VIN range is subject to this recall. Refer to your campaign responsibility report for the individual affected VINs. According to Federal law, those vehicles cannot be sold or leased until they are repaired. CUSTOMER NOTIFICATION All owners of affected vehicles will be mailed a notification of this recall. An example of the customer notification is at the end of this service bulletin. CORRECTIVE ACTION Inspect the fuel return hoses to determine the lot number. Replace any fuel return hose with a lot number of 0707. PARTS INFORMATION Fuel Return Hose: P/N 8-97165-096-1, H/C 5649793 Fuel Hose Assembly (Manual Transmission): P/N 8-97233-142-1, H/C 6391197 Fuel Hose Assembly (Automatic Transmission): P/N 8-97233-141-1, H/C 6391189 12 mm Hose Clamp: P/N 8-97148-892-0, H/C 5421441 11.5 mm Hose Clamp: P/N 8-97173-219-0, H/C 5421474 Page 1025 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. Electrode Gap Spark Plug: Specifications Electrode Gap 0.040 in (1.05 mm) Page 7408 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 5484 Fan Control Switch Page 7309 Hazard Warning Switch: Service and Repair Hazard Warning Light Switch 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 2936 2. Press down until the catch engages. - An audible "click" will be heard. 3. Install the fuse and relay box cover. Page 4535 The wire insulation has one color or one color with another color stripe. The second color is the stripe. Specifications Camshaft Gear/Sprocket: Specifications Camshaft Drive Gear Assembly Bolts (3) 10 Nm Camshaft Drive Gear Assembly Pulley Bolt 98 Nm Page 7731 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 1840 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 201 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 megaohms 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 (ODM) - Quad Driver Module (QDM) PCM Input/Outputs PCM Input/Outputs Page 5007 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 6180 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 Brake Warning Indicator: Diagram Information and Instructions How to Identify Wiring Color-Coded Insulation Wire Color Wire Color Coding Page 6820 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. Testing and Inspection Air Filter Element: Testing and Inspection Check the air cleaner filter for damage or dust clogging. Replace if it is damaged, or clean if it is clogged. 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. Testing and Inspection Page 887 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 5605 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 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 6501 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 corner garnish. - Pull the garnish to disconnect the retaining clip. 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. Page 2877 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 3343 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 4460 Ground - "G" Shielding Sheilding This represents RFI (Radio Frequency Interference) shielding around a wire. The shielding is always connected to ground. Splices Page 6364 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: 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 tailgate lock assembly fixing bolts to the specified torque. Torque: 7 N.m (81 lb in) 5. Tighten the hatchgate lock assembly fixing bolts to the specified torque. Torque: 9 N.m (78 lb in) Diagram Information and Instructions Alternator: Diagram Information and Instructions How to Identify Wiring Color-Coded Insulation Wire Color Wire Color Coding Page 3064 Fuel Pump Relay: Description and Operation In order to control the FPS operation, the FPS relay is provided. When the starter switch is turned to "ON" position, the FPS relay operates the FPS for 2 seconds. When the key 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 FPS to feed fuel. Page 6573 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 2636 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 7231 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 5856 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 7684 - 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. Removal and Installation Powertrain Control Module: Service and Repair Removal and Installation Removal Procedure 1. Disconnect the negative battery cable. 2. Block the wheels. 3. Remove the two screws from the PCM electrical connectors. 4. Disconnect the PCM electrical connectors. 5. After removing the clip which fixes the PCM to the bracket, remove PCM. Installation Procedure Page 2446 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 4002 Transmission Range Switch Page 6514 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 N.m (61 lb in) 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 6825 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 93 Compressor Clutch Relay: Testing and Inspection Heater (X-1), Thermostat (X-8), Condenser Fan (X-11) And Compressor (X-2) Relay 1. Disconnect relays and check for continuity and resistance between relay terminals. - For handling of these relays, refer to Heater Relay. Page 4083 Wheel Speed Sensor: Diagrams Front Wheel Speed Sensor and Associated Parts Replacement w/ Related Components Page 7142 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 1123 3. Reinstall the drain plug with a new washer, and refill with the recommended oil. NOTE: Under normal conditions, the oil filter should be replaced at every other oil change. Under severe conditions, the oil filter should be replaced at each oil change. The numbers in the middle of the API Service label tell you the oil's SAE viscosity or weight. Select the oil for your vehicle according to this chart: An oil with a viscosity of 5W - 30 is preferred for improved fuel economy and year-round protection in the vehicle. You may use a 10W - 30 oil if the climate in your area is limited to the temperature range shown on the chart. 4. Run the engine for more than three minutes, then check for oil leakage. OIL FILTER Replacement Except M/T With ATTS: WARNING: After the engine has been run, the exhaust pipe will be hot; be careful when working around the exhaust pipe. - Be careful when loosening the drain bob while the engine is hot. Burns can result because the oil temperature is very high. Page 5983 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. Irregular and Premature Wear Tires: Testing and Inspection Irregular and Premature Wear 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 1770 Individual circuit schematics begin with a fuse. The first half of Power Distribution, however, shows the wiring "upstream" between the battery 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 4526 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 5844 The wire insulation has one color or one color with another color stripe. The second color is the stripe. Page 4797 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 5113 3. Photocopy the template that is shown. Cut out the template. Page 462 Seat Belt, Lights-on, And Ignition Key Reminders Image 73-1 Service and Repair Radiator Cap: Service and Repair For further information regarding this component and the system that it is a part of, please refer to Radiator; Service and Repair. Locations 33. Bottom Center Front of Engine Page 2714 Positive Crankcase Ventilation Valve: Service and Repair Removal Procedure 1. Remove the vacuum hose at the PCV valve. - Slide the clamp back to release the hose. 2. 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 4377 Part 2 of 3 Page 1292 ^ 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 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. Locations Coolant Temperature Sensor/Switch (For Computer): Locations 17. Front of Engine ECT Sensor Page 750 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 (gm/s). At idle, the Tech 2 should read between 4 - 7 gm/s 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 2855 Fuel Line Coupler: Service and Repair Fuel Tube/Quick - Connector Fittings Removal 1. Open the fuel cap to relieve the fuel pressure in the tank. Use compressed air to remove any dirt on the fuel quick connect fittings prior to disconnecting the fittings. When disconnecting the fuel pipe, cover the area with a cloth to prevent fuel from splashing as the fuel pipe may still have some pressure in it. 2. For removal of the quick connector, hold the quick connector in one hand, and pull out the connector with the other hand while pressing the square relieve button of the connector, as illustrated. Page 176 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 6565 Ground - "G" Shielding Sheilding This represents RFI (Radio Frequency Interference) shielding around a wire. The shielding is always connected to ground. Splices Page 122 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 5829 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 5745 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 435 Fuel Gauge Sender: Service and Repair Fuel Gage Unit Removal and Installation Refer to Fuel Tank for removal and installation of the fuel gauge unit since the fuel gauge unit is linked to the fuel pump and sender. Page 2592 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 1125 2) Tighten the filter by turning it clockwise seven numbers from the marked point. For example, if a mark is made under the number 2 when the rubber seal is seated, the filter should be tightened until the number 1 comes up to the marked point. 5. After installation, fill the engine with oil up to the specified level, run the engine for more than three minutes, then check for oil leakage. CAUTION: Using any procedure other than those shown could result in serious engine damage due to oil leakage. Replacement M/T With ATTS: WARNING: Be careful when loosening the drain plug while the engine is hot. Burns can result because the oil temperature is very high. 1. Remove the oil filter with the special tool. 2. Inspect the threads and rubber seal on the new filter. Wipe off seat on the engine block. Apply a light coat of oil to the filter rubber seal. NOTE: Use only filters with a built-in bypass system. 3. Install the oil filter by hand. Removal/Installation Air Filter Element: Service and Repair Removal/Installation Engine Driveability and Emissions System Air Cleaner/Air Filter Removal Procedure 1. Loosen the clamp between the air cleaner lid and the mass air flow sensor. 2. Release the tour latches securing the lid to the air cleaner housing. 3. Remove the air cleaner lid. 4. Remove the air filter element. 5. Remove the retaining bolts and the air cleaner housing from the vehicle. Installation Procedure 1. Install the air cleaner housing in the vehicle with the retaining bolts. 2. Install the air filter element in the air cleaner housing. Page 3176 Ion Sensing Module Connectors A - C Page 1551 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 5087 - Inspect screw/taper area of ball for damage. - If any defects are found by the inspections, replace the ball joint assembly with a 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 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: 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: 147 Nm (108 ft. lbs.) Page 5251 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 7097 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 3474 Transmission Range 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 7094 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 Carrier Pinion Shaft: 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. Page 2456 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 2247 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 6431 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 5216 If you need more labels, order them from Helm using reorder number Y0895.* Page 2793 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. Component Locations 54. Below Center of Dash (Console Removed) Page 76 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 7543 Combination Light Switch Connectors A And B Page 4595 Audio, Clock, Cigarette Lighter And ACC Socket Page 7238 Brake Lamp: Electrical Diagrams Brake System Indicator Light Image 71-0 Page 2963 7. Working at the back of the engine, remove the hose clamps from the fuel hose assembly. Spray silicone lubricant on the clamps to make them easier to remove. 8. Remove the fuel hose assembly from the fuel lines. If necessary, carefully slit the hoses so they are easier to remove. Remove the fuel hose assembly from the vehicle. Discard the assembly and the clamps. 9. Install the new hose clamps on the hoses in the new fuel hose assembly. These clamps have plastic pieces over the ends to keep them expanded. 10. Install the fuel hose assembly in the vehicle. Make sure it is routed properly through the brackets. 11. Connect the fuel hose assembly to the fuel lines at the back of the engine. Slide the clamps into position, then remove the plastic holders from the clamps. Make sure the hoses are clamped securely. 12. Verify that the fuel hose assembly is aligned properly. The white mark on the assembly should align with the edge of the bracket. 13. Lower the floor jack. Remove the jack and block of wood from under the vehicle. 14. Install the plastic engine cover and the fuel pump relay. 15. Raise the vehicle on the hoist. 16. Verify that the fuel hose assembly is properly routed through the brackets. 17. Connect the fuel hose assembly to the fuel lines (quick disconnect fittings). Listen for each fitting to click into place, then pull on the fitting to make sure it is locked in place. 18. Install the O2 harness sensor clip. 19. Install the transmission mounting nuts. Torque the nuts to 41 N.m (30 lb-ft). 20. Go to COMPLETION PROCEDURE. COMPLETION PROCEDURE 1. Lower the vehicle. Front Wheel Speed Sensor: Testing and Inspection 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. Page 7632 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 6900 Ground - "G" Shielding Sheilding This represents RFI (Radio Frequency Interference) shielding around a wire. The shielding is always connected to ground. Splices Page 5752 The wire insulation has one color or one color with another color stripe. The second color is the stripe. Page 1755 Powertrain Control Module: Service and Repair Reprogramming the PCM EEPROM General Description The Electronically Erasable Programmable Read Only Memory (EEPROM) is a permanent memory that is physically soldered within the PCM. The EEPROM contains program and calibration information that the PCM needs to control powertrain operation. 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 one minute. 3. Scan for DTCs using the Tech 2. Oil and Filter Service Engine Oil: Service and Repair Oil and Filter Service ENGINE OIL Inspection 1. Park the vehicle on level ground, and turn off the engine. Allow the oil a few minutes to drain back into the oil pan so the dipstick will show the actual level. 2. Make certain that the oil level indicated on the dipstick is between the upper and lower marks. 3. If the level has dropped close to the lower mark, add oil until it reaches the upper mark. CAUTION: Insert the dipstick carefully to avoid bending it. Replacement CAUTION: Remove the drain bolt carefully while the engine is hot; the hot oil may cause scalding. 1. Warm up the engine. 2. Drain the engine oil. Page 2666 Catalytic Converter: Service and Repair Three Way Catalytic Converter LH & 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 front exhaust pipe assembly 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 2108 Valve Inspection Chart Page 2249 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 60. Under Rear of Center Console Page 3766 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 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. Page 4753 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 Rear Door Trim Panel Page 461 Key Reminder Switch: Electrical Diagrams Seat Belt, Lights-on, And Ignition Key Reminders Image 73-0 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. 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. Page 3109 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 5699 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 3493 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 2410 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 2296 Ground - "G" Shielding Sheilding This represents RFI (Radio Frequency Interference) shielding around a wire. The shielding is always connected to ground. Splices Page 4256 3. Install support bracket and tighten the bolt (7) to the specified torque. Torque: 155 Nm (115 ft. lbs.) 4. Install caliper assembly. 5. Install lock bolt (9) and guide bolt (8) and tighten the bolt to the specified torque. Torque: 74 Nm (54 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 1-bolt (10) to the specified torque. Torque: 35 Nm (26 ft. lbs.) 7. Install wheel and tire assembly. 8. Bleed brakes. Disassembly and Reassembly Page 7469 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. Service and Repair System Relay: Service and Repair Air Conditioning Thermo Relay 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. - The screwdriver blade will release the catch inside. 4. Pull the relay straight up and out of the fuse and relay box. Page 3164 Crankshaft Position Sensor: Service and Repair Removal 1. Disconnect battery ground cable 2. Wiring connector from crankshaft position sensor. 3. Remove crankshaft position sensor from cylinder block. Installation 1. Install crankshaft position sensor into the cylinder block. Before installation,apply small amount of engine oil to the O-ring. Torque: 10 N.m (87 lb.in) 2. Reconnect wiring connector to crankshaft position sensor. Page 1037 Drive Belt: Service and Repair Drive Belt and Cooling Fan The drive belt adjustment is not required as automatic drive belt tensioner is equipped. Removal Move the tension pulley drive belt loosen side, remove the drive belt. Inspection Check drive belt for wear or damage, and replace with a new one as necessary. Installation 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 98MY-> 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 <-97MY 6VD1 with no interchangeability. Therefore, incorrect installation of a fan may cause the air to flow in the opposite direction, thus resulting in poor performance of the air conditioner and an increase in engine water temperature. Page 4534 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 3380 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 4723 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 36. Bottom Right Side of Engine CKP Sensor Page 2280 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 234 The wire insulation has one color or one color with another color stripe. The second color is the stripe. Page 3138 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 TP1 about 0.4 V, TP2 about 4.6 V and TP3 about 4.6 V. - If the reading is abnormal value, check the throttle shaft to see if it is binding. Page 665 Transmission Range Switch Page 3205 Spark Plug: Specifications Plug Torque 13 ft lb (18 Nm) Page 6184 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 6848 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 5869 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 6363 Trunk / Liftgate Lock Cylinder: Service and Repair Tailgate Lock and Hatchgate Lock (LWB) Tailgate Lock, Hatchgate Lock And Associated Parts (LWB) Removal 1. Disconnect the battery ground cable 2. Remove the tailgate trim cover assembly (3). - Remove the 2 screws (2) holding the hatchgate 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. Locations 100. Rear Underside of Vehicle Page 3775 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 lip 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. SLIP JOINT REASSEMBLY Page 914 DIAGNOSTIC WORKSHEET REPAIR PROCEDURE A Page 6010 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 223 Above 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 begins in Wire Color Abbreviations. 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 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 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 2590 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 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. Diagrams 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 1470 3. Reinstall the drain plug with a new washer, and refill with the recommended oil. NOTE: Under normal conditions, the oil filter should be replaced at every other oil change. Under severe conditions, the oil filter should be replaced at each oil change. The numbers in the middle of the API Service label tell you the oil's SAE viscosity or weight. Select the oil for your vehicle according to this chart: An oil with a viscosity of 5W - 30 is preferred for improved fuel economy and year-round protection in the vehicle. You may use a 10W - 30 oil if the climate in your area is limited to the temperature range shown on the chart. 4. Run the engine for more than three minutes, then check for oil leakage. OIL FILTER Replacement Except M/T With ATTS: WARNING: After the engine has been run, the exhaust pipe will be hot; be careful when working around the exhaust pipe. - Be careful when loosening the drain bob while the engine is hot. Burns can result because the oil temperature is very high. Page 4043 Individual circuit schematics begin with a fuse. The first half of Power Distribution, however, shows the wiring "upstream" between the battery 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 453 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 1061 Hose/Line HVAC: Service and Repair Repair Of Refrigerant Leaks Repair Of Refrigerant Leaks Refrigerant Line Connections 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. O-ring (2) must be fitted in the groove (1) of refrigerant line Page 7402 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 6450 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. Locations Sunroof / Moonroof Motor: Locations 61. Front Center of Ceiling (Headliner Removed) 62. Front of Roof (Headliner Removed) Locations 51. Behind Gauge Assembly Page 1873 Fuel Tank Pressure Sensor: Testing and Inspection Inspection Procedure 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 7226 Ground - "G" Shielding Sheilding This represents RFI (Radio Frequency Interference) shielding around a wire. The shielding is always connected to ground. Splices Page 4380 Electronic Brake Control Module: Description and Operation System Components Electronic Hydraulic Control Unit (EHCU), three Wheel Speed Sensors, Warning Light, and G-sensor. Electronic Hydraulic Control Unit (EHCU) The Electronic Hydraulic Control Unit (EHCU) consists of Anti-lock Brake System (ABS) control circuits, fault detector, and a fail-safe. The signal received from each sensor activates the hydraulic unit accordingly and cancels the ABS to return to normal braking if a malfunction occurs in the ABS system. 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 4145 Brake System Indicator Light Image 71-0 Page 5968 Seat Belt: Specifications Torque Specifications Part 1 Front Door Trim Panel Trim Panel: Service and Repair Front Door Trim Panel Front Door Trim Panel And Associated Parts Removal 1. Disconnect the battery ground cable. 2. Remove the door mirror assembly. Page 643 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 4887 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 6870 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 6034 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 6517 5. Remove the 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 bracket. 8. Peel the upper half of the waterproof sheet. - Taking notice of the door harness, peel the waterproof sheet off the door panel carefully. 9. 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 fell owing points. 1. Apply chassis grease to the lock assembly and striker moving surface. Page 3476 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) (V6). 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 Page 5438 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 3401 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.) 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 269 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 7574 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 2786 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 2259 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. Exploded Views Page 1872 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 2413 Powertrain Control Module: Connector Views ECM (M/T) Or PCM (A/T) Connector A Page 1027 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 6979 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 1650 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. Page 502 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 1235 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 7449 CAUTION: Never apply force to the steering wheel shaft 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. INSTALLATION 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 counter clockwise to full, return about 3 turns and align the neutral mark. CAUTION: Turn the SRS coil counter clockwise until some resistance is felt, or damage may occur to the SRS coil. Page 5195 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 6396 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 Page 2663 Catalytic Converter: Diagrams Three Way Catalytic Converter LH & Forked Exhaust Pipe Three Way Catalytic Converter LH and Forked Exhaust Pipe and Associated Parts 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 1329 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. 2. Tighten the hub nut to the value given, 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 lb - 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. Component Locations Condenser Fan: Component Locations 5. Behind Right Side of Grille Condenser Fan Motor and Associated Parts Page 5627 Evaporator Temperature Sensor / Switch: Description and Operation Electronic Thermostat The electronic thermostat senses the temperature of cool air from the evaporator by means of the evaporator temperature sensor This information determines whether the thermostat will provide ground to the thermo switch relay. When the temperature becomes too low, ground is not provided. OFF: Below 1.0 ± 0.5 °C (33.8 ± 0.9 °F) ON: Above 3.5 ± 0.3 °C (38.3 ± 0.9 °F) 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 4448 Disassembled View Locations 9. Fuse/Relay Box (Cover Removed) Page 6693 Hood Sensor/Switch (For Alarm): Service and Repair Engine Hood Switch 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 510 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 2654 3. Connect the VSS electrical connector. 4. Check the transfer case oil level. Add fluid if necessary. 5. Connect the negative battery cable. Page 3315 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 7010 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 1969 VSS Image 33-0 Page 4484 - 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 by 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. 2. Install pulley on the rotor. Secure the pulley directly in the vise between two copper plates, and tighten nut to the specified torque. Diagram Information and Instructions Headlamp Reminder Indicator: Diagram Information and Instructions How to Identify Wiring Color-Coded Insulation Wire Color Wire Color Coding Page 2888 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 5849 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 6059 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 6897 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. 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 6335 2. Adjust the clearance between outer quarter panel (1) and fuel filler door (2). Diagram Information and Instructions Powertrain Control Module: Diagram Information and Instructions How to Identify Wiring Color-Coded Insulation Wire Color Wire Color Coding Page 5709 Refrigerant Oil: Service and Repair Checking/Adjusting Oil For Used Compressor Checking and Adjusting Oil Quantity for Used Compressor 1. Perform 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. 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 preform 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 of refrigerant. 8. Perform the oil return operation. 9. Remove the compressor and recheck the amount of oil. 10. Adjust the compressor oil, if necessary. 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 4322 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 6842 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 4521 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 4763 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 3237 2. Connect the terminals as shown in figure. Shift rod of the motor actuator moves and stops at 4WD position. 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. Transfer Position Switch 1. With ball being free. Page 5233 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 5608 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 7196 Test Description Page 2557 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 Diagram Information and Instructions Vehicle Speed Sensor: Diagram Information and Instructions How to Identify Wiring Color-Coded Insulation Wire Color Wire Color Coding Page 2193 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 6788 Cruise Control Switch: Service and Repair Cruise Control Main Switch Removal 1. Disconnect the battery ground cable. 2. Remove the meter cluster assembly (1). 3. Remove the cruise control main 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 5143 Locations 74. Rear of Driver's Door (Frt. Pass. Similar) Page 6731 Spare Tire Carrier: Removal and Replacement Spare Tire Hanger Spare Tire Hanger Spare Tire Hanger Special Tools Removal Page 1727 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. 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 5897 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 178 Ground - "G" Shielding Sheilding This represents RFI (Radio Frequency Interference) shielding around a wire. The shielding is always connected to ground. Splices Page 6439 Consoles Page 6574 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 27 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. Upper Page 2428 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 the 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 202 Inputs - Operating conditions Read - Air Conditioning "ON" or "OFF" - 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 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-megohm 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 518 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 6926 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. 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 515 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 2792 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 1. Install the MAF sensor on the air cleaner with the clamp. 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. Specifications Fuel Pressure: Specifications PRESSURE PRESSURE With Regulator Vacuume Hose Disconnected 42-55 Psi. Page 4064 Part 3 of 3 Locations 90. Left Side of Automatic Transmission (A/T) Diagrams Mirror Control Switch 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. Front Suspension Strut / Shock Absorber: Specifications Front Shock Absorber Type Hydraulic, Double Acting, Telescopic Piston Diameter 30.0 mm Stroke Without ISC Shock Absorber 125.0 mm With ISC Shock Absorber 120.0 mm Compressed Length Without ISC Shock Absorber 255.0 mm With ISC Shock Absorber 261.0 mm Extended Length Without ISC Shock Absorber 380.0 mm With ISC Shock Absorber 381.0 mm Page 5339 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 - Disc - Caliper - Shift on the fly system parts (Cap, Hub flange, Shim, Snap ring) - ABS sensor ring Reassembly Page 5035 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 2126 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 777 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 ground 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 driver knee bolster (reinforcement). 7. 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 4842 Relay/Fuse Box (Engine Room) Component Locations Oxygen Sensor: Component Locations HO2S (Sensor) 94. Rear of Left Catalytic Converter Page 1424 Valve Shims (While 41 shims are available, the 10 sizes will cover most valve adjustments): Testing and Inspection Cruise Control Indicator Lamp: Testing and Inspection Lamps Test This test is conducted to check MIL, Up Shift Lamp, Low Fuel Lamp, Reduced Power Lamp and Cruise Control Lamp for its working. 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 F0: Lamps Test in the Miscellaneous Test. Locations Relay Box: Locations Fuse To Component view, Image 6-2 Page 3743 4. Use installer J-36828 and grip J-8092 then install the outer bearing by driving it into the hub. 5. Apply grease (NLGI 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. Grease Amount Hub: 35 g (1.23 oz) Outer bearing: 10 g (0.35 oz) Inner bearing: 15 g (0.53 oz) Page 440 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 2100 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) 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 5792 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. 3. Install the fuse and relay box cover. Page 2632 Above 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 begins in Wire Color Abbreviations. 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 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 Page 6348 Hood Sensor/Switch (For Alarm): Service and Repair Engine Hood Switch 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 3531 7. Slide sleeve and disconnect cable assembly. 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. Page 5648 Heater Core: Service and Repair Heater Core And/or Mode Door - Disassembled View 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 4529 Ground - "G" Shielding Sheilding This represents RFI (Radio Frequency Interference) shielding around a wire. The shielding is always connected to ground. Splices Page 7564 Above 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 begins in Wire Color Abbreviations. 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 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 Locations 67. Behind Glove Box Page 7566 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. Exhaust Silencer Exhaust Pipe: 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 5033 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 5813 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 5002 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 457 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 6499 7. 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. 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. Locations Evaporator Temperature Sensor / Switch: Locations 65. Behind Glove Box Electronic Thermostat, Evaporator Core And/Or Expansion Valve - Disassembled View Page 5571 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) Page 5615 Evaporator Assembly and Associated Parts Page 4720 Ground - "G" Shielding Sheilding This represents RFI (Radio Frequency Interference) shielding around a wire. The shielding is always connected to ground. Splices Page 4143 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 7642 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 5862 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 1664 Page 7267 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. Service and Repair 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 to the vehicle. Page 861 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 874 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. Locations Crankshaft Position Sensor: Locations 36. Bottom Right Side of Engine CKP Sensor Page 1639 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). 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. Page 6119 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. 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. Compressor Clutch Check Compressor Clutch: Testing and Inspection Compressor Clutch Check 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 4208 - 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 Page 4636 Fuse Block: Electrical Diagrams Fuse Block Circuit-1 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. 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 adapter case oil pan twelve fixing 10 mm screws, adapter case oil pan, and gasket. NOTE: Oil pan still contains transmission fluid. Place a large drain container under the oil pan and 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 11 mm bolt and converter clutch solenoid with two O-rings. 7. Remove 11 mm bolt, retainer, and force motor solenoid. Installation 1. Install force motor solenoid, retainer, and 11 mm bolt to adapter case valve body. Tighten the bolt to the specified torque. Torque: 10 Nm (87 inch lbs.) 2. Install converter clutch solenoid with two O-rings, and 11 mm bolt to adapter case valve body. Tighten the bolt to the specified torque. Torque: 10 Nm (87 inch lbs.) 3. Connect wiring harness assembly to solenoids. 4. Install adapter case oil pan, new gasket, and twelve 10 mm screws. Tighten the screws to the specified torque. Torque: 11 Nm (96 inch lbs.) 5. Fill transmission through overfill screw hole oil pan, using ATF DEXRON III. 6. Connect battery ground cable. Page 978 Air Filter Element: Service and Repair Cleaning Method 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 6777 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 6513 - 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 (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 4927 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 3012 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 3735 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 Page 7396 Above 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 begins in Wire Color Abbreviations. 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 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 Description and Operation Tachometer: Description and Operation Tachometer 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 1526 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 522 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 7763 Wiper Motor: Diagrams Rear Wiper Motor Windshield Wiper Motor Page 6865 Each schematic represents one circuit. A circuit's wires and components are arranged to show current flow, from power at the top 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 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. Page 3328 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 6013 The wire insulation has one color or one color with another color stripe. The second color is the stripe. Page 825 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 171 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 Coolant Temperature Sensor/Switch (For Computer): Locations 17. Front of Engine ECT Sensor Diagrams Cruise Control Main Switch Page 4610 Fuse To Component view, Image 6-2 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 1961 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 6683 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 7614 72. Driver's Door (Frt. Pass. Similar) Page 6830 Seat Belt, Lights-on, And Ignition Key Reminders Image 73-1 Locations 67. Behind Glove Box Page 543 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 5024 Individual circuit schematics begin with a fuse. The first half of Power Distribution, however, shows the wiring "upstream" between the battery 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 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 7546 CAUTION: Never apply force to the steering wheel shaft 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. INSTALLATION 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 counter clockwise to full, return about 3 turns and align the neutral mark. CAUTION: Turn the SRS coil counter clockwise until some resistance is felt, or damage may occur to the SRS coil. Page 3245 4WD Motor Actuator PCM Service Precautions Powertrain Control Module: Service Precautions PCM Service Precautions Powertrain Control Module (PCM) Service Precaution NOTE: To prevent possible electrostatic discharge damage to the PCM, do not touch the connector pins or soldered components on the circuit board. 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. Information On PCM 1. The Powertrain Control Module (PCM) is located in the engine room and is the control center of the electronic transmission control system. 2. The PCM must be maintained at a temperature below 85°C (185°F) at all times. This is most essential if the vehicle is put through a paint baking process. The PCM will become inoperative if its temperature exceeds 85°C (185°F). Therefore, it is recommended that the PCM be removed or that temporary insulation be placed around the PCM during the time the vehicle is in a paint oven or other high temperature process. 3. The PCM is designed to process the various inputs and then respond by sending the appropriate electrical signals to control transmission upshift, downshift, shift feel and torque converter clutch engagement. 4. The PCM constantly interprets information from the various sensors, and controls the systems that affect transmission and vehicle performance. By analyzing operational problems, the PCM is able to perform a diagnostic function by displaying DTC(s) and aid the technician in making repairs. Page 2057 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 934 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. Procedures Spare Tire Carrier: Procedures Spare Tire Carrier - Parts Locations 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 7140 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 5948 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 719 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 4703 Relay/Fuse Box (Engine Room) Page 999 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 1.05 mm (0.04 in). NOTE: Do not adjust the spark plugs gap without new spark plugs. - Do not damage to tip of spark plugs. - Do not cleaning the spark plugs. If require the cleaning it due to heavy dirt, it is allowed only 20 seconds to be used spark plug cleaner. - 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 Locations Windshield - Parts Locations Page 2339 95. Right Front Exhaust Downpipe 96. Rear of Right Catalytic Converter Page 5308 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 3548 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 6776 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 1229 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 Tie Rod End: Specifications Tie Rod End Lock Nut 98 N.m (72 lb-ft) Nm Page 5739 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 4651 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 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 4286 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 as described. Page 4785 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 90. Left Side of Automatic Transmission (A/T) Page 3056 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 5178 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 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 4830 Fuse To Component Index (Fuse No. 1 - 20) Image 6-3 Page 4046 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 6220 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 7628 Front Passenger's Power Window And Door Lock Switch Driver's Power Window And Door Lock Switch Page 20 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 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 1625 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 4854 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 5313 Tires: Testing and Inspection Diagnosis List Diagnosis List If the 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 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. Three Way Catalytic Converter RH & Forked Exhaust Pipe Catalytic Converter: Diagrams Three Way Catalytic Converter RH & Forked Exhaust Pipe Three Way Catalytic Converter RH and Forked Exhaust Pipe and Associated Parts Page 7669 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 4218 Brake Drum: Service and Repair Servicing The Brake Drum Whenever the brake drums are removed, they should be thoroughly cleaned and inspected for cracks, scores, deep grooves and out-of-round. Cracked, Scored or Grooved Drum A cracked drum is unsafe and must be replaced. Do not attempt to weld a cracked drum. Smooth any slight scores. Heavy or extensive scoring will cause excessive brake lining wear, and it will probably be necessary to machine the drum braking surface. If the brake linings are slightly worn and the drum is grooved, the drum should be polished with fine emery cloth but should not be machined. At this stage, eliminating all the grooves in the drum and smoothing the ridges on the lining would require the removal of too much metal and lining. If left alone, the grooves and ridges match and satisfactory service can be obtained. If brake linings are to be replaced, a grooved drum should be machined. Using a grooved drum with new linings will create inefficient braking performance and cause the linings to wear quicker. Out-Of-Round Drum An out-of-round drum makes accurate brake shoe adjustment impossible and is likely to cause excessive wear to other parts of the brake mechanism due to its eccentric action. An out-of-round drum can also cause severe and irregular tire tread wear as well as a pulsing brake pedal. When the braking surface of a brake drum exceeds the specification limit of 0.15 mm (0.006 inch) in out-of-round, the drum should be machined to true up the braking surface. Out-of-round can be accurately measured with an inside micrometer fitted with proper extension rods. When measuring a drum for out-of-round and wear, take measurements at the open and closed edges of machines surfaces and at right angles to each other. Maximum out-of-round: 0.15 mm (0.006 inch) Machining The Drum If a drum is to be machined, only enough metal should be removed to obtain a true, smooth braking surface. If a drum does not clean-up when machined to a maximum diameter, it must be replaced. Removal of more metal will affect dissipation of heat and may cause distortion of the drum. After refinishing, replace any drum that exceeds a maximum inside diameter of 296.5 mm (11.673 inch). Do not use a brake drum that is not within the specification. Maximum inside diameter: 296.5 mm (11.673 inch) Page 5374 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 2913 Each schematic represents one circuit. A circuit's wires and components are arranged to show current flow, from power at the top 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 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. Page 4943 27. Left Side of Engine Page 2246 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 1658 Locations 56. Top Right Side of Transfer Case Service and Repair 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 To install, follow the removal steps in the reverse order, noting the following points. Torque: Nut (1) 8 Nm (69 inch lbs.) Service and Repair Fuel Pressure Release: Service and Repair Fuel Pressure Relief Procedure CAUTION: To reduce the risk of fire and personal injury, there are necessary to relieve the fuel system pressure before filler and gauge unit 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 disconnect 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 179 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 5381 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 6215 Trailer Lamps: Connector Locations 79. Left Rear of Cargo Compartment 82. Left Rear of Cargo Comp. Page 1242 7. Right Side of Engine Compartment Page 2863 Fuel Meter Body: Description and Operation Fuel Metering System Components Fuel Injector 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. Fuel Pressure Regulator 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. Page 1597 Water Pump: Description and Operation Water Pump The Engine Coolant (EC) pump is a centrifugal impeller type and is driven by a timing belt. Alignment Alignment: Specifications Alignment Locations 61. Front Center of Ceiling (Headliner Removed) Page 1140 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 2266 Inputs - Operating conditions Read - Air Conditioning "ON" or "OFF" - 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 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-megohm 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 406 Blower Motor Switch: Testing and Inspection Fan Control Knob (Fan Switch) Check for continuity between the fan switch and the A/C switch side connector terminals. Page 4747 Fuse To Component Index (Fuse 11 - 23) Image 6-1 Locations Sunshade - Disassembled View (LWB) Page 4126 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 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 6826 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 3969 92. Beneath Center of Vehicle, on Transfer Case (A/T) Page 2617 Transmission Range Switch Page 4159 3. Install support bracket and tighten the bolt (7) to the specified torque. Torque: 155 Nm (115 ft. lbs.) 4. Install caliper assembly. 5. Install lock bolt (9) and guide bolt (8) and tighten the bolt to the specified torque. Torque: 74 Nm (54 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 1-bolt (10) to the specified torque. Torque: 35 Nm (26 ft. lbs.) 7. Install wheel and tire assembly. 8. Bleed brakes. Disassembly and Reassembly Page 5561 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 3001 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. Page 7172 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. Description and Operation Transmission Temperature Sensor/Switch: Description and Operation Transmission Fluid Temperature (TFT) Sensor The transmission fluid temperature sensor is a thermistor which changes its resistance based on the temperature of the transmission fluid. For a complete description of the TFT sensor, refer to 4L30-E Automatic Transmission Diagnosis (Transmission Control System Diagnosis). A failure in the TFT sensor or associated wiring will cause DTC P0712 or DTC P0713 to set. In this case, engine coolant temperature will be substituted for the TFT sensor value and the transmission will operate normally. Page 65 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 Front Brake Pad: Service and Repair Front Removal NOTE: If a squealing noise occurs from the front 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 640 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 5051 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. 4X4 model 1. Remove the torsion bar. 2. Remove the lower control arm bolt (Frame side). 3. Apply a setting mark across the crossmember and frame so parts can be reassembled in their original position. 4. Remove the crossmember fixing bolt. 5. Remove the power steering unit with the crossmember. 6. Remove the power steering unit. INSTALLATION 1. Install power steering unit to crossmember. Tighten fixing bolt to specified torque. Torque: 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: 173 Nm (128 ft. lbs.) 3. Install lower control arm bolt. 4. Install torsion bar. 5. Connect the feed line and return line. Torque: 25 Nm (18 ft. lbs.) 6. Install tie-rod end assembly to knuckle. Torque: 118 Nm (87 ft. lbs.) 7. Install Joint assembly and transfer gear assembly. Align the setting marks made at removal. Joint assembly bolt Torque: 53 Nm (39 ft. lbs.) Transfer gear assembly bolt Torque: 31 Nm (23 ft. lbs.) 8. Install the stone guard. 9. Bleed the system. Refer to Steering; Service and Repair. Page 1299 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 3963 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 5750 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 1640 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 replenishing with coolant tighten 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 idle for 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 4549 1. Check for continuity between the end of the field coil and yoke body. Replace the field coil, if there is continuity. 2. Check continuity between the lead wire of terminal C and brush. Replace the yoke assembly, if there is no continuity. Overrunning Clutch 1. Visual check for excessive wear or damage. 2. Test the pinion rotation, it must rotate smoothly when rotated clockwise and it shouldn't rotate when turned counterclockwise. Page 5504 6. Install the drive plate to the compressor drive shaft together with the original shim(s) (1). Press the drive plate by hand. 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 N.m (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. 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. Testing and Inspection Air Filter Element: Testing and Inspection Check the air cleaner filter for damage or dust clogging. Replace if it is damaged, or clean if it is clogged. Page 2322 14. Push "On" of soft key. 15. Make sure Lamp illuminates. 16. If Lamp illuminates, the Lamp is operating correctly. 17. Select F3: Reduced Power Lamp 18. Push "On" of soft key. 19. Make sure Lamp illuminates. 20. If Lamp illuminates, the Lamp is operating correctly. 21. Select F5: Cruise Control Lamp 22. Push "On" of soft key. 23. Make sure Lamp illuminates. 24. It Lamp illuminates, the Lamp is operating correctly. Page 4825 Earth Location (Cabin) Page 4673 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 6019 Seat Belt Reminder Lamp: Electrical Diagrams Seat Belt, Lights-on, And Ignition Key Reminders Image 73-0 Page 601 Fuel Tank Pressure Sensor: Testing and Inspection Inspection Procedure 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 4761 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 2321 5. Select F0: Malfunction Indicator Lamp. 6. Push "On" soft key. 7. Make sure Lamp illuminates. 8. If lamp illuminates, the Lamp is operating correctly 9. Select F2: Up Shift Lamp 10. Push "On" of soft key. 11. Make sure Lamp illuminates. 12. If Lamp illuminates, the Lamp is operating correctly. 13. Select F2: Low Fuel Lamp Page 4965 Power Steering Pump: Service and Repair Overhaul 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 O-ring. 6. Remove the 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 Page 1377 - 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. Service and Repair Spot Lamp: Service and Repair Spotlight Bulb 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 1211 Fuse To Component Index (Fuse No. 1 - 20) Image 6-3 Page 1032 - 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 413 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-ring can not 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 (17 fl.oz.) of new compressor oil to the new core. 8. Tighten the refrigerant lines to the specified torque. 9. Apply an adhesive to the parting face of the lining when assembling the evaporator assembly. Locations 88. Left Side of Front Axle Page 4536 Starter 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 4660 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 5687 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 3776 1. Apply grease evenly to both the female and male splices. 2. Apply a small amount of grease by finger to the outer lips of the boot. 3. Slide the boot (smaller diameter side) onto the spline yoke shaft being careful not to damage the spline coating or boot. 4. Insert the spline yoke shaft spline into the tube assembly being careful to maintain proper phasing. The spider holes should be in line as originally marked prior to disassembly. 5. Position boot onto tube and yoke shaft in its assembled position. 6. Attach boot clamps and secure using pliers. 7. Be sure clamp is properly seated and secure. CAUTION: Only use a similar type or same as the original type clamp. Using any other clamp may create an imbalanced shaft or lead to grease leakage. Locations 44. Below Left Side of Dash Page 4625 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 4113 Page 243 13. Control A/C Clutch Relay and check data list. 14. If the data list changes, the Fuel Pump Relay is normal. Page 6908 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 3177 Ignition Control Module: Service and Repair 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. 3. Connect the negative battery cable. Page 4463 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 5107 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 6356 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 902 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 Stabilizer Bar: Specifications Stabilizer Bar Diameter 25.0 mm Page 1744 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 2991 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 6874 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 678 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 2329 Steps 1 - 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 inch 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. 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 6543 73. Rear of Driver's Door (Frt. Pass. Similar) Service and Repair Map Light Bulb: Service and Repair Spotlight Bulb 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 1637 Radiator: Service and Repair Removal 1. Disconnect battery ground cable. 2. Loosen a drain plug (2) to drain EC. 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). Page 2252 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 2230 30. Left Side of Engine Compartment Page 4435 Jump Starting: Service and Repair 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. Jump Starting Procedure 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 will 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 7343 Headlight Switch Image 100-1 Page 4307 Brake Master Cylinder: Service and Repair Bleeding the Master Cylinder For further information regarding this component and the system that it is a part of, please refer to Brake Bleeding; Service and Repair. Component Locations 72. Driver's Door (Frt. Pass. Similar) Page 2272 1. Install the PCM to bracket and fix with the clip. 2. Connect the PCM electrical connectors. 3. Install the two screws to PCM electrical connectors. Page 4275 Brake Fluid Level Sensor/Switch: Description and Operation Brake Fluid Level Switch 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 336 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 6236 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 6545 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. Removal/Installation Air Filter Element: Service and Repair Removal/Installation Engine Driveability and Emissions System Air Cleaner/Air Filter Removal Procedure 1. Loosen the clamp between the air cleaner lid and the mass air flow sensor. 2. Release the tour latches securing the lid to the air cleaner housing. 3. Remove the air cleaner lid. 4. Remove the air filter element. 5. Remove the retaining bolts and the air cleaner housing from the vehicle. Installation Procedure 1. Install the air cleaner housing in the vehicle with the retaining bolts. 2. Install the air filter element in the air cleaner housing. Page 2141 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 3227 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.) 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 67. Behind Glove Box Page 2289 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 Firing Order: Specifications Firing Order Firing Order Firing Order 1-2-3-4-5-6 Page 2930 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 4730 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 4051 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 2764 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 74. Rear of Driver's Door (Frt. Pass. Similar) Page 7359 Ground - "G" Shielding Sheilding This represents RFI (Radio Frequency Interference) shielding around a wire. The shielding is always connected to ground. Splices Page 5176 Page 5546 Condenser Fan: Description and Operation Condenser Fan How the Circuit Works 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 tan 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. Page 6000 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 4981 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 Locations Coolant Temperature Sensor/Switch (For Computer): Locations 17. Front of Engine ECT Sensor PCM Service Precautions Powertrain Control Module: Service Precautions PCM Service Precautions Powertrain Control Module (PCM) Service Precaution NOTE: To prevent possible electrostatic discharge damage to the PCM, do not touch the connector pins or soldered components on the circuit board. 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. Information On PCM 1. The Powertrain Control Module (PCM) is located in the engine room and is the control center of the electronic transmission control system. 2. The PCM must be maintained at a temperature below 85°C (185°F) at all times. This is most essential if the vehicle is put through a paint baking process. The PCM will become inoperative if its temperature exceeds 85°C (185°F). Therefore, it is recommended that the PCM be removed or that temporary insulation be placed around the PCM during the time the vehicle is in a paint oven or other high temperature process. 3. The PCM is designed to process the various inputs and then respond by sending the appropriate electrical signals to control transmission upshift, downshift, shift feel and torque converter clutch engagement. 4. The PCM constantly interprets information from the various sensors, and controls the systems that affect transmission and vehicle performance. By analyzing operational problems, the PCM is able to perform a diagnostic function by displaying DTC(s) and aid the technician in making repairs. Page 5342 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. 2. Tighten the hub nut to the value given, 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 lb - 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. Page 2008 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. Locations 51. Behind Gauge Assembly Page 698 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 224 Individual circuit schematics begin with a fuse. The first half of Power Distribution, however, shows the wiring "upstream" between the battery 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 5761 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. 3. Install the fuse and relay box cover. Page 4308 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 734 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 3047 Above 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 begins in Wire Color Abbreviations. 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 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 Page 4840 Relay Box: Diagrams Relay/Fuse Box (Instrument Panel) Page 2150 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 7143 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 903 ^ 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 4635 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 4244 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 4758 Individual circuit schematics begin with a fuse. The first half of Power Distribution, however, shows the wiring "upstream" between the battery 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 954 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: This illustration shows view from the front of the vehicle. 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. Toe-in: Locations Vapor Pressure Sensor / Fuel Gage And Fuel Pump Connector Page 5041 Seat Belt, Lights-on, And Ignition Key Reminders Image 73-1 Specifications Compression Check: Specifications Compression Pressure Limit 1,000 kPa Compression Ratio 9.1 : 1 Copmression Pressure At 300 rpm 145 psi. Page 1787 Fuel Pump Relay: Testing and Inspection Relays Test This testis 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 7326 Individual circuit schematics begin with a fuse. The first half of Power Distribution, however, shows the wiring "upstream" between the battery 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 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 7181 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. Specifications Compression Check: Specifications Compression Pressure Limit 1,000 kPa Compression Ratio 9.1 : 1 Copmression Pressure At 300 rpm 145 psi. Page 6280 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 1138 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 7474 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 10. Fuse/Relay Box (Cover Removed) Locations 40. Dash Fuse Box 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 5582 HVAC Control Bezel Exploded Views Page 5191 ^ 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 5548 Condenser Fan: Service and Repair Condenser Fan Motor and Associated Parts 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 O-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 2546 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 2199 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 5981 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) Testing and Inspection Throttle Body: Testing and Inspection Inspection Procedure 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. Page 5207 ^ 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 2911 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 2034 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 TP1 about 0.4 V, TP2 about 4.6 V and TP3 about 4.6 V. - If the reading is abnormal value, check the throttle shaft to see if it is binding. Page 4376 Electronic Brake Control Module: Electrical Diagrams Circuit Diagram Part 1 of 3 Page 4821 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 2520 Manifold Absolute Pressure 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 Service and Repair Shift Indicator: Service and Repair A/T Shift Indicator Light Bulb Removal 1. Disconnect the battery ground cable. 2. Pry up the bended portions (2) of the metal cover (1). 3. Remove the meter lense (3) from the meter visor (4). 4. Remove the meter visor from the meter case (5). Page 1859 Crankshaft Position Sensor: Service and Repair Removal 1. Disconnect battery ground cable 2. Wiring connector from crankshaft position sensor. 3. Remove crankshaft position sensor from cylinder block. Installation 1. Install crankshaft position sensor into the cylinder block. Before installation,apply small amount of engine oil to the O-ring. Torque: 10 N.m (87 lb.in) 2. Reconnect wiring connector to crankshaft position sensor. Diagram Information and Instructions Fuel Pump Relay: Diagram Information and Instructions How to Identify Wiring Color-Coded Insulation Wire Color Wire Color Coding Page 2803 Fuel Filler Cap: Testing and Inspection Engine Fuel System Inspect the fuel filler cap seal condition for any signs of wear. The fuel filler cap must be replaced in case of fuel filler cap seal wear. CAUTION: The fuel filler cap valve is designed to be used on this vehicle. Decreased engine efficiency will occur if the fuel filler cap valve becomes defective or an incorrect fuel filler cap is installed. Always install the same type fuel filler cap similar to the one previously installed in this vehicle or visit your local Honda dealer for the correct fuel filler cap replacement. 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 330 Power Seat Switch Page 6163 Speaker: Service and Repair Rear Door Speaker Removal 1. Disconnect the battery ground cable. 2. Remove the inside handle (3). 3. Remove the rear door trim pad (2). 4. Remove the rear speaker (1). - Disconnect the connector. Installation To install, follow the removal steps in the reverse order. Page 188 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 6266 Front Door Exterior Handle: Service and Repair Front Outside Handle And Associated Parts 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 N.m (78 lb in) Page 815 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 1731 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 650 ^ 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 6076 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 4315 Page 780 CAUTION: Turn the SRS coil counter clockwise until some resistance is felt, or damage may occur to the SRS coil. 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 shaft 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 ground cable. Service and Repair 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. Page 2843 - 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 4164 5. Remove lock bolt (3). 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 166 30. Left Side of Engine Compartment Page 2528 Oxygen Sensor: Connector Locations 93. Left Front Exhaust Downpipe 94. Rear of Left Catalytic Converter Page 5864 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. Symptom Diagnosis Malfunction Indicator Lamp: Testing and Inspection Symptom Diagnosis Malfunction Indicator Lamp The instrument panel "CHECK ENGINE" Malfunction Indicator Lamp (MIL) illuminates by self diagnostic system when the system checks the starting of engine, or senses malfunctions. Page 5299 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 Locations 98. Top Rear of Fuel Tank Page 3705 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-86101. 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 5503 7. Loosen three screws and remove the field coil. Installation 1. Install field coil. - Align the located portion (1) of the field coil and compressor. - Tighten the mounting screw to the specified torque. Torque: 5 N.m (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). Page 6243 Trailer Lamps: Description and Operation Trailer Lighting Connector How the Circuit Works Early Production only 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 1814 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). Locations Manifold Absolute Pressure Sensor: Locations 24. Top Rear of Engine MAP Sensor 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 4044 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 3962 2. Connect the terminals as shown in figure. Shift rod of the motor actuator moves and stops at 4WD position. 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. Transfer Position Switch 1. With ball being free. Page 4671 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. 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 2886 ^ 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 Air Flow Meter/Sensor: Locations 28. Left Side of Engine Compartment MAF Sensor Page 1607 Check the specific gravity of engine coolant in the cooling system temperature ranges from 0°C to 50°C using a suction type hydrometer, then determine the density of the engine coolant by referring to the table. Page 2330 Manifold Absolute Pressure 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 Page 4486 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. 2. Check for continuity across one of the stator coils and stator core If a continuity exists, replace the coil. Page 2479 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 (gm/s). At idle, the Tech 2 should read between 4 - 7 gm/s 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 1769 Above 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 begins in Wire Color Abbreviations. 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 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 Diagrams Page 7767 Torque: 10 N.m (87 lb in) 4. Tighten the wiper arm nut to the specified torque. Torque: 14 N.m (122 lb in) 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 1499 NOTE: Take care that dowel positions are different between the manual transmission and the automatic transmission. Otherwise, the transmission may be damaged. Page 3111 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 7240 TURN, HAZARD, STOP, Back Up, Horn And Air Shift Lock Page 2414 ECM (M/T) Or PCM (A/T) Connector B Page 2748 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 6336 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. Locations Safing Sensor: Locations The safing sensor is located inside the SRS Unit, refer to SRS Unit / Service and Repair. Fan Control Lever (Fan Switch) Blower Motor Switch: Testing and Inspection Fan Control Lever (Fan Switch) Check for continuity between the terminals of the fan switch. Locations 67. Behind Glove Box Page 7478 The wire insulation has one color or one color with another color stripe. The second color is the stripe. Page 1280 ^ 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 1221 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 2593 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 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 966 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 5564 Above 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 begins in Wire Color Abbreviations. 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 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 Locations Page 4594 Auxiliary Power Outlet: Electrical Diagrams Cigarette Lighter And Accessory Power Sockets Image 155 Page 5468 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 7073 14. Push "On" of soft key. 15. Make sure Lamp illuminates. 16. If Lamp illuminates, the Lamp is operating correctly. 17. Select F3: Reduced Power Lamp 18. Push "On" of soft key. 19. Make sure Lamp illuminates. 20. If Lamp illuminates, the Lamp is operating correctly. 21. Select F5: Cruise Control Lamp 22. Push "On" of soft key. 23. Make sure Lamp illuminates. 24. It Lamp illuminates, the Lamp is operating correctly. Page 2597 The wire insulation has one color or one color with another color stripe. The second color is the stripe. Page 5469 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 268 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 7640 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 5456 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 6629 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) Service and Repair Trunk 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 4052 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 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. 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 2750 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 3197 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 ground 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 driver knee bolster (reinforcement). 7. 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 7250 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 2409 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 3340 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 191 ECM (M/T) Or PCM (A/T) Connector B Page 4834 Relay/Fuse Box (Engine Room) Page 4823 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 5434 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 Brake Hose/Line: Diagrams Front Front Caliper Brake Hose and Associated Parts Replacement w/ Related Components Page 4166 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 5936 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 4539 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 2035 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 1838 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 220 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 4340 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. 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 7130 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 4341 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 4160 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 1578 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 MOhms or more Page 7249 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 829 27. Left Side of Engine Page 485 Combination Light Switch Connectors A And B Page 4004 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) (V6). 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 Page 3007 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 6472 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 3189 Crankshaft Position Sensor: Testing and Inspection Inspection Procedure 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. 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 N.m (30 lb.ft) M8 bolt: 21 N.m (15 lb.ft) 3. Connect wiring harness connector and direct terminal "B". 4. Move drive belt tensioner to loose side using wrench, then install drive belt to normal position. 5. Reconnect battery ground cable. Locations Intake Air Temperature Sensor: Locations 26. Left Front of Engine IAT Sensor Page 4130 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 7185 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 702 3. Connect the VSS electrical connector. 4. Check the transfer case oil level. Add fluid if necessary. 5. Connect the negative battery cable. Page 1190 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 7562 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 4822 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 Fuel Filler Door - Parts Location Page 2368 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 555 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 5026 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 7084 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 1111 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 Locations 18. Right Side of Engine 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 7696 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 4885 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. Service and Repair Intake Air Plenum: Service and Repair Removal 1. Disconnect battery ground cable. 2. Remove air cleaner duct assembly. 3. Disconnect vacuum booster hose from common chamber. 4. Disconnect connector from manifold absolute pressure sensor, Ion sensing module, throttle position sensor, solenoid valve, electric vacuum sensing valve, and EGR valve. 5. Disconnect vacuum hose on canister VSV and positive crankcase ventilation hose, fuel rail assembly with pressure control valve bracket. 6. Remove ventilation hose from throttle valve and intake duct and remove water hose. 7. Remove the four throttle body fixing bolts. 8. Remove exhaust gas recirculation valve assembly fixing bolt and nut on common chamber and remove EGR valve assembly. 9. Remove two bolts from common chamber rear side to remove fuel hose bracket. 10. 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 (87 inch lbs.) 3. Install exhaust gas recirculation valve assembly and tighten bolt and nut to the specified torque. Page 4816 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 2889 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 7522 The wire insulation has one color or one color with another color stripe. The second color is the stripe. Page 6662 Sunroof Frame Complete Assembly And Associated Parts (LWB) Page 6813 Individual circuit schematics begin with a fuse. The first half of Power Distribution, however, shows the wiring "upstream" between the battery 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 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 6325 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 6218 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 61. Front Center of Ceiling (Headliner Removed) Diagrams Engine Hood Latch Page 1715 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 6510 Door Locks: Diagrams Front Door Lock Assembly And Associated Parts Rear Door Lock Assembly And Associated Parts Page 3883 92. Beneath Center of Vehicle, on Transfer Case (A/T) Page 7412 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 2392 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 Turn Signal Bulb: Service and Repair Rear Turn Signal Light Bulb 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. Page 1212 7. Right Side of Engine Compartment 38. Left Side of Dash Page 170 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 89. Left Side of Manual Transmission (M/T) Page 2612 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 TP1 about 0.4 V, TP2 about 4.6 V and TP3 about 4.6 V. - If the reading is abnormal value, check the throttle shaft to see if it is binding. Irregular and Premature Wear Tires: Testing and Inspection Irregular and Premature Wear 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. Description and Operation 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 6981 Headlamp Reminder Indicator: Electrical Diagrams Seat Belt, Lights-on, And Ignition Key Reminders Image 73-0 Page 63 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 4186 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 7354 Above 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 begins in Wire Color Abbreviations. 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 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 Page 1723 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 295 Heated Glass Element Relay: Service and Repair Rear Defogger Switch 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 4323 Page 5720 Refrigerant Pressure Sensor / Switch: Service and Repair Pressure Switch And Associated Parts Pressure Switch 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 N.m (113 lb in) Page 7055 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 1779 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 4774 Fuse Block: Electrical Diagrams Fuse Block Circuit-1 Service and Repair Synchronizer Hub: 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. Page 2263 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 6407 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 7179 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 4897 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 6107 - 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 2449 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. Testing and Inspection Turn Signal Switch: Testing and Inspection Turn Signal Switch This diagnosis covers mechanical problems only. Component Locations Power Seat Motor: Component Locations 105. Left Side of Driver's Seat 106. Under Driver's Seat Page 2411 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 Rear Wiper/Washer Switch Page 267 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 1243 Relay Box: Diagrams Relay/Fuse Box (Instrument Panel) Exploded Views Page 4838 Fuse To Component Index (Fuse No. 1 - 20) Image 6-3 Page 4988 ^ 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 4899 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 1017 Page 4573 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 Description and Operation 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 5799 Locations Page 3207 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 1.05 mm (0.04 in). NOTE: Do not adjust the spark plugs gap without new spark plugs. - Do not damage to tip of spark plugs. - Do not cleaning the spark plugs. If require the cleaning it due to heavy dirt, it is allowed only 20 seconds to be used spark plug cleaner. - 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 Page 542 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 4117 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 5439 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 5198 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 5030 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 7633 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 7754 2. Finally, check that the click of the stay has caught in the hole of the rubber. Page 4487 Brush Measure the brush length. Replace the brush if it exceeds the limit. Rectifier Assembly 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 12 V 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 "V1" 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 measured voltage should be within the specified (14.4 ± 0.3 volts) limits. If it is not, the regulator must be replaced. Page 6679 Power Seat Switch Page 7194 Steps 1 - 9 Page 2990 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 4119 15. Connect the yellow 3 way Supplemental Restraint System (SRS) connector located under the steering column. 16. Connect the battery "-" terminal cable. Three Way Catalytic Converter RH & Forked Exhaust Pipe Catalytic Converter: Service and Repair Three Way Catalytic Converter RH & 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 front exhaust pipe assembly 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). Page 742 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 5808 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 7268 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 3952 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.) 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 7588 Heated Glass Element Relay: Service and Repair Rear Defogger Switch 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. Service and Repair Band Control Solenoid Valve: Service and Repair For further information regarding this component and the system that it is a part of, please refer to Shift Solenoid; Service and Repair. Page 6354 Liftgate Window Glass: Service and Repair Rear Hatchgate Rear Hatchgate (LWB) Removal 1. Disconnect the battery ground cable. 2. Disconnect the high mount stoplight and rear defogger harness connectors. Locations 61. Front Center of Ceiling (Headliner Removed) Page 4337 Vacuum Brake Booster: Description and Operation Brake Booster 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 both sides of the diaphragm to provide the power assist. When the service brake is released, the atmospheric air is shut off from both sides of the 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 944 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 5675 Housing Assembly HVAC: Service and Repair Heater Mode Control Link Unit Heater Mode Control Link Unit Heater Mode Control Link Unit - Disassembled View 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. 9. Pull out the door lever while raising up the catch of the door lever. 10. Remove clip. Installation Page 7709 - 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 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 Page 5326 - 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 (4.1 kg.m) 3. Tighten the spare tire hanger fixing bolts to the specified torque. Torque: 19 N.m (1.9 kg.m) Page 1813 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 4202 Brake Rotor/Disc: Description and Operation Rear 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. 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 5978 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 Page 7044 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 85 Electronic Brake Control Module: Description and Operation System Components Electronic Hydraulic Control Unit (EHCU), three Wheel Speed Sensors, Warning Light, and G-sensor. Electronic Hydraulic Control Unit (EHCU) The Electronic Hydraulic Control Unit (EHCU) consists of Anti-lock Brake System (ABS) control circuits, fault detector, and a fail-safe. The signal received from each sensor activates the hydraulic unit accordingly and cancels the ABS to return to normal braking if a malfunction occurs in the ABS system. 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. 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. BLEEDING BRAKE HYDRAULIC SYSTEM 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. When replenishing the brake fluid reservoir, carefully pour in the brake fluid to prevent air bubbles from entering the brake system. 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 described. Bleeding the Master Cylinder 7. Disconnect the rear wheel brake pipe (1) from the master cylinder. Check the fluid level and replenish as necessary. If replenished, leave the Page 5920 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). Locations 33. Bottom Center Front of Engine Page 2631 Each schematic represents one circuit. A circuit's wires and components are arranged to show current flow, from power at the top 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 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. Page 444 Above 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 begins in Wire Color Abbreviations. 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 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 Page 4941 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 3765 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 5495 Compressor Clutch: Testing and Inspection Compressor Clutch Circuit A/C Clutch Control Circuit Diagnosis Circuit Description When air conditioning and blower fan are selected, and if the system has a sufficient refrigerant charge, a 12-volt signal is supplied to the A/C request input of the powertrain control module (PCM). The A/C request signal may be temporarily canceled during system operation by the electronic thermostat in the evaporator case. When the A/C request signal is received by the PCM, the PCM supplies a ground from the compressor clutch relay if the engine operating conditions are within acceptable ranges. With the A/C compressor relay energized, voltage is supplied to the compressor clutch coil. The PCM will enable the compressor clutch to engage whenever A/C has been selected with the engine running, unless any of the following conditions are present: - The throttle is greater than 90 %. - The ignition voltage is below 10.5 volts. - The engine speed is greater than 4500 RPM for 5 seconds or 5400 RPM. - The engine coolant temperature (ECT) is greater than 125 °C (257 °F). - The intake air temperature (IAT) is less than 5 °C (41 °F). - The power steering pressure switch signals a high pressure condition. Diagnostic Aids To diagnose an the intermittent fault, check for following conditions: - Poor connection at the PCM-Inspect connections for backed-out terminals, improper mating, broken locks, improperly formed or damaged terminals, and poor terminal-to-wire connection. - Damaged harness-Inspect the wiring harness for damage. If the harness appears to OK, observe the A/C clutch while moving connectors and wiring harnesses related to the A/C. A sudden clutch malfunction will indicate the source of the intermittent fault. A/C Clutch Diagnosis Page 172 Each schematic represents one circuit. A circuit's wires and components are arranged to show current flow, from power at the top 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 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. 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 2584 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 3681 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: Carefully insert the drive shaft into the knuckle, to avoid damaging the oil seal. 5. Align the bolt hole of the lower control arm, then install the bolts and nuts. NOTE: Adjust the buffer clearance before tightening the bolts and nuts of the lower control arm. 6. Install the hose of the shift on the fly. 7. Install the actuator connector 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 speed 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 443 Each schematic represents one circuit. A circuit's wires and components are arranged to show current flow, from power at the top 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 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. Page 6969 Ground - "G" Shielding Sheilding This represents RFI (Radio Frequency Interference) shielding around a wire. The shielding is always connected to ground. Splices Page 2040 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. Refer to Electronic Ignition System for additional information. Page 2382 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 4213 Brake Rotor/Disc: Service and Repair Refinishing Brake Rotors Front Replacing Brake Rotors When installing new brake rotors, do not refinish the surfaces. These parts are at the correct level of surface finish. 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 exceeds the manufacturers specifications. Minimum wear dimension: 24.60 mm (0.969 inch) Refinish dimension: 24.97 mm (0.983 inch) Rear Replacing Brake Rotors When installing new brake rotors, do not refinish the surfaces. These parts are at the correct level of surface finish. 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 16.6 mm (0.654 inch). The minimum refinish dimension is 16.97 mm (0.668 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 16.97 mm (0.668 inch). Do not use a brake rotor that exceeds the manufacturers specifications. Minimum wear dimension: 16.6 mm (0.654 inch) Refinish dimension: 16.97 mm (0.668 inch) Page 1491 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 gauges. 9. Install the oil pressure unit. 10. Start the engine and check for leaks. Page 2999 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 5429 Blower Motor And Associated Parts Diagrams Page 6751 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 4990 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 1676 Catalytic Converter: Diagrams Three Way Catalytic Converter LH & Forked Exhaust Pipe Three Way Catalytic Converter LH and Forked Exhaust Pipe and Associated Parts Page 1790 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. - The screwdriver blade will release the catch inside. 4. 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. Page 5859 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 4045 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 4128 Above 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 begins in Wire Color Abbreviations. 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 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 Service and Repair Differential Case: 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. Page 6862 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 Headlamp Bulb: Service and Repair Headlight Bulb 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: Do not touch the headlight bulb with your fingers. The oil on your fingers will leave a residue which will shorten the life of the halogen bulb. In order to prevent this problem, clean the bulb lens before installing the headlight bulb. Installation To install, follow the removal steps in the reverse order. noting the following point: 1. Make sure to set the retaining ring and the bulb cover. If the set is incomplete, there is a possibility that the water comes in the light. 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 1692 Exhaust Pipe: Service and Repair 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 7395 Each schematic represents one circuit. A circuit's wires and components are arranged to show current flow, from power at the top 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 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. Locations 58. Under Center Console Page 5052 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 (3) and band (5), then remove bellows (4). 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 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. REASSEMBLY 1. Install mounting rubber and dust cover (If removed). 2. Install oil line. Torque: 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: 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. Page 1953 Individual circuit schematics begin with a fuse. The first half of Power Distribution, however, shows the wiring "upstream" between the battery 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 7335 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 4913 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 10.8 mm (0.425 inch) or less. Tighten the fulcrum pin bolt to the specified torque. Torque: 152 Nm 112 ( ft. lbs.) Camber Adjustment 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' CAUTION: Left and right side must be equal within 30'. Page 5600 Ground - "G" Shielding Sheilding This represents RFI (Radio Frequency Interference) shielding around a wire. The shielding is always connected to ground. Splices Removal/Installation Air Filter Element: Service and Repair Removal/Installation Engine Driveability and Emissions System Air Cleaner/Air Filter Removal Procedure 1. Loosen the clamp between the air cleaner lid and the mass air flow sensor. 2. Release the tour latches securing the lid to the air cleaner housing. 3. Remove the air cleaner lid. 4. Remove the air filter element. 5. Remove the retaining bolts and the air cleaner housing from the vehicle. Installation Procedure 1. Install the air cleaner housing in the vehicle with the retaining bolts. 2. Install the air filter element in the air cleaner housing. Locations Intake Air Temperature Sensor: Locations 26. Left Front of Engine IAT Sensor Page 5147 4. Install bolt and nut, then tighten the nut to the specified torque. Torque: 31 Nm (27 ft. lbs.) Page 4624 Ground - "G" Shielding Sheilding This represents RFI (Radio Frequency Interference) shielding around a wire. The shielding is always connected to ground. Splices Page 779 WARNING: THE INFLATOR MODULE SHOULD ALWAYS BE CARRIED WITH THE TRIM COVER AWAY FROM YOUR BODY AND SHOULD ALWAYS BE LAID ON A FLAT SURFACE WITH THE URETHANE SIDE UP. THIS IS NECESSARY BECAUSE 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. 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. 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 counter clockwise to full, return about 3 turns and align the neutral mark. Page 1991 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 Synchronizer Ring: 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. Page 5935 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 4766 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 426 Dimmer Switch: Service and Repair Illumination Controller 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 31 Alarm/Immobilizer Control Unit: Electrical Diagrams Alarm And Relay Controls Image 70-0 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 6332 Fuel Fill Door Specifications Fuel Pressure: Specifications PRESSURE PRESSURE With Regulator Vacuume Hose Disconnected 42-55 Psi. Locations 9. Fuse/Relay Box (Cover Removed) Page 7686 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 5577 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. 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). Removal and Installation Powertrain Control Module: Service and Repair Removal and Installation Removal Procedure 1. Disconnect the negative battery cable. 2. Block the wheels. 3. Remove the two screws from the PCM electrical connectors. 4. Disconnect the PCM electrical connectors. 5. After removing the clip which fixes the PCM to the bracket, remove PCM. Installation Procedure Locations Manifold Absolute Pressure Sensor: Locations 24. Top Rear of Engine MAP Sensor Page 68 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 56. Top Right Side of Transfer Case Page 430 Door 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 2845 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. Page 6009 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 45 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 169 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 1088 Fluid - A/T: Fluid Type Specifications A/T Fluid Type ..................................................................................................................................................... .............................................. ATF DEXRON (R) III Page 3334 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 2596 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 2288 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 6894 Each schematic represents one circuit. A circuit's wires and components are arranged to show current flow, from power at the top 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 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. Page 2646 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 7002 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 475 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. Locations 2. Behind Left Side of Front Grille Page 1933 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 697 VSS Image 33-0 Page 4725 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 7464 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 5636 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-ring can not 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 (17 fl.oz.) of new compressor oil to the new core. 8. Tighten the refrigerant lines to the specified torque. 9. Apply an adhesive to the parting face of the lining when assembling the evaporator assembly. Page 7621 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 3459 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. 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 2241 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 18. Right Side of Engine Page 5010 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. 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 5218 Page 4505 CAUTION: Turn the SRS coil counter clockwise until some resistance is felt, or damage may occur to the SRS coil. 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 shaft 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 ground cable. Page 5263 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 - Disc - Caliper - Shift on the fly system parts (Cap, Hub flange, Shim, Snap ring) - ABS sensor ring Reassembly Page 7344 Headlight Switch Image 100-2 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 Diagrams Hydraulic Control Assembly - Antilock Brakes: Diagrams ELECTRONIC HYDRAULIC CONTROL UNIT AND ASSOCIATED PARTS Replacement Overhaul Locations 9. Fuse/Relay Box (Cover Removed) Page 3520 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.) 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 3349 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 2140 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 56. Top Right Side of Transfer Case Page 6883 Cigarette Lighter: Electrical Diagrams Cigarette Lighter And Accessory Power Sockets Image 155 Page 2953 2. If you have replaced any hoses, start the engine and inspect for any fuel leaks. 3. Fill out the information on a campaign completion label. Affix this label to the driver's doorjamb above the manufacturer's identification label. DISCLAIMER Page 5193 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 6139 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 2916 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 6757 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: 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 tailgate lock assembly fixing bolts to the specified torque. Torque: 7 N.m (81 lb in) 5. Tighten the hatchgate lock assembly fixing bolts to the specified torque. Torque: 9 N.m (78 lb in) Page 4814 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 4784 ^ 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 67 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 6576 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 9. Fuse/Relay Box (Cover Removed) Page 1263 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 6918 5. Select F0: Malfunction Indicator Lamp. 6. Push "On" soft key. 7. Make sure Lamp illuminates. 8. If lamp illuminates, the Lamp is operating correctly 9. Select F2: Up Shift Lamp 10. Push "On" of soft key. 11. Make sure Lamp illuminates. 12. If Lamp illuminates, the Lamp is operating correctly. 13. Select F2: Low Fuel Lamp Page 5106 3. Photocopy the template that is shown. Cut out the template. 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 2328 Manifold Absolute Pressure 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 7046 Ground - "G" Shielding Sheilding This represents RFI (Radio Frequency Interference) shielding around a wire. The shielding is always connected to ground. Splices Page 3845 Control Module: Service and Repair 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 2050 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. 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 shaft 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. Page 2628 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 1313 - 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 (4.1 kg.m) 3. Tighten the spare tire hanger fixing bolts to the specified torque. Torque: 19 N.m (1.9 kg.m) Page 1077 Coolant: Description and Operation Antifreeze Solution - Relation between the mixing ratio and freezing temperature of the Engine Coolant (EC) 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 NOTE: Antifreeze solution + Water = Total cooling system capacity. - Total Cooling System Capacity - M/T 11.1 L (2.93 Us gal) - A/T 10.0 L (2.64 Us gal) - Mixing ratio Page 5442 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 5814 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 655 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 2723 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 3030 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. 8. Connect vacuum booster hose. 9. Connect the ion sensing module connectors. 10. Install air cleaner duct assembly. 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 2191 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 6279 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 2153 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 5987 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 2864 Fuel Pump Electrical Circuit Fuel Pump Electrical Circuit When the key is first turned "ON," the PCM energizes the fuel pump relay for two seconds to build up the fuel pressure quickly. If the engine is not started within two seconds, the PCM shuts the fuel pump off and waits until the engine is cranked. When the engine is cranked and the 58X crankshaft position signal has been detected by the PCM, the PCM supplies 12 volts to the fuel pump relay to energize the electric in-tank fuel pump. An inoperative fuel pump will cause a "no-start" condition. A fuel pump which does not provide enough pressure will result in poor performance. Fuel Rail 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. Throttle Body Unit 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 4146 Brake Warning Indicator: Description and Operation How the Circuit Works 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. Parking Brake Switch 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. Brake Fluid Level Switch 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.) Bulb Check 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 4523 Each schematic represents one circuit. A circuit's wires and components are arranged to show current flow, from power at the top 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 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. 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 240 Fuel Pump Relay: Description and Operation In order to control the FPS operation, the FPS relay is provided. When the starter switch is turned to "ON" position, the FPS relay operates the FPS for 2 seconds. When the key 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 FPS to feed fuel. Page 2475 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 5896 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 3011 Individual circuit schematics begin with a fuse. The first half of Power Distribution, however, shows the wiring "upstream" between the battery 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 Hydraulic System Bleeding Clutch Slave Cylinder: Service and Repair Hydraulic System Bleeding Bleeding 1. Check the level of clutch fluid in the reservoir and replenish if necessary. 2. Bleeding the slave cylinder. 1. Remove the rubber cap from the bleeder screw and wipe clean. Connect a vinyl tube to the bleeder screw and insert the other end of the vinyl tube into a transparent container. 2. Pump the clutch pedal repeatedly and hold it depressed. 3. Loosen the bleeder screw to release clutch fluid with air bubbles into the container, then tighten the bleeder screw immediately. 4. Release the clutch pedal carefully. Repeat the operation until air bubbles disappear from the clutch fluid being pumped out into the container. During the bleeding operation, keep the clutch fluid reservoir filled to the specified level. Reinstall the rubber cap. Page 5806 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 3400 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. Page 5606 The wire insulation has one color or one color with another color stripe. The second color is the stripe. Page 1237 Fuse Block Circuit-2 (V6) Diagrams 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 3689 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. Page 6577 Rear Wiper/washer, Rear Defogger and Mirror Defogger Page 2196 The wire insulation has one color or one color with another color stripe. The second color is the stripe. Page 4090 Wheel Speed Sensor: Service and Repair Rear Removal 1. Disconnect harness connector (1). 2. Remove sensor fixing bolt (2). 3. Remove speed sensor (3). Installation 1. Install speed sensor (3). 2. Tighten the sensor fixing bolt (2) to the specified torque. Torque: 24 Nm (17 ft. lbs.) 3. Connect harness connector (1). Page 4809 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 1303 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. Radial Tire Waddle 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 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. Radial Tire Lead/Pull Correction Chart Radial Tire Lead/Pull Correction Chart Page 5054 Locations Electronic Thermostat, Evaporator Core And/Or Expansion Valve - Disassembled View Description and Operation Windshield Washer Spray Nozzle: Description and Operation Windshield Washer Spray Pattern Rear Washer Spray Pattern Page 4667 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 5630 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-ring can not 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 (17 fl.oz.) of new compressor oil to the new core. 8. Tighten the refrigerant lines to the specified torque. 9. Apply an adhesive to the parting face of the lining when assembling the evaporator assembly. Page 6905 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 2572 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 4L30-E Automatic Transmission (Transmission Control System Diagnosis). Page 266 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 4385 Brake Fluid Level Sensor/Switch: Description and Operation Brake Fluid Level Switch 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 5617 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 N.m (18 lb.ft) 3. Tighten the refrigerant inlet line to the specified torque. Torque: 15 N.m(11 lb.ft) 4. O-ring cannot be reused. Always replace with new ones. 5. Be sure to apply new compressor oil to the O-ring when connecting lines. Diagram Information and Instructions Fuel Pump Relay: Diagram Information and Instructions How to Identify Wiring Color-Coded Insulation Wire Color Wire Color Coding Page 7352 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 3443 Fluid should be changed according to maintenance schedule. Page 7750 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. 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 2371 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 5253 Page 5705 Refrigerant Oil: Fluid Type Specifications A/C Oil Specifications A/C Oil Specifications Lubricant Type Poly Alkaline Glycol (PAG) Locations 59. Under Center Console Diagrams Power Window Switch: Diagrams Left Rear Power Window Switch Right Rear Power Window Switch Page 6932 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 558 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 4135 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 977 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 6006 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 4804 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 7222 Individual circuit schematics begin with a fuse. The first half of Power Distribution, however, shows the wiring "upstream" between the battery 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 6141 ^ 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 239 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 1256 5. Select F0: Malfunction Indicator Lamp. 6. Push "On" soft key. 7. Make sure Lamp illuminates. 8. If lamp illuminates, the Lamp is operating correctly 9. Select F2: Up Shift Lamp 10. Push "On" of soft key. 11. Make sure Lamp illuminates. 12. If Lamp illuminates, the Lamp is operating correctly. 13. Select F2: Low Fuel Lamp 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 3684 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 6073 Alarm/Immobilizer 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 2749 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 654 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 Initial Inspection and Diagnostic Overview Powertrain Control Module: Initial Inspection and Diagnostic Overview Functional Check 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 6002 Above 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 begins in Wire Color Abbreviations. 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 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 Page 5570 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 5528 Individual circuit schematics begin with a fuse. The first half of Power Distribution, however, shows the wiring "upstream" between the battery 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 2527 95. Right Front Exhaust Downpipe Page 1527 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 2759 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 Specifications Wheels: Specifications Size 16 X 7JJ Offset 38.0 mm P.C.D., Wheel Studs 139.7 mm Page 644 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 7358 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 1004 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 MOhms or more Page 7030 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 679 Each schematic represents one circuit. A circuit's wires and components are arranged to show current flow, from power at the top 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 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. Page 5852 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 621 95. Right Front Exhaust Downpipe Page 5020 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 Differential Clutch: 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. Page 6907 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. Page 4714 Each schematic represents one circuit. A circuit's wires and components are arranged to show current flow, from power at the top 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 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. Page 2243 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" Front Drive Shaft Page 5013 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 108 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 6852 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 4562 Starter Motor: Service and Repair Removal And Installation Starter Removal 1. Battery ground cable. 2. Disconnect Heated O2 Sensor connector (1). 3. Remove exhaust front left pipe (2). 4. Disconnect starter wiring connector from terminals "30" (1) and "50" (2). 5. Remove starter assembly mounting bolts on inside and outside (3). 6. Remove starter assembly (4) toward the bottom of engine. Installation 1. Install starter assembly (4). 2. Install mounting bolts and tighten bolts to specified torque (3). Torque: 40 N.m (30 lb.ft) Locations 33. Bottom Center Front of Engine Page 7060 Low Fuel Lamp/Indicator: Testing and Inspection Lamps Test This test is conducted to check MIL, Up Shift Lamp, Low Fuel Lamp, Reduced Power Lamp and Cruise Control Lamp for its working. 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 F0: Lamps Test in the Miscellaneous Test. Page 4931 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 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 S (2) and ground. If there is no voltage present, then perform appropriate repair. 3. Reconnect the wiring connector to the generator, run the engine at must indicate idle 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 4926 ^ 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 4979 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). Specifications Parking Brake Lever: Specifications Parking Brake Lever Stroke 6 - 8 Notches When Pulled With a Force of 30 kg (66 lbs.) Diagrams Rear Hatchgate (LWB) Page 6290 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 6669 Sunroof / Moonroof Module: Service and Repair Sunroof Control Unit 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 5611 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 5999 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 4852 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 6012 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 6713 Power Seat Switch Front Brake Caliper: Diagrams Front Front Disc Brake Caliper Assembly and Associated Parts Replacement w/ Related Components Front Disc Brake Caliper Disassembled View Overhaul w/ Related Components Page 2251 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 5682 Receiver Dryer: Service and Repair Receiver/Drier and Associated Parts 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 part, 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 N.m (52 lb in) 4. O-ring 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. 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. Page 7016 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. 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 N.m (13 lb.ft) Page 2142 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 74 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 Rear Outside Handle And Associated Parts 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 917 ^ 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 2607 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 Procedure 1. Install the VSS in the transfer case with the notch for the connector facing the rear. 2. Secure the VSS in place with the clamp and the bolt. Tighten Tighten the bolt to 16 N.m (12 lb.ft.). Page 2691 Evaporative Emissions Hose: Service and Repair EVAP Canister Hoses Service Information To view the routing of the EVAP canister hoses, refer to Vehicle Emission Control Information in Diagnosis. Use 6148M or equivalent when you replace the EVAP canister hoses. 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 6640 5. Remove 2 sunshade stopper fixing screws and remove sunshade stopper (1) 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 5942 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 1302 Tires: Testing and Inspection Irregular and Premature Wear 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 Diagnosis List If the 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 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. Page 5309 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 146 Relay Box: Diagrams Relay/Fuse Box (Instrument Panel) Page 326 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). 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 1157 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 4623 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 290 Control Module: Service and Repair 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 4900 DIAGNOSTIC WORKSHEET REPAIR PROCEDURE A 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 919 ^ 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. 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. Page 368 Wheel Speed Sensor: Testing and Inspection 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 4541 Disassembled View Page 107 Individual circuit schematics begin with a fuse. The first half of Power Distribution, however, shows the wiring "upstream" between the battery 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 574 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 1. Install the MAF sensor on the air cleaner with the clamp. Page 2337 95. Right Front Exhaust Downpipe Page 1780 The wire insulation has one color or one color with another color stripe. The second color is the stripe. Page 7363 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 2311 Multiplex Control Unit Page 7261 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 2472 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 2372 27. Left Side of Engine Page 114 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 5712 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 2015 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 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). Locations 58. Under Center Console Page 1783 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 6075 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 1475 An oil with a viscosity of 5W - 30 is preferred for improved fuel economy and year-round protection in the vehicle. You may use a 10W - 30 oil if the climate in your area is limited to the temperature range shown on the chart. 4. Run the engine for more than three minutes, then check for oil leakage. Page 7027 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 2995 The wire insulation has one color or one color with another color stripe. The second color is the stripe. Page 7074 Malfunction Indicator Lamp: Service and Repair Removal and Installation Procedure Refer to Warning light bulb, indicator light valve, illumination light bulb, A/T indicator light bulb in Meter and Gauge. 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 3726 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, teal! guide, ball retainer 3. Bellows 4. Bearing 5. Dust seal, oil seal Bushing Replacement Page 5542 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 3742 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 6872 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 720 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 7170 Individual circuit schematics begin with a fuse. The first half of Power Distribution, however, shows the wiring "upstream" between the battery 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 2840 Steps 1 - 4 Page 5567 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 7643 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 1119 Engine Oil: Service Precautions SAFETY PRECAUTIONS WARNING: Prolonged and repeated contact with used engine oil may cause skin cancer. Avoid prolonged and repeated contact with oils, particularly used engine oils. - Wear protective clothing, including impervious gloves where practicable. - Do not put oily rags in pockets. - Avoid contaminating clothes, particularly underpants, with oil. - Heavily soiled clothing and oil-impregnated footwear should not be worn. Overalls must be cleaned regularly. - First Aid treatment should be obtained immediately for open cuts and wounds. - Use barrier creams, applying them before each work period, to help the removal of oil from the skin. - Wash with soap and water to ensure all oil is removed (skin cleansers and nail brushes will help). Preparations containing lanolin replace the natural skin oils which have been removed. - Do not use gasoline, kerosine, diesel fuel, gas oil, thinner or solvents for cleaning skin. - If skin disorders develop, obtain medical advice without delay. - Where practicable, degrease components prior to handling. - Where there is a risk of eye contact, eye protection should be worn, for example, chemical goggles or face shields; in addition an eye wash facility should be provided. Page 5120 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: 152 Nm (112 ft. lbs.) 10. Install upper ball joint and tighten it to the specified torque. Torque: 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: 98 Nm (72 ft. lbs.) 12. Install speed sensor cable. Page 2952 7. Working at the back of the engine, remove the hose clamps from the fuel hose assembly. Spray silicone lubricant on the clamps to make them easier to remove. 8. Remove the fuel hose assembly from the fuel lines. If necessary, carefully slit the hoses so they are easier to remove. Remove the fuel hose assembly from the vehicle. Discard the assembly and the clamps. 9. Install the new hose clamps on the hoses in the new fuel hose assembly. These clamps have plastic pieces over the ends to keep them expanded. 10. Install the fuel hose assembly in the vehicle. Make sure it is routed properly through the brackets. 11. Connect the fuel hose assembly to the fuel lines at the back of the engine. Slide the clamps into position, then remove the plastic holders from the clamps. Make sure the hoses are clamped securely. 12. Verify that the fuel hose assembly is aligned properly. The white mark on the assembly should align with the edge of the bracket. 13. Lower the floor jack. Remove the jack and block of wood from under the vehicle. 14. Install the plastic engine cover and the fuel pump relay. 15. Raise the vehicle on the hoist. 16. Verify that the fuel hose assembly is properly routed through the brackets. 17. Connect the fuel hose assembly to the fuel lines (quick disconnect fittings). Listen for each fitting to click into place, then pull on the fitting to make sure it is locked in place. 18. Install the O2 harness sensor clip. 19. Install the transmission mounting nuts. Torque the nuts to 41 N.m (30 lb-ft). 20. Go to COMPLETION PROCEDURE. COMPLETION PROCEDURE 1. Lower the vehicle. Page 4082 Wheel Speed Sensor: Connector Locations 3. Behind Left Front Wheel (Right Wheel Similar) 99. Under Rear of Vehicle (On Differential) Page 1045 3. Install the air cleaner lid on the MAF sensor and the air cleaner housing. 4. Tighten the clamp and secure the four latches between the lid and the air cleaner housing. Induction System 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). Page 2841 Steps 5 - 8 Page 7379 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. Page 5124 Torque: 235 Nm (174 ft. lbs.) 14. Install front nut then tighten lower link nut finger-tight. NOTE: Torque lower control arm nut after adjusting buffer clearance Buffer clearance: 22 mm (0.87 inch) Torque: 190 Nm (140 ft. lbs.) NOTE: Adjust the trim height. Refer to Alignment; Adjustments. See: Alignment 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 7398 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. Removal/Installation Air Filter Element: Service and Repair Removal/Installation Engine Driveability and Emissions System Air Cleaner/Air Filter Removal Procedure 1. Loosen the clamp between the air cleaner lid and the mass air flow sensor. 2. Release the tour latches securing the lid to the air cleaner housing. 3. Remove the air cleaner lid. 4. Remove the air filter element. 5. Remove the retaining bolts and the air cleaner housing from the vehicle. Installation Procedure 1. Install the air cleaner housing in the vehicle with the retaining bolts. 2. Install the air filter element in the air cleaner housing. Paint Code List Page 5340 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 4728 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 6088 Hood Sensor/Switch (For Alarm): Service and Repair Engine Hood Switch 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 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 adapter case oil pan twelve fixing 10 mm screws, adapter case oil pan, and gasket. NOTE: Oil pan still contains transmission fluid. Place a large drain container under the oil pan and 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 11 mm bolt and converter clutch solenoid with two O-rings. 7. Remove 11 mm bolt, retainer, and force motor solenoid. Installation 1. Install force motor solenoid, retainer, and 11 mm bolt to adapter case valve body. Tighten the bolt to the specified torque. Torque: 10 Nm (87 inch lbs.) 2. Install converter clutch solenoid with two O-rings, and 11 mm bolt to adapter case valve body. Tighten the bolt to the specified torque. Torque: 10 Nm (87 inch lbs.) 3. Connect wiring harness assembly to solenoids. 4. Install adapter case oil pan, new gasket, and twelve 10 mm screws. Tighten the screws to the specified torque. Torque: 11 Nm (96 inch lbs.) 5. Fill transmission through overfill screw hole oil pan, using ATF DEXRON III. 6. Connect battery ground cable. Page 736 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. Front Brake Caliper: Specifications Type Floating, Pin Slide Adjusting Method Self-Adjusting Piston Diameter 60.33 mm Page 1120 Engine Oil: Testing and Inspection INSPECTION: 1. Park the vehicle on level ground, and turn off the engine. Allow the oil a few minutes to drain back into the oil pan so the dipstick will show the actual level. 2. Make certain that the oil level indicated on the dipstick is between the upper and lower marks. 3. If the level has dropped close to the lower mark, add oil until it reaches the upper mark. CAUTION: Insert the dipstick carefully to avoid bending it. Locations 18. Right Side of Engine Page 209 Powertrain Control Module: Service and Repair Reprogramming the PCM EEPROM General Description The Electronically Erasable Programmable Read Only Memory (EEPROM) is a permanent memory that is physically soldered within the PCM. The EEPROM contains program and calibration information that the PCM needs to control powertrain operation. 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 one minute. 3. Scan for DTCs using the Tech 2. Specifications Clutch Fluid: Specifications Dot 3 Hydraulic Brake Fluid Page 4773 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 507 Individual circuit schematics begin with a fuse. The first half of Power Distribution, however, shows the wiring "upstream" between the battery 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 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 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 toward 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 6. Right Front of Engine Compartment Page 185 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 7328 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 2844 Fuel Injector: Testing and Inspection Fuel Injectors 1. Inspect the O-rings for cracks or leaks. 2. Replace worn or damaged O-rings. 3. Lubricate the new O-rings with engine oil before installation. Page 5314 Tires: Testing and Inspection Radial Tire Waddle 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. Specifications Suspension Spring ( Coil / Leaf ): Specifications Coil Spring Free Length 389.5 mm Spring Diameter 12.2 mm Coil Diameter (Inner) 105 mm Effective No. Of Turns 5.74 Total No. Of Turns 7.24 Page 5337 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: 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 7528 Trailer Lighting Connector Page 6030 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 7666 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 4010 57. Top of Transfer Case Page 2273 Powertrain Control Module: Service and Repair Reprogramming the PCM EEPROM General Description The Electronically Erasable Programmable Read Only Memory (EEPROM) is a permanent memory that is physically soldered within the PCM. The EEPROM contains program and calibration information that the PCM needs to control powertrain operation. 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 one minute. 3. Scan for DTCs using the Tech 2. Page 7360 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 4260 Brake Caliper: Service and Repair Rear 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. 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 Diagram Information and Instructions Audible Warning Device: Diagram Information and Instructions How to Identify Wiring Color-Coded Insulation Wire Color Wire Color Coding Locations 33. Bottom Center Front of Engine Page 683 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 4366 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 1915 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 Component Locations 54. Below Center of Dash (Console Removed) Page 7056 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 7266 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 3970 4WD Motor Actuator Specifications Camshaft Bearing: Specifications Camshaft Bearing Cap Fixing Bolt 10 Nm Page 25 Alarm/Immobilizer 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 5179 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 (l) applied during disassembly. NOTE: Adjust the trim height. Refer to Alignment; Adjustments.See: Alignment Page 1530 - 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. Upper Ball Joint: Specifications Ball Joint, Upper Castle Nut 98 Nm Attaching Bolts 57 Nm Preload Torque 0.5 - 3.2 Nm Page 2526 96. Rear of Right Catalytic Converter 93. Left Front Exhaust Downpipe Page 5747 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 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, M/T; Service and Repair. Page 7028 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 4687 Earth Location (Cabin) Page 7355 Individual circuit schematics begin with a fuse. The first half of Power Distribution, however, shows the wiring "upstream" between the battery 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 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. Component Locations Page 4063 Part 2 of 3 Page 5870 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 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. Page 1375 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. Page 449 Ground - "G" Shielding Sheilding This represents RFI (Radio Frequency Interference) shielding around a wire. The shielding is always connected to ground. Splices Page 1911 ^ 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 4582 Ground - "G" Shielding Sheilding This represents RFI (Radio Frequency Interference) shielding around a wire. The shielding is always connected to ground. Splices Page 3854 Transmission Range Switch Page 2862 Fuel Meter Body: Description and Operation Fuel Metering System Purpose Fuel Metering System Purpose The basic function of the air/fuel metering system is to control the air/fuel delivery to the engine. Fuel is delivered to the engine by individual fuel injectors mounted in the intake manifold near each intake valve. The main control sensor is the heated oxygen sensor (HO2S) located in the exhaust system. The HO2S tells the PCM how much oxygen is in the exhaust gas. The PCM changes the air/fuel ratio to the engine by controlling the amount of time that fuel injector is "ON." The best mixture to minimize exhaust emissions is 14.7 parts of air to 1 part of gasoline by weight, which allows the catalytic converter to operate most efficiently. Because of the constant measuring and adjusting of the air/fuel ratio, the fuel injection system is called a "closed loop" system. The PCM monitors signals from several sensors in order to determine the fuel needs of the engine. Fuel is delivered under one of several conditions called "modes." All modes are controlled by the PCM. Page 2058 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 7224 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 1528 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. Capacity Specifications Fluid - A/T: Capacity Specifications A/T Fluid Capacity ............................................................................................................................................... ........................................................................... 8.6L Page 5879 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 4354 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 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 3526 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 (4x4). 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 3000 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 735 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 3066 5. Select F0:Fuel Pump Relay. 6. Push "On" soft key. 7. Control Fuel Pump Relay and check data list. 8. If the data list changes, the Fuel Pump Relay is normal. 9. Select F1 A/C Clutch Relay. 10. Run the Engine at idle. 11. Turn on Air Conditioning. 12. Turn "On" and "Off" A/C Switch. Page 181 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 5058 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 the entire transfer gear assembly. INSTALLATION 1. Install transfer gear assembly with shim and tighten bolt and nut to the specified torque. Torque: 54 Nm (40 ft. lbs.) 2. Connect universal joint (both side) and tighten the bolt to the specified torque. Torque: 31 Nm (23 ft. lbs.) Locations Trim Panel: Locations Interior Trim Panels And Associated Parts (LWB) Page 626 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 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. 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 1172 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 6383 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 5325 Tires: Service and Repair Spare Tire Spare Tire Hanger - Parts Locations Spare Tire Hanger Removal 1. Open the hatch gate and tail gate. 2. Remove the spare tire (3). Page 7511 Above 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 begins in Wire Color Abbreviations. 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 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 Page 4896 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 1222 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 3100 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 1970 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. 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 5331 Wheels: Service Precautions Service Precaution 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 5959 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. Diagrams Audio Unit (LX) Audio Unit/CD Changer (EX) Connectors A And B(Optional) Locations 59. Under Center Console 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 4904 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 3477 a. Place selector lever in neutral. b. Disconnect transmission harness connector from mode switch connector. 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 (approximately 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 4060 Part 2 of 3 Page 4342 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. Page 6929 - Refer to the scrapping procedures for disposal of the damaged airbag. Page 5673 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 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 7561 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 5261 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: 24.5 N (4.4 - 5.5 lbs.) Used bearing and New oil seal: 11.8 - 17.7 N (2.6 - 4.0 lbs.) 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 4527 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. Diagrams Page 2399 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 912 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 7361 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 111 Ground - "G" Shielding Sheilding This represents RFI (Radio Frequency Interference) shielding around a wire. The shielding is always connected to ground. Splices Page 7014 Above 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 begins in Wire Color Abbreviations. 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 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 Page 3386 92. Beneath Center of Vehicle, on Transfer Case (A/T) Page 4165 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. Disassembly and Reassembly Page 1613 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. Page 6866 Above 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 begins in Wire Color Abbreviations. 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 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 Page 4736 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. 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 4290 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 torque. 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. Page 827 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 916 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 2139 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 4637 Fuse Block Circuit-2 (V6) Page 843 Transmission Range Switch Page 4056 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. Diagrams Page 2660 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 Light and Bulb Specifications (LWB) - View Page 2988 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 2981 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 898 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 2370 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 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 2949 WARRANTY CLAIM INFORMATION INSPECTION PROCEDURE 1. Raise the vehicle on a hoist. 2. Pull back the insulation on the fuel return hose. Examine the hose for the lot number. Record the lot number. Page 4041 Each schematic represents one circuit. A circuit's wires and components are arranged to show current flow, from power at the top 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 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. Page 2358 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. Procedures Power Mirror Switch: Procedures 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 7697 Window Track: Service and Repair Rear Door Rear Window Regulator, Glass and Glass Run Rear Window Regulator, Glass And Glass Run - Parts Locations Removal 1. Disconnect the battery ground cable. 2. Remove the rear corner garnish. - Pull the garnish to disconnect the retaining clip. Locations 10. Fuse/Relay Box (Cover Removed) Page 3440 Fluid - A/T: Fluid Type Specifications A/T Fluid Type ..................................................................................................................................................... .............................................. ATF DEXRON (R) III Description and Operation 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 4401 Wheel Speed Sensor: Diagrams Front Wheel Speed Sensor and Associated Parts Replacement w/ Related Components Page 4504 WARNING: THE INFLATOR MODULE SHOULD ALWAYS BE CARRIED WITH THE TRIM COVER AWAY FROM YOUR BODY AND SHOULD ALWAYS BE LAID ON A FLAT SURFACE WITH THE URETHANE SIDE UP. THIS IS NECESSARY BECAUSE 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. 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. 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 counter clockwise to full, return about 3 turns and align the neutral mark. Locations 58. Under Center Console Page 4261 5. Remove lock bolt (3). 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 7715 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 1952 Above 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 begins in Wire Color Abbreviations. 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 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 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 2445 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 2890 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 Locations Locations Page 7407 The wire insulation has one color or one color with another color stripe. The second color is the stripe. Page 959 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: 152 Nm (112 ft. lbs.) Toe-in Adjustment 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 to +2 mm (0 to +0.08 inch) 2. Tighten the lock nut to the specified torque. Torque: 98 Nm (72 ft. lbs.) Page 2291 Above 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 begins in Wire Color Abbreviations. 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 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 Page 5029 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 4222 Brake Shoe: Service and Repair Removal 1. Raise the vehicle and support with suitable safety stands. 2. Remove wheel and tire assembly (1). 3. Remove Drum (2). - If difficulty is encountered in removing the drum: - Mark the position of the drum to the axle. - Make sure the parking brake is released. - Use a rubber mallet to tap gently on the outer rim of the drum and/or around the inner drum. Be careful to avoid damaging the drum. 4. Remove upper (other) return spring (6) and auto adjuster lever. 5. Remove lower return spring (5). 6. Remove hold-down spring and cups (4) and hold-down pin (15). 7. Remove adjuster assembly (12) 8. Remove leading shoe assembly (8) with upper (inner) return spring (9). NOTE: Do not over stretch the return spring. 9. Remove upper (inner) return spring (9). Page 6839 Above 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 begins in Wire Color Abbreviations. 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 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 Gas Tank - Fuel Pump/Sending Unit Installation Tip Fuel Gauge Sender: Technical Service Bulletins Gas Tank - Fuel Pump/Sending Unit Installation Tip SOURCE: Honda Service News March 2003 TITLE: Installing an In-Tank Fuel Pump/Sending Unit? Don't Forget a New Base Gasket, Locknut, and Fuel Line Retainers APPLIES TO: See Models Listed In Illustration SERVICE TIP: Whenever you install an in-tank fuel pump/sending unit into a plastic fuel tank, the S/M tells you to install a new base gasket. But did you know you also need to replace the locknut and the fuel line retainers as well? Make a note in the Fuel Supply System subsection of the appropriate S/Ms to also replace the locknut and the fuel line retainers. Then follow this handy chart to order the appropriate parts. Install the new gasket on the fuel tank side, not on the fuel pump/sending unit side; this ensures that the gasket doesn't get pinched or rolled. If you don't install the fuel pump/sending unit correctly, the MIL could come on with an EVAP control system leakage DTC set. The gasket and the locknut are currently available in Honda parts stock under separate part numbers. But soon, they'll be packaged under a single part number. The fuel sending unit, gasket, and locknut will also be packaged together under a single part number. The gasket and the locknut will then be discontinued as separate part numbers. Page 1233 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 2848 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. Locations 88. Left Side of Front Axle Locations Tailgate Lock, Hatchgate Lock And Associated Parts (LWB) Diagram Information and Instructions Starter Motor: Diagram Information and Instructions How to Identify Wiring Color-Coded Insulation Wire Color Wire Color Coding Page 2395 Each schematic represents one circuit. A circuit's wires and components are arranged to show current flow, from power at the top 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 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. Page 1013 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 7124 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 4139 The wire insulation has one color or one color with another color stripe. The second color is the stripe. Page 4903 ^ 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 2407 The wire insulation has one color or one color with another color stripe. The second color is the stripe. Diagrams Hazard Warning Switch Page 3923 4WD Control Unit Page 1788 5. Select F0:Fuel Pump Relay. 6. Push "On" soft key. 7. Control Fuel Pump Relay and check data list. 8. If the data list changes, the Fuel Pump Relay is normal. 9. Select F1 A/C Clutch Relay. 10. Run the Engine at idle. 11. Turn on Air Conditioning. 12. Turn "On" and "Off" A/C Switch. Page 2625 Vehicle Speed Sensor Page 5382 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. Diagrams Front Fender Panel Page 949 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 2298 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 4158 5. Remove guide bolt (2). 6. Remove lock bolt (3). 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. 2. Apply special grease (approximately 0.2 g) to both contacting surfaces of the inner shims (4). Wipe off extruded grease after installing. Install pad assembly with shim. Page 696 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 6035 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 846 a. Place selector lever in neutral. b. Disconnect transmission harness connector from mode switch connector. 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 (approximately 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 5115 Page 5574 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 4871 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 4422 WARNING: THE INFLATOR MODULE SHOULD ALWAYS BE CARRIED WITH THE TRIM COVER AWAY FROM YOUR BODY AND SHOULD ALWAYS BE LAID ON A FLAT SURFACE WITH THE URETHANE SIDE UP. THIS IS NECESSARY BECAUSE 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. 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. 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 counter clockwise to full, return about 3 turns and align the neutral mark. Page 661 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 2830 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 1627 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 1318 Wheels: Service Precautions Service Precaution 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 3768 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. REASSEMBLY Page 7054 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 55. Right Side of Gear Selector Page 7026 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. Diagrams Front Door Trim Panel Page 5028 Ground - "G" Shielding Sheilding This represents RFI (Radio Frequency Interference) shielding around a wire. The shielding is always connected to ground. Splices Page 6561 Individual circuit schematics begin with a fuse. The first half of Power Distribution, however, shows the wiring "upstream" between the battery 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 4252 Brake Caliper: Diagrams Rear Rear Disc Brake Caliper Assembly and Associated Parts Replacement w/ Related Components Rear Disc Brake Caliper Disassembled View Overhaul w/ Related Components Removal and Installation 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 bracket fixing bolts. 3. Disconnect red clip from harness connector. 4. Remove harness connector. 5. Remove Electronic Hydraulic Control Unit (EHCU) ASM. 6. Remove EHCU. Installation To install, follow the removal steps in the reverse order, noting the following points: Torque: Page 5603 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 3594 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 752 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 14 Individual circuit schematics begin with a fuse. The first half of Power Distribution, however, shows the wiring "upstream" between the battery 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 1588 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 4361 Ground - "G" Shielding Sheilding This represents RFI (Radio Frequency Interference) shielding around a wire. The shielding is always connected to ground. Splices Page 5036 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 145 7. Right Side of Engine Compartment Page 2198 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 6071 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 2776 129 - Below Left Side Of I/P Page 7144 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 6471 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. Locations 48. Below Left Side of Dash Page 7367 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 7258 Ground - "G" Shielding Sheilding This represents RFI (Radio Frequency Interference) shielding around a wire. The shielding is always connected to ground. Splices Page 1789 13. Control A/C Clutch Relay and check data list. 14. If the data list changes, the Fuel Pump Relay is normal. Specifications Clutch Fluid: Specifications Dot 3 Hydraulic Brake Fluid Page 6422 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. Diagrams Body Mounting Page 5149 - 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 hte upper link is in its correct position. 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 1649 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 228 Ground - "G" Shielding Sheilding This represents RFI (Radio Frequency Interference) shielding around a wire. The shielding is always connected to ground. Splices Locations 39. Dash Fuse Box Page 5267 11. Install snap ring and shim. - Adjust the clearance between the free wheeling hub body and the snap ring. Clearance: 0 mm 0.3 mm (0 in - 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. 13. Tighten the bolts to the specified torque. Torque: 59 Nm (43 ft. lbs.) Page 1309 Tires: Service and Repair Inflation of Tires 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 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 2629 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 7019 Ground - "G" Shielding Sheilding This represents RFI (Radio Frequency Interference) shielding around a wire. The shielding is always connected to ground. Splices Page 4858 ^ 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. Locations 8. Fuse/Relay Box (Cover Removed) Page 7471 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 6961 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 6116 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: Locations Air Flow Meter/Sensor: Locations 28. Left Side of Engine Compartment MAF Sensor Exploded Views Page 2107 Valve Shims (While 41 shims are available, the 10 sizes will cover most valve adjustments): Application and ID 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 Honda Dealership. Page 1189 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 7101 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 1367 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 5974 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 6571 The wire insulation has one color or one color with another color stripe. The second color is the stripe. Page 7128 Above 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 begins in Wire Color Abbreviations. 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 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 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. Diagram Information and Instructions Seat Belt Reminder Lamp: Diagram Information and Instructions How to Identify Wiring Color-Coded Insulation Wire Color Wire Color Coding Page 22 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 Page 7236 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 105 Each schematic represents one circuit. A circuit's wires and components are arranged to show current flow, from power at the top 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 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. Page 446 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 2157 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 (gm/s). At idle, the Tech 2 should read between 4 - 7 gm/s 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 7333 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 6081 Alarm And Relay Controls Image 70-2 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 7209 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. Locations 14. Right Rear of Engine Compartment Component Locations 92. Beneath Center of Vehicle, on Transfer Case (A/T) Page 5861 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 4722 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 3277 Transmission Range Switch Page 452 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 4914 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: 152 Nm (112 ft. lbs.) Toe-in Adjustment 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 to +2 mm (0 to +0.08 inch) 2. Tighten the lock nut to the specified torque. Torque: 98 Nm (72 ft. lbs.) Page 4764 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 5610 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 6004 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 2600 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 2582 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 4810 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 - Transfer Case: Capacity Specifications Transfer Case Fluid Capacity ............................................................................................................................................... .......................................................... 1.45 L (1.5 Qt) Audio System - CD/DVD Precautions Compact Disc Player (CD): 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. Diagram Information and Instructions Brake Lamp: Diagram Information and Instructions How to Identify Wiring Color-Coded Insulation Wire Color Wire Color Coding Page 1531 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 2041 Crankshaft Position Sensor: Testing and Inspection Inspection Procedure 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 960 Alignment: Service and Repair Front End Alignment Inspection Before making any adjustments affecting caster, camber or toe-in, the 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 4357 Individual circuit schematics begin with a fuse. The first half of Power Distribution, however, shows the wiring "upstream" between the battery 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 2561 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 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. Locations 39. Dash Fuse Box Diagrams Mirror Control Switch Page 2486 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. Page 5085 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 to confirm its normal movement. - Inspect screw/taper area of ball for damage. - If any defects are found by the inspections, replace the ball joint assembly with a 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 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: 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: 98 Nm (72 ft. lbs.) Page 4713 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 718 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 1614 2. Install the ECT sensor in the coolant crossover. Tighten Tighten the ECT sensor to 30 N.m (22 lb.ft.). 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 261 SRS Unit Page 5787 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 5876 SRS Unit Page 4874 ^ 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 5860 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 7021 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 2605 Vehicle Speed Sensor: Testing and Inspection Inspection Procedure 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 2671 Canister Purge Control Valve: Testing and Inspection Evaporative (EVAP) Emissions Canister Purge Valve 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. Page 7563 Each schematic represents one circuit. A circuit's wires and components are arranged to show current flow, from power at the top 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 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. Locations 44. Below Left Side of Dash Page 4264 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 4479 Alternator: Testing and Inspection Bench Test Conduct a bench test of the generator. Preparation Remove generator from the vehicle (see "Generator removal"). 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. Diagrams Page 2194 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 3116 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 (gm/s). At idle, the Tech 2 should read between 4 - 7 gm/s 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 6225 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 7012 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 4472 Disassembled View Page 5676 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. 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 4265 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 (Approximately 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 5838 Ground - "G" Shielding Sheilding This represents RFI (Radio Frequency Interference) shielding around a wire. The shielding is always connected to ground. Splices Page 1294 Spare Tire Hanger - Parts Locations Page 4749 Fuse To Component Index (Fuse No. 1 - 20) Image 6-3 Page 6618 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. Diagrams Power/Winter Switch Locations 40. Dash Fuse Box Page 3318 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 2752 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 7139 The wire insulation has one color or one color with another color stripe. The second color is the stripe. Page 1830 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 466 Parking Brake Warning Switch: Description and Operation Parking Brake Switch 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 2989 Ground - "G" Shielding Sheilding This represents RFI (Radio Frequency Interference) shielding around a wire. The shielding is always connected to ground. Splices Page 7235 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 2997 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 363 Wheel Speed Sensor: Connector Locations 3. Behind Left Front Wheel (Right Wheel Similar) 99. Under Rear of Vehicle (On Differential) Page 6304 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 3565 57. Top of Transfer Case Page 4462 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 6033 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. Exploded Views Page 7168 Each schematic represents one circuit. A circuit's wires and components are arranged to show current flow, from power at the top 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 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. Page 7133 Ground - "G" Shielding Sheilding This represents RFI (Radio Frequency Interference) shielding around a wire. The shielding is always connected to ground. Splices Page 7322 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 5001 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 265 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 1132 Power Steering Fluid: Service Precautions Use Genuine Honda Power Steering Fluid, or another brand of power steering fluid as a temporary replacement. Page 3793 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. 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. Electrode Gap Spark Plug: Specifications Electrode Gap 0.040 in (1.05 mm) Page 4977 ^ 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 4187 3. Carefully use adjustable pliers to bottom the piston into the caliper bore. Do not pull or twist the flex hose or damage will occur. 4. Install lock bolt (5) and tighten the bolt to the specified torque. Torque: 44 Nm (32 ft. lbs.) 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. Locations Resin Top Assembly And Associated Parts 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 propeller shaft. Page 1638 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 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 150 kPa (22 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. Page 1606 Coolant: Description and Operation Antifreeze Solution - Relation between the mixing ratio and freezing temperature of the Engine Coolant (EC) 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 NOTE: Antifreeze solution + Water = Total cooling system capacity. - Total Cooling System Capacity - M/T 11.1 L (2.93 Us gal) - A/T 10.0 L (2.64 Us gal) - Mixing ratio Page 126 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. 3. Install the fuse and relay box cover. Page 1957 Ground - "G" Shielding Sheilding This represents RFI (Radio Frequency Interference) shielding around a wire. The shielding is always connected to ground. Splices 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 (17 ft. lbs.) 4. Install speed sensor cable fixing bolt (Upper side) and tighten the fixing bolt to the specified torque. Torque: 6 Nm (52 inch lbs.) 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 5437 Individual circuit schematics begin with a fuse. The first half of Power Distribution, however, shows the wiring "upstream" between the battery 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 40. Dash Fuse Box Page 6074 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 Roof Rail - Parts Location Page 4167 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 688 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 5535 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 1571 Spark Plug: Specifications Plug Torque 13 ft lb (18 Nm) Page 7766 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. 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 meter 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 Locations 62. Front of Roof (Headliner Removed) Page 6313 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 2195 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 566 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 6036 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 Component Locations 99. Under Rear of Vehicle (On Differential) Locations 90. Left Side of Automatic Transmission (A/T) Page 1473 4. After the rubber seal seats, tighten the oil filter clockwise with the tool. Tightening torque: 22 Nm (2.2 kgf.m, 16 ft. lbs.) CAUTION: Using any procedure other than shown could result in serious engine damage due to oil leakage. 5. After installation, fill the engine with oil up to the specified level, run the engine for more than three minutes, then check for oil leakage. Page 3680 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. 14. Disconnect the actuator connector. 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. 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. Make sure the axle assembly is supported securely when performing repairs. 2. Do not damage the power steering unit when performing the repairs. 3. Do not damage the shift-on-the fly hose bracket when performing the repairs. Installation 1. Support the differential case with a 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. Do not damage the power steering unit when performing the repairs. 2. Do not damage the shift-on-the fly hose bracket when performing the repairs. 3. When installing the drive shaft to the knuckle, be careful not to damage the oil seal inside of the knuckle. Page 2929 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 Radiator Grille - Parts Locations Page 6494 Front Door Trim Panel And Associated Parts Diagram Information and Instructions Powertrain Control Module: Diagram Information and Instructions How to Identify Wiring Color-Coded Insulation Wire Color Wire Color Coding Page 7432 Auto Light Sensor Connector (Canada Only) Locations Door Locks: Locations Front Door Lock Assembly And Associated Parts Rear Door Lock Assembly And Associated Parts Page 5444 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 90. Left Side of Automatic Transmission (A/T) Page 2462 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 5693 Refrigerant: Fluid Type Specifications Refrigerant Type HFC-134a (R-134a) Page 4057 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 1426 Page 6014 Seat Belt Reminder 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 2016 129 - Below Left Side Of I/P Page 2912 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 1264 Supportable Point: Rear - Position the chassis stands at the bottom of the rear axle case. Service and Repair System Relay: Service and Repair Air Conditioning Thermo Relay 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. - The screwdriver blade will release the catch inside. 4. Pull the relay straight up and out of the fuse and relay box. Page 6723 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 3162 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. Refer to Electronic Ignition System for additional information. Page 579 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. Diagram Information and Instructions Fuel Injector: Diagram Information and Instructions How to Identify Wiring Color-Coded Insulation Wire Color Wire Color Coding Cylinder Head Cover LH Valve Cover: Service and Repair Cylinder Head Cover LH Removal 1. Disconnect battery ground cable. 2. Remove engine cover from the dowels on the common chamber. 3. Disconnect positive crankcase ventilation hose. 4. Remove ground cable fixing bolt on cylinder head cover. 5. Ignition coil connector and ignition coil. - Disconnect the three connectors from the ignition coils. Page 6172 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 3172 Ignition Coil: Service and Repair Inspection 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 2567 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. Description and Operation Temperature Gauge: Description and Operation The 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 5372 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" 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 5770 Fan Control Switch Page 6849 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 6183 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 2006 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 2702 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. Front Differential Differential Axle Housing: Service and Repair Front Differential Removal 1. Jack up the vehicle and support it using jack stand. 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. 7. Remove the propeller shaft. 8. Loosen the height control arm of the torsion bar, then remove the torsion bar from lower control arm. 9. Remove the suspension crossmember. 10. Remove the lower nut (1) of the stabilizer link. Page 2287 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 7726 Rear Wiper/Washer Switch Page 3369 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.) 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 4813 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" 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. Specifications Wheel Fastener: Specifications Wheel Fastener 118 Nm Page 3308 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 1729 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 4668 Each schematic represents one circuit. A circuit's wires and components are arranged to show current flow, from power at the top 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 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. Page 6029 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 1194 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 Locations 56. Top Right Side of Transfer Case Page 6237 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 525 Headlight Switch Image 100-2 Page 5177 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 4352 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 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 To install, follow the removal steps in the reverse order, noting the following points. Torque: Nut (1) 8 Nm (69 inch lbs.) Page 2369 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. Component Locations 73. Rear of Driver's Door (Frt. Pass. Similar) Description and Operation Malfunction Indicator Lamp: Description and Operation Malfunction Indicator Lamp (MIL) The Malfunction Indicator Lamp (MIL) looks the same as the MIL you are already familiar with ("Check Engine" lamp). However, OBD II requires that it illuminate under a strict set of guide lines. Basically, the MIL is turned on when the PCM detects a DTC that will impact vehicle emissions. The MIL is under the control of the Diagnostic Executive. The MIL will be turned on if an emissions-related diagnostic test indicates a malfunction has occurred. It will stay on until the system or component passes the same test, for three consecutive trips, with no emissions related faults. If the vehicle is experiencing a misfire malfunction which may cause damage to the Three-Way Catalytic Converter (TWC), the MIL will flash once per second. This will continue until the vehicle is outside of speed and load conditions which could cause possible catalyst damage, and the MIL will stop flashing and remain on steady. Extinguishing the MIL When the MIL is on, the Diagnostic Executive will turn off the MIL after three(3) consecutive trips that a "test passed" has been reported for the diagnostic test that originally caused the MIL to illuminate. Although the MIL has been turned off, the DTC will remain in the PCM memory (both Freeze Frame and Failure Records) until forty (40) warm-up cycles after no faults have been completed. If the MIL was set by either a fuel trim or misfire-related DTC, additional requirements must be met. In addition to the requirements stated in the previous paragraph, these requirements are as follows: - The diagnostic tests that are passed must occur within 375 RPM of the RPM data stored at the time the last test failed. - Plus or minus ten (10) percent of the engine load that was stored at the time the last failed. - Similar engine temperature conditions (warmed up or warming up) as those stored at the time the last test failed. Meeting these requirements ensures that the fault which turned on the MIL has been corrected. The MIL ("Check Engine" lamp) is on the instrument panel and has the following function: - It informs the driver that a fault affects vehicle emission levels has occurred and that the vehicle should be taken for service as soon as possible. - As a bulb and system check, the MIL will come "ON" with the key "ON" and the engine not running. When the engine is started, the MIL will turn "OFF." - When the MIL remains "ON" while the engine is running, or when a malfunction is suspected due to a driveability or emissions problem, a Powertrain On-Board Diagnostic (OBD II) System Check must be performed. The procedures for these checks are given in On-Board Diagnostic (OBD) System Check. These checks will expose faults which may not be detected if other diagnostics are performed first. Page 5845 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. Page 692 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 3182 Ion Sensing Module Connectors A - C 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. Removal and Installation Hose/Line HVAC: Service and Repair Removal and Installation Refrigerant Line and Associated Parts 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-ring 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. See: Specifications Page 1230 The wire insulation has one color or one color with another color stripe. The second color is the stripe. Page 377 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 3368 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. Page 2924 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 7255 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. 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 581 2. Install the ECT sensor in the coolant crossover. Tighten Tighten the ECT sensor to 30 N.m (22 lb.ft.). 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 318 73. Rear of Driver's Door (Frt. Pass. Similar) Page 4133 Ground - "G" Shielding Sheilding This represents RFI (Radio Frequency Interference) shielding around a wire. The shielding is always connected to ground. Splices Page 7631 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 3006 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 1754 1. Install the PCM to bracket and fix with the clip. 2. Connect the PCM electrical connectors. 3. Install the two screws to PCM electrical connectors. 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 1599 - 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 EC. 6. Connect battery ground cable. Page 508 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 4994 27. Left Side of Engine Page 5448 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. 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). Locations 90. Left Side of Automatic Transmission (A/T) Page 1474 Engine Oil: Service and Repair Oil Service REPLACEMENT: CAUTION: Remove the drain bolt carefully while the engine is hot; the hot oil may cause scalding. 1. Warm up the engine. 2. Drain the engine oil. 3. Reinstall the drain plug with a new washer, and refill with the recommended oil. NOTE: Under normal conditions, the oil filter should be replaced at every other oil change. Under severe conditions, the oil filter should be replaced at each oil change. The numbers in the middle of the API Service label tell you the oil's SAE viscosity or weight. Select the oil for your vehicle according to this chart: Locations 9. Fuse/Relay Box (Cover Removed) Page 4281 Brake Hose/Line: Description and Operation 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 2775 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 7131 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 4592 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 6120 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. 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 7154 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 7525 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 1772 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 6227 Ground - "G" Shielding Sheilding This represents RFI (Radio Frequency Interference) shielding around a wire. The shielding is always connected to ground. Splices Locations Page 189 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 7265 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. 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 (17 ft. lbs.) 4. Install speed sensor cable fixing bolt (Upper side) and tighten the fixing bolt to the specified torque. Torque: 6 Nm (52 inch lbs.) 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 3721 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 2737 Page 2406 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 5866 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 1422 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. Service and Repair Fuel Pressure Release: Service and Repair Fuel Pressure Relief Procedure CAUTION: To reduce the risk of fire and personal injury, there are necessary to relieve the fuel system pressure before filler and gauge unit 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 disconnect 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 5067 Steering Wheel: 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 ground 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. 6. Disconnect the yellow 2-way SRS connector located behind the inflator module. WARNING: THE INFLATOR MODULE SHOULD ALWAYS BE CARRIED WITH THE TRIM COVER AWAY FROM YOUR BODY AND SHOULD ALWAYS BE LAID ON A FLAT SURFACE WITH THE URETHANE SIDE UP. THIS IS NECESSARY BECAUSE FREE SPACE IS PROVIDED TO ALLOW THE AIR CUSHION TO EXPAND IN THE UNLIKELY EVENT OF ACCIDENTAL DEPLOYMENT. OTHERWISE, PERSONAL INJURY MAY RESULT. Page 5446 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 4993 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 PCM Service Precautions Powertrain Control Module: Service Precautions PCM Service Precautions Powertrain Control Module (PCM) Service Precaution NOTE: To prevent possible electrostatic discharge damage to the PCM, do not touch the connector pins or soldered components on the circuit board. 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. Information On PCM 1. The Powertrain Control Module (PCM) is located in the engine room and is the control center of the electronic transmission control system. 2. The PCM must be maintained at a temperature below 85°C (185°F) at all times. This is most essential if the vehicle is put through a paint baking process. The PCM will become inoperative if its temperature exceeds 85°C (185°F). Therefore, it is recommended that the PCM be removed or that temporary insulation be placed around the PCM during the time the vehicle is in a paint oven or other high temperature process. 3. The PCM is designed to process the various inputs and then respond by sending the appropriate electrical signals to control transmission upshift, downshift, shift feel and torque converter clutch engagement. 4. The PCM constantly interprets information from the various sensors, and controls the systems that affect transmission and vehicle performance. By analyzing operational problems, the PCM is able to perform a diagnostic function by displaying DTC(s) and aid the technician in making repairs. Locations 10. Fuse/Relay Box (Cover Removed) Page 6495 Rear Door Trim Panel And Associated Parts Page 33 Alarm And Relay Controls Image 70-2 Locations 10. Fuse/Relay Box (Cover Removed) Page 1215 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 7476 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 40. Dash Fuse Box 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 3278 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 4L30-E Automatic Transmission (Transmission Control System Diagnosis). Locations Heater Core: Locations Heater Core And/or Mode Door - Disassembled View Page 6182 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 5949 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 5025 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 Vehicle Speed Sensor: Diagram Information and Instructions How to Identify Wiring Color-Coded Insulation Wire Color Wire Color Coding Page 6775 - 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 5719 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. 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 651 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 7573 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 Page 5744 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 3314 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 1968 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 6324 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 4661 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 Locations Front Outside Handle And Associated Parts Page 6060 Each schematic represents one circuit. A circuit's wires and components are arranged to show current flow, from power at the top 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 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. 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 5833 Above 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 begins in Wire Color Abbreviations. 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 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 Page 5593 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 6487 2. To install the sunroof finisher (1), first lit 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 4800 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 3010 Above 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 begins in Wire Color Abbreviations. 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 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 Page 5728 Compressor Clutch Relay: Testing and Inspection Heater (X-1), Thermostat (X-8), Condenser Fan (X-11) And Compressor (X-2) Relay 1. Disconnect relays and check for continuity and resistance between relay terminals. - For handling of these relays, refer to Heater Relay. Page 2842 Steps 9 - 11 Test Description Number(s) below refer to the step number(s) on the Diagnostic Chart: 2. Relieve the fuel pressure by connecting the J34730-1 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. 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. Page 3025 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. 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 N.m (35 lb.in) Page 6192 Alarm/Immobilizer Control Unit: Electrical Diagrams Alarm And Relay Controls Image 70-0 Page 5428 Blower Link Unit And/or Mode Door - Disassembled View Page 2650 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 2192 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 88. Left Side of Front Axle Page 3244 92. Beneath Center of Vehicle, on Transfer Case (A/T) Page 796 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. 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 shaft 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. 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 2630 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 4162 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 (approximately 1 g) onto the dust boot inner surface. 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: 74 Nm (54 ft. lbs.) Page 6138 ^ 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. Page 1748 Inputs - Operating conditions Read - Air Conditioning "ON" or "OFF" - 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 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-megohm 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 1899 Oxygen Sensor: Testing and Inspection Inspection Procedure 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 louvered end of the sensor for grease, din, or other contaminations. Locations 40. Dash Fuse Box Page 6124 ^ 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 4451 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 3532 (4x4) 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. 7. Set select lever "P" position and connect inner cable to select lever. 8. Push lock into adjust end fitting attachment. 9. Install grommet. Page 2861 Fuel Meter Body: Description and Operation Fuel Metering Basic System Operation Fuel Metering System Components The fuel metering system is made up of the following parts: - The fuel injectors. - The throttle body. - The fuel rail. - The fuel pressure regulator. - The PCM. - The crankshaft position (CKP) sensor. - The ION sensing module. - The fuel pump. - The fuel pump relay. Basic System Operation The fuel metering system starts with the fuel in the fuel tank. An electric fuel pump, located in the fuel tank, pumps fuel to the fuel rail through an in-line fuel filter. The pump is designed to provide fuel at a pressure above the pressure needed by the injectors. A fuel pressure regulator in the fuel rail keeps fuel available to the fuel injectors at a constant pressure. A return line delivers unused fuel back to the fuel tank. Refer to fuel tank, line filter, and fuel pipes for further information. 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 3267 4WD Control Unit Page 4062 Electronic Brake Control Module: Electrical Diagrams Circuit Diagram Part 1 of 3 Removal and Installation Powertrain Control Module: Service and Repair Removal and Installation Removal Procedure 1. Disconnect the negative battery cable. 2. Block the wheels. 3. Remove the two screws from the PCM electrical connectors. 4. Disconnect the PCM electrical connectors. 5. After removing the clip which fixes the PCM to the bracket, remove PCM. Installation Procedure Page 4040 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 3844 4WD Control Unit Page 2048 Ignition Switch Lock Cylinder: Testing and Inspection System Inspection Turn the ignition switch to the "ON" position and observe the warning lamp. The lamp should flash 7 times. If the lamp does not operate correctly, refer to "Restraints". Page 1234 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 5118 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 pans replacement if wear, damage, corrosion or any other abnormal conditions are found through inspection. Check the parts: Upper control arm - Bushing - Fulcrum pin INSTALLATION Page 4812 Ground - "G" Shielding Sheilding This represents RFI (Radio Frequency Interference) shielding around a wire. The shielding is always connected to ground. Splices Page 5230 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 628 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 5208 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 4561 Bearing 1. Inspect excessive wear or damage. Replace the bearing if an abnormal noise is heard under normal operating condition. Page 7569 Ground - "G" Shielding Sheilding This represents RFI (Radio Frequency Interference) shielding around a wire. The shielding is always connected to ground. Splices Page 4174 Brake Pad: Specifications Pad Dimension 33 cm2 Page 7531 Trailer Lighting Connector Image 118-2 Page 5914 SRS Unit Page 1948 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 5135 Acceleration Position Sensor Assembly Page 7740 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 6305 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 2837 Fuel Injector Test Connector/C146 Page 4646 ^ 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 2404 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 4586 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 844 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 4L30-E Automatic Transmission (Transmission Control System Diagnosis). Page 340 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 1161 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 456 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 7513 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 59 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 180 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 14. Right Rear of Engine Compartment Page 4760 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 97 Condenser Fan Motor Relay: Testing and Inspection Heater (X-1), Thermostat (X-8), Condenser Fan (X-11) And Compressor (X-2) Relay 1. Disconnect relays and check for continuity and resistance between relay terminals. - For handling of these relays, refer to Heater Relay. Page 2269 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 the 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 1800 Ignition Control Module: Service and Repair 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. 3. Connect the negative battery cable. Page 1711 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 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 2974 Fuel Gauge Sender: Service and Repair Fuel Gage Unit Removal and Installation Refer to Fuel Tank for removal and installation of the fuel gauge unit since the fuel gauge unit is linked to the fuel pump and sender. Testing and Inspection Shifter A/T: Testing and Inspection Inspection 1. Make sure that when the selector 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 selector lever can be shifted as shown in illustration. Page 4588 The wire insulation has one color or one color with another color stripe. The second color is the stripe. Removal/Installation Air Filter Element: Service and Repair Removal/Installation Engine Driveability and Emissions System Air Cleaner/Air Filter Removal Procedure 1. Loosen the clamp between the air cleaner lid and the mass air flow sensor. 2. Release the tour latches securing the lid to the air cleaner housing. 3. Remove the air cleaner lid. 4. Remove the air filter element. 5. Remove the retaining bolts and the air cleaner housing from the vehicle. Installation Procedure 1. Install the air cleaner housing in the vehicle with the retaining bolts. 2. Install the air filter element in the air cleaner housing. Page 2921 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 2602 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 6111 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? Page 997 Spark Plug: Specifications Plug Torque 13 ft lb (18 Nm) 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 1811 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 39. Dash Fuse Box Page 30 Alarm And Relay Control Unit Connectors A And B Page 2239 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. 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 1301 Tires: Testing and Inspection Radial Tire Waddle 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 6592 Alliston (Canada) Produced Cars, VIN: 2HKRL1 _ _ *1H _ _ _ _ _ _ (Odyssey) 2HGES1 _ _ *1H _ _ _ _ _ _ (Civic) East Liberty (U.S.) Produced Cars, VIN: 1HG _ _ _ _ _ *1L _ _ _ _ _ _ (Civic) Tochigi (Japan) Produced Cars, VIN: JHMAP1 _ _ *1T _ _ _ _ _ _ (S2000) JHMZE1 _ _ *1T _ _ _ _ _ _ (Insight) Page 4262 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. Disassembly and Reassembly Page 1151 - 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 3099 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 5575 The wire insulation has one color or one color with another color stripe. The second color is the stripe. Description and Operation Lateral Accelerometer: Description and Operation G-SENSOR/LATERAL ACCELEROMETER The G-sensor installed inside the Electronic Hydraulic Control Unit (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 Anti-lock Brake System (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 1304 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 905 ^ 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 Fluid Pan: Specifications Pan Bottom, Main Case 11 Nm Pan Bottom, Adapter Case 11 Nm Page 5628 Evaporator Temperature Sensor / Switch: 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. Locations 90. Left Side of Automatic Transmission (A/T) Page 1885 Steps 1 - 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 inch 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. 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 40 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 3961 Axle Disconnect Controller 1. Connect 12V with terminal (3) and the ground with the terminal (6). 2. Send the signal to the terminal (4) 2WD -> 4WD less than 2.4V 4WD -> 2WD more than 9.0V 3. Confirm the output signal from the terminals (1) & (2) (2 seconds output) 4. If the trouble occurs after test, charge the Axle Disconnect Controller to the new one. Motor Actuator Assembly (Transfer) Inspect the function of the motor actuator assembly as follows: 1. Disassemble the motor actuator from transfer rear case. Page 2417 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 199 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 4626 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 6314 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. Specifications Engine Oil Pressure: Specifications Oil Pressure 392-550 kPa at 3000 rpm Page 7331 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 7368 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 4633 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 1524 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 2448 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 1143 HVAC / Heating Diagrams Power/Winter Switch Locations Crankshaft Position Sensor: Locations 36. Bottom Right Side of Engine CKP Sensor Page 7187 A/T Gear Position Indicator Image 89-1 Diagram Information and Instructions Key Reminder Switch: Diagram Information and Instructions How to Identify Wiring Color-Coded Insulation Wire Color Wire Color Coding Page 828 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 5646 Heater Mode Control Link Unit - Disassembled View Heater Temperature Control Link Unit - Disassembled View Page 7167 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 61. Front Center of Ceiling (Headliner Removed) 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 2203 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 lower 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 5740 Each schematic represents one circuit. A circuit's wires and components are arranged to show current flow, from power at the top 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 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. Page 1673 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 2359 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 1999 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 5544 Condenser Fan Motor and Associated Parts Page 2532 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 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 797 WARNING: THE INFLATOR MODULE SHOULD ALWAYS BE CARRIED WITH THE TRIM COVER AWAY FROM YOUR BODY AND SHOULD ALWAYS BE LAID ON A FLAT SURFACE WITH THE URETHANE SIDE UP. THIS IS NECESSARY BECAUSE 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. 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. 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 counter clockwise to full, return about 3 turns and align the neutral mark. Page 3171 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. 2. Connect battery ground cable. Locations Heater Unit And Associated Parts Engine Controls - High/Erratic Engine Idle 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. Specifications Idle Speed: Specifications Idle speed is PCM controlled Description and Operation Transmission Temperature Sensor/Switch: Description and Operation Transmission Fluid Temperature (TFT) Sensor The transmission fluid temperature sensor is a thermistor which changes its resistance based on the temperature of the transmission fluid. For a complete description of the TFT sensor, refer to 4L30-E Automatic Transmission Diagnosis (Transmission Control System Diagnosis). A failure in the TFT sensor or associated wiring will cause DTC P0712 or DTC P0713 to set. In this case, engine coolant temperature will be substituted for the TFT sensor value and the transmission will operate normally. Page 2356 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 5681 Receiver/Drier and Associated Parts Page 2800 Fuel Filler Cap: Description and Operation Fuel Cap Fuel Cap. The fuel cap is designed to be an integral part of the EVAP system. Page 2926 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 4050 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. 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 2935 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. - The screwdriver blade will release the catch inside. 4. 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. Page 3710 6. Break retainer ring with hammer and chisel. 7. Break bearing cane 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 spelling or grooves from seal wear. ^ Retainer - bent or damaged. ^ Replace items if required. Installation 1. Emergency brake assembly. Page 6899 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 7049 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 6550 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: 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 tailgate lock assembly fixing bolts to the specified torque. Torque: 7 N.m (81 lb in) 5. Tighten the hatchgate lock assembly fixing bolts to the specified torque. Torque: 9 N.m (78 lb in) Page 614 Manifold Absolute Pressure 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 Page 2402 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 6135 ^ 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 7411 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 668 a. Place selector lever in neutral. b. Disconnect transmission harness connector from mode switch connector. 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 (approximately 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 881 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 5597 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 2983 Each schematic represents one circuit. A circuit's wires and components are arranged to show current flow, from power at the top 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 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. Page 4622 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 3559 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) (V6). 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 Page 112 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 6518 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 N.m (61 lb in) 4. Check that the door lock operates smoothly. Page 7045 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 1408 Harmonic Balancer - Crankshaft Pulley: Service and Repair Removal 1. Disconnect battery ground cable. 2. Remove Air cleaner assembly. 3. Remove radiator upper fan shroud from radiator. 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. Page 5224 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 1150 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. Upshift Lamp System Check (Manual Transmission Only) Upshift Indicator: Testing and Inspection Upshift Lamp System Check (Manual Transmission Only) Upshift Lamp System Check (Manual Transmisssion Only) Circuit Description The Upshift Lamp should always be illuminated and steady with the ignition "ON" and the engine stopped. Ignition feed voltage is supplied to the Upshift Lamp bulb through the meter fuse. The powertrain control module (PCM) orders the Upshift Lamp "ON" signal for Multiplex Control Unit. When Multiplex Control Unit is received Upshift Lamp "ON" signal that turn Upshift Lamp "ON" by grounding the Upshift Lamp driver circuit. Diagnostic Aids An intermittent Upshift Lamp may be cased by a poor connection, rubbed-through wire insulation, or a wire broken inside the insulation. Check for the following items: - Inspect the PCM and Multiplex Control Unit harness and connections for improper mating, broken locks, improperly formed or damaged terminals, poor terminal-to-wire connection, and damaged harness. - If the engine runs OK, check for a faulty light bulb, an open in the MIL driver circuit, or an open in the instrument cluster ignition feed. - If the engine cranks but will not run, check for an open PCM ignition or battery feed, or a poor PCM to engine ground. Locations 48. Below Left Side of Dash Page 6769 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 1226 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 5671 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 611 Manifold Absolute Pressure 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 2295 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 Driveability and Emissions System Fuel Filler Cap: Testing and Inspection Engine Driveability and Emissions System Inspection Procedure NOTE: Replace the fuel filler cap with the same type of filler cap that was originally installed on the vehicle. - Check the seal ring in the filler cap for any abnormality and for seal condition. - Replace the filler cap if any abnormality is found. Page 1018 Valve Shim Replacement Chart Page 4141 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 4058 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 6774 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 5262 Wheel Bearing: Service and Repair 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. 9. Use wrench J-36827, remove hub nut. 10. Remove hub and disc assembly. Page 1076 Coolant: Fluid Type Specifications Mixture of water and good quality ethylene glycol base type antifreeze mixed 50/50. Page 3316 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 5985 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. Diagrams Power/Winter Switch Locations Manifold Absolute Pressure Sensor: Locations 24. Top Rear of Engine MAP Sensor Service and Repair Maintenance Required Lamp/Indicator: Service and Repair The OEM does not equip this model with a Maintenace Required Indicator. Page 484 Combination Switch: Connector Locations 45. Below Left Side of Dash 46. Below Left Side of Dash Page 110 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 1745 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 5986 - 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. Locations 18. Right Side of Engine Page 6178 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 4369 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 1927 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 Coolant Temperature Sensor/Switch (For Computer): Locations 17. Front of Engine ECT Sensor Page 6123 ^ 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, 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 4967 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. 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: 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: 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: 59 Nm (43 ft. lbs.) 14. Install pressure switch assembly and tighten it to specified torque. Torque: 18 Nm (13 ft. lbs.) Page 7403 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 417 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 5032 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 2004 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 4257 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 2613 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 5196 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 3199 WARNING: THE INFLATOR MODULE SHOULD ALWAYS BE CARRIED WITH THE TRIM COVER AWAY FROM YOUR BODY AND SHOULD ALWAYS BE LAID ON A FLAT SURFACE WITH THE URETHANE SIDE UP. THIS IS NECESSARY BECAUSE 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. 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. 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 counter clockwise to full, return about 3 turns and align the neutral mark. Page 506 Above 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 begins in Wire Color Abbreviations. 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 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 Page 104 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 7178 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 2591 Ground - "G" Shielding Sheilding This represents RFI (Radio Frequency Interference) shielding around a wire. The shielding is always connected to ground. Splices Page 6810 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 6664 NOTE: Be sure to remove the frame assembly while supporting it. Installation 1. Install the sunroof frame assembly. 2. After installing the frame 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 222 Each schematic represents one circuit. A circuit's wires and components are arranged to show current flow, from power at the top 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 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. Page 6556 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 6372 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 2914 Above 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 begins in Wire Color Abbreviations. 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 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 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 6719 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 4724 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. 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 3759 Drive/Propeller Shaft: Description and Operation General Description Torque is transmitted from the transmission to the axle through 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 balanced carefully welding or any other modification is not permitted. ^ Alignment marks should be applied to each propeller shaft before removal. ^ Park, turn the engine off and apply the parking brake to secure the vehicle. ^ Carefully attach the propeller shaft to the vise, do not overtighten the vise when securing the propeller shaft, this may 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 spins. 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 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 Page 4940 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 2052 CAUTION: Turn the SRS coil counter clockwise until some resistance is felt, or damage may occur to the SRS coil. 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 shaft 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 ground cable. Page 4421 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. 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 shaft 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. Page 2355 ^ 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 2182 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 3196 Ignition Switch Lock Cylinder: Testing and Inspection System Inspection Turn the ignition switch to the "ON" position and observe the warning lamp. The lamp should flash 7 times. If the lamp does not operate correctly, refer to "Restraints". Page 5387 Control Lever Assembly, Control Cable And Associated Parts Page 666 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 4L30-E Automatic Transmission (Transmission Control System Diagnosis). Page 622 Oxygen Sensor: Connector Locations 93. Left Front Exhaust Downpipe 94. Rear of Left Catalytic Converter Page 2644 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. Locations 61. Front Center of Ceiling (Headliner Removed) Page 2679 3. Connect the vacuum hoses to the EVAP canister purge solenoid. 4. Connect the electrical connector to the EVAP canister purge solenoid. Page 4898 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. Locations Coolant Temperature Sensor/Switch (For Computer): Locations 17. Front of Engine ECT Sensor Page 6575 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 7512 Individual circuit schematics begin with a fuse. The first half of Power Distribution, however, shows the wiring "upstream" between the battery 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 2425 Inputs - Operating conditions Read - Air Conditioning "ON" or "OFF" - 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 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-megohm 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. 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 4343 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 227 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 6762 Disclaimer Page 6597 Locations 56. Top Right Side of Transfer Case Page 7058 Low Fuel Indicator System Image 74-0 Page 1092 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. Refer to Tech 2 OBD II Connection in Transmission Control System (4L30-E). Page 2987 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 5204 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 4856 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 4954 Power Steering Fluid: Service Precautions Use Genuine Honda Power Steering Fluid, or another brand of power steering fluid as a temporary replacement. Page 5323 Tires: Service and Repair Tire Replacement Tire Replacement When replacement is necessary, the original metric tire 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 capon 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): Page 904 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 4556 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. Check for continuity between segment and segment on the commutator. Replace commutator if there is no continuity (i.e., disconnected). 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). Page 364 Wheel Speed Sensor: Diagrams Front Wheel Speed Sensor and Associated Parts Replacement w/ Related Components Page 2900 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 7114 Door 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 48. Below Left Side of Dash Page 5245 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. 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 6146 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 Front Door Window Track: Service and Repair Front Door Front Window Regulator, Glass and Glass Run Front Window Regulator, Glass And Glass Run - Parts Location Removal 1. Disconnect the battery ground cable. 2. Remove the power window switch/regulator handle. Diagrams Refrigerant Line and Associated Parts Page 2412 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 4889 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 6161 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. Page 2068 3. Install the air cleaner lid on the MAF sensor and the air cleaner housing. 4. Tighten the clamp and secure the four latches between the lid and the air cleaner housing. Induction System 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). Page 3764 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. UNIVERSAL JOINT DISASSEMBLY Page 6424 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 Diagrams Page 2238 Individual circuit schematics begin with a fuse. The first half of Power Distribution, however, shows the wiring "upstream" between the battery 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 727 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 1437 Valve Cover: Service and Repair Cylinder Head Cover RH Removal 1. Disconnect battery ground cable. 2. Remove engine cover from the dowel on the common chamber. 3. Disconnect ventilation hose from cylinder head cover. 4. 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. 5. Disconnect fuel injector harness connector then remove fuel injector harness bracket bolt. 6. Remove eight fixing bolts then the cylinder head cover. Installation 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) bead (diameter 2-3 mm) at eight places of arched areas 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 (78 inch lbs.) 2. Tighten fuel injector harness bracket bolts to specified torque then reconnect fuel injector harness connector. Torque: 7.8 Nm (69 inch lbs.) 3. Connect ignition coil connector and tighten ignition coil fixing bolts to specified torque. Page 6886 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. Page 6837 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 1955 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 7409 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 642 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 4118 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. Page 6811 Each schematic represents one circuit. A circuit's wires and components are arranged to show current flow, from power at the top 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 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. Diagram Information and Instructions Key Reminder Switch: Diagram Information and Instructions How to Identify Wiring Color-Coded Insulation Wire Color Wire Color Coding Page 4855 DIAGNOSTIC WORKSHEET REPAIR PROCEDURE A Page 5037 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 6770 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 2638 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 2134 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 Description and Operation Transmission Temperature Sensor/Switch: Description and Operation Transmission Fluid Temperature (TFT) Sensor The transmission fluid temperature sensor is a thermistor which changes its resistance based on the temperature of the transmission fluid. For a complete description of the TFT sensor, refer to 4L30-E Automatic Transmission Diagnosis (Transmission Control System Diagnosis). A failure in the TFT sensor or associated wiring will cause DTC P0712 or DTC P0713 to set. In this case, engine coolant temperature will be substituted for the TFT sensor value and the transmission will operate normally. Description and Operation 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 53. Above Center of Dash (Console Removed) Page 7571 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 3317 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 5172 Suspension Strut / Shock Absorber: Service and Repair Rear 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 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: 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: 20 Nm (14 ft. lbs.) Page 2183 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 2185 Above 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 begins in Wire Color Abbreviations. 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 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 Description and Operation 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 5277 Supportable Point: Rear - Position the chassis stands at the bottom of the rear axle case. Page 4694 Relay Box: Diagrams Relay/Fuse Box (Instrument Panel) Page 4374 Part 2 of 3 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. Locations Sunroof Deflector - Parts Locations (SWB) Page 6675 105. Left Side of Driver's Seat Page 5969 Torque Specifications Part 2 Page 5206 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 6500 Trim Panel: Service and Repair Rear Door Trim Panel Rear Door Trim Panel And Associated Parts Removal 1. Disconnect the battery ground cable. Page 5159 Page 2571 Transmission Range Switch 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 5711 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. Locations 39. Dash Fuse Box Page 2961 3. Inspect the end of either hose in the fuel hose assembly. Record the lot number. 4. Check the lot numbers you recorded. ^ If the fuel return hose has the lot number 0707 or both the fuel return hose and the fuel hose assembly have the lot number 0707, go to FUEL RETURN HOSE REPLACEMENT ^ If only the fuel hose assembly has the lot number 0707, go to FUEL HOSE ASSEMBLY REPLACEMENT ^ If you cannot determine the lot number of a hose, replace the hose. Go to the appropriate procedure. ^ If none of the hoses have the lot number 0707 go to COMPLETION PROCEDURE. FUEL RETURN HOSE REPLACEMENT 1. Slide back the clamps on both ends of the fuel return hose. 2. Remove the fuel return hose. Fuel will come out of the hose and fuel lines; wrap the hose with shop towels and use a container to catch the fuel. 3. Install the new fuel return hose with the original hose clamps. ^ If only the fuel return hose had the 0707 lot number, go to COMPLETION PROCEDURE. ^ If the fuel hose assembly also has the 0707 lot number, go to FUEL HOSE ASSEMBLY REPLACEMENT FUEL HOSE ASSEMBLY REPLACEMENT Page 1574 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 MOhms or more Page 6434 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 6895 Above 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 begins in Wire Color Abbreviations. 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 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 Page 1776 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 2831 The wire insulation has one color or one color with another color stripe. The second color is the stripe. Page 1328 4. Use installer J-36828 and grip J-8092 then install the outer bearing by driving it into the hub. 5. Apply grease (NLGI 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. Grease Amount Hub: 35 g (1.23 oz) Outer bearing: 10 g (0.35 oz) Inner bearing: 15 g (0.53 oz) Page 4144 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 1572 Spark Plug: Application and ID NGK Platinum: NGK 2647 Bosch Platinum +4: BSA 4417 Bosch Platinum +2: BSA 4303 Bosch Platinum: BSA 4202 Locations 90. Left Side of Automatic Transmission (A/T) Locations Vapor Pressure Sensor / Fuel Gage And Fuel Pump Connector Page 519 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 445 Individual circuit schematics begin with a fuse. The first half of Power Distribution, however, shows the wiring "upstream" between the battery 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 7283 Dimmer Switch: Service and Repair Illumination Controller 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 2323 Malfunction Indicator Lamp: Service and Repair Removal and Installation Procedure Refer to Warning light bulb, indicator light valve, illumination light bulb, A/T indicator light bulb in Meter and Gauge. Page 1181 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/sec), 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 3960 Actuator: Testing and Inspection Axle Shaft Connection and Disconnection Actuator Assembly Page 768 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. Refer to Electronic Ignition System for additional information. Page 5884 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 2401 Ground - "G" Shielding Sheilding This represents RFI (Radio Frequency Interference) shielding around a wire. The shielding is always connected to ground. Splices Page 7483 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 948 ^ 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 4099 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 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 4820 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 5119 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) Torque: 108 Nm (80 ft. lbs.) 5. Install upper control arm assembly with the fulcrum pin projections turned inward. Page 3251 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. Diagram Information and Instructions Fuse Block: Diagram Information and Instructions How to Identify Wiring Color-Coded Insulation Wire Color Wire Color Coding Page 2588 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 4344 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 2327 Manifold Absolute Pressure 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 7228 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 Tailgate Lock, Hatchgate Lock And Associated Parts (LWB) Page 6965 Individual circuit schematics begin with a fuse. The first half of Power Distribution, however, shows the wiring "upstream" between the battery 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 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 7233 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 7182 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 6108 ^ 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. Locations 61. Front Center of Ceiling (Headliner Removed) Page 4789 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 7031 Key Reminder Switch: Electrical Diagrams Seat Belt, Lights-on, And Ignition Key Reminders Image 73-0 Page 6879 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 5392 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: 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 4324 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). Diagram Information and Instructions Vanity Lamp: Diagram Information and Instructions How to Identify Wiring Color-Coded Insulation Wire Color Wire Color Coding Page 2090 Spark Plug: Application and ID NGK Platinum: NGK 2647 Bosch Platinum +4: BSA 4417 Bosch Platinum +2: BSA 4303 Bosch Platinum: BSA 4202 Page 3727 ^ 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. 12. Using snap ring pliers, install the snap ring (1) securing the ball retainer to the shaft. Page 4824 Grounding Point: Electrical Diagrams Earth Location (Engine Room) Front Wipers (In Combination Switch) Combination Light Switch Connectors A And B Page 2645 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. 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. 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 5188 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 3641 Actuator: Testing and Inspection Axle Shaft Connection and Disconnection Actuator Assembly Page 205 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 the 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 5343 11. Install snap ring and shim. - Adjust the clearance between the free wheeling hub body and the snap ring. Clearance: 0 mm 0.3 mm (0 in - 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. 13. Tighten the bolts to the specified torque. Torque: 59 Nm (43 ft. lbs.) Page 6822 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 2964 2. If you have replaced any hoses, start the engine and inspect for any fuel leaks. 3. Fill out the information on a campaign completion label. Affix this label to the driver's doorjamb above the manufacturer's identification label. DISCLAIMER Service and Repair Axle Bearing: Service and Repair 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. Use a wire to hang the caliper to the frame to prevent damage to the caliper. 3. Remove four nuts and lockwashers. 4. Remove shaft assembly from the axle housing. 5. Remove snap ring and bearing cup. Specifications Idle Speed: Specifications Idle speed is PCM controlled Page 2346 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 3026 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 7017 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 1258 Malfunction Indicator Lamp: Service and Repair Removal and Installation Procedure Refer to Warning light bulb, indicator light valve, illumination light bulb, A/T indicator light bulb in Meter and Gauge. Page 1325 Wheel Bearing: Service and Repair 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. 9. Use wrench J-36827, remove hub nut. 10. Remove hub and disc assembly. Page 7507 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 3670 2. Connect the terminals as shown in figure. Shift rod of the motor actuator moves and stops at 4WD position. 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. Transfer Position Switch 1. With ball being free. 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 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 Locations Door Switch: Locations 78. Left "C" Pillar (Right Similar) 77. Left "B" Pillar (Right Similar) 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 2152 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 7615 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 660 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 TP1 about 0.4 V, TP2 about 4.6 V and TP3 about 4.6 V. - If the reading is abnormal value, check the throttle shaft to see if it is binding. 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 2421 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 6106 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 1916 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 2159 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 9. Fuse/Relay Box (Cover Removed) Locations 53. Above Center of Dash (Console Removed) Page 4890 DIAGNOSTIC WORKSHEET REPAIR PROCEDURE A 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 Page 1139 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 5082 Diagrams Rear Wiper/Washer Switch 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 N.m (13 lb.ft) Removal and Installation Hose/Line HVAC: Service and Repair Removal and Installation Refrigerant Line and Associated Parts 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-ring 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. See: Heating and Air Conditioning/Specifications Locations 48. Below Left Side of Dash Page 7655 Rear Quarter Glass (Resin Top) 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 5692 HVAC / Heating Page 1368 Camshaft: Service and Repair Disassembly, Inspection and Assembly DISASSEMBLY 1. Remove fixing bolt (5) for camshaft drive gear pulley using J-43041 universal holder. Quarter Glass Quarter Window Glass: Service and Repair Quarter Glass Rear Quarter Glass (LWB) Rear Quarter Glass (LWB) - Parts Locations 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 the rear quarter glass for any signs of water leak 2. Install the rear quarter trim panel. Page 7186 Transmission Shift Position Indicator Lamp: Electrical Diagrams A/T Gear Position Indicator Image 89-0 Diagram Information and Instructions Headlamp Switch: Diagram Information and Instructions How to Identify Wiring Color-Coded Insulation Wire Color Wire Color Coding Page 5836 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 5834 Individual circuit schematics begin with a fuse. The first half of Power Distribution, however, shows the wiring "upstream" between the battery 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 7685 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 4420 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 ground 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 driver knee bolster (reinforcement). 7. 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. 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 2005 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 5478 Blower Resistor Page 7668 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 Locations Intake Air Temperature Sensor: Locations 26. Left Front of Engine IAT Sensor Page 4991 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 2398 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 3884 4WD Motor Actuator Diagrams Page 3423 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 6117 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: Locations Seat Belt Cross Bar Assembly And Associated Parts Page 3067 13. Control A/C Clutch Relay and check data list. 14. If the data list changes, the Fuel Pump Relay is normal. Page 4297 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 1717 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 4531 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 2918 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 4395 Parking Brake Warning Switch: Description and Operation Parking Brake Switch 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. Diagrams Exhaust Pipe: Diagrams Page 4901 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 2994 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 1988 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 6743 3. Photocopy the template that is shown. Cut out the template. Page 4524 Above 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 begins in Wire Color Abbreviations. 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 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 Page 3550 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. Service and Repair 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 To install, follow the removal steps in the reverse order, noting the following points. Torque: Nut (1) 8 Nm (69 inch lbs.) Page 2110 Valve Shim Replacement Chart Page 4140 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 2560 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 745 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 82 Part 2 of 3 Procedures Fuel Door: Procedures Fuel Filler Door - Parts Location Fuel Filler 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 1369 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) Trim Height Adjustment Alignment: Service and Repair Trim Height Adjustment Trim Height Adjustment 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 Adjustment Page 2492 Crankshaft Position Sensor: Testing and Inspection Inspection Procedure 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 6896 Individual circuit schematics begin with a fuse. The first half of Power Distribution, however, shows the wiring "upstream" between the battery 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 4129 Individual circuit schematics begin with a fuse. The first half of Power Distribution, however, shows the wiring "upstream" between the battery 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 2799 Fuel Filler Cap: Description and Operation Engine Fuel System A vacuum valve and pressure valve are built into the fuel filler cap which adjusts the fuel pressure in the fuel tank to prevent fuel tank damage. Page 936 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 Component Locations Locations 2. Behind Left Side of Front Grille Page 2507 Fuel Tank Pressure Sensor: Testing and Inspection Inspection Procedure 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 5451 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 1773 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 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 4839 7. Right Side of Engine Compartment Page 5980 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 3856 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) (V6). 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 Page 900 DIAGNOSTIC WORKSHEET REPAIR PROCEDURE A Locations Air Flow Meter/Sensor: Locations 28. Left Side of Engine Compartment MAF Sensor Page 57 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 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 5545 Condenser Fan - Automatic Transmission Only Image 63-0 Page 5894 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 2673 Steps 8 - 15 Test Description 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 6910 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. 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. BLEEDING BRAKE HYDRAULIC SYSTEM 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. When replenishing the brake fluid reservoir, carefully pour in the brake fluid to prevent air bubbles from entering the brake system. 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 described. Bleeding the Master Cylinder 7. Disconnect the rear wheel brake pipe (1) from the master cylinder. Check the fluid level and replenish as necessary. If replenished, leave the Page 6037 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. Locations Headlining - Parts Locations (LWB) Page 4477 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. 2. Check for continuity across one of the stator coils and stator core If a continuity exists, replace the coil. Page 7271 Ceiling, Cargo Area, Courtesy, And Map Lights Image 114-3 Page 3054 Terminals - "T" Each "T" terminal (ring type) is numbered for reference and location. A "T" terminal is secured with a screw or bolt. Wires Capacity Specifications Fluid - Transfer Case: Capacity Specifications Transfer Case Fluid Capacity ............................................................................................................................................... .......................................................... 1.45 L (1.5 Qt) Page 7061 5. Select F0: Malfunction Indicator Lamp. 6. Push "On" soft key. 7. Make sure Lamp illuminates. 8. If lamp illuminates, the Lamp is operating correctly 9. Select F2: Up Shift Lamp 10. Push "On" of soft key. 11. Make sure Lamp illuminates. 12. If Lamp illuminates, the Lamp is operating correctly. 13. Select F2: Low Fuel Lamp Page 3379 2. Connect the terminals as shown in figure. Shift rod of the motor actuator moves and stops at 4WD position. 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. Transfer Position Switch 1. With ball being free. Procedures Power Mirror Switch: Procedures 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). Testing and Inspection Air Filter Element: Testing and Inspection Check the air cleaner filter for damage or dust clogging. Replace if it is damaged, or clean if it is clogged. Page 1853 2. Install the ECT sensor in the coolant crossover. Tighten Tighten the ECT sensor to 30 N.m (22 lb.ft.). 3. Connect the electrical connector. 4. Fill the radiator with coolant. Refer to Draining and Refilling Cooling System. 5. Connect the negative battery cable. Locations 98. Top Rear of Fuel Tank Page 6080 Alarm And Relay Controls Image 70-1 Page 7547 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 shaft 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. 11. Turn the ignition switch to the "ON" position and observe the warning lamp. Diagram Information and Instructions Grounding Point: Diagram Information and Instructions How to Identify Wiring Color-Coded Insulation Wire Color Wire Color Coding Locations 58. Under Center Console Page 7372 TURN, HAZARD, STOP, Back Up, Horn And Air Shift Lock Page 2601 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 4195 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 5604 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. 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 6062 Individual circuit schematics begin with a fuse. The first half of Power Distribution, however, shows the wiring "upstream" between the battery 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 6828 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 177 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 1472 2) Tighten the filter by turning it clockwise seven numbers from the marked point. For example, if a mark is made under the number 2 when the rubber seal is seated, the filter should be tightened until the number 1 comes up to the marked point. 5. After installation, fill the engine with oil up to the specified level, run the engine for more than three minutes, then check for oil leakage. CAUTION: Using any procedure other than those shown could result in serious engine damage due to oil leakage. Replacement M/T With ATTS: WARNING: Be careful when loosening the drain plug while the engine is hot. Burns can result because the oil temperature is very high. 1. Remove the oil filter with the special tool. 2. Inspect the threads and rubber seal on the new filter. Wipe off seat on the engine block. Apply a light coat of oil to the filter rubber seal. NOTE: Use only filters with a built-in bypass system. 3. Install the oil filter by hand. 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 5563 Each schematic represents one circuit. A circuit's wires and components are arranged to show current flow, from power at the top 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 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. Page 5287 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 1912 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 6557 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 7053 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 244 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. - The screwdriver blade will release the catch inside. 4. 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. Page 6432 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 769 Crankshaft Position Sensor: Testing and Inspection Inspection Procedure 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 1689 Page 1892 96. Rear of Right Catalytic Converter 93. Left Front Exhaust Downpipe 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. 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 Locations Relay Box: Locations Fuse To Component view, Image 6-2 Page 6928 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 6968 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 6583 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). 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. Page 1775 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 7337 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. 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. Locations Light and Bulb Specifications (LWB) - View 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 812 ^ 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 5598 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 5812 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 1029 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. Description and Operation 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 4732 Auxiliary Power Outlet: Electrical Diagrams Cigarette Lighter And Accessory Power Sockets Image 155 Page 942 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. 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 3342 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 4583 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 1033 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). Fuel Metering System Description Fuel Meter Body: Description and Operation Fuel Metering System Description Fuel Metering The Powertrain Control Module (PCM) is in complete control of this fuel delivery system during normal driving conditions. The intake manifold function, like that of a diesel, is used only to let air into the engine. The fuel is injected by separate injectors that are mounted over the intake manifold. The Manifold Absolute Pressure (MAP) sensor measures the changes in the intake manifold pressure which result from engine load and speed changes, which the MAP sensor converts to a voltage output. This sensor generates the voltage to change corresponding to the flow of the air drawn into the engine. The changing voltage is transformed into an electric signal and provided to the PCM. With receipt of the signals sent from the MAP sensor, Intake Air Temperature sensor and others, the PCM determines an appropriate fuel injection pulse width feeding such information to the fuel injector valves to affect an appropriate air/fuel ratio. The Multiport Fuel Injection system utilizes an injection system where the injectors turn on at every crankshaft revolution. The PCM controls the injector on time so that the correct amount of fuel is metered depending on driving conditions. Two interchangeable "O" rings are used on the injector that must be replaced when the injectors are removed. The fuel rail is attached to the top of the intake manifold and supplies fuel to all the injectors. Fuel is recirculated through the rail continually while the engine is running. This removes air and vapors from the fuel as well as keeping the fuel cool during hot weather operation. The fuel pressure control valve that is mounted on the fuel rail maintains a pressure differential across the injectors under all operating conditions. It is accomplished by controlling the amount of fuel that is recirculated back to the fuel tank based on engine demand. See "Driveability and Emission" for more information and diagnosis. Page 5307 Spare Tire Hanger - Parts Locations Page 7580 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 4895 ^ 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 4372 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 4860 ^ 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 2821 Individual circuit schematics begin with a fuse. The first half of Power Distribution, however, shows the wiring "upstream" between the battery 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 1582 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 4670 Individual circuit schematics begin with a fuse. The first half of Power Distribution, however, shows the wiring "upstream" between the battery 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 4447 Alternator: Locations 16. Right Front of Engine 34. Lower Right Front of Engine Page 5846 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 1822 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 2686 1. Slide the into EVAP canister vent solenoid from mounting bracket. 2. Connect the connector and hose. 3. Connect the negative battery cable. Page 7604 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 4373 Electronic Brake Control Module: Connector Views Part 1 of 3 Specifications Page 6319 Rear Door Window Motor: Connector Locations 76. Left Rear Door (Right Similar) 107. Left Rear Door (Right Similar) Page 3560 a. Place selector lever in neutral. b. Disconnect transmission harness connector from mode switch connector. 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 (approximately 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. Locations 67. Behind Glove Box Page 6668 Moonroof Control Unit Connectors A And B Page 5784 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. Specifications Idle Speed: Specifications Idle speed is PCM controlled Page 454 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 2585 Each schematic represents one circuit. A circuit's wires and components are arranged to show current flow, from power at the top 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 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. Page 2641 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 7134 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 84 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 7038 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. 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 6488 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. Diagram Information and Instructions Alarm/Immobilizer Control Unit: Diagram Information and Instructions How to Identify Wiring Color-Coded Insulation Wire Color Wire Color Coding Page 4309 1. O-ring (1) must be set onto the fluid reservoir (2), before installing fluid reservoir. Diagram Information and Instructions Vehicle Speed Sensor: Diagram Information and Instructions How to Identify Wiring Color-Coded Insulation Wire Color Wire Color Coding Locations 67. Behind Glove Box Service and Repair Oil Filter: Service and Repair 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 7145 Key Reminder Switch: Electrical Diagrams Seat Belt, Lights-on, And Ignition Key Reminders Image 73-0 Page 3092 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 4548 1. Pull in test Connect the ground (-) to terminal C and magnetic switch body. Verify that the pinion pulls out when the battery (+) pole is connected to terminal 50. 2. Hold in test Observe that the pinion stays when the lead wire is disconnected from terminal C. 3. Return test Connect the ground (-) to terminal 50 and magnetic switch body. Verify that the pinion pulls out when the battery (+) pole is connected to terminal C and the pinion pulls away when the lead wire is disconnected from terminal 50. Field Coil Specifications Wheels: Specifications Size 16 X 7JJ Offset 38.0 mm P.C.D., Wheel Studs 139.7 mm 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 Band Control Solenoid Valve: Service and Repair For further information regarding this component and the system that it is a part of, please refer to Shift Solenoid; Service and Repair. Page 1660 Thermostat: Service and Repair 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. 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 74.5C - 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 EC leakage. Page 6066 Ground - "G" Shielding Sheilding This represents RFI (Radio Frequency Interference) shielding around a wire. The shielding is always connected to ground. Splices Specifications Brake Fluid: Specifications Fluid type DOT 3 or 4 Diagram Information and Instructions Alarm/Immobilizer Control Unit: Diagram Information and Instructions How to Identify Wiring Color-Coded Insulation Wire Color Wire Color Coding Testing and Inspection Turn Signal Switch: Testing and Inspection Turn Signal Switch This diagnosis covers mechanical problems only. Page 4748 Fuse To Component view, Image 6-2 Specifications Crankshaft Gear/Sprocket: Specifications Camshaft Drive Gear ........................................................................................................................... ....................................................... 98 Nm (72 lb. ft.) Page 165 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 2920 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 6451 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 Rear Heater Duct, Defroster Nozzle, Ventilation Duct And Associated Parts 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 2303 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 2550 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 514 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 3226 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. Page 2158 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 1. Install the MAF sensor on the air cleaner with the clamp. Page 6072 The wire insulation has one color or one color with another color stripe. The second color is the stripe. Locations Coolant Temperature Sensor/Switch (For Computer): Locations 17. Front of Engine ECT Sensor Page 5863 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 4788 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 7129 Individual circuit schematics begin with a fuse. The first half of Power Distribution, however, shows the wiring "upstream" between the battery 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 Front Brake Caliper: Service and Repair Front Removal and Installation Removal 1. Raise the vehicle and support with suitable safety stands. 2. Concerning wheel and tire assembly, refer to Wheels, Tires and Alignment. 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. 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 5203 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 5019 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 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 6566 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 1200 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 1550 3. Install the air cleaner lid on the MAF sensor and the air cleaner housing. 4. Tighten the clamp and secure the four latches between the lid and the air cleaner housing. Induction System 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). Page 7486 Headlight Switch Image 100-2 Page 998 Spark Plug: Application and ID NGK Platinum: NGK 2647 Bosch Platinum +4: BSA 4417 Bosch Platinum +2: BSA 4303 Bosch Platinum: BSA 4202 Locations Ignition Control Module: Locations 24. Top Rear of Engine ION Sensing Module 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 2556 ^ 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 6188 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 5246 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 941 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 3085 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 6190 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 6389 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) Locations Light and Bulb Specifications (LWB) - View Page 1951 Each schematic represents one circuit. A circuit's wires and components are arranged to show current flow, from power at the top 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 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. Page 1471 1. Remove the oil filter with the special oil filter wrench. 2. Inspect the threads and rubber seal on the new filter. Wipe off the seat on the engine block, then apply a light coat of oil to the filter rubber seal. NOTE: Use only filters with a built-in bypass system. 3. Install the oil filter by hand. 4. After rubber seal seats, tighten the oil filter three quarter turn, then torque it with the special tool. Tighten: three quarter turn clockwise. Tightening torque: 22 Nm (2.2 kgf.m, 16 ft. lbs.) Eight numbers (1 to 8) are printed on the surface of the filter. The following explains the procedure for tightening filters using these numbers. 1) Make a mark on the engine oil cooler under the number that shows at the bottom of the filter when the rubber seal is seated. Page 1255 Malfunction Indicator Lamp: Testing and Inspection Lamps Test Lamps Test This test is conducted to check MIL, Up Shift Lamp, Low Fuel Lamp, Reduced Power Lamp and Cruise Control Lamp for its working. 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 F0: Lamps Test in the Miscellaneous Test. Diagram Information and Instructions Vehicle Speed Sensor: Diagram Information and Instructions How to Identify Wiring Color-Coded Insulation Wire Color Wire Color Coding Page 3339 ^ 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 411 Evaporator Temperature Sensor / Switch: 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 1209 Fuse To Component Index (Fuse 11 - 23) Image 6-1 Page 5161 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: 78 Nm (58 ft. lbs.) 5. Install stabilizer bar. Torque: 31 Nm (23 ft. lbs.) 6. Install upper link with rubber plate and tighten fixing bolt. Torque: 137 Nm (101 ft. lbs.) 7. Install breather hose. 8. Connect brake hose and bleed the brake system. Page 627 Oxygen Sensor: Testing and Inspection Inspection Procedure 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 louvered end of the sensor for grease, din, or other contaminations. Page 7649 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 3129 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 5654 Heater Core Case: Service and Repair Heater Unit And Associated Parts Heater Unit 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 knee bolster bracket. 9. Remove duct. 10. Remove evaporator assembly (A/C only). 11. Remove ventilation lower duct. 12. Remove rear heater duct. - Remove foot rest, carpet and 3 clips. 13. 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. Page 4717 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. 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 2320 Malfunction Indicator Lamp: Testing and Inspection Lamps Test Lamps Test This test is conducted to check MIL, Up Shift Lamp, Low Fuel Lamp, Reduced Power Lamp and Cruise Control Lamp for its working. 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 F0: Lamps Test in the Miscellaneous Test. Page 4453 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 4587 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 58. Under Center Console Page 5234 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.* Diagram Information and Instructions Fuel Pump Relay: Diagram Information and Instructions How to Identify Wiring Color-Coded Insulation Wire Color Wire Color Coding 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 71 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 1374 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.) 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 64 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 100. Rear Underside of Vehicle Page 49 Moonroof Control Unit Connectors A And B Page 7180 The wire insulation has one color or one color with another color stripe. The second color is the stripe. Page 5487 Blower Motor Switch: Testing and Inspection Fan Control Knob (Fan Switch) Check for continuity between the fan switch and the A/C switch side connector terminals. Page 7032 Seat Belt, Lights-on, And Ignition Key Reminders Image 73-1 Page 845 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) (V6). 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 Page 1365 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. Page 3052 Ground - "G" Shielding Sheilding This represents RFI (Radio Frequency Interference) shielding around a wire. The shielding is always connected to ground. Splices Page 2766 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 6892 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 899 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 2189 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 Service and Repair Valve Guide: Service and Repair For further information regarding this component and the system that it is a part of, please refer to Cylinder Head Assembly; Service and Repair. Page 4658 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 3593 Clutch Slave Cylinder: Service and Repair Unit Overhaul 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 2635 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 6558 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 5882 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 7454 Door 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 2095 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 1.05 mm (0.04 in). NOTE: Do not adjust the spark plugs gap without new spark plugs. - Do not damage to tip of spark plugs. - Do not cleaning the spark plugs. If require the cleaning it due to heavy dirt, it is allowed only 20 seconds to be used spark plug cleaner. - 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 Page 7234 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 2235 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 6311 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 2573 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) (V6). 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 Page 2819 Each schematic represents one circuit. A circuit's wires and components are arranged to show current flow, from power at the top 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 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. 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). Locations 62. Front of Roof (Headliner Removed) Page 2481 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 7369 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 5586 Control Assembly: 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. Description and Operation Malfunction Indicator Lamp: Description and Operation Malfunction Indicator Lamp (MIL) The Malfunction Indicator Lamp (MIL) looks the same as the MIL you are already familiar with ("Check Engine" lamp). However, OBD II requires that it illuminate under a strict set of guide lines. Basically, the MIL is turned on when the PCM detects a DTC that will impact vehicle emissions. The MIL is under the control of the Diagnostic Executive. The MIL will be turned on if an emissions-related diagnostic test indicates a malfunction has occurred. It will stay on until the system or component passes the same test, for three consecutive trips, with no emissions related faults. If the vehicle is experiencing a misfire malfunction which may cause damage to the Three-Way Catalytic Converter (TWC), the MIL will flash once per second. This will continue until the vehicle is outside of speed and load conditions which could cause possible catalyst damage, and the MIL will stop flashing and remain on steady. Extinguishing the MIL When the MIL is on, the Diagnostic Executive will turn off the MIL after three(3) consecutive trips that a "test passed" has been reported for the diagnostic test that originally caused the MIL to illuminate. Although the MIL has been turned off, the DTC will remain in the PCM memory (both Freeze Frame and Failure Records) until forty (40) warm-up cycles after no faults have been completed. If the MIL was set by either a fuel trim or misfire-related DTC, additional requirements must be met. In addition to the requirements stated in the previous paragraph, these requirements are as follows: - The diagnostic tests that are passed must occur within 375 RPM of the RPM data stored at the time the last test failed. - Plus or minus ten (10) percent of the engine load that was stored at the time the last failed. - Similar engine temperature conditions (warmed up or warming up) as those stored at the time the last test failed. Meeting these requirements ensures that the fault which turned on the MIL has been corrected. The MIL ("Check Engine" lamp) is on the instrument panel and has the following function: - It informs the driver that a fault affects vehicle emission levels has occurred and that the vehicle should be taken for service as soon as possible. - As a bulb and system check, the MIL will come "ON" with the key "ON" and the engine not running. When the engine is started, the MIL will turn "OFF." - When the MIL remains "ON" while the engine is running, or when a malfunction is suspected due to a driveability or emissions problem, a Powertrain On-Board Diagnostic (OBD II) System Check must be performed. The procedures for these checks are given in On-Board Diagnostic (OBD) System Check. These checks will expose faults which may not be detected if other diagnostics are performed first. Page 4482 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 the front cover. 4. Remove the 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. 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. Specifications Brake Fluid: Specifications Fluid type DOT 3 or 4 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 6137 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 3683 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 2229 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 4353 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 7667 - 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. 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. Diagrams License Plate Garnish Page 4358 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 3341 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 7040 Each schematic represents one circuit. A circuit's wires and components are arranged to show current flow, from power at the top 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 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. 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 2255 ECM (M/T) Or PCM (A/T) Connector B Page 5014 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 3082 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 7095 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 Brake Caliper: Diagrams Front Front Disc Brake Caliper Assembly and Associated Parts Replacement w/ Related Components Front Disc Brake Caliper Disassembled View Overhaul w/ Related Components Page 7660 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. Page 3704 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-8614-13. 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 2648 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 2431 1. Install the PCM to bracket and fix with the clip. 2. Connect the PCM electrical connectors. 3. Install the two screws to PCM electrical connectors. Page 4966 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 finger nail. The parts with minor scores may 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. Bushing fitting face must be free from damage and wear. O-ring, Oil Seal, Snap 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. Page 7659 - 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 6563 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 Fuse Block: Locations Fuse To Component Index (Fuse No. 1 - 10) Image 6 Page 7370 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 10. Fuse/Relay Box (Cover Removed) Page 2992 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. Testing and Inspection Blower Motor Relay: Testing and Inspection Heater Relay 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 6413 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 1883 Manifold Absolute Pressure 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. Service and Repair Fuel Pressure Release: Service and Repair Fuel Pressure Relief Procedure CAUTION: To reduce the risk of fire and personal injury, there are necessary to relieve the fuel system pressure before filler and gauge unit 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 disconnect 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. 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. Page 3643 2. Connect the terminals as shown in figure. Shift rod of the motor actuator moves and stops at 4WD position. 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. Transfer Position Switch 1. With ball being free. Page 4547 Brush Measure the length of brush. Replace with a new one, if it is below the limit. Brush Holder Check for continuity between brush holder (+) (4) and base (-). Replace, it there is continuity (i.e., insulation is broken). Brush Spring Use spring balancer to measure the spring setting force when remove the spring from the brush. Standard: 17.65 - 23.54 N (38.9 - 51.9 lb) Limit: 11.77 N (25.9 lb) Magnetic Switch Temporarily connect the magnetic switch between the overrunning clutch and housing. Perform the steps described below in 3 to 5 seconds. Page 7171 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 5972 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. Page 3772 1. Apply alignment marks on the yokes of the universal joint, then remove the snap ring. 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 7269 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 6020 Seat Belt, Lights-on, And Ignition Key Reminders Image 73-1 Page 7189 Transmission Shift Position Indicator Lamp: Service and Repair Shift Lever Illumination Light Bulb (A/T) 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 Carrier Pinion Gears: 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. Page 955 This illustration shows view from the top of the vehicle. Toe-in is the measured amount the front wheels are turned 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 6934 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 Fuse Block: Locations Fuse To Component Index (Fuse No. 1 - 10) Image 6 Page 7690 Rear Window Regulator, Glass And Glass Run - Parts Locations Page 5452 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 1722 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 3857 a. Place selector lever in neutral. b. Disconnect transmission harness connector from mode switch connector. 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 (approximately 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 1346 Supportable Point: Rear - Position the chassis stands at the bottom of the rear axle case. Diagram Information and Instructions Data Link Connector: Diagram Information and Instructions How to Identify Wiring Color-Coded Insulation Wire Color Wire Color Coding Page 3744 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. 2. Tighten the hub nut to the value given, 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 lb - 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. 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 3280 a. Place selector lever in neutral. b. Disconnect transmission harness connector from mode switch connector. 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 (approximately 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 2521 1. Install the MAP sensor in the mounting bracket. 2. Install the mounting bracket retaining bolt on the common chamber. Tighten Tighten the bolt to 20 N.m (12 lb.ft.). 3. Connect the MAP electrical connector. 4. Connect the negative battery cable. Page 6152 Audio Unit (LX) Audio Unit/CD Changer (EX) Connectors A And B(Optional) Page 2917 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 6658 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 Page 682 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 3299 Transmission Temperature Sensor/Switch: Service and Repair Transmission Oil Temperature Sensor (Main Case) (V6) Removal 1. Raise the vehicle and support it on jack stands. 2. Disconnect battery ground cable. 3. Drain fluid. 4. Remove sixteen 10 mm main case oil pan fixing screws, main case oil pan, and gasket. 5. Disconnect wiring harness from shift solenoids, band apply solenoid, and 7 way 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 assembly with transmission oil temperature sensor to band apply solenoid, shift solenoids, and 7 way 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 inch lbs.) 3. Fill transmission through the overfill screw hole of oil pan, using ATF DEXRON III. 4. Connect battery ground cable. Page 5966 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 1296 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 7364 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 2880 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 198 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 390 Cruise Control Switch: Service and Repair Cruise Control Main Switch Removal 1. Disconnect the battery ground cable. 2. Remove the meter cluster assembly (1). 3. Remove the cruise control main 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 6233 The wire insulation has one color or one color with another color stripe. The second color is the stripe. Page 573 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 (gm/s). At idle, the Tech 2 should read between 4 - 7 gm/s 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 5238 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 7188 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 6173 Each schematic represents one circuit. A circuit's wires and components are arranged to show current flow, from power at the top 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 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. Locations 33. Bottom Center Front of Engine Page 3084 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 2506 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. Diagrams Power/Winter Switch Page 3144 4. Select F6: Variable Intake Manifold Solenoid Test. 5. Push "On" or "Off" of soft key. 6. Control VIM Solenoid check data list. 7. If data list changes, the VIM Solenoid is normal. Page 6229 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 98. Top Rear of Fuel Tank Page 1008 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 516 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 4503 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. 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 shaft 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. 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 5867 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). Page 2184 Each schematic represents one circuit. A circuit's wires and components are arranged to show current flow, from power at the top 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 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. Page 6228 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 5169 Page 5505 Thickness - 0.1 mm (0.0039 in.) - 0.3 mm (0.0118 in.) - 0.5 mm (0.0197 in.) Locations 14. Right Rear of Engine Compartment Locations 89. Left Side of Manual Transmission (M/T) Page 1404 Crankshaft: Service and Repair For further information regarding this component and the system that it is a part of, please refer to Cylinder Block Assembly; Service and Repair. Page 7092 Ground - "G" Shielding Sheilding This represents RFI (Radio Frequency Interference) shielding around a wire. The shielding is always connected to ground. Splices Page 1319 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 4962 Power Steering Pump: Description and Operation Hydraulic Pump 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. 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. 5. Remove upper ball joint. Page 7560 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 5286 3. Photocopy the template that is shown. Cut out the template. Page 5941 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 4629 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 937 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 1719 Above 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 begins in Wire Color Abbreviations. 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 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 Locations Control Lever Assembly, Control Cable And Associated Parts 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 cut the front accessory socket from the socket cover (3). Installation To install, follow the removal steps in the reverse order. Page 183 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 Cruise Control Main Switch Page 5409 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 3062 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 Power/Winter Switch Page 686 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 Brake Warning Indicator: Diagram Information and Instructions How to Identify Wiring Color-Coded Insulation Wire Color Wire Color Coding Page 1466 Engine Oil: Service Precautions SAFETY PRECAUTIONS WARNING: Prolonged and repeated contact with used engine oil may cause skin cancer. Avoid prolonged and repeated contact with oils, particularly used engine oils. - Wear protective clothing, including impervious gloves where practicable. - Do not put oily rags in pockets. - Avoid contaminating clothes, particularly underpants, with oil. - Heavily soiled clothing and oil-impregnated footwear should not be worn. Overalls must be cleaned regularly. - First Aid treatment should be obtained immediately for open cuts and wounds. - Use barrier creams, applying them before each work period, to help the removal of oil from the skin. - Wash with soap and water to ensure all oil is removed (skin cleansers and nail brushes will help). Preparations containing lanolin replace the natural skin oils which have been removed. - Do not use gasoline, kerosine, diesel fuel, gas oil, thinner or solvents for cleaning skin. - If skin disorders develop, obtain medical advice without delay. - Where practicable, degrease components prior to handling. - Where there is a risk of eye contact, eye protection should be worn, for example, chemical goggles or face shields; in addition an eye wash facility should be provided. Page 5497 Steps 7 - 20 Page 2820 Above 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 begins in Wire Color Abbreviations. 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 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 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 Locations Fuse And Relay Panel (Underhood Electrical Center) Page 7329 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 1590 Valve Inspection Chart Page 4665 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 1046 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 6799 Cruise Control Switch: Service and Repair Cruise Control Main Switch Removal 1. Disconnect the battery ground cable. 2. Remove the meter cluster assembly (1). 3. Remove the cruise control main 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 6733 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 5502 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). 6. Loosen screw and disconnect the field coil wire connector. Page 5148 Stabilizer Bar: Service and Repair Stabilizer 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 corrections 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. Locations 29. Left Side of Engine Compartment Page 4224 NOTE: Do not over stretch the return spring. 8. Install adjuster assembly (12). 9. Install hold-down pin (15) and hold-down spring and cups (4). 10. Install lower return spring (5). - Use brake spring tool. 11. Install auto adjuster lever (10). 12. Install upper (outer) return spring (6). - Use brake spring tool. 13. Install brake drum (2). - Adjust the brakes 14. Install wheel and tire assembly (1). Page 1874 Fuel Tank Pressure Sensor: Service and Repair Removal Procedure 1. Remove the fuel pump assembly. Refer to Fuel Tank In Fuel Pump. 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. - Insert the sensor nipple firmly into the grommet. - Keep twisting and pushing the sensor until the wide portion of the nipple shows on the other side of the grommet. 3. Install the fuel pump assembly on the fuel tank. Refer to Fuel Tank In Fuel Pump. Service and Repair Shift Fork: 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. Page 3502 ^ 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 2826 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 6069 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 6337 2. Adjust the clearance between outer quarter panel (1) and fuel filler door (2). Locations 83. Top of Tailgate (Trim Removed) Page 6232 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 743 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 6377 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 5840 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 5477 65. Behind Glove Box Specifications Child Seat Tether Attachment Page 6567 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 6136 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. Locations Condenser HVAC: Locations 17. Front of Engine Condenser Assembly and Associated Parts Page 613 Steps 1 - 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 inch 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. 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 4365 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 3020 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 2833 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 5021 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 11 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 932 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 3190 Crankshaft Position Sensor: Service and Repair Removal 1. Disconnect battery ground cable 2. Wiring connector from crankshaft position sensor. 3. Remove crankshaft position sensor from cylinder block. Installation 1. Install crankshaft position sensor into the cylinder block. Before installation,apply small amount of engine oil to the O-ring. Torque: 10 N.m (87 lb.in) 2. Reconnect wiring connector to crankshaft position sensor. Service and Repair Seals and Gaskets: Service and Repair 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. 3. Use the oil seal installer J-39208 to install the rear seal (3) to the transfer rear case. Page 4775 Fuse Block Circuit-2 (V6) Page 2305 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 2336 96. Rear of Right Catalytic Converter 93. Left Front Exhaust Downpipe Page 814 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 4948 Acceleration Position Sensor Assembly Page 3701 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. Page 4712 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 Air Flow Meter/Sensor: Locations 28. Left Side of Engine Compartment MAF Sensor Page 7693 - 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 236 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. Specifications Crankshaft Gear/Sprocket: Specifications Camshaft Drive Gear ........................................................................................................................... ....................................................... 98 Nm (72 lb. ft.) 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. Check for continuity between segment and segment on the commutator. Replace commutator if there is no continuity (i.e., disconnected). 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). Component Locations 99. Under Rear of Vehicle (On Differential) Page 5499 Steps 32 - 42 Test Description IMPORTANT: Do not engage the A/C compressor clutch with the engine running if an A/C mode is not selected at the A/C control switch. The numbers below refer to the step numbers on the Diagnostic Chart: 3. This a test determine is the problem is with the refrigerant system. If the switch is open, A/C pressure gauges will be used to determine if the pressure switch is faulty or if the system is partially discharged or empty. 4. Although the normal complaint will be the A/C clutch failing to engage, it is possible for a short circuit to cause the clutch to run when A/C has not been selected. This step is a test for that condition. 7. There is an extremely low probability that both relays will fail at the same time, so the substitution process is one way to check the A/C Thermostat relay. Use a known good relay to do a substitution check. Testing and Inspection Blower Motor Relay: Testing and Inspection Heater Relay 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 7371 Horn: Electrical Diagrams Horns Image 40-0 Locations Page 3671 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 4155 Brake Caliper: Diagrams Rear Rear Disc Brake Caliper Assembly and Associated Parts Replacement w/ Related Components Rear Disc Brake Caliper Disassembled View Overhaul w/ Related Components Page 7105 Seat Belt, Lights-on, And Ignition Key Reminders Image 73-1 Page 540 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 1992 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 4772 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 3021 The wire insulation has one color or one color with another color stripe. The second color is the stripe. Page 3018 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 1665 Water Pump: Description and Operation Water Pump The Engine Coolant (EC) pump is a centrifugal impeller type and is driven by a timing belt. 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 6569 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 1003 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 1.05 mm (0.04 in). NOTE: Do not adjust the spark plugs gap without new spark plugs. - Do not damage to tip of spark plugs. - Do not cleaning the spark plugs. If require the cleaning it due to heavy dirt, it is allowed only 20 seconds to be used spark plug cleaner. - 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 Page 242 5. Select F0:Fuel Pump Relay. 6. Push "On" soft key. 7. Control Fuel Pump Relay and check data list. 8. If the data list changes, the Fuel Pump Relay is normal. 9. Select F1 A/C Clutch Relay. 10. Run the Engine at idle. 11. Turn on Air Conditioning. 12. Turn "On" and "Off" A/C Switch. 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 148 Relay/Fuse Box (Engine Room) 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 2300 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 Diode: Locations 8. Fuse/Relay Box (Cover Removed) 40. Dash Fuse Box 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 2925 The wire insulation has one color or one color with another color stripe. The second color is the stripe. Page 1845 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 (gm/s). At idle, the Tech 2 should read between 4 - 7 gm/s 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 580 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. Page 6611 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 3045 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 1327 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 3200 CAUTION: Turn the SRS coil counter clockwise until some resistance is felt, or damage may occur to the SRS coil. 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 shaft 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 ground cable. Page 1965 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 2751 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 1274 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 641 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 5003 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 6162 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 Page 1000 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 MOhms or more Page 7755 Wiper Blade: Service and Repair Rear Window Rear Wiper Arm/Blade Rear Wiper Arm/Blade Removal 1. Remove the arm nut (2). 2. Remove the wiper arm/blade (1). Installation Refer to Rear Wiper Motor. Removal 1. Remove the arm nut (2). 2. Remove the wiper arm/blade (1). Installation Refer to Rear Wiper Motor. See: Wiper Motor Rear Wiper Blade Rubber Removal Page 233 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 7059 Low Fuel Lamp/Indicator: Description and Operation How the Circuit Works 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 fuel tank. When the fuel 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 PCM Tester. In the "ENGINE\MISC TESTS\FUEL GAUGE" menu, the PCM Tester can command the PCM to move the gauge in 10% increments. Page 4550 Bearing 1. Inspect excessive wear or damage. Replace the bearing if an abnormal noise is heard under normal operating condition. Page 226 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 Valve Guide Seal: Service and Repair For further information regarding this component and the system that it is a part of, please refer to Cylinder Head Assembly; Service and Repair. Page 5496 This chart should be used for diagnosing the electrical portion of the A/C compressor clutch circuit. A Tech 2 will be used in diagnosing the system. The Tech 2 has the ability to read the A/C request input to the PCM. The Tech 2 can display when the PCM has commanded the A/C clutch "ON". The Tech 2 should have the ability to override the A/C request signal and energize the A/C compressor relay. Steps 1 - 6 Page 7013 Each schematic represents one circuit. A circuit's wires and components are arranged to show current flow, from power at the top 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 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. Component Locations 76. Left Rear Door (Right Similar) Page 3992 4WD Control Unit Page 4905 ^ 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 3903 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 Page 5447 The wire insulation has one color or one color with another color stripe. The second color is the stripe. Dual Pressure Switch Refrigerant Pressure Sensor / Switch: Testing and Inspection Dual Pressure Switch Disconnect pressure switch connector and check for continuity between pressure switch side connector terminals (1) and (2). Page 2608 3. Connect the VSS electrical connector. 4. Check the transfer case oil level. Add fluid if necessary. 5. Connect the negative battery cable. Page 6144 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 2187 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 237 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 4305 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 functionality described. Replace if necessary. 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. Page 6646 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 5737 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 Carrier Side Gears: 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. Page 5066 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 5621 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 6974 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 3134 4. Secure the gasket and the throttle body with the four bolts. - 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). 5. Install the coolant lines. 6. Connect all the vacuum lines. 7. Install the intake. air duct. 8. Tighten the intake air duct clamp. 9. Connect all the electrical connectors: - Throttle position (TP) sensor. - Intake air temperature (IAT) sensor. Refer to Intake Air Temperature Sensor. 10. Install the accelerator cable assembly. Refer to Accelerator Cable in Engine Speed Control System. 11. Fill the cooling system. Refer to Cooling System. 12. Install the negative battery cable. Page 5973 Seat Belt: Testing and Inspection Page 1847 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 7572 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. Control Assembly / Control Cable Control Assembly: Service and Repair Control Assembly / Control Cable Control Lever Assembly, Control Cable And Associated Parts 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. 6. Pull the control lever assembly out and disconnect the fan switch and air conditioning switch connectors. Page 1523 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 5023 Above 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 begins in Wire Color Abbreviations. 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 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 Page 2022 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 (gm/s). At idle, the Tech 2 should read between 4 - 7 gm/s 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. Front Brake Caliper: Service and Repair Front Removal and Installation Removal 1. Raise the vehicle and support with suitable safety stands. 2. Concerning wheel and tire assembly, refer to Wheels, Tires and Alignment. 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. Page 5215 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 4574 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 4937 ^ 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 1967 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 7373 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. Locations Intake Air Temperature Sensor: Locations 26. Left Front of Engine IAT Sensor Locations 33. Bottom Center Front of Engine Page 5777 Evaporator Temperature Sensor / Switch: Description and Operation Electronic Thermostat The electronic thermostat senses the temperature of cool air from the evaporator by means of the evaporator temperature sensor This information determines whether the thermostat will provide ground to the thermo switch relay. When the temperature becomes too low, ground is not provided. OFF: Below 1.0 ± 0.5 °C (33.8 ± 0.9 °F) ON: Above 3.5 ± 0.3 °C (38.3 ± 0.9 °F) Page 7324 Each schematic represents one circuit. A circuit's wires and components are arranged to show current flow, from power at the top 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 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. Page 4360 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 2393 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 4042 Above 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 begins in Wire Color Abbreviations. 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 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 Page 4685 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 5809 - Refer to the scrapping procedures for disposal of the damaged airbag. Page 7712 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 5514 Condenser HVAC: Service and Repair Condenser Assembly and Associated Parts 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 pant 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 N.m (52 lb in) 2. Connect refrigerant line. - Tighten the inlet line connector fixing bolt to the specified torque. Torque: 15 N.m (11 lb.ft) - Tighten the outlet line connector fixing bolt to the specified torque. Torque: 6 N.m (52 lb in) - O-ring cannot be reused. Always replace with new ones. Page 3110 129 - Below Left Side Of I/P Locations 58. Under Center Console Page 4841 Relay/Fuse Box (Engine Room) Page 6902 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 Rear Window Regulator, Glass And Glass Run - Parts Locations Page 1741 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 1734 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 3024 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 4908 Alignment: Specifications Trim Height Trim Height .......................................................................................................................................... ................................. 119 +/- 5 mm (4.69 +/- 0.2 in.) Page 6628 Roof Rail Page 2408 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 3928 4. Install the rear companion flange (2) and O-ring (2). 5. Use the companion flange holder J-8614-11 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.) Locations 8. Fuse/Relay Box (Cover Removed) Control Lever Assembly and/or Control Cable Air Door Cable: Service and Repair Control Lever Assembly and/or Control Cable Control Lever Assembly, Control Cable And Associated Parts 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. 6. Pull the control lever assembly out and disconnect the fan switch and air conditioning switch connectors. Locations Air Flow Meter/Sensor: Locations 28. Left Side of Engine Compartment MAF Sensor 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. Specifications Power Steering Pump: Specifications Oil Pump Type Vane Operating Fluid ATF DEXRON-III 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 5421 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 Locations 14. Right Rear of Engine Compartment Page 6170 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 Relay Box: Locations Fuse To Component view, Image 6-2 Locations Rear Window Regulator, Glass And Glass Run - Parts Locations Page 4108 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/sec), 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 4084 Wheel Speed Sensor: Description and Operation Wheel Speed Sensor 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 front sensor rotor is attached to the each brake rotor by bolts. The rear rotor is press-fit in the differential case. The magnetic 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 6846 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 4542 Starter And Generator (V6) Page 1626 Heater Core: Service and Repair Heater Core And/or Mode Door - Disassembled View 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 2024 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. Tightening Specifications Flex Plate: Specifications Flywheel Fixing Bolts 54 Nm -- Do not reuse the bolts. Do not apply oil or thread lock to the bolts. Page 2367 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 2181 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 1416 Piston Ring: Service and Repair For further information regarding this component and the system that it is a part of, please refer to Cylinder Block Assembly; Service and Repair. Specifications Brake Pedal Assy: Specifications Pedal Free Play 6 - 10 mm Pedal Height 173 - 185 mm Page 2169 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. Page 6978 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 59. Under Center Console Page 5330 Page 245 2. Press down until the catch engages. - An audible "click" will be heard. 3. Install the fuse and relay box cover. Page 873 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 5746 Ground - "G" Shielding Sheilding This represents RFI (Radio Frequency Interference) shielding around a wire. The shielding is always connected to ground. Splices Page 813 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 1785 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 4345 Page 2639 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 7083 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 Diagram Information and Instructions Control Assembly: Diagram Information and Instructions How to Identify Wiring Color-Coded Insulation Wire Color Wire Color Coding Diagrams Page 7529 Trailer Lamps: Electrical Diagrams Trailer Lighting Connector Image 118-0 Service and Repair Antenna Mast: Service and Repair 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. See: Restraint Systems 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. Diagram Information and Instructions Blower Motor: Diagram Information and Instructions How to Identify Wiring Color-Coded Insulation Wire Color Wire Color Coding Page 3354 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 5585 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: 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 6064 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 2533 Oxygen Sensor: Testing and Inspection Inspection Procedure 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 louvered end of the sensor for grease, din, or other contaminations. 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 3773 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 Checking/Adjusting Oil For New Compressor Refrigerant Oil: Service and Repair Checking/Adjusting Oil For New Compressor Checking and Adjusting for Compressor Replacement 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 6109 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. Page 2829 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 44. Below Left Side of Dash Safety Stop Switch Sunroof/Moonroof Limit Switch: Service and Repair Safety Stop Switch 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 7166 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 3238 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 4038 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 1078 Check the specific gravity of engine coolant in the cooling system temperature ranges from 0°C to 50°C using a suction type hydrometer, then determine the density of the engine coolant by referring to the table. Page 2344 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 1016 Valve Inspection Chart Page 2250 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 1031 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 4356 Above 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 begins in Wire Color Abbreviations. 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 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 Page 7175 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 1427 Valve Shim Replacement Chart Page 3538 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. Page 744 129 - Below Left Side Of I/P Page 5370 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 221 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 4585 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 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. 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 24 The wire insulation has one color or one color with another color stripe. The second color is the stripe. Page 4501 Ignition Switch Lock Cylinder: Testing and Inspection System Inspection Turn the ignition switch to the "ON" position and observe the warning lamp. The lamp should flash 7 times. If the lamp does not operate correctly, refer to "Restraints". Page 442 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 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 6878 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. Specifications Torsion Bar: Specifications Torsion Bar Spring Length 1142 mm Diameter 27.0 mm 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 1326 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 - Disc - Caliper - Shift on the fly system parts (Cap, Hub flange, Shim, Snap ring) - ABS sensor ring Reassembly Page 1720 Individual circuit schematics begin with a fuse. The first half of Power Distribution, however, shows the wiring "upstream" between the battery 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 5741 Above 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 begins in Wire Color Abbreviations. 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 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 Page 4558 Brush Measure the length of brush. Replace with a new one, if it is below the limit. Brush Holder Check for continuity between brush holder (+) (4) and base (-). Replace, if there is continuity (i.e., insulation is broken). Brush Spring Use spring balancer to measure the spring setting force when remove the spring from the brush. Standard: 17.65 - 23.54 N (38.9 - 51.9 lb) Limit: 11.77 N (25.9 lb) Magnetic Switch Temporarily connect the magnetic switch between the overrunning clutch and housing. Perform the steps described below in 3 to 5 seconds. Page 6231 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 5146 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 parts: Stabilizer bar - Rubber bushing - Link INSTALLATION 1. Install rubber bushing. 2. Install bracket to axle housing and tighten to the specified torque. Torque: 25 Nm (119 ft. lbs.) 3. Install link. Page 4465 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 1726 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 6844 Ground - "G" Shielding Sheilding This represents RFI (Radio Frequency Interference) shielding around a wire. The shielding is always connected to ground. Splices Page 6809 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 6181 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 Vapor Pressure Sensor / Fuel Gage And Fuel Pump Connector Page 2649 VSS Image 33-0 Page 4546 Measure runout of the commutator with a dial gauge. Repair or replace, if it exceeds the limit. Polish the commutator surface with sandpaper #500 to #600 if it is rough. Measure the depth of insulator in commutator. Replace, if it is below the limit. 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 2512 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. Diagram Information and Instructions Cargo Lamp: Diagram Information and Instructions How to Identify Wiring Color-Coded Insulation Wire Color Wire Color Coding Page 5751 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 7524 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 Center Mounted Brake Lamp Bulb: Service and Repair Removal 1. Disconnect the battery ground cable. 2. Remove the cover. 3. Remove the bulb (1). - Remove the socket by turning it counterclockwise. Installation To install, follow the removal steps in the reverse order. Page 2202 DLC Page 6498 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. Service and Repair Keyless Entry Transmitter Battery: Service and Repair Transmitter Battery Replacement 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 3894 Control Module: Service and Repair 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. 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 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 8. Fuse/Relay Box (Cover Removed) Locations 39. Dash Fuse Box Page 421 Refrigerant Pressure Sensor / Switch: Service and Repair Pressure Switch And Associated Parts Pressure Switch 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 N.m (113 lb in) Page 7475 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 6142 - 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 2640 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. 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 6654 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 2985 Individual circuit schematics begin with a fuse. The first half of Power Distribution, however, shows the wiring "upstream" between the battery 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 2473 129 - Below Left Side Of I/P Page 6873 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 3118 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 6606 Moonroof Control Unit Connectors A And B Page 5432 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 6564 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 Safing Sensor: Locations The safing sensor is located inside the SRS Unit, refer to SRS Unit / Service and Repair. 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 6607 Sunroof / Moonroof Module: Service and Repair Sunroof Control Unit 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 2598 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 2151 129 - Below Left Side Of I/P Page 117 The wire insulation has one color or one color with another color stripe. The second color is the stripe. Page 2089 Spark Plug: Specifications Plug Torque 13 ft lb (18 Nm) Page 358 Parking Brake Warning Switch: Description and Operation Parking Brake Switch 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. Service and Repair Band Control Solenoid Valve: Service and Repair For further information regarding this component and the system that it is a part of, please refer to Shift Solenoid; Service and Repair. Page 630 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 2405 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 6343 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 4240 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 3323 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 Fuel Pressure Release: Service and Repair Fuel Pressure Relief Procedure CAUTION: To reduce the risk of fire and personal injury, there are necessary to relieve the fuel system pressure before filler and gauge unit 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 disconnect 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 3093 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 4502 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 ground 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 driver knee bolster (reinforcement). 7. 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 1841 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 7678 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 3802 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 541 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. 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 adapter case oil pan twelve fixing 10 mm screws, adapter case oil pan, and gasket. NOTE: Oil pan still contains transmission fluid. Place a large drain container under the oil pan and 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 11 mm bolt and converter clutch solenoid with two O-rings. 7. Remove 11 mm bolt, retainer, and force motor solenoid. Installation 1. Install force motor solenoid, retainer, and 11 mm bolt to adapter case valve body. Tighten the bolt to the specified torque. Torque: 10 Nm (87 inch lbs.) 2. Install converter clutch solenoid with two O-rings, and 11 mm bolt to adapter case valve body. Tighten the bolt to the specified torque. Torque: 10 Nm (87 inch lbs.) 3. Connect wiring harness assembly to solenoids. 4. Install adapter case oil pan, new gasket, and twelve 10 mm screws. Tighten the screws to the specified torque. Torque: 11 Nm (96 inch lbs.) 5. Fill transmission through overfill screw hole oil pan, using ATF DEXRON III. 6. Connect battery ground cable. Page 6312 - 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. Specifications Firing Order: Specifications Firing Order Firing Order Firing Order 1-2-3-4-5-6 Page 2653 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 Procedure 1. Install the VSS in the transfer case with the notch for the connector facing the rear. 2. Secure the VSS in place with the clamp and the bolt. Tighten Tighten the bolt to 16 N.m (12 lb.ft.). Page 4306 Make sure there is no rise in pressure while adjusting the bolt to the "5" line. There should be a pressure increase of 0.5 kg/cm2 or more. NOTE: When checking the front (or primary) side, be sure to mount the master cylinder plug in the rear (or secondary) port. 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. Component Locations 14. Right Rear of Engine Compartment Locations 59. Under Center Console Page 6058 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 7518 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 726 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 4476 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. 3. Check resistance between slip rings, and replace if there is no continuity. Page 4733 Audio, Clock, Cigarette Lighter And ACC Socket Page 2768 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 2984 Above 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 begins in Wire Color Abbreviations. 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 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 Page 3524 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. (4x4) Page 4632 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 5984 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 Locations 29. Left Side of Engine Compartment Page 5937 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 4611 Fuse To Component Index (Fuse No. 1 - 20) Image 6-3 Page 5333 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: 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 5479 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 823 ^ 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 2813 26. Left Front of Engine Page 3525 (4x2) 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. 4. Connect select cable. Diagrams Hydraulic Control Assembly - Antilock Brakes: Diagrams ELECTRONIC HYDRAULIC CONTROL UNIT AND ASSOCIATED PARTS Replacement Overhaul Page 4125 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 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 6270 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. Diagram Information and Instructions Horn: Diagram Information and Instructions How to Identify Wiring Color-Coded Insulation Wire Color Wire Color Coding Page 1467 Engine Oil: Testing and Inspection INSPECTION: 1. Park the vehicle on level ground, and turn off the engine. Allow the oil a few minutes to drain back into the oil pan so the dipstick will show the actual level. 2. Make certain that the oil level indicated on the dipstick is between the upper and lower marks. 3. If the level has dropped close to the lower mark, add oil until it reaches the upper mark. CAUTION: Insert the dipstick carefully to avoid bending it. Page 7510 Each schematic represents one circuit. A circuit's wires and components are arranged to show current flow, from power at the top 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 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. Specifications Exhaust Manifold: Specifications Exhaust Manifold LH 57 Nm RH 57 Nm Page 3495 ^ 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 4362 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 5616 Evaporator Case: Service and Repair Evaporator Assembly and Associated Parts 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. - 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 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 9 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 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. 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 6176 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. Specifications Power Steering Fluid: Specifications Power Steering Fluid ........................................................................................................................... ................................................................. Dexron III Page 6867 Individual circuit schematics begin with a fuse. The first half of Power Distribution, however, shows the wiring "upstream" between the battery 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 2637 Ground - "G" Shielding Sheilding This represents RFI (Radio Frequency Interference) shielding around a wire. The shielding is always connected to ground. Splices Page 7708 - 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. - 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 cutaway the surplus at the other end of the glass for length adjustment. Page 5201 - 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 3876 Transmission Temperature Sensor/Switch: Service and Repair Transmission Oil Temperature Sensor (Main Case) (V6) Removal 1. Raise the vehicle and support it on jack stands. 2. Disconnect battery ground cable. 3. Drain fluid. 4. Remove sixteen 10 mm main case oil pan fixing screws, main case oil pan, and gasket. 5. Disconnect wiring harness from shift solenoids, band apply solenoid, and 7 way 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 assembly with transmission oil temperature sensor to band apply solenoid, shift solenoids, and 7 way 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 inch lbs.) 3. Fill transmission through the overfill screw hole of oil pan, using ATF DEXRON III. 4. Connect battery ground cable. Page 159 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 2127 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. Service and Repair Valve: Service and Repair For further information regarding this component and the system that it is a part of, please refer to Cylinder Head Assembly; Service and Repair. 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 3015 Ground - "G" Shielding Sheilding This represents RFI (Radio Frequency Interference) shielding around a wire. The shielding is always connected to ground. Splices Page 2343 Oxygen Sensor: Testing and Inspection Inspection Procedure 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 louvered end of the sensor for grease, din, or other contaminations. Page 7753 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. Page 6851 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. Locations 53. Above Center of Dash (Console Removed) Page 2922 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 4073 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 3993 Control Module: Service and Repair 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 2070 Air Filter Element: Service and Repair Cleaning Method 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 5027 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 5038 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 7096 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 2579 Vehicle Speed Sensor Page 6293 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: Locations 48. Below Left Side of Dash Page 700 Vehicle Speed Sensor: Service and Repair Removal Procedure CAUTION: The VSS is located on the right side of the transfer case lust 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. Page 2513 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 4756 Each schematic represents one circuit. A circuit's wires and components are arranged to show current flow, from power at the top 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 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. Page 5930 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 5913 Driver's Inflator Module Connector Page 7477 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 7052 The wire insulation has one color or one color with another color stripe. The second color is the stripe. Page 1400 Crankshaft Main Bearing: Service and Repair For further information regarding this component and the system that it is a part of, please refer to Cylinder Block Assembly; Service and Repair. Page 1923 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 32 Alarm And Relay Controls Image 70-1 Locations 98. Top Rear of Fuel Tank Page 2996 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 9. Fuse/Relay Box (Cover Removed) Page 5857 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 6221 Each schematic represents one circuit. A circuit's wires and components are arranged to show current flow, from power at the top 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 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. Page 5540 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 6327 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 6911 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 1378 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 5492 Compressor Clutch: Locations 37. Left Lower Side of Engine Magnetic Clutch Assembly (DKV-14G Type) - Parts Location View Page 620 96. Rear of Right Catalytic Converter 93. Left Front Exhaust Downpipe Page 1821 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 Evaporator Temperature Sensor / Switch: Locations 65. Behind Glove Box Electronic Thermostat, Evaporator Core And/Or Expansion Valve - Disassembled View Page 241 Fuel Pump Relay: Testing and Inspection Relays Test This testis 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 1945 Vehicle Speed Sensor Description and Operation Transmission Temperature Sensor/Switch: Description and Operation Transmission Fluid Temperature (TFT) Sensor The transmission fluid temperature sensor is a thermistor which changes its resistance based on the temperature of the transmission fluid. For a complete description of the TFT sensor, refer to 4L30-E Automatic Transmission Diagnosis (Transmission Control System Diagnosis). A failure in the TFT sensor or associated wiring will cause DTC P0712 or DTC P0713 to set. In this case, engine coolant temperature will be substituted for the TFT sensor value and the transmission will operate normally. Page 6638 Sunshade - Disassembled View (LWB) Page 7072 5. Select F0: Malfunction Indicator Lamp. 6. Push "On" soft key. 7. Make sure Lamp illuminates. 8. If lamp illuminates, the Lamp is operating correctly 9. Select F2: Up Shift Lamp 10. Push "On" of soft key. 11. Make sure Lamp illuminates. 12. If Lamp illuminates, the Lamp is operating correctly. 13. Select F2: Low Fuel Lamp Page 7711 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 6841 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 6856 Brake System Indicator Light Image 71-0 Page 4805 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 Shift Indicator: Service and Repair A/T Shift Indicator Light Bulb Removal 1. Disconnect the battery ground cable. 2. Pry up the bended portions (2) of the metal cover (1). 3. Remove the meter lense (3) from the meter visor (4). 4. Remove the meter visor from the meter case (5). Page 3128 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 TP1 about 0.4 V, TP2 about 4.6 V and TP3 about 4.6 V. - If the reading is abnormal value, check the throttle shaft to see if it is binding. Page 2418 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 1624 Heater Mode Control Link Unit - Disassembled View Heater Temperature Control Link Unit - Disassembled View 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 6767 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 7138 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 1201 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 6989 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 6515 4. Check that the door lock operates smoothly. Exhaust Manifold LH Exhaust Manifold: Service and Repair Exhaust Manifold LH Removal 1. Disconnect battery ground cable. 2. Disconnect O2 sensor connector. 3. Remove exhaust front pipe three stud nuts from exhaust side and two bolts from rear end of exhaust front pipe 4. 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.) 2. Install exhaust front pipe and tighten three stud nuts and two bolts to the specified torque. Torque: Stud nuts: 67 Nm (49 ft. lbs.) Bolts: 43 Nm (32 ft. lbs.) 3. Reconnect O2 sensor connector. Page 348 Brake Fluid Level Sensor/Switch: Description and Operation Brake Fluid Level Switch 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 5410 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 5317 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. Oil and Filter Service Engine Oil: Service and Repair Oil and Filter Service ENGINE OIL Inspection 1. Park the vehicle on level ground, and turn off the engine. Allow the oil a few minutes to drain back into the oil pan so the dipstick will show the actual level. 2. Make certain that the oil level indicated on the dipstick is between the upper and lower marks. 3. If the level has dropped close to the lower mark, add oil until it reaches the upper mark. CAUTION: Insert the dipstick carefully to avoid bending it. Replacement CAUTION: Remove the drain bolt carefully while the engine is hot; the hot oil may cause scalding. 1. Warm up the engine. 2. Drain the engine oil. Page 4423 CAUTION: Turn the SRS coil counter clockwise until some resistance is felt, or damage may occur to the SRS coil. 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 shaft 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 ground cable. 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 2091 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 1.05 mm (0.04 in). NOTE: Do not adjust the spark plugs gap without new spark plugs. - Do not damage to tip of spark plugs. - Do not cleaning the spark plugs. If require the cleaning it due to heavy dirt, it is allowed only 20 seconds to be used spark plug cleaner. - 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 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 7136 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 4716 Individual circuit schematics begin with a fuse. The first half of Power Distribution, however, shows the wiring "upstream" between the battery 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 7237 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 4161 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 seal, boot ring and dust boot are to be replaced each time the caliper is overhauled. Discard these used rubber parts and replace them 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 inch lbs.) 3. 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 Above 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 begins in Wire Color Abbreviations. 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 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 Page 1525 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 1091 Fluid should be changed according to maintenance schedule. Page 5048 Steering Gear: Diagrams Page 5847 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 Fuse Block: Diagram Information and Instructions How to Identify Wiring Color-Coded Insulation Wire Color Wire Color Coding Service and Repair 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 To install, follow the removal steps in the reverse order, noting the following points. Torque: Nut (1) 8 Nm (69 inch lbs.) Page 2105 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 6589 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 1372 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 6419 ^ 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 2342 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 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 6286 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 4589 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. Specifications Engine Oil Pressure: Specifications Oil Pressure 392-550 kPa at 3000 rpm 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. Page 7256 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 1767 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 Canister Purge Control Valve: Locations 21. Top Front of Engine (Intake Duct Removed) Canister Purge Valve 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 7085 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 4054 Electronic Brake 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 517 The wire insulation has one color or one color with another color stripe. The second color is the stripe. Page 6031 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 2823 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. 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 5931 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 Door Switch: Locations 78. Left "C" Pillar (Right Similar) 77. Left "B" Pillar (Right Similar) 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 1273 3. Photocopy the template that is shown. Cut out the template. Page 7323 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 2485 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. Service and Repair Oil Pan: Service and Repair 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. (for 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 1257 14. Push "On" of soft key. 15. Make sure Lamp illuminates. 16. If Lamp illuminates, the Lamp is operating correctly. 17. Select F3: Reduced Power Lamp 18. Push "On" of soft key. 19. Make sure Lamp illuminates. 20. If Lamp illuminates, the Lamp is operating correctly. 21. Select F5: Cruise Control Lamp 22. Push "On" of soft key. 23. Make sure Lamp illuminates. 24. It Lamp illuminates, the Lamp is operating correctly. Specifications Power Steering Fluid: Specifications Power Steering Fluid ........................................................................................................................... ................................................................. Dexron III Page 7119 Fuel Gauge Sender: Service and Repair Fuel Gage Unit Removal and Installation Refer to Fuel Tank for removal and installation of the fuel gauge unit since the fuel gauge unit is linked to the fuel pump and sender. 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 1831 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 5247 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 7436 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. 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 2214 Steps 6 - 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. 10. Following DTC: Software detect Error for ETC system. 11. Following DTC: Software detect Error for ETC system. Page 6449 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. Specifications Firing Order: Specifications Firing Order Firing Order Firing Order 1-2-3-4-5-6 Page 2559 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 2432 Powertrain Control Module: Service and Repair Reprogramming the PCM EEPROM General Description The Electronically Erasable Programmable Read Only Memory (EEPROM) is a permanent memory that is physically soldered within the PCM. The EEPROM contains program and calibration information that the PCM needs to control powertrain operation. 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 one minute. 3. Scan for DTCs using the Tech 2. Page 2508 Fuel Tank Pressure Sensor: Service and Repair Removal Procedure 1. Remove the fuel pump assembly. Refer to Fuel Tank In Fuel Pump. 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. - Insert the sensor nipple firmly into the grommet. - Keep twisting and pushing the sensor until the wide portion of the nipple shows on the other side of the grommet. 3. Install the fuel pump assembly on the fuel tank. Refer to Fuel Tank In Fuel Pump. Page 4066 Electronic Brake Control Module: Description and Operation System Components Electronic Hydraulic Control Unit (EHCU), three Wheel Speed Sensors, Warning Light, and G-sensor. Electronic Hydraulic Control Unit (EHCU) The Electronic Hydraulic Control Unit (EHCU) consists of Anti-lock Brake System (ABS) control circuits, fault detector, and a fail-safe. The signal received from each sensor activates the hydraulic unit accordingly and cancels the ABS to return to normal braking if a malfunction occurs in the ABS system. 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 7472 Ground - "G" Shielding Sheilding This represents RFI (Radio Frequency Interference) shielding around a wire. The shielding is always connected to ground. Splices Page 3951 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. Page 6750 3. Photocopy the template that is shown. Cut out the template. Page 4199 Brake Rotor/Disc: Specifications Disc Type Ventilated Disc Thickness 18 mm Disc Effective Diameter 269.2 mm Front Brake Pad: Testing and Inspection Front Front Disc Brake Pads Inspection 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. Wear indicators are installed on disc brake pads, disc brake pads need replacement when the wear indicator is heard. Minimum limit (1): 1.0 mm (0.039 inch) Page 238 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 5527 Above 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 begins in Wire Color Abbreviations. 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 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 Diagram Information and Instructions Electronic Brake Control Module: Diagram Information and Instructions How to Identify Wiring Color-Coded Insulation Wire Color Wire Color Coding Page 7025 The wire insulation has one color or one color with another color stripe. The second color is the stripe. Page 5039 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. 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 7270 Cargo Lamp: Electrical Diagrams Ceiling, Cargo Area, Courtesy, And Map Lights Image 114-2 Recall - Fuel Return Hose Inspection/Replacement Technical Service Bulletin # 00-077 Date: 001017 Recall - Fuel Return Hose Inspection/Replacement 00-077 October 17, 2000 Applies To: 2001 Passport - See VEHICLES AFFECTED Safety Recall: Passport Fuel Return Hose BACKGROUND Some fuel return hoses were not properly treated for ozone protection during manufacture. The outer surface can deteriorate from contact with ozone in the atmosphere, and the hose can eventually crack and leak fuel. VEHICLES AFFECTED 2001 Passport: From VIN 4S6..58W.14400001 thru 4S6..58W.14401765 Not every vehicle in the above VIN range is subject to this recall. Refer to your campaign responsibility report for the individual affected VINs. According to Federal law, those vehicles cannot be sold or leased until they are repaired. CUSTOMER NOTIFICATION All owners of affected vehicles will be mailed a notification of this recall. An example of the customer notification is at the end of this service bulletin. CORRECTIVE ACTION Inspect the fuel return hoses to determine the lot number. Replace any fuel return hose with a lot number of 0707. PARTS INFORMATION Fuel Return Hose: P/N 8-97165-096-1, H/C 5649793 Fuel Hose Assembly (Manual Transmission): P/N 8-97233-142-1, H/C 6391197 Fuel Hose Assembly (Automatic Transmission): P/N 8-97233-141-1, H/C 6391189 12 mm Hose Clamp: P/N 8-97148-892-0, H/C 5421441 11.5 mm Hose Clamp: P/N 8-97173-219-0, H/C 5421474 Page 7682 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. Locations 58. Under Center Console Page 6007 Ground - "G" Shielding Sheilding This represents RFI (Radio Frequency Interference) shielding around a wire. The shielding is always connected to ground. Splices Page 4517 Starter Motor: Locations 35. Bottom Left of Engine Disassembled View Page 3767 (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 Preload should be 0 to 49 N (0 to 11.0 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. Page 1126 4. After the rubber seal seats, tighten the oil filter clockwise with the tool. Tightening torque: 22 Nm (2.2 kgf.m, 16 ft. lbs.) CAUTION: Using any procedure other than shown could result in serious engine damage due to oil leakage. 5. After installation, fill the engine with oil up to the specified level, run the engine for more than three minutes, then check for oil leakage. Page 81 Electronic Brake Control Module: Electrical Diagrams Circuit Diagram Part 1 of 3 Page 4223 10. Remove hold-down spring and cup (3) and hold-down pin (16). 11. Remove trailing shoe assembly (7) with parking brake lever (16). 12. Remove parking brake cable from parking brake lever (11). 13. Remove retainer (14), wave washer (13), and parking brake lever (11). Brake Lining Inspection Check the shoe assemblies for wear by removing brake drum. Replace the shoe assemblies, if lining thickness is less than 1.0 mm (0.039 inch). The shoe assemblies have a wear indicator that makes a noise when the linings wear to a degree where replacement is required. Minimum limit: 1.0 mm (0.039 inch) Installation 1. Apply grease lightly to back place A. 2. Install parking brake lever (11), wave washer (13), and retainer (14). 3. Install trailing shoe assembly (7) with parking brake lever (16). 4. Install the parking brake cable to parking brake lever (11). 5. Install hold-down pin (16) and hold-down spring and cup (3). 6. Install upper (inner) return spring (9). 7. Install leading shoe assembly (8) with upper (inner) return spring (9). Page 2338 Oxygen Sensor: Connector Locations 93. Left Front Exhaust Downpipe 94. Rear of Left Catalytic Converter Page 208 1. Install the PCM to bracket and fix with the clip. 2. Connect the PCM electrical connectors. 3. Install the two screws to PCM electrical connectors. Page 4872 ^ 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 4543 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 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. Page 4866 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 6756 Tailgate Lock Cylinder: Service and Repair Tailgate Lock and Hatchgate Lock (LWB) Tailgate Lock, Hatchgate Lock And Associated Parts (LWB) Removal 1. Disconnect the battery ground cable 2. Remove the tailgate trim cover assembly (3). - Remove the 2 screws (2) holding the hatchgate 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. Page 1483 4. Install axle housing assembly and tighten to the specified torque. (for 4x4) Axle case bolts Torque: 82 Nm (61 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 (33 ft. lbs.) 7. Install suspension cross member 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 4255 5. Remove guide bolt (2). 6. Remove lock bolt (3). 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. 2. Apply special grease (approximately 0.2 g) to both contacting surfaces of the inner shims (4). Wipe off extruded grease after installing. Install pad assembly with shim. Page 7050 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 1068 Brake Fluid: Service and Repair 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. Diagram Information and Instructions Electronic Brake Control Module: Diagram Information and Instructions How to Identify Wiring Color-Coded Insulation Wire Color Wire Color Coding Page 4818 The wire insulation has one color or one color with another color stripe. The second color is the stripe. Page 5670 Housing Assembly HVAC: Service and Repair Blower Link Unit and/or Mode Door Blower Link Unit And/or Mode Door - Disassembled View 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 lace with a knife. 7. Pull out the mode door while raising up the catch of door lever. 8. Remove sub-lever. 9. Remove door lever. Installation 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. Refer to Maintenance and Lubrication in General Information for maintenance information and servicing interval. 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 NO T 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. Fluid Condition Page 5534 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 194 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 4815 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 5599 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 1227 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 487 7. Loosen the inflator module fixing bolt from behind the steering wheel assembly using a T0RX(R) 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 TRIM COVER AWAY FROM YOUR BODY AND SHOULD ALWAYS BE LAID ON A FLAT SURFACE WITH ' THE URETHANE SIDE UP. THIS IS NECESSARY BECAUSE FREE SPACE IS PROVIDED TO ALLOW THE AIR CUSHION TO EXPAND IN THE UNLIKELY EVENT OF ACCIDENTAL DEPLOYMENT. OTHERWISE, PERSONAL INJURY MAY RESULT. 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. Page 4285 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 as described. Page 2816 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 Capacity Specifications Fluid - M/T: Capacity Specifications M/T Fluid Capacity ............................................................................................................................................... ......................................................................... 2.95L Page 7445 Combination Switch: Connector Locations 45. Below Left Side of Dash 46. Below Left Side of Dash Safety Stop Switch Sunroof/Moonroof Limit Switch: Service and Repair Safety Stop Switch 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 7545 7. Loosen the inflator module fixing bolt from behind the steering wheel assembly using a T0RX(R) 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 TRIM COVER AWAY FROM YOUR BODY AND SHOULD ALWAYS BE LAID ON A FLAT SURFACE WITH ' THE URETHANE SIDE UP. THIS IS NECESSARY BECAUSE FREE SPACE IS PROVIDED TO ALLOW THE AIR CUSHION TO EXPAND IN THE UNLIKELY EVENT OF ACCIDENTAL DEPLOYMENT. OTHERWISE, PERSONAL INJURY MAY RESULT. 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. Page 3720 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 6187 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 1231 Fuse Block: 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. 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 44. Below Left Side of Dash 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 4131 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 6812 Above 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 begins in Wire Color Abbreviations. 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 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 Page 2360 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 7078 Parking Brake Warning Switch: Description and Operation Parking Brake Switch 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 1352 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 7577 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 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 2007 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). Locations 59. Under Center Console Page 2940 9. If removal of the fuel injectors is necessary, refer to Fuel Injectors. Installation Procedure 1. If the fuel injectors were removed, install them. Refer to Fuel Injectors. 2. If the fuel pressure regulator was removed, install it. Refer to Fuel Pressure Regulator. 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 6254 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. Locations 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. Front Wheel Speed Sensor: Testing and Inspection 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. Page 2619 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) (V6). 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 Page 5661 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 3377 Actuator: Testing and Inspection Axle Shaft Connection and Disconnection Actuator Assembly 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 567 129 - Below Left Side Of I/P Page 4799 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 6593 Suzuka (Japan) Produced Cars, VIN: JHMRD _ _ _ *1S _ _ _ _ _ _ (CR-V) JHMEM _ _ _ *1S _ _ _ _ _ _ (Civic) Passport Paint Suppliers American Honda does not endorse any paint company or type of paint; this information is for reference only. Disclaimer Page 5755 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 7482 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 677 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 3043 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 1598 Water Pump: Service and Repair 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 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. 2. Install water pump assembly and tighten bolts to the specified torque. Torque: 25 Nm (18 ft. lbs.) Tightening order The tightening order are in the illustration. NOTE: To prevent the oil leakage, apply the LOCTITE 262 or an equivalent, to the arrow marked fixing bolt thread. 3. Idle pulley Page 77 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 1751 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 the 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. 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. Diagrams Rear Hatchgate (LWB) Page 5919 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 5667 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 1960 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 5255 Page 1587 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 4516 Torque Specification (Part 2) Page 6823 The wire insulation has one color or one color with another color stripe. The second color is the stripe. Page 4127 Each schematic represents one circuit. A circuit's wires and components are arranged to show current flow, from power at the top 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 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. Specifications Compression Check: Specifications Compression Pressure Limit 1,000 kPa Compression Ratio 9.1 : 1 Copmression Pressure At 300 rpm 145 psi. Page 5305 ^ 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 5400 Air Register: Service and Repair Rear Heater Duct, Defroster Nozzle, Ventilation Duct And Associated Parts 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. Diagrams Hazard Warning Switch Component Locations 92. Beneath Center of Vehicle, on Transfer Case (A/T) Page 5316 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. Radial Tire Waddle 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 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. Radial Tire Lead/Pull Correction Chart Radial Tire Lead/Pull Correction Chart Page 7756 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 7366 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. Page 1667 - 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 EC. 6. Connect battery ground 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). Locations Housing Assembly HVAC: Locations Heater Core And/or Mode Door - Disassembled View Page 5839 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 2828 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 5244 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). Procedures Power Mirror Switch: Procedures 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 4729 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 2282 Fuel Tank Pressure Sensor: Service and Repair Removal Procedure 1. Remove the fuel pump assembly. Refer to Fuel Tank In Fuel Pump. 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. - Insert the sensor nipple firmly into the grommet. - Keep twisting and pushing the sensor until the wide portion of the nipple shows on the other side of the grommet. 3. Install the fuel pump assembly on the fuel tank. Refer to Fuel Tank In Fuel Pump. Page 3734 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. Page 73 Electronic Brake 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 2106 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 1345 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 3669 Axle Disconnect Controller 1. Connect 12V with terminal (3) and the ground with the terminal (6). 2. Send the signal to the terminal (4) 2WD -> 4WD less than 2.4V 4WD -> 2WD more than 9.0V 3. Confirm the output signal from the terminals (1) & (2) (2 seconds output) 4. If the trouble occurs after test, charge the Axle Disconnect Controller to the new one. Motor Actuator Assembly (Transfer) Inspect the function of the motor actuator assembly as follows: 1. Disassemble the motor actuator from transfer rear case. Page 6077 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 7126 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 6619 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 6591 Paint: Technical Service Bulletins Paint - 2001 Paint Codes 01-001 January 16, 2001 Applies To: 2001 Models ALL 2001 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. The number following the paint description is the paint process used during the vehicle manufacture. 1: Two-stage process. Clear coat is applied over the color coat. 2: Two-stage process. A small amount of color is mixed in the clear coat and applied over the color coat. 3: Single-stage process. No clear coat is applied. Sayama (Japan) Produced Cars, VIN: JHMBB6 _ _ *1C _ _ _ _ _ _ (Prelude) JHLRD _ _ _ *1C _ _ _ _ _ _ (CR-V) JHM _ _ _ _ _ *1C _ _ _ _ _ _ (Accord) Marysville (U.S.) Produced Cars, VIN: 1HG _ _ _ _ _ *1A _ _ _ _ _ _ (Accord) Page 3016 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 8. Fuse/Relay Box (Cover Removed) 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 adapter case oil pan twelve fixing 10 mm screws, adapter case oil pan, and gasket. NOTE: Oil pan still contains transmission fluid. Place a large drain container under the oil pan and 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 11 mm bolt and converter clutch solenoid with two O-rings. 7. Remove 11 mm bolt, retainer, and force motor solenoid. Installation 1. Install force motor solenoid, retainer, and 11 mm bolt to adapter case valve body. Tighten the bolt to the specified torque. Torque: 10 Nm (87 inch lbs.) 2. Install converter clutch solenoid with two O-rings, and 11 mm bolt to adapter case valve body. Tighten the bolt to the specified torque. Torque: 10 Nm (87 inch lbs.) 3. Connect wiring harness assembly to solenoids. 4. Install adapter case oil pan, new gasket, and twelve 10 mm screws. Tighten the screws to the specified torque. Torque: 11 Nm (96 inch lbs.) 5. Fill transmission through overfill screw hole oil pan, using ATF DEXRON III. 6. Connect battery ground cable. Page 1330 11. Install snap ring and shim. - Adjust the clearance between the free wheeling hub body and the snap ring. Clearance: 0 mm 0.3 mm (0 in - 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. 13. Tighten the bolts to the specified torque. Torque: 59 Nm (43 ft. lbs.) Component Locations 99. Under Rear of Vehicle (On Differential) Page 5998 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 2774 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 5837 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 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 5538 The wire insulation has one color or one color with another color stripe. The second color is the stripe. Page 2104 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. 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. Locations Front Window Regulator, Glass And Glass Run - Parts Location Page 7683 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 1425 Valve Inspection Chart Page 3682 Differential Axle Housing: Service and Repair Rear Differential 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 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. 8. Disconnect the ABS connectors (1) and remove the brackets attached to the frame and center link. Page 1962 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 2915 Individual circuit schematics begin with a fuse. The first half of Power Distribution, however, shows the wiring "upstream" between the battery 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 5242 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 4681 Grounding Point: 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 6134 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 5788 Refrigerant Pressure Sensor / Switch: Service and Repair Pressure Switch And Associated Parts Pressure Switch 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 N.m (113 lb in) Page 2190 Ground - "G" Shielding Sheilding This represents RFI (Radio Frequency Interference) shielding around a wire. The shielding is always connected to ground. Splices Page 3279 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) (V6). 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 Page 6461 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 Specifications Timing Belt: Specifications Replace Timing Belt every 75,000 miles (120,000 km) Locations 58. Under Center Console Page 6881 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 2923 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 2566 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 TP1 about 0.4 V, TP2 about 4.6 V and TP3 about 4.6 V. - If the reading is abnormal value, check the throttle shaft to see if it is binding. Page 6015 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. Specifications Brake Drum: Specifications Drum Inside Diameter 210 mm Page 2447 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 4680 The wire insulation has one color or one color with another color stripe. The second color is the stripe. Page 6005 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. Gas Tank - Fuel Pump/Sending Unit Installation Tip Fuel Gauge Sender: Technical Service Bulletins Gas Tank - Fuel Pump/Sending Unit Installation Tip SOURCE: Honda Service News March 2003 TITLE: Installing an In-Tank Fuel Pump/Sending Unit? Don't Forget a New Base Gasket, Locknut, and Fuel Line Retainers APPLIES TO: See Models Listed In Illustration SERVICE TIP: Whenever you install an in-tank fuel pump/sending unit into a plastic fuel tank, the S/M tells you to install a new base gasket. But did you know you also need to replace the locknut and the fuel line retainers as well? Make a note in the Fuel Supply System subsection of the appropriate S/Ms to also replace the locknut and the fuel line retainers. Then follow this handy chart to order the appropriate parts. Install the new gasket on the fuel tank side, not on the fuel pump/sending unit side; this ensures that the gasket doesn't get pinched or rolled. If you don't install the fuel pump/sending unit correctly, the MIL could come on with an EVAP control system leakage DTC set. The gasket and the locknut are currently available in Honda parts stock under separate part numbers. But soon, they'll be packaged under a single part number. The fuel sending unit, gasket, and locknut will also be packaged together under a single part number. The gasket and the locknut will then be discontinued as separate part numbers. Page 5371 Ground - "G" Shielding Sheilding This represents RFI (Radio Frequency Interference) shielding around a wire. The shielding is always connected to ground. Splices Page 2586 Above 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 begins in Wire Color Abbreviations. 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 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 Page 1705 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 1924 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). 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. BLEEDING BRAKE HYDRAULIC SYSTEM 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. When replenishing the brake fluid reservoir, carefully pour in the brake fluid to prevent air bubbles from entering the brake system. 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 described. Bleeding the Master Cylinder 7. Disconnect the rear wheel brake pipe (1) from the master cylinder. Check the fluid level and replenish as necessary. If replenished, leave the Page 3285 57. Top of Transfer Case Page 109 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 5918 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 6871 Ground - "G" Shielding Sheilding This represents RFI (Radio Frequency Interference) shielding around a wire. The shielding is always connected to ground. Splices Page 5306 Tires: Specifications P225/75R16 Pressure Front 200 kPa Rear 200 kPa P245/70R16 Pressure Front 200 kPa Rear 180 kPa Page 7658 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 5367 Individual circuit schematics begin with a fuse. The first half of Power Distribution, however, shows the wiring "upstream" between the battery 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 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 Locations Fuse Block: Locations Fuse To Component Index (Fuse No. 1 - 10) Image 6 Page 4259 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 (approximately 1 g) onto the dust boot inner surface. 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: 74 Nm (54 ft. lbs.) Page 7400 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 7102 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 3496 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 2389 30. Left Side of Engine Compartment Page 1972 Vehicle Speed Sensor: Service and Repair Removal Procedure CAUTION: The VSS is located on the right side of the transfer case lust 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. 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 184 The wire insulation has one color or one color with another color stripe. The second color is the stripe. Page 3057 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 Window Track: Locations Front Window Regulator, Glass And Glass Run - Parts Location Page 186 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 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. Page 2562 27. Left Side of Engine Diagram Information and Instructions Condenser Fan: Diagram Information and Instructions How to Identify Wiring Color-Coded Insulation Wire Color Wire Color Coding Page 7414 Parking, Tail, And Licence Lights Image 110-1 Page 938 ^ 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 2899 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 5875 Driver's Inflator Module Connector Page 585 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. Refer to Electronic Ignition System for additional information. Locations 59. Under Center Console Page 3828 Transmission Temperature Sensor/Switch: Service and Repair Transmission Oil Temperature Sensor (Main Case) (V6) Removal 1. Raise the vehicle and support it on jack stands. 2. Disconnect battery ground cable. 3. Drain fluid. 4. Remove sixteen 10 mm main case oil pan fixing screws, main case oil pan, and gasket. 5. Disconnect wiring harness from shift solenoids, band apply solenoid, and 7 way 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 assembly with transmission oil temperature sensor to band apply solenoid, shift solenoids, and 7 way 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 inch lbs.) 3. Fill transmission through the overfill screw hole of oil pan, using ATF DEXRON III. 4. Connect battery ground cable. Page 6863 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 5235 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 511 Ground - "G" Shielding Sheilding This represents RFI (Radio Frequency Interference) shielding around a wire. The shielding is always connected to ground. Splices Page 6277 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 7229 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 6140 ^ 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, 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 930 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 5379 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 7099 Seat Belt Reminder 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 19 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 5420 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). 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. Specifications Fuel Injector: Specifications Information not provided by the manufacturer. Page 6219 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 3060 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. 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 Capacity Specifications Coolant: Capacity Specifications Total Cooling System Capacity M/T 11.1 L A/T 10.0 L Engine Coolant Capacity M/T 2.5 L A/T 2.4 L Page 5189 REQUIRED MATERIALS TOOL INFORMATION Page 5982 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 Page 106 Above 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 begins in Wire Color Abbreviations. 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 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 Page 6174 Above 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 begins in Wire Color Abbreviations. 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 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 Specifications Firing Order: Specifications Firing Order Firing Order Firing Order 1-2-3-4-5-6 Page 4061 Part 3 of 3 Page 693 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 6875 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 950 ^ 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 2960 WARRANTY CLAIM INFORMATION INSPECTION PROCEDURE 1. Raise the vehicle on a hoist. 2. Pull back the insulation on the fuel return hose. Examine the hose for the lot number. Record the lot number. Page 2023 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 1. Install the MAF sensor on the air cleaner with the clamp. Page 3101 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 2817 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 4258 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 seal, boot ring and dust boot are to be replaced each time the caliper is overhauled. Discard these used rubber parts and replace them 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 inch lbs.) 3. 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 7519 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 4755 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 5130 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: 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: 78 Nm (58 ft. lbs.) Locations Air Flow Meter/Sensor: Locations 28. Left Side of Engine Compartment MAF Sensor Page 5929 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 4891 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 Gas Tank - Fuel Pump/Sending Unit Installation Tip Fuel Gauge Sender: Technical Service Bulletins Gas Tank - Fuel Pump/Sending Unit Installation Tip SOURCE: Honda Service News March 2003 TITLE: Installing an In-Tank Fuel Pump/Sending Unit? Don't Forget a New Base Gasket, Locknut, and Fuel Line Retainers APPLIES TO: See Models Listed In Illustration SERVICE TIP: Whenever you install an in-tank fuel pump/sending unit into a plastic fuel tank, the S/M tells you to install a new base gasket. But did you know you also need to replace the locknut and the fuel line retainers as well? Make a note in the Fuel Supply System subsection of the appropriate S/Ms to also replace the locknut and the fuel line retainers. Then follow this handy chart to order the appropriate parts. Install the new gasket on the fuel tank side, not on the fuel pump/sending unit side; this ensures that the gasket doesn't get pinched or rolled. If you don't install the fuel pump/sending unit correctly, the MIL could come on with an EVAP control system leakage DTC set. The gasket and the locknut are currently available in Honda parts stock under separate part numbers. But soon, they'll be packaged under a single part number. The fuel sending unit, gasket, and locknut will also be packaged together under a single part number. The gasket and the locknut will then be discontinued as separate part numbers. Page 7146 Seat Belt, Lights-on, And Ignition Key Reminders Image 73-1 Page 794 Ignition Switch Lock Cylinder: Testing and Inspection System Inspection Turn the ignition switch to the "ON" position and observe the warning lamp. The lamp should flash 7 times. If the lamp does not operate correctly, refer to "Restraints". Page 4336 Vacuum Brake Booster: Diagrams Locations 14. Right Rear of Engine Compartment Page 2724 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 6996 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 3608 Pressure Plate: 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. Page 6943 Dimmer Switch: Service and Repair Illumination Controller 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 3506 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. 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 Page 3590 Clutch Slave Cylinder: Description and Operation Slave Cylinder 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. Page 6065 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 6486 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. Page 976 3. Install the air cleaner lid on the MAF sensor and the air cleaner housing. 4. Tighten the clamp and secure the four latches between the lid and the air cleaner housing. Induction System 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). Page 6179 Ground - "G" Shielding Sheilding This represents RFI (Radio Frequency Interference) shielding around a wire. The shielding is always connected to ground. Splices Page 2705 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. Locations 62. Front of Roof (Headliner Removed) Page 4137 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 6568 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 7252 Each schematic represents one circuit. A circuit's wires and components are arranged to show current flow, from power at the top 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 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. Page 2174 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. Refer to Electronic Ignition System for additional information. Component Locations Oxygen Sensor: Component Locations HO2S (Sensor) 94. Rear of Left Catalytic Converter Page 5341 4. Use installer J-36828 and grip J-8092 then install the outer bearing by driving it into the hub. 5. Apply grease (NLGI 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. Grease Amount Hub: 35 g (1.23 oz) Outer bearing: 10 g (0.35 oz) Inner bearing: 15 g (0.53 oz) Page 1453 Drive Belt: Service and Repair Drive Belt and Cooling Fan The drive belt adjustment is not required as automatic drive belt tensioner is equipped. Removal Move the tension pulley drive belt loosen side, remove the drive belt. Inspection Check drive belt for wear or damage, and replace with a new one as necessary. Installation 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 98MY-> 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 <-97MY 6VD1 with no interchangeability. Therefore, incorrect installation of a fan may cause the air to flow in the opposite direction, thus resulting in poor performance of the air conditioner and an increase in engine water temperature. Description and Operation Refueling Vapor Recovery System: Description and Operation Fuel vapor recovery system Separator attaches after hose evaporative fuel. It protects EVAP Canister from liquid fuel. It guarantees EVAP Canister performance. When vibration bounces fuel level, liquid fuel will accrete to EVAP Canister. It separates liquid fuel. Page 4675 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 2836 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 6306 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. Initial Inspection and Diagnostic Overview Powertrain Control Module: Initial Inspection and Diagnostic Overview Functional Check 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 4183 1. Install clip. 2. Apply special grease (approximately 0.2 g) to both contacting surfaces of the inner shims (2). Wipe off extruded grease after installing. Install pad assembly with shim. Page 5264 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 623 95. Right Front Exhaust Downpipe 96. Rear of Right Catalytic Converter Page 79 Part 2 of 3 Page 1373 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. Description and Operation Transmission Temperature Sensor/Switch: Description and Operation Transmission Fluid Temperature (TFT) Sensor The transmission fluid temperature sensor is a thermistor which changes its resistance based on the temperature of the transmission fluid. For a complete description of the TFT sensor, refer to 4L30-E Automatic Transmission Diagnosis (Transmission Control System Diagnosis). A failure in the TFT sensor or associated wiring will cause DTC P0712 or DTC P0713 to set. In this case, engine coolant temperature will be substituted for the TFT sensor value and the transmission will operate normally. 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 3719 6. Break retainer ring with hammer and chisel. 7. Break bearing cane 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 spelling or grooves from seal wear. ^ Retainer - bent or damaged. ^ Replace items if required. Installation 1. Emergency brake assembly. Page 7365 The wire insulation has one color or one color with another color stripe. The second color is the stripe. Electrode Gap Spark Plug: Specifications Electrode Gap 0.040 in (1.05 mm) Page 3268 Control Module: Service and Repair 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 1392 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. 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 3049 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 6504 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. 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). Locations Ignition Control Module: Locations 24. Top Rear of Engine ION Sensing Module Page 559 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. 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 5506 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 4124 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 3023 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 5893 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 6320 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 459 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 83 Part 3 of 3 Component Locations Fuel Injector: Component Locations 22. Left Side of Engine Page 5212 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 1900 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 1366 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. Page 10 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 51. Behind Gauge Assembly Page 6633 Roof Rack Frame: Service and Repair Roof Rail - Parts Location 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) 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 1124 1. Remove the oil filter with the special oil filter wrench. 2. Inspect the threads and rubber seal on the new filter. Wipe off the seat on the engine block, then apply a light coat of oil to the filter rubber seal. NOTE: Use only filters with a built-in bypass system. 3. Install the oil filter by hand. 4. After rubber seal seats, tighten the oil filter three quarter turn, then torque it with the special tool. Tighten: three quarter turn clockwise. Tightening torque: 22 Nm (2.2 kgf.m, 16 ft. lbs.) Eight numbers (1 to 8) are printed on the surface of the filter. The following explains the procedure for tightening filters using these numbers. 1) Make a mark on the engine oil cooler under the number that shows at the bottom of the filter when the rubber seal is seated. 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 6966 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 565 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 6876 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 7125 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 4682 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 5560 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 6423 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 3758 Page 7473 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 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. Diagrams Refrigerant Line and Associated Parts Description and Operation Lateral Accelerometer: Description and Operation G-SENSOR/LATERAL ACCELEROMETER The G-sensor installed inside the Electronic Hydraulic Control Unit (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 Anti-lock Brake System (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 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 2618 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 4L30-E Automatic Transmission (Transmission Control System Diagnosis). Page 2017 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. Diagrams Diagram Information and Instructions Clock: Diagram Information and Instructions How to Identify Wiring Color-Coded Insulation Wire Color Wire Color Coding Page 5970 Torque Specifications Part 3 Page 4787 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 5533 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 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 To install, follow the removal steps in the reverse order, noting the following points. Torque: Nut (1) 8 Nm (69 inch lbs.) Page 6078 Alarm And Relay Control Unit Connectors A And B Page 7342 Headlamp Switch: Electrical Diagrams Headlight Switch Image 100-0 Locations Safing Sensor: Locations The safing sensor is located inside the SRS Unit, refer to SRS Unit / Service and Repair. Page 5650 To install follow the removal steps in the reverse order noting the following point; 1. Check that each mode door operates properly. Page 733 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 4138 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 2388 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 5688 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 64. Behind Glove Box Page 320 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 6964 Above 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 begins in Wire Color Abbreviations. 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 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 Page 1145 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 6206 Hood Sensor/Switch (For Alarm): Service and Repair Engine Hood Switch 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 2765 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). Tire Rotation Tires: Service and Repair Tire Rotation Tire Rotation Tire rotation is recommended to equalize wear for longer tire life. If the 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 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 7582 Vanity Lamp: Service and Repair Vanity Mirror Illumination Light Bulb 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. 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. Diagrams Page 3725 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. Page 4367 The wire insulation has one color or one color with another color stripe. The second color is the stripe. Page 886 Rear Wiper/Washer Switch Page 5938 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. Front Brake Rotor/Disc: Specifications Disc Type Ventilated Disc Thickness 26 mm Disc Effective Diameter 222 mm Page 5660 Hose/Line HVAC: Service and Repair Repair Of Refrigerant Leaks Repair Of Refrigerant Leaks Refrigerant Line Connections 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. O-ring (2) must be fitted in the groove (1) of refrigerant line Page 3482 57. Top of Transfer Case Page 1956 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 2587 Individual circuit schematics begin with a fuse. The first half of Power Distribution, however, shows the wiring "upstream" between the battery 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 3740 Wheel Bearing: Service and Repair 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. 9. Use wrench J-36827, remove hub nut. 10. Remove hub and disc assembly. Dual Pressure Switch Refrigerant Pressure Sensor / Switch: Testing and Inspection Dual Pressure Switch Disconnect pressure switch connector and check for continuity between pressure switch side connector terminals (1) and (2). Page 7605 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 3576 Clutch Disc: 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. Page 685 Ground - "G" Shielding Sheilding This represents RFI (Radio Frequency Interference) shielding around a wire. The shielding is always connected to ground. Splices Page 7527 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 1827 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 - 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 6489 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 26 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 7093 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 1178 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 1718 Each schematic represents one circuit. A circuit's wires and components are arranged to show current flow, from power at the top 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 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. Locations 10. Fuse/Relay Box (Cover Removed) Page 4163 Brake Caliper: Service and Repair Rear 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. Page 2822 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 Crankshaft Position Sensor: Locations 36. Bottom Right Side of Engine CKP Sensor Page 5214 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 6997 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 2891 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 15 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 2176 Crankshaft Position Sensor: Service and Repair Removal 1. Disconnect battery ground cable 2. Wiring connector from crankshaft position sensor. 3. Remove crankshaft position sensor from cylinder block. Installation 1. Install crankshaft position sensor into the cylinder block. Before installation,apply small amount of engine oil to the O-ring. Torque: 10 N.m (87 lb.in) 2. Reconnect wiring connector to crankshaft position sensor. 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 4619 Above 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 begins in Wire Color Abbreviations. 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 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 Front Brake Caliper: Specifications Type Floating, Pin Slide Adjusting Method Self-Adjusting Piston Diameter 60.33 mm Page 901 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 2262 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 229 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 4627 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 6973 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 7165 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 2534 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. Locations 53. Above Center of Dash (Console Removed) Diagram Information and Instructions Fuel Tank Unit: Diagram Information and Instructions How to Identify Wiring Color-Coded Insulation Wire Color Wire Color Coding Page 5932 - Refer to the scrapping procedures for disposal of the damaged airbag. Page 4483 6. Separate the rear cover from the stator. 7. Remove bolts which secure stator terminal to rectifier terminal and remove stator 8. Remove Bolts which secure regulator, rectifier and brush-holder, and separate these parts. 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. Front Door Lock Door Locks: Service and Repair Front Door Lock Front Door Lock Assembly And Associated Parts 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. Page 1149 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. Component Locations 73. Rear of Driver's Door (Frt. Pass. Similar) Page 3108 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 1591 Description and Operation Temperature Gauge: Description and Operation The 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 5396 Air Duct: Service and Repair Rear Heater Duct, Defroster Nozzle, Ventilation Duct And Associated Parts 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 5436 Above 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 begins in Wire Color Abbreviations. 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 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 Page 5818 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 7575 The wire insulation has one color or one color with another color stripe. The second color is the stripe. Page 1067 Brake Fluid: Service Precautions 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 1341 Jump Starting: Service and Repair 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. Jump Starting Procedure 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 will 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 2950 3. Inspect the end of either hose in the fuel hose assembly. Record the lot number. 4. Check the lot numbers you recorded. ^ If the fuel return hose has the lot number 0707 or both the fuel return hose and the fuel hose assembly have the lot number 0707, go to FUEL RETURN HOSE REPLACEMENT ^ If only the fuel hose assembly has the lot number 0707, go to FUEL HOSE ASSEMBLY REPLACEMENT ^ If you cannot determine the lot number of a hose, replace the hose. Go to the appropriate procedure. ^ If none of the hoses have the lot number 0707 go to COMPLETION PROCEDURE. FUEL RETURN HOSE REPLACEMENT 1. Slide back the clamps on both ends of the fuel return hose. 2. Remove the fuel return hose. Fuel will come out of the hose and fuel lines; wrap the hose with shop towels and use a container to catch the fuel. 3. Install the new fuel return hose with the original hose clamps. ^ If only the fuel return hose had the 0707 lot number, go to COMPLETION PROCEDURE. ^ If the fuel hose assembly also has the 0707 lot number, go to FUEL HOSE ASSEMBLY REPLACEMENT FUEL HOSE ASSEMBLY REPLACEMENT Page 6955 Fuel Gauge Sender: Service and Repair Fuel Gage Unit Removal and Installation Refer to Fuel Tank for removal and installation of the fuel gauge unit since the fuel gauge unit is linked to the fuel pump and sender. Page 5756 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 253 Ion Sensing Module Connectors A - C Component Locations Oxygen Sensor: Component Locations HO2S (Sensor) 94. Rear of Left Catalytic Converter Page 6927 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. 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 6189 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. Fuel Pump O-ring (Gasket) Application Fuel Pump Mounting Gasket: Technical Service Bulletins Fuel Pump O-ring (Gasket) Application SOURCE: Honda Service News March 2003 TITLE: Picking the Right Fuel Pump O-Ring APPLIES TO: 2001-02 Passport SERVICE TIP: When installing the fuel pump/sending unit in a 2001-02 Passport, make sure you're using the right fuel pump O-ring (gasket). Look at the embossed ID panel on the top of the front part of the fuel tank. The second to the last line on the panel starts with CARPLASTIC, followed by an alphanumeric code ending in a -1 or a -2. - If the alphanumeric code ends in -1, install the solid green fuel pump O-ring, P/N 8-97329-935-0, H/C 7065592. - If the alphanumeric code ends in -2, install the green fuel pump O-ring with the painted marks, P/N 8-97329-099-0, H/C 7063969. Page 1937 Transmission Range Switch Page 7259 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 Fuel Line Coupler: Technician Safety Information Fuel Tube/Quick - Connector Fittings Precautions - Do not light a match or create a flame. - keep flames away from your work area to prevent flammable materials from catching fire. - Disconnect battery ground cable to prevent electrical shorts. - Pre-treat piping system or associated parts from thermal damage or from spattering when welding or similar heat-generating work. Page 1024 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 7260 Terminals - "T" Each "T" terminal (ring type) is numbered for reference and location. A "T" terminal is secured with a screw or bolt. Wires Capacity Specifications Fluid - Differential: Capacity Specifications Front Differential Differential Oil Front Differential ........................................................................................................................................... ......................................................... 1.25L (1.32 Qt) Actuator Housing: Shift on the fly ..................... ........................................................................................................................................... 0.12L (0.13 Qt) Rear Differential Differential Oil Capacity ............................................................................................................................................... ......................................................... 1.77L (1.87 Qt) Page 5543 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 1030 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 7446 Combination Light Switch Connectors A And B Page 3504 ^ 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 3760 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 695 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 - 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 607 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 5123 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: 116 Nm (85 ft. lbs.) 9. Install shock absorber and tighten it to the specified torque. Torque: 93 Nm (69 ft. lbs.) 10. Install stabilizer link and tighten it to the specified torque. Torque: 50 Nm (37 ft. lbs.) 11. Install torsion bar arm bracket and tighten it to the specified torque. Torque: 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) Page 3212 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 MOhms or more Page 4440 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 4263 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 3586 Clutch Master Cylinder: Service and Repair Unit Overhaul Master Cylinder NOTE: Disassembling and assembling the master cylinder is not approved. Page 5443 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 455 The wire insulation has one color or one color with another color stripe. The second color is the stripe. 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 5815 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 5773 Blower Motor Switch: Testing and Inspection Fan Control Knob (Fan Switch) Check for continuity between the fan switch and the A/C switch side connector terminals. Windshield Wiper Arm/Blade Wiper Arm: Service and Repair Windshield Wiper Arm/Blade Windshield Wiper Arm/Blade Removal 1. Dry 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 N.m (17 lb.ft) 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 701 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 Procedure 1. Install the VSS in the transfer case with the notch for the connector facing the rear. 2. Secure the VSS in place with the clamp and the bolt. Tighten Tighten the bolt to 16 N.m (12 lb.ft.). Page 7071 Malfunction Indicator Lamp: Testing and Inspection Lamps Test Lamps Test This test is conducted to check MIL, Up Shift Lamp, Low Fuel Lamp, Reduced Power Lamp and Cruise Control Lamp for its working. 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 F0: Lamps Test in the Miscellaneous Test. Page 5510 Compressor Clutch Relay: Testing and Inspection Heater (X-1), Thermostat (X-8), Condenser Fan (X-11) And Compressor (X-2) Relay 1. Disconnect relays and check for continuity and resistance between relay terminals. - For handling of these relays, refer to Heater Relay. Page 2049 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 ground 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 driver knee bolster (reinforcement). 7. 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 676 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 1241 Fuse To Component Index (Fuse No. 1 - 20) Image 6-3 Page 4992 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 5732 Condenser Fan Motor Relay: Testing and Inspection Heater (X-1), Thermostat (X-8), Condenser Fan (X-11) And Compressor (X-2) Relay 1. Disconnect relays and check for continuity and resistance between relay terminals. - For handling of these relays, refer to Heater Relay. Page 4364 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 260 Driver's Inflator Module Connector Page 6975 The wire insulation has one color or one color with another color stripe. The second color is the stripe. Page 4857 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 7353 Each schematic represents one circuit. A circuit's wires and components are arranged to show current flow, from power at the top 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 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. Locations Rear Heater Duct, Defroster Nozzle, Ventilation Duct And Associated Parts Page 5819 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 6008 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 1062 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 4757 Above 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 begins in Wire Color Abbreviations. 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 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 Page 6819 Terminals - "T" Each "T" terminal (ring type) is numbered for reference and location. A "T" terminal is secured with a screw or bolt. Wires Testing and Inspection Turn Signal Switch: Testing and Inspection Turn Signal Switch This diagnosis covers mechanical problems only. Page 1458 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 gauges. 9. Install the oil pressure unit. 10. Start the engine and check for leaks. Page 3444 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. Refer to Tech 2 OBD II Connection in Transmission Control System (4L30-E). 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 378 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. Page 5160 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 parts: Coil spring - Insulator INSTALLATION Page 6061 Above 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 begins in Wire Color Abbreviations. 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 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 Page 4375 Part 3 of 3 Page 1012 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 6840 Individual circuit schematics begin with a fuse. The first half of Power Distribution, however, shows the wiring "upstream" between the battery 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 6505 15. Remove the upper quarter trim cover (1). - Pry the twelve clip positions (2) free from the body panel. 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 N.m (29 lb.ft) Page 763 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 4087 Wheel Speed Sensor: Testing and Inspection 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 7173 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 10. Fuse/Relay Box (Cover Removed) Page 4192 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 4528 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 6143 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 Locations Crankshaft Position Sensor: Locations 36. Bottom Right Side of Engine CKP Sensor Page 1784 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 5227 ^ 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 2461 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 6906 The wire insulation has one color or one color with another color stripe. The second color is the stripe. Page 691 The wire insulation has one color or one color with another color stripe. The second color is the stripe. Page 4109 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. 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. Page 6382 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 4471 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 3055 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 36 Alarm/Immobilizer Control Unit: Service and Repair Alarm and Relay Control Unit Alarm and Relay Control Unit Removal 1. Disconnect the battery ground cable. 2. Remove the grove box (1). 3. Remove the alarm and relay control unit (2). Disconnect the connector. Installation To install follow the removal steps in the reverse order. Locations 48. Below Left Side of Dash Service and Repair Marker Lamp Bulb: Service and Repair Side Marker Light Bulb Removal 1. Disconnect the battery ground cable. 2. Remove the radiator grille. 3. Remove the front combination light (2). - Remove three screws. 4. Remove the bulb (1). - Remove the side marker 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. Locations Consoles And Associated Parts Page 6829 Audible Warning Device: Electrical Diagrams Seat Belt, Lights-on, And Ignition Key Reminders Image 73-0 Page 4676 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 2051 WARNING: THE INFLATOR MODULE SHOULD ALWAYS BE CARRIED WITH THE TRIM COVER AWAY FROM YOUR BODY AND SHOULD ALWAYS BE LAID ON A FLAT SURFACE WITH THE URETHANE SIDE UP. THIS IS NECESSARY BECAUSE 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. 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. 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 counter clockwise to full, return about 3 turns and align the neutral mark. Page 5748 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 6853 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. 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 7150 Parking Brake Warning Switch: Description and Operation Parking Brake Switch 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 6032 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 7294 Door 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 13 Above 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 begins in Wire Color Abbreviations. 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 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 Locations Manifold Absolute Pressure Sensor: Locations 24. Top Rear of Engine MAP Sensor Page 5576 Control Assembly: 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 2133 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 5515 - 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. Page 4559 1. Pull in test Connect the ground (-) to terminal C and magnetic switch body. Verify that the pinion pulls out when the battery (+) pole is connected to terminal 50. 2. Hold in test Observe that the pinion stays when the lead wire is disconnected from terminal C. 3. Return test Connect the ground (-) to terminal 50 and magnetic switch body. Verify that the pinion pulls out when the battery (+) pole is connected to terminal C and the pinion pulls away when the lead wire is disconnected from terminal 50. Field Coil Page 2690 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. Service and Repair Carrier Bearings: 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. Page 75 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 4618 Each schematic represents one circuit. A circuit's wires and components are arranged to show current flow, from power at the top 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 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. Page 7100 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 2739 2. Install the two screws to the accelerator pedal assembly. Tighten the screws to 22 N.m (16 lb.ft.). 3. Connect the electrical harness to the accelerator position sensor. 4. Install the negative battery cable. 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 4454 Each schematic represents one circuit. A circuit's wires and components are arranged to show current flow, from power at the top 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 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. Page 673 Vehicle Speed Sensor 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 6057 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 7699 11. Remove the speaker with the speaker harness connector from the door inner panel. 12. Remove the waterproof sheet (1). - Taking notice of the door harness, peel the waterproof sheet off the door panel carefully. 13. Remove the speaker bracket. - Remove the six fixing screws. 14. Remove the fixed glass. - Remove one bolt and screw as shown in the figure, then pull it upward. 15. Remove the glass. Locations 59. Under Center Console Page 7705 Windshield Page 600 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 310 Hood Sensor/Switch (For Alarm): Service and Repair Engine Hood Switch 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 Locations 33. Bottom Center Front of Engine Page 4768 The wire insulation has one color or one color with another color stripe. The second color is the stripe. Page 5520 5. Behind Right Side of Grille Page 5572 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 2529 95. Right Front Exhaust Downpipe 96. Rear of Right Catalytic Converter Service and Repair Oil Filter: Service and Repair 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. Diagram Information and Instructions Parking Lamp: Diagram Information and Instructions How to Identify Wiring Color-Coded Insulation Wire Color Wire Color Coding Locations Coolant Temperature Sensor/Switch (For Computer): Locations 17. Front of Engine ECT Sensor Diagram Information and Instructions Air Bag: Diagram Information and Instructions How to Identify Wiring Color-Coded Insulation Wire Color Wire Color Coding 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 7239 Brakes Lights Image 110-8 Page 1879 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 3068 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. - The screwdriver blade will release the catch inside. 4. 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. Page 6562 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 4711 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 2594 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 7039 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 Diagram Information and Instructions Trailer Lamps: Diagram Information and Instructions How to Identify Wiring Color-Coded Insulation Wire Color Wire Color Coding Page 1685 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 bolts then disconnect exhaust front pipe. 4. Remove exhaust manifold eight fixing nuts then the exhaust manifold. Installation 1. Install exhaust manifold and tighten nuts to the specified torque. Torque: 57 Nm (42 ft. lbs.) 2. Install exhaust front pipe and tighten three stud nuts and two bolts to the specified torque. Torque: Stud nuts: 67 Nm (49 ft. lbs.) Bolts: 43 Nm (32 ft. lbs.) 3. Install the torsion bar and readjust the vehicle height. Page 2471 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 4659 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 6549 Trunk / Liftgate Lock Cylinder: Service and Repair Tailgate Lock and Hatchgate Lock (LWB) Tailgate Lock, Hatchgate Lock And Associated Parts (LWB) Removal 1. Disconnect the battery ground cable 2. Remove the tailgate trim cover assembly (3). - Remove the 2 screws (2) holding the hatchgate 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. Page 1217 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 58. Under Center Console Page 3718 Axle Shaft: Service and Repair 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. Use a wire to hang the caliper to the frame to prevent damage to the caliper. 3. Remove four nuts and lockwashers. 4. Remove shaft assembly from the axle housing. 5. Remove snap ring and bearing cup. Page 687 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 1596 Page 4059 Electronic Brake Control Module: Connector Views Part 1 of 3 Page 568 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 5898 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 7771 Wiper Motor Linkage: Service and Repair Windshield Wiper Linkage 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. Page 410 Evaporator Temperature Sensor / Switch: Description and Operation Electronic Thermostat The electronic thermostat senses the temperature of cool air from the evaporator by means of the evaporator temperature sensor This information determines whether the thermostat will provide ground to the thermo switch relay. When the temperature becomes too low, ground is not provided. OFF: Below 1.0 ± 0.5 °C (33.8 ± 0.9 °F) ON: Above 3.5 ± 0.3 °C (38.3 ± 0.9 °F) Page 824 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 7776 Rear Wiper/Washer Switch Locations 8. Fuse/Relay Box (Cover Removed) Page 5266 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. 2. Tighten the hub nut to the value given, 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 lb - 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. Page 7184 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 2595 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 3702 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. 5. Install flange nut, refer to Differential Assembly Overhaul for flange nut reassembly. NOTE: Discard the used nut and install a new one. Page 629 - 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 1774 Ground - "G" Shielding Sheilding This represents RFI (Radio Frequency Interference) shielding around a wire. The shielding is always connected to ground. Splices Page 5312 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 5079 Ball Joint: Specifications Ball Joint, Lower Castle Nut 147 Nm Attaching Bolts 116 Nm Preload Torque 0.5 - 6.4 Nm Page 5114 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 5672 Housing Assembly HVAC: Service and Repair Heater Core and/or Mode Door Heater Core and/or Mode Door Heater Core And/or Mode Door - Disassembled View 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 5881 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 6815 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 7198 5. Select F0: Malfunction Indicator Lamp. 6. Push "On" soft key. 7. Make sure Lamp illuminates. 8. If lamp illuminates, the Lamp is operating correctly 9. Select F2: Up Shift Lamp 10. Push "On" of soft key. 11. Make sure Lamp illuminates. 12. If Lamp illuminates, the Lamp is operating correctly. 13. Select F2: Low Fuel Lamp Locations 8. Fuse/Relay Box (Cover Removed) Page 7509 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 6901 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 1160 Refrigerant Oil: Service and Repair Checking/Adjusting Oil For Used Compressor Checking and Adjusting Oil Quantity for Used Compressor 1. Perform 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. 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 preform 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 of refrigerant. 8. Perform the oil return operation. 9. Remove the compressor and recheck the amount of oil. 10. Adjust the compressor oil, if necessary. Diagram Information and Instructions Powertrain Control Module: Diagram Information and Instructions How to Identify Wiring Color-Coded Insulation Wire Color Wire Color Coding Page 2606 Vehicle Speed Sensor: Service and Repair Removal Procedure CAUTION: The VSS is located on the right side of the transfer case lust 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. Page 4590 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 2237 Above 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 begins in Wire Color Abbreviations. 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 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 PCM Service Precautions Powertrain Control Module: Service Precautions PCM Service Precautions Powertrain Control Module (PCM) Service Precaution NOTE: To prevent possible electrostatic discharge damage to the PCM, do not touch the connector pins or soldered components on the circuit board. 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. Information On PCM 1. The Powertrain Control Module (PCM) is located in the engine room and is the control center of the electronic transmission control system. 2. The PCM must be maintained at a temperature below 85°C (185°F) at all times. This is most essential if the vehicle is put through a paint baking process. The PCM will become inoperative if its temperature exceeds 85°C (185°F). Therefore, it is recommended that the PCM be removed or that temporary insulation be placed around the PCM during the time the vehicle is in a paint oven or other high temperature process. 3. The PCM is designed to process the various inputs and then respond by sending the appropriate electrical signals to control transmission upshift, downshift, shift feel and torque converter clutch engagement. 4. The PCM constantly interprets information from the various sensors, and controls the systems that affect transmission and vehicle performance. By analyzing operational problems, the PCM is able to perform a diagnostic function by displaying DTC(s) and aid the technician in making repairs. Page 1851 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 2125 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. Symptom Diagnosis Malfunction Indicator Lamp: Testing and Inspection Symptom Diagnosis Malfunction Indicator Lamp The instrument panel "CHECK ENGINE" Malfunction Indicator Lamp (MIL) illuminates by self diagnostic system when the system checks the starting of engine, or senses malfunctions. Page 5532 Ground - "G" Shielding Sheilding This represents RFI (Radio Frequency Interference) shielding around a wire. The shielding is always connected to ground. Splices Page 2878 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 6612 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 3208 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 MOhms or more Page 173 Above 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 begins in Wire Color Abbreviations. 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 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 Page 7022 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 4615 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 6880 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 1628 To install follow the removal steps in the reverse order noting the following point; 1. Check that each mode door operates properly. Page 460 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 1778 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 1716 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. Technician Safety Information Steering Wheel: Technician Safety Information Service Precautions 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. Page 1232 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 6701 73. Rear of Driver's Door (Frt. Pass. Similar) Page 2345 - 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 2164 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 2847 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 412 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 - 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. Locations 13. Right Rear Corner of Engine Compartment Page 7220 Each schematic represents one circuit. A circuit's wires and components are arranged to show current flow, from power at the top 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 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. Page 2423 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 megaohms 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 (ODM) - Quad Driver Module (QDM) Page 6017 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 1782 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 5239 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. 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 3761 Page 5121 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 (Except 2WD model). 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. 16. Remove torsion bar arm bolt. 17. Remove lower ball joint bolt. Page 2069 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 5665 Heater Mode Control Link Unit - Disassembled View Heater Temperature Control Link Unit - Disassembled View Page 4271 Brake Fluid: Service and Repair 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 4808 Individual circuit schematics begin with a fuse. The first half of Power Distribution, however, shows the wiring "upstream" between the battery 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 2248 The wire insulation has one color or one color with another color stripe. The second color is the stripe. Page 6702 Power Door Lock Switch: Diagrams Front Passenger's Power Window And Door Lock Switch Driver's Power Window And Door Lock Switch Specifications Drive/Propeller Shaft: Specifications SHIFT ON THE FLY SYSTEM General Specifications Disassembly and Reassembly Starter Motor: Service and Repair Disassembly and Reassembly Disassembly 1. Remove the lead wire (1) from the magnetic switch. 2. Remove the through bolts (2). 3. Remove the yoke from the magnetic. 4. Remove the yoke cover. 5. Use the long nose pliers to remove the brush and brush holder. Page 5228 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. Locations 88. Left Side of Front Axle Page 6342 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 Page 4578 Individual circuit schematics begin with a fuse. The first half of Power Distribution, however, shows the wiring "upstream" between the battery 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 6118 ^ 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 3313 ^ 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 4683 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 851 57. Top of Transfer Case 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 4980 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 1926 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 5433 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. 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 4551 Diagnosis Locations 56. Top Right Side of Transfer Case Page 6732 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 4886 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 1901 - 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 471 Auto Light Sensor Connector (Canada Only) Locations PCV Valve Page 606 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. Diagrams Cruise Control Main Switch Page 1747 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 megaohms 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 (ODM) - Quad Driver Module (QDM) PCM Input/Outputs PCM Input/Outputs Specifications Torque Specifications Page 4770 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 2299 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 5975 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 4666 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 5368 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. Procedures Headliner: Procedures Headlining - Parts Locations (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. 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 Locations 67. Behind Glove Box Page 6223 Individual circuit schematics begin with a fuse. The first half of Power Distribution, however, shows the wiring "upstream" between the battery 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 3046 Each schematic represents one circuit. A circuit's wires and components are arranged to show current flow, from power at the top 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 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. Page 3893 4WD Control Unit Page 3168 Ignition Coil: Testing and Inspection 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 5743 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 4532 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 5917 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 4678 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 5086 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 (Except 2WD model). 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 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 to confirm its normal movement. Page 4672 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 2931 Fuel Pump Relay: Description and Operation In order to control the FPS operation, the FPS relay is provided. When the starter switch is turned to "ON" position, the FPS relay operates the FPS for 2 seconds. When the key 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 FPS to feed fuel. Page 6663 Sunroof / Moonroof Frame: Service and Repair Sunroof Frame Complete Assembly And Associated Parts (LWB) Sunroof Frame Complete Assembly (LWB) 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 assembly fixing nuts (front side) and six fixing bolts from the frame complete assembly, and then remove the sunroof frame complete assembly. Locations 83. Top of Tailgate (Trim Removed) Page 4894 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. 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. Page 6193 Alarm And Relay Controls Image 70-1 Page 4721 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 778 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. 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 shaft 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. Page 7251 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 Initial Inspection and Diagnostic Overview Powertrain Control Module: Initial Inspection and Diagnostic Overview Functional Check 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. Component Locations Oxygen Sensor: Component Locations HO2S (Sensor) 94. Rear of Left Catalytic Converter Page 4555 11. Remove the idle pinion from the magnetic switch. 12. Remove the retainer from the magnetic switch. 13. Remove the magnetic switch. Reassembly To install, follow the removal steps in the reverse order, noting the following points: Grease application places - Bearing in rear cover - Gears in reduction gear - Sliding portion of pinion Page 7676 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 4355 Each schematic represents one circuit. A circuit's wires and components are arranged to show current flow, from power at the top 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 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. Front Wheel Speed Sensor: Testing and Inspection 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. Page 3607 Pressure Plate: Description and Operation Pressure Plate Assembly 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 5008 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 7047 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 2827 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 4989 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 5257 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: 137 Nm (101 ft. lbs.) 3. Install parking brake cable. CAUTION: The parking brake cable should not be overstrained or slackened. Page 3729 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 4649 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 6478 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 5210 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 4370 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 5573 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 2018 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 7062 14. Push "On" of soft key. 15. Make sure Lamp illuminates. 16. If Lamp illuminates, the Lamp is operating correctly. 17. Select F3: Reduced Power Lamp 18. Push "On" of soft key. 19. Make sure Lamp illuminates. 20. If Lamp illuminates, the Lamp is operating correctly. 21. Select F5: Cruise Control Lamp 22. Push "On" of soft key. 23. Make sure Lamp illuminates. 24. It Lamp illuminates, the Lamp is operating correctly. Locations 18. Right Side of Engine Page 7232 The wire insulation has one color or one color with another color stripe. The second color is the stripe. Page 5375 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 1732 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 3344 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 7661 - 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 5842 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 2879 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 5706 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) Diagram Information and Instructions Control Module HVAC: Diagram Information and Instructions How to Identify Wiring Color-Coded Insulation Wire Color Wire Color Coding Page 6197 Alarm/Immobilizer Control Unit: Service and Repair Alarm and Relay Control Unit Alarm and Relay Control Unit Removal 1. Disconnect the battery ground cable. 2. Remove the grove box (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 3711 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 7174 Ground - "G" Shielding Sheilding This represents RFI (Radio Frequency Interference) shielding around a wire. The shielding is always connected to ground. Splices Page 7508 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 1857 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. Refer to Electronic Ignition System for additional information. Page 2962 1. Disconnect the fuel hose assembly from the fuel lines (quick disconnect fittings). 2. Remove the O2 harness sensor clip. 3. Remove the two transmission mounting nuts. 4. Lower the vehicle. 5. Open the hood. Remove the fuel pump relay from the underhood fuse/relay box. Remove the plastic engine cover. If any of the engine cover mounting grommets stayed on the engine, remove them and install them back in the engine cover. 6. Place a floor jack cushioned by a block of wood under the transfer case (4WD) or the transmission pan (2WD). Jack up the transmission until it bottoms against the body and the vehicle starts to lift on the suspension. Do not lift the wheels off the floor. Locations 9. Fuse/Relay Box (Cover Removed) Page 6300 Rear Door Exterior Handle: Service and Repair Rear Outside Handle And Associated Parts Removal 1. Disconnect the battery ground cable. 2. Remove the door trim panel. 3. Peel the upper half of 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 N.m (78 lb in) Page 4692 Fuse To Component Index (Fuse No. 1 - 20) Image 6-3 Page 2738 Accelerator Pedal: Service and Repair Accelerator Pedal Replacement Removal Procedure 1. Disconnect the negative battery cable. 2. Disconnect the electrical harness from the accelerator position sensor. 3. Remove the two screws from the accelerator pedal assembly. 4. Remove the accelerator pedal assembly from the bulkhead. Installation Procedure 1. Install the accelerator pedal assembly on the bulkhead. Page 6818 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 3415 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 451 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) Page 4540 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 7654 Quarter Window Glass: Diagrams Rear Quarter Glass (LWB) Page 6355 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 1737 ECM (M/T) Or PCM (A/T) Connector B Page 4715 Above 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 begins in Wire Color Abbreviations. 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 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 Page 2143 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 6709 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 4378 Part 3 of 3 Page 3771 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. 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. Page 2124 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 61 Above 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 begins in Wire Color Abbreviations. 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 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 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 4696 Relay/Fuse Box (Engine Room) Page 1721 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 2986 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 2535 - 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 4470 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 1228 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 7357 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 1293 Tires: Specifications P225/75R16 Pressure Front 200 kPa Rear 200 kPa P245/70R16 Pressure Front 200 kPa Rear 180 kPa Page 6835 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 5883 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 3741 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 - Disc - Caliper - Shift on the fly system parts (Cap, Hub flange, Shim, Snap ring) - ABS sensor ring Reassembly Page 4762 Ground - "G" Shielding Sheilding This represents RFI (Radio Frequency Interference) shielding around a wire. The shielding is always connected to ground. Splices Locations Fuse And Relay Panel (Underhood Electrical Center) Page 5380 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 3817 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 4811 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 225 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 7762 Wiper Motor: Connector Locations 14. Right Rear of Engine Compartment 84. Center of Tailgate Page 939 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 2175 Crankshaft Position Sensor: Testing and Inspection Inspection Procedure 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 1725 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 7393 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 4873 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 1971 Vehicle Speed Sensor: Testing and Inspection Inspection Procedure 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 2366 ^ 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 5841 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 940 ^ 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. 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 5753 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 6868 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 5826 Passenger's Inflator Module Connector Page 3413 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 3008 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 102. Below Left Side of Rear Bumper (Honda Acc.) Page 7037 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 602 Fuel Tank Pressure Sensor: Service and Repair Removal Procedure 1. Remove the fuel pump assembly. Refer to Fuel Tank In Fuel Pump. 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. - Insert the sensor nipple firmly into the grommet. - Keep twisting and pushing the sensor until the wide portion of the nipple shows on the other side of the grommet. 3. Install the fuel pump assembly on the fuel tank. Refer to Fuel Tank In Fuel Pump. Page 371 Wheel Speed Sensor: Service and Repair Rear Removal 1. Disconnect harness connector (1). 2. Remove sensor fixing bolt (2). 3. Remove speed sensor (3). Installation 1. Install speed sensor (3). 2. Tighten the sensor fixing bolt (2) to the specified torque. Torque: 24 Nm (17 ft. lbs.) 3. Connect harness connector (1). Page 2149 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 3058 The wire insulation has one color or one color with another color stripe. The second color is the stripe. Diagram Information and Instructions Headlamp Switch: Diagram Information and Instructions How to Identify Wiring Color-Coded Insulation Wire Color Wire Color Coding Page 113 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 6824 Audible Warning Device: 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 6235 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. 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 1014 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 1902 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 5607 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. 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 7448 7. Loosen the inflator module fixing bolt from behind the steering wheel assembly using a T0RX(R) 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 TRIM COVER AWAY FROM YOUR BODY AND SHOULD ALWAYS BE LAID ON A FLAT SURFACE WITH ' THE URETHANE SIDE UP. THIS IS NECESSARY BECAUSE FREE SPACE IS PROVIDED TO ALLOW THE AIR CUSHION TO EXPAND IN THE UNLIKELY EVENT OF ACCIDENTAL DEPLOYMENT. OTHERWISE, PERSONAL INJURY MAY RESULT. 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. Page 2713 Positive Crankcase Ventilation Valve: Testing and Inspection Inspection Procedure 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 4294 Hydraulic Control Assembly - Antilock Brakes: Service Precautions 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. The following are general precautions which should be observed when servicing and diagnosing the Anti-lock Brake System and/or other vehicle systems. Failure to observe these precautions may result in Anti-lock Brake System damage. If welding work is to be performed on the vehicle using an electric arc welder, the EHCU and valve block connectors should be disconnected before the welding operation begins. - The EHCU and valve block connectors should never be connected or disconnected with the ignition "ON". - If only rear wheels are rotated using jacks or drum tester, the system will diagnose a speed sensor malfunction and the "ABS" warning light will illuminate. But actually no trouble exists. After inspection stop the engine once and re-start it, then make sure that the "ABS" warning light does not illuminate. If the battery has been discharged The engine may stall if the battery has been completely discharged and the engine is started via jumper cables. This is because the Anti-lock Brake System (ABS) requires a large quantity of electricity. In this case, wait until the battery is recharged, or set the ABS to a non-operative state by removing the fuse for the ABS (60A). After the battery has been recharged, stop the engine and install the ABS fuse. Start the engine again, and confirm that the ABS warning light does not light. Page 5921 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) Description and Operation Malfunction Indicator Lamp: Description and Operation Malfunction Indicator Lamp (MIL) The Malfunction Indicator Lamp (MIL) looks the same as the MIL you are already familiar with ("Check Engine" lamp). However, OBD II requires that it illuminate under a strict set of guide lines. Basically, the MIL is turned on when the PCM detects a DTC that will impact vehicle emissions. The MIL is under the control of the Diagnostic Executive. The MIL will be turned on if an emissions-related diagnostic test indicates a malfunction has occurred. It will stay on until the system or component passes the same test, for three consecutive trips, with no emissions related faults. If the vehicle is experiencing a misfire malfunction which may cause damage to the Three-Way Catalytic Converter (TWC), the MIL will flash once per second. This will continue until the vehicle is outside of speed and load conditions which could cause possible catalyst damage, and the MIL will stop flashing and remain on steady. Extinguishing the MIL When the MIL is on, the Diagnostic Executive will turn off the MIL after three(3) consecutive trips that a "test passed" has been reported for the diagnostic test that originally caused the MIL to illuminate. Although the MIL has been turned off, the DTC will remain in the PCM memory (both Freeze Frame and Failure Records) until forty (40) warm-up cycles after no faults have been completed. If the MIL was set by either a fuel trim or misfire-related DTC, additional requirements must be met. In addition to the requirements stated in the previous paragraph, these requirements are as follows: - The diagnostic tests that are passed must occur within 375 RPM of the RPM data stored at the time the last test failed. - Plus or minus ten (10) percent of the engine load that was stored at the time the last failed. - Similar engine temperature conditions (warmed up or warming up) as those stored at the time the last test failed. Meeting these requirements ensures that the fault which turned on the MIL has been corrected. The MIL ("Check Engine" lamp) is on the instrument panel and has the following function: - It informs the driver that a fault affects vehicle emission levels has occurred and that the vehicle should be taken for service as soon as possible. - As a bulb and system check, the MIL will come "ON" with the key "ON" and the engine not running. When the engine is started, the MIL will turn "OFF." - When the MIL remains "ON" while the engine is running, or when a malfunction is suspected due to a driveability or emissions problem, a Powertrain On-Board Diagnostic (OBD II) System Check must be performed. The procedures for these checks are given in On-Board Diagnostic (OBD) System Check. These checks will expose faults which may not be detected if other diagnostics are performed first. Page 4020 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. Fan Control Lever (Fan Switch) Blower Motor Switch: Testing and Inspection Fan Control Lever (Fan Switch) Check for continuity between the terminals of the fan switch. 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 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 cut the front accessory socket from the socket cover (3). Installation To install, follow the removal steps in the reverse order. Page 60 Each schematic represents one circuit. A circuit's wires and components are arranged to show current flow, from power at the top 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 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. Page 7011 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 1295 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 4868 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 2307 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 4910 This illustration shows view from the top of the vehicle. Toe-in is the measured amount the front wheels are turned 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 175 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 - 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 6972 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 2397 Individual circuit schematics begin with a fuse. The first half of Power Distribution, however, shows the wiring "upstream" between the battery 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 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 Locations 39. Dash Fuse Box Page 4185 Brake Pad: Service and Repair Rear 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 Diagram Information and Instructions Control Module HVAC: Diagram Information and Instructions How to Identify Wiring Color-Coded Insulation Wire Color Wire Color Coding Page 6292 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 4930 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 7098 The wire insulation has one color or one color with another color stripe. The second color is the stripe. Page 7700 - 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. 16. Remove the window regulator. - Remove the window regulator fixing bolts and pull the regulator out from the lower hole of the door panel. 17. 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: Page 1197 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 1128 An oil with a viscosity of 5W - 30 is preferred for improved fuel economy and year-round protection in the vehicle. You may use a 10W - 30 oil if the climate in your area is limited to the temperature range shown on the chart. 4. Run the engine for more than three minutes, then check for oil leakage. Page 2835 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 289 4WD Control Unit Locations 45. Below Left Side of Dash Service and Repair Keyless Entry Transmitter Battery: Service and Repair Transmitter Battery Replacement 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 5197 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 3017 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 Alarm/Immobilizer Control Unit: Diagram Information and Instructions How to Identify Wiring Color-Coded Insulation Wire Color Wire Color Coding Page 2014 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. 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. 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 7520 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 4628 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 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 7135 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 13. Right Rear Corner of Engine Compartment Diagrams Page 4695 Relay/Fuse Box (Engine Room) Page 5252 If you need more labels, order them from Helm using reorder number Y0895.* Page 5629 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 - 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. Page 7516 Ground - "G" Shielding Sheilding This represents RFI (Radio Frequency Interference) shielding around a wire. The shielding is always connected to ground. Splices Page 1679 Catalytic Converter: Service and Repair Three Way Catalytic Converter LH & 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 front exhaust pipe assembly 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). Capacity Specifications Coolant: Capacity Specifications Total Cooling System Capacity M/T 11.1 L A/T 10.0 L Engine Coolant Capacity M/T 2.5 L A/T 2.4 L Hydraulic System Bleeding Clutch Master Cylinder: Service and Repair Hydraulic System Bleeding Bleeding 1. Check the level of clutch fluid in the reservoir and replenish if necessary. 2. Bleeding the slave cylinder. 1. Remove the rubber cap from the bleeder screw and wipe clean. Connect a vinyl tube to the bleeder screw and insert the other end of the vinyl tube into a transparent container. 2. Pump the clutch pedal repeatedly and hold it depressed. 3. Loosen the bleeder screw to release clutch fluid with air bubbles into the container, then tighten the bleeder screw immediately. 4. Release the clutch pedal carefully. Repeat the operation until air bubbles disappear from the clutch fluid being pumped out into the container. During the bleeding operation, keep the clutch fluid reservoir filled to the specified level. Reinstall the rubber cap. Page 7521 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 Checking/Adjusting Oil For New Compressor Refrigerant Oil: Service and Repair Checking/Adjusting Oil For New Compressor Checking and Adjusting for Compressor Replacement 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. Diagram Information and Instructions Key Reminder Switch: Diagram Information and Instructions How to Identify Wiring Color-Coded Insulation Wire Color Wire Color Coding Page 3642 Axle Disconnect Controller 1. Connect 12V with terminal (3) and the ground with the terminal (6). 2. Send the signal to the terminal (4) 2WD -> 4WD less than 2.4V 4WD -> 2WD more than 9.0V 3. Confirm the output signal from the terminals (1) & (2) (2 seconds output) 4. If the trouble occurs after test, charge the Axle Disconnect Controller to the new one. Motor Actuator Assembly (Transfer) Inspect the function of the motor actuator assembly as follows: 1. Disassemble the motor actuator from transfer rear case. Page 6018 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 4892 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 5122 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 parts: Lower control arm - Bushing Page 1324 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: 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 5476 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 4530 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 Low Fuel Lamp/Indicator: Diagram Information and Instructions How to Identify Wiring Color-Coded Insulation Wire Color Wire Color Coding Page 7204 Auto Light Sensor Connector (Canada Only) Page 6442 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 6869 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 7257 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 5166 Suspension Strut / Shock Absorber: Specifications Shock Absorber Type Hydraulic, Double Acting, Telescopic Piston Diameter Without ISC Shock Absorber 175.0 mm With ISC Shock Absorber 159.0 mm Stroke Without ISC Shock Absorber 473.5 mm With ISC Shock Absorber 518.0 mm Extended Length Without ISC Shock Absorber 298.5 mm With ISC Shock Absorber 359.0 mm Page 6998 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 1964 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 1940 a. Place selector lever in neutral. b. Disconnect transmission harness connector from mode switch connector. 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 (approximately 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 776 Ignition Switch Lock Cylinder: Testing and Inspection System Inspection Turn the ignition switch to the "ON" position and observe the warning lamp. The lamp should flash 7 times. If the lamp does not operate correctly, refer to "Restraints". Page 2685 Canister Vent Valve: Service and Repair EVAP Canister Vent Solenoid Removal Procedure 1. Disconnect the negative battery cable. 2. Disconnect the connector and hose. 3. Slide the out of EVAP. canister vent solenoid from mounting bracket. Installation Procedure Page 6191 Alarm And Relay Control Unit Connectors A And B 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. Procedures Console: Procedures Consoles And Associated Parts 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 2652 Vehicle Speed Sensor: Service and Repair Removal Procedure CAUTION: The VSS is located on the right side of the transfer case lust 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. 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 6462 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 1791 2. Press down until the catch engages. - An audible "click" will be heard. 3. Install the fuse and relay box cover. Page 174 Individual circuit schematics begin with a fuse. The first half of Power Distribution, however, shows the wiring "upstream" between the battery 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 1380 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 4. Install camshaft assembly and camshaft bearing caps, tighten twenty bolts on one side bank to the specified torque. 1. Apply engine oil to camshaft journal and bearing surface of camshaft bearing caps. Page 1191 - Refer to the scrapping procedures for disposal of the damaged airbag. Page 319 Power Door Lock Switch: Diagrams Front Passenger's Power Window And Door Lock Switch Driver's Power Window And Door Lock Switch Page 5979 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). Service and Repair Fuel Pressure Release: Service and Repair Fuel Pressure Relief Procedure CAUTION: To reduce the risk of fire and personal injury, there are necessary to relieve the fuel system pressure before filler and gauge unit 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 disconnect 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 1895 95. Right Front Exhaust Downpipe 96. Rear of Right Catalytic Converter Page 5895 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 7253 Above 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 begins in Wire Color Abbreviations. 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 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 Page 4466 The wire insulation has one color or one color with another color stripe. The second color is the stripe. Capacity Specifications Fluid - M/T: Capacity Specifications M/T Fluid Capacity ............................................................................................................................................... ......................................................................... 2.95L Locations Vapor Pressure Sensor / Fuel Gage And Fuel Pump Connector Page 6914 Clock: Service and Repair Digital Clock Removal 1. Disconnect the battery ground cable. 2. Remove the dash side trim panel-LH (1). 3. Remove the lower cover assembly (2). 4. Remove the meter cluster assembly (4). 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 1224 Ground - "G" Shielding Sheilding This represents RFI (Radio Frequency Interference) shielding around a wire. The shielding is always connected to ground. Splices Page 7225 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 798 CAUTION: Turn the SRS coil counter clockwise until some resistance is felt, or damage may occur to the SRS coil. 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 shaft 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 ground cable. Page 5128 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. - 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) Page 4669 Above 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 begins in Wire Color Abbreviations. 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 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 Page 5830 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 450 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 1225 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 4700 Fuse To Component Index (Fuse No. 1 - 20) Image 6-3 Page 1156 Refrigerant Oil: Fluid Type Specifications A/C Oil Specifications A/C Oil Specifications Lubricant Type Poly Alkaline Glycol (PAG) Page 4853 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 195 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. 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 5807 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 4575 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 2200 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. Description and Operation Fuel Gauge: Description and Operation Fuel Gauge The fuel gauge consists of two intersecting coils wound around a permanent magnet rotor (see 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 5390 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: 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 72 The wire insulation has one color or one color with another color stripe. The second color is the stripe. Page 953 Alignment: Specifications Trim Height Trim Height .......................................................................................................................................... ................................. 119 +/- 5 mm (4.69 +/- 0.2 in.) Page 7714 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. Page 7103 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 6016 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 7089 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. 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 5248 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 1218 Each schematic represents one circuit. A circuit's wires and components are arranged to show current flow, from power at the top 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 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. Page 1286 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 5445 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 7677 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 1771 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 7698 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 comer garnish. 7. Pull out the trim panel at the 8 clip positions. - Disconnect the power window switch connector. 8. Remove the power window switch and pull case, if equipped. - Remove the fixing screws from back side of the rear door trim panel. 9. Remove the bracket. 10. Disconnect the speaker harness connector. Component Locations Air Bag: Component Locations Passenger's Inflator Module Connector Component Locations 72. Driver's Door (Frt. Pass. Similar) Page 3019 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 5592 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 4152 Brake Caliper: Specifications Type Floating, Pin Slide Adjusting Method Self-Adjusting Piston Diameter 41.3 mm Page 1958 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 4368 Electronic Brake 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. Description and Operation Lateral Accelerometer: Description and Operation G-SENSOR/LATERAL ACCELEROMETER The G-sensor installed inside the Electronic Hydraulic Control Unit (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 Anti-lock Brake System (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 6850 The wire insulation has one color or one color with another color stripe. The second color is the stripe. Page 4769 Fuse Block: 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 Page 5689 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 1435 - Remove harness bracket bolt on cylinder head cover. - Remove fixing bolts on ignition coils. 6. Disconnect fuel injector harness connector then remove fuel injector harness bracket bolt. 7. Remove eight fixing bolts, then the cylinder head cover. NOTE: Where do you refer the tech in case of bolt removal difficulties. Installation 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 (a or equivalent) of bead diameter 2-3 mm at eight place of arched area of camshaft bearing cap 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 (78 inch lbs.) 2. Install fuel injection harness bracket and tighten bolt to the specified torque. Torque: 9 Nm (78 inch lbs.) Page 7607 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 2186 Individual circuit schematics begin with a fuse. The first half of Power Distribution, however, shows the wiring "upstream" between the battery 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 105. Left Side of Driver's Seat Page 3549 Disclaimer Page 2264 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 megaohms 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 (ODM) - Quad Driver Module (QDM) Page 7401 Ground - "G" Shielding Sheilding This represents RFI (Radio Frequency Interference) shielding around a wire. The shielding is always connected to ground. Splices Diagrams Page 1423 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 3198 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. 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 shaft 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. 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 inch lbs.) DISASSEMBLY Page 7362 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 5226 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 29 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 Fuel Pressure Release: Service and Repair Fuel Pressure Relief Procedure CAUTION: To reduce the risk of fire and personal injury, there are necessary to relieve the fuel system pressure before filler and gauge unit 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 disconnect 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 3086 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 6175 Individual circuit schematics begin with a fuse. The first half of Power Distribution, however, shows the wiring "upstream" between the battery 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 235 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 2583 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 509 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 4938 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 4679 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 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 5749 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 3571 Valve Body: Service and Repair Adapter Case Valve Body 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 way (V6) or 5 way (HEC) 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 inch lbs.) 6. Fill transmission through the overfill screw hole of oil pan, using ATF DEXRON III. 7. Connect battery ground cable. 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 7176 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 2704 EGR Valve: Service and Repair Linear Exhaust Gas Recirculation (EGR) Valve 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 1724 Ground - "G" Shielding Sheilding This represents RFI (Radio Frequency Interference) shielding around a wire. The shielding is always connected to ground. Splices Page 4759 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 - 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 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 230 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 6285 72. Driver's Door (Frt. Pass. Similar) Page 116 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 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 70 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 4796 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 4234 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 2547 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 5892 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 6544 Power Door Lock Switch: Diagrams Front Passenger's Power Window And Door Lock Switch Driver's Power Window And Door Lock Switch 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 N.m (13 lb.ft) Page 5211 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 1636 Radiator: Description and Operation Radiator The radiator is a tube type with corrugated fins. In order to raise the boiling point of the coolant, the radiator is fitted with a cap in which the valve is operated at 88.2 - 117.6 kPa (12.8 - 17.0 psi) pressure. (No oil cooler provided for M/T) 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. Locations 67. Behind Glove Box Page 4693 7. Right Side of Engine Compartment Page 4833 Relay/Fuse Box (Engine Room) Page 817 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 and Repair Band Control Solenoid Valve: Service and Repair For further information regarding this component and the system that it is a part of, please refer to Shift Solenoid; Service and Repair. Diagrams Power Window Switch: Diagrams Left Rear Power Window Switch Right Rear Power Window Switch Page 6230 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 Front Crankshaft Seal: Service and Repair For further information regarding this component and the system that it is a part of, please refer to Cylinder Block Assembly; Service and Repair. Page 5649 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 2422 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 Diagram Information and Instructions Control Module HVAC: Diagram Information and Instructions How to Identify Wiring Color-Coded Insulation Wire Color Wire Color Coding Page 4870 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 5566 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 1465 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 6128 Front Disc Brake Rotor Brake Rotor/Disc: Testing and Inspection Front Disc Brake Rotor 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. Checking Lateral Runout 1. Adjust the wheel bearing correctly. 2. Attach the dial indicator accordingly so that the stem contacts the rotor surface to approximately 29 mm (1.14 inch) from the rotor edge. 3. Rotate the rotor one complete turn and inspect for signs of lateral runout. Lateral runout should not exceed 0.13 mm (0.005 inch). Maximum runout: 0.13 mm (0.005 inch) Page 2519 Steps 1 - 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 inch 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. 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 3703 Seals and Gaskets: Service and Repair Rear Differential PINION OIL SEAL AND ASSOCIATED PARTS Removal 1. Remove the rear 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 232 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 6814 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 5236 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 4704 Relay/Fuse Box (Engine Room) Page 913 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 1379 Camshaft: Service and Repair Camshaft Replacement 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. 6. Remove twenty fixing bolts from inlet and exhaust camshaft bearing cap on one side bank, then camshaft bearing cap. 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 (87 inch lbs.) 2. Tighten bolt for camshaft drive gear assembly pulley to the specified torque. Torque: 98 Nm (72 ft. lbs.) Page 1651 2. Install the ECT sensor in the coolant crossover. Tighten Tighten the ECT sensor to 30 N.m (22 lb.ft.). 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 2549 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 4598 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. Page 2265 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 megaohms 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 (ODM) - Quad Driver Module (QDM) PCM Input/Outputs PCM Input/Outputs Page 2919 Ground - "G" Shielding Sheilding This represents RFI (Radio Frequency Interference) shielding around a wire. The shielding is always connected to ground. Splices Page 6898 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 1963 The wire insulation has one color or one color with another color stripe. The second color is the stripe. Testing and Inspection Air Filter Element: Testing and Inspection Check the air cleaner filter for damage or dust clogging. Replace if it is damaged, or clean if it is clogged. Page 523 Headlamp Switch: Electrical Diagrams Headlight Switch Image 100-0