Chevrolet - Civic - Workshop Manual - 2003 - 2003

Page 4103 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 Locater) 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. Troubleshooting Precautions Troubleshooting Precautions Before Troubleshooting 1. Check the main fuse and the fuse 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, or you will damage the alternator diodes. - Do not attempt to crank the engine with the ground cable disconnected 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. Page 7798 WARRANTY CLAIM INFORMATION In warranty: The normal warranty applies. Failed Part: P/N 68500-S5P-A90ZZ H/C 6528640 *Defect Code: 07406* Symptom Code: 03220 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 A 1. Check the side-to-side alignment of the trunk lid latch to the striker: ^ Refer to page 20-132 of the 2001-04 Civic Service Manual. ^ In ISIS, use the keyword TRUNK ADJUST, and select Trunk Lid Adjustment from the list. 2. Make sure the gaps of the trunk lid are even on all sides. ^ If the trunk is misaligned, go to step 3. ^ If the trunk lid is properly aligned on all sides, go to REPAIR PROCEDURE B. 3. Adjust the trunk lid hinges: ^ Refer to page 20-132 of the 2001-04 Civic Service Manual. ^ In ISIS, use the keyword TRUNK ADJUST, and select Trunk Lid Adjustment from the list. 4. Check the trunk operation: ^ If the trunk opens and closes smoothly and is properly aligned, return the vehicle to the customer. ^ If the trunk lid is still difficult to close, go to REPAIR PROCEDURE B. REPAIR PROCEDURE B Page 2664 Valve Clearance: Adjustments Adjustment NOTE: Adjust the valves only when the cylinder head temperature is less than 100°F (38°C). 1. Remove the ignition coil cover, then remove the four ignition coils. 2. Remove the throttle cable clamps and harness holder from the cylinder head cover. 3. Remove the cylinder head cover. 4. Remove the grommet from the upper cover, and disconnect the camshaft position (CMP) (top dead center (TDC)) sensor connector. Remove the upper cover. 5. Set the No. 1 piston at TDC. The "UP" mark (A) on the camshaft pulley should be at the top, and the TDC marks (B) on the pulley should line up with the top edge of the head. 6. Select the correct thickness feeler gauge for the valves you're going to check. Intake: 0.18 - 0.22 mm (0.007 - 0.009 inch) Exhaust: 0.23 - 0.27 mm (0.009 - 0.011 inch) Adjusting screw location: Page 2880 21. Check for continuity between PGM-FI main relay 1 4P connector terminal No.1 and body ground. Is there continuity? YES - Repair short in the wire between PGM-FI main relay 1 and each item. Also replace the No.6 ECU (ECM/PCM) (15A) fuse. NO - Replace the PGM-FI main relay 1. Also replace the No 6 ECU (ECM/PCM) (15A) fuse. 22. Inspect the No.17 FUEL PUMP (15A) fuse in the under-dash fuse/relay box. Is the fuse OK? YES - Go to step 34. NO - Go to step 23. 23. Remove the blown No.17 FUEL PUMP (15A) fuse. 24. Disconnect ECM/PCM connector E (31P). 25. Check for continuity between ECM/PCM connector terminal E9 and body ground. Is there continuity? YES - Go to step 26. NO - Replace the No.17 FUEL PUMP (15A) fuse, and update the ECM/PCM if it does not have the latest software, or substitute a known-good ECM/PCM, then recheck. If the symptom/indication goes away with a known-good ECM/PCM, replace the original ECM/PCM. Page 2038 Splices Components Ground - "G" Page 5784 Under-hood Fuse And Relay Box (4-door) Page 3703 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 Locater) 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. Troubleshooting Precautions Troubleshooting Precautions Before Troubleshooting 1. Check the main fuse and the fuse 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, or you will damage the alternator diodes. - Do not attempt to crank the engine with the ground cable disconnected 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. Connector Views 41. EVAP Canister Purge Valve (except GX) Page 3277 93. VTEC Oil Pressure Switch (EX, HX) Page 1096 Transmission Position Switch/Sensor: Service and Repair Transmission Range Switch Replacement 1. Raise the vehicle, and make sure it is securely supported. 2. Shift to the N position. 3. Remove the transmission range switch cover (A). 4. Disconnect the transmission range switch connector (B). 5. Remove the old transmission range switch, and install the new switch. 6. Make sure that the control shaft is in the N position. If necessary, move the shift lever to the N position. Page 7450 - 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. Troubleshooting Tests 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 test 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 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. 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 Drop Page 5464 223. ABS Modulator-Control Unit (EX, GX) Page 5415 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 Continuously Variable Transmission Transmission Position Switch/Sensor: Testing and Inspection Continuously Variable Transmission Transmission Range Switch Test 1. Disconnect the transmission range switch connector. 2. Check for continuity between terminals at the switch connector. There should be continuity between terminals below listed for each switch position. 3. If there is no continuity between any terminals, adjust the transmission range switch installation. If the transmission range switch installation is OK, replace the transmission range switch. 4. If the transmission range switch continuity check was OK, replace the faulty transmission harness. Page 6702 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 a VIN status inquiry before selling it. CUSTOMER NOTIFICATION Recall 10V364000: Ignition Interlock Defect Shift Interlock Switch: All Technical Service Bulletins Recall 10V364000: Ignition Interlock Defect VEHICLE MAKE/MODEL: MODEL YEAR(S): Honda/Accord 2003 Honda/Civic 2003 Honda/Element 2003-2004 MANUFACTURER: Honda (American Honda Motor Co.) MFR'S REPORT DATE: August 04, 2010 NHTSA CAMPAIGN ID NUMBER: 10V364000 NHTSA ACTION NUMBER: EA09001 COMPONENT: Electrical System: Ignition POTENTIAL NUMBER OF UNITS AFFECTED: 384220 SUMMARY: Honda is recalling certain model year 2003 Honda Accord, Civic two and four door, and model year 2003-2004 Honda Element vehicles. The interlock lever of the ignition switch may unexpectedly deform, which can allow the interlock function of a vehicle with an automatic transmission to be defeated. CONSEQUENCE: Removal of the ignition key when the gear selector of a vehicle with an automatic transmission has not been shifted to the park position can allow the vehicle to roll away, increasing the risk of a crash. REMEDY: Dealers will remove the original interlock pin and lever within the ignition switch, and replace them with newly, designed components. This service will be performed free of charge. The safety recall is expected to begin on or about September 29, 2010. Owners may contact Honda at 1-800-999-1009. NOTES: Honda safety recall No. R44. 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. Locations Parking Brake Warning Switch: Locations Gauges Component Location Index (Part 1 Of 4) Page 1037 13. Remove the solenoid cover, and make sure the solenoid plunger groove is installed in the fork on the lever. ^ If needed, correct the position of the solenoid plunger, then go to step 14. ^ If the solenoid plunger is correctly installed, there is an electrical problem with the key interlock system; refer to the Automatic Transmission section of the appropriate service manual for troubleshooting information. Once the key interlock is working normally, go to step 14. 14. Install the solenoid cover. 15. Reinstall the steering column covers. 16. Center-punch a completion mark above the seventh character of the engine compartment VIN. Disclaimer Service and Repair Trunk / Liftgate Weatherstrip: Service and Repair Trunk Lid Weatherstrip Replacement 1. Remove the trunk lid weatherstrip (A) by pulling it off. 2. Locate the painted alignment mark (B or C) on the trunk lid weatherstrip. Align the painted mark with the alignment tab in the center of the trunk, and install the weatherstrip. Make sure it's seated completely and facing in the direction shown. Make sure there are no wrinkles in the weatherstrip. 3. Check for water leaks. Locations Throttle Position Sensor: Locations PGM-FI System - Component Location Index Locations Page 6073 235. Under-dash Fuse/Relay Box Part 8 Page 8842 Fuel Gauge Sender: Testing and Inspection Fuel Gauge Sending Unit Test Special Tools Required Fuel sender wrench 07XAA-001010A NOTE: For the fuel gauge system circuit diagram, refer to the Gauges Circuit Diagram. 1. Check the No.10 METER (7.5A) fuse in the under-dash fuse/relay box before testing. 2. Do the gauge drive circuit check. - If the fuel gauge needle sweeps from minimum to maximum position and then returns to the minimum position, the gauge is OK. Go to step 3. - If the fuel gauge needle does not sweep from minimum to maximum position and then return to the minimum position, replace the gauge assembly and retest. 3. Turn the ignition switch OFF. 4. Remove the rear seat cushion. 5. Remove the access panel from the floor. 6. Disconnect the fuel pump 5P connector. 7. Measure voltage between fuel pump 5P connector terminals No.1 and No.2 with the ignition switch ON (II). There should be battery voltage. - If the voltage is OK, go to step 7. - If the voltage is not as specified, check for: a short in the YEL/BLK wire to ground. - an open in the YEL/BLK or BLK wire. - poor ground (G551). 8. Turn the ignition switch OFF. Remove the No.9 BACK UP (10A) fuse from the under-hood fuse/relay box for at least 10 seconds, then reinstall it. Page 5250 Use the tools from Pin Tool Set. First, check the connector that you are about to repair. - If it has a secondary terminal lock, go to Connectors With a Secondary Lock. A secondary lock, found on most connectors on some models, is an additional locking device on the connector housing as a backup for the primary lock on the terminal. - If the connector does not have a secondary lock, go to Connectors Without a Secondary Lock. Connectors With a Secondary Lock All examples are shown with the connector lock facing up. The illustrations are examples of the secondary terminal locks; however, the connector you are repairing may vary in size. Identify the connector by the type of secondary lock, not by the number of terminal cavities. EXAMPLE A: 1. Release the secondary lock. 2. Remove the terminal. 3. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE B: Page 7698 ^ If the trunk opens and closes smoothly, return the vehicle to the customer. ^ If the trunk lid is still difficult to close, go to REPAIR PROCEDURE E. REPAIR PROCEDURE E 1. Look at the back of the lock cylinder while you turn the key from lock to unlock. ^ Refer to page 20-158 of the 2001-04 Civic Service Manual. ^ In ISIS, use the keyword LID LOCK, and select Trunk Lid Lock Cylinder Replacement from the list. 2. Check the operation of the trunk lid lock cylinder: ^ If the lock cylinder is difficult to turn or binds, go to step 3. ^ If the lock cylinder operates properly, and the trunk lid is still difficult to close, refer to the appropriate body repair manual, and check for body inaccuracies. 3. Replace the lock cylinder, and re-key the cylinder to the customer's original key; on 2-door Civics, replace the lock cylinder and the lock cylinder rod: ^ Refer to page 20-158 of the 2001-04 Civic Service Manual. ^ In ISIS, use the keyword LID LOCK, and select Trunk Lid Lock Cylinder Replacement from the list. 4. Check the trunk operation, and return the vehicle to the customer. Disclaimer Page 9654 1. Remove the terminal. 2. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE G: 1. Remove the terminal. 2. Go to HOW TO INSTALL NEW TERMINALS. How to Install New Terminals HOW TO INSTALL NEW TERMINALS 1. Carefully match the old terminal with a new one from the terminal repair kit. Choose the correct replacement terminal based on the wire size range the terminal will accommodate. NOTE: If the replacement terminal quantities are low, reorder them by using the terminal part number listed on the inside lid of the terminal repair kit. Replacement terminals are available through your parts department using normal parts ordering procedures. 2. Depending on the size of the wire you are repairing, use the proper size slot in the crimping tool. Page 1468 5. After checking and repairing leaks, the system must be evacuated. Page 9074 Connectors - "C" Page 2383 PGM-F1 Main Relay 1, 2 Type 1, 2 Check for continuity between the terminals. - There should be continuity between the No.1 and No.2 terminals when power and ground are connected to the No.3 and No.4 terminals. - There should be no continuity between the No.1 and No.2 terminals when power is disconnected. Normally-open type B: Rear Window Defogger Relay Page 4100 - Before connecting connectors, make sure the terminals (A) are in place and not bent. - Check for loose retainer (A) and rubber seals (B). - The backs of some connectors are packed with dielectric grease. Add grease if necessary. If the grease is contaminated, replace it. - Insert the connector all the way and make sure it is securely locked. - Position wires so that the open end of the cover faces down. Handling Wires and Harnesses - Secure wires and wire harnesses to the frame with their respective wire ties at the designated locations. Page 3205 - Before connecting connectors, make sure the terminals (A) are in place and not bent. - Check for loose retainer (A) and rubber seals (B). - The backs of some connectors are packed with dielectric grease. Add grease if necessary. If the grease is contaminated, replace it. - Insert the connector all the way and make sure it is securely locked. - Position wires so that the open end of the cover faces down. Handling Wires and Harnesses - Secure wires and wire harnesses to the frame with their respective wire ties at the designated locations. Page 8346 Use the double action sander and #60-#80 disc paper. - Sand the area larger than the damaged area. Use the double action sander and #180-#240 disc paper. - If a double action sander is not available, use a rubber pad and wet or dry sandpaper. Use the flexible block and #280, #346, #400, #600 sandpaper. Damage to undercoat, intermediate coat and top coat: Sand the damage area flat and smooth Use the double action sander and #180 - #240 - #320 disc paper 2. Preparation of metal surface Remove all corrosion from the damaged area. Use a product that removes corrosion. 3. Air blowing/degreasing Use alcohol, and wax and grease remover. Treatment of Metal Surface Treatment of Metal Surface 1. Filling/drying Small cracks or pinholes in the sheet metal should be repaired with a body filler and sanded flat and smooth. Use the 2-part polyester resin putty. - Mix the putty with the hardener in the correct ratio. - Follow the body filler manufacturer's instructions. Page 5832 Exterior Lights Component Location Index Continuously Variable Transmission Transmission Position Switch/Sensor: Testing and Inspection Continuously Variable Transmission Transmission Range Switch Test 1. Disconnect the transmission range switch connector. 2. Check for continuity between terminals at the switch connector. There should be continuity between terminals below listed for each switch position. 3. If there is no continuity between any terminals, adjust the transmission range switch installation. If the transmission range switch installation is OK, replace the transmission range switch. 4. If the transmission range switch continuity check was OK, replace the faulty transmission harness. Page 3139 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 Locater) 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. Troubleshooting Precautions Troubleshooting Precautions Before Troubleshooting 1. Check the main fuse and the fuse 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, or you will damage the alternator diodes. - Do not attempt to crank the engine with the ground cable disconnected 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. Page 5001 Transmission Position Switch/Sensor: Electrical Diagrams Circuit Diagram Page 9637 Power Distribution schematics show how power is supplied from the positive battery terminal to various circuits in the vehicle. Refer to the Power Distribution diagram set to get a more detailed understanding of how picture is supplied to the circuit you're working on. Individual circuit schematics begin with a fuse. So 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 Ground Distribution Schematics This sample Ground Distribution schematic shows all of the components that share the same ground point. Page 3132 Circuit Schematics Each schematic represents one circuit. A circuit's wires and components are arranged to show current flow from power at the top of the diagram 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 Page 1877 Rocker Arm Assembly: Service and Repair Rocker Arms and Shafts Disassembly/Reassembly Disassembly/Reassembly NOTE: ^ Identify parts as they are removed to ensure reinstallation in original location. ^ Inspect the rocker shafts and rocker arms. ^ The rocker arms must be installed in the same positions if reused. ^ When removing or installing the rocker arm assembly, do not remove the camshaft holder bolts. The bolts will keep the holders, springs and rocker arms on the shaft. ^ Prior to reassembling, clean all the parts in solvent, dry them, and apply lubricant to any contact points. ^ Bundle the intake rocker arm assemblies with rubber bands to keep them together as a set. Page 637 Brake Light Switch: Testing and Inspection Brake Pedal Position Switch Test 1. Disconnect the 4P connector (A) from the brake pedal position switch (B). 2. Check for continuity between the No.1 and No.2 terminals. - There should be continuity when the brake pedal is pressed. - There should be no continuity when the brake pedal is released. 3. Check for continuity between the No.3 and No.4 terminals (with cruise control). - There should be no continuity when the brake pedal is pressed. - There should be continuity when the brake pedal is released. 4. If necessary, adjust or replace the switch, or adjust the pedal height. Page 9362 2. Remove the terminal (same procedure for male and female). 3. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE E: 1. Remove the secondary locks. 2. Remove the terminal (same procedure for male and female). 3. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE F: Page 9091 Use the tools from Pin Tool Set. First, check the connector that you are about to repair. - If it has a secondary terminal lock, go to Connectors With a Secondary Lock. A secondary lock, found on most connectors on some models, is an additional locking device on the connector housing as a backup for the primary lock on the terminal. - If the connector does not have a secondary lock, go to Connectors Without a Secondary Lock. Connectors With a Secondary Lock All examples are shown with the connector lock facing up. The illustrations are examples of the secondary terminal locks; however, the connector you are repairing may vary in size. Identify the connector by the type of secondary lock, not by the number of terminal cavities. EXAMPLE A: 1. Release the secondary lock. 2. Remove the terminal. 3. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE B: Component Locations Shift Interlock Switch: Component Locations Component Location Index Page 6802 Impact Sensor: Diagrams 54. Impact Sensor, Left Front 55. Impact Sensor, Right Front 77. Side Impact Sensor, Driver's Page 346 Air Bag Control Module: Diagrams 231. OPDS Unit Page 6835 1. On Accords and Pilots, remove the front passenger's seat-back panel by prying out the bottom. Replace the two lower clips. 2. On all models except Accords and Pilots, unzip the two seat cover zippers on the back of the front passenger's seat. 3. Pull back the seat-back cover from the left side bolster to access the OPDS unit cover. 4. Remove the OPDS unit cover from the seat frame. 5. Check the part number of the installed OPDS unit. Page 7953 Air Bag(s) Arming and Disarming: Description and Operation SRS Components SRS Components Airbags The SRS is a safety device which, when used 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 (A), the cable reel (B), the driver's airbag (C), the front passenger's airbag (D), seat belt tensioners (I), seat belt buckle tensioners (J), and front impact sensors (K). Since the driver's and front passenger's airbags use the same sensors, both normally inflate at the same time. However, it is possible for only one airbag to inflate. This can occur when the severity of a collision is at the margin, or threshold, that determines whether or not the airbags will deploy. In such cases, the seat belt will provide sufficient protection, and the supplemental protection offered by the airbag would be minimal. Side Airbags The side airbags (E) are in each front seat-back. They help protect the upper torso of the driver or front seat passenger during a moderate to severe side impact. Side impact sensors (F) in each door sill and in the SRS unit detect such an impact and instantly inflate the driver's or the passenger's side airbag. Only one side airbag will deploy during a side impact. If the impact is on the passenger's side, the passenger's side airbag will deploy even if there is no passenger. 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. OPDS The side airbag system also includes an occupant position detection system (OPDS). This system consists of sensors (G) and a OPDS unit (H) in the front passenger's seat-back. The OPDS unit sends occupant height and position data to the SRS unit. If the OPDS unit determines that the front passenger is of small stature (for example, a child) and the front passenger is leaning into the side airbag deployment path, the SRS unit will automatically disable the passenger's side airbag. The SRS unit will also disable the airbag when the OPDS detects certain objects on the seat. When the side airbag is disabled, the side airbag cutoff indicator on the instrument panel alerts the driver that the passenger's side airbag will not deploy in a side impact. When the object is removed, or the passenger sits upright, the Side Airbag Cutoff indicator will go off after a few seconds, alerting the driver that the passenger's side airbag will deploy in a side impact. Body - Power Windows Inoperative/Intermittent Operation Power Window Switch: Customer Interest Body - Power Windows Inoperative/Intermittent Operation 06-010 March 8, 2006 Applies To: 2001-05 Civic - All LX and EX 4-door 2003-05 Civic Hybrid - ALL 2001-05 Civic GX ALL Power Window Does Not Work or Works Intermittently SYMPTOM One or more of the power windows does not work or works intermittently from the power window master switch (in the driver's door). PROBABLE CAUSE The power window master switch is faulty. CORRECTIVE ACTION Replace the power window master switch. PARTS INFORMATION WARRANTY CLAIM INFORMATION In warranty: The normal warranty applies. Operation Number: 744100 Flat Rate Time: 0.2 hr Failed Part: P/N 35750-S5A-A01ZA H/C 6453419 Defect Code: 03217 Symptom Code: 01201 Template ID: 06-010A (Black Switch) 06-010B (Medium Taupe Switch) 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 1017 7. Apply a small amount of Permalube grease to the base of the new lever. Then attach the slide hammer to the new lever pin, insert the lever into the ignition switch, and seat the pin with the slide hammer. 8. Check the installed height of the pin with vernier calipers. If the height is more than 5.0 mm, the pin is not seated. If needed, reattach the slide hammer, and seat the pin. NOTE: It's normal for the interlock lever to be loose, even when the pin is fully seated. 9. Install a new spring on the lever. Make sure you attach the ends of the spring correctly: ^ The right end goes into the slot on the ignition switch. Engine Controls - DTC P0171 Set Absolute Pressure Sensor: Technical Service Bulletins Engine Controls - DTC P0171 Set SOURCE: Honda Service News TITLE: Got a DTC P0171? Check the Short-Term Fuel Trim APPLIES TO: 03-04 Accord 01-04 Civic 02-04 CR-V 03-04 Element 02-04 Odyssey 03-04 Pilot SERVICE TIP: Got a vehicle in your shop that purrs like a kitten but it sets a DTC P0171 (fuel system too lean)? Check the short-term fuel trim (ST FUEL TRIM B1). If the value reads higher than 1.05, then check the MAP SENSOR value with the engine turned off and the ignition switch turned to ON (II). - If the MAP SENSOR and BARO SENSOR values match, the MAP sensor is working OK. Do the normal troubleshooting for DTC P0171. - If the MAP SENSOR and BARO SENSOR values don't match, install a known-good MAP sensor, and retest. If the sensor values now match, clear the DTC, and make sure the ST FUEL TRIM B1 value is normal (it reads about 1.0). Page 616 Key Reminder Switch: Locations Entry Light Control System Component Location Index Page 7742 1. Check the depth adjustment of the trunk lid: ^ Refer to page 20-132 of the 2001-04 Civic Service Manual. ^ In ISIS, use the keyword TRUNK ADJUST, and select Trunk Lid Adjustment from the list. 2. Make sure the trunk lid is flush on all sides and corners. ^ If the trunk is misaligned, go to step 3. ^ If the trunk lid is properly aligned on all sides and corners, go to REPAIR PROCEDURE C. 3. Adjust the striker depth position and the trunk lid edge cushions: ^ Refer to page 20-132 of the 2001-04 Civic Service Manual. ^ In ISIS, use the keyword TRUNK ADJUST, and select Trunk Lid Adjustment from the list. 4. Check the trunk operation: ^ If the trunk opens and closes smoothly, return the vehicle to the customer. ^ If the trunk lid is still difficult to close, go to REPAIR PROCEDURE C. REPAIR PROCEDURE C 1. Use a small screwdriver to manually set and release the trunk lid latch. Check the operation of the latch: ^ If the latch is difficult to set or release, go to step 2. ^ If the latch operates properly, go to REPAIR PROCEDURE D. 2. Replace the trunk lid latch: ^ Refer to page 20-157 of the 2001-04 Civic Service Manual. ^ In ISIS, use the keyword LID LATCH, and select Trunk Lid Latch Replacement from the list. 3. Check the trunk operation: ^ If the trunk opens and closes smoothly, return the vehicle to the customer. ^ If the trunk lid is still difficult to close, go to REPAIR PROCEDURE D. REPAIR PROCEDURE D 1. Disconnect the trunk lid opener cable from the trunk lid latch. Check the cable operation: ^ Refer to page 20-157 of the 2001-04 Civic Service Manual. ^ In ISIS, use the keyword LID LATCH, and select Trunk Lid Latch Replacement from the list. 2. Check that there is no friction or binding of the cable by holding the outside casing and pulling back and forth on the inner cable: ^ If the cable is difficult to move or binds, go to step 3. ^ If the cable operates smoothly, go to REPAIR PROCEDURE E. 3. Replace the trunk lid opener cable: ^ Refer to page 20-151 of the 2001-04 Civic Service Manual. ^ In ISIS, use the keyword LID OPEN, and select Trunk Lid Opener/Fuel Fill Door Opener Cable Replacement from the list. 4. Check the trunk operation: Page 7326 ^ 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 9686 Power Windows Component Location Index Page 3615 Knock Sensor: Description and Operation Knock Sensor The knock control system adjusts the ignition timing to minimize knock. Service and Repair Power Steering Line/Hose: Service and Repair Power Steering Hoses, Lines, and Pressure Switch Replacement Note these items during installation: ^ Connect each hose to the corresponding line securely until it contacts the stop on the line. Install the clamp or adjustable clamp at the specified distance from the hose end as shown. ^ Check all clamps for deterioration or deformation; replace the clamps with new ones, if necessary. ^ Add the recommended power steering fluid to the specified level on the reservoir and check for leaks. Page 6720 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 a VIN status inquiry before selling it. CUSTOMER NOTIFICATION Page 85 Cruise Control Module: Testing and Inspection Cruise Control Unit Input Test Except 2-door D17A1, D17A2 engines: SRS components are located in this area. Review the SRS component locations, precautions, and procedures, in the SRS before performing repairs or service. 1. Remove the driver's dashboard lower cover. 2. Disconnect the 14P connector from the control unit. 3. Inspect the connector and socket terminals to be sure they are all making good contact. - If the terminals are bent, loose, or corroded, repair them as necessary, and recheck the system. - If the terminals look OK, go to step 4. Page 7699 Trunk / Liftgate Latch: Testing and Inspection Trunk Latch Switch Test 1. Open the trunk lid. 2. Disconnect the 2P connector (A) from the trunk lid latch (B). 3. Check for continuity between the No.1 and No.2 terminals. - There should be continuity with the trunk lid open. - There should be no continuity with the trunk lid closed. 4. If the continuity is not as specified, replace the trunk lid latch. Diagrams Multiple Junction Connector: Diagrams 217. C102 (Junction Connector) Page 280 ECM/PCM Inputs And Outputs At Connector B (24P) Page 9127 Diodes Light Emitting Diode (LED) Motor Pressure Sensor Page 6254 4. Install the right gearbox mounting bracket (A) on the frame. 5. Slip the right side of the steering gearbox over the mounting stud (A) on the right gearbox mounting bracket. Install the washer (B) and the gearbox mounting nut (C) and lightly tighten. 6. Insert the pinion shaft up through the bulkhead, and install the left gearbox mounting bolts (A) anal washer (B), and tighten them to the specified torque. Then tighten the right side of the gearbox mounting nut to the specified torque value. Page 9652 1. Remove the terminal. 2. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE B: 1. Remove the terminal. 2. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE C: 1. Remove the terminal. 2. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE D: Page 5932 2. Insert the terminal tool into the female terminal, and then remove the terminal tool. NOTE: Make sure you do not select a terminal tool that is larger than the mating male terminal because it would spread the female terminal and cause a loose fit. 3. Compare the drag to the other terminals in the connector. If the drag is less, replace the terminal with a replacement terminal from the appropriate terminal repair kit. Service and Repair Vehicle Lifting: Service and Repair Lift and Support Points NOTE: If you are going to remove heavy components such as the suspension or the fuel tank from the rear of the vehicle, first support the front of the vehicle with tall safety stands. When substantial weight is removed from the rear of the vehicle, the center of gravity can change and cause the vehicle to tip forward on the hoist. Frame Hoist 1. Position the hoist lift blocks (A), or safety stands, under the vehicle's front support points (B) and rear support points (C). 2. Raise the hoist a few inches, and rock the vehicle gently to be sure it is firmly supported. 3. Raise the hoist to full height, and inspect the lift points for solid contact with the lift blocks. Safety Stands To support the vehicle on safety stands, use the same support points (B and C) as for a frame hoist. Always use safety stands when working on or under any vehicle that is supported only by a jack. Floor Jack 1. Set the parking brake. 2. Block the wheels that are not being lifted. 3. When lifting the rear of the vehicle, put the gearshift lever in reverse (or the automatic transmission in [P] position). 4. Position the floor jack under the front jacking bracket (A) or rear jacking bracket (B), center the jacking bracket in the jack lift platform (C), and jack up the vehicle high enough to fit the safety stands under it. 5. Position the safety stands under the support points and adjust them so the vehicle will level. 6. Lower the vehicle onto the stands. Page 2004 10. Install the back cover (A), then install the camshaft pulley (B). Page 1196 6. Separate the master switch plate (A) from the armrest (B). 7. Remove the three screws and replace the switch. 2-door Page 7273 Diodes Light Emitting Diode (LED) Motor Pressure Sensor Page 4060 3. Install the oil seal (A) in the transmission housing with the special tools. 4. Install the oil seal (A) in the torque converter housing with the special tools. Carrier Bearing Side Clearance Inspection Special Tools Required Driver 40 mm I.D. 07746-0030100 Page 4979 - Remove clips carefully; don't damage their locks (A). - Slip pliers (A) under the clip base and through the hole at an angle, then squeeze the expansion tabs to release the clip. - After installing harness clips, make sure the harness doesn't interfere with any moving parts. - Keep wire harnesses away from exhaust pipes and other hot parts, from sharp edges of brackets and holes, and from exposed screws and bolts. - Seat grommets in their grooves properly (A). Do not leave grommets distorted (B). Testing and Repairs - Do not use wires or harnesses with broken insulation. Replace them or repair them by wrapping the break with electrical tape. - After installing parts, make sure that no wires are pinched under them. - When using electrical test equipment, follow the manufacturer's instructions and those described. - If possible, insert the probe of the tester from the wire side (except waterproof connector). - Use back probe adaptor 07TAZ-001020A. - Refer to the instructions in the Honda Terminal Kit for identification and replacement of connector terminals. Five-Step Troubleshooting Five-Step Troubleshooting 1. Verify The Complaint Page 4550 1. Remove the final driven gear from the differential carrier. The final driven gear bolts have left-hand threads. 2. Install the final driven gear with the chamfered side on the inner bore (A) facing the differential carrier. 3. Tighten the bolts to 98 Nm (10.0 kgf-cm, 72 ft. lbs.) in a crisscross pattern. Carrier Bearing Replacement Special Tools Required Driver 40 mm I.D. 07746-0030100 1. Remove the bearings (A) with a commercially available bearing puller (B), and adapter (C). Page 1242 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 6426 12. Loosen the damper pinch bolts (A) while holding the nuts (B), and remove the bolts and nuts. 13. Remove the driveshaft outboard joint (C) from the knuckle (D) by tapping the driveshaft end (E) with a plastic hammer while pulling the knuckle outward, then remove the knuckle. NOTE: Do not pull the driveshaft end outward. The driveshaft joint may come off. 14. Separate the hub (A) from the knuckle (B) using the special tool and a hydraulic press. Be careful not to deform the splash guard. Hold onto the hub to keep it from falling when pressed clear. 15. Press the wheel bearing inner race (A) out of the hub (B) using the special tool, a commercially available bearing separator (C), and a press. Page 4693 3. If there is no continuity between any terminal, remove the transmission range switch cover, and disconnect the connector (A) at the switch (B). 4. Check for continuity between terminals at the switch connector (c). There should be continuity between the terminals listed for each position. In the P position, between terminals: ^ No. 4 and No. 5 ^ No. 4 and No. 6 ^ No. 5 and No. 6 In the R position, between terminals: ^ No. 1 and No. 4 In the N position, between terminals: ^ No. 4 and No. 5 ^ No. 4 and No. 7 ^ No.5 and No.7 In the D position, between terminals: ^ No.2 and No.4 ^ No. 2 and No. 10 ^ No. 4 and No. 10 In the D3 position, between terminals: ^ No. 4 and No. 8 ^ No. 4 and No. 10 ^ No. 8 and No. 10 In the 2 position, between terminals: ^ No.3 and No.4 5. If there is no continuity between any terminals, adjust the transmission range switch installation. If the transmission range switch installation is OK, replace the switch. 6. If the transmission range switch continuity check was OK, replace the faulty transmission range switch harness. Page 6892 2. Disconnect the side airbag harness 2P connector (A). 3. Remove the seat assembly and seat-back cover. 4. Remove the mounting nut (A) and the side airbag (B). Installation NOTE: - If the side airbag lid is secured by a tape, remove the tape. - Do not open the lid of the side airbag cover. - Use new mounting nuts tightened to the specified torque. - Make sure that the seat-back cover is installed properly. Improper installation may prevent proper deployment. - Be sure to install the harness wires so that they are not pinched or interfering with other parts. 1. Place the new side airbag on the seat-back frame (A). Tighten the side airbag mounting nuts (B). 2. Install the seat-back cover. 3. Install the seat assembly, then connect the side airbag harness 2P connector. 4. Move the front seat and the seat-back through their full ranges of movement, making sure the harness wires are not pinched or interfering with other parts. Page 164 Circuit Schematics Each schematic represents one circuit. A circuit's wires and components are arranged to show current flow from power at the top of the diagram 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 Locations 57. Under Left Side Of Dash Page 4564 Fluid - CVT: Service and Repair ATF Replacement ATF Replacement NOTE: Keep all foreign particles out of the transmission. Change Intervals: Replace at 48,000 miles (80,000 km) or 48 months, then replace every 36,000 miles (60,000 km) or 36 months in normal conditions Replace every 24,000 miles (40,000 km) or 24 months in severe conditions 1. Park the vehicle on level ground. 2. Remove the drain plug (A), and drain the automatic transmission fluid (ATF). NOTE: If a cooler flusher is to be used, refer to ATF Cooler Flushing. 3. Reinstall the drain plug with a new sealing washer (B). 4. Refill the transmission with the recommended fluid into the dipstick hole (A). Always use Honda ATF-Z1 Automatic Transmission Fluid (ATF). Using non Honda ATF can affect shift quality. Automatic Transmission Fluid Capacity: 3.1 L (3.3 US qt) at changing 5.6 L (5.9 US qt) at overhaul 5. Check that the fluid level is between the upper mark (E) and lower mark (F) on COLD gauge (D), if the dipstick has COLD gauge. 6. Insert the dipstick back into the transmission. 7. Warm up the engine to normal operating temperature (the radiator fan comes on). 8. Check that the fluid level is between the upper mark (A) and lower mark (B) on HOT gauge (C). Do not check the level with COLD gauge (D) when the ATF wormed up. Page 5851 234. Under-dash Fuse/Relay Box Part 4 Page 2138 Coolant: Fluid Type Specifications Coolant Type .................................................................................................................................................. Honda All Season Antifreeze/Coolant Type 2 Page 3154 2. Cut off the wire about an inch back from where it connects to the damaged or faulty terminal, then strip about half of the insulation off that piece. This will be used to size the wire end of the replacement pigtail terminal. NOTE: If you are not sure of the wire size, start with a large enough hole on the stripper that will not nick or cut off any strands of wires. 3. Select a pigtail terminal that matches the original wire at both ends (same kind of terminal and same diameter bare wire). 4. Select the smallest splice connector (yellow, pink, or blue) that will fit onto the stripped end of the original wire. 5. Insert the pigtail terminal into the connector cavity; push it in until it locks in place. 6. Lay the pigtail and the original wire side-by-side, and cut off both ends at once. If you are making more than one splice, do not cut each pigtail at the same location; the resulting "lump" of splice connectors would interfere with rewrapping the harness. Instead, cut the first pigtail close enough to the terminal so you will have room to make each remaining cut about 20 mm (3/4 inch) farther down on the next pigtail. 7. If you are using a yellow splice connector, strip about 6 mm (1/4 inch) of insulation off the ends of both wires. If you are using a pink or blue splice connector, strip off about 8 mm (5/16 inch) of insulation. Page 6025 1. Right Side Of Engine Compartment Page 3935 Disclaimer Page 9209 13. Plug in the heat gun, and turn it on. Start at the middle of the splice connector, and move the gun toward the ends as the tube shrinks. Apply heat evenly by rotating the curved heat spreader around the splice connector. Shrinking is complete when a small amount of sealant appears at each end of the tube. Pigtail Terminal Selection Chart PIGTAIL TERMINAL SELECTION CHART Select the proper size pigtail terminal by matching the replacement terminal part number and the wire size being repaired to the corresponding pigtail terminal part number. Then use the color (size) splice connector listed. In some instances you may also have to match the wire seal style to select the proper pigtail terminal. Pigtail terminals are available through your parts department, in quantities of 10, using normal parts ordering procedures. Checking For Poor Fir of Terminals CHECKING FOR POOR FIT OF TERMINALS Loose terminal fit can cause a number of intermittent problems in electrical circuits. By using the Terminal Inspection Feeler Tool Set you can inspect the terminal fit between the two matching connectors without removing the terminals from the connector body. 1. Find the terminal tool that best matches the male terminal in the mating connector. Page 7710 1. Check the depth adjustment of the trunk lid: ^ Refer to page 20-132 of the 2001-04 Civic Service Manual. ^ In ISIS, use the keyword TRUNK ADJUST, and select Trunk Lid Adjustment from the list. 2. Make sure the trunk lid is flush on all sides and corners. ^ If the trunk is misaligned, go to step 3. ^ If the trunk lid is properly aligned on all sides and corners, go to REPAIR PROCEDURE C. 3. Adjust the striker depth position and the trunk lid edge cushions: ^ Refer to page 20-132 of the 2001-04 Civic Service Manual. ^ In ISIS, use the keyword TRUNK ADJUST, and select Trunk Lid Adjustment from the list. 4. Check the trunk operation: ^ If the trunk opens and closes smoothly, return the vehicle to the customer. ^ If the trunk lid is still difficult to close, go to REPAIR PROCEDURE C. REPAIR PROCEDURE C 1. Use a small screwdriver to manually set and release the trunk lid latch. Check the operation of the latch: ^ If the latch is difficult to set or release, go to step 2. ^ If the latch operates properly, go to REPAIR PROCEDURE D. 2. Replace the trunk lid latch: ^ Refer to page 20-157 of the 2001-04 Civic Service Manual. ^ In ISIS, use the keyword LID LATCH, and select Trunk Lid Latch Replacement from the list. 3. Check the trunk operation: ^ If the trunk opens and closes smoothly, return the vehicle to the customer. ^ If the trunk lid is still difficult to close, go to REPAIR PROCEDURE D. REPAIR PROCEDURE D 1. Disconnect the trunk lid opener cable from the trunk lid latch. Check the cable operation: ^ Refer to page 20-157 of the 2001-04 Civic Service Manual. ^ In ISIS, use the keyword LID LATCH, and select Trunk Lid Latch Replacement from the list. 2. Check that there is no friction or binding of the cable by holding the outside casing and pulling back and forth on the inner cable: ^ If the cable is difficult to move or binds, go to step 3. ^ If the cable operates smoothly, go to REPAIR PROCEDURE E. 3. Replace the trunk lid opener cable: ^ Refer to page 20-151 of the 2001-04 Civic Service Manual. ^ In ISIS, use the keyword LID OPEN, and select Trunk Lid Opener/Fuel Fill Door Opener Cable Replacement from the list. 4. Check the trunk operation: Page 859 172. EGR Valve And EGR Valve Position Sensor (EX, HX; '04-'05: DX, LX) Page 7102 Engine - Connecting Rod Damage Information Connecting Rod: Technical Service Bulletins Engine - Connecting Rod Damage Information Why Do Connecting Rods Break? Curious why connecting rods break? Afier all, these are heavy-duty parts specifically designed to endure punishing forces and temperatures. Yet, every once in a while they do bend or break and wind up as cool conversation pieces for a coffee table or desk. Connecting rods break only after they've gotten bent. And they won't get bent unless the engine hydro-locks or the rod bearings fail. When troubleshooting a bent or broken connecting rod, here are some things to consider: ^ The number one culprit for connecting rod breakage is hydro-lock. This happens when liquid (water or fuel) entering the combustion chamber exceeds the chamber's volume. Since liquids don't compress, that extra volume in the chamber causes the rod to bend. You won't really notice anything wrong, until that bent rod finally gives out and breaks. This could happen if you're driving through deep, standing water and someone coming the other way splashes water over your hood. On very rare occasions, a bad ECM/PCM or fuel injector can cause too much fuel to enter a cylinder, causing hydro-lock and resulting in a bent rod. Before this happens, though, there are usually some kind of drive ability problems that crop up and remain afier the engine is fixed. A bent rod might not show any symptoms until it actually breaks. But bent rods leave a wider-than-normal carbon witness line in the cylinder because they're shorter. Typically, a healthy engine has a carbon line that's 6 mm deep. An engine that's suffering from bent rods has a second carbon line that's 9 to 12 mm deep. ^ Connecting rod bearings fail for a number of reasons. To properly determine what actually caused a rod bearing to fail, you've got to take apart all rod bearings and main bearings and compare them side by side. If all or most of the bearings and journals show similar damage (scoring, exposed copper, or heat discoloration) the likely cause is oil starvation, poor maintenance, customer abuse, or running the engine with an aftermarket power booster (nitrous oxide setup, supercharger, turbocharger). If only the bearing or journal for the failed rod looks bad but all the other ones look good (no scoring, no exposed copper or heat discoloration) and the crankshaft journals are smooth with no heat discoloration, then that particular bearing/ clearance would be suspect. Page 6283 3. Install the steering wheel bolt (A) or nut and tighten it. 4. Connect the horn switch connector and the cruise control set/resume switch connector. 5. Install the driver's airbag, and confirm that the system is operating properly 6. Check the horn and turn signal cancelling for proper operation. 7. Reconnect the battery and do the following: ^ PCM idle learn procedure. ^ Enter the anti-theft code for the radio, then enter the customer's radio station presets. ^ Reset the clock. Page 3252 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 Locater) 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. Troubleshooting Precautions Troubleshooting Precautions Before Troubleshooting 1. Check the main fuse and the fuse 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, or you will damage the alternator diodes. - Do not attempt to crank the engine with the ground cable disconnected 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. Service and Repair Oil Filter: Service and Repair Engine Oil Filter Replacement Special Tools Required ^ Oil filter wrench 07HAA-PJ70100 3/4-turn type 1. Remove the oil filter with the special oil filter wrench. 2. Inspect the threads (A) and rubber seal (B) on the new filter. Wipe off the seat on the engine block, then apply a light coat of oil to the filter rubber seal. Use only filters with a built-in bypass system. 3. Install the oil filter by hand. 4. After the rubber seal seats, tighten the oil filter clockwise with the special tool. Tighten:3/4 turn clockwise. Tightening torque: 12 Nm (1.2 kgf-cm, 8.7 ft. lbs.) Page 8927 consideration by the District Parts and Service Manager or your Zone Office. You must request consideration, and get a decision, before starting work. WARRANTY MILEAGE CONVERSION NOTE: Follow normal warranty claim coding when submitting a claim. SERVICE BULLETINS AFFECTED BY EXTENDED MILEAGE COVERAGE Disclaimer Page 2478 Oxygen Sensor: Connector Locations 10. Middle Of Engine 11. Middle Of Engine (except EX) Page 7437 Connectors - "C" Page 3077 Knock Sensor: Description and Operation Knock Sensor The knock control system adjusts the ignition timing to minimize knock. Page 6837 12. On Accords and Pilots, install the new seat-back clips on the seat-back panel. Turn the clips so their retaining tabs are horizontal. 13. On Accords and Pilots, install the seat-back panel. 14. On all models except Accords and Pilots, zip the seat-back cover closed. 15. Initialize the OPDS unit. ^ To initialize with the HDS, go to Initializing the OPDS Unit: HDS Method. ^ To initialize with the SCS service connector, go to Initializing the OPDS Unit: Manual Mode. Initializing the OPDS Unit: HDS Method NOTE: Non-Honda seat covers will interfere with the performance of the OPDS and are not recommended. 1. Adjust the front passenger's seat-back to an upright position, then remove anything on or near the seat. 2. Turn the ignition switch to LOCK (0). 3. Connect the HDS to the vehicle's DLC (data link connector). 4. Turn the ignition switch to ON (II), then turn on the HDS. 5. At the screen prompts, enter the VIN and the odometer reading. Also verify the correct date and time. 6. From the System Selection menu, select SRS. Page 5928 8. Inspect the quality of the wire crimp. If it has any of the following NO GOOD crimps, cut it off and start over. 9. Insert the terminal into the connector. Make sure the wire seals are pushed all the way into the connector. Lightly pull on the wires to make sure the terminal is locked into place. 10. Close or insert the secondary terminal lock, if applicable, and reconnect the connector. How to Install Pigtail Terminals HOW TO INSTALL PIGTAIL TERMINALS Pigtail terminals (short pieces of wire with a factory crimped terminal) are used when the wire is too short or when access to the connector is too restricted to make a terminal repair. NOTE: To replace just a connector terminal, go to How to Replace Connector Terminals. IMPORTANT SAFETY INFORMATION: On some models, the SRS wires are in a separate harness. If the SRS harness is damaged, replace the harness; do not repair it. On other models, wire harnesses include yellow SRS wires. If any SRS wire is damaged, replace the entire harness; do not repair it. 1. Remove the damaged or faulty terminal from the connector. Use the proper removal tool from Pin Tool Set. Service and Repair Cross-Member: Service and Repair Middle Cross-member Gusset Replacement 2-door NOTE: - Put on gloves to protect your hands. - Take care not to scratch the body. 1. Remove these items: - Rear seat-back - Rear seat cushion - Side trim panel 2. Pull back the rear part of the carpet, as necessary. 3. Detach the floor wire harness clip (A), and remove the cushion tape (B), then release the harness from the middle cross-member gusset (C). 4. Remove the bolts (A) and nuts (B), then remove the middle cross-member gusset (C). Page 4427 5. Align the hole in the flywheel with the crankshaft dowel pin, and install the flywheel. Install the mounting bolts finger-tight. 6. Install the special tool, then torque the flywheel mounting bolts in a crisscross pattern in several steps. Locations 13. Middle Of Engine (EX, HX) Removal and Installation Power Steering Pump: Service and Repair Removal and Installation Replacement 1. Place a suitable container under the vehicle. 2. Drain the power steering fluid from the reservoir. 3. Remove the belt (A) by loosening the adjusting bolt (B), pump mounting nut (C), and pump locknut (D). 4. Cover the A/C compressor with several shop towels to protect it from spilled power steering fluid. Disconnect the pump inlet hose (E) and pump outlet hose (F) from the pump (G), and plug them. Take care not to spill the fluid on the body or parts. Wipe off any spilled fluid at once. 5. Remove the adjusting bolt, pump mounting bolt (H), pump mounting nut, pump locknut, and lock bolt (I), then remove the pump from the pump bracket. Do not turn the steering wheel with the pump removed. 6. Cover the opening of the pump with a piece of tape to prevent foreign material from entering the pump. 7. Connect the pump inlet hose and pump outlet hose. Tighten the pump fittings securely. 8. Loosely install the pump in the pump bracket with the mounting bolt and lock bolt. 9. Install the pump belt. Note these item during belt installation: ^ Make sure that the power steering belt (A) is properly positioned on the pulleys (B). ^ Do not get power steering fluid or grease on the power steering belt or pulley faces. Clean off any fluid or grease before installation. 10. Adjust the pump belt adjustment 11. Fill the reservoir to the upper level line. Page 3304 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 Pressure Regulating Solenoid: Locations Electronic Controls Location Page 816 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. How to Replace Connector Terminals Terminal Replacement Procedure HOW TO REPLACE CONNECTOR TERMINALS The terminal repair kits provide necessary tools and materials (terminals, wire seals, and splice connectors) to repair many damaged or faulty connector terminals. However, not all terminals for all connectors are available. Refer to the labels on the lids of the repair kits for replacement terminal availability. IMPORTANT SAFETY INFORMATION: On some models, the SRS wires are in a separate harness. If the SRS harness is damaged, replace the harness; do not repair it. On other models, wire harnesses include yellow SRS wires. If any SRS wire is damaged, replace the entire harness; do not repair it. Before you begin, inspect the wire you are about to repair for damage and length. Make sure the wire will be long enough to make a terminal repair without stretching it when you reinstall the terminal in the connector. If the wire is too short, or if access to the connector is too restricted to make a terminal repair, you may need to install a pigtail terminal (a short length of wire with a factory-crimped terminal on it). Refer to HOW TO INSTALL PIGTAIL TERMINALS. Removing the Terminal Under-Dash Fuse/Relay Box Fuse: Locations Under-Dash Fuse/Relay Box Under-dash Fuse/Relay Box Page 7791 ^ Going from front to back, use the middle lock pin to set the first cam to the appropriate key code number in the code book. (The cam is properly set when the number on the cam lines up with the red scribe mark on the clamp unit.) ^ Slide the lock pin through the notch in the cam. (This locks the cam in place.) ^ Keep doing this for each of the remaining cams in the set until all the cams are set and locked, then push the lock pin all the way in. Repeat this process to set and lock the cams for the right cam set. NOTE: Make sure you set the MIS cam in the right cam set for the type of key you are cutting. For a master key, set the cam to M; for a valet key, set it to S. When you are done, push all the cam blades to the left until they touch the cams in the left cam set. 10. Pull the vertical carriage lever toward you until the tracer touches the flat surface on the right side at the front of the cams. Gently twist the lever clockwise to lock the vertical carriage at this height. Do not overtighten the lever. 11. Turn on the cutter motor with the motor start switch. [NOTICE] ^ To avoid damaging the locking jaws while cutting, keep your hand off the vertical carriage lever. Pressure on the lever will change the cutting depth. * ^ To avoid breaking the cutter bit, never back up while cutting.* ^ Wear proper eye protection (safety glasses, goggles, etc.) 12. Use the clamp carriage lever and the tracer to follow the contours of the cam blades from front to back. (The cutter bit cuts the same contours into the right edge of the key blank, from head to tip.) Page 6961 Page 5138 3. Strip the insulation off the end of the wire so the wire fits in the new terminal as shown. (If the wire has a wire seal, replace it with a new one from the kit.) NOTE: After stripping the end of the wire, make sure you did not cut any wire strands. If you did, cut the wire off even with the insulation, and strip it again. 4. Position the terminal in the crimping tool slot with the solid portion of the terminal toward the anvil and the open section toward the former. 5. Insert the wire in the terminal to the position shown in step 3. 6. Squeeze the tool with both hands until the stops make contact. 7. Crimp the insulation crimp. - If you do not have a wire seal, then use the next larger size crimp slot. Position the crimping tool over the insulation crimp section of the terminal, then squeeze the tool with both hands until the stops make contact. - If you have a wire seal, position the insulation crimp in the 5.5 crimping slot, then carefully squeeze the crimp closed until its ends are touching and making a full-circle shape. Page 3916 14. After finishing the updating procedure, the MVCI gives you the option of updating the same system on another vehicle. For more information on updating several vehicles, see the MVCI User Guide. 15. If an error occurs during the updating procedure, an error message appears. Keep the ignition switch in ON (II). Press ENTER to display the error code. Refer to the CM Update Error Code Table in the MVCI User Guide for more information about the code and its solutions.* UPDATING WITH THE GNA600 NOTE: For more information on the GNA6OO, refer to the GNA600 User's Guide. This guide is on ISIS, under the Tool Information heading. Two modes of updating can be used with the GNA600: Pass-Thru mode and Storage mode. Use Pass-Thru mode when the GNA6OO can be connected to an iN workstation and the vehicle at the same time. Use Storage mode when the GNA6OO cannot be connected to the iN workstation and the vehicle at the same time. GNA600 Updating in Pass-Thru Mode 1. If not already done, load the latest HDS PC software onto your iN workstation. For loading instructions, refer to the Tool Information publication Installation Instructions for HDS PC Software on ISIS. Page 1285 1. Raise the front of the vehicle, and support it with safety stands in the proper locations. Remove the front wheels. 2. Loosen the damper pinch nuts and bolts (A), and adjust the camber by moving the bottom of the damper within the range of the damper pinch bolt free play 3. Tighten the bolts to the specified torque. 4. Reinstall the front wheels. Lower the front of the vehicle to the ground, and bounce the vehicle several times to stabilize the suspension. 5. Check the camber angle. If it is within the specification, check the front toe. If it is not within the specification, go to step 6. 6. Raise the front of the vehicle, and support it with safety stands in the proper locations. Remove the front wheels. 7. Replace the damper pinch bolts with the adjusting bolts (A), and adjust the camber angle. NOTE: The camber angle can be adjusted up to ± 15' (center of tolerance) by replacing one damper pinch bolt with the adjusting bolt. The camber angle can be adjusted up to ± 30' by replacing both upper and lower damper pinch bolts with the adjusting bolts. 8. Tighten the bolts to the specified torque. 9. Reinstall the front wheels. Lower the front of the vehicle to the ground, and bounce the vehicle several times to stabilize the suspension. 10. Check the camber angle. if it is within the specification, check the front toe, and adjust it if necessary. If it is not within the specification, readjust, and recheck. If the camber angle cannot be adjusted to the specification, check for bent or damaged suspension components. Rear Camber Inspection Use commercially-available computerized four wheel alignment equipment to measure wheel alignment (caster, camber, toe, and turning angle). Follow the equipment manufacturer's instructions. Check the camber angle. If the camber angle is not within the specification, check for bent or damaged suspension components. Rear camber angle: - 0°45' ± 45' Front Toe Inspection/Adjustment Use commercially-available computerized four wheel alignment equipment to measure wheel alignment (caster, camber, toe, and turning angle). Follow the equipment manufacturer's instructions. 1. Center the steering wheel spokes. 2. Check the toe. If it is not within the specification, go to step 3. Front toe-in: 0 ± 3 mm (0 ± 0.12 inch) Page 8676 Relay And Control Unit Locations - Dashboard Page 4780 - Before connecting connectors, make sure the terminals (A) are in place and not bent. - Check for loose retainer (A) and rubber seals (B). - The backs of some connectors are packed with dielectric grease. Add grease if necessary. If the grease is contaminated, replace it. - Insert the connector all the way and make sure it is securely locked. - Position wires so that the open end of the cover faces down. Handling Wires and Harnesses - Secure wires and wire harnesses to the frame with their respective wire ties at the designated locations. Page 9008 Circuit Schematics Each schematic represents one circuit. A circuit's wires and components are arranged to show current flow from power at the top of the diagram 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 Page 6557 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 4272 7. Apply a small amount of Permalube grease to the base of the new lever. Then attach the slide hammer to the new lever pin, insert the lever into the ignition switch, and seat the pin with the slide hammer. 8. Check the installed height of the pin with vernier calipers. If the height is more than 5.0 mm, the pin is not seated. If needed, reattach the slide hammer, and seat the pin. NOTE: It's normal for the interlock lever to be loose, even when the pin is fully seated. 9. Install a new spring on the lever. Make sure you attach the ends of the spring correctly: ^ The right end goes into the slot on the ignition switch. Application and ID Grounding Point: Application and ID Ground To Components Index (4-door) Page 8585 17. Using a small screwdriver, push down on the tip of the last tumbler to release it, then remove the cylinder from the housing, being careful not to drop any tumblers and springs. Use your thumb and forefinger to hold the tumblers in place. Then go to step 20. 18. While turning the key left and right and pushing on the rear of the inner cylinder to release the spring, slowly remove the cylinder from the housing. Key Beeper, Light Chime & Ceiling Light Don't Work Dome Lamp: Technical Service Bulletins Key Beeper, Light Chime & Ceiling Light Don't Work SOURCE: Honda Service News April 2003 TITLE: Key Beeper, Light Chime, Ceiling Light Don't Work APPLIES TO: 2001-03 Civic, 2002-03 CR-V SERVICE TIP: If the ignition key-in beeper, the headlights-on chime, the ceiling light, and the driver's-dooropen indicator are all on the fritz check the driver's door switch in the doorjamb. A faulty door switch can cause all of these symptoms. Locations 162. Right Side Of Engine Compartment Page 2291 Page 3944 HDS Tablet: HDS Pocket Tester: Page 7528 - If applicable, install the regulator handle so it points forward and up at a 45 ° angle with the glass fully closed. Locations Parking Brake Warning Switch: Locations Gauges Component Location Index (Part 1 Of 4) Page 7741 WARRANTY CLAIM INFORMATION In warranty: The normal warranty applies. Failed Part: P/N 68500-S5P-A90ZZ H/C 6528640 *Defect Code: 07406* Symptom Code: 03220 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 A 1. Check the side-to-side alignment of the trunk lid latch to the striker: ^ Refer to page 20-132 of the 2001-04 Civic Service Manual. ^ In ISIS, use the keyword TRUNK ADJUST, and select Trunk Lid Adjustment from the list. 2. Make sure the gaps of the trunk lid are even on all sides. ^ If the trunk is misaligned, go to step 3. ^ If the trunk lid is properly aligned on all sides, go to REPAIR PROCEDURE B. 3. Adjust the trunk lid hinges: ^ Refer to page 20-132 of the 2001-04 Civic Service Manual. ^ In ISIS, use the keyword TRUNK ADJUST, and select Trunk Lid Adjustment from the list. 4. Check the trunk operation: ^ If the trunk opens and closes smoothly and is properly aligned, return the vehicle to the customer. ^ If the trunk lid is still difficult to close, go to REPAIR PROCEDURE B. REPAIR PROCEDURE B Page 1672 Power Distribution schematics show how power is supplied from the positive battery terminal to various circuits in the vehicle. Refer to the Power Distribution diagram set to get a more detailed understanding of how picture is supplied to the circuit you're working on. Individual circuit schematics begin with a fuse. So 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 Ground Distribution Schematics This sample Ground Distribution schematic shows all of the components that share the same ground point. Page 2519 Circuit Schematics Each schematic represents one circuit. A circuit's wires and components are arranged to show current flow from power at the top of the diagram 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 Locations SRS Component Location Index Page 666 11. Horn Switch Diagrams 223. ABS Modulator-Control Unit (EX, GX) Page 7301 243. Hands - Free Telephone Control Unit (Honda Accessory) Page 2766 228. ECM/PCM Part 3 228. ECM/PCM Part 4 Page 5966 1. Right Side Of Engine Compartment Page 6706 7. Use shop air to clean any debris that may be on the inflator, then remove the inflator from the airbag. NOTE: ^ Do not allow any debris to enter the inflator opening in the airbag. ^ Do not deploy the inflator. The inflator must be returned to its supplier in the box the new inflator came in (see INFLATOR PACKING AND GROUND SHIPPING INSTRUCTIONS: DEALERS IN THE 48 CONTIGUOUS STATES or INFLATOR PACKING AND AIR SHIPPING INSTRUCTIONS: DEALERS IN ALASKA AND HAWAII). 8. Turn over the airbag (inflator side down), and shake it to remove any debris from the inflator opening. 9. Install the new inflator in the airbag with new locknuts. Torque the locknuts to 3.9 N.m (2.8 lb-ft, 34 lb-in). NOTE: The 55A inflator is slightly taller than the S84 inflator, but they are still interchangeable. 10. Cover the lower two inflator locknuts with new felt tape. 11. Reinstall the horn plate with new felt washers on its mounting bolts. Torque the mounting bolts to 3.4 N.m (2.5 lb-ft, 30 lb-in), then make sure the horn plate moves freely. 12. Reinstall the driver's airbag using new Torx bolts: ^ Refer to page 23-279 of the service manual, or ^ Online, enter keywords DRIVER AIR, and select Driver's Airbag Replacement from the list. 13. Center-punch a completion mark below the third character of the engine compartment VIN: 14. Give your warranty clerk the 13-digit inflator serial number you wrote down in step 1. For the warranty claim to be paid, your w3arranty clerk must enter the appropriate 13-digit serial number in the Diagnostic Trouble Codes field on the warranty claim. *REPAIR PROCEDURE - CIVIC, CR-V, ODYSSEY, AND PILOT* NOTE: Be careful not to damage any parts when replacing the inflator, and follow the procedure exactly. 1. Write down the 13-digit serial number located on the right side of the new inflator's box. For the warranty claim to be paid, your warranty clerk must enter this 13-digit serial number in the Diagnostic Trouble Codes field on the warranty claim. Page 8993 Parking Brake Warning Switch: Testing and Inspection Parking Brake Switch Test 1. Remove the console, and disconnect the connector (A) from the switch (B). 2. Check for continuity between the positive terminal and body ground: ^ With the brake lever up, there should be continuity. ^ With the brake lever down, there should be no continuity. Page 193 Diagram 115-3 (Coupe EX) Page 896 ^ Incorrect: "If a Master Key is to be cut, put a five (5) in the blank space. Use a two (2) if a valet key is needed." ^ Correct: "If a Master Key is to be cut, put an M in the blank space. Use an S if a valet key is needed." Page 2, legend at the bottom: ^ Incorrect: "C. If a Master key is desired, then the number five (5) should be placed in the M/S position. Place the number two (2) in the M/S column if a Sub (Valet) key is needed." ^ Correct: "C. If a Master Key is desired, then an M should be placed in the M/S position. Place an S in the MIS column if a Sub (Valet) key is needed." Page 4350 Follow these instructions to keep the ATF cooler cleaner working properly: ^ Replace the two magnetic nonbypass spin-on filters once a year or when you notice a restriction in the ATF flow. Check the level and condition of the fluid in the tank before each use. ^ Replace the ATF in the tank when it looks dark or dirty. Page 7557 drop the glass inside the door. 3. Power window: Disconnect and detach the connector (A) and harness clip (B) from the door. 4. Remove the bolts (C), and loosen the bolts (D, E), then remove the regulator (F) through the hole in the door. Power window is shown, manual window is similar. 5. Apply multipurpose grease to the sliding surfaces of the regulator (A) where shown. Ignition/Locks - Cutting Sidewinder-Type Keys Technical Service Bulletin # 01-077 Date: 060419 Ignition/Locks - Cutting Sidewinder-Type Keys 01-077 April 19, 2006 Applies To: Models With Sidewinder-Type Keys - All Cutting Sidewinder-Type Keys With the MATRIX H Key Cutting Machine (Supersedes 01-077, dated January 12, 2005) Updated information is noted by asterisks. MATRIX H Key Cutting Machine, manufactured by Silca and supplied by Kaba Ilco Corporation, is a portable, power-operated tool that cuts sidewinder-type automotive keys exclusively. The machine lets you cut these keys either by copying or by code. The code function is designed and built to meet the Honda code requirements. No other similar machine has this capability. This service bulletin gives you information for ordering and servicing this special tool, and guides you through the entire key cutting process from setting up the machine to cutting the key blank. TOOL INFORMATION Order through the Honda Tool and Equipment Program: MATRIX H Key Cutting Machine: Model No. ILCMATRIXSH Cutter Bit: Model No. ILCF3O Fixed Jaw: Model No. ILCMTX-H Mobile Jaw (Right Side): Model No. ILCRTMTX-H Mobile Jaw (Left Side): Model No. ILCLTMTX-H *Remanufactured Clamp Unit: Model No. ILCMATRIXHCR* PARTS INFORMATION *For some models, there are two choices for sidewinder-type key blanks: ^ T-5 sidewinder key blanks ^ Honda sidewinder key blanks For other models, only Honda sidewinder key blanks can be used. See DETERMINING WHICH KEY TO USE to determine which key blank you should choose. Ordering T-5 key blanks through the Honda Tool and Equipment Program: T-5 Programmable Key Blank (Master): P/N ILC-35111-T-5H T-5 Programmable Key Blank (Valet): P/N ILC-35112-T-5H Practice Key Blanks (five per pack): ILC-35111DEMO* NOTE: Do not use practice key blanks for replacement purposes. Practice keys do not have an immobilizer chip. Page 2199 10. Middle Of Engine Locations Hazard Flasher Relay: Locations Turn Signal/Hazard Flasher - Component Location Index Page 1267 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 4226 1. Remove the terminal. 2. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE B: 1. Remove the terminal. 2. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE C: 1. Remove the terminal. 2. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE D: Page 651 Door Switch: Diagrams 4. Door Switch, Driver's 5. Door Switch, Front Passenger's (Sedan) 6. Door Switch, Left Rear Or Right Rear 7. Door Switch, Passenger's (Coupe) Testing and Inspection A/C Signal: Testing and Inspection A/C Signal Circuit Troubleshooting 1. Turn the ignition switch ON (II). 2. Momentarily connect ECM/PCM connector terminals A24 and E18 with a jumper wire several times. Is there a clicking noise from the A/C compressor clutch? YES - Go to step 3. NO - Go to step 6. 3. Start the engine. 4. Turn the blower switch ON. 5. Turn the A/C switch ON. Does the A/C operate? YES - The air conditioning signal is OK. NO - Update the ECM/PCM if it does not have the latest software, or substitute a known-good ECM/PCM, then recheck. If the symptom/indication goes away with a known-good ECM/PCM, replace the original ECM/PCM. 6. Momentarily connect under-hood fuse/relay box 14P connector terminal No.10 to body ground with a jumper wire several times. Is there clicking noise from the A/C compressor clutch? YES - Repair open in the wire between the ECM/PCM (E18) and the A/C clutch relay. NO - Check the A/C system for other symptoms. Page 3467 15. Measure resistance between the No.1 and No.2 terminals with the float at E (EMPTY), 1/2 (HALF FULL), and F (FULL) positions. If you do not get the shown readings, replace the fuel gauge sending unit. NOTE: Remove the No.9 BACK UP (10A) fuse from the under-hood fuse/relay box for at least 10 seconds after completing troubleshooting, otherwise it may take up to 20 minutes for the fuel gauge to indicate the correct fuel level. Page 3888 Transmission Speed Sensor: Locations 25. Transmission Housing (CVT) 26. Transmission Housing (CVT) Page 5526 13. Parking Brake Switch Page 7950 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 6220 Air Bag(s) Arming and Disarming: Description and Operation SRS Components SRS Components Airbags The SRS is a safety device which, when used 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 (A), the cable reel (B), the driver's airbag (C), the front passenger's airbag (D), seat belt tensioners (I), seat belt buckle tensioners (J), and front impact sensors (K). Since the driver's and front passenger's airbags use the same sensors, both normally inflate at the same time. However, it is possible for only one airbag to inflate. This can occur when the severity of a collision is at the margin, or threshold, that determines whether or not the airbags will deploy. In such cases, the seat belt will provide sufficient protection, and the supplemental protection offered by the airbag would be minimal. Side Airbags The side airbags (E) are in each front seat-back. They help protect the upper torso of the driver or front seat passenger during a moderate to severe side impact. Side impact sensors (F) in each door sill and in the SRS unit detect such an impact and instantly inflate the driver's or the passenger's side airbag. Only one side airbag will deploy during a side impact. If the impact is on the passenger's side, the passenger's side airbag will deploy even if there is no passenger. 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. OPDS The side airbag system also includes an occupant position detection system (OPDS). This system consists of sensors (G) and a OPDS unit (H) in the front passenger's seat-back. The OPDS unit sends occupant height and position data to the SRS unit. If the OPDS unit determines that the front passenger is of small stature (for example, a child) and the front passenger is leaning into the side airbag deployment path, the SRS unit will automatically disable the passenger's side airbag. The SRS unit will also disable the airbag when the OPDS detects certain objects on the seat. When the side airbag is disabled, the side airbag cutoff indicator on the instrument panel alerts the driver that the passenger's side airbag will not deploy in a side impact. When the object is removed, or the passenger sits upright, the Side Airbag Cutoff indicator will go off after a few seconds, alerting the driver that the passenger's side airbag will deploy in a side impact. Page 7043 Seat Belt Tensioner: Connector Locations 100. Under Driver's Seat 101. Under Front Passenger's Seat (passenger's similar) 103. Under Front Passenger's Seat (GX) Page 7829 Trunk / Liftgate Lock Cylinder: Service and Repair Trunk Lid Lock Cylinder Replacement NOTE: Put on gloves to protect your hands. 1. Disconnect the cylinder rod (A). 2. Remove the bolts securing the lock cylinder (A). Then turn the trunk lid lock cylinder 45 °, and remove it. 3. Install the lock cylinder in the reverse order of removal, and note these items: - Make sure the cylinder rod is connected properly. - Make sure the trunk lid opens properly and locks securely. Page 460 122. Driver's Door (Sedan Except DX) Page 2050 - 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. Troubleshooting Tests 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 test 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 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. 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 Drop Page 7510 5. Remove the maintenance hole seal (A). Disconnect the outer handle rod (B), and remove the nuts, then remove the outer handle protector (C) from the outer handle (D). 6. Pull out the outer handle (A) in the numbered sequence, and remove it. 7. Install the handle in the reverse order of removal, and note these items: - Make sure each rod is connected securely. - Make sure the door locks and opens properly. - When installing the lock cylinder, leave the outer door handle bolts loose so the inner protector does not interfere with the lock cylinder installation, then tighten the handle bolts. - Install the lock cylinder retaining clip on the handle, then install the lock cylinder in the door. Be sure the clip is fully seated in the slot on the lock cylinder. - When reinstalling the door panel, make sure the plastic cover is installed properly and sealed around its outside perimeter to seal out water. Page 2485 Oxygen Sensor: Description and Operation Secondary Heated Oxygen Sensor (Secondary HO2S) Secondary Heated Oxygen Sensor (Secondary HO2S) The secondary HO2S detects the oxygen content in the exhaust gas downstream of the TWC and sends signals to the ECM/PCM which checks the efficiency of the TWC. To stabilize its output, the sensor has an internal heater. The secondary HO2S is installed in the TWC. Page 5695 6. Measure the commutator (A) runout. - If the commutator runout is within the service limit, check the commutator for carbon dust or brass chips between the segments. - If the commutator runout is not within the service limit, replace the armature. 7. Check the mica depth (A). If the mica is too high (B), undercut the mica with a hacksaw blade to the proper depth. Cut away all the mica (C) between the commutator segments. The undercut should not be too shallow, too narrow, or V-shaped (D). 8. Check for continuity between the segments of the commutator. If an open circuit exists between any segments, replace the armature. Page 4771 Connectors - "C" Page 9346 Resistor Variable Sensor Solenoid Transistors Circuit Schematics Page 6427 16. Remove the snap ring (A) and the splash guard (B) from the knuckle (C). 17. Press the wheel bearing (A) out of the knuckle (B) using the special tool and a press. 18. Wash the knuckle and hub thoroughly in high flash point solvent before reassembly. 19. Press a new wheel bearing (A) into the knuckle (B) using the old bearing (C), a steel plate (D), the special tool, and a press. Place the wheel bearing on the knuckle with the pack seal side facing (metal color) toward the inside. Be careful not to damage the sleeve of the pack seal. 20. Install the snap ring (A) securely in the knuckle (B). 21. Install the splash guard (C), and tighten the screws (D) to the specified torque. Page 6335 - Cut and remove the wheelhouse upper member, and replace the front wheelhouse. - Check the front damper extension and damper housing position, and check for damage. If necessary, remove the wheelhouse upper member, and replace the damper housing and front damper extension as an assembly, if possible. Page 7457 2. Remove the terminal (same procedure for male and female). 3. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE E: 1. Remove the secondary locks. 2. Remove the terminal (same procedure for male and female). 3. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE F: Page 5190 ^ The left end goes behind the notch on the interlock lever. ^ Once the spring is correctly installed, make sure the lever moves freely and returns properly. 10. Insert the plunger into the interlock solenoid, then install the solenoid using a new screw. Make sure the groove of the solenoid plunger is in the fork on the lever. 11. Install a new plastic cover on the interlock solenoid. 12. Check the operation of the ignition switch key interlock: ^ Set the parking brake, and turn the ignition switch to ON (I I). ^ While pressing the brake pedal, shift the transmission to Neutral. ^ Try turning the ignition switch to LOCK (0) - If you cannot turn the switch to LOCK (0), your repair was successful; go to step 15. - If you can turn the switch to LOCK (0), the interlock is not working; go to step 13. Page 8892 Key Reminder Switch: Testing and Inspection Ignition Key Switch Test NOTE: For more key-in beeper information, refer to the circuit diagram and input test. When the ignition key is in the ignition switch the multiplex control unit senses ground through the closed ignition key switch. When you open the driver's door, the beeper circuit senses ground through the closed door switch and sounds the beeper. 1. Remove the steering column upper and lower covers. 2. Disconnect the 6P connector. 3. Check for continuity between the No.1 and No.2 terminals. - There should be continuity with the key in the ignition switch. - There should be no continuity with the key removed. 4. If the continuity is not as specified, replace the ignition switch. Page 3787 13. Remove the solenoid cover, and make sure the solenoid plunger groove is installed in the fork on the lever. ^ If needed, correct the position of the solenoid plunger, then go to step 14. ^ If the solenoid plunger is correctly installed, there is an electrical problem with the key interlock system; refer to the Automatic Transmission section of the appropriate service manual for troubleshooting information. Once the key interlock is working normally, go to step 14. 14. Install the solenoid cover. 15. Reinstall the steering column covers. 16. Center-punch a completion mark above the seventh character of the engine compartment VIN. Disclaimer Page 6124 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 4424 9. Measure the clutch disc thickness. If the thickness is less than the service limit, replace the clutch disc. Standard (New): '01 model: 8.3 - 9.0 mm (0.33 - 0.35 inch) max. '02-03 models: 8.5 - 9.1 mm (0.34 - 0.36 inch) max. Service Limit: '01 model: 5.7 mm (0.22 inch) '02-03 models: 5.8 mm (0.23 inch) 10. Measure the rivet depth from the clutch disc lining surface (A) to the rivets (B) on both sides. If the rivet depth is less than the service limit, replace the clutch disc. Standard (New): 1.65 - 2.25 mm (0.065 - 0.089 inch) max. Service Limit: 0.8 mm (0.03 inch) Page 3900 WARRANTY CLAIM INFORMATION In warranty: The normal warranty applies. Out of warranty: Any repair performed after warranty expiration may be eligible for goodwill consideration by the District Parts and Service Manager or your Zone Office. You must request consideration, and get a decision, before starting work. REPAIR PROCEDURE 1. Replace the A/T. See S/B 98-061, Automatic Transmission In-Warranty Exchange Program, for detailed requirements of the A/T ordering, removal, and installation process. 2. '01-03 models only: Make sure you have the iN CD (July '04 or later) loaded into your iN master terminal. If not, load the CD using the instructions that come with it. Also, make sure the vehicle's battery is fully charged. [Low voltage or turning the ignition switch to LOCK (0) can permanently damage the PCM.] 3. '01-03 models only: Use the Honda Interface Module (HIM) to update the PCM software. Refer to S/B 01-023, Using the Honda Interface Module to Update Control Units/Modules. 4. Use the Honda Diagnostic System (HDS) with version 1.012.023 or later software to clear the DTC. 5. Do the idle learn procedure: ^ Make sure all electrical items (A/C, audio unit, defogger, lights, etc.) are off. ^ Start the engine, and let it reach normal operating temperature (cooling fans cycle twice). ^ Let the engine idle with the throttle closed for 10 minutes. 6. 2001 Civic 2-door EX, LX models from VIN 1HGEM2... 1L000001 thru 1HGEM2... 1L016502: Do the cruise control learn procedure: ^ Drive the vehicle, and set the cruise control above 40 miles per hour. ^ Keep driving the vehicle for 5 to 10 minutes. NOTE: You can use a smog/chassis dynamometer to do this step instead of driving the vehicle. Do not do this step with the vehicle on a lift. Page 3671 Shift Solenoid: Testing and Inspection Solenoid Valve Test - Continuously Variable Transmission Solenoid Valve Test 1. Disconnect solenoid harness connector (BP). 2. Measure CVT speed change control valve assembly resistance between solenoid harness connector terminals No. 3 and No. 7. STANDARD: 3.8 - 6.8 Ohms 3. Measure CVT pulley pressure control valve assembly resistance between terminals No. 2 and No. 6. STANDARD: 3.8 - 6.8 Ohms 4. Measure CVT start clutch pressure control valve assembly resistance between terminals No. 4 and No. 8. STANDARD: 3.8 - 6.8 Ohms 5. Measure the inhibitor solenoid resistance between terminal No. 5 and body ground. STANDARD: 11.7 - 21.0 Ohms 6. Replace the CVT speed change control valve assembly or CVT start clutch pressure control valve assembly, if the measurements are out of standard. Replace the lower valve body assembly, if the measurements of CVT pulley pressure control valve assembly or inhibitor solenoid are out of standard. 7. If all of the resistance are within the standard, a clicking sound should be heard when connecting the battery terminals to the solenoid harness connector terminals below. ^ CVT speed change control valve assembly No. 3 to battery positive terminal No. 7 to battery negative terminal ^ CVT pulley pressure control valve assembly No. 2 to battery positive terminal No. 6 to battery negative terminal ^ CVT start clutch pressure control valve assembly No. 4 to battery positive terminal No. 8 to battery negative terminal ^ Inhibitor solenoid No.5 to battery positive terminal and body ground to negative terminal 8. If no clicking sound is heard, remove the lower valve body assembly, and check the solenoid. Page 538 Radiator Cooling Fan Temperature Sensor / Switch: Service and Repair Radiator Fan Switch Replacement 1. Disconnect the radiator fan switch connector, then remove the radiator fan switch (A). 2. Install the radiator fan switch using a new O-ring (B). Page 5116 Diodes Light Emitting Diode (LED) Motor Pressure Sensor Page 8481 7. With side airbag: Release the hooks (A), and unzip the seat-back cover (B). Pull the side airbag harness (C) and the OPDS harness (D) (passenger's seat) out through the harness guides (E) and holes (F) in the seat-back cover. 8. With side airbag: Remove the side airbag, and release the hooks (A) from the airbag module holder (B). 9. Release the hooks (A) and hook springs (B), then loosen the seat-back cover (C). Page 6766 Relay And Control Unit Locations - Door, Roof And Seat Locations Power Steering Pressure Switch: Locations Idle Control System - Component Location Index 34. Left Side Of Engine Compartment Page 3920 8. Verify that the Program ID and the Program Part No. are correct, then click on the check mark. 9. Confirm the control module update by Program ID and Program Part No. Make sure this corresponds with any information provided in the service bulletin for the update you are doing. Click on Yes to continue. Within a few seconds, the CM Update software loads the program file onto the GNA600. 10. Disconnect the GNA600 from the USB PC interface cable, then connect the trigger switch adapter block (yellow) and the trigger switch to the GNA600 as shown below. (The DLC cable should still be connected to the GNA600.) 11. Reconnect the DLC cable to the vehicle's DLC. 12. Turn the ignition switch to ON (II), and wait until the green No.2 LED on the GNA600 stays on. Press and release the trigger switch button. 13. The yellow No.1 LED blinks, and the green No.2 LED stays on. This indicates that the control uniti module is being updated. Page 4659 Shift Solenoid: Service and Repair Shift Solenoid Valves A and B Replacement NOTE: Shift solenoid valves A and B must be removed/ replaced as an assembly. 1. Remove the harness clamp (c) form the clamp bracket (D). 2. Remove the mounting bolts and the shift solenoid valves A and B. 3. Clean the mounting surface and fluid passage. 4. Install a new shift solenoid valves A and B with a new filter/gasket (E), and install the harness clamp on the clamp bracket. 5. Check the connector for rust, dirt, or oil, then reconnect the connector securely. Page 5600 3. Remove the four through bolts. 4. Heat the rear bearing seat with a 1,000 W hair drier for about 5 minutes (50 - 60 °C, 129 - 140 °F). 5. Separate the rear housing from the drive-end housing by inserting a flat tip screwdriver into the openings and prying them a part. NOTE: Be careful not to damage the stator with the tip of the screwdriver. Page 3521 Throttle Body: Testing and Inspection Throttle Body Test NOTE: - Do not adjust the throttle stop screw. It is preset at the factory. - If the malfunction indicator lamp (MIL) has been reported on, check for diagnostic trouble codes (DTCs). 1. With the engine off, check the throttle cable movement. The cable should move without binding or sticking. - If the cable moves OK, go to step 2. - If the cable binds or sticks, check it and its routing. - If the cable is faulty, reroute it or replace it and adjust it, then go to step 2. 2. Operate the throttle lever by hand to see if the throttle valve and/or shaft are too loose or too tight. - If there is excessive play in the throttle valve shaft, or any binding in the throttle valve at the fully closed position, replace the throttle body. - If the throttle valve and shaft are OK, go to step 3. 3. Connect the scan tool to the data link connector (DLC). 4. Turn the ignition switch ON (II). 5. Check the throttle position with the scan tool. The reading should be about 10 % when the throttle is fully closed and about 90 % when the throttle is fully opened. If the throttle position is correct, the throttle body is OK. - If the throttle position is not correct, replace the throttle body. Page 1503 6. Disconnect both seat belt buckle tensioner 4P connectors (A). Page 4059 2. Install the new bearings with the special tool and a press. Press the bearing on until it bottoms. Oil Seal Replacement Special Tools Required Driver 07749-0010000 - Driver Attachment 07NAD-PX40100 - Driver attachment 07JAD-PH80101 1. Remove the oil seal (A) from the transmission housing (B). 2. Remove the oil seal (A) from the torque converter housing (B). Page 4131 Page 5098 107. Behind A/T Shift Lever (except M/T) Page 3163 7. Align the cutouts (A) on the rotary-frame with the neutral positioning cutouts (B) on the transmission range switch, then put a 2.0 mm (0.08 inch) feeler gauge blade (C) in the cutouts to hold it in the N position. NOTE: Be sure to use a 2.0 mm (0.08 inch) blade or equivalent to hold the switch in the N position. 8. Install the transmission range switch (A) gently on the control shaft (B) with holding the N position with the 2.0 mm (0.08 inch) blade (C). 9. Tighten the bolts on the transmission range switch while you continue to hold it in the N position. Do not move the transmission range switch when tightening the bolts. Remove the feeler gauge. Page 6919 Relay And Control Unit Locations - Door, Roof And Seat Master Switch Replacement Power Window Switch: Service and Repair Master Switch Replacement Master Switch Test/Replacement 4-door 1. Remove the door grip cover. 2. Disconnect the 20P connector from the power window master switch. Page 3322 163. Under Left Side Of Floor Page 806 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. Below most connector numbers and component names are PHOTO and VIEW numbers. The PHOTO number refers to a photo in the back of the book that shows the connector's location on the car. The VIEW number refers to an illustration in the back of the book that shows the connector terminals, wire colors, connector cavity numbers, and other details. The connector cavity numbering sequence begins at the top left corner of the connector as seen from either of the viewpoints shown on diagram [8] . Except for the DLC (data link 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 C554, for example, means those terminals join in cavity 2 of connector C554. Power Distribution Schematics Power Distribution Schematics Page 2856 5. Reconnect the connectors to the under-dash fuse/relay box, and make sure these input tests at the appropriate connectors on the under-dash fuse/relay box. If any test indicates a problem, find and correct the cause, then recheck the system. - If all the input tests prove OK, the multiplex control unit must be faulty, replace the under-dash fuse/relay box assembly. Locations Intake Air Temperature Sensor: Locations PGM-FI System - Component Location Index Page 6061 Under-hood Fuse And Relay Box (4-door) Page 9555 Combination Switch: Testing and Inspection Combination Light Switch Test/Replacement 1. Remove the dashboard lower cover. 2. Remove the steering column covers. 3. Disconnect the 16P connector (A) from the combination light switch (B). 4. Remove the two screws, then slide out the combination light switch. 5. Inspect the connector terminals to be sure they are all making good contact. - If the terminals are bent, loose or corroded, repair them as necessary, and recheck the system. - If the terminals look OK, check for continuity between the terminals in each switch position according to the tables. 6. If the continuity is not as specified, replace the switch. Page 486 Sunroof / Moonroof Switch: Service and Repair Switch Test/Replacement 1. Remove the driver's pocket. 2. Disconnect the 6P connector (A) from the moonroof switch (B), and remove the moonroof switch. 3. Check for continuity between the terminals in each switch position according to the table. 4. If the continuity is not as specified, replace the illumination bulb (C) or the moonroof switch. Page 8473 14. Remove the three nuts and washers from the inboard link and the inboard seat track. Remove and discard the old bushings. 15. 2001-02 Models: Remove and discard the spacer from the inboard link. 16. Install the new bushings. 17. Install three spacers on the rear mounting stud for the seat track. 18. Reassemble the inboard side of the seat track in the reverse order of removal using new nuts. Torque the seat track mounting nuts to 24 N.m (17 lb-ft). Torque the seat belt buckle mounting bolt to 32 N.m (23 lb-ft). Page 188 13. Plug in the heat gun, and turn it on. Start at the middle of the splice connector, and move the gun toward the ends as the tube shrinks. Apply heat evenly by rotating the curved heat spreader around the splice connector. Shrinking is complete when a small amount of sealant appears at each end of the tube. Pigtail Terminal Selection Chart PIGTAIL TERMINAL SELECTION CHART Select the proper size pigtail terminal by matching the replacement terminal part number and the wire size being repaired to the corresponding pigtail terminal part number. Then use the color (size) splice connector listed. In some instances you may also have to match the wire seal style to select the proper pigtail terminal. Pigtail terminals are available through your parts department, in quantities of 10, using normal parts ordering procedures. Checking For Poor Fir of Terminals CHECKING FOR POOR FIT OF TERMINALS Loose terminal fit can cause a number of intermittent problems in electrical circuits. By using the Terminal Inspection Feeler Tool Set you can inspect the terminal fit between the two matching connectors without removing the terminals from the connector body. 1. Find the terminal tool that best matches the male terminal in the mating connector. Page 174 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 Short Circuit Locator (Short Finder) 1. Remove the blown fuse. Leave the battery connected. Page 4036 23. Transmission Housing (A/T) Page 285 Engine Control Module: Service Precautions 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. Specifications Timing Cover: Specifications Page 6924 Air Bag Control Module: Description and Operation SRS Operation The main circuit in the SRS unit senses and judges the force of impact and, if necessary, ignites the inflator charges. 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: Driver's and Front Passenger's Airbag(s) 1. The frontal impact sensor must activate, and send electric signals to the microprocessor. 2. The microprocessor must compute the signals, and depending on the severity of the collision and whether the seat belt buckle switch is ON or OFF, it sends the appropriate signals to the airbag inflator(s). 3. The inflators that received signals must ignite and deploy the airbags. Side Airbag(s) 1. The side impact sensors must activate, and send electric signals to the microprocessor. 2. The microprocessor must compute the signals and send them to the side airbag inflator(s). However, the microprocessor cuts off the signals to the front passenger's side airbag if the SRS unit determines that the front passenger's head is in the deployment path of the side airbag. 3. The inflator that received the signal must ignite and deploy the side airbag. 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 6 seconds if the system is operating normally. If the indicator does not come on, or does not go off after 6 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 SRS unit memory stores a DTC that relates to the cause of the malfunction, and the unit is connected to the data link connector (DLC). This information can be read with the Honda PGM Tester when it is connected to the DLC (16P). Front Stabilizer Link: Service and Repair Front Removal/Installation 1. Raise the front of the vehicle, and support it with safety stands in the proper locations. Remove the front wheels. 2. Remove the self-locking nut (A) and flange nut (B) while holding the respective joint pin (C) with a hex wrench (D), and remove the stabilizer link (E). 3. Install the stabilizer link on the stabilizer bar and lower arm with the joint pins set at the center of each moving range. 4. Install the self-locking nut and flange nut, and lightly tighten them. NOTE: Use a new self-locking nut on reassembly. 5. Place the floor jack under the lower arm ball joint, and raise the suspension to load it with the vehicle's weight. NOTICE: Do not place the jack against the flat section of the lower arm. Lifting the arm in this area might bend it. Page 9365 1. Remove the terminal. 2. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE E: 1. Remove the terminal. 2. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE F: Page 3210 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. Circuits must be operating when checking voltage drop. 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. 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 off, 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 Self-Powered Test Light or DVOM 1. Remove the blown fuse and disconnect the battery and load. Page 2573 172. EGR Valve And EGR Valve Position Sensor (EX, HX; '04-'05: DX, LX) Page 9022 2. Remove the terminal from the female half. 3. Remove the terminal from the male half. 4. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE D: 1. Remove the secondary locks. Page 7329 Tires - Tubless Tire Repair Information Tires: 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 1345 9. Clean all oil off the inside face (A) of the crankshaft pulley, and apply lubricant to the pulley bolt (B) and washer (C). 10. Install the crankshaft pulley, and hold the pulley with holder handle (A) and holder attachment (B). 11. Tighten the bolt to 20 Nm (2.0 kgf-cm, 14 ft. lbs.) with a torque wrench and 19 mm socket (C). 12. Tighten the pulley bolt an additional 90°. 13. Rotate the crankshaft pulley about five or six turns counter clockwise so that the timing belt positions on the pulleys. 14. Turn the crankshaft pulley so its TDC mark (A) lines up with the pointers (B). Page 1271 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 8612 13. Push the top of the retainer clip with a flat-tip screwdriver, and hold it. Release the retainer clip with a hook-shaped tool, then remove the lock cylinder. Go to step 14. 14. With the door lock cylinder out of the door handle remove the E-clip and the arm. 15. Try to insert the key into the cylinder and turn it. ^ If you can insert and turn the key, go to step 18. ^ If you cannot insert the key or turn it, go to step 16. 16. Carefully remove the spring and plastic retainer. Locations Relay And Control Unit Locations - Dashboard Page 6038 234. Under-dash Fuse/Relay Box Part 7 Page 3934 WARRANTY CLAIM INFORMATION In warranty: The normal warranty applies. Out of warranty: Any repair performed after warranty expiration may be eligible for goodwill consideration by the District Parts and Service Manager or your Zone Office. You must request consideration, and get a decision, before starting work. REPAIR PROCEDURE 1. Replace the A/T. See S/B 98-061, Automatic Transmission In-Warranty Exchange Program, for detailed requirements of the A/T ordering, removal, and installation process. 2. '01-03 models only: Make sure you have the iN CD (July '04 or later) loaded into your iN master terminal. If not, load the CD using the instructions that come with it. Also, make sure the vehicle's battery is fully charged. [Low voltage or turning the ignition switch to LOCK (0) can permanently damage the PCM.] 3. '01-03 models only: Use the Honda Interface Module (HIM) to update the PCM software. Refer to S/B 01-023, Using the Honda Interface Module to Update Control Units/Modules. 4. Use the Honda Diagnostic System (HDS) with version 1.012.023 or later software to clear the DTC. 5. Do the idle learn procedure: ^ Make sure all electrical items (A/C, audio unit, defogger, lights, etc.) are off. ^ Start the engine, and let it reach normal operating temperature (cooling fans cycle twice). ^ Let the engine idle with the throttle closed for 10 minutes. 6. 2001 Civic 2-door EX, LX models from VIN 1HGEM2... 1L000001 thru 1HGEM2... 1L016502: Do the cruise control learn procedure: ^ Drive the vehicle, and set the cruise control above 40 miles per hour. ^ Keep driving the vehicle for 5 to 10 minutes. NOTE: You can use a smog/chassis dynamometer to do this step instead of driving the vehicle. Do not do this step with the vehicle on a lift. Page 7752 WARRANTY CLAIM INFORMATION In warranty: The normal warranty applies. Failed Part: P/N 68500-S5P-A90ZZ H/C 6528640 *Defect Code: 07406* Symptom Code: 03220 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 A 1. Check the side-to-side alignment of the trunk lid latch to the striker: ^ Refer to page 20-132 of the 2001-04 Civic Service Manual. ^ In ISIS, use the keyword TRUNK ADJUST, and select Trunk Lid Adjustment from the list. 2. Make sure the gaps of the trunk lid are even on all sides. ^ If the trunk is misaligned, go to step 3. ^ If the trunk lid is properly aligned on all sides, go to REPAIR PROCEDURE B. 3. Adjust the trunk lid hinges: ^ Refer to page 20-132 of the 2001-04 Civic Service Manual. ^ In ISIS, use the keyword TRUNK ADJUST, and select Trunk Lid Adjustment from the list. 4. Check the trunk operation: ^ If the trunk opens and closes smoothly and is properly aligned, return the vehicle to the customer. ^ If the trunk lid is still difficult to close, go to REPAIR PROCEDURE B. REPAIR PROCEDURE B Recall 10V364000: Ignition Interlock Defect Shift Interlock Switch: Recalls Recall 10V364000: Ignition Interlock Defect VEHICLE MAKE/MODEL: MODEL YEAR(S): Honda/Accord 2003 Honda/Civic 2003 Honda/Element 2003-2004 MANUFACTURER: Honda (American Honda Motor Co.) MFR'S REPORT DATE: August 04, 2010 NHTSA CAMPAIGN ID NUMBER: 10V364000 NHTSA ACTION NUMBER: EA09001 COMPONENT: Electrical System: Ignition POTENTIAL NUMBER OF UNITS AFFECTED: 384220 SUMMARY: Honda is recalling certain model year 2003 Honda Accord, Civic two and four door, and model year 2003-2004 Honda Element vehicles. The interlock lever of the ignition switch may unexpectedly deform, which can allow the interlock function of a vehicle with an automatic transmission to be defeated. CONSEQUENCE: Removal of the ignition key when the gear selector of a vehicle with an automatic transmission has not been shifted to the park position can allow the vehicle to roll away, increasing the risk of a crash. REMEDY: Dealers will remove the original interlock pin and lever within the ignition switch, and replace them with newly, designed components. This service will be performed free of charge. The safety recall is expected to begin on or about September 29, 2010. Owners may contact Honda at 1-800-999-1009. NOTES: Honda safety recall No. R44. 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 8483 6. Pull back the edge of the seat cushion cover all the way around, and release the clips (A), then remove the seat cushion cover. 7. Install the cover in the reverse order of removal, and note these items: - To prevent wrinkles when installing a seat cushion cover, make sure the material is stretched evenly over the pad before securing the clips and hooks. - Replace any clips you removed with new ones (A). Install them with commercially available upholstery ring pliers (B). Locations Throttle Position Sensor: Locations PGM-FI System - Component Location Index Page 3091 Oxygen Sensor: Connector Locations 10. Middle Of Engine 11. Middle Of Engine (except EX) Page 4727 8. Remove the flange bolt (A) and wheel sensor (B) from the knuckle. Do not disconnect the wheel sensor connector. 9. Remove the flange nut (A) while holding the joint pin (B) with a hex wrench (C), and disconnect the stabilizer link (D) from the lower arm (E). 10. Remove the lock pin (A) from the lower arm ball joint, and remove the castle nut (B). NOTE: During installation, insert the lock pin into the ball joint pin in the range of 180 degrees or below from the inside of the vehicle. Insert the lock pin from the inside to the outside of the vehicle. 11. Disconnect the lower arm from the knuckle using the special too. Page 5720 Terminals - "T" Shielding Switches Fuses Page 8225 WARRANTY CLAIM INFORMATION In warranty: The normal warranty applies. Failed Part: P/N 68500-S5P-A90ZZ H/C 6528640 *Defect Code: 07406* Symptom Code: 03220 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 A 1. Check the side-to-side alignment of the trunk lid latch to the striker: ^ Refer to page 20-132 of the 2001-04 Civic Service Manual. ^ In ISIS, use the keyword TRUNK ADJUST, and select Trunk Lid Adjustment from the list. 2. Make sure the gaps of the trunk lid are even on all sides. ^ If the trunk is misaligned, go to step 3. ^ If the trunk lid is properly aligned on all sides, go to REPAIR PROCEDURE B. 3. Adjust the trunk lid hinges: ^ Refer to page 20-132 of the 2001-04 Civic Service Manual. ^ In ISIS, use the keyword TRUNK ADJUST, and select Trunk Lid Adjustment from the list. 4. Check the trunk operation: ^ If the trunk opens and closes smoothly and is properly aligned, return the vehicle to the customer. ^ If the trunk lid is still difficult to close, go to REPAIR PROCEDURE B. REPAIR PROCEDURE B Page 3094 141. HO2S, Secondary (except HX) Or Third (HX) Page 4992 1. Remove the terminal. 2. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE E: 1. Remove the terminal. 2. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE F: Page 7046 Seat Belt Tensioner: Service Precautions Airbag / Seat Belt Tensioner Handling and Storage Do not try to disassemble an airbag or a seat belt tensioner. They have no serviceable parts. Once an airbag or a seat belt tensioner have been deployed, they cannot be repaired or reused. For temporary storage of an airbag or a seat belt tensioner during service, please observe the following precautions: * Store the removed airbag with the pad surface up. The driver's/front passenger's airbag connectors and seat belt tensioner connectors have a built-in short contact. WARNING: If the airbag is improperly stored face down, accidental deployment could propel the unit with enough force to cause serious injury. * Store the removed airbag on a secure flat surface away from any high heat source (exceeding 212 °F/100 °C) and free of any oil, grease, detergent or water. * Improper handling or storage can internally damage the airbag and seat belt tensioner, making them inoperative. If you suspect the airbag and seat belt tensioner have been damaged, install new units and refer to the Deployment/Disposal Procedures for disposing of the damaged units. See: Air Bag Systems/Air Bag/Service and Repair Page 4337 Torque Converter Clutch Solenoid: Service and Repair Torque Converter Clutch Solenoid Valve Replacement 1. Remove the mounting bolt and the torque converter clutch solenoid valve (A). 2. Install a new torque converter clutch solenoid valve with new O-rings (B). While installing the valve, do not allow dust or other foreign particles to enter the transmission. 3. Check the connector for rust, dirt, or oil, then connect the connector securely. Page 9739 (Coupe Except DX, HX) 167. Power Window Switch, Front Passenger's (Sedan Except DX) 168. Power Window Switch, Left Rear Or Right Rear (Sedan Except DX) Page 2943 DTC P0A94 thru P0157 Locations Relay And Control Unit Locations - Engine Compartment Page 8974 Fuel Gauge Sender: Testing and Inspection Fuel Gauge Sending Unit Test Special Tools Required Fuel sender wrench 07XAA-001010A NOTE: For the fuel gauge system circuit diagram, refer to the Gauges Circuit Diagram. 1. Check the No.10 METER (7.5A) fuse in the under-dash fuse/relay box before testing. 2. Do the gauge drive circuit check. - If the fuel gauge needle sweeps from minimum to maximum position and then returns to the minimum position, the gauge is OK. Go to step 3. - If the fuel gauge needle does not sweep from minimum to maximum position and then return to the minimum position, replace the gauge assembly and retest. 3. Turn the ignition switch OFF. 4. Remove the rear seat cushion. 5. Remove the access panel from the floor. 6. Disconnect the fuel pump 5P connector. 7. Measure voltage between fuel pump 5P connector terminals No.1 and No.2 with the ignition switch ON (II). There should be battery voltage. - If the voltage is OK, go to step 7. - If the voltage is not as specified, check for: a short in the YEL/BLK wire to ground. - an open in the YEL/BLK or BLK wire. - poor ground (G551). 8. Turn the ignition switch OFF. Remove the No.9 BACK UP (10A) fuse from the under-hood fuse/relay box for at least 10 seconds, then reinstall it. Page 5074 Shift Solenoid: Service and Repair Shift Solenoid Valves A and B Replacement NOTE: Shift solenoid valves A and B must be removed/ replaced as an assembly. 1. Remove the harness clamp (c) form the clamp bracket (D). 2. Remove the mounting bolts and the shift solenoid valves A and B. 3. Clean the mounting surface and fluid passage. 4. Install a new shift solenoid valves A and B with a new filter/gasket (E), and install the harness clamp on the clamp bracket. 5. Check the connector for rust, dirt, or oil, then reconnect the connector securely. Page 9846 13. Attach the upper molding (A), side moldings (B), and lower molding (C) with adhesive tape around the edge of the rear window (D): - Attach the moldings in the numbered sequence. - After installing the moldings, cut the corner edge areas (E) of the moldings as shown. - Be careful not to touch the rear window where adhesive will be applied. 14. Attach the upper fasteners (A) and side fasteners (B) with adhesive tape to the rear window opening flange (C) of the body. Page 8817 PARTS INFORMATION REPAIR PROCEDURE 1. Tilt the steering wheel all the way up. 2. Remove the three upper cover mounting screws from the lower steering column cover, then tilt the steering wheel all the way down, and remove the column covers. 3. Remove the two mounting screws from the instrument panel trim. Gently pull on the bottom of the trim to release the two clips and the two hooks. Carefully pull the trim out of the dashboard. Page 5169 Control Module: Service and Repair How to Substitute the PCM How to Substitute the PCM 1. Remove the PCM from the vehicle. 2. Install a known-good PCM in the vehicle. 3. Rewrite the immobilizer code with the PCM replacement procedure in the Honda PGM Tester; It allows you to start the engine. 4. After completing your tests, reinstall the original PCM and rewrite the immobilizer code with the PCM replacement procedure in the HDS Tester again. Page 7524 3. Remove the switch panel (A) (power window model) or the pull pocket (B) (manual window model). 1. Using a trim tool, pry the cap (C), then remove the screw(D). 2. Pry out the panel or pocket to release the clips (E). 3. Release the clip (F) by pulling the cover or pocket forward. 4. Power window model: Disconnect the power window switch connector (G). 4. Remove the screws (H) securing the door panel. 5. Remove the mirror mount cover. 6. Release the clips that hold the door panel (A) with a commercially available trim pad remover (B), then remove the door panel by pulling it upward. Remove the door panel with as little bending as possible to avoid creasing or breaking it. Page 215 Turn Signal/Hazard Flasher - Component Location Index Page 6101 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 9309 Use the tools from Pin Tool Set. First, check the connector that you are about to repair. - If it has a secondary terminal lock, go to Connectors With a Secondary Lock. A secondary lock, found on most connectors on some models, is an additional locking device on the connector housing as a backup for the primary lock on the terminal. - If the connector does not have a secondary lock, go to Connectors Without a Secondary Lock. Connectors With a Secondary Lock All examples are shown with the connector lock facing up. The illustrations are examples of the secondary terminal locks; however, the connector you are repairing may vary in size. Identify the connector by the type of secondary lock, not by the number of terminal cavities. EXAMPLE A: 1. Release the secondary lock. 2. Remove the terminal. 3. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE B: Page 2919 95. Behind Glove Box (HX; '04-'05: DX, EX, LX) Page 6709 NOTE: Multiple boxes cannot be bundled together. 5. Prior to shipment, make sure that all steps have been properly completed. All boxes must be prepared in accordance with all U.S. Department of Transportation (DOT) and FedEx Ground requirements. Incomplete or missing information will result in return to sender and delay of return credit. 6. Retain your copy of the OP-950 Hazardous Materials Certification form for at least 1 year. This is required per DOT regulations and for your proof of shipment via Tracking ID. INFLATOR PACKING AND AIR SHIPPING INSTRUCTIONS: DEALERS IN ALASKA AND HAWAII NOTE: ^ Do not deploy the original inflator. Claims for deployed inflators will be charged back to your dealership. ^ There is a 48-hour return shipment objective for the inflator. ^ Dealers in Alaska and Hawaii require Fed Ex Air shipping documents and instructions. Call the WPI administrative office at 937-642-2737 for the documents and instructions. 1. Carefully insert the original inflator into the round opening in the return shipping box (the box that the new inflator came in). 2. Close the top flap on the box, then double-tape the the box closed with 2-inch clear packing tape on the entire front seam and the side seams. Press down on the tape for good adhesion. 3. Fill in this information on the Fed Ex airbill: ^ In the From section, add your name, address, and telephone number. ^ In the Your Internal Billing Reference section, add your 6-digit dealer number and the VIN. ^ In the Does this shipment contain dangerous goods? section, check the box next to Yes per attached Shipper's Declaration. ^ In the Total Declared Value section, do not add an amount. 4. Fill in this information on the SHIPPER'S DECLARATION FOR DANGEROUS GOODS form: NOTE: If not already done, cross out the words CARGO AIRCRAFT ONLY in the TRANSPORTATION DETAILS box at the top left of the form. The shipper may reject your shipment if CARGO AIRCRAFT ONLY is not crossed out. ^ In the Shipper section, add your name and address. ^ In the Air Waybill No. section, add the 12-digit tracking number from the top of the airbill. ^ In the Page of Pages section, add 1 of 1. ^ In the lower right corner of the form, print your name and title, your city, state, and the shipment date. Then add your signature. 5. For your records, keep one copy of the shipper's declaration and the sender's copy of the airbill. Insert the completed shipper's declaration and the airbill into an adhesive FedEx envelope, then attach the envelope to the box, most likely on the bottom. Do not cover any of the hazard markings or labels on the box. 6. Attach a From label (your dealership address) and a To label (1K Holdings, Inc., as listed on the airbill) to the outside of the box. Do not cover any of the hazard markings or labels on the box. 7. Before shipment, make sure steps 1 thru 6 have been completed. Incomplete or missing information may cause the box to be returned to you. NOTE: You (the shipper) are responsible for proper packing and document completion before shipping this box. The DOT (U.S. Department of Transportation) will impose substantial fines and/or penalties on the shipper (you) if the packaging, labeling, and/or documentation is/are not properly prepared. The person signing the document must be trained, and the training records must be on file at your place of business. Retain all documents for at least 2 years. Page 3921 NOTE: To avoid control unit/module damage, do not interrupt the update. 14. When the No.1 LED stays on and the No.2 LED goes off, turn the ignition switch to LOCK (0). 15. Turn the ignition switch to ON (II). When the No.1 and No.2 LEDs stay on, the control unit/module is updated. 16. Turn the ignition switch to LOCK (0), and disconnect the DLC cable from the vehicle. To do the same update on an identical vehicle, repeat steps 11 thru 16. UPDATING WITH THE HDS TABLET AND THE HDS POCKET TESTER NOTE: This procedure explains how to update with the HDS tablet. Updating with the HDS pocket tester is similar, but the user interface is modified to fit its smaller screen. 1. If not already done, load the latest HDS PC sofiware onto your HDS tablet or HDS pocket tester. Refer to the instructions included with the HDS Installation Disc. NOTE: If the latest sofiware is not loaded and you do a control unit/module update, the software may indicate the vehicle has the latest update when it doesn't. Updates not done with the latest software are not covered under warranty. 2. On the HDS Switchboard screen, click on the CM update icon. Page 951 7. From the Mode menu, select Miscellaneous Test. 8. From the Miscellaneous Test menu, select OPDS Initialization. 9. Follow the remaining screen prompts to complete the OPDS initialization. If the initialization fails repeat the process two more times. If the initialization fails again, check for SRS DTCs, then troubleshoot them using the appropriate service manual. Initializing the OPDS Unit: Manual Mode NOTE: Non-Honda seat covers will interfere with the performance of the OPDS and are not recommended. 1. Adjust the front passenger's seat-back to an upright position, then remove anything on or near the seat. 2. Turn the ignition switch to LOCK (0). 3. Connect the HDS to the vehicle's DLC (data link connector). 4. Keep the ignition switch at LOCK (0), and turn on the HDS. 5. At the screen prompts, enter the VIN and the odometer reading. 6. From the Select Mode screen, select SCS, and follow the screen prompts. Page 8234 ^ If the trunk opens and closes smoothly, return the vehicle to the customer. ^ If the trunk lid is still difficult to close, go to REPAIR PROCEDURE E. REPAIR PROCEDURE E 1. Look at the back of the lock cylinder while you turn the key from lock to unlock. ^ Refer to page 20-158 of the 2001-04 Civic Service Manual. ^ In ISIS, use the keyword LID LOCK, and select Trunk Lid Lock Cylinder Replacement from the list. 2. Check the operation of the trunk lid lock cylinder: ^ If the lock cylinder is difficult to turn or binds, go to step 3. ^ If the lock cylinder operates properly, and the trunk lid is still difficult to close, refer to the appropriate body repair manual, and check for body inaccuracies. 3. Replace the lock cylinder, and re-key the cylinder to the customer's original key; on 2-door Civics, replace the lock cylinder and the lock cylinder rod: ^ Refer to page 20-158 of the 2001-04 Civic Service Manual. ^ In ISIS, use the keyword LID LOCK, and select Trunk Lid Lock Cylinder Replacement from the list. 4. Check the trunk operation, and return the vehicle to the customer. Disclaimer Body - Trunk Lid Hard to Close Trunk / Liftgate Lock Cylinder: All Technical Service Bulletins Body - Trunk Lid Hard to Close 02-061 November 5, 2004 Applies To: See VEHICLES AFFECTED Trunk Lid is Difficult to Close (Supersedes 02-061, dated July 23, 2004) Updated information is shown with asterisks. SYMPTOM The trunk lid may be difficult to close or won't latch closed. PROBABLE CAUSE The trunk lid may be misaligned, and the trunk lid opener cable, trunk lid latch, lock cylinder, lock rod, and/or the trunk lid latch striker may need adjustment or replacement. VEHICLES AFFECTED CORRECTIVE ACTION Adjust the trunk lid and/or the trunk lid latch, or replace components as needed. PARTS INFORMATION Page 4664 5. Disconnect the shift lock solenoid connector (2P) (A) and park pin switch connector (4P) (B). 6. Remove the four bolts, then remove the shift lever assembly. Specifications Fuel Pressure: Specifications Fuel Pressure at idle .................................................................................................................................... 270 - 320 kPa (2.8 - 3.3 kgf/sq.cm, 40 - 47 psi) Body - Door Lock Cylinders Bind Trunk / Liftgate Lock Cylinder: Customer Interest Body - Door Lock Cylinders Bind 03-068 October 29, 2004 Applies To: See VEHICLES AFFECTED Door Lock Cylinder Binds (Supersedes 03-068, dated April 20, 2004) Updated information is shown with asterisks and black bars. SYMPTOM The key will not go into the door lock cylinder, or if it goes in, it will not turn. PROBABLE CAUSE The door lock tumblers are damaged or worn. VEHICLES AFFECTED CORRECTIVE ACTION Remove the door lock cylinder, and replace the inner cylinder, springs, and tumblers. Page 3948 NOTE: If the Database Update is an earlier version than the one listed in a Honda service communication (service bulletin, product update, iN message, etc.), press ESC, then update your MVCI before continuing. 6. Wait for the MVCI to check the vehicle for reprogrammable systems. This may take up to 90 seconds. 7. If there are multiple reprogrammable systems that need to be updated, select the applicable system. Press ENTER to continue, or press ESC to exit. 8. The current program ID, the recommended update, and other details appear. Press ENTER to continue, or press ESC to exit. Page 9152 8. Put the splice connector in the proper size slot in the Crimper Tool, slide it to one end (where the flare begins), and close the crimper handles far enough to hold it in place. To release the ratchet mechanism at any point after the first click, squeeze the handles slightly and push the release lever, then let the handles open. 9. Insert one of the bare wires into the splice connector end that is in the crimper jaws. Push the wire all the way into the splice connector, and squeeze the crimper handles. Keep squeezing until the jaws touch, and hold it at that position until the ratchet clicks again. 10. Crimp the other wire in the same way into the other end of the splice connector. 11. After crimping, gently pull on the wires in the opposite directions to make sure they are secure in the connector. 12. Separate the other wires in the harness from the repaired wire(s), and shield them with nonflammable material. Page 4270 1. Remove and discard the plastic cover from the ignition switch key interlock solenoid. 2. Note the position of the interlock solenoid plunger; you'll need to install it the same way. 3. Remove the screw from the solenoid, but keep the solenoid attached to its electrical connector. Discard the screw. NOTE: ^ Be careful not to lose the solenoid plunger; it slides out easily. ^ Keep the plunger free of dirt and grease while it's removed from the solenoid. 4. Note the position of the interlock lever spring; you'll need to install the new spring the same way. Front Wheel Bearing: Service and Repair Front Knuckle/Hub/Wheel Bearing Replacement Special Tools Required Hub dis/assembly tool 07GAF-SE00100 - Ball joint remover, 28 mm 07MAC-SL00200 - Attachment 62 x 68 mm 07746-0010500 - Driver 07749-0010000 - Support base 07965-SD90100 1. Raise the front of the vehicle, and support it with safety stands in the proper locations. 2. Remove the wheel cap, wheel nuts, and front wheel. Locations Page 895 13. After completing the right edge, push all of the cam blades to the right until they touch the cams, then trace the cam blades from back to front. (The cutter bit cuts the same contours into the left edge of the key from tip to head.) Turn off the cutter motor. 14. Release the vertical carriage lever. Push all the cam blades to the left until they touch the cams. Pull the vertical carriage lever towards you until the tracer touches the flat surface on the right side, at the front of the cams. Gently twist the lever clockwise to lock the vertical carriage at this height. Do not overtighten the lever. 15. Turn on the cutter motor, then retrace the cam blades from front to back. Push all the cam blades to the right until they touch the cams, and then retrace the cam blades from back to front (retracing cleans up the cuts on the key). Turn off the cutter motor. 16. Release the vertical carriage lever. Open the jaw and remove the key. Make sure the jaw is free of any metal shavings or debris. Turn the key over so the blank side is up, then slide it into the jaw up to the key stop. Close the jaw to lock the key in place. 17. Push all the cam blades to the left until they touch the cams. Repeat steps 10 through 15 to cut both edges on the other side of the key. 18. When you are done making the required cuts, release the vertical carriage lever. Open the jaw and remove the key. 19. Make sure the key works in the ignition switch and the locks. If the key does not work, recut the key, and try it again. 20. Depending on the type of key, code the key transponder. Equipment Service and Warranty To service the MATRIX H Key Cutting Machine, refer to section 7 of the MATRIX H Operating Manual. It tells you how to replace parts that commonly wear out such as the drive belt, the work light bulb, and the tension spring on the vertical carriage. It also covers checking and replacing fuses and replacing the printed circuit board for the setting unit keypad. If you have technical questions on the equipment, contact the Ilco Technical Assistance Department. Mail: Kaba Ilco Technical Assistance Department 400 Jeffreys Road Rocky Mount, NC 27804 Phone: 800-452-6872 Ext: 200, 384, 323, 398, 356 Fax: 252-446-4702 The MATRIX H Key Cutting Machine comes with a 3-year limited warranty. This warranty does not cover the cutter bit or the work light bulb. CODE BOOK CORRECTIONS In the code book Honda High Security key Codes, correct these errors: Pages 4 thru 51, code headings: ^ Incorrect: J H G F Z X E D C B M/S X ^ Correct: J H G F A X E D C B M/S X Page 2, last paragraph: Page 6001 1. Remove the terminal. 2. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE G: 1. Remove the terminal. 2. Go to HOW TO INSTALL NEW TERMINALS. Page 1636 Wheel Bearing: Service and Repair Rear Hub Bearing Unit Replacement 1. Raise the rear of the vehicle, and support it with safety stands in the proper locations. 2. Remove the wheel cap, wheel nuts, and rear wheel. Description and Operation Temperature Gauge: Description and Operation How the Circuit Works The indicators are controlled by relative conditions in their associated systems. For the following indicators the information supplied to the gauge assembly is received via the multiplex control unit: - Charging System - Door Indicator Light - Maintenance Required Indicator - Seat Belt Reminder - Trunk Indicator Light Refer to each associated system to see its entire schematic. Engine Coolant Temperature Gauge The engine coolant temperature gauge is controlled by the CPU built-in the gauge assembly. The CPU receives coolant temperature information from the ECM/PCM via the multiplex control unit, The ECM/PCM receives coolant temperature information from the ECT sensor. Page 1696 Variable Valve Timing Actuator: Electrical Diagrams Diagram 31 (EX, HX) Diagrams: Other diagrams referred to by number (See Diagram ##-#, etc.)within these diagrams can be found at Diagrams by Number. See: Diagrams/Electrical Diagrams/Diagrams By Number Locations: Location photographs (references to PHOTOS) referred to within these diagrams can be found at Locations by Photo Number. See: Locations/Component Locations/Locations By Photo Number Connector Views: Connector terminal views (references to VIEWS) referred to within these diagrams can be found at Connector Views by View Number. See: Diagrams/Connector Views/Connector Views By View Number Page 7087 7. Connect the SCS service connector to the 2P MES (memory erase signal) connector, as shown. Do not use a jumper wire. 8. Turn the ignition switch to ON (II). 9. Watch the SRS indicator. (It comes on for about 6 seconds and then goes off.) Disconnect the SCS service connector from the MES connector within 4 seconds after the indicator goes off. 10. When the SRS indicator comes on again, connect the SCS service connector to the MES connector within 4 seconds after the indicator comes on. 11. When the SRS indicator goes off, disconnect the SCS service connector from the MES connector within 4 seconds. Page 2023 Timing Belt Tensioner: Testing and Inspection Auto-Tensioner Inspection 1. Remove the auto-tensioner. NOTE: Do not apply force to the tensioner pulley. 2. Put the auto-tensioner on a surface plate. 3. Measure the height at point A (A) and point B (B). 4. Calculate the difference in height between point A and point B. If the difference in height is out of tolerance, replace the auto-tensioner. Difference in height: Specification: 0.75 mm (0.030 inch) 5. Inspect the spring grommet (A). Replace the grommet if it is damaged or deteriorated. Page 7590 Rear Door Window Motor: Diagrams (Sedan Except DX) 63. Power Window Motor, Left Rear Or Right Rear (Sedan Except DX) Page 5210 Page 8405 Sunroof / Moonroof Motor: Service and Repair Motor Replacement 1. Remove the headliner. 2. Put on gloves to protect your hands. Disconnect the connector (A), and remove the bolts, then remove the motor (B). 3. Install the motor in the reverse order of removal, and note these items: - Make sure the connector is plugged in properly. - Check the motor operation. Locations 151. Middle Of Trunk Lid Page 4991 1. Remove the terminal. 2. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE B: 1. Remove the terminal. 2. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE C: 1. Remove the terminal. 2. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE D: Page 1273 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 261 DTC P0563 thru P0748 Service and Repair Rear Door Window Glass Weatherstrip: Service and Repair Rear Door Glass Outer Weatherstrip Replacement 4-door NOTE: - Put on gloves to protect your hands. - Take care not to scratch the door. 1. Starting at the front, pry the door glass outer weatherstrip (A) up to detach the clips (B, C, D), then remove the weatherstrip. 2. Install the weatherstrip in the reverse order of removal, and replace any damaged clips. Diagrams Multiple Junction Connector: Diagrams 217. C102 (Junction Connector) Page 4955 143. Park Pin/Shift Switch (A/T) Page 2531 Use the tools from Pin Tool Set. First, check the connector that you are about to repair. - If it has a secondary terminal lock, go to Connectors With a Secondary Lock. A secondary lock, found on most connectors on some models, is an additional locking device on the connector housing as a backup for the primary lock on the terminal. - If the connector does not have a secondary lock, go to Connectors Without a Secondary Lock. Connectors With a Secondary Lock All examples are shown with the connector lock facing up. The illustrations are examples of the secondary terminal locks; however, the connector you are repairing may vary in size. Identify the connector by the type of secondary lock, not by the number of terminal cavities. EXAMPLE A: 1. Release the secondary lock. 2. Remove the terminal. 3. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE B: Page 3174 Vehicle Speed Sensor: Locations Gauges Component Location Index (Part 1 Of 4) Page 7013 4. Pull the lower anchor cover (A) back, and remove the lower anchor bolt (B). 5. Remove the B-pillar lower trim panel. 6. Remove the upper anchor cover (A), and remove the upper anchor bolt (B). 7. Disconnect the seat belt tensioner connector (A). Remove the retractor mounting bolt (B), and the retractor bolt (C), then remove the front seat belt (D) and retractor (E). 8. If necessary, remove the front seat belt protector (F). 9. Remove the B-pillar upper trim. Page 3141 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. Circuits must be operating when checking voltage drop. 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. 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 off, 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 Self-Powered Test Light or DVOM 1. Remove the blown fuse and disconnect the battery and load. Page 6365 Suspension Strut / Shock Absorber: Specifications Rear TIGHTENING SPECIFICATIONS Damper Shaft Nut ................................................................................................................................ ................................ 29 N.m (3.0 kgf-m, 22 lbf-ft) Upper Flange Nut .................................................. .............................................................................................................................. 59 N.m (43 ft. lbs.) Rear Lower Bolt ................................................................................................................................... ............................................... 61 N.m (45 ft. lbs.) Page 9031 8. Put the splice connector in the proper size slot in the Crimper Tool, slide it to one end (where the flare begins), and close the crimper handles far enough to hold it in place. To release the ratchet mechanism at any point after the first click, squeeze the handles slightly and push the release lever, then let the handles open. 9. Insert one of the bare wires into the splice connector end that is in the crimper jaws. Push the wire all the way into the splice connector, and squeeze the crimper handles. Keep squeezing until the jaws touch, and hold it at that position until the ratchet clicks again. 10. Crimp the other wire in the same way into the other end of the splice connector. 11. After crimping, gently pull on the wires in the opposite directions to make sure they are secure in the connector. 12. Separate the other wires in the harness from the repaired wire(s), and shield them with nonflammable material. Page 9201 1. Remove the secondary locks. 2. Remove the terminal from the female half. 3. Remove the terminal from the male half. 4. Go to HOW TO INSTALL NEW TERMINALS. Connectors Without a Secondary Lock All examples are shown with the connector lock facing up. The illustrations are examples of connector terminals without a secondary lock; however, the connector you are repairing may vary in size and shape. EXAMPLE A: Page 7882 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. DIAGNOSIS Pull up the outer edge of the windshield molding. Check if the inner lip is folded over anywhere. ^ If the inner lip is folded over, go to REPAIR PROCEDURE. ^ If the inner lip is not folded, disregard this bulletin, and look for other possible causes. REPAIR PROCEDURE 1. Protect the roof by applying a strip of 2-inch-wide masking tape along the outer edge of the windshield molding. 2. Pull up the outer edge of the molding, and use scissors or an X-Acto knife to remove its entire inner lip. Page 9141 Use the tools from Pin Tool Set. First, check the connector that you are about to repair. - If it has a secondary terminal lock, go to Connectors With a Secondary Lock. A secondary lock, found on most connectors on some models, is an additional locking device on the connector housing as a backup for the primary lock on the terminal. - If the connector does not have a secondary lock, go to Connectors Without a Secondary Lock. Connectors With a Secondary Lock All examples are shown with the connector lock facing up. The illustrations are examples of the secondary terminal locks; however, the connector you are repairing may vary in size. Identify the connector by the type of secondary lock, not by the number of terminal cavities. EXAMPLE A: 1. Release the secondary lock. 2. Remove the terminal. 3. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE B: Page 7252 Programming the Transmitter NOTES: ^ The system accepts up to three transmitters. The transmitter codes are stored in a stacking-type memory. If a fourth transmitter code is programmed, the code for the first transmitter is erased. ^ Entering the programming mode cancels all learned transmitter codes, so none of the previously programmed transmitters will work. You must reprogram all of the transmitters once you are in the programming mode. ^ You must complete steps 1-6 within 4 seconds of the previous step to keep the system from exiting the programming mode. 1. Turn the ignition switch to ON (II). 2. Press the "Lock" or "Unlock" button on one of the transmitters. (An unprogrammed transmitter can be used for this step.) 3. Turn the ignition switch to LOCK (0). 4. Repeat steps 1, 2, and 3 two more times using the same transmitter used in step 2. 5. Turn the ignition switch to ON (II). 6. Press the "Lock" or "Unlock" button on the same transmitter. Make sure the power door locks cycle to confirm that the system is in programming mode. 7. Within 10 seconds, press the "Lock" or "Unlock" button on each transmitter. Make sure the power door locks cycle after you press each transmitter button to confirm that the system accepted the transmitter's code. 8. Turn the ignition switch to LOCK (0) to exit the programming mode. Ordering a Transmitter Transmitters can be ordered only by authorized Honda dealers. Order them from American Honda using normal parts ordering procedures. Batteries for the Transmitter The battery number is CR2025. Each transmitter uses one battery. 88-91 Prelude With Dealer-Installed Security System 1988-91 Prelude with dealer-installed security system Page 7086 Locations Heated Glass Element Switch: Locations Rear Window Defogger Component Location Index Page 1737 Rocker Arm Assembly: Service and Repair Rocker Arm Assembly Removal Removal 1. Loosen the adjusting screws (A). 2. Remove the bolts and the rocker arm assembly. -1 Unscrew the camshaft holder bolts two turns at a time, in a crisscross pattern, to prevent damaging the valves or rocker arm assembly. -2 When removing the rocker arm assembly, do not remove the camshaft holder bolts. The bolts will keep the camshaft holders, the springs and the rocker arms on the shafts. Camshaft Holder Bolt Loosening Sequence Page 3102 Oxygen Sensor: Service and Repair Secondary HO2S Replacement Secondary HO2S Replacement Special Tools Required O2 sensor wrench, Snap-on YA8875, SP Tools 93750, or equivalent, commercially available NOTE: The secondary HO2S and the third HO2S must be replaced together (D17A6 engine except '01 model) 1. Disconnect the secondary HO2S 4P connector (A), then remove the secondary HO2S (B). 2. Install the secondary HO2S in the reverse order of removal. Page 4236 Transmission Position Switch/Sensor: Electrical Diagrams Circuit Diagram Page 3971 Pressure Regulating Solenoid: Diagrams 25. A/T Clutch Pressure Control Solenoid Valve A 26. A/T Clutch Pressure Control Solenoid Valve B Page 9367 3. Strip the insulation off the end of the wire so the wire fits in the new terminal as shown. (If the wire has a wire seal, replace it with a new one from the kit.) NOTE: After stripping the end of the wire, make sure you did not cut any wire strands. If you did, cut the wire off even with the insulation, and strip it again. 4. Position the terminal in the crimping tool slot with the solid portion of the terminal toward the anvil and the open section toward the former. 5. Insert the wire in the terminal to the position shown in step 3. 6. Squeeze the tool with both hands until the stops make contact. 7. Crimp the insulation crimp. - If you do not have a wire seal, then use the next larger size crimp slot. Position the crimping tool over the insulation crimp section of the terminal, then squeeze the tool with both hands until the stops make contact. - If you have a wire seal, position the insulation crimp in the 5.5 crimping slot, then carefully squeeze the crimp closed until its ends are touching and making a full-circle shape. Key Beeper, Light Chime & Ceiling Light Don't Work Door Switch: Technical Service Bulletins Key Beeper, Light Chime & Ceiling Light Don't Work SOURCE: Honda Service News April 2003 TITLE: Key Beeper, Light Chime, Ceiling Light Don't Work APPLIES TO: 2001-03 Civic, 2002-03 CR-V SERVICE TIP: If the ignition key-in beeper, the headlights-on chime, the ceiling light, and the driver's-dooropen indicator are all on the fritz check the driver's door switch in the doorjamb. A faulty door switch can cause all of these symptoms. Page 4788 Use the tools from Pin Tool Set. First, check the connector that you are about to repair. - If it has a secondary terminal lock, go to Connectors With a Secondary Lock. A secondary lock, found on most connectors on some models, is an additional locking device on the connector housing as a backup for the primary lock on the terminal. - If the connector does not have a secondary lock, go to Connectors Without a Secondary Lock. Connectors With a Secondary Lock All examples are shown with the connector lock facing up. The illustrations are examples of the secondary terminal locks; however, the connector you are repairing may vary in size. Identify the connector by the type of secondary lock, not by the number of terminal cavities. EXAMPLE A: 1. Release the secondary lock. 2. Remove the terminal. 3. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE B: Page 1280 ^ 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 5211 Page 5840 Under-dash Fuse/Relay Box (2-door) Locations SRS Component Location Index Page 8954 108. Middle Of Floor Page 2181 Blower Motor Relay Type 1, Type 2 Check for continuity between the terminals. - There should be continuity between the No.1 and No.3 terminals when power and ground are connected to the No.2 and No.4 terminals. - There should be no continuity between the No.1 and No.3 terminals when power is disconnected. Five-terminal type Check for continuity between the terminals. - There should be continuity between the No.1 and No.2 terminals when power and ground are connected to the No.3 and No.5 terminals. - There should be continuity between the No.1 and No.4 terminals when power is disconnected. Page 5280 Transmission Speed Sensor: Service and Repair Countershaft Speed Sensor Replacement Countershaft Speed Sensor Replacement 1. Disconnect the countershaft speed sensor connector. 2. Remove the countershaft speed sensor (A). 3. Install the new countershaft speed sensor with the new O-ring (B). 4. Check the countershaft speed sensor connector for rust, dirt, or oil, then connect the connector securely. Page 6295 13. Install the new ball joint into the knuckle. 14. Install the thread protector onto the ball joint. 15. Insert the base installer adapter B into the C-frame press. 16. Position adapter A over the ball joint, and position adapter H and the C-frame press. 17. Tighten the C-frame press to press the ball joint into the knuckle. 18. Install the knuckle in the reverse order of removal, and note these items: ^ Be careful not to damage the ball joint boot when installing the knuckle. ^ Tighten all mounting hardware to the specified torque values. ^ Torque the castle nut to the lower torque specification, then tighten it only far enough to align the slot with the ball joint pin hole. Do not align the nut by loosening it. ^ Install a new lock pin in the castle nut after torquing. ^ Use a new spindle nut. ^ Before installing the new spindle nut, apply a small amount of engine oil to the seating surface of the nut. After tightening, use a drift to stake the spindle nut shoulder against the driveshaft. ^ Before installing the wheel, clean the mating surface of the brake disc and the inside of the wheel. 19. Check the wheel alignment. Disclaimer Recall 10V364000: Ignition Interlock Defect Shift Interlock Switch: Recalls Recall 10V364000: Ignition Interlock Defect VEHICLE MAKE/MODEL: MODEL YEAR(S): Honda/Accord 2003 Honda/Civic 2003 Honda/Element 2003-2004 MANUFACTURER: Honda (American Honda Motor Co.) MFR'S REPORT DATE: August 04, 2010 NHTSA CAMPAIGN ID NUMBER: 10V364000 NHTSA ACTION NUMBER: EA09001 COMPONENT: Electrical System: Ignition POTENTIAL NUMBER OF UNITS AFFECTED: 384220 SUMMARY: Honda is recalling certain model year 2003 Honda Accord, Civic two and four door, and model year 2003-2004 Honda Element vehicles. The interlock lever of the ignition switch may unexpectedly deform, which can allow the interlock function of a vehicle with an automatic transmission to be defeated. CONSEQUENCE: Removal of the ignition key when the gear selector of a vehicle with an automatic transmission has not been shifted to the park position can allow the vehicle to roll away, increasing the risk of a crash. REMEDY: Dealers will remove the original interlock pin and lever within the ignition switch, and replace them with newly, designed components. This service will be performed free of charge. The safety recall is expected to begin on or about September 29, 2010. Owners may contact Honda at 1-800-999-1009. NOTES: Honda safety recall No. R44. 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 7487 2. Install the bumper in the reverse order of removal, and note these items: - Make sure the front bumper engages the hooks of the side spacers and upper beams on both sides securely. - Replace any damaged clips. Page 5968 Under-hood Fuse And Relay Box (4-door) Page 1066 Circuit Schematics Each schematic represents one circuit. A circuit's wires and components are arranged to show current flow from power at the top of the diagram 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 Page 8350 4. Polishing Check that the top coat enamel has dried thoroughly, then sand the top coat enamel. Use the double action sander and #600 - #800 disc papers. NOTE: Be careful not to polish down to the primer surfacer. When the painting repair is almost done, polish the area that will be top coated. Use the #2000 sandpaper and compound. 5. Air blowing/degreasing Use alcohol, and wax and grease remover. Also clean and degrease surfaces where the masking tape will be attached. Top Coating Top Coating 1. Masking Mask the area surrounding the damage to protect it from the top coat overspray. Use masking tape and paper. 2. Spraying top coat enamel/clear coat Spray 2 - 3 double coat until the intermediate coat is fully covered. Use the 2-part polyester urethane top coat enamel and a spray gun. - Mix the top coat enamel with the additive and solvent in the correct ratio. - Follow the top coat manufacturer's instructions. Drying After spraying the top coat enamel, allow it to air dry, then force dry it with infrared lamps or other industrial dryer. NOTE: Follow the top coat manufacturer's instructions for drying time. Page 9164 Daytime Running Lamp Control Unit: Testing and Inspection Daytime Running Lights Control Unit Input Test - Canada The DRL indicator light in the gauge assembly will come on when you turn the ignition switch to ON (II) with the headlight switch off and the parking brake set. If should go off when you turn on the headlight switch, release the parking brake. If it comes on at any other time, do the control unit input test. NOTE: When the daytime running lights are on, the high beam indicator will glow at half its normal intensity. 1. Remove the driver's dashboard lower cover. 2. Disconnect the 14P connector (A) from the daytime running lights control unit (B). 3. Inspect the connector and socket terminals to be sure they are all making good contact. - If the terminals are bent, loose or corroded, repair them as necessary, and recheck the system. - If the terminals look OK, go to step 4. '01-03 models Page 554 Cruise Control Switch: Diagrams 139. Cruise Control Set/Resume/Cancel Switch (except DX) 157. Cruise Control Main Switch (except DX) Page 5486 108. Middle Of Floor Page 8125 On the order form, you must include the serial number of the keyless control unit or the number from one of the original transmitters. If you need a transmitter shipped overnight, fill out the order form, then call Kenwood at (500) 552-4690, or fax them at (310) 595-1029 (weekdays from 5:30A.M. thru 4:00 P.M. Pacific time). You will need to give the information on the order form to the Kenwood representative. The transmitter will be sent to your dealership COD. Additional shipping and handling charges will be applied to the order. Batteries for the Transmitter The battery number is CR1220. Each transmitter uses two batteries. 94-97 Accord 5-Door EX, 95-98 Odyssey EX 1994-97 Accord 5-door EX with factory-installed keyless entry system 1995-98 Odyssey EX with factory-installed keyless entry system Programming the Transmitter NOTE: ^ The system accepts up to two transmitters. ^ Entering the programming mode cancels all learned transmitter codes, so none of the previously programmed transmitters will work. You must reprogram all of the transmitters once you are in the programming mode. 1. Open the driver's door. 2. Push the driver's power door lock switch to the unlock position and hold it. (Continue to hold the switch during this procedure.) 3. Insert the key into the ignition switch, then remove it. Repeat this four more times (five times total) within 10 seconds. (You must complete steps 3 and 4 within 10 seconds or the system will exit the programming mode.) 4. Insert the key into the ignition switch. After you insert the key, make sure the power door locks cycle to confirm that the system is in the programming mode. 5. Press the "LOCK" or "UNLOCK" button on the transmitter. All the power door locks (except the driver's door) should cycle to confirm that the system accepted the transmitter's code. 6. To program a second transmitter, press its "LOCK" or "UNLOCK" button within 10 seconds of programming the first transmitter. 7. Release the master power door lock switch to exit the programming mode. Ordering a Transmitter Transmitters can be ordered only by authorized Honda dealers. Order them from American Honda using normal parts ordering procedures. Batteries for the Transmitter The battery number is CR2016. Each transmitter uses two batteries. 96-04 Accord, CRV, DelSOL, Ody., Prelude, S2000, Insight, Pilot 1996-02 Accord with dealer-installed security system 1998-02 Accord DX & LX with dealer-installed keyless entry system Page 6499 connectors connected. Is there battery voltage? YES - Reprogram the ECM/PCM if it does not have the latest software, or substitute a known-good ECM/PCM, then recheck. If the symptom/indication goes away with a known-good ECM/PCM, replace the original ECM/PCM. NO - Repair open in the wire between the compressor clutch relay and the ECM/PCM. 14. Disconnect the jumper wire. 15. Disconnect the compressor clutch 1P connector. 16. Check for continuity between the No.1 terminal of the compressor clutch relay 4P socket and the No.1 terminal of the compressor clutch 1P connector. Is there continuity? YES - Check the compressor clutch clearance, the thermal protector, and the compressor clutch field coil. NO - Repair open in the wire between the compressor clutch relay and the compressor clutch. 17. Disconnect the jumper wire. 18. Disconnect the compressor clutch 3P connector. 19. Check for continuity between the No.1 terminal of the compressor clutch relay 4P socket and the No.2 terminal of the compressor clutch 3P connector. Is there continuity? YES - Check the compressor clutch clearance and the compressor clutch field coil. NO - Repair open in the wire between the compressor clutch relay and the compressor clutch. Master Switch Replacement Power Window Switch: Service and Repair Master Switch Replacement Master Switch Test/Replacement 4-door 1. Remove the door grip cover. 2. Disconnect the 20P connector from the power window master switch. Rocker Arms and Shaft Inspection Rocker Arm Assembly: Testing and Inspection Rocker Arms and Shaft Inspection Inspection 1. Measure the diameter of the shaft at the first rocker location. 2. Zero the gauge (A) to the shaft diameter. 3. Measure the inside diameter of the rocker arm, and check it for an out-of-round condition. Rocker Arm-to-Shaft Clearance: Standard (New): Intake: 0.017 - 0.050 mm (0.0007 - 0.0020 inch) Exhaust: 0.018 - 0.054 mm (0.0007 - 0.0021 inch) Service Limit: 0.08 mm (0.003 inch) 4. Repeat for all rockers and both shafts. If the clearance is over the limit, replace the rocker shaft and all over tolerance rocker arms. If any VTEC intake rocker arm needs replacement, replace both rocker arms in that set (primary and secondary). Page 6261 11. Remove the valve body unit (A) from the steering gearbox. Remove the O-ring (B) and discard it. 12. Remove the two boot bands (B) from boot A. Compress boot A by hand, and apply vinyl tape (C) so the boots stay collapsed and pulled back. 13. Attach the yoke (A) of a universal puller to the steering gearbox mounts with bolts. Securely clamp the yoke in a vise with jaws as shown. Do not clamp the gearbox housing in the vise. Capacity Specifications Fluid - CVT: Capacity Specifications ATF Change ................................................................................................................................................ .............................................................. 2.7L (2.9 Qt) Overhaul .......................................................... .................................................................................................................................................. 6.0L (6.3 Qt) CVT fluid Change ................................................................................................................................ .............................................................................. 3.1L (3.3 Qt) Overhaul .......................................... .............................................................................................................................................................. .... 5.6L (6.0 Qt) Page 7168 Part 1 5. Reconnect all connections to the under-dash fuse/relay box, and make these input tests at the appropriate connectors on the under-dash fuse/relay box. If any test indicates a problem, find and correct the cause, then recheck the system. - If all the input tests prove OK, go to step 6. Part 2 Page 2867 94. Behind Glove Box (except GX) Starting System - Starter Grinds While Engine Cranks Starter Motor: Customer Interest Starting System - Starter Grinds While Engine Cranks 06-025 May 18, 2006 Applies To: 2001-05 Civic 2-door - ALL except CVI 2001-05 Civic 4-door - ALL except Hybrid and GX Starter Grinds While Cranking the Engine SYMPTOM The starter motor intermittently grinds while cranking the engine. PROBABLE CAUSE The female terminal at the starter solenoid may have spread apart, causing a loss of current to the solenoid. CORRECTIVE ACTION Replace the female terminal at the starter solenoid. PARTS INFORMATION Spade Receiver Terminal: P/N 07JAZ-001420A, H/C 8362675 TOOL INFORMATION Terminal Crimping Tool: T/N 07JAZ-001020A WARRANTY CLAIM INFORMATION In warranty: The normal warranty applies. Operation Number: 7370C3 Flat Rate Time: 0.4 hour Failed Part: P/N 31200-PLM-A51 H/C 6452429 Defect Code: 06601 Symptom Code: 09004 Template ID: 06-025A 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. DIAGNOSIS 1. If applicable, make sure you have the anti-theft code for the audio system. Write down the customer's audio unit presets. 2. Disconnect the negative cable from the battery, then disconnect the positive cable. 3. Remove the resonator: Page 5775 Rear Window Defogger Component Location Index Page 5093 Shift Solenoid: Testing and Inspection Solenoid Valve Test - Continuously Variable Transmission Solenoid Valve Test 1. Disconnect solenoid harness connector (BP). 2. Measure CVT speed change control valve assembly resistance between solenoid harness connector terminals No. 3 and No. 7. STANDARD: 3.8 - 6.8 Ohms 3. Measure CVT pulley pressure control valve assembly resistance between terminals No. 2 and No. 6. STANDARD: 3.8 - 6.8 Ohms 4. Measure CVT start clutch pressure control valve assembly resistance between terminals No. 4 and No. 8. STANDARD: 3.8 - 6.8 Ohms 5. Measure the inhibitor solenoid resistance between terminal No. 5 and body ground. STANDARD: 11.7 - 21.0 Ohms 6. Replace the CVT speed change control valve assembly or CVT start clutch pressure control valve assembly, if the measurements are out of standard. Replace the lower valve body assembly, if the measurements of CVT pulley pressure control valve assembly or inhibitor solenoid are out of standard. 7. If all of the resistance are within the standard, a clicking sound should be heard when connecting the battery terminals to the solenoid harness connector terminals below. ^ CVT speed change control valve assembly No. 3 to battery positive terminal No. 7 to battery negative terminal ^ CVT pulley pressure control valve assembly No. 2 to battery positive terminal No. 6 to battery negative terminal ^ CVT start clutch pressure control valve assembly No. 4 to battery positive terminal No. 8 to battery negative terminal ^ Inhibitor solenoid No.5 to battery positive terminal and body ground to negative terminal 8. If no clicking sound is heard, remove the lower valve body assembly, and check the solenoid. Page 3185 48. Middle Of Engine (except GX) 49. Middle Of Engine (GX) Page 5959 Rear Window Defogger Component Location Index Page 8777 8. Put the splice connector in the proper size slot in the Crimper Tool, slide it to one end (where the flare begins), and close the crimper handles far enough to hold it in place. To release the ratchet mechanism at any point after the first click, squeeze the handles slightly and push the release lever, then let the handles open. 9. Insert one of the bare wires into the splice connector end that is in the crimper jaws. Push the wire all the way into the splice connector, and squeeze the crimper handles. Keep squeezing until the jaws touch, and hold it at that position until the ratchet clicks again. 10. Crimp the other wire in the same way into the other end of the splice connector. 11. After crimping, gently pull on the wires in the opposite directions to make sure they are secure in the connector. 12. Separate the other wires in the harness from the repaired wire(s), and shield them with nonflammable material. Page 2265 Page 1576 234. Under-dash Fuse/Relay Box Part 3 Page 6775 brackets. 2. Reinstall the dashboard center lower cover. 3. Reconnect the driver's and front passenger's airbag connectors. 4. Reconnect the side airbag connectors. 5. Reconnect both seat belt tensioner connectors and both seat belt buckle tensioner connectors. 6. Reconnect the battery negative cable. 7. Initialize the OPDS unit. 8. After installing the SRS unit, confirm proper system operation: Turn the ignition switch ON (II); the SRS indicator should come on for about 6 seconds and then go off. Page 4205 Splices Components Ground - "G" Page 1729 Rocker Arm Assembly: Testing and Inspection VTEC Rocker Arm Test VTEC Rocker Arm Test Special Tools Required ^ Air pressure regulator 07AAJ-PNAA100 ^ Air stopper 07LAJ-PR3020B 1. Remove the resonator. 2. Remove the ignition coil cover, then remove the four ignition coils. 3. Remove the throttle cable clamps and harness holder from the cylinder head cover. 4. Remove the cylinder head cover. 5. Set the No. 1 piston at Top Dead Center (TDC). 6. Verify that the intake secondary rocker arm (A) moves independently of the intake primary rocker arm (B). ^ If the intake secondary rocker arm does not move, remove the primary and secondary rocker arms as an assembly and check that the pistons in the secondary and primary rocker arms move smoothly. If any rocker arm needs replacing, replace the primary and secondary rocker arms as an assembly, and retest. ^ If the intake secondary rocker arm moves freely, go to step 7. 7. Repeat step 6 on the remaining intake secondary rocker arms with each piston at TDC. When all the secondary rocker arms pass the test, go to step 8. 8. Check that the air pressure on the shop air compressor gauge indicates over 400 kPa (4 kgf/cm2, 57 psi). 9. Inspect the valve clearance. 10. Cover the timing belt with a shop towel to protect the belt. 11. Plug the relief hole with the air stopper. Page 6091 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 5724 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. Below most connector numbers and component names are PHOTO and VIEW numbers. The PHOTO number refers to a photo in the back of the book that shows the connector's location on the car. The VIEW number refers to an illustration in the back of the book that shows the connector terminals, wire colors, connector cavity numbers, and other details. The connector cavity numbering sequence begins at the top left corner of the connector as seen from either of the viewpoints shown on diagram [8] . Except for the DLC (data link 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 C554, for example, means those terminals join in cavity 2 of connector C554. Power Distribution Schematics Power Distribution Schematics Page 8026 3. Use the clamp carriage lever to position the clamp unit so the tracer is directly over the flat surface of the code device, just ahead of the cam blades. 4. Pull the vertical carriage lever toward you until the tracer just touches the flat surface ahead of the cam blades. Watch the arrows on the keypad: ^ If the double-headed arrow in the middle of the keypad lights green, the tracer and cutter bit are properly aligned. ^ If the arrow on the left of the keypad lights red, the cutter bit is not touching the jaw. Turn the micrometric ring nut above the tracer to the left until the double-headed arrow lights green. ^ If the vertical arrow on the right of the keypad lights red, the tracer is not touching the jaw. Turn the micrometric ring nut above the tracer to the right until the double-headed arrow lights green. *5. Turn the micrometric ring nut to the right five clicks so the cutter bit is slightly higher than the tracer. The arrow on the left should light red. Raise the vertical carriage. NOTE: Setting the tracer five clicks lower than the cutter bit at this point has the effect of making the cutter bit cut the duplicated key a little shallower. This will protect the locking jaws from being damaged.* 6. Optional: Loosen the set screw, and adjust the hand rest to a comfortable position. Tighten the screw. 7. Pull the clamp carriage lever toward you until the clamp carriage clicks into its end-of-run position. 8. Clean any metal shavings or debris out of the center jaw. (A soft-bristle toothbrush is ideal for this purpose.) Then open the jaws with the jaws knob, and slide the key blank with its flat side down into the jaw up to the key stop. Close the jaw with the jaws knob to lock the key blank into place. Visually inspect the key for proper alignment in the jaw. 9. Set and lock the cam sets on the code device. ^ Starting with the left cam set, make sure the lock pin is pulled all the way out. (This releases the cams.) Page 699 Crankshaft Position Sensor: Description and Operation Crankshaft Position (CKP) Sensor The CKP sensor detects engine speed, and is used by the ECM/PCM to determine ignition timing and timing for fuel injection of each cylinder. Page 3693 Terminals - "T" Shielding Switches Fuses Page 5908 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. Below most connector numbers and component names are PHOTO and VIEW numbers. The PHOTO number refers to a photo in the back of the book that shows the connector's location on the car. The VIEW number refers to an illustration in the back of the book that shows the connector terminals, wire colors, connector cavity numbers, and other details. The connector cavity numbering sequence begins at the top left corner of the connector as seen from either of the viewpoints shown on diagram [8] . Except for the DLC (data link 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 C554, for example, means those terminals join in cavity 2 of connector C554. Power Distribution Schematics Power Distribution Schematics Key Beeper, Light Chime & Ceiling Light Don't Work Door Switch: Technical Service Bulletins Key Beeper, Light Chime & Ceiling Light Don't Work SOURCE: Honda Service News April 2003 TITLE: Key Beeper, Light Chime, Ceiling Light Don't Work APPLIES TO: 2001-03 Civic, 2002-03 CR-V SERVICE TIP: If the ignition key-in beeper, the headlights-on chime, the ceiling light, and the driver's-dooropen indicator are all on the fritz check the driver's door switch in the doorjamb. A faulty door switch can cause all of these symptoms. Page 5839 Under-dash Fuse/Relay Box (4-door) Page 8041 ^ If no key code can be found on the iN or with the Matrix H High Security key Codes Book, remove one tumbler at a time from the old inner cylinder, and match the number stamped on the old tumbler to a new tumbler from the kit. Insert the new tumbler and spring in the appropriate new inner cylinder cavity. ^ Do not use the old inner cylinder, springs, or tumblers. ^ Using your thumb and forefinger, hold the tumblers in place, insert the key in the cylinder and verify that all tumblers are flush with the cylinder. If not, double-check the key number, the cutting key code, the tumbler numbers, and the cavity locations. NOTE: If the key cannot be inserted, check the tumbler in the "J" cavity. It may be out of position. 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 6106 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 Diagram Information and Instructions Map Light: Diagram Information and Instructions Terminal Numbering System Terminal Numbering System Connector terminals are numbered according to the cavities they're in. The cavities are numbered starting from the upper left, looking at the male terminals from the terminal side or looking at the female terminals from the wire side. Both views are in the same direction so the numbers are the same. All actual cavities are numbered, even if they have no wire terminals in them. NOTE: Data Link Connector (DLC) terminals are numbered according 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 below is #6. Page 7853 WARRANTY CLAIM INFORMATION In warranty: The normal warranty applies. Failed Part: P/N 68500-S5P-A90ZZ H/C 6528640 *Defect Code: 07406* Symptom Code: 03220 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 A 1. Check the side-to-side alignment of the trunk lid latch to the striker: ^ Refer to page 20-132 of the 2001-04 Civic Service Manual. ^ In ISIS, use the keyword TRUNK ADJUST, and select Trunk Lid Adjustment from the list. 2. Make sure the gaps of the trunk lid are even on all sides. ^ If the trunk is misaligned, go to step 3. ^ If the trunk lid is properly aligned on all sides, go to REPAIR PROCEDURE B. 3. Adjust the trunk lid hinges: ^ Refer to page 20-132 of the 2001-04 Civic Service Manual. ^ In ISIS, use the keyword TRUNK ADJUST, and select Trunk Lid Adjustment from the list. 4. Check the trunk operation: ^ If the trunk opens and closes smoothly and is properly aligned, return the vehicle to the customer. ^ If the trunk lid is still difficult to close, go to REPAIR PROCEDURE B. REPAIR PROCEDURE B Page 6140 ^ 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. Antitheft System - Alarm Will Not Arm/Arms By Itself Alarm Module: All Technical Service Bulletins Antitheft System - Alarm Will Not Arm/Arms By Itself 05-025 July 1, 2005 Applies To: 2001-05 Civic - ALL 2002-05 CR-V - ALL 2003-04 Element - ALL Accessory Security System Changes Modes By Itself (Supersedes 05-025, dated June 10, 2005, to update the information indicated by black bars and asterisks.) SYMPTOM The security system will not arm or it arms by itself. PROBABLE CAUSE Key switch contact chatter causes the control unit to change modes. CORRECTIVE ACTION * Civic: Replace the security control unit, and reprogram the remote(s).* * CR-V and Element: Replace the security control unit and the microphone, then reprogram the remote(s).* * NOTE: You must replace the microphone on the CR-V and Element because the security control units are matched to their microphones when they are manufactured. Using the original microphone may result in security system problems.* PARTS INFORMATION WARRANTY CLAIM INFORMATION In warranty: The normal warranty applies. Out of warranty: Any repair performed after warranty expiration may be eligible for goodwill consideration by the District Parts and Service Manager or your Zone Office. You must request consideration, and get a decision, before starting work. REPAIR PROCEDURE NOTE: Before starting, make sure you have all of the remotes (three maximum) the customer wishes to use. Page 8741 Cruise Control Switch: Service and Repair Set/Resume/Cancel Switch Set/Resume/Cancel Switch Test/Replacement 1. Remove the two screws, then remove the switch. 2. Check for continuity between the terminals in switch position according to the table. - If there is continuity, and it matches the table, but switch failure is occurred on the cruise control unit input test, check and repair the wire harness on the switch circuit. - If there is no continuity in one or both positions, replace the switch. Page 767 141. HO2S, Secondary (except HX) Or Third (HX) Page 8230 2. Replace the trunk lid latch: ^ Refer to page 20-157 of the 2001-04 Civic Service Manual. ^ In ISIS, use the keyword LID LATCH, and select Trunk Lid Latch Replacement from the list. 3. Check the trunk operation: ^ If the trunk opens and closes smoothly, return the vehicle to the customer. ^ If the trunk lid is still difficult to close, go to REPAIR PROCEDURE D. REPAIR PROCEDURE D 1. Disconnect the trunk lid opener cable from the trunk lid latch. Check the cable operation: ^ Refer to page 20-157 of the 2001-04 Civic Service Manual. ^ In ISIS, use the keyword LID LATCH, and select Trunk Lid Latch Replacement from the list. 2. Check that there is no friction or binding of the cable by holding the outside casing and pulling back and forth on the inner cable: ^ If the cable is difficult to move or binds, go to step 3. ^ If the cable operates smoothly, go to REPAIR PROCEDURE E. 3. Replace the trunk lid opener cable: ^ Refer to page 20-151 of the 2001-04 Civic Service Manual. ^ In ISIS, use the keyword LID OPEN, and select Trunk Lid Opener/Fuel Fill Door Opener Cable Replacement from the list. 4. Check the trunk operation: ^ If the trunk opens and closes smoothly, return the vehicle to the customer. ^ If the trunk lid is still difficult to close, go to REPAIR PROCEDURE E. REPAIR PROCEDURE E 1. Look at the back of the lock cylinder while you turn the key from lock to unlock. ^ Refer to page 20-158 of the 2001-04 Civic Service Manual. ^ In ISIS, use the keyword LID LOCK, and select Trunk Lid Lock Cylinder Replacement from the list. 2. Check the operation of the trunk lid lock cylinder: ^ If the lock cylinder is difficult to turn or binds, go to step 3. ^ If the lock cylinder operates properly, and the trunk lid is still difficult to close, refer to the appropriate body repair manual, and check for body inaccuracies. 3. Replace the lock cylinder, and re-key the cylinder to the customer's original key; on 2-door Civics, replace the lock cylinder and the lock cylinder rod: ^ Refer to page 20-158 of the 2001-04 Civic Service Manual. ^ In ISIS, use the keyword LID LOCK, and select Trunk Lid Lock Cylinder Replacement from the list. 4. Check the trunk operation, and return the vehicle to the customer. Page 4487 64. Under Left Side Of Dash (M/T) Body - Trunk Lid Hard to Close Trunk / Liftgate Striker: Customer Interest Body - Trunk Lid Hard to Close 02-061 November 5, 2004 Applies To: See VEHICLES AFFECTED Trunk Lid is Difficult to Close (Supersedes 02-061, dated July 23, 2004) Updated information is shown with asterisks. SYMPTOM The trunk lid may be difficult to close or won't latch closed. PROBABLE CAUSE The trunk lid may be misaligned, and the trunk lid opener cable, trunk lid latch, lock cylinder, lock rod, and/or the trunk lid latch striker may need adjustment or replacement. VEHICLES AFFECTED CORRECTIVE ACTION Adjust the trunk lid and/or the trunk lid latch, or replace components as needed. PARTS INFORMATION Page 2278 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 7404 Alarm Module: Description and Operation How the Circuit Works The immobilizer system is designed to prevent the car from being started without the owner's ignition key. If an attempt is made to Start the car with any other key, the immobilizer system will disable the car's fuel supply. The immobilizer system consists of the ignition key, immobilizer control unit-receiver, immobilizer indicator light, PGM-FI main relays, injector relay (GX), fuel pump (except GX), fuel tank internal solenoid valve (GX), and the ECM/PCM. With the ignition switch in ON (II) or START (III), the immobilizer control unit-receiver and the ECM/PCM receive an "ignition on" signal through fuse 6 and the PGM-FI main relay 1. The ECM/PCM then sends power to the ignition key transponder through the immobilizer control unit-receiver. The transponder then sends a coded signal back to the ECM/PCM through the receiver. If the signal is correct, the ECM/PCM will energize the car's fuel supply system by grounding the PGM-FI main relay 2 (except GX) or injector relay (GX). The immobilizer indicator light flashes a code to indicate that the correct key has been inserted. If the ignition key signal is not correct, the ECM/PCM will not energize the car's fuel supply system by not grounding the PGM-FI main relay 2 (except GX) or injector relay (GX). The immobilizer indicator light then flashes a code to indicate that an incorrect key has been inserted. Page 6236 Page 3813 Terminals - "T" Shielding Switches Fuses Page 5843 Under-hood Fuse And Relay Box (4-door) Page 6840 7. Connect the SCS service connector to the 2P MES (memory erase signal) connector, as shown. Do not use a jumper wire. 8. Turn the ignition switch to ON (II). 9. Watch the SRS indicator. (It comes on for about 6 seconds and then goes off.) Disconnect the SCS service connector from the MES connector within 4 seconds after the indicator goes off. 10. When the SRS indicator comes on again, connect the SCS service connector to the MES connector within 4 seconds after the indicator comes on. 11. When the SRS indicator goes off, disconnect the SCS service connector from the MES connector within 4 seconds. Page 8883 3. Move the spotlight assembly away from the side that sticks, then tighten the mounting screws. 4. Use a small screwdriver to push back any headliner material that comes through the lens slot. 5. Reinstall the lenses and test the light. ^ If the lens no longer sticks, the repair is complete. ^ If the lens still sticks, remove the spotlight assembly and use a razor blade to trim the headliner material. Disclaimer Page 7773 10. Pull down on the retainer clip with a hook-shaped tool. Remove the lock cylinder. Then go to step 14. 11. Pull the glass run channel away as necessary, and remove the bolt, then remove the center lower channel by pulling it downward. 12. Remove the access seal, and disconnect the outer handle rod and the cylinder rod. Page 5005 7. Align the cutouts (A) on the rotary-frame with the neutral positioning cutouts (B) on the transmission range switch, then put a 2.0 mm (0.08 inch) feeler gauge blade (C) in the cutouts to hold it in the N position. NOTE: Be sure to use a 2.0 mm (0.08 inch) blade or equivalent to hold the switch in the N position. 8. Install the transmission range switch (A) gently on the control shaft (B) with holding the N position with the 2.0 mm (0.08 inch) blade (C). 9. Tighten the bolts on the transmission range switch while you continue to hold it in the N position. Do not move the transmission range switch when tightening the bolts. Remove the feeler gauge. Page 3748 Control Module: Service and Repair Updating the ECM/PCM PCM Updating and Substitution for Testing Special Tools Required Honda Interface Module (HIM) P/N EQS05A35570 Use this procedure when you have to substitute a known-good PCM in a troubleshooting procedure. Update the PCM only if the PCM does not already have the latest software loaded. NOTE: Do not turn the ignition switch OFF while updating; the PCM can be damaged. How to Update the PCM NOTE: To ensure the latest program is installed, do an PCM update whenever the PCM is substituted or replaced. - Before you update the PCM, make sure the vehicle's battery is fully charged. - To prevent PCM damage, do not operate anything electrical (audio system, brakes, A/C, power windows, moon roof, door locks, etc.) during the update. - If you need to diagnose the Honda Interface Module (HIM) because the HIM's red (#3) light came on or was flashing during the update, leave the ignition switch in the ON (II) position when you disconnect the HIM from the Data Link Connector (DLC). This will prevent PCM damage. 1. Turn the ignition switch ON (II). Do not start the engine. 2. Connect the HIM to the DLC (A) located under the driver's side of dashboard. 3. Do the PCM update procedure as described on the HIM label and in the PCM update system. If the software in the PCM is the latest version, replace the PCM. How to End a Troubleshooting Session This procedure must be done after any troubleshooting. 1. Clear the DTC(s) with the Scan Tool or HDS, or reset the PCM by removing the No. 6 (PCM) fuse in the under-hood fuse/relay box for more than 10 seconds. 2. Turn the ignition switch ON (II). 3. Start the engine in the P or N position, and warm it up to normal operating temperature (the radiator fans come on). 4. To verify that the problem is repaired, test-drive the vehicle for several minutes at speeds over 30 mph (50 km/h) or in freeze data range. Page 4310 Shift Solenoid: Diagrams 185. CVT Control Valves And Inhibitor Solenoid Assembly 73. Shift Solenoid Valve A And B (A/T Except CVT) Capacity Specifications Refrigerant Oil: Capacity Specifications Refrigerant oil Capacity of components Condenser ........................................................................................................................................... ............................................... 25 ml (5/6 fl oz) Evaporator ................................................................. .................................................................................................................... 45 ml (1 1/2 fl oz) Each line and hose ....................................................................................................................................... ..................................... 10 ml (1/3 fl oz) Receiver ............................................................................... ............................................................................................................. 10 ml (1/3 fl oz) Compressor . .............................................................................................................................................................. ..... 130 - 150 ml (4 1/3 - 5 fl oz) Page 9089 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 Short Circuit Locator (Short Finder) 1. Remove the blown fuse. Leave the battery connected. Page 584 82. Under Middle Of Dash Page 6338 - From the wheelhouse side, plug weld the holes in the dashboard upper and damper housing extension. - Weld the front wheelhouse, damper housing, and front side - Weld the wheelhouse upper member. When replacing the front wheelhouse only, but weld the wheelhouse upper member. Page 4007 Shift Solenoid: Testing and Inspection Solenoid Valve Test - Continuously Variable Transmission Solenoid Valve Test 1. Disconnect solenoid harness connector (BP). 2. Measure CVT speed change control valve assembly resistance between solenoid harness connector terminals No. 3 and No. 7. STANDARD: 3.8 - 6.8 Ohms 3. Measure CVT pulley pressure control valve assembly resistance between terminals No. 2 and No. 6. STANDARD: 3.8 - 6.8 Ohms 4. Measure CVT start clutch pressure control valve assembly resistance between terminals No. 4 and No. 8. STANDARD: 3.8 - 6.8 Ohms 5. Measure the inhibitor solenoid resistance between terminal No. 5 and body ground. STANDARD: 11.7 - 21.0 Ohms 6. Replace the CVT speed change control valve assembly or CVT start clutch pressure control valve assembly, if the measurements are out of standard. Replace the lower valve body assembly, if the measurements of CVT pulley pressure control valve assembly or inhibitor solenoid are out of standard. 7. If all of the resistance are within the standard, a clicking sound should be heard when connecting the battery terminals to the solenoid harness connector terminals below. ^ CVT speed change control valve assembly No. 3 to battery positive terminal No. 7 to battery negative terminal ^ CVT pulley pressure control valve assembly No. 2 to battery positive terminal No. 6 to battery negative terminal ^ CVT start clutch pressure control valve assembly No. 4 to battery positive terminal No. 8 to battery negative terminal ^ Inhibitor solenoid No.5 to battery positive terminal and body ground to negative terminal 8. If no clicking sound is heard, remove the lower valve body assembly, and check the solenoid. Page 3986 Shift Solenoid: Diagrams 185. CVT Control Valves And Inhibitor Solenoid Assembly 73. Shift Solenoid Valve A And B (A/T Except CVT) Page 6268 45. Apply power steering fluid to the seal ring lip of the new valve oil seal (A), then install the seal in the valve housing (B) using a hydraulic press and special tools. Install the seal with its grooved side (C) facing the tool. 46. Press the bushing (D) into the valve housing with a hydraulic press and special tool. 47. Apply vinyl tape (A) to the pinion shaft, then coat the vinyl tape with power steering fluid. 48. Insert the pinion shaft into the valve housing (B). Be careful not to damage the valve seal rings (C). 49. Remove the vinyl tape from the pinion shaft, then remove any residue from the tape adhesive. 50. Press the pinion shaft/sleeve into the valve housing with a hydraulic press. Check that the pinion shaft/sleeve turns smoothly by hand after installing it. 51. Coat the special tool with power steering fluid, then slide it onto the rack, big end first. Specifications Camshaft Bearing: Specifications Put the camshaft and the camshaft holders on the cylinder head, then tighten the bolts to the specified torque. Page 9319 2. Cut off the wire about an inch back from where it connects to the damaged or faulty terminal, then strip about half of the insulation off that piece. This will be used to size the wire end of the replacement pigtail terminal. NOTE: If you are not sure of the wire size, start with a large enough hole on the stripper that will not nick or cut off any strands of wires. 3. Select a pigtail terminal that matches the original wire at both ends (same kind of terminal and same diameter bare wire). 4. Select the smallest splice connector (yellow, pink, or blue) that will fit onto the stripped end of the original wire. 5. Insert the pigtail terminal into the connector cavity; push it in until it locks in place. 6. Lay the pigtail and the original wire side-by-side, and cut off both ends at once. If you are making more than one splice, do not cut each pigtail at the same location; the resulting "lump" of splice connectors would interfere with rewrapping the harness. Instead, cut the first pigtail close enough to the terminal so you will have room to make each remaining cut about 20 mm (3/4 inch) farther down on the next pigtail. 7. If you are using a yellow splice connector, strip about 6 mm (1/4 inch) of insulation off the ends of both wires. If you are using a pink or blue splice connector, strip off about 8 mm (5/16 inch) of insulation. Page 3696 Circuit Schematics Each schematic represents one circuit. A circuit's wires and components are arranged to show current flow from power at the top of the diagram 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 Page 123 208. DRL Control Unit (Canada) Page 7070 Seat Belt Buckle Switch: Diagrams 121. Seat Belt Switch, Driver's 122. Seat Belt Switch, Front Passenger's (Sedan) 123. Seat Belt Switch, Passenger's (Coupe) Page 5137 1. Remove the terminal. 2. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE G: 1. Remove the terminal. 2. Go to HOW TO INSTALL NEW TERMINALS. How to Install New Terminals HOW TO INSTALL NEW TERMINALS 1. Carefully match the old terminal with a new one from the terminal repair kit. Choose the correct replacement terminal based on the wire size range the terminal will accommodate. NOTE: If the replacement terminal quantities are low, reorder them by using the terminal part number listed on the inside lid of the terminal repair kit. Replacement terminals are available through your parts department using normal parts ordering procedures. 2. Depending on the size of the wire you are repairing, use the proper size slot in the crimping tool. Page 7206 Page 1750 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. Below most connector numbers and component names are PHOTO and VIEW numbers. The PHOTO number refers to a photo in the back of the book that shows the connector's location on the car. The VIEW number refers to an illustration in the back of the book that shows the connector terminals, wire colors, connector cavity numbers, and other details. The connector cavity numbering sequence begins at the top left corner of the connector as seen from either of the viewpoints shown on diagram [8] . Except for the DLC (data link 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 C554, for example, means those terminals join in cavity 2 of connector C554. Power Distribution Schematics Power Distribution Schematics Specifications Spark Plug: Specifications NGK ..................................................................................................................................................... ............................................................... PZFR6F-11 DENSO ................................................................................................................................................ ......................................................... PKJ20CR-M11 Gap ...................................................................................................................................................... ................................. 1.0 -1.1 mm (0.039 - 0.043 in) Torque ................................................................................................................................................. ...................................................... 18 N.m (13 lb.ft) Diagrams 45. Fog Light Diode (Honda Accessory) Page 1130 3. If there is no continuity between any terminal, remove the transmission range switch cover, and disconnect the connector (A) at the switch (B). 4. Check for continuity between terminals at the switch connector (c). There should be continuity between the terminals listed for each position. In the P position, between terminals: ^ No. 4 and No. 5 ^ No. 4 and No. 6 ^ No. 5 and No. 6 In the R position, between terminals: ^ No. 1 and No. 4 In the N position, between terminals: ^ No. 4 and No. 5 ^ No. 4 and No. 7 ^ No.5 and No.7 In the D position, between terminals: ^ No.2 and No.4 ^ No. 2 and No. 10 ^ No. 4 and No. 10 In the D3 position, between terminals: ^ No. 4 and No. 8 ^ No. 4 and No. 10 ^ No. 8 and No. 10 In the 2 position, between terminals: ^ No.3 and No.4 5. If there is no continuity between any terminals, adjust the transmission range switch installation. If the transmission range switch installation is OK, replace the switch. 6. If the transmission range switch continuity check was OK, replace the faulty transmission range switch harness. Page 1248 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 4230 8. Inspect the quality of the wire crimp. If it has any of the following NO GOOD crimps, cut it off and start over. 9. Insert the terminal into the connector. Make sure the wire seals are pushed all the way into the connector. Lightly pull on the wires to make sure the terminal is locked into place. 10. Close or insert the secondary terminal lock, if applicable, and reconnect the connector. How to Install Pigtail Terminals HOW TO INSTALL PIGTAIL TERMINALS Pigtail terminals (short pieces of wire with a factory crimped terminal) are used when the wire is too short or when access to the connector is too restricted to make a terminal repair. NOTE: To replace just a connector terminal, go to How to Replace Connector Terminals. IMPORTANT SAFETY INFORMATION: On some models, the SRS wires are in a separate harness. If the SRS harness is damaged, replace the harness; do not repair it. On other models, wire harnesses include yellow SRS wires. If any SRS wire is damaged, replace the entire harness; do not repair it. 1. Remove the damaged or faulty terminal from the connector. Use the proper removal tool from Pin Tool Set. Page 167 Interior Lighting Module: Diagnostic Aids General Troubleshooting Information General Troubleshooting Information Tips and Precautions Before Troubleshooting 1. Check applicable fuses in the appropriate fuse/relay box. 2. Check the battery for damage, state of charge, and clean and tight connections. NOTE: 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. Handling Connectors - Make sure the connectors are clean and have no loose wire terminals. - Make sure multiple cavity connectors are packed with dielectric grease (except watertight connectors). - All connectors have push-down release type locks (A). - Some connectors have a clip on their side used to attach them to a mount bracket on the body or on another component. This clip has a pull type lock. - Some mounted connectors cannot be disconnected unless you first release the lock and remove the connector from its mount bracket (A). - Never try to disconnect connectors by pulling on their wires; pull on the connector halves instead. - Always reinstall plastic covers. Page 4117 8. Inspect the quality of the wire crimp. If it has any of the following NO GOOD crimps, cut it off and start over. 9. Insert the terminal into the connector. Make sure the wire seals are pushed all the way into the connector. Lightly pull on the wires to make sure the terminal is locked into place. 10. Close or insert the secondary terminal lock, if applicable, and reconnect the connector. How to Install Pigtail Terminals HOW TO INSTALL PIGTAIL TERMINALS Pigtail terminals (short pieces of wire with a factory crimped terminal) are used when the wire is too short or when access to the connector is too restricted to make a terminal repair. NOTE: To replace just a connector terminal, go to How to Replace Connector Terminals. IMPORTANT SAFETY INFORMATION: On some models, the SRS wires are in a separate harness. If the SRS harness is damaged, replace the harness; do not repair it. On other models, wire harnesses include yellow SRS wires. If any SRS wire is damaged, replace the entire harness; do not repair it. 1. Remove the damaged or faulty terminal from the connector. Use the proper removal tool from Pin Tool Set. Page 7295 3. Strip the insulation off the end of the wire so the wire fits in the new terminal as shown. (If the wire has a wire seal, replace it with a new one from the kit.) NOTE: After stripping the end of the wire, make sure you did not cut any wire strands. If you did, cut the wire off even with the insulation, and strip it again. 4. Position the terminal in the crimping tool slot with the solid portion of the terminal toward the anvil and the open section toward the former. 5. Insert the wire in the terminal to the position shown in step 3. 6. Squeeze the tool with both hands until the stops make contact. 7. Crimp the insulation crimp. - If you do not have a wire seal, then use the next larger size crimp slot. Position the crimping tool over the insulation crimp section of the terminal, then squeeze the tool with both hands until the stops make contact. - If you have a wire seal, position the insulation crimp in the 5.5 crimping slot, then carefully squeeze the crimp closed until its ends are touching and making a full-circle shape. Page 3845 3. If there is no continuity between any terminal, remove the transmission range switch cover, and disconnect the connector (A) at the switch (B). 4. Check for continuity between terminals at the switch connector (c). There should be continuity between the terminals listed for each position. In the P position, between terminals: ^ No. 4 and No. 5 ^ No. 4 and No. 6 ^ No. 5 and No. 6 In the R position, between terminals: ^ No. 1 and No. 4 In the N position, between terminals: ^ No. 4 and No. 5 ^ No. 4 and No. 7 ^ No.5 and No.7 In the D position, between terminals: ^ No.2 and No.4 ^ No. 2 and No. 10 ^ No. 4 and No. 10 In the D3 position, between terminals: ^ No. 4 and No. 8 ^ No. 4 and No. 10 ^ No. 8 and No. 10 In the 2 position, between terminals: ^ No.3 and No.4 5. If there is no continuity between any terminals, adjust the transmission range switch installation. If the transmission range switch installation is OK, replace the switch. 6. If the transmission range switch continuity check was OK, replace the faulty transmission range switch harness. Page 9067 Backup Lamp Switch: Testing and Inspection Back-Up Light Switch Test 1. Disconnect the back-up light switch (A) connector. 2. Check for continuity between the back-up light switch 3P connector No. 1 and No. 2 terminals. There should be continuity when the shift lever is in reverse. 3. If necessary, replace the switch. Page 5901 Wires Page 5422 Brake Drum: Testing and Inspection Rear Drum Brake Inspection CAUTION: Frequent inhalation of brake pad dust, regardless of material composition, could be hazardous to your health. ^ Avoid breathing dust particles ^ Never use an air hose or brush to clean brake assemblies. Use an OSHA-approved vacuum cleaner. NOTE: ^ Contaminated brake linings or drums reduce stopping ability. ^ Block the front wheels before jacking up the rear of the vehicle. 1. Raise the rear of the vehicle, and support it with safety stands in the proper locations. Remove the rear wheels. 2. Release the parking brake, and remove the rear brake drum. 3. Check the wheel cylinder (A) for leakage. 4. Check the brake linings (B) for cracking, glazing, wear, and contamination. 5. Measure the brake lining thickness (C). Measurement does not include brake shoe thickness. Brake Lining Thickness: Standard: 4.0 mm (0.16 inch) Service Limit: 2.0 mm (0.08 inch) Page 1757 - 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. Troubleshooting Tests 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 test 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 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. 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 Drop Page 8948 12. Oil Pressure Switch Page 8752 Diodes Light Emitting Diode (LED) Motor Pressure Sensor Page 7390 ^ Start the engine and let it warm up to its normal operating temperature (the cooling fans cycle twice). ^ Let the engine idle (throttle closed and all electrical items off) for 10 minutes. 17. CR-V only: Reset the power window control unit: ^ Turn the ignition switch to ON (II). ^ Make sure the driver's window is fully closed. ^ Push down and hold the window switch until the window goes all the way down. ^ Pull back and hold the window switch until the window goes all the way up, then hold the switch for at least 2 more seconds. 18. Enter the audio unit anti-theft code, and set the clock. Enter the audio presets. Disclaimer Page 9634 Resistor Variable Sensor Solenoid Transistors Circuit Schematics Page 5100 Shift Interlock Solenoid: Testing and Inspection Shift Lock Solenoid Test 1. Remove the center console panel and center console. 2. Disconnect the shift lock solenoid connector (2P). 3. Connect the No. 1 terminal of the shift lock solenoid connector (2P) to the battery positive terminal, and connect the No. 2 terminal to the battery negative terminal. 4. Check that the shift lever can be moved from the P position. Release the battery terminals from the shift lock solenoid connector. Move the shift lever back to the P position, and make sure it locks. NOTE: Do not connect power to the No. 2 terminal (reverse polarity) or you will damage the diode inside the solenoid. 5. Check that the shift lock releases when the shift lock release is pushed, and check that it locks when the shift lock release is released. 6. If the shift lock solenoid does not work properly, replace it. Page 7611 19. Using your thumb and forefinger to hold the tumblers, remove the key from the inner cylinder, being careful not to drop any tumblers and springs. 20. *Using the key code from the iN that you have written down at step 2, build a new inner cylinder with new springs, new cylinder, and tumblers from the door lock cylinder kit. Make sure you put the appropriate numbered tumbler in the proper inner cylinder cavity. Apply a thin layer of Permalube to each tumbler to help lubricate and retain it.* NOTE: ^ There are two types of tumblers. The "SUBLOCK" tumbler goes only in cavity A." The "DISC" tumbler goes in cavities "B" through "J." ^ Cavity "E" is empty on all cylinders. Locations Clutch Switch: Locations Starting System Component Location Index Page 6006 13. Plug in the heat gun, and turn it on. Start at the middle of the splice connector, and move the gun toward the ends as the tube shrinks. Apply heat evenly by rotating the curved heat spreader around the splice connector. Shrinking is complete when a small amount of sealant appears at each end of the tube. 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. Locations Gasoline Page 3613 160. Left Side Of Engine Compartment (except GX) Page 848 20. Transmission Housing Page 3798 Shift Interlock Switch: Testing and Inspection Park Pin Switch Test 1. Remove the center console panel and center console. 2. Disconnect the park pin switch connector (4P). 3. Shift to the P position, then check for continuity between the No. 3 and No. 4 terminals. There should be no continuity. 4. Shift out of the P position, and check for continuity between terminals No. 3 and No. 4. There should be continuity. 5. If the park pin switch is faulty, replace it. Page 1585 Relay Box: Service and Repair Removal and Installation SRS components are located in this area. Review the SRS component locations and precautions and procedures in the SRS section before performing repairs or service. Removal 1. Make sure you have the anti-theft code for the radio, then write down the frequencies for the radio's preset buttons. 2. Disconnect the battery negative cable, then disconnect the positive cable, and wait at least 3 minutes. 3. Remove the dashboard lower cover. 4. Disconnect the connectors from the fuse side of the under-dash fuse/relay box. 5. Remove the mounting bolt and slide the under-dash fuse/relay box (A) down from the bracket (B). 6. Disconnect the connectors from the back side of the under-dash fuse/relay box, and remove the fuse/relay box. NOTE: The SRS connector is a spring-loaded lock type. Installation 1. Install the under-dash fuse/relay box in the reverse order of removal and connect all connectors to the under-dash fuse/relay box. 2. Install the dashboard lower cover. 3. Connect both the negative cable and positive cable to the battery. 4. Enter the anti-theft code for the radio, then enter the customer's radio station presets. 5. Confirm that all systems work properly. 6. Do the ECM/PCM idle learn procedure. Component Locations Fuse Block: Component Locations Fuse and Relay Box Starting System Component Location Index Page 619 Emissions - OBD II DTC's And Associated Monitors Engine Control Module: Technical Service Bulletins Emissions - OBD II DTC's And Associated Monitors 03-020 April 2, 2010 Applies To: All OBD II-equipped models except Passport OBD II DTCs and Their Associated Monitors (Supersedes 03-020, dated March 29, 2003, to revise the information marked by the black bars and asterisks) *REVISION SUMMARY Numerous DTCs were added. Refer to the list for details.* Following is a list of all OBD II DTCs and their associated monitors for all Honda automobiles with OBD II. No one model has every DTC in the list. DTC P0AA6 thru P0A9E Page 3678 Shift Interlock Solenoid: Testing and Inspection Shift Lock Solenoid Test 1. Remove the center console panel and center console. 2. Disconnect the shift lock solenoid connector (2P). 3. Connect the No. 1 terminal of the shift lock solenoid connector (2P) to the battery positive terminal, and connect the No. 2 terminal to the battery negative terminal. 4. Check that the shift lever can be moved from the P position. Release the battery terminals from the shift lock solenoid connector. Move the shift lever back to the P position, and make sure it locks. NOTE: Do not connect power to the No. 2 terminal (reverse polarity) or you will damage the diode inside the solenoid. 5. Check that the shift lock releases when the shift lock release is pushed, and check that it locks when the shift lock release is released. 6. If the shift lock solenoid does not work properly, replace it. Page 7237 Page 5304 7. Align the cutouts (A) on the rotary-frame with the neutral positioning cutouts (B) on the transmission range switch, then put a 2.0 mm (0.08 inch) feeler gauge blade (C) in the cutouts to hold it in the N Position. NOTE: Be sure to use a 2.0 mm (0.08 inch) blade or equivalent to hold the switch in the N position. 8. Install the transmission range switch (A) gently on the control shaft (B) while holding it in the N position with the 2.0 mm (0.08 inch) blade (C). 9. Tighten the bolts on the transmission range switch while you continue to hold the N position. Do not move the transmission range switch when tightening the bolts. Remove the feeler gauge. How to Remove the PCM Control Module: Service and Repair How to Remove the PCM How to Remove the PCM for Testing 1. Remove the passenger's dashboard lower cover, the right kick panel, and the glove box. 2. Remove the bolt. Cut the plastic cross brace in the glove box opening with diagonal cutters in the area shown, and discard it. 3. Remove the relays (A), then remove the bolts and the glove box frame (B). 4. Remove the gray 20P PCM wire harness connector from the PCM mounting bracket. Remove the PCM mounting bolt (A) and the bracket. 5. Remove the nuts, then remove the PCM (B). 6. Install the PCM in the reverse order of removal. Page 8776 2. Cut off the wire about an inch back from where it connects to the damaged or faulty terminal, then strip about half of the insulation off that piece. This will be used to size the wire end of the replacement pigtail terminal. NOTE: If you are not sure of the wire size, start with a large enough hole on the stripper that will not nick or cut off any strands of wires. 3. Select a pigtail terminal that matches the original wire at both ends (same kind of terminal and same diameter bare wire). 4. Select the smallest splice connector (yellow, pink, or blue) that will fit onto the stripped end of the original wire. 5. Insert the pigtail terminal into the connector cavity; push it in until it locks in place. 6. Lay the pigtail and the original wire side-by-side, and cut off both ends at once. If you are making more than one splice, do not cut each pigtail at the same location; the resulting "lump" of splice connectors would interfere with rewrapping the harness. Instead, cut the first pigtail close enough to the terminal so you will have room to make each remaining cut about 20 mm (3/4 inch) farther down on the next pigtail. 7. If you are using a yellow splice connector, strip about 6 mm (1/4 inch) of insulation off the ends of both wires. If you are using a pink or blue splice connector, strip off about 8 mm (5/16 inch) of insulation. Page 9354 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 Locater) 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. Troubleshooting Precautions Troubleshooting Precautions Before Troubleshooting 1. Check the main fuse and the fuse 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, or you will damage the alternator diodes. - Do not attempt to crank the engine with the ground cable disconnected 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. Page 5917 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 Short Circuit Locator (Short Finder) 1. Remove the blown fuse. Leave the battery connected. Page 781 Power Steering Pressure Switch: Description and Operation Power Steering Pressure (PSP) Switch The PSP switch signals the ECM/PCM when the power steering load is high. Page 3704 - 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. Troubleshooting Tests 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 test 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 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. 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 Drop Service and Repair Brake Bleeding: Service and Repair Brake System Bleeding NOTE: ^ Do not spill brake fluid on the vehicle, it may damage the paint; if brake fluid does contact the paint, wash it off immediately with water. ^ The reservoir on the master cylinder must be at the MAX (upper) level mark at the start of the bleeding procedure and checked after bleeding each brake caliper. Add fluid as required. ^ Do not reuse the drained fluid. ^ Always use Honda DOT 3 brake fluid. Non-Honda brake fluid can cause corrosion and shorten the life of the system. ^ Make sure no dirt or other foreign matter is allowed to contaminate the brake fluid. 1. Make sure the brake fluid level in the reservoir is at the MAX (upper) level line (A). 2. Slide a piece of clear plastic hose over the first bleed screw, and submerge the other end in a container of new brake fluid. 3. Have someone slowly pump the brake pedal several times, then apply steady pressure. 4. Starting at the left front, loosen the brake bleed screw to allow air to escape from the system. Then tighten the bleed screw securely. 5. Repeat the procedure for each wheel in the sequence shown until air bubbles no longer appear in the fluid. Page 2013 14. Remove the upper bracket. 15. Remove the grommet (A) from the upper cover, and disconnect the CMP (TDC) sensor connector (B). 16. Remove the upper cover (C) and lower cover (D). 17. Remove the side engine mount bracket. Page 4347 Transmission Cooler: Technical Service Bulletins A/T - Leak From Cooler Line Banjo Bolt SOURCE: Honda Service News December 2003 TITLE: ATF Leaks From Cooler Line Banjo Bolt APPLIES TO: 1998-04 Accords, 2001-04 Civics, 1997-04 CR-Vs, 1999-04 Odysseys, 2003-04 Pilots SERVICE TIP: The banjo bolts and sealing washers on the ATF cooler lines are delicate and can be easily damaged if the line or the banjo bolt gets hit. Any movement of the line or the banjo bolt crushes the two sealing washers and lets ATF leak past the seals. Before you install an A/T or try finding an ATF leak, check the banjo bolt torque on the ATF cooler lines. If a banjo bolt is loose, remove the bolt along with the sealing washers. And if the cooler line has a bracket, remove that bolt too. Inspect the sealing surface on the A/T housing. If the surface is OK, reinstall the banjo bolt with new sealing washers, and torque the bolt to 28 Nm (21 lb-ft). Reinstall the bolt for the line bracket (if applicable), and torque the bolt to 9.8 Nm (7.2 lb-ft). Page 5203 ^ The vehicle is shown as eligible on a VIN status inquiry. In addition, check for a punch mark above the seventh character of the engine compartment VIN. A punch mark in that location means the ignition switch key interlock has already been inspected/repaired. 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 a VIN status inquiry before selling it. CUSTOMER NOTIFICATION All owners of affected vehicles will be sent a notification of this campaign. An example of the customer notification is at the end of this service bulletin. CORRECTIVE ACTION Inspect the ignition switch and, if needed, install a Key Interlock Repair Kit. PARTS INFORMATION Key Interlock Repair Kit: P/N 06351-SDA-000 REQUIRED SPECIAL TOOLS Interlock Slide Hammer: T/N 07AAC-S84A100 NOTE: ^ An initial quantity of Permalube grease to lubricate the sliding surface of the interlock lever is included with the slide hammer. To order more Permalube, use P/N 08734-0030. ^ To order a replacement clamping bolt for the slide hammer, use T/N 07AAC-S84A400. WARRANTY CLAIM INFORMATION Failed Part: P/N 35100-SDA-A31 Defect Code: 5GC00 Symptom Code: R4400 Page 3768 ^ The left end goes behind the notch on the interlock lever. ^ Once the spring is correctly installed, make sure the lever moves freely and returns properly. 10. Insert the plunger into the interlock solenoid, then install the solenoid using a new screw. Make sure the groove of the solenoid plunger is in the fork on the lever. 11. Install a new plastic cover on the interlock solenoid. 12. Check the operation of the ignition switch key interlock: ^ Set the parking brake, and turn the ignition switch to ON (I I). ^ While pressing the brake pedal, shift the transmission to Neutral. ^ Try turning the ignition switch to LOCK (0) - If you cannot turn the switch to LOCK (0), your repair was successful; go to step 15. - If you can turn the switch to LOCK (0), the interlock is not working; go to step 13. Page 3469 8. Remove the locknut (A) and the fuel tank unit. 9. Remove the stopper (O). Release the hook (P) and remove the fuel filter (B), the fuel gauge sending unit (C), the case (D), the wire harness (E), and the fuel pressure regulator (F). 10. When connecting the fuel tank unit, make sure the connection is secure and the suction filter (G) is firmly connected to the fuel pump (H). 11. Install in the reverse order of removal with a new base gasket (I) and new O-rings (J), then check these items: - When connecting the wire harness, make sure the connection is secure and the connector (K) is firmly locked into the place. - When installing the fuel gauge sending unit, make sure the connection is secure and the connector is firmly locked into place. Be careful not to bend or twist the connector excessively. - When installing the fuel tank unit, align the marks (L) on the fuel tank (M) and the fuel tank unit (N). Primary HO2S and A/F Sensor Replacement Oxygen Sensor: Service and Repair Primary HO2S and A/F Sensor Replacement Primary HO2S and A/F Sensor Replacement Special Tools Required O2 sensor wrench, Snap-on YA8875, SP Tools 93750, or equivalent, commercially available 1. Disconnect the primary HO2S or A/F sensor 4P connector (A), then remove the primary HO2S or A/F sensor (B). 2. Install the primary HO2S or A/F sensor in the reverse order of removal. A/C - Refrigerant Leak Detection Refrigerant: Technical Service Bulletins A/C - Refrigerant Leak Detection 07-030 October 12, 2007 Applies To: ALL Vehicles With Conventional A/C Compressors A/C Leak Detection (Supersedes 07-030, dated June 15, 2007, to update the information marked by asterisks) The OPTIMAX Jr. (TM)A/C Leak Detection Kit for Honda vehicles, P/N TRP124893, is a new required tool. The kit is used to add small amounts of dye to A/C systems to help locate smaller leaks that an electronic leak detector might not find. When searching for leaks, always begin by using an electronic leak detector. Refer to Service Bulletin 97-027, Denso HLD-100 Halogen Leak Detector; for tips on using this tool, then follow up with the OPTIMAX Jr. This new detection kit complements but does not replace the electronic detector. The kit contains: ^ TRP8640CS, OPTIMAX Jr. (TM) cordless, fluorescent leak detection flashlight lamp (includes 3 standard AA batteries) ^ TRP38600601, (6) 0.06 oz. (1.7 g) Tracer-Stick(R) R134a/PAG A/C dye capsules with ID labels ^ TRP3887, R-134a Universal Connect Set(TM) ^ TRP120884, GLO-AWAY(TM) dye cleaner ^ TRP9940, fluorescence-enhancing glasses ^ TRP1143, (1) empty Tracer-Stick dye capsule ORDERING INFO *One OPTIMAX Jr. A/C Leak Detection Kit was shipped to each current dealer as a required special tool. Additional kits and replacement capsules may be ordered through the Honda Tool and Equipment Program. On the iN, click on Service, Service Bay, Tool and Equipment Program, Online Catalog tab, and Air Conditioning Equipment, or call.* NOTICE ^ Do not use leak-trace dye in any Honda hybrid vehicle equipped with a dual-scroll compressor This can increase the chance of electric shock. The compressor is easily identified by the orange high-voltage cable that is connected to the compressor body. ^ Only Tracer-Stick single-dose fluorescent dye capsules from Tracer Products (Tracerline(R)) are approved for use in Honda vehicles. Other dyes contain solvents that may contaminate the system's refrigerant oil, leading to component failure. ^ Adding excessive amounts of dye can lead to compressor damage and failure. USING THE OPTIMAX JR. Page 2272 Water Pump: Service and Repair Replacement 1. Remove the timing belt. 2. Remove the water pump (A) by removing four bolts. 3. Inspect and clean the O-ring groove and mating surface with the cylinder block. 4. Install the water pump with a new O-ring (B) in the reverse order of removal. 5. Clean up any spilled engine coolant. Page 5905 Diodes Light Emitting Diode (LED) Motor Pressure Sensor Page 4387 1. Remove the secondary locks. 2. Remove the terminal from the female half. 3. Remove the terminal from the male half. 4. Go to HOW TO INSTALL NEW TERMINALS. Connectors Without a Secondary Lock All examples are shown with the connector lock facing up. The illustrations are examples of connector terminals without a secondary lock; however, the connector you are repairing may vary in size and shape. EXAMPLE A: Page 8666 Brake Switch (Cruise Control): Testing and Inspection Brake Pedal Position Switch Test 1. Disconnect the 4P connector (A) from the brake pedal position switch (B). 2. Check for continuity between the No.1 and No.2 terminals. - There should be continuity when the brake pedal is pressed. - There should be no continuity when the brake pedal is released. 3. Check for continuity between the No.3 and No.4 terminals (with cruise control). - There should be no continuity when the brake pedal is pressed. - There should be continuity when the brake pedal is released. 4. If necessary, adjust or replace the switch, or adjust the pedal height. Technician Safety Information Air Bag(s) Arming and Disarming: Technician Safety Information Technician Safety Information Page 9313 1. Remove the secondary locks. 2. Remove the terminal from the female half. 3. Remove the terminal from the male half. 4. Go to HOW TO INSTALL NEW TERMINALS. Connectors Without a Secondary Lock All examples are shown with the connector lock facing up. The illustrations are examples of connector terminals without a secondary lock; however, the connector you are repairing may vary in size and shape. EXAMPLE A: Fuel Gauge & Low Fuel Indicator Accuracy Check Fuel Gauge: All Technical Service Bulletins Fuel Gauge & Low Fuel Indicator Accuracy Check SOURCE: Honda Service News March 2003 TITLE: Charting the Fuel Gauge and the Low Fuel Indicator APPLIES TO: 1998-03 Accord, 1996-03 Civic, or 1999-03 Odyssey SERVICE TIP: If an owner is leery of the fuel gauge or low fuel indicator accuracy and worries about running out of fuel, you may be able to restore faith in the accuracy of this hardware by charting the operation. If the fuel gauge, the low fuel indicator, or both doesn't give your customer a warm, fuzzy feeling, don't replace the fuel gauge or the sending unit until you've first charted the fuel gauge needle position and low fuel indicator status. You rarely improve accuracy by replacing fuel gauges and sending units. To chart the fuel gauge needle position and the low fuel indicator status, do this: 1. Have your customer bring in the vehicle when the fuel tank is nearly empty. 2. Drain any remaining fuel from the tank. 3. Park the vehicle on a flat surface, and add 2 gallons of fuel to the tank with the ignition switch turned to LOCK (0). 4. Start the engine, and note the fuel gauge needle position after 2 minutes. Draw a picture of the fuel gauge showing the position of the needle. Also note on your drawing if the low fuel indicator is on or off. Turn the ignition switch to LOCK (0). 5. Add 2 more gallons of fuel to the tank. Start the engine, and note the position of the needle after 2 minutes. Draw another picture of the fuel gauge showing the current position of the needle. Note the status of the low fuel indicator. Turn the ignition switch to LOCK (0). 6. Repeat step 5 until the fuel tank is full. Then give your customer all of the pictures you've drawn. They're usually enough to convince even the staunchest Doubting Thomas. Page 1559 Rear Window Defogger Component Location Index Page 6985 6. Disconnect both seat belt buckle tensioner 4P connectors (A). Page 3911 HIM: UPDATING TIPS AND PRECAUTIONS ^ If you're updating a control module/unit on a new vehicle, make sure all its fuses were installed at PDI. ^ To prevent control unit/module damage, do not operate anything electrical (audio system, brakes, A/C, power windows, moonroof, etc.) during the update. ^ Make sure the HDS Tablet, the HDS Pocket Tester, or the iN workstation has the latest version of HDS software. The HDS version number is on the HDS start-up screen. To find the latest HDS software information on ISIS, select Search by Vehicle, select Technical Library, expand the ServiceNews branch, select Keyword (All Models), enter keywords HDS VERSION, then select the latest article. NOTE: The screen is from an iN workstation. The HDS tablet and pocket tester screens are similar. *^Make sure the Database Update listed in a Honda service communication (service bulletin, product update, iN message, etc.) is the same or earlier than the ones listed on the Reprogramming screen of the MVCI (on the MVCI, select CM Update Mode, then select Reprogramming), or on the Page 4039 Shift Solenoid: Service and Repair Shift Solenoid Valves A and B Replacement NOTE: Shift solenoid valves A and B must be removed/ replaced as an assembly. 1. Remove the harness clamp (c) form the clamp bracket (D). 2. Remove the mounting bolts and the shift solenoid valves A and B. 3. Clean the mounting surface and fluid passage. 4. Install a new shift solenoid valves A and B with a new filter/gasket (E), and install the harness clamp on the clamp bracket. 5. Check the connector for rust, dirt, or oil, then reconnect the connector securely. Page 9049 88. Test Tachometer Connector Page 2235 Radiator Cooling Fan Motor Relay: Testing and Inspection Power Relay Test Use this chart to identify the type of relay, then do the test listed for it. NOTE: See the turn signal/hazard relay input test. Normally-open type A: Page 152 Blower Motor Relay Type 1, Type 2 Check for continuity between the terminals. - There should be continuity between the No.1 and No.3 terminals when power and ground are connected to the No.2 and No.4 terminals. - There should be no continuity between the No.1 and No.3 terminals when power is disconnected. Five-terminal type Check for continuity between the terminals. - There should be continuity between the No.1 and No.2 terminals when power and ground are connected to the No.3 and No.5 terminals. - There should be continuity between the No.1 and No.4 terminals when power is disconnected. Page 7257 6. Press and hold the green programming button on the side of the control unit until the LED on the instrument panel begins to flash, then release the button. (Steps 6 and 7 must be done within 5 seconds of each other.) 7. Press and release the bottom button on the transmitter. Verify that the LED goes out, the siren chirps twice, and the front sidemarker lights flash twice to confirm that the transmitter's code was accepted by the control unit. 8. Turn the ignition switch to LOCK. Test the transmitter you just programmed. If it doesn't work repeat steps 2 thru 7. 9. If you have another transmitter to program, repeat steps 2 thru 7. Ordering a Transmitter Transmitters can be ordered only by authorized Honda dealers. Order them from American Honda using normal parts ordering procedures. Batteries for the Transmitter The battery number is CR2025. Each transmitter uses one battery. 98-02 Passport With Factory-Installed Security System 1998-02 Passport with factory-installed security system Programming the Transmitter To program the transmitters, use one of these two procedures: ^ Procedure One cancels all learned transmitter codes and adds one new transmitter. None of the previously programmed transmitters will work. Use this programming procedure only if all transmitters were lost or stolen, or if a new control unit has been installed. ^ Procedure Two adds additional transmitters without cancelling any of the previously learned codes. The system will accept up to four transmitters. Procedure One (cancels all codes, adds one new transmitter) 1. Open the driver's door. 2. Turn the ignition switch to the ACC position and then to the LOCK position three times. (This step must be completed within 10 seconds, or the system will not enter the programming mode.) 3. Within 10 seconds, close and open the door two times. 4. Turn the ignition switch to the ACC position and then to the LOCK position five times. Close and open the door. (Complete this process within 10 seconds.) Verify that the power door locks cycle once to confirm that the system is in programming mode. 5. Within 20 seconds, press the "LOCK" button on the transmitter you are programming. Verify that the door locks cycle once. 6. Within 20 seconds, press the "UNLOCK" button on the transmitter. Verify that the door locks cycle once to confirm that the system has accepted the transmitter's code. Procedure Two (adds transmitters) 1. Open the driver's door. 2. Turn the ignition switch to the ACC position and then to the LOCK position three times. (This step must be completed within 10 seconds, or the Page 2797 Fuel Tank Pressure Sensor: Locations EVAP System - Component Location Index Page 5400 Brake Caliper: Service and Repair Disassembly and Reassembly Overhaul CAUTION: Frequent inhalation of brake pad dust, regardless of material composition, could be hazardous to your health. ^ Avoid breathing dust particles. ^ Never use an air hose or brush to clean brake assemblies. Use an OSHA-approved vacuum cleaner. Remove, disassemble, inspect, reassemble, and install the caliper, and note these items: ^ Do not spill brake fluid on the vehicle; it may damage the paint; if brake fluid gets on the paint, wash it off immediately with water. ^ To prevent dripping, cover disconnected hose joints with rags or shop towels. ^ Clean all parts in brake fluid and air dry; blow out all passages with compressed air. Before reassembling, check that all parts are free of dust and other foreign particles. ^ Replace parts with new ones as specified in the illustration. ^ Make sure no dirt or other foreign matter is allowed to contaminate the brake fluid. ^ When reusing pads, always reinstall them in their original positions to prevent loss of braking efficiency. ^ Do not reuse drained brake fluid. ^ Always use Honda DOT 3 brake fluid. Non-Honda brake fluid can cause corrosion and shorten the life of the system. Do not mix different brands of brake fluid, as they may not be compatible. ^ Coat the piston, piston seal groove, and caliper bore with clean brake fluid. Make sure no grease or oil gets on the brake discs or pads. Replace all rubber parts with new ones whenever disassembled. After installing the caliper, check the brake hose and line for leaks, interference, and twisting. Page 4374 Transmission Position Switch/Sensor: Diagnostic Aids General Troubleshooting Information General Troubleshooting Information Tips and Precautions Before Troubleshooting 1. Check applicable fuses in the appropriate fuse/relay box. 2. Check the battery for damage, state of charge, and clean and tight connections. NOTE: 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. Handling Connectors - Make sure the connectors are clean and have no loose wire terminals. - Make sure multiple cavity connectors are packed with dielectric grease (except watertight connectors). - All connectors have push-down release type locks (A). - Some connectors have a clip on their side used to attach them to a mount bracket on the body or on another component. This clip has a pull type lock. - Some mounted connectors cannot be disconnected unless you first release the lock and remove the connector from its mount bracket (A). - Never try to disconnect connectors by pulling on their wires; pull on the connector halves instead. - Always reinstall plastic covers. Page 8779 2. Insert the terminal tool into the female terminal, and then remove the terminal tool. NOTE: Make sure you do not select a terminal tool that is larger than the mating male terminal because it would spread the female terminal and cause a loose fit. 3. Compare the drag to the other terminals in the connector. If the drag is less, replace the terminal with a replacement terminal from the appropriate terminal repair kit. Page 5112 Wires Page 4479 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. DIAGNOSIS Have an assistant press the clutch pedal while you grasp the clutch line at the clutch master cylinder, and then at the slave cylinder. If you feel a vibration through the clutch line when you hear the noise or the noise stops, go to REPAIR PROCEDURE. If you feel no vibration or the noise does not stop, look for other causes. REPAIR PROCEDURE NOTICE Do not spill brake fluid on the vehicle; it may damage the paint. If brake fluid does contact the paint, wash it off immediately with water. 1. Remove the clutch master cylinder. Refer to the appropriate service manual: 2003-04 Accord (L4): page 12-6 2003-04 Accord (V6): page 12-8 2001-04 Civic: page 12-5 2002-04 Civic Si: page 12-5 2003-04 Civic Hybrid: page 13-5 2002-04 CR-V: page 12-5 2003-04 Element: page 12-6 Enter keyword CLUTCH MASTER, and select Clutch Master Cylinder Replacement from the list. 2. Install the new clutch master cylinder, but do not attach the clutch line fitting. 3. Apply a thin coat of silicone grease to the clutch line fitting and to the opening in the clutch master cylinder. Do not use silicone spray; it could damage the 0-ring. 4. Connect the clutch line fitting to the clutch master cylinder. 5. Bleed the clutch hydraulic system, then top off the reservoir with brake fluid. 6. Check to see if the noise is gone when pressing the clutch pedal. ^ If the noise is gone, the repair is complete. Page 9326 Diagram 115-3 (Coupe EX) Page 7290 2. Remove the terminal (same procedure for male and female). 3. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE E: 1. Remove the secondary locks. 2. Remove the terminal (same procedure for male and female). 3. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE F: Valves, Springs and Valve Seals Removal Valve Spring: Service and Repair Valves, Springs and Valve Seals Removal Removal Identify the valves and valve springs as they are removed, so that each item can be reinstalled in its original position. 1. Using an appropriate-sized socket (A) and plastic mallet (B), lightly tap the valve retainer to loosen the valve keepers. 2. Install the spring compressor. Compress the spring and remove the valve keepers. 3. Install the valve guide seal remover. Page 1268 ^ 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 5729 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. Test Equipment 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. Page 9832 6. Separate the master switch plate (A) from the armrest (B). 7. Remove the three screws and replace the switch. 2-door Page 9038 Shift Indicator: Testing and Inspection Continuously Variable Transmission Indicator Input Test SRS components are located in this area. Review the SRS component locations, precautions, and procedures in the SRS section before performing repairs or service. 1. If the MIL has been reported, check for a DTC, and repair the system as indicated by DTC. 2. If the MIL does not come on, and the A/T gear position indicator P, N, or R does not come on. Turn the ignition switch off, remove the gauge assembly from the dashboard, then disconnect gauge assembly connector A (22P) and B (22P). 3. Inspect the connectors and connector terminals to be sure they are making good contact. 4. If the terminals are bent, loose, or corroded, repair them as necessary, and recheck the system. 5. Shift to the P position, and check for continuity between AS terminal (BLU/BLK) and ground. There should be continuity in the P position and no continuity in any other shift lever position. If your test results are different, check for a faulty transmission range switch or an open in the wire. 6. Shift to the N position, and check for continuity between AS terminal (BLK/RED) and ground. There should be continuity in the N position and no continuity in any-other shift lever position. If your test results are different, check for a faulty transmission range switch or an open in the wire. 7. Turn the ignition switch ON (II), shift to the R position, and check for voltage between A11 terminal (WHT) and ground. There should be 0 V in the R position. There should be about 5 V in any other shift lever position. If your test results are different, check for a faulty transmission range switch or an open in the wire. 8. Check for voltage between B17 terminal (YEL) and ground with the ignition switch ON (II). There should be battery voltage. If your test results are different, check for a blown No. 10 (7.5A) fuse in the under-dash fuse/relay box or an open in the wire. 9. Turn the ignition switch OFF, and check for continuity between B16terminal (BLK) and ground under all conditions. There should be continuity. If your test results are different, check for a poor ground (G501) or an open in the wire. 10. If all input tests prove OK, but the indicator is faulty, replace the printed circuit board. Page 7754 ^ If the trunk opens and closes smoothly, return the vehicle to the customer. ^ If the trunk lid is still difficult to close, go to REPAIR PROCEDURE E. REPAIR PROCEDURE E 1. Look at the back of the lock cylinder while you turn the key from lock to unlock. ^ Refer to page 20-158 of the 2001-04 Civic Service Manual. ^ In ISIS, use the keyword LID LOCK, and select Trunk Lid Lock Cylinder Replacement from the list. 2. Check the operation of the trunk lid lock cylinder: ^ If the lock cylinder is difficult to turn or binds, go to step 3. ^ If the lock cylinder operates properly, and the trunk lid is still difficult to close, refer to the appropriate body repair manual, and check for body inaccuracies. 3. Replace the lock cylinder, and re-key the cylinder to the customer's original key; on 2-door Civics, replace the lock cylinder and the lock cylinder rod: ^ Refer to page 20-158 of the 2001-04 Civic Service Manual. ^ In ISIS, use the keyword LID LOCK, and select Trunk Lid Lock Cylinder Replacement from the list. 4. Check the trunk operation, and return the vehicle to the customer. Disclaimer Page 3181 Vehicle Speed Sensor: Service and Repair VSS Replacement 1. Remove the intake resonator. 2. Disconnect the 3P connector (A) from the vehicle speed sensor (VSS) (B). 3. Remove the mounting bolt, then remove the VSS. 4. Install the VSS in the reverse order of removal. Page 8908 21. Check for continuity between PGM-FI main relay 1 4P connector terminal No.1 and body ground. Is there continuity? YES - Repair short in the wire between PGM-FI main relay 1 and each item. Also replace the No.6 ECU (ECM/PCM) (15A) fuse. NO - Replace the PGM-FI main relay 1. Also replace the No 6 ECU (ECM/PCM) (15A) fuse. 22. Inspect the No.17 FUEL PUMP (15A) fuse in the under-dash fuse/relay box. Is the fuse OK? YES - Go to step 34. NO - Go to step 23. 23. Remove the blown No.17 FUEL PUMP (15A) fuse. 24. Disconnect ECM/PCM connector E (31P). 25. Check for continuity between ECM/PCM connector terminal E9 and body ground. Is there continuity? YES - Go to step 26. NO - Replace the No.17 FUEL PUMP (15A) fuse, and update the ECM/PCM if it does not have the latest software, or substitute a known-good ECM/PCM, then recheck. If the symptom/indication goes away with a known-good ECM/PCM, replace the original ECM/PCM. Fuel Gauge Sending Unit - New Wrench Available Fuel Gauge Sender: Technical Service Bulletins Fuel Gauge Sending Unit - New Wrench Available SOURCE: Honda Service News February 2003 TITLE: New Fuel Gauge Sending Unit Wrench Available APPLIES TO: All Models SERVICE TIP: There's a new fuel gauge sending unit wrench available in Honda parts stock. The new wrench T/N 07AAA-S0XA100) is a beefier version of the old one (T/N 07XAA-001010A) and supersedes it. The new wrench is much less prone to bending when you're removing a stubborn fuel pump/sender assembly locknut. Order it through normal parts ordering channels. Page 2815 Terminals - "T" Shielding Switches Fuses Page 2964 ECM/PCM Inputs And Outputs At Connector A (31P) Page 3116 48. Middle Of Engine (except GX) 49. Middle Of Engine (GX) Page 1898 4. Remove the valve seal. Page 3783 1. Remove and discard the plastic cover from the ignition switch key interlock solenoid. 2. Note the position of the interlock solenoid plunger; you'll need to install it the same way. 3. Remove the screw from the solenoid, but keep the solenoid attached to its electrical connector. Discard the screw. NOTE: ^ Be careful not to lose the solenoid plunger; it slides out easily. ^ Keep the plunger free of dirt and grease while it's removed from the solenoid. 4. Note the position of the interlock lever spring; you'll need to install the new spring the same way. Page 8331 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 4237 Transmission Position Switch/Sensor: Testing and Inspection Transmission Range Switch Test 1. Remove the transmission range switch harness connector (A) from the connector bracket (B), then disconnect the connector. 2. Check for continuity between terminals at the harness connector. There should be continuity between the terminals listed for each switch position. In the P position, between terminals: ^ No. 1 and No. 3 ^ No. 1 and No. 8 ^ No. 3 and No. 8 In the R position, between terminals: ^ No. 1 and No. 9 In the N position and between terminals: ^ No. 1 and No. 3 ^ No. 1 and No. 10 ^ No. 3 and No. 10 In the D position, between terminals: ^ No. 1 and No. 2 ^ No. 1 and No. 4 ^ No.2 and No.4 In the D3 position, between terminals: ^ No. 1 and No. 2 ^ No. 1 and No. 5 ^ No.2 and No.5 In the 2 position, between terminals: ^ No. 1 and No. 6 M/T - Clutch Pedal Squeak/Twang or Notchy Feel Hydraulic Hose: All Technical Service Bulletins M/T - Clutch Pedal Squeak/Twang or Notchy Feel 02-002 January 11, 2005 Applies To: See VEHICLES AFFECTED Squeak at the Clutch Pedal (Supersedes 02-002, dated September 21, 2004) SYMPTOM A squeak, a twang, or a notchy feel when the clutch pedal is pressed. PROBABLE CAUSE The clutch master cylinder spring is rubbing on the outer diameter of the piston when the pedal is pressed, or the master cylinder quick connect is moving. Component Locations Sunroof / Moonroof Switch: Component Locations Moonroof Component Location Index 57. Under Left Side Of Dash Page 2497 12. Check for continuity between PSP switch 2P connector terminal No.2 and body ground. Is there continuity? YES - Repair open in the wire between the PSP switch and ECM/PCM (E16). NO - Repair open in the wire between the PSP switch and G201. 13. Turn the ignition switch OFF. 14. Disconnect the PSP switch 2P connector. 15. Turn the ignition switch ON (II). 16. Measure voltage between ECM/PCM connector terminals A24 and E16. Is there battery voltage? YES - Replace the PSP switch. NO - Go to step 17. 17. Turn the ignition switch OFF. 18. Disconnect ECM/PCM connector E (31P). 19. Check for continuity between body ground and ECM/PCM connector terminal E16. Is there continuity? YES - Repair short in the wire between ECM/PCM (E16) and the PSP switch. NO - Update the ECM/PCM if it does not have the latest software, or substitute a known-good ECM/PCM, then recheck. If the Page 1172 125. Passenger's Door (Coupe except DX, HX) 126. Front Passenger's Door (Sedan except DX) 127. Left Rear Door (Sedan except DX) (Right Similar) Service and Repair Fuel Pressure Release: Service and Repair Fuel Pressure Relieving Before disconnecting fuel lines or hoses, relieve pressure from the system by disconnecting the fuel tube/quick connect fitting in the engine compartment. 1. Make sure you have the antitheft code for the radio, then write down the frequencies for the radio's preset buttons. 2. Turn the ignition switch OFF. 3. Remove the glove box, then remove the PGM-FI main relay 2 (A). 4. Start the engine, and let it idle until it is stalls. NOTE: The DTCs or Temporary DTCs P0301, P0302, P0303, P0304 may come on during this procedure. If any DTCs are stored, ignore them. 5. Turn the ignition switch OFF. 6. Remove the fuel fill cap to relieve fuel pressure in the fuel tank. 7. Disconnect the negative cable from the battery. 8. Remove the bolt (A) and the fuel feed pipe mounting bracket (B), then remove the quick-connect fining covers (C). 9. Check the fuel quick-connect fitting for dirt, and clean if necessary. 10. Place a rag or shop towel over the quick-connect fitting (D). Page 8790 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 6563 Heating Component Location Index Page 20 ^ Within 1 to 4 seconds, turn the ignition switch to LOCK (0). ^ Within 1 to 4 seconds, turn the ignition to ON (II). ^ Within 1 to 4 seconds, push the transmitter lock or unlock button. ^ Confirm you can hear the sound of the door lock actuators. Within 1 to 4 seconds, push the transmitter lock or unlock button again. ^ Within 10 seconds, aim the transmitters (up to two additional ones) whose codes you want to store at the receiver, and press the transmitter lock or unlock button. Confirm that you can hear the sound of the door lock actuators after each transmitter code is stored. ^ Turn the ignition switch to LOCK (0), and pull out the key. 4. Confirm proper operation of the transmitters. Disclaimer Page 5788 Under-dash Fuse/Relay Box Page 9641 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. Test Equipment 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. Page 7901 Front Fender Liner: Service and Repair Front Fender Fairing Replacement Front Fender Fairing Replacement 1. Remove the front inner fender as necessary. 2. Open the front door. From outside the door, remove the upper clip (A), and from inside the door, remove the lower clip (A) securing the front fender fairing (B) and front fender (C). 3. From the wheel arch, remove the clip (A), and release the clip (B), then remove the front fender fairing (C). Page 8035 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. Obtain the customer's key code from the iN (Key Code Inquiry). Refer to the Honda High Security key Codes book that comes with the Matrix H key cutting machine. Write down the applicable cutting code for the key code number. Make sure the corrections to the code book listed in Service Bulletin 01-077, Cutting Sidewinder-Type keys With the Matrix H key Cutting Machine, have been made. 2. Use the chart shown to write down the numbers found in the key code book. 3. Remove the door panel. Refer to the appropriate service manual or use ISIS keyword Door Panel. 4. Remove the plastic cover as necessary. 5. Raise the window glass fully. 6. Remove the lock cylinder. ^ For Civic, go to step 7. ^ For CR-V, go to step 8. ^ For Element, go to step 11. 7. Pull down on the retainer clip with a hook-shaped tool. Remove the lock cylinder and disconnect the cylinder rod. Then go to step 14. Page 1692 2. Cut off the wire about an inch back from where it connects to the damaged or faulty terminal, then strip about half of the insulation off that piece. This will be used to size the wire end of the replacement pigtail terminal. NOTE: If you are not sure of the wire size, start with a large enough hole on the stripper that will not nick or cut off any strands of wires. 3. Select a pigtail terminal that matches the original wire at both ends (same kind of terminal and same diameter bare wire). 4. Select the smallest splice connector (yellow, pink, or blue) that will fit onto the stripped end of the original wire. 5. Insert the pigtail terminal into the connector cavity; push it in until it locks in place. 6. Lay the pigtail and the original wire side-by-side, and cut off both ends at once. If you are making more than one splice, do not cut each pigtail at the same location; the resulting "lump" of splice connectors would interfere with rewrapping the harness. Instead, cut the first pigtail close enough to the terminal so you will have room to make each remaining cut about 20 mm (3/4 inch) farther down on the next pigtail. 7. If you are using a yellow splice connector, strip about 6 mm (1/4 inch) of insulation off the ends of both wires. If you are using a pink or blue splice connector, strip off about 8 mm (5/16 inch) of insulation. Page 9133 - Before connecting connectors, make sure the terminals (A) are in place and not bent. - Check for loose retainer (A) and rubber seals (B). - The backs of some connectors are packed with dielectric grease. Add grease if necessary. If the grease is contaminated, replace it. - Insert the connector all the way and make sure it is securely locked. - Position wires so that the open end of the cover faces down. Handling Wires and Harnesses - Secure wires and wire harnesses to the frame with their respective wire ties at the designated locations. Page 5071 23. Transmission Housing (A/T) Page 7651 9. Open the jaws with the jaws knob, and slide the original key with its flat side down into the center jaw up to the key stop. Slide the key blank with its flat side down into the right jaw up to the key stop. Close the jaws with the jaws knob to lock the keys into place. Visually inspect both keys for proper alignment in the jaws. 10. Loosen the lateral and spring tension adjustment knobs on the clamp carriage. With the clamp carriage lever, adjust the clamp carriage to position the tracer and the cutter bit over the middle of the two locked key blades. Tighten only the spring tension knob when done. NOTE: The clamp carriage has a spring system that puts lateral pressure on the tracer and cutting bit to make it easier to cut sidewinder-type keys. Do not tighten the lateral tension adjustment knob. This knob should be left loose. 11. Turn on the cutter motor with the motor start switch. [NOTICE] ^ To avoid damaging the locking jaws while cutting, keep your hand off the vertical carriage lever. Pressure on the lever will change the cutting depth. * ^ To avoid breaking the cutter bit, never back up while cutting.* ^ Wear proper eye protection (safety glasses, goggles, etc.) Page 9083 - Before connecting connectors, make sure the terminals (A) are in place and not bent. - Check for loose retainer (A) and rubber seals (B). - The backs of some connectors are packed with dielectric grease. Add grease if necessary. If the grease is contaminated, replace it. - Insert the connector all the way and make sure it is securely locked. - Position wires so that the open end of the cover faces down. Handling Wires and Harnesses - Secure wires and wire harnesses to the frame with their respective wire ties at the designated locations. Page 9356 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. Circuits must be operating when checking voltage drop. 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. 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 off, 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 Self-Powered Test Light or DVOM 1. Remove the blown fuse and disconnect the battery and load. Page 4452 VEHICLES AFFECTED CORRECTIVE ACTION Replace the master cylinder, and apply a thin film of silicone grease to the clutch line fitting. REQUIRED MATERIALS Silicone Grease: P/N 08C30-B0234M, H/C 6110928 Brake Fluid: P/N 08798-9008, H/C 4423802 PARTS INFORMATION Civic/Civic Hybrid Master Cylinder: P/N 46920-S5A-G04, H/C 7569452 Accord/Civic Si/CR-V/Element Master Cylinder: P/N 46920-57A-A02, H/C 7604507 WARRANTY CLAIM INFORMATION In warranty: The normal warranty applies. Operation Number: 211101 Flat Rate Time: 0.6 hour (All Civics) 0.8 hour (Accord/CR-V/Element) Failed Part: Civic/Civic Hybrid: P/N 46920-55A-G01 H/C 6571103 Accord/Civic Si/CR-V/Element: P/N 46920-S7A-A01 H/C 6729031 Defect Code: 03214 Symptom Code: 04201 Page 3239 Wires Page 5572 Starter Relay: Testing and Inspection Power Relay Test Use this chart to identify the type of relay, then do the test listed for it. NOTE: See the turn signal/hazard relay input test. Normally-open type A: Check for continuity between the terminals. - There should be continuity between the No.1 and No.2 terminals when power and ground are connected to the No.3 and No.4 terminals. - There should be no continuity between the No.1 and No.2 terminals when power is disconnected. Body - Power Windows Inoperative/Intermittent Operation Power Window Switch: All Technical Service Bulletins Body - Power Windows Inoperative/Intermittent Operation 06-010 March 8, 2006 Applies To: 2001-05 Civic - All LX and EX 4-door 2003-05 Civic Hybrid - ALL 2001-05 Civic GX ALL Power Window Does Not Work or Works Intermittently SYMPTOM One or more of the power windows does not work or works intermittently from the power window master switch (in the driver's door). PROBABLE CAUSE The power window master switch is faulty. CORRECTIVE ACTION Replace the power window master switch. PARTS INFORMATION WARRANTY CLAIM INFORMATION In warranty: The normal warranty applies. Operation Number: 744100 Flat Rate Time: 0.2 hr Failed Part: P/N 35750-S5A-A01ZA H/C 6453419 Defect Code: 03217 Symptom Code: 01201 Template ID: 06-010A (Black Switch) 06-010B (Medium Taupe Switch) 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 2772 ECM/PCM Inputs And Outputs At Connector E (31P) Page 4097 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. Below most connector numbers and component names are PHOTO and VIEW numbers. The PHOTO number refers to a photo in the back of the book that shows the connector's location on the car. The VIEW number refers to an illustration in the back of the book that shows the connector terminals, wire colors, connector cavity numbers, and other details. The connector cavity numbering sequence begins at the top left corner of the connector as seen from either of the viewpoints shown on diagram [8] . Except for the DLC (data link 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 C554, for example, means those terminals join in cavity 2 of connector C554. Power Distribution Schematics Power Distribution Schematics Page 2173 66. Radiator Fan Motor Page 8978 8. Remove the locknut (A) and the fuel tank unit. 9. Remove the stopper (O). Release the hook (P) and remove the fuel filter (B), the fuel gauge sending unit (C), the case (D), the wire harness (E), and the fuel pressure regulator (F). 10. When connecting the fuel tank unit, make sure the connection is secure and the suction filter (G) is firmly connected to the fuel pump (H). 11. Install in the reverse order of removal with a new base gasket (I) and new O-rings (J), then check these items: - When connecting the wire harness, make sure the connection is secure and the connector (K) is firmly locked into the place. - When installing the fuel gauge sending unit, make sure the connection is secure and the connector is firmly locked into place. Be careful not to bend or twist the connector excessively. - When installing the fuel tank unit, align the marks (L) on the fuel tank (M) and the fuel tank unit (N). Page 3157 2. Insert the terminal tool into the female terminal, and then remove the terminal tool. NOTE: Make sure you do not select a terminal tool that is larger than the mating male terminal because it would spread the female terminal and cause a loose fit. 3. Compare the drag to the other terminals in the connector. If the drag is less, replace the terminal with a replacement terminal from the appropriate terminal repair kit. Page 9467 PGM-F1 Main Relay 1, 2 Type 1, 2 Check for continuity between the terminals. - There should be continuity between the No.1 and No.2 terminals when power and ground are connected to the No.3 and No.4 terminals. - There should be no continuity between the No.1 and No.2 terminals when power is disconnected. Normally-open type B: Rear Window Defogger Relay Page 2542 8. Put the splice connector in the proper size slot in the Crimper Tool, slide it to one end (where the flare begins), and close the crimper handles far enough to hold it in place. To release the ratchet mechanism at any point after the first click, squeeze the handles slightly and push the release lever, then let the handles open. 9. Insert one of the bare wires into the splice connector end that is in the crimper jaws. Push the wire all the way into the splice connector, and squeeze the crimper handles. Keep squeezing until the jaws touch, and hold it at that position until the ratchet clicks again. 10. Crimp the other wire in the same way into the other end of the splice connector. 11. After crimping, gently pull on the wires in the opposite directions to make sure they are secure in the connector. 12. Separate the other wires in the harness from the repaired wire(s), and shield them with nonflammable material. Page 2079 17. VTEC Solenoid Valve (EX, HX) Page 7622 Disclaimer Cutting Procedure - By Copying 1. Press the ON/OFF button in the middle of the setting unit keypad. (This powers up the keypad.) 2. Turn the clamp unit lock lever to the left to release the clamp unit, and slide it all the way to the left until it stops. Turn the lever to the right to lock the clamp unit in place. 3. Use the clamp carriage lever to position the clamp unit so the tracer and cutter bit are centered directly over the base of the center and right jaws. 4. Pull the vertical carriage lever toward you until the tracer and the cutter bit just touch the base of each fixed jaw. Watch the arrows on the keypad: ^ If the double-headed arrow in the middle of the keypad lights green, the tracer and cutter bit are properly aligned. ^ If the arrow on the left of the keypad lights red, the cutter bit is not touching the fixed jaw. Turn the micrometric ring nut above the tracer to the left until the double-headed arrow lights green. ^ If the arrow on the right of the keypad lights red, the tracer is not touching the fixed jaw. Turn the micrometric ring nut above the tracer to the right until the double-headed arrow lights green. *5. Turn the micrometric ring nut to the right three clicks so the cutter bit is slightly higher than the tracer. The arrow on the left should light red. Raise the vertical carriage. NOTE: Setting the tracer three clicks lower than the cutter bit has the effect of making the cutter bit cut the duplicated key a little shallower. This will protect the locking jaws from being damaged.* 6. Optional: Loosen the setscrew, and adjust the hand rest to a comfortable position. Tighten the screw. 7. Pull the clamp carriage lever toward you until the clamp carriage clicks into its end-of-run position. Tighten both the lateral and spring tension adjustment knobs. 8. Make sure the center and right jaws are free of any metal shavings or debris. (A soft-bristle toothbrush is ideal for this purpose.) Locations Radiator Cooling Fan Temperature Sensor / Switch: Locations Page 2747 DTC P0A94 thru P0157 Page 5344 Wheel Speed Sensor: Service and Repair Replacement NOTE: Install the sensors carefully to avoid twisting the wires. Page 5140 2. Cut off the wire about an inch back from where it connects to the damaged or faulty terminal, then strip about half of the insulation off that piece. This will be used to size the wire end of the replacement pigtail terminal. NOTE: If you are not sure of the wire size, start with a large enough hole on the stripper that will not nick or cut off any strands of wires. 3. Select a pigtail terminal that matches the original wire at both ends (same kind of terminal and same diameter bare wire). 4. Select the smallest splice connector (yellow, pink, or blue) that will fit onto the stripped end of the original wire. 5. Insert the pigtail terminal into the connector cavity; push it in until it locks in place. 6. Lay the pigtail and the original wire side-by-side, and cut off both ends at once. If you are making more than one splice, do not cut each pigtail at the same location; the resulting "lump" of splice connectors would interfere with rewrapping the harness. Instead, cut the first pigtail close enough to the terminal so you will have room to make each remaining cut about 20 mm (3/4 inch) farther down on the next pigtail. 7. If you are using a yellow splice connector, strip about 6 mm (1/4 inch) of insulation off the ends of both wires. If you are using a pink or blue splice connector, strip off about 8 mm (5/16 inch) of insulation. Specifications Firing Order: Specifications Ignition coil Firing order .......................................................................................................................................... ............................................................ 1 - 3 - 4 - 2 Page 2915 Oxygen Sensor: Service and Repair Third HO2S Replacement Third HO2S Replacement Special Tools Required O2 sensor wrench, Snap-on YA8875, SP Tools 93750, or equivalent, commercially available NOTE: The secondary HO2S and the third HO2S must be replaced together. 1. Disconnect the third HO2S 4P connector (A), then remove the third HO2S (B). 2. Install the third HO2S in the reverse order of removal. Page 7220 Programming the Transmitter NOTES: ^ The system accepts up to three transmitters. The transmitter codes are stored in a stacking-type memory. If a fourth transmitter code is programmed, the code for the first transmitter is erased. ^ Entering the programming mode cancels all learned transmitter codes, so none of the previously programmed transmitters will work. You must reprogram all of the transmitters once you are in the programming mode. ^ You must complete each step within 4 seconds of the previous step to keep the system from exiting the programming mode. Program the transmitters within 10 seconds. 1. Turn the ignition switch to ON (II). 2. Press the "Lock" or "Unlock" button on one of the transmitters. (An unprogrammed transmitter can be used for this step.) 3. Turn the ignition switch to LOCK (0). 4. Repeat steps 1 2, and 3 two more times using the same transmitter used in step 2. 5. Turn the ignition switch to ON (II). 6. Press the "Lock" or "Unlock" button on the same transmitter. Make sure the power door locks cycle to confirm that the system is in programming mode. 7. Within 10 seconds, press the "Lock" or "Unlock" button on each transmitter. Make sure the power door locks cycle after you press each transmitter button to confirm that the system accepted the transmitter's code. 8. Turn the ignition switch to LOCK (0) to exit the programming mode. Ordering a Transmitter Transmitters can be ordered only by authorized Honda dealers. Order them from American Honda using normal parts ordering procedures. Batteries for the Transmitter The battery number is CR2025. Each transmitter uses one battery. 99-04 Odyssey EX 1999-00 Odyssey EX with factory-installed keyless entry system or dealer-installed security system *2001-04 Odyssey EX models with factory- installed security system* *Transmitter Identification Mainshaft Speed Sensor Replacement Transmission Speed Sensor: Service and Repair Mainshaft Speed Sensor Replacement Mainshaft Speed Sensor Replacement 1. Disconnect the mainshaft speed sensor connector. 2. Remove the mainshaft speed sensor (A). 3. Install the new mainshaft speed sensor with the new O-ring (B) and mainshaft speed sensor washer (C). NOTE: The mainshaft speed sensor washer is equipped on the SLXA automatic transmission; the BMXA does not have it. 4. Check the mainshaft speed sensor connector for rust, dirt, or oil, then connect the connector securely. Automatic Transmission Flex Plate: Service and Repair Automatic Transmission Drive Plate Removal and Installation 1. Remove the drive plate (A) and washer (B) from the engine crankshaft. 2. Install the drive plate and washer on the engine crankshaft, and tighten the six bolts in a crisscross pattern. A/T - Vehicle Speed Sensor Installation Precautions Vehicle Speed Sensor: Technical Service Bulletins A/T - Vehicle Speed Sensor Installation Precautions Install VSS Properly to Avoid Reman A/T Damage We can't emphasize enough how important it is to follow, to the letter, the installation instructions that come with a reman A/T. These instructions help ensure that you avoid damaging the A/T and score a successful repair. This is particularly true when it comes to installing the vehicle speed sensor (VSS). Step 6 of the instructions tells you to make sure its gear is fully engaged and the VSS is fully seated before you tighten the retaining bolt. If you don't install the VSS properly, the speed sensor gear will get stripped and the A/T will be seriously damaged. So don't take risks with your customer's vehicle. Always follow these instructions to the letter. You can rest assured you're doing the job right. Locations Neutral Safety Switch: Locations Starting System Component Location Index Page 387 12. Watch the SRS indicator: ^ If the indicator blinks twice and then goes off, the OPDS unit is initialized. Turn the ignition switch to LOCK (0), and disconnect the HDS. ^ If the indicator blinks twice and then stays on, the OPDS unit is initialized, but SRS DTCs need to be cleared. Go to step 13. ^ If the indicator stays on without first blinking, the OPDS unit is not initialized. Repeat steps 3 thru 12. 13. Turn the ignition switch to LOCK (0), then disconnect the HDS. 14. Reconnect the SCS service connector to the MES connector. Do not use a jumper wire. 15. Turn the ignition switch to ON (II). 16. Watch the SRS indicator. (It comes on for about 6 seconds and then goes off.) Disconnect the SCS service connector from the MES connector within 4 seconds after the indicator goes off. 17. When the SRS indicator comes on again, connect the SCS service connector to the MES connector within 4 seconds after the indicator comes on. 18. When the SRS indicator goes off, disconnect the SCS service connector from the MES connector within 4 seconds. (The SRS indicator blinks twice to indicate that the memory has been cleared.) 19. Turn the ignition switch to LOCK (0), and wait for 10 seconds. 20. Turn the ignition switch to ON (II). (The SRS is OK if the SRS indicator comes on for 6 seconds and then goes off.) If the DTC clearing fails, repeat the process two more times. If the DTC clearing fails again, check for set SRS DTCs, and troubleshoot them with the appropriate service manual. REPAIR PROCEDURE B: OPDS SENSOR REPLACEMENT 1. Remove the seat-back cover from the front passenger's seat: ^ Using the appropriate service manual, go to section 20 (Body), and do the removal steps under Front Seat Cover Replacement, or ^ Online, enter keyword SEAT COVER, then select Front Seat Cover Replacement from the list, and do the removal steps in the procedure. 2. Slide the seat-back cushion (foam) off the seat-back frame. (The OPDS sensor is built into the seat-back cushion.) 3. Slide a new seat-back cushion over the seat-back frame. Make sure the cushion is centered. 4. Install the seat-back cover: ^ Using the appropriate service manual, go to section 20 (Body), and do the installation step under Front Seat Cover Replacement, or ^ Online, enter keyword SEAT COVER, then select Front Seat Cover Replacement from the list, and do the installation step in the procedure. 5. Initialize the OPDS unit: ^ To initialize with the HDS, go to Initializing the OPDS Unit: HDS Method in this service bulletin. ^ To initialize with the SCS service connector, go to Initializing the OPDS Unit: Manual Mode in this service bulletin. Disclaimer Page 7744 Trunk / Liftgate Lock: By Symptom Technical Service Bulletin # 02-061 Date: 041105 Body - Trunk Lid Hard to Close 02-061 November 5, 2004 Applies To: See VEHICLES AFFECTED Trunk Lid is Difficult to Close (Supersedes 02-061, dated July 23, 2004) Updated information is shown with asterisks. SYMPTOM The trunk lid may be difficult to close or won't latch closed. PROBABLE CAUSE The trunk lid may be misaligned, and the trunk lid opener cable, trunk lid latch, lock cylinder, lock rod, and/or the trunk lid latch striker may need adjustment or replacement. VEHICLES AFFECTED CORRECTIVE ACTION Adjust the trunk lid and/or the trunk lid latch, or replace components as needed. PARTS INFORMATION Page 812 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 Locater) 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. Troubleshooting Precautions Troubleshooting Precautions Before Troubleshooting 1. Check the main fuse and the fuse 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, or you will damage the alternator diodes. - Do not attempt to crank the engine with the ground cable disconnected 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. Ball Joint Removal Ball Joint: Service and Repair Ball Joint Removal Removal Special Tools Required Ball joint remover, 28 mm 07MAC-SL00200 NOTICE: Always use a ball joint remover to disconnect a ball joint. Do not strike the housing or any other part of the ball joint connection to disconnect it. 1. Install a hex nut (A) onto the threads of the ball joint (B). Make sure the nut is flush with the ball joint pin end to prevent damage to the thread end of the ball joint pin. 2. Apply grease to the special tool on the areas shown (A). This will ease installation of the tool and prevent damage to the pressure bolt (B) threads. Page 6265 28. Remove the snap ring (A) and sleeve (B) from the pinion shaft. 29. Using a cutter or an equivalent tool, cut and remove the four seal rings from the sleeve. Be careful not to damage the edges of the sleeve grooves and the outer surface when removing the seal rings. 30. Using a cutter or an equivalent tool, cut the valve seal ring (A) and O-ring (B) at the groove (C) in the pinion shaft. Remove the valve seal ring and O-ring. Be careful not to damage the edges of the pinion shaft groove and outer surface when removing the valve seal ring and O-ring. 31. Remove the valve oil seal (A) and wave washer (B) from the pinion shaft. Note these items during disassembly: ^ Inspect the ball bearing (C) by rotating the outer race slowly. If there is any excessive play, replace the pinion shaft and sleeve as an assembly. ^ The pinion shaft and sleeve are a precise fit; do not intermix old and new pinion shafts and sleeves. Page 3833 1. Remove the terminal. 2. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE B: 1. Remove the terminal. 2. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE C: 1. Remove the terminal. 2. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE D: Page 3099 Oxygen Sensor: Description and Operation Third Heated Oxygen Sensor (Third HO2S) Third Heated Oxygen Sensor (Third HO2S) (D17A6 engine) The third HO2S detects the oxygen content in the exhaust gas downstream of the NOX Adsorptive Three Way Catalytic Converter (NOX Adsorptive TWC) and sends signals to the ECM/PCM which varies the duration of fuel injection accordingly. To stabilize its output, the sensor has an internal heater. The third HO2S is installed behind the NOX Adsorptive TWC. Door Lock Knob Switch Test Power Door Lock Switch: Testing and Inspection Door Lock Knob Switch Test Door Lock Knob Switch Test 4-door 1. Remove the driver's door panel. 2. Disconnect the 3P connector from the actuator. 3. Check for continuity between the No.1 and No.2 terminals. - There should be continuity when the door lock knob switch is in the LOCKED position. - There should be no continuity when the door lock knob switch is in the UNLOCKED position. 4. If the continuity is not as specified, replace the door lock actuator. 2-door 1. Remove the driver's door panel. 2. Disconnect the 3P connector from the actuator. 3. Check for continuity between the No.1 and No.2 terminals. - There should be continuity when the door lock knob switch is in the LOCKED position. - There should be no continuity when the door lock knob switch is in the UNLOCKED position. 4. Check for continuity between the No.1 and No.3 terminals. - There should be continuity when the door lock knob switch is in the UNLOCKED position. Page 849 128. VSS (except CVT) Page 1036 ^ The left end goes behind the notch on the interlock lever. ^ Once the spring is correctly installed, make sure the lever moves freely and returns properly. 10. Insert the plunger into the interlock solenoid, then install the solenoid using a new screw. Make sure the groove of the solenoid plunger is in the fork on the lever. 11. Install a new plastic cover on the interlock solenoid. 12. Check the operation of the ignition switch key interlock: ^ Set the parking brake, and turn the ignition switch to ON (I I). ^ While pressing the brake pedal, shift the transmission to Neutral. ^ Try turning the ignition switch to LOCK (0) - If you cannot turn the switch to LOCK (0), your repair was successful; go to step 15. - If you can turn the switch to LOCK (0), the interlock is not working; go to step 13. Service and Repair Rear Door Panel: Service and Repair Rear Door Panel Removal/Installation Special Tools Required - KTC trim tool set SOJATP2014 - Trim pad remover. Snap-on A 177A or equivalent, commercially available 4-door NOTE: Use the appropriate tool from the KTC trim tool set to avoid damage when prying components. 1. If applicable, remove the regulator handle (A) by pulling the clip (B) out with a wire hook (C). 2. Remove the inner handle (A). Take care not to scratch the door panel. 1. Pry out on the upper portion of the cover (B) to release the hooks (C, D), then remove the cover. 2. Remove the screws. 3. Pull the inner handle forward and out half-way to release the hook (E). 4. Disconnect the inner handle rod (F). Page 3959 NOTE: Update the systems one at a time. 7. Verify that the Program ID and the Program Part No. are for the vehicle you are updating, then click on the check mark. 8. Confirm the control module update by Program ID and Program Part No. Make sure this corresponds with any information provided in the service bulletin for the update you are doing. Click on Yes to continue. Within a few seconds, the CM Update sofiware loads the program file onto the HIM. Page 9283 11. Horn Switch Page 1972 Locations Interior Lights Component Location Index Shift Lever Removal Shifter A/T: Service and Repair Shift Lever Removal Shift Lever Removal 1. Shift the transmission into the N position. 2. Remove the center console panel and center console. 3. Remove the nut securing the shift cable end (A), then separate the cable end from the shift lever assembly. 4. Rotate the socket holder (A) on the shift cable (B) toward the shift lever a quarter turn, then slide the holder out to remove the shift cable from the shift cable bracket base (C). NOTE: Do not remove the shift cable by twisting the shift cable guide (D). Page 5721 Diodes Light Emitting Diode (LED) Motor Pressure Sensor Page 7109 Seat Occupant Sensor: Description and Operation OPDS (Occupant Position Detection System) The side airbag system also includes an Occupant Position Detection System (OPDS). This system consists of Sensors (G) and a OPDS Unit (H) in the front passenger's seat-back. The OPDS unit sends occupant height and position data to the SRS unit. If the SRS unit determines that the front passenger is of small stature (for example, a child) and the front passenger is leaning into the side airbag deployment path, it will automatically disable the airbag. The SRS unit will also disable the airbag when the OPDS detects certain objects on the seat. Side Airbag Cutoff Indicator When the side airbag is disabled, the Side Airbag Cutoff Indicator on the instrument panel alerts the driver that the passenger's side airbag will not deploy in a side impact. When the object is removed, or the passenger sits upright, the Side Airbag Cutoff indicator will go off, alerting the driver that the side airbag will deploy in a side impact. Front Suspension Strut / Shock Absorber: Specifications Front TIGHTENING SPECIFICATIONS Damper Shaft Nut ................................................................................................................................ ............................... 44 N.m (4.5 kgf-m, 33 lbf-ft) Upper Flange Nut ............................................................................................................................................................ 59 N.m ((6.0 kgf-m, 43 ft. lbs.) Damper Pinch Bolt 01-02 models.................................................................................................................................. 103 N.m (10.5 kgf-m, 75.9 ft-lb) Damper Pinch Bolt 03 model ......................................................................................................................................... 157 N.m (16.0 kgf-m, 116 ft-lb) Brake Hose Bracket Bolt ..................................................................................................................................................... 22 N.m (2.2 kgf-m, 16 lbf-ft) Wheel Sensor Bracket ....................................................................................................................................................... 9.8 N.m (1.0 kgf-m, 7.2 lbf-ft) Tie-rod End to Steer Arm ................................................................................................................................................ 44 N.m (4.5 kgf-m, 33 lbf-ft) Page 8108 1. Remove the driver's dashboard lower cover. (See the body section of the appropriate service manual.) 2. Replace the security control unit. ^ Civic: Remove the security control unit, and install the new security control unit. ^ * CR-V and Element: Remove the security control unit and microphone. Install the new security control unit and new microphone.* 3. Reprogram the keyless receiver unit. NOTE: The codes of up to three transmitters can be stored in the keyless receiver unit memory. If a fourth code is stored, the code that was input first will be erased. It is important to maintain the time limits between the steps. Make sure the doors and the trunk/tailgate/hatch are closed, and that you have all of the remotes the customer wishes to use. ^ Turn the ignition switch to ON (II). ^ Within 1 to 4 seconds, push the transmitter lock or unlock button. ^ Within 1 to 4 seconds, turn the ignition switch to LOCK (0). ^ Within 1 to 4 seconds, turn the ignition to ON (II). ^ Within 1 to 4 seconds, push the transmitter lock or unlock button. ^ Within 1 to 4 seconds, turn the ignition switch to LOCK (0). ^ Within 1 to 4 seconds, turn the ignition switch to ON (II). ^ Within 1 to 4 seconds, push the transmitter lock or unlock button. Locations Under-dash Fuse/Relay Box Page 2052 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 Short Circuit Locator (Short Finder) 1. Remove the blown fuse. Leave the battery connected. Page 5725 Power Distribution schematics show how power is supplied from the positive battery terminal to various circuits in the vehicle. Refer to the Power Distribution diagram set to get a more detailed understanding of how picture is supplied to the circuit you're working on. Individual circuit schematics begin with a fuse. So 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 Ground Distribution Schematics This sample Ground Distribution schematic shows all of the components that share the same ground point. Page 3752 156. A/T Reverse Relay (A/T, CVT) Page 348 Air Bag Control Module: Description and Operation SRS Operation The main circuit in the SRS unit senses and judges the force of impact and, if necessary, ignites the inflator charges. 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: Driver's and Front Passenger's Airbag(s) 1. The frontal impact sensor must activate, and send electric signals to the microprocessor. 2. The microprocessor must compute the signals, and depending on the severity of the collision and whether the seat belt buckle switch is ON or OFF, it sends the appropriate signals to the airbag inflator(s). 3. The inflators that received signals must ignite and deploy the airbags. Side Airbag(s) 1. The side impact sensors must activate, and send electric signals to the microprocessor. 2. The microprocessor must compute the signals and send them to the side airbag inflator(s). However, the microprocessor cuts off the signals to the front passenger's side airbag if the SRS unit determines that the front passenger's head is in the deployment path of the side airbag. 3. The inflator that received the signal must ignite and deploy the side airbag. 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 6 seconds if the system is operating normally. If the indicator does not come on, or does not go off after 6 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 SRS unit memory stores a DTC that relates to the cause of the malfunction, and the unit is connected to the data link connector (DLC). This information can be read with the Honda PGM Tester when it is connected to the DLC (16P). Specifications Clutch Fluid: Specifications Clutch Fluid ..................................................................................................................................... Genuine Honda DOT 3 Brake Fluid (P/N 08798-9008) Page 8642 Front Door Weatherstrip: Service and Repair Front Door Upper Seal Replacement Front Door Upper Seal Replacement 4-door NOTE: - Take care not to scratch the door. - Use a clip remover to remove the clips. 1. Remove these items: - Power mirror/manual mirror, as necessary - Door sash trim 2. Detach the door weatherstrip clip (A), then remove the door upper seal (B). 3. Install the seal in the reverse order of removal, and note these items: - Replace the clip if it's damaged. - Make sure the upper seal is installed in the holder (C) securely. - Check for water leaks. - Test-drive and check for wind noise. Page 2842 13. Plug in the heat gun, and turn it on. Start at the middle of the splice connector, and move the gun toward the ends as the tube shrinks. Apply heat evenly by rotating the curved heat spreader around the splice connector. Shrinking is complete when a small amount of sealant appears at each end of the tube. Pigtail Terminal Selection Chart PIGTAIL TERMINAL SELECTION CHART Select the proper size pigtail terminal by matching the replacement terminal part number and the wire size being repaired to the corresponding pigtail terminal part number. Then use the color (size) splice connector listed. In some instances you may also have to match the wire seal style to select the proper pigtail terminal. Pigtail terminals are available through your parts department, in quantities of 10, using normal parts ordering procedures. Checking For Poor Fir of Terminals CHECKING FOR POOR FIT OF TERMINALS Loose terminal fit can cause a number of intermittent problems in electrical circuits. By using the Terminal Inspection Feeler Tool Set you can inspect the terminal fit between the two matching connectors without removing the terminals from the connector body. 1. Find the terminal tool that best matches the male terminal in the mating connector. Page 5674 5. With the wire inserted in the new terminal as shown in step 3, crimp the wire by squeezing the tool with both hands until the stops make contact. 6. Crimp the insulation by positioning the 5.5 slot on the tool over the insulation crimp section of the terminal and squeezing the tool with both hands until the stops make contact. 7. Inspect the quality of the wire crimp. If it has any of the following NO GOOD crimps, cut it off and start over. 8. Clean the starter side of the S terminal as needed using electric contact cleaner and an electrical connector cleaning brush (Snap-on P/N YA385A or equivalent). Blow out any debris remaining on or around the terminal with compressed air. 9. Apply silicone dielectric grease (3M silicone paste P/N 08946, Permatex Dielectric Tune-up grease P/N 67VR, or equivalent) to the female side of the S terminal, then carefully insert the terminal into the S terminal on the starter side. 10. Slide the boot completely over the S terminal. 11. Reconnect the positive battery cable, then reconnect the negative battery cable. 12. Enter the anti-theft code for the audio unit (if applicable), then enter the customer's audio presets. Set the clock. 13. Confirm that the starter engages properly by starting the engine several times. 14. Do the idle learn procedure: ^ Make sure all electrical items (A/C, audio unit, defogger, lights, etc.) are off. Page 1430 Fluid - CVT: Service and Repair ATF Replacement ATF Replacement NOTE: Keep all foreign particles out of the transmission. Change Intervals: Replace at 48,000 miles (80,000 km) or 48 months, then replace every 36,000 miles (60,000 km) or 36 months in normal conditions Replace every 24,000 miles (40,000 km) or 24 months in severe conditions 1. Park the vehicle on level ground. 2. Remove the drain plug (A), and drain the automatic transmission fluid (ATF). NOTE: If a cooler flusher is to be used, refer to ATF Cooler Flushing. 3. Reinstall the drain plug with a new sealing washer (B). 4. Refill the transmission with the recommended fluid into the dipstick hole (A). Always use Honda ATF-Z1 Automatic Transmission Fluid (ATF). Using non Honda ATF can affect shift quality. Automatic Transmission Fluid Capacity: 3.1 L (3.3 US qt) at changing 5.6 L (5.9 US qt) at overhaul 5. Check that the fluid level is between the upper mark (E) and lower mark (F) on COLD gauge (D), if the dipstick has COLD gauge. 6. Insert the dipstick back into the transmission. 7. Warm up the engine to normal operating temperature (the radiator fan comes on). 8. Check that the fluid level is between the upper mark (A) and lower mark (B) on HOT gauge (C). Do not check the level with COLD gauge (D) when the ATF wormed up. Page 5072 Shift Solenoid: Diagrams 185. CVT Control Valves And Inhibitor Solenoid Assembly 73. Shift Solenoid Valve A And B (A/T Except CVT) Page 9372 2. Insert the terminal tool into the female terminal, and then remove the terminal tool. NOTE: Make sure you do not select a terminal tool that is larger than the mating male terminal because it would spread the female terminal and cause a loose fit. 3. Compare the drag to the other terminals in the connector. If the drag is less, replace the terminal with a replacement terminal from the appropriate terminal repair kit. Locations 94. Behind Glove Box (except GX) Page 1533 Under-dash Fuse/Relay Box (2-door) Page 7492 1. Remove the rear bumper as shown. 2. Install the bumper in the reverse order of removal, and note these items: - Make sure the rear bumper engages the hooks of the side spacers, side brackets and upper brackets on both sides securely. - Make sure the side spacers of the rear bumper engage the clips on the body securely. - Replace any damaged clips. Page 1083 1. Remove the terminal. 2. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE B: 1. Remove the terminal. 2. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE C: 1. Remove the terminal. 2. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE D: Page 4946 Page 3528 Throttle Cable/Linkage: Adjustments 1. Check cable free play at the throttle linkage. Cable free play (A) should be 10 - 12 mm (3/8 - 1/2 in.). 2. If free play (A) is not within spec (10 - 12 mm, 3/8 - 1/2 in.), loosen the locknut (B), turn the adjusting nut (C) until the free play (A) is as specified, then retighten the locknut. 3. With the cable properly adjusted, check the throttle valve to be sure it opens fully when you push the accelerator pedal to the floor. Also check the throttle valve to be sure it returns to the idle position whenever you release the accelerator pedal. Page 2321 Engine Control Module: Technical Service Bulletins Engine Controls - Replace ECM/PCM For DTC P1607 SOURCE: Honda Service News May 2003 TITLE: Replace ECM/PCM for DTC P1607 APPLIES TO: 2002-03 Civic SERVICE TIP If you've got a DTC P1607 (ECM/PCM internal circuit malfunction) set, you need to replace the ECM/PCM. These units may have defective printed circuit boards. Page 892 12. Pull the vertical carriage lever toward you while you position the tracer on the right edge of the original key at its head, using the clamp carriage lever. Let the cutter bit cut into the key blank, then stop. Gently twist the lever clockwise to lock the vertical carriage at this height. Do not overtighten the lever. 13. Use the clamp carriage lever and the tracer to follow the contours of the original key. (The cutter bit cuts the same contours into the key blank.) Working from right to left, follow the right edge of the original key from head to tip, then the left edge of the key from tip to head. Turn off the cutter motor. 14. Reposition the tracer on the right edge of the original key at its head, using the clamp carriage lever. Turn on the cutter motor. Retrace the key from head to tip, then from tip to head. (This retracing cleans up the cuts on the key.) Turn off the cutter motor. 15. Release the vertical carriage lever. Open the jaw and remove only the new key. Make sure the jaw is free of any metal shavings or debris, then turn the new key over and slide the key with its blank side up into the jaw up to the key stop. Close the jaw to lock the key into place. 16. Turn on the cutter motor, and repeat steps 12 thru 14 to cut both edges of the other side of the key. 17. When you are finished making the required cuts, turn off the cutter motor, and release the vertical carriage lever. Open the jaws, and remove the keys. 18. Use a wire brush to smooth the cut surfaces on the new key. 19. Make sure the key works in the ignition switch and all the locks. If the key does not work, recut the key, and try it again. 20. Depending on the type of key blank you have used, do this: ^ If you have used a Honda key blank, add the transponder code of the new key to the immobilizer system with the Honda Diagnostic System (HDS). ^ If you have used a T-5 programmable key blank ("T-5" stamped on the shank), code the key's transponder with the Ilco Immobilizer Key Code Duplicator (see S/B 99-053, Ilco Immobilizer key Code Duplicator). Cutting Procedure - By Code 1. Press the ON/OFF button in the middle of the setting unit keypad. (This powers up the keypad.) 2. Turn the clamp unit lock lever to the left to release the clamp unit, and slide it to the right until the bottom left side is flush with the base edge. Turn the lever to the right to lock the clamp unit in place. Loosen the lateral and spring tension adjustment knobs on the clamp carriage. Page 3799 Shift Interlock Switch: Service and Repair Park Pin Switch Replacement 1. Remove the center console panel and center console. 2. Remove the screws (A), then remove the shift lever knob (B) 3. Remove the A/T gear position indicator panel light (c) from the A/T gear position indicator panel. 4. Remove the A/T gear position indicator panel and panel bracket as an assembly (D). 5. Disconnect the park pin switch connector (4P) (E), and remove it from the shift lever bracket base (F). 6. Remove the shift lock release (G) and spring (H). 7. Open the lock tabs (A) on the shift lever bracket base, then remove the park pin switch (B). 8. Install the new park pin switch. 9. Install the removed parts in the reverse order of removal. Page 7825 3. Use the clamp carriage lever to position the clamp unit so the tracer is directly over the flat surface of the code device, just ahead of the cam blades. 4. Pull the vertical carriage lever toward you until the tracer just touches the flat surface ahead of the cam blades. Watch the arrows on the keypad: ^ If the double-headed arrow in the middle of the keypad lights green, the tracer and cutter bit are properly aligned. ^ If the arrow on the left of the keypad lights red, the cutter bit is not touching the jaw. Turn the micrometric ring nut above the tracer to the left until the double-headed arrow lights green. ^ If the vertical arrow on the right of the keypad lights red, the tracer is not touching the jaw. Turn the micrometric ring nut above the tracer to the right until the double-headed arrow lights green. *5. Turn the micrometric ring nut to the right five clicks so the cutter bit is slightly higher than the tracer. The arrow on the left should light red. Raise the vertical carriage. NOTE: Setting the tracer five clicks lower than the cutter bit at this point has the effect of making the cutter bit cut the duplicated key a little shallower. This will protect the locking jaws from being damaged.* 6. Optional: Loosen the set screw, and adjust the hand rest to a comfortable position. Tighten the screw. 7. Pull the clamp carriage lever toward you until the clamp carriage clicks into its end-of-run position. 8. Clean any metal shavings or debris out of the center jaw. (A soft-bristle toothbrush is ideal for this purpose.) Then open the jaws with the jaws knob, and slide the key blank with its flat side down into the jaw up to the key stop. Close the jaw with the jaws knob to lock the key blank into place. Visually inspect the key for proper alignment in the jaw. 9. Set and lock the cam sets on the code device. ^ Starting with the left cam set, make sure the lock pin is pulled all the way out. (This releases the cams.) Locations Cruise Control Module: Locations Cruise Control Component Location Index Page 272 Engine Control Module: Locations Multiplex Control System Component Location Index Page 5746 8. Put the splice connector in the proper size slot in the Crimper Tool, slide it to one end (where the flare begins), and close the crimper handles far enough to hold it in place. To release the ratchet mechanism at any point after the first click, squeeze the handles slightly and push the release lever, then let the handles open. 9. Insert one of the bare wires into the splice connector end that is in the crimper jaws. Push the wire all the way into the splice connector, and squeeze the crimper handles. Keep squeezing until the jaws touch, and hold it at that position until the ratchet clicks again. 10. Crimp the other wire in the same way into the other end of the splice connector. 11. After crimping, gently pull on the wires in the opposite directions to make sure they are secure in the connector. 12. Separate the other wires in the harness from the repaired wire(s), and shield them with nonflammable material. Recall - Ignition/Shift Interlock Defect Technical Service Bulletin # 10-059 Date: 101001 Recall - Ignition/Shift Interlock Defect 10-059 October 1, 2010 Applies To: See VEHICLES AFFECTED Safety Recall: Accord, Civic, and Element Ignition Switch Key Interlock BACKGROUND Under certain conditions, the interlock lever of the ignition switch may unexpectedly deform. The interlock ensures the transmission is in Park before the ignition key can be removed. Interlock failure may allow the ignition key to be removed when the shift lever is not in Park. If the driver fails to engage the parking brake, the vehicle could roll away, increasing the risk of a crash. VEHICLES AFFECTED Not all vehicles within the VIN ranges are affected by this recall. Before beginning work on a vehicle, verify its eligibility by checking at least one of these items: ^ The customer has a notification letter. Page 2616 119. Knock Sensor (except GX) Page 4572 Fluid Line/Hose: Service and Repair ATF Cooler Hoses Replacement 1. Connect the ATF cooler inlet hose (A) to the cooler inlet line (B) with the dot (C) on the hose facing the dipstick (D). 2. Connect the cooler hoses to the line, ATF filter (E), and ATF cooler, and secure them with the clips (F) as shown. 3. Install the cooler hose clamps on the white line on the cooler inlet hoses. 4. Install the radiator hose/ATF cooler hose clamp. Page 607 Fuel Gauge Sender: Testing and Inspection Fuel Gauge Sending Unit Test Special Tools Required Fuel sender wrench 07XAA-001010A NOTE: For the fuel gauge system circuit diagram, refer to the Gauges Circuit Diagram. 1. Check the No.10 METER (7.5A) fuse in the under-dash fuse/relay box before testing. 2. Do the gauge drive circuit check. - If the fuel gauge needle sweeps from minimum to maximum position and then returns to the minimum position, the gauge is OK. Go to step 3. - If the fuel gauge needle does not sweep from minimum to maximum position and then return to the minimum position, replace the gauge assembly and retest. 3. Turn the ignition switch OFF. 4. Remove the rear seat cushion. 5. Remove the access panel from the floor. 6. Disconnect the fuel pump 5P connector. 7. Measure voltage between fuel pump 5P connector terminals No.1 and No.2 with the ignition switch ON (II). There should be battery voltage. - If the voltage is OK, go to step 7. - If the voltage is not as specified, check for: a short in the YEL/BLK wire to ground. - an open in the YEL/BLK or BLK wire. - poor ground (G551). 8. Turn the ignition switch OFF. Remove the No.9 BACK UP (10A) fuse from the under-hood fuse/relay box for at least 10 seconds, then reinstall it. Page 6853 WARRANTY CLAIM INFORMATION Out of warranty: Any repairs to the SRS system for problems other than the 15-1, 15-2, and 15-3 DTCs that are done 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. INSPECTION PROCEDURE NOTE: ^ When you check for SRS DTCs with the HDS, codes other than 15-1, 15-2, and 15-3 are not covered by this warranty extension bulletin. ^ If the vehicle is covered by warranty, repair it using the normal warranty repair procedures. If the vehicle's warranty is expired, give your customer an estimate for the cost of the repair. Do the appropriate inspection, based on the DTC. SRS DTC 15-1 Clear the DTC with the HDS. ^ If DTC 15-1 does not set again, go to REPAIR PROCEDURE A: OPDS UNIT REPLACEMENT. ^ If DTC 15-1 sets again, continue with normal troubleshooting. ^ If the OPDS unit causes DTC 15-1 to set repeatedly, yet passes the other troubleshooting steps, go to REPAIR PROCEDURE A: OPDS UNIT REPLACEMENT. SRS DTC 15-2 1. Inspect the connections and the wiring in the side airbag cutoff indicator circuit. ^ If all the connections and the wiring are OK, go to step 2. ^ If any of the connections or the wiring are faulty, repair the circuit, then go to step 2. 2. Clear the DTC with the HDS. ^ If DTC 15-2 does not set again, go to REPAIR PROCEDURE A: OPDS UNIT REPLACEMENT. ^ If DTC 15-2 sets again, continue with normal troubleshooting. ^ If the OPDS unit causes DTC 15-2 to set repeatedly, yet passes the other troubleshooting steps, go to REPAIR PROCEDURE A: OPDS UNIT REPLACEMENT. SRS DTC 15-3 1. Clear the DTC with the HDS. ^ If DTC 15-3 does not set again, go to step 2. ^ If DTC 15-3 sets again, continue with normal troubleshooting. 2. Ask your customer if electrical devices such as a laptop computer or a fluorescent map light are ever used near the front passenger's seat-back. (Some electrical devices that plug into the vehicle's accessory power socket, especially those using a power inverter/converter, can interfere with the seat-back sensors and cause SRS DTC 15-3 to set.) ^ If your customer uses any of these devices operate the device near the front passenger's seat-back. If DTC 15-3 sets again, clear it, then return the vehicle to the customer. Advise the customer to avoid using the device near the front passenger's seat-back. ^ If your customer does not use any of these devices and DTC 15-3 does not set again, go to REPAIR PROCEDURE A: OPDS UNIT REPLACEMENT. REPAIR PROCEDURE A: OPDS UNIT REPLACEMENT Page 4855 3. Remove and discard the shift fork. 4. Apply vinyl tape to the mainshaft splines to protect the seal, then remove the mainshaft and shift forks as an assembly from the clutch housing. 5. Disassemble the countershaft assembly; see page 13-32 (13-45 for Hybrid) of the service manual. Page 2737 7. Remove the four screws that hold the two fuses, and remove the fuses. 8. Release the tab that holds the ELD, and pull up on the ELD to remove it. 9. Remove the bus bar from the ELD, and insert the bar into the new ELD. 10. Install the new ELD and bus bar into the fuse/relay box. 11. Reinstall the two fuses. 12. Reinstall the 3P ELD connector and the lower fusel relay box cover. 13. Reinstall the fuse/relay box onto its holder. CR-V only: Reinstall the wire harness clip onto the holder. 14. Reinstall the fuse/relay box cover. 15. Reconnect the negative battery cable. 16. Do the idle learn procedure: ^ Make sure all electrical items (A/C, audio unit, defogger, lights, etc.) are off. Page 3393 Air Filter Element: Service and Repair Air Cleaner Element Replacement 1. Open the air cleaner housing cover (A). 2. Remove the air cleaner (B) from the air cleaner housing (C). 3. Install in the reverse order of removal. Page 5362 Splices Components Ground - "G" Connector Views 30. Blower Motor Page 6425 8. Remove the flange bolt (A) and wheel sensor (B) from the knuckle. Do not disconnect the wheel sensor connector. 9. Remove the flange nut (A) while holding the joint pin (B) with a hex wrench (C), and disconnect the stabilizer link (D) from the lower arm (E). 10. Remove the lock pin (A) from the lower arm ball joint, and remove the castle nut (B). NOTE: During installation, insert the lock pin into the ball joint pin in the range of 180 degrees or below from the inside of the vehicle. Insert the lock pin from the inside to the outside of the vehicle. 11. Disconnect the lower arm from the knuckle using the special too. Page 6373 1. Install all the parts except the self-locking nut onto the damper unit by referring to the Exploded View. Align the bottom of the spring (A) and the stepped part of the lower spring seat (B) as illustrated. The hole in the upper spring seat and the arrow on the damper mounting base must point toward the knuckle mounting area. 2. Install the damper assembly on a commercially available strut spring compressor (C). 3. Compress the damper spring with the strut spring compressor. 4. Install a new self-locking nut (A) on the damper shaft. 5. Hold the damper shaft with a hex wrench (B), and tighten the self-locking nut to the specified torque. Installation 1. Lower the lower arm, and position the damper assembly in the body. 2. Loosely install the flange nuts (A) onto the top of the damper. Page 1511 Under-dash Fuse/Relay Box (2-door) Page 3216 2. Remove the terminal (same procedure for male and female). 3. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE E: 1. Remove the secondary locks. 2. Remove the terminal (same procedure for male and female). 3. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE F: Page 3126 Wires Engine Won't Start - Check Alternator Bolts Alternator: Technical Service Bulletins Engine Won't Start - Check Alternator Bolts SOURCE: Honda Service News August 2004 TITLE: Engine Won't Start? Check for Loose Alternator Bolts APPLIES TO: 2001-04 Civic SERVICE TIP: Got a 2001-04 Civic in your shop with any or all of these symptoms? - The engine cranks but it won't start. - The MIL comes on. - The immobilizer indicator blinks while the engine cranks. - The HDS can't communicate with the ECM/PCM. Check for loose alternator bolts. If these bolts are loose for any reason such as the alternator was R&R;'ed or an accessory A/C was installed on a DX model at the dealership, the alternator can overcharge and fry the ECM/PCM. If the alternator bolts are loose, tighten them, and try restarting the engine. If the engine still won't start, then check the ECM/PCM connector for battery voltage and ground. If you're reading battery voltage and ground at the connector, then replace the ECM/PCM. Keep in mind, though, any ECM/PCM damage that's caused by loose alternator bolts from A/C installation or body repair isn't covered by warranty. Page 509 108. Middle Of Floor Page 9104 2. Insert the terminal tool into the female terminal, and then remove the terminal tool. NOTE: Make sure you do not select a terminal tool that is larger than the mating male terminal because it would spread the female terminal and cause a loose fit. 3. Compare the drag to the other terminals in the connector. If the drag is less, replace the terminal with a replacement terminal from the appropriate terminal repair kit. Page 5849 234. Under-dash Fuse/Relay Box Part 2 Blower (Heater) Motor Gets Hot and Blows A Fuse Blower Motor: 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. Driver's Air Bag - Replace Torx Bolts Properly Air Bag: All 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. 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 8444 NOTE: For color information, refer to PIB A05-0005, Child Seat Anchor Buttons. Click PARTS, then click PARTS LIBRARY, then click Parts Bulletins. Select Child Seat Anchor Buttons from the list. (Each part contains fabric washers, button posts, and back portions.) WARRANTY CLAIM INFORMATION In warranty: The normal warranty applies. Failed Part: 82123-SDA-305ZA Defect Code: 07801 Symptom Code: 03220 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. Remove the rear seat-back cover just enough to allow access to the opening where the button will be attached: ^ Refer to Section 20, Rear Seat-back Cover Replacement, in the appropriate service manual, or ^ Online, enter keyword SEAT COVER, and select the appropriate Rear Seat-back Cover Replacement procedure from the list. 2. Select the appropriate button from the Child Seat Anchor Service Set. 3. Attach the button to the rear seat-back cover: ^ Place a fabric washer over the button post. ^ Insert the post through the opening in the cover. ^ Snap the back portion onto the post. Page 4945 13. Remove the solenoid cover, and make sure the solenoid plunger groove is installed in the fork on the lever. ^ If needed, correct the position of the solenoid plunger, then go to step 14. ^ If the solenoid plunger is correctly installed, there is an electrical problem with the key interlock system; refer to the Automatic Transmission section of the appropriate service manual for troubleshooting information. Once the key interlock is working normally, go to step 14. 14. Install the solenoid cover. 15. Reinstall the steering column covers. 16. Center-punch a completion mark above the seventh character of the engine compartment VIN. Disclaimer Diagram Information and Instructions Shift Indicator: Diagram Information and Instructions Terminal Numbering System Terminal Numbering System Connector terminals are numbered according to the cavities they're in. The cavities are numbered starting from the upper left, looking at the male terminals from the terminal side or looking at the female terminals from the wire side. Both views are in the same direction so the numbers are the same. All actual cavities are numbered, even if they have no wire terminals in them. NOTE: Data Link Connector (DLC) terminals are numbered according 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 below is #6. Specifications Piston Ring: Specifications Piston Ring groove width Top Standard or New .................................................................................................................................... 1.020 - 1.030 mm (0.0402 - 0.0406 inch) Service Limit ............................................................................................. .......................................................................... 1.05 mm (0.041 inch) Second Standard or New .................................................................................................................................... 1.220 - 1.230 mm (0.0481 - 0.0484 inch) Service Limit ............................................................................................. .......................................................................... 1.25 mm (0.049 inch) Oil Standard or New .................................................................................................................................... 2.005 - 2.020 mm (0.0789 - 0.0795 inch) Service Limit ............................................................................................. .......................................................................... 2.05 mm (0.081 inch) Piston ring Ring-to-groove clearance Top Standard or New .................................................................................................................................... 0.035 - 0.060 mm (0.0014 - 0.0024 inch) Service Limit ............................................................................................. .......................................................................... 0.13 mm (0.005 inch) Second Standard or New .................................................................................................................................... 0.030 - 0.055 mm (0.0012 - 0.0022 inch) Service Limit ............................................................................................. .......................................................................... 0.13 mm (0.005 inch) Ring end gap Top Standard or New ............................................................................................................................................ 0.15 0.30 mm (0.006 - 0.012 inch) Service Limit ......................................................................................... .............................................................................. 0.60 mm (0.024 inch) Second Standard or New ............................................................................................................................................ 0.30 0.45 mm (0.012 - 0.018 inch) Service Limit ......................................................................................... .............................................................................. 0.60 mm (0.024 inch) Oil Standard or New ............................................................................................................................................ 0.20 0.70 mm (0.008 - 0.028 inch) Service Limit ......................................................................................... .............................................................................. 0.80 mm (0.031 inch) Diagram Information and Instructions Dome Lamp: Diagram Information and Instructions Terminal Numbering System Terminal Numbering System Connector terminals are numbered according to the cavities they're in. The cavities are numbered starting from the upper left, looking at the male terminals from the terminal side or looking at the female terminals from the wire side. Both views are in the same direction so the numbers are the same. All actual cavities are numbered, even if they have no wire terminals in them. NOTE: Data Link Connector (DLC) terminals are numbered according 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 below is #6. Page 2527 - 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. Troubleshooting Tests 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 test 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 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. 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 Drop Page 735 163. Under Left Side Of Floor (except GX) Page 9480 Wires Page 8843 9. Install a 2 Ohms resistor between fuel pump 5P connector terminals No.1 and No.2, then turn the ignition switch ON (II). 10. Check that the pointer of the fuel gauge indicates "F". - If the pointer of the fuel gauge does not indicates "F", replace the gauge. - If the gauge is OK, inspect the fuel gauge sending unit. NOTE: The pointer of the fuel gauge returns to the bottom on the gauge dial when the ignition switch is OFF, regardless of the fuel level. 11. Relieve the fuel pressure. 12. Remove the fuel fill cap. 13. Disconnect the quick-connect fittings from the fuel pump. 14. Using the special tool, loosen the fuel tank unit locknut (A). Page 3972 Pressure Regulating Solenoid: Testing and Inspection A/T Clutch Pressure Control Solenoid Valves A and B Test 1. Disconnect the connectors from the A/T clutch pressure control solenoid valves A and B. 2. Measure the resistance of the A/T clutch pressure control solenoid valves A and B between the No. 1 and No. 2 terminals of each connector. STANDARD: About 5.0 Ohms 3. If the resistance of either A/T clutch pressure control solenoid is out of standard, replace the A/T clutch pressure control solenoid valves A and B. 4. Connect the No. 1 terminal of the A/T clutch pressure control solenoid valve A (and B) to the battery positive terminal, and connect the No. 2 terminal to the battery negative terminal. A clicking sound should be heard. 5. If no sound is heard, remove the A/T clutch pressure control solenoid valves A and B. 6. Check the fluid passage of the A/T clutch pressure control solenoid valve for dust and dirt. 7. Connect the No. 1 terminal of the A/T clutch pressure control solenoid valves A and B to the battery positive terminal, and connect the No. 2 terminal to the battery negative terminal. Make sure the A/T clutch pressure control solenoid valves A and B move. 8. Disconnect one of the battery terminal and check valve movement. NOTE: You can see valve movement through the fluid passage in the mounting surface of the A/T clutch pressure control solenoid valves A and B body (c). 9. If either valve binds or moves sluggishly, or if the A/T clutch pressure control solenoid does not operate, replace the A/T clutch pressure control solenoid valves A and B. Page 5260 2. Cut off the wire about an inch back from where it connects to the damaged or faulty terminal, then strip about half of the insulation off that piece. This will be used to size the wire end of the replacement pigtail terminal. NOTE: If you are not sure of the wire size, start with a large enough hole on the stripper that will not nick or cut off any strands of wires. 3. Select a pigtail terminal that matches the original wire at both ends (same kind of terminal and same diameter bare wire). 4. Select the smallest splice connector (yellow, pink, or blue) that will fit onto the stripped end of the original wire. 5. Insert the pigtail terminal into the connector cavity; push it in until it locks in place. 6. Lay the pigtail and the original wire side-by-side, and cut off both ends at once. If you are making more than one splice, do not cut each pigtail at the same location; the resulting "lump" of splice connectors would interfere with rewrapping the harness. Instead, cut the first pigtail close enough to the terminal so you will have room to make each remaining cut about 20 mm (3/4 inch) farther down on the next pigtail. 7. If you are using a yellow splice connector, strip about 6 mm (1/4 inch) of insulation off the ends of both wires. If you are using a pink or blue splice connector, strip off about 8 mm (5/16 inch) of insulation. Page 5094 Shift Solenoid: Service and Repair Shift Solenoid Valves A and B Replacement NOTE: Shift solenoid valves A and B must be removed/ replaced as an assembly. 1. Remove the harness clamp (c) form the clamp bracket (D). 2. Remove the mounting bolts and the shift solenoid valves A and B. 3. Clean the mounting surface and fluid passage. 4. Install a new shift solenoid valves A and B with a new filter/gasket (E), and install the harness clamp on the clamp bracket. 5. Check the connector for rust, dirt, or oil, then reconnect the connector securely. Page 6612 Add the recommended refrigerant oil in the amount listed if you replace any of the following parts. - To avoid contamination, do not return the oil to the container once dispensed, and never mix it with other refrigerant oils. - Immediately after using the oil, replace the cap on the container, and seal it to avoid moisture absorption. - Do not spill the refrigerant oil on the vehicle; it may damage the paint; if it gets on the paint, wash it off immediately. Page 1509 Under-dash Fuse/Relay Box Page 3323 (Except GX) Page 6509 PGM-F1 Main Relay 1, 2 Type 1, 2 Check for continuity between the terminals. - There should be continuity between the No.1 and No.2 terminals when power and ground are connected to the No.3 and No.4 terminals. - There should be no continuity between the No.1 and No.2 terminals when power is disconnected. Normally-open type B: Rear Window Defogger Relay Page 106 Air Conditioning Component Location Index Page 1230 DIAGNOSTIC WORKSHEET REPAIR PROCEDURE A Page 783 12. Check for continuity between PSP switch 2P connector terminal No.2 and body ground. Is there continuity? YES - Repair open in the wire between the PSP switch and ECM/PCM (E16). NO - Repair open in the wire between the PSP switch and G201. 13. Turn the ignition switch OFF. 14. Disconnect the PSP switch 2P connector. 15. Turn the ignition switch ON (II). 16. Measure voltage between ECM/PCM connector terminals A24 and E16. Is there battery voltage? YES - Replace the PSP switch. NO - Go to step 17. 17. Turn the ignition switch OFF. 18. Disconnect ECM/PCM connector E (31P). 19. Check for continuity between body ground and ECM/PCM connector terminal E16. Is there continuity? YES - Repair short in the wire between ECM/PCM (E16) and the PSP switch. NO - Update the ECM/PCM if it does not have the latest software, or substitute a known-good ECM/PCM, then recheck. If the Recall - Ignition/Shift Interlock Defect Technical Service Bulletin # 10-059 Date: 101001 Recall - Ignition/Shift Interlock Defect 10-059 October 1, 2010 Applies To: See VEHICLES AFFECTED Safety Recall: Accord, Civic, and Element Ignition Switch Key Interlock BACKGROUND Under certain conditions, the interlock lever of the ignition switch may unexpectedly deform. The interlock ensures the transmission is in Park before the ignition key can be removed. Interlock failure may allow the ignition key to be removed when the shift lever is not in Park. If the driver fails to engage the parking brake, the vehicle could roll away, increasing the risk of a crash. VEHICLES AFFECTED Not all vehicles within the VIN ranges are affected by this recall. Before beginning work on a vehicle, verify its eligibility by checking at least one of these items: ^ The customer has a notification letter. Primary Oxygen Sensor Oxygen Sensor: Description and Operation Primary Oxygen Sensor Primary Heated Oxygen Sensor (Primary HO2S) (D17A1, D17A2 engines) The primary HO2S detects the oxygen content in the exhaust gas and sends signals to the ECM/PCM which varies the duration of fuel injection accordingly. To stabilize its output, the sensor has an internal heater. The primary HO2S is installed in the three way catalytic converter (TWC) (D17A1 engine) or in the exhaust manifold (D17A2 engine). By controlling the air fuel ratio with primary HO2S and secondary HO2S, the deterioration of the primary HO2S can be evaluated by its feedback period. When the feedback period exceeds a certain value during stable driving conditions, the sensor is considered deteriorated and the ECM/PCM sets a DTC. Page 5047 Page 5115 Terminals - "T" Shielding Switches Fuses Page 151 PGM-F1 Main Relay 1, 2 Type 1, 2 Check for continuity between the terminals. - There should be continuity between the No.1 and No.2 terminals when power and ground are connected to the No.3 and No.4 terminals. - There should be no continuity between the No.1 and No.2 terminals when power is disconnected. Normally-open type B: Rear Window Defogger Relay Page 8655 Rear Door Weatherstrip: Service and Repair Rear Door Weatherstrip Replacement Rear Door Weatherstrip Replacement 4-door NOTE: - Take care not to scratch the door. - Use a clip remover to remove the clips. 1. At the B-pillar, remove the door checker mounting bolt (A). 2. Detach the clips (B), then remove the door weatherstrip (C). 3. Install the weatherstrip in the reverse order of removal, and note these items: - Replace any damaged clips. - Make sure the weatherstrip is installed in the holder (D) securely. - Apply liquid thread lock to the door checker mounting bolt before in5tallation. - Check for water leaks. - Test-drive and check for wind noise. Page 3223 2. Cut off the wire about an inch back from where it connects to the damaged or faulty terminal, then strip about half of the insulation off that piece. This will be used to size the wire end of the replacement pigtail terminal. NOTE: If you are not sure of the wire size, start with a large enough hole on the stripper that will not nick or cut off any strands of wires. 3. Select a pigtail terminal that matches the original wire at both ends (same kind of terminal and same diameter bare wire). 4. Select the smallest splice connector (yellow, pink, or blue) that will fit onto the stripped end of the original wire. 5. Insert the pigtail terminal into the connector cavity; push it in until it locks in place. 6. Lay the pigtail and the original wire side-by-side, and cut off both ends at once. If you are making more than one splice, do not cut each pigtail at the same location; the resulting "lump" of splice connectors would interfere with rewrapping the harness. Instead, cut the first pigtail close enough to the terminal so you will have room to make each remaining cut about 20 mm (3/4 inch) farther down on the next pigtail. 7. If you are using a yellow splice connector, strip about 6 mm (1/4 inch) of insulation off the ends of both wires. If you are using a pink or blue splice connector, strip off about 8 mm (5/16 inch) of insulation. Page 9151 2. Cut off the wire about an inch back from where it connects to the damaged or faulty terminal, then strip about half of the insulation off that piece. This will be used to size the wire end of the replacement pigtail terminal. NOTE: If you are not sure of the wire size, start with a large enough hole on the stripper that will not nick or cut off any strands of wires. 3. Select a pigtail terminal that matches the original wire at both ends (same kind of terminal and same diameter bare wire). 4. Select the smallest splice connector (yellow, pink, or blue) that will fit onto the stripped end of the original wire. 5. Insert the pigtail terminal into the connector cavity; push it in until it locks in place. 6. Lay the pigtail and the original wire side-by-side, and cut off both ends at once. If you are making more than one splice, do not cut each pigtail at the same location; the resulting "lump" of splice connectors would interfere with rewrapping the harness. Instead, cut the first pigtail close enough to the terminal so you will have room to make each remaining cut about 20 mm (3/4 inch) farther down on the next pigtail. 7. If you are using a yellow splice connector, strip about 6 mm (1/4 inch) of insulation off the ends of both wires. If you are using a pink or blue splice connector, strip off about 8 mm (5/16 inch) of insulation. Page 9180 Connectors - "C" Page 6202 65. PSP Switch Service and Repair Arm Rest: Service and Repair Front Seat Armrest Replacement For Some Models NOTE: Take care not to tear the seams or damage the seat covers. 1. Unzip the armrest cover (A), and pull back the armrest cover. 2. Remove the nut, the wave washer (B), and the washer (C), then remove the armrest (D). If necessary, remove the bushings (E) from the armrest 3. Remove the bolts, then remove the armrest bracket(A). 4. Install the armrest in the reverse order of removal. Page 6459 Air Door Actuator / Motor: Service and Repair Recirculation Control Motor Recirculation Control Motor Replacement 1. Remove the ECM/PCM. 2. Remove the bolt and the bracket (A). Disconnect the 7P connector (B) and the harness clip (C) from the recirculation control motor (D). Remove the self-tapping screws and the recirculation control motor from the blower unit. 3. Install the motor in the reverse order of removal. Make sure the pin on the motor is properly engaged with the linkage. After installation, make sure the motor runs smoothly. Page 9347 Circuit Schematics Each schematic represents one circuit. A circuit's wires and components are arranged to show current flow from power at the top of the diagram 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 Page 347 233. SRS Unit Locations Cruise Control Switch: Locations Cruise Control Component Location Index Electrical - DTC P1298 Stored in ECM/PCM Electric Load Sensor: All Technical Service Bulletins Electrical - DTC P1298 Stored in ECM/PCM 05-006 May 6, 2005 Updated information is noted by asterisks. Applies To: 2001-05 Civic - ALL *2002-04 CR-V - ALL* DTC P1298 Is Stored in the ECM/PCM (Supersedes 05-006, dated February 25, 2005, to change the CR-V model-year range) SYMPTOM DTC P1298 (electrical load detector (ELD) circuit high voltage) is stored in the ECM/PCM. PROBABLE CAUSE The electronic load detector (ELD) has a faulty solder joint. CORRECTIVE ACTION Replace the ELD. NOTE: Previously, if an ELD required replacement, you had to replace the under-hood fuse/relay box. To reduce repair costs, replacement ELDs are now available. PARTS INFORMATION Electronic Load Detector: P/N 38255-S5A-003, H/C 7987571 WARRANTY CLAIM INFORMATION In warranty: The normal warranty applies. Operation Number: 121195 Flat Rate Time: 0.4 hour Failed Part: Civic P/N 38250-S5A-A03 H/C 7472277 CR-V P/N 38250-S9A-A01 H/C 6890594 Defect Code: 06402 Symptom Code: 01201 Template ID: 05-006A 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. Locations Power Door Lock Switch: Locations Doors - Component Location Index 2-door Page 6833 PARTS INFORMATION TOOL INFORMATION Page 8023 Disclaimer Cutting Procedure - By Copying 1. Press the ON/OFF button in the middle of the setting unit keypad. (This powers up the keypad.) 2. Turn the clamp unit lock lever to the left to release the clamp unit, and slide it all the way to the left until it stops. Turn the lever to the right to lock the clamp unit in place. 3. Use the clamp carriage lever to position the clamp unit so the tracer and cutter bit are centered directly over the base of the center and right jaws. 4. Pull the vertical carriage lever toward you until the tracer and the cutter bit just touch the base of each fixed jaw. Watch the arrows on the keypad: ^ If the double-headed arrow in the middle of the keypad lights green, the tracer and cutter bit are properly aligned. ^ If the arrow on the left of the keypad lights red, the cutter bit is not touching the fixed jaw. Turn the micrometric ring nut above the tracer to the left until the double-headed arrow lights green. ^ If the arrow on the right of the keypad lights red, the tracer is not touching the fixed jaw. Turn the micrometric ring nut above the tracer to the right until the double-headed arrow lights green. *5. Turn the micrometric ring nut to the right three clicks so the cutter bit is slightly higher than the tracer. The arrow on the left should light red. Raise the vertical carriage. NOTE: Setting the tracer three clicks lower than the cutter bit has the effect of making the cutter bit cut the duplicated key a little shallower. This will protect the locking jaws from being damaged.* 6. Optional: Loosen the setscrew, and adjust the hand rest to a comfortable position. Tighten the screw. 7. Pull the clamp carriage lever toward you until the clamp carriage clicks into its end-of-run position. Tighten both the lateral and spring tension adjustment knobs. 8. Make sure the center and right jaws are free of any metal shavings or debris. (A soft-bristle toothbrush is ideal for this purpose.) Page 1199 1. Remove the screw and passenger's power window switch (A) from the door panel. 2. Disconnect the 5P connector (B) from the switch. 3. Check for continuity between the terminals in each switch position according to the table. 4. If the continuity is not as specified remove the two screws and replace the switch. Locations Keyless Entry Module: Locations Relay And Control Unit Locations - Dashboard 78. Under Middle of Dash (Honda Accessory) Page 74 Relay And Control Unit Locations - Engine Compartment Page 8137 6. Press and hold the green programming button on the side of the control unit until the LED on the instrument panel begins to flash, then release the button. (Steps 6 and 7 must be done within 5 seconds of each other.) 7. Press and release the bottom button on the transmitter. Verify that the LED goes out, the siren chirps twice, and the front sidemarker lights flash twice to confirm that the transmitter's code was accepted by the control unit. 8. Turn the ignition switch to LOCK. Test the transmitter you just programmed. If it doesn't work repeat steps 2 thru 7. 9. If you have another transmitter to program, repeat steps 2 thru 7. Ordering a Transmitter Transmitters can be ordered only by authorized Honda dealers. Order them from American Honda using normal parts ordering procedures. Batteries for the Transmitter The battery number is CR2025. Each transmitter uses one battery. 98-02 Passport With Factory-Installed Security System 1998-02 Passport with factory-installed security system Programming the Transmitter To program the transmitters, use one of these two procedures: ^ Procedure One cancels all learned transmitter codes and adds one new transmitter. None of the previously programmed transmitters will work. Use this programming procedure only if all transmitters were lost or stolen, or if a new control unit has been installed. ^ Procedure Two adds additional transmitters without cancelling any of the previously learned codes. The system will accept up to four transmitters. Procedure One (cancels all codes, adds one new transmitter) 1. Open the driver's door. 2. Turn the ignition switch to the ACC position and then to the LOCK position three times. (This step must be completed within 10 seconds, or the system will not enter the programming mode.) 3. Within 10 seconds, close and open the door two times. 4. Turn the ignition switch to the ACC position and then to the LOCK position five times. Close and open the door. (Complete this process within 10 seconds.) Verify that the power door locks cycle once to confirm that the system is in programming mode. 5. Within 20 seconds, press the "LOCK" button on the transmitter you are programming. Verify that the door locks cycle once. 6. Within 20 seconds, press the "UNLOCK" button on the transmitter. Verify that the door locks cycle once to confirm that the system has accepted the transmitter's code. Procedure Two (adds transmitters) 1. Open the driver's door. 2. Turn the ignition switch to the ACC position and then to the LOCK position three times. (This step must be completed within 10 seconds, or the Page 1734 10. Install the back cover (A), then install the camshaft pulley (B). Page 817 Use the tools from Pin Tool Set. First, check the connector that you are about to repair. - If it has a secondary terminal lock, go to Connectors With a Secondary Lock. A secondary lock, found on most connectors on some models, is an additional locking device on the connector housing as a backup for the primary lock on the terminal. - If the connector does not have a secondary lock, go to Connectors Without a Secondary Lock. Connectors With a Secondary Lock All examples are shown with the connector lock facing up. The illustrations are examples of the secondary terminal locks; however, the connector you are repairing may vary in size. Identify the connector by the type of secondary lock, not by the number of terminal cavities. EXAMPLE A: 1. Release the secondary lock. 2. Remove the terminal. 3. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE B: 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 8520 201. Power Mirror Switch (except DX) Page 6447 66. Under Left Side Of Dash 91. Behind Glove Box Page 8807 110. Left B Pillar (Right Similar) 111. Left C Pillar (Sedan) (Right Similar) Page 4218 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. Circuits must be operating when checking voltage drop. 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. 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 off, 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 Self-Powered Test Light or DVOM 1. Remove the blown fuse and disconnect the battery and load. Page 1409 Coolant: Service and Repair Replacement 1. Start the engine. Set the heater temperature control dial to maximum heat, then turn off the ignition switch. Make sure the engine and radiator are cool to the touch. 2. Make sure you have the anti-theft code for the radio, then write down the frequencies for the radio's preset buttons. 3. Remove the battery. 4. Remove the radiator cap. 5. Loosen the drain plug (A), and drain the coolant. 6. Remove the drain bolt (A) from the rear of the cylinder block. 7. After the coolant has drained, apply liquid gasket to the drain bolt threads, then reinstall the bolt with a new washer and tighten it securely. 8. Tighten the radiator drain plug securely. Exploded Views Alternator Overhaul - Exploded View Page 6678 Air Bag(s) Arming and Disarming: Vehicle Damage Warnings 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. - To prevent damage to the airbag assembly, keep free from any oil, grease, detergent, or water. - Store the removed airbag on a secure, fiat surface away from any high heat source (exceeding 200 °F / 93 °C). Page 2970 Engine Control Module: Service Precautions 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 1032 Skill Level: Repair Technician INSPECTION PROCEDURE 1. Remove the steering column covers. Refer to section 17 of the appropriate service manual. 2. On the lower side of the ignition switch, look at the interlock cylinder cover: ^ If the cover is square, the ignition switch was already replaced with an updated part, and a key interlock repair kit is not needed. Go to step 3. ^ If the cover is round, go to REPAIR PROCEDURE. 3. Reinstall the steering column covers. 4. Center-punch a completion mark above the seventh character of the engine compartment VIN. REPAIR PROCEDURE Page 9461 Under-dash Fuse/Relay Box Page 38 80. Under Middle of Dash Page 4732 3. Remove the hub cap (A), raise the stake (B), and remove the spindle nut (C). 4. Screw two 8 x 1.25 mm bolts (A) into the drum to push it away from the hub. Turn each bolt 2 turns at a time to prevent cocking the drum excessively. 5. Remove the brake drum (A), and remove the hub bearing unit (B) from the spindle. If the brake drum has stuck to the hub bearing unit, pull them out together. Do not tap on the aluminum brake drum. 6. Install the hub bearing unit in the reverse order of removal, and note these items: - Tighten all mounting hardware to the specified torque values. - Before installing the brake drum, clean the mating surface of the hub and the inside of the brake drum. - Use a new spindle nut on reassembly. - Before installing the spindle nut, apply a small amount of engine oil to the seating surface of the nut. After tightening, use a drift to stake the spindle nut shoulder against the spindle. - Use a new hub cap on reassembly. - Before installing the wheel, clean the mating surface of the brake drum and the inside of the wheel. Page 7552 Front Door Window Motor: Diagrams (Sedan Except DX) (Coupe Except DX, HX) (Except DX, HX) Page 700 Crankshaft Position Sensor: Service and Repair CKP Sensor Replacement 1. Remove the grommet (A) from the upper cover, and disconnect the camshaft position (CMP) (top dead center (TDC)) sensor connector (B). 2. Remove the upper cover (C) and lower cover (D). 3. Disconnect the crankshaft position (CKP) sensor connector, then remove the CKP sensor from the oil pump. 4. Install the CKP sensor in reverse order of removal. Page 6069 234. Under-dash Fuse/Relay Box Part 4 Page 3817 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. Below most connector numbers and component names are PHOTO and VIEW numbers. The PHOTO number refers to a photo in the back of the book that shows the connector's location on the car. The VIEW number refers to an illustration in the back of the book that shows the connector terminals, wire colors, connector cavity numbers, and other details. The connector cavity numbering sequence begins at the top left corner of the connector as seen from either of the viewpoints shown on diagram [8] . Except for the DLC (data link 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 C554, for example, means those terminals join in cavity 2 of connector C554. Power Distribution Schematics Power Distribution Schematics Page 9522 Low Beam Relay: Testing and Inspection Power Relay Test Use this chart to identify the type of relay, then do the test listed for it. NOTE: See the turn signal/hazard relay input test. Normally-open type A: Page 67 Electronic Brake Control Module: Description and Operation ABS Control Unit Main Control The ABS control unit detects the wheel speed based on the wheel sensor signal it received, then it calculates the vehicle speed based on the detected wheel speed. The control unit detects the vehicle speed during deceleration based on the rate of deceleration. The ABS control unit calculates the slip rate of each wheel and transmits the control signal to the modulator unit solenoid valve when the slip rate is high. The pressure reduction control has three modes: pressure reducing, pressure retaining, and pressure intensifying. Self-diagnosis Function 1. The ABS control unit is equipped with a main CPU and a sub-CPU. Each CPU checks the other for problems. 2. The CPUs check the circuit of the system. 3. The ABS control unit turns on the ABS indicator when the unit detects a problem and the unit stops the system. 4. The self-diagnosis can be classified into these two categories: ^ Initial diagnosis ^ Regular diagnosis On-board Diagnosis Function The ABS can be diagnosed with the Honda PGM Tester. The ALB Checker cannot be used with this system. For air bleeding and checking wheel sensor signals, use the Honda PGM Tester. See the Honda PGM Tester user's manual for specific operating instructions. Page 3500 94. Behind Glove Box (except GX) Page 2320 DTC U0100 thru U1288 Disclaimer Page 2814 Splices Components Ground - "G" Page 810 - Remove clips carefully; don't damage their locks (A). - Slip pliers (A) under the clip base and through the hole at an angle, then squeeze the expansion tabs to release the clip. - After installing harness clips, make sure the harness doesn't interfere with any moving parts. - Keep wire harnesses away from exhaust pipes and other hot parts, from sharp edges of brackets and holes, and from exposed screws and bolts. - Seat grommets in their grooves properly (A). Do not leave grommets distorted (B). Testing and Repairs - Do not use wires or harnesses with broken insulation. Replace them or repair them by wrapping the break with electrical tape. - After installing parts, make sure that no wires are pinched under them. - When using electrical test equipment, follow the manufacturer's instructions and those described. - If possible, insert the probe of the tester from the wire side (except waterproof connector). - Use back probe adaptor 07TAZ-001020A. - Refer to the instructions in the Honda Terminal Kit for identification and replacement of connector terminals. Five-Step Troubleshooting Five-Step Troubleshooting 1. Verify The Complaint 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 4677 4. Select the appropriate pair of fittings, and attach them to the radiator, to the hoses, or to the banjo bolts for flow through the ATF cooler cleaner. 5. Connect the red hose to the cooler outlet line (the line that normally goes to the external filter on the transmission). 6. Connect the blue hose to the cooler inlet line. 7. Connect a shop air hose (regulated to 100 to 125 psi) 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. 8. Flip the MOTOR toggle switch to ON; the green indicator above the toggle switch comes on. 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. Always open the valve slowly. At the end of the 5 minutes cleaning period, leave the air purge valve open. NOTE: While the pump is running with the air purge valve open, it is normal to see vapor coming from the filler/breather tube vents. 9. With the air purge valve open, flip the MOTOR toggle switch to OFF; the green indicator goes off. Leave the air purge valve open for at least 15 seconds to purge the lines and hoses of residual ATF, then close the valve. 10. Disconnect the red and blue hoses from the ATF cooler. Now connect the red hose to the cooler inlet line. 11. Now connect the blue hose to the cooler outlet line. 12. 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. Always open the valve slowly. At the end of the 5 minutes cleaning period, leave the air purge valve open. NOTE: While the pump is running with the air purge valve open, it is normal to see vapor coming from the filler/breather tube vents. 13. With the air purge valve open, flip the MOTOR toggle switch to OFF. Leave the air purge valve open for at least 15 seconds to purge the lines and hoses of residual ATF, then close the valve. 14. Disconnect the red and blue hoses from the ATF cooler lines. 15. Connect the red and blue hoses to each other. 16. Disconnect the shop air from the air purge valve. Disconnect and stow the coupler if used. 17. Disconnect and stow the fittings from the ATF cooler inlet and outlet lines. 18. Unplug the cooler cleaner from the 110 V outlet. Tool Maintenance Locations EVAP System - Component Location Index Page 751 Knock Sensor: Service and Repair Replacement 1. Remove the oil filter with the special oil filter wrench. 2. Disconnect the knock sensor connector, then remove the knock sensor. 3. Install the knock sensor and oil filter. Page 2654 Spark Plug: Application and ID NGK ..................................................................................................................................................... ............................................................... PZFR6F-11 DENSO ................................................................................................................................................ ......................................................... PKJ20CR-M11 Gap ...................................................................................................................................................... ................................. 1.0 -1.1 mm (0.039 - 0.043 in) Torque ................................................................................................................................................. ...................................................... 18 N.m (13 lb.ft) Page 9075 Splices Components Ground - "G" Page 2264 Thermostat: Pressure, Vacuum and Temperature Specifications Thermostat Opening temperature Begins to open ..................................................................................................................................... .................................. 169 - 176°F (76 - 80°C) Fully open .................................................................. ............................................................................................................................. 194°F (90°C) Service and Repair Rear Door Window Glass Weatherstrip: Service and Repair Rear Door Glass Outer Weatherstrip Replacement 4-door NOTE: - Put on gloves to protect your hands. - Take care not to scratch the door. 1. Starting at the front, pry the door glass outer weatherstrip (A) up to detach the clips (B, C, D), then remove the weatherstrip. 2. Install the weatherstrip in the reverse order of removal, and replace any damaged clips. Page 3766 5. Attach the slide hammer to the interlock lever pin, and tighten the slide hammer clamping bolt. Then use the slide hammer to remove the pin. Discard the pin, the lever, and the spring. 6. Wipe off any debris from the lever's sliding surface on the ignition switch with a clean cloth or a cotton swab. NOTE: To keep debris out of the ignition switch, do not clean it with compressed air. Page 3585 Camshaft Position Sensor: Description and Operation Camshaft Position (CMP) Sensor (Top Dead Center (TDC) Sensor) The CMP (TDC) sensor detects the position of the No.1 cylinder as a reference for sequential fuel injection to each cylinder. Restraints - Child Seat Anchor Locating Button Missing Child Seat: All Technical Service Bulletins Restraints - Child Seat Anchor Locating Button Missing 05-016 May 17, 2005 Applies To: See VEHICLES AFFECTED Child Seat Anchor Locating Button Is Missing PROBLEM The small button on the rear seat-back cover that marks the location of each child seat LATCH lower anchor is missing. VEHICLES AFFECTED 2001-05 Accord - ALL 2001-05 Civic - ALL 2003-05 Civic Hybrid - ALL 2002-05 Civic Si - ALL 2001-05 CR-V - ALL 2003-05 Element - ALL 2001-05 Odyssey - ALL 2003-05 Pilot - ALL CORRECTIVE ACTION Replace the button. NOTE: Older vehicles have buttons without a child seat icon. The buttons in newer vehicles and the replacement buttons all have an icon. If your customer requests matching buttons, replace all the buttons at the same time as a set. PARTS INFORMATION Child Seat ISOFIX Button Kit: (Kit contains buttons in nine different colors; 10 buttons of each color.) P/N 070AZ-SHJA190, H/C 7979016 Child Seat ISOFIX Button Kit Replacement Parts: Page 3627 88. Test Tachometer Connector Page 1674 - Before connecting connectors, make sure the terminals (A) are in place and not bent. - Check for loose retainer (A) and rubber seals (B). - The backs of some connectors are packed with dielectric grease. Add grease if necessary. If the grease is contaminated, replace it. - Insert the connector all the way and make sure it is securely locked. - Position wires so that the open end of the cover faces down. Handling Wires and Harnesses - Secure wires and wire harnesses to the frame with their respective wire ties at the designated locations. Page 3811 Connectors - "C" How To Replace Connector Terminals Multiple Junction Connector: Service and Repair How To Replace Connector Terminals Terminal Replacement Procedure HOW TO REPLACE CONNECTOR TERMINALS The terminal repair kits provide necessary tools and materials (terminals, wire seals, and splice connectors) to repair many damaged or faulty connector terminals. However, not all terminals for all connectors are available. Refer to the labels on the lids of the repair kits for replacement terminal availability. IMPORTANT SAFETY INFORMATION: On some models, the SRS wires are in a separate harness. If the SRS harness is damaged, replace the harness; do not repair it. On other models, wire harnesses include yellow SRS wires. If any SRS wire is damaged, replace the entire harness; do not repair it. Before you begin, inspect the wire you are about to repair for damage and length. Make sure the wire will be long enough to make a terminal repair without stretching it when you reinstall the terminal in the connector. If the wire is too short, or if access to the connector is too restricted to make a terminal repair, you may need to install a pigtail terminal (a short length of wire with a factory-crimped terminal on it). Refer to HOW TO INSTALL PIGTAIL TERMINALS. Removing the Terminal Use the tools from Pin Tool Set. First, check the connector that you are about to repair. - If it has a secondary terminal lock, go to Connectors With a Secondary Lock. A secondary lock, found on most connectors on some models, is an additional locking device on the connector housing as a backup for the primary lock on the terminal. - If the connector does not have a secondary lock, go to Connectors Without a Secondary Lock. Connectors With a Secondary Lock All examples are shown with the connector lock facing up. The illustrations are examples of the secondary terminal locks; however, the connector you are repairing may vary in size. Identify the connector by the type of secondary lock, not by the number of terminal cavities. EXAMPLE A: 1. Release the secondary lock. Description and Operation Child Seat Tether Attachment: Description and Operation Attachment points are provided for a rear seat mounted child restraint system which uses a top tether. The attachment points are located on the rear shelf, just behind the rear seat-back. When using a child seat with a top tether, install the child seat anchor plates securely. WARNING: Do not use the child seat anchor plate for any other purpose; it is designed exclusively for installation of a child seat. Page 5692 Starter Motor: Service and Repair Overhaul Starter Overhaul Starting System - Starting Overhaul Part 1 Disassembly/Reassembly - M/T, CVT Page 3439 PGM-F1 Main Relay 1, 2 Type 1, 2 Check for continuity between the terminals. - There should be continuity between the No.1 and No.2 terminals when power and ground are connected to the No.3 and No.4 terminals. - There should be no continuity between the No.1 and No.2 terminals when power is disconnected. Normally-open type B: Rear Window Defogger Relay Page 4717 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 8411 Sunroof / Moonroof Relay: Testing and Inspection Power Relay Test Use this chart to identify the type of relay, then do the test listed for it. NOTE: See the turn signal/hazard relay input test. Five-terminal type Check for continuity between the terminals. - There should be continuity between the No.1 and No.2 terminals when power and ground are connected to the No.3 and No.5 terminals. - There should be continuity between the No.1 and No.4 terminals when power is disconnected. Service and Repair Air Bag Safety Switch/Connector: Service and Repair When checking voltage or resistance on this type of connector the first time, you must remove the retainer to insert the tester probe from the wire side. NOTE: It is not necessary to reinstall the removed retainer; the terminals will stay locked in the connector housing. To remove the retainer (A), insert a flat-tip screwdriver (B) between the connector body and the retainer, then carefully pry out the retainer. Take care not to break the connector. Spring-loaded Lock Connector Some SRS system connectors have a spring-loaded lock. Front Airbag Connectors: Disconnecting To release the lock, pull the spring-loaded sleeve (A) toward the stop (B) while holding the opposite half of the connector. Then pull the connector halves apart. Be sure to pull on the sleeve and not on the connector half. Connecting Service and Repair Muffler: Service and Repair Exhaust Pipe and Muffler Replacement NOTE: Use new gaskets and self-locking nuts when reassembling. Page 2911 Oxygen Sensor: Description and Operation Third Heated Oxygen Sensor (Third HO2S) Third Heated Oxygen Sensor (Third HO2S) (D17A6 engine) The third HO2S detects the oxygen content in the exhaust gas downstream of the NOX Adsorptive Three Way Catalytic Converter (NOX Adsorptive TWC) and sends signals to the ECM/PCM which varies the duration of fuel injection accordingly. To stabilize its output, the sensor has an internal heater. The third HO2S is installed behind the NOX Adsorptive TWC. Page 6623 Blower Motor Relay: Testing and Inspection Power Relay Test Use this chart to identify the type of relay, then do the test listed for it. NOTE: See the turn signal/hazard relay input test. Normally-open type B: Blower Motor Relay Type 1, Type 2 Check for continuity between the terminals. - There should be continuity between the No.1 and No.3 terminals when power and ground are connected to the No.2 and No.4 terminals. - There should be no continuity between the No.1 and No.3 terminals when power is disconnected. Body - Windshield Moulding Warped/Deformed Windshield Moulding / Trim: Customer Interest Body - Windshield Moulding Warped/Deformed 00-064 March 17, 2009 Applied Vehicles Deformed Windshield Molding (Supersedes 00-064, dated November 13, 2007, to update the information marked by the black bars) REVISION SUMMARY SYMPTOM The windshield molding is warped or deformed. PROBABLE CAUSE The inner lip is folded, causing a poor fit against the body. CORRECTIVE ACTION Remove the entire inner lip, and fill the channel between the molding and the body with silicone sealant. REQUIRED MATERIALS WARRANTY CLAIM INFORMATION In warranty: The normal warranty applies. Operation Number: 831004 Flat Rate Time: 0.7 hour Failed Part: P/N 73150-S84-A01 H/C 5443387 Defect Code: 00401 Symptom Code: 00101 Template ID: 00-064A Skill Level: Repair Technician Pressure Test Pressure Test Locations Pressure Regulating Solenoid: Locations 23. Transmission Housing (A/T) Page 4409 Page 9462 Hazard Flasher Relay: Testing and Inspection Turn Signal/Hazard Relay Input Test 1. Remove the turn signal/hazard relay (A) from the under-dash fuse/relay box (B). 2. Inspect the relay and fuse/relay box socket terminals to be sure they are all making good contact. - If the terminals are bent, loose, or corroded, repair them as necessary, and recheck the system. - If the terminals look OK, go to step 3. 3. Make these input tests at the fuse/relay box. - If any test indicates a problem, find and correct the cause, then recheck the system. - If all the input tests prove OK, the turn signal/hazard relay must be faulty; replace it. Page 8410 165. Moonroof Close And Open Relay (EX) Page 8759 - Remove clips carefully; don't damage their locks (A). - Slip pliers (A) under the clip base and through the hole at an angle, then squeeze the expansion tabs to release the clip. - After installing harness clips, make sure the harness doesn't interfere with any moving parts. - Keep wire harnesses away from exhaust pipes and other hot parts, from sharp edges of brackets and holes, and from exposed screws and bolts. - Seat grommets in their grooves properly (A). Do not leave grommets distorted (B). Testing and Repairs - Do not use wires or harnesses with broken insulation. Replace them or repair them by wrapping the break with electrical tape. - After installing parts, make sure that no wires are pinched under them. - When using electrical test equipment, follow the manufacturer's instructions and those described. - If possible, insert the probe of the tester from the wire side (except waterproof connector). - Use back probe adaptor 07TAZ-001020A. - Refer to the instructions in the Honda Terminal Kit for identification and replacement of connector terminals. Five-Step Troubleshooting Five-Step Troubleshooting 1. Verify The Complaint Locations Transmission Position Switch/Sensor: Locations Component Location Index, A/T Page 2604 Disclaimer Cutting Procedure - By Copying 1. Press the ON/OFF button in the middle of the setting unit keypad. (This powers up the keypad.) 2. Turn the clamp unit lock lever to the left to release the clamp unit, and slide it all the way to the left until it stops. Turn the lever to the right to lock the clamp unit in place. 3. Use the clamp carriage lever to position the clamp unit so the tracer and cutter bit are centered directly over the base of the center and right jaws. 4. Pull the vertical carriage lever toward you until the tracer and the cutter bit just touch the base of each fixed jaw. Watch the arrows on the keypad: ^ If the double-headed arrow in the middle of the keypad lights green, the tracer and cutter bit are properly aligned. ^ If the arrow on the left of the keypad lights red, the cutter bit is not touching the fixed jaw. Turn the micrometric ring nut above the tracer to the left until the double-headed arrow lights green. ^ If the arrow on the right of the keypad lights red, the tracer is not touching the fixed jaw. Turn the micrometric ring nut above the tracer to the right until the double-headed arrow lights green. *5. Turn the micrometric ring nut to the right three clicks so the cutter bit is slightly higher than the tracer. The arrow on the left should light red. Raise the vertical carriage. NOTE: Setting the tracer three clicks lower than the cutter bit has the effect of making the cutter bit cut the duplicated key a little shallower. This will protect the locking jaws from being damaged.* 6. Optional: Loosen the setscrew, and adjust the hand rest to a comfortable position. Tighten the screw. 7. Pull the clamp carriage lever toward you until the clamp carriage clicks into its end-of-run position. Tighten both the lateral and spring tension adjustment knobs. 8. Make sure the center and right jaws are free of any metal shavings or debris. (A soft-bristle toothbrush is ideal for this purpose.) Page 5757 Under-dash Fuse/Relay Box Page 854 Vehicle Speed Sensor: Service and Repair VSS Replacement 1. Remove the intake resonator. 2. Disconnect the 3P connector (A) from the vehicle speed sensor (VSS) (B). 3. Remove the mounting bolt, then remove the VSS. 4. Install the VSS in the reverse order of removal. Page 2704 Crankshaft Position Sensor: Description and Operation Crankshaft Position (CKP) Sensor The CKP sensor detects engine speed, and is used by the ECM/PCM to determine ignition timing and timing for fuel injection of each cylinder. Page 3721 2. Insert the terminal tool into the female terminal, and then remove the terminal tool. NOTE: Make sure you do not select a terminal tool that is larger than the mating male terminal because it would spread the female terminal and cause a loose fit. 3. Compare the drag to the other terminals in the connector. If the drag is less, replace the terminal with a replacement terminal from the appropriate terminal repair kit. Locations Transmission Position Switch/Sensor: Locations Electronic Controls Location, CVT 25. Transmission Housing (CVT) Page 2774 Engine Control Module: Service Precautions 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 4894 Control Module: Service and Repair Updating the ECM/PCM PCM Updating and Substitution for Testing Special Tools Required Honda Interface Module (HIM) P/N EQS05A35570 Use this procedure when you have to substitute a known-good PCM in a troubleshooting procedure. Update the PCM only if the PCM does not already have the latest software loaded. NOTE: Do not turn the ignition switch OFF while updating; the PCM can be damaged. How to Update the PCM NOTE: To ensure the latest program is installed, do an PCM update whenever the PCM is substituted or replaced. - Before you update the PCM, make sure the vehicle's battery is fully charged. - To prevent PCM damage, do not operate anything electrical (audio system, brakes, A/C, power windows, moon roof, door locks, etc.) during the update. - If you need to diagnose the Honda Interface Module (HIM) because the HIM's red (#3) light came on or was flashing during the update, leave the ignition switch in the ON (II) position when you disconnect the HIM from the Data Link Connector (DLC). This will prevent PCM damage. 1. Turn the ignition switch ON (II). Do not start the engine. 2. Connect the HIM to the DLC (A) located under the driver's side of dashboard. 3. Do the PCM update procedure as described on the HIM label and in the PCM update system. If the software in the PCM is the latest version, replace the PCM. How to End a Troubleshooting Session This procedure must be done after any troubleshooting. 1. Clear the DTC(s) with the Scan Tool or HDS, or reset the PCM by removing the No. 6 (PCM) fuse in the under-hood fuse/relay box for more than 10 seconds. 2. Turn the ignition switch ON (II). 3. Start the engine in the P or N position, and warm it up to normal operating temperature (the radiator fans come on). 4. To verify that the problem is repaired, test-drive the vehicle for several minutes at speeds over 30 mph (50 km/h) or in freeze data range. Computers/Controls - Updating Control Units And Modules PROM - Programmable Read Only Memory: All Technical Service Bulletins Computers/Controls Updating Control Units And Modules 01-023 April 10, 2010 Applies To: Honda Vehicles With Programmable Control Units/Modules Updating Control Units/Modules (Supersedes 01-023, dated May 15, 2009, to revise the information marked by the black bars and asterisks) REVISION SUMMARY *^Under REQUIRED TOOLS AND EQUIPMENT, the MVCI was added. ^ Under UPDATING TIPS AND PRECAUTIONS MVCI information was added. ^ UPDATING WITH THE MVCI was added.* The procedures in this service bulletin are used and referenced in other service bulletins. Most 2002 and later Hondas have reprogrammable control units/modules. To update (reprogram) any of these control units/modules, you need the vehicle you're working on and one of these systems: *^MVCI unit with latest control module (CM) update software installed* ^ GNA600 gateway device and an iN workstation with the latest HDS software installed ^ HDS Tablet with the latest HDS software installed ^ HDS Pocket Tester with the latest HDS software installed ^ HIM and an iN workstation with the latest HDS software installed ^ A compatible J2534 device and a PC with Honda's J2534 software installed This service bulletin describes these subjects: ^ Who to contact for questions or problems when using Honda-supplied updating equipment or the iN. ^ Required Tools and Equipment - MVCI - GNA600 - HDS Tablet - HDS Pocket Tester - HIM ^ Updating Tips and Precautions ^ Updating with the MVCI ^ Updating with the GNA600 - GNA6OO Updating in Pass-Thru Mode - GNA6OO Updating in Storage Mode ^ Updating with the HDS Tablet and the HDS Pocket Tester Page 1837 Piston: Service and Repair Piston, Pin and Connecting Rod Replacement Replacement Special Tools Required ^ Piston base 07973-6570500 ^ Piston base spring 07973-6570600 ^ Piston pin base insert 07973-PE00400 ^ Piston base head 07973-SB00100 or 07TGF-001000A ^ Pilot collar 07973-PE00200 ^ Piston pin driver shaft 07973-PE00310 ^ Piston pin driver head 07973-PE00320 Disassembly 1. Remove the piston from the cylinder block 2. Assemble the special tool as shown. 3. Assemble and adjust the length of the piston pin driver head and shaft to 53 mm (2.1 inch). Service and Repair Carpet: Service and Repair Carpet Replacement SRS components are located in this area. Review the SRS component locations and the precautions and procedures before performing repairs or service. NOTE: - Put on gloves to protect your hands. - Take care not to damage, wrinkle or twist the carpet. - Be careful not to damage the dashboard or other interior trim pieces. 1. Remove these items: - Front seats, both sides - Rear seat cushion - Rear seat side bolsters, both sides, 4-door - Kick panels, both sides - Door sill trim, both sides, 2-door - Front door sill trim, both sides, 4-door - Seat side trim, both sides, 4-door - Center console, without console armrest , with console armrest - Driver's dashboard under cover - Passenger's dashboard lower cover 2. Remove the nut (A), and using a 6 mm hex wrench, release the clip (B), then remove the footrest (C). 3. Using a utility knife, cut the carpet (A) under the heater area (B) on the driver's side, and cut out the shift lever area (C) and parking brake lever area (D) as shown. Release the hook (E), then pull back the carpet. Locations Keyless Entry Module: Locations Relay And Control Unit Locations - Dashboard 78. Under Middle of Dash (Honda Accessory) Page 5672 ^ Refer to page 11-199 of the 2001-2005 Civic Service Manual, or ^ Online, enter keyword RESONATOR, and select Resonator Removal/Replacement from the list. 4. Disconnect the female terminal (BLK/WHT wire) from the S terminal of the starter solenoid. NOTE: A/T is shown. M/T is similar 5. Pull the boot back from the female S terminal, and check the terminal for signs of arcing. 6. Check the male S terminal at the starter for signs of arcing. 7. If either terminal has signs of arcing, go to REPAIR PROCEDURE. If neither terminal has signs of arcing, continue your diagnosis using the appropriate service manual. REPAIR PROCEDURE Page 1308 11. Disconnect the quick-connect fitting (A): Hold the connector (B) with one hand and squeeze the retainer tabs (C) with the other hand to release them from the locking pawls (D). Pull the connector off. NOTE: Prevent the remaining fuel in the fuel feed line or hose from flowing out with a rag or shop towel. - Be careful not to damage the line (E) or other parts. - Do not use tools. - If the connector does not move, keep the retainer tabs pressed down, and alternately pull and push the connector until it comes off easily. - Do not remove the retainer from the line; once removed, the retainer must be replaced with a new one. 12. After disconnecting the quick-connect fitting, check it for dirt or damage (see step 4). Page 6824 7. Connect the SCS service connector to the 2P MES (memory erase signal) connector, as shown. Do not use a jumper wire. 8. Turn the ignition switch to ON (II). 9. Watch the SRS indicator. (It comes on for about 6 seconds and then goes off.) Disconnect the SCS service connector from the MES connector within 4 seconds after the indicator goes off. 10. When the SRS indicator comes on again, connect the SCS service connector to the MES connector within 4 seconds after the indicator comes on. 11. When the SRS indicator goes off, disconnect the SCS service connector from the MES connector within 4 seconds. Testing and Inspection Power Door Lock Control Module: Testing and Inspection Control Unit Input Test 1. Before testing, troubleshoot the multiplex control system.See: Body Control Systems/Testing and Inspection 2. Remove the dashboard lower cover. 3. Disconnect the under-dash fuse/relay box connectors. NOTE: All connectors are wire side of female terminals. 4. Inspect the connector and socket terminals to be sure they are all making good contact. - If the terminals are bent, loose or corroded, repair them as necessary, and recheck the system. - If the terminals look OK, go to step 5. Page 9013 - Remove clips carefully; don't damage their locks (A). - Slip pliers (A) under the clip base and through the hole at an angle, then squeeze the expansion tabs to release the clip. - After installing harness clips, make sure the harness doesn't interfere with any moving parts. - Keep wire harnesses away from exhaust pipes and other hot parts, from sharp edges of brackets and holes, and from exposed screws and bolts. - Seat grommets in their grooves properly (A). Do not leave grommets distorted (B). Testing and Repairs - Do not use wires or harnesses with broken insulation. Replace them or repair them by wrapping the break with electrical tape. - After installing parts, make sure that no wires are pinched under them. - When using electrical test equipment, follow the manufacturer's instructions and those described. - If possible, insert the probe of the tester from the wire side (except waterproof connector). - Use back probe adaptor 07TAZ-001020A. - Refer to the instructions in the Honda Terminal Kit for identification and replacement of connector terminals. Five-Step Troubleshooting Five-Step Troubleshooting 1. Verify The Complaint Page 9389 Circuit Schematics Each schematic represents one circuit. A circuit's wires and components are arranged to show current flow from power at the top of the diagram 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 Page 2594 Crankshaft Position Sensor: Description and Operation Crankshaft Position (CKP) Sensor The CKP sensor detects engine speed, and is used by the ECM/PCM to determine ignition timing and timing for fuel injection of each cylinder. Page 3208 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 Locater) 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. Troubleshooting Precautions Troubleshooting Precautions Before Troubleshooting 1. Check the main fuse and the fuse 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, or you will damage the alternator diodes. - Do not attempt to crank the engine with the ground cable disconnected 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. Page 6897 Deploying Airbags/Tensioner (Outside Vehicle) Airbag Disposal Special Tool Required Deployment tool 07HAZ-SG00500 Before scrapping any airbags, side airbags, seat belt tensioners or seat belt buckle tensioners (including those in a whole vehicle to be scrapped), the airbags, side airbags, seat belt tensioners or seat belt buckle tensioners must be deployed. If the vehicle is still within the warranty period, the Honda District Service Manager must give approval and/or special instruction before deploying the airbags, side airbags, seat belt tensioners or seat belt buckle tensioners. Only after the airbags, side airbags, seat belt tensioners or seat belt buckle tensioners have been deployed (as the result of vehicle collision, for example), can they be scrapped. If the airbags, side airbags, seat belt tensioners and seat belt buckle tensioners appear intact (not deployed), treat them with extreme caution. Follow this procedure. Deploying the Components Out of the Vehicle If an intact airbag or tensioner has been removed from a scrapped vehicle, or has been found defective or damaged during transit, storage, or service, it should be deployed as follows: 1. Confirm that the special tool is functioning properly by following the check procedure or on the tool label. 2. Position the airbag face up, outdoors on flat ground at least 30 feet (10 meters) from any obstacles or people. 3. Follow steps 10, 11, and 12 of the in-vehicle deployment procedure. 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, 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. Page 9810 125. Passenger's Door (Coupe Except DX, HX) 126. Front Passenger's Door (Sedan Except DX) Page 1773 13. Plug in the heat gun, and turn it on. Start at the middle of the splice connector, and move the gun toward the ends as the tube shrinks. Apply heat evenly by rotating the curved heat spreader around the splice connector. Shrinking is complete when a small amount of sealant appears at each end of the tube. Pigtail Terminal Selection Chart PIGTAIL TERMINAL SELECTION CHART Select the proper size pigtail terminal by matching the replacement terminal part number and the wire size being repaired to the corresponding pigtail terminal part number. Then use the color (size) splice connector listed. In some instances you may also have to match the wire seal style to select the proper pigtail terminal. Pigtail terminals are available through your parts department, in quantities of 10, using normal parts ordering procedures. Checking For Poor Fir of Terminals CHECKING FOR POOR FIT OF TERMINALS Loose terminal fit can cause a number of intermittent problems in electrical circuits. By using the Terminal Inspection Feeler Tool Set you can inspect the terminal fit between the two matching connectors without removing the terminals from the connector body. 1. Find the terminal tool that best matches the male terminal in the mating connector. Page 6420 Page 7897 - Replace the front damper extension, damper housing, and damper housing extension as an assembly. Installation 1. Set the new damper housing assembly, front wheelhouse, and front bulkhead into position, and measure the front compartment diagonally. Check the body dimensions. 2. Tack weld the clamped position. 3. Temporarily install the front sub-frame, and check the front side frame position. 4. Temporarily install the hood, front fender, headlight, and front bumper, and check for difference in level and clearance. Make sure the body lines flow smoothly. 5. Do the main welding. Page 1190 Power Window Switch: Testing and Inspection Passenger's Window Switch Input Test Passenger's Switch Input Test 1. Remove the switch panel. 2. Disconnect the 5P connector (A) from the switch (B). 3. Inspect the connector and socket terminals to be sure they are all making good contact. - If the terminals are bent, loose or corroded, repair them as necessary, and recheck the system. - If the terminals look OK, go to step 4. Locations Power Door Lock Actuator: Locations Doors - Component Location Index 2-door Page 2544 2. Insert the terminal tool into the female terminal, and then remove the terminal tool. NOTE: Make sure you do not select a terminal tool that is larger than the mating male terminal because it would spread the female terminal and cause a loose fit. 3. Compare the drag to the other terminals in the connector. If the drag is less, replace the terminal with a replacement terminal from the appropriate terminal repair kit. Page 8391 6. Pivot the glass bracket (A) down by sliding the link lifter (B) back, then slide both glass brackets back with the link lifter 7. Slide the cable assembly (A) and both glass brackets (B) back, then remove them from the frame (C). 8. Install the slider and cable assembly in the reverse order of removal, and note these items: - Damaged parts should be replaced. - Apply multipurpose grease to the glass bracket (A) and guide rail portion of the frame (B) indicated by the arrows. - Before reinstalling the motor, make sure both link lifters are parallel, and in the fully closed position. - Before reinstalling the motor, install the frame and glass, then check the opening drag. Page 7256 96-97 Passport With Dealer-Installed Security System 1996-97 Passport with dealer-installed security system NOTES: ^ The system uses a stacking-type memory that accepts up to two transmitters. If you program a third transmitter, the memory for the first transmitter is pushed out, and it will no longer work. ^ To clear a lost or stolen transmitter from the system's memory, program a transmitter two times. This will remove the missing transmitter from memory, since only two transmitter codes can be accepted. ^ Another way to clear a lost or stolen transmitter is to erase all transmitter codes and then reprogram them. To do this, refer to the security system owner's manual. Programming the Transmitter 1. Move the driver's seat forward. Locate the security system control unit mounted on the floor underneath the seat. 2. Turn the ignition switch to ON. 3. Use a pen or pencil to press and hold the green programming button on the side of the control unit. When the security system LED on the instrument panel comes on, release the programming button. (Steps 3 and 4 must be done within 5 seconds of each other.) 4. Press and release the top button on the transmitter. Verify that the LED goes out, the siren chirps once, and the front sidemarker lights flash to confirm that the transmitter's code was accepted by the control unit. 5. Turn the ignition switch to LOCK, then to ON. Continuously Variable Transmission Transmission Position Switch/Sensor: Testing and Inspection Continuously Variable Transmission Transmission Range Switch Test 1. Disconnect the transmission range switch connector. 2. Check for continuity between terminals at the switch connector. There should be continuity between terminals below listed for each switch position. 3. If there is no continuity between any terminals, adjust the transmission range switch installation. If the transmission range switch installation is OK, replace the transmission range switch. 4. If the transmission range switch continuity check was OK, replace the faulty transmission harness. Page 25 Alarm Module: Description and Operation How the Circuit Works The immobilizer system is designed to prevent the car from being started without the owner's ignition key. If an attempt is made to Start the car with any other key, the immobilizer system will disable the car's fuel supply. The immobilizer system consists of the ignition key, immobilizer control unit-receiver, immobilizer indicator light, PGM-FI main relays, injector relay (GX), fuel pump (except GX), fuel tank internal solenoid valve (GX), and the ECM/PCM. With the ignition switch in ON (II) or START (III), the immobilizer control unit-receiver and the ECM/PCM receive an "ignition on" signal through fuse 6 and the PGM-FI main relay 1. The ECM/PCM then sends power to the ignition key transponder through the immobilizer control unit-receiver. The transponder then sends a coded signal back to the ECM/PCM through the receiver. If the signal is correct, the ECM/PCM will energize the car's fuel supply system by grounding the PGM-FI main relay 2 (except GX) or injector relay (GX). The immobilizer indicator light flashes a code to indicate that the correct key has been inserted. If the ignition key signal is not correct, the ECM/PCM will not energize the car's fuel supply system by not grounding the PGM-FI main relay 2 (except GX) or injector relay (GX). The immobilizer indicator light then flashes a code to indicate that an incorrect key has been inserted. Page 5323 4. With the engine off, inspect the play (A) on the pedal pad (B) by pushing the pedal by hand. Free Play: 0.4 - 3.0 mm (0.016 - 0.118 inch) 5. If the pedal free play is out of specification, adjust the brake pedal position switch (C). If the pedal free play is insufficient, it may result in brake drag. 6. Push in the brake pedal position switch until its plunger is fully pressed (threaded end (A) touching the pad (B) on the pedal arm). Then, turn the brake pedal position switch clockwise to lock it. Make sure the brake lights go off when the pedal is released. 7. Check the brake pedal free play. Page 744 Intake Air Temperature Sensor: Service and Repair IAT Sensor Replacement 1. Disconnect the IAT sensor 2P connector. 2. Remove the IAT sensor (A). 3. Install the sensor in the reverse order of removal Page 6894 Side Air Bag: 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. Deploying Airbags/Tensioner (Inside Vehicle) Airbag Disposal Special Tool Required Deployment tool 07HAZ-SG00500 Before scrapping any airbags, side airbags, seat belt tensioners or seat belt buckle tensioners (including those in a whole vehicle to be scrapped), the airbags, side airbags, seat belt tensioners or seat belt buckle tensioners must be deployed. If the vehicle is still within the warranty period, the Honda District Service Manager must give approval and/or special instruction before deploying the airbags, side airbags, seat belt tensioners or seat belt buckle tensioners. Only after the airbags, side airbags, seat belt tensioners or seat belt buckle tensioners have been deployed (as the result of vehicle collision, for example), can they be scrapped. If the airbags, side airbags, seat belt tensioners and seat belt buckle tensioners appear intact (not deployed), treat them with extreme caution. Follow this procedure. Deploying Airbags In the vehicle If an SRS equipped vehicle is to be entirely scrapped, its airbags, side airbags, seat belt tensioners and seat belt buckle tensioners should be deployed while still in the vehicle. The airbags, side airbags, seat belt tensioners and seat belt buckle tensioners should not be considered as salvageable parts and should never be installed in another vehicle. 1. Turn the ignition switch OFF, then disconnect the battery negative cable, and wait at least 3 minutes. 2. Confirm that each airbag, side airbag, and seat belt tensioner is securely mounted. 3. Confirm that the special tool is functioning properly by following the check procedure on the tool label. Driver's Airbag: 4. Remove the access panel from the steering wheel (A), then disconnect the driver's airbag 4P connector (B) from the cable reel. Front Passenger's Airbag: Automatic Transmission Shift Indicator: Testing and Inspection Automatic Transmission Indicator Input Test SRS components are located in this area. Review the SRS component locations, precautions, and procedures in the SRS section before performing repairs or service. 1. If the MIL has been reported, check for a DTC, and repair the system as indicated by DTC. 2. If the MIL does not come on, and the A/T gear position indicator P, N, or R does not come on. Turn the ignition switch off, remove the gauge assembly from the dashboard, then disconnect gauge assembly connector A (22P) and B (22P). 3. Inspect the connectors and connector terminals to be sure they are making good contact. 4. If the terminals are bent, loose, or corroded, repair them as necessary, and recheck the system. 5. Shift to the P position, and check for continuity between AS terminal (BLU/BLK) and ground. There should be continuity in the P position and no continuity in any other shift lever position. If your test results are different, check for a faulty transmission range switch or an open in the wire. 6. Shift to the N position, and check for continuity between AS terminal (BLK/RED) and ground. There should be continuity in the N position and no continuity in any other shift lever position. If your test results are different, check for a faulty transmission range switch or an open in the wire. 7. Turn the ignition switch ON (II), shift to the R position, and check for voltage between All terminal (WHT) and ground. There should be 0 V in the [A position. There should be about 5 V in any other shift lever position. If your test results are different, check for a faulty transmission range switch or an open in the wire. 8. Check for voltage between B17 terminal (YEL) and ground with the ignition switch ON (II). There should be battery voltage. If your test results are different, check for a blown No. 10 (7.5A) fuse in the under-dash fuse/relay box or an open in the wire. 9. Turn the ignition switch OFF, and check for continuity between B16 terminal (BLK) and ground under all conditions. There should be continuity. If your test results are different, check for a poor ground (G501) or an open in the wire. 10. If all input tests prove OK, but the indicator is faulty, replace the printed circuit board. Page 2037 Connectors - "C" Page 7221 The 1999-00 transmitter is not interchangeable with the 2001-04 transmitter. To tell them apart, look at the FCC ID on the back. 1999-00 - FCC ID: E4EG8DN 2001-04 - FCC ID: OUCG8D-440H-A* Programming the Transmitter NOTES: ^ The system accepts up to three transmitters. The transmitter codes are stored in a stacking-type memory. If a fourth transmitter code is programmed, the code for the first transmitter is erased. ^ Entering the programming mode cancels all learned transmitter codes, so none of the previously programmed transmitters will work. You must reprogram all of the transmitters once you are in the programming mode. You must complete steps 1-6 within 4 seconds of the previous step to keep the system from exiting the programming mode. 1. Turn the ignition switch to ON (II). 2. Press the "Lock" or "Unlock" button on one of the transmitters. (An unprogrammed transmitter can be used for this step.) 3. Turn the ignition switch to LOCK (0). 4. Repeat steps 1, 2, and 3 two more times using the same transmitter used in step 2. 5. Turn the ignition switch to ON (II). 6. Press the "Lock" or "Unlock" button on the same transmitter. Make sure the power door locks cycle to confirm that the system is in programming mode. 7. Within 10 seconds, press the "Lock" or "Unlock" button on each transmitter. Make sure the power door locks cycle after you press each transmitter button to confirm that the system accepted the transmitter's code. 8. Turn the ignition switch to LOCK (0) to exit the programming mode. Ordering a Transmitter Transmitters can be ordered only by authorized Honda dealers. Order them from American Honda using normal parts ordering procedures. Batteries for the Transmitter The battery number is CR2025. Each transmitter uses one battery. 99-01 Prelude With Factory-Installed Keyless Entry System 1999-01 Prelude with factory-installed keyless entry system Page 878 159. Left Side Of Engine Compartment Page 9746 Power Window Switch: Testing and Inspection Master Switch Input Test Master Switch Input Test 4-door NOTE: The power window control unit is built into the power window master switch, and it only controls the driver's window operations. 1. Remove the door grip cover. 2. Disconnect the 20P connector (A) from the master switch (B). 3. Inspect the connector and socket terminals to be sure they are all making good contact. - If the terminals are bent, loose or corroded, repair them as necessary, and recheck the system. - If the terminals look OK, make the following input tests at the connector. If a test indicates a problem, find and correct the cause, then recheck the system. - If all the input tests prove OK, the power window master switch must be faulty; replace it. Page 3691 Connectors - "C" Page 811 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. Test Equipment 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. Page 8489 Seat Cover: Service and Repair Rear Seat Cushion Cover Replacement Rear Seat Cushion Cover Replacement 1. Remove the rear seat cushion, 2-door, 4-door. 2. Release all the clips (A) from under the seat cushion, and fold back the seat cushion cover (B). 3. Pull back the edge of the seat cushion cover all the way around, and release the clips (A), then remove the seat cushion cover. 4. Install the cover in the reverse order of removal, and note these items: - To prevent wrinkles, make sure the material is stretched evenly over the pad before securing the clips. - Replace any clips (A) you removed with new ones. Install them with commercially available upholstery ring pliers (B). Page 9629 Wires Page 440 - If all the input tests prove OK, the multiplex control unit must be faulty; replace the under-dash fuse/relay box assembly. '04 model 6. Disconnect the X connector from the under-dash fuse/relay box, and make these input tests at the connector. If this input test proves OK, the multiplex control unit must be faulty; replace the under-dash fuse/relay box assembly. Page 7689 1. Check the depth adjustment of the trunk lid: ^ Refer to page 20-132 of the 2001-04 Civic Service Manual. ^ In ISIS, use the keyword TRUNK ADJUST, and select Trunk Lid Adjustment from the list. 2. Make sure the trunk lid is flush on all sides and corners. ^ If the trunk is misaligned, go to step 3. ^ If the trunk lid is properly aligned on all sides and corners, go to REPAIR PROCEDURE C. 3. Adjust the striker depth position and the trunk lid edge cushions: ^ Refer to page 20-132 of the 2001-04 Civic Service Manual. ^ In ISIS, use the keyword TRUNK ADJUST, and select Trunk Lid Adjustment from the list. 4. Check the trunk operation: ^ If the trunk opens and closes smoothly, return the vehicle to the customer. ^ If the trunk lid is still difficult to close, go to REPAIR PROCEDURE C. REPAIR PROCEDURE C 1. Use a small screwdriver to manually set and release the trunk lid latch. Check the operation of the latch: ^ If the latch is difficult to set or release, go to step 2. ^ If the latch operates properly, go to REPAIR PROCEDURE D. 2. Replace the trunk lid latch: ^ Refer to page 20-157 of the 2001-04 Civic Service Manual. ^ In ISIS, use the keyword LID LATCH, and select Trunk Lid Latch Replacement from the list. 3. Check the trunk operation: ^ If the trunk opens and closes smoothly, return the vehicle to the customer. ^ If the trunk lid is still difficult to close, go to REPAIR PROCEDURE D. REPAIR PROCEDURE D 1. Disconnect the trunk lid opener cable from the trunk lid latch. Check the cable operation: ^ Refer to page 20-157 of the 2001-04 Civic Service Manual. ^ In ISIS, use the keyword LID LATCH, and select Trunk Lid Latch Replacement from the list. 2. Check that there is no friction or binding of the cable by holding the outside casing and pulling back and forth on the inner cable: ^ If the cable is difficult to move or binds, go to step 3. ^ If the cable operates smoothly, go to REPAIR PROCEDURE E. 3. Replace the trunk lid opener cable: ^ Refer to page 20-151 of the 2001-04 Civic Service Manual. ^ In ISIS, use the keyword LID OPEN, and select Trunk Lid Opener/Fuel Fill Door Opener Cable Replacement from the list. 4. Check the trunk operation: Page 3373 172. EGR Valve And EGR Valve Position Sensor (EX, HX; '04-'05: DX, LX) Specifications Specifications Fuel Pressure: Specifications Fuel Pressure at idle .................................................................................................................................... 270 - 320 kPa (2.8 - 3.3 kgf/sq.cm, 40 - 47 psi) Page 9524 Blower Motor Relay Type 1, Type 2 Check for continuity between the terminals. - There should be continuity between the No.1 and No.3 terminals when power and ground are connected to the No.2 and No.4 terminals. - There should be no continuity between the No.1 and No.3 terminals when power is disconnected. Five-terminal type Check for continuity between the terminals. - There should be continuity between the No.1 and No.2 terminals when power and ground are connected to the No.3 and No.5 terminals. - There should be continuity between the No.1 and No.4 terminals when power is disconnected. Master Switch Replacement Power Window Switch: Service and Repair Master Switch Replacement Master Switch Test/Replacement 4-door 1. Remove the door grip cover. 2. Disconnect the 20P connector from the power window master switch. Page 5927 3. Strip the insulation off the end of the wire so the wire fits in the new terminal as shown. (If the wire has a wire seal, replace it with a new one from the kit.) NOTE: After stripping the end of the wire, make sure you did not cut any wire strands. If you did, cut the wire off even with the insulation, and strip it again. 4. Position the terminal in the crimping tool slot with the solid portion of the terminal toward the anvil and the open section toward the former. 5. Insert the wire in the terminal to the position shown in step 3. 6. Squeeze the tool with both hands until the stops make contact. 7. Crimp the insulation crimp. - If you do not have a wire seal, then use the next larger size crimp slot. Position the crimping tool over the insulation crimp section of the terminal, then squeeze the tool with both hands until the stops make contact. - If you have a wire seal, position the insulation crimp in the 5.5 crimping slot, then carefully squeeze the crimp closed until its ends are touching and making a full-circle shape. Locations Turn Signal Relay: Locations Turn Signal/Hazard Flasher Component Location Index Page 7336 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 9831 3. Check for continuity between the terminals in each switch position according to the tables. Driver's Switch: The driver's switch is combined with the control unit so you cannot isolate the switch to test it. Instead, run the master switch input test procedures. If the tests are normal, the driver's switch must be faulty. Replace the switch. 4. If the continuity is not as specified, remove the driver's door panel. 5. Remove the armrest from the door panel. Service and Repair Fuel Pressure Release: Service and Repair Fuel Pressure Relieving Before disconnecting fuel lines or hoses, relieve pressure from the system by disconnecting the fuel tube/quick connect fitting in the engine compartment. 1. Make sure you have the antitheft code for the radio, then write down the frequencies for the radio's preset buttons. 2. Turn the ignition switch OFF. 3. Remove the glove box, then remove the PGM-FI main relay 2 (A). 4. Start the engine, and let it idle until it is stalls. NOTE: The DTCs or Temporary DTCs P0301, P0302, P0303, P0304 may come on during this procedure. If any DTCs are stored, ignore them. 5. Turn the ignition switch OFF. 6. Remove the fuel fill cap to relieve fuel pressure in the fuel tank. 7. Disconnect the negative cable from the battery. 8. Remove the bolt (A) and the fuel feed pipe mounting bracket (B), then remove the quick-connect fining covers (C). 9. Check the fuel quick-connect fitting for dirt, and clean if necessary. 10. Place a rag or shop towel over the quick-connect fitting (D). Page 2339 ECM/PCM Inputs And Outputs At Connector B (24P) Page 1082 1. Remove the secondary locks. 2. Remove the terminal from the female half. 3. Remove the terminal from the male half. 4. Go to HOW TO INSTALL NEW TERMINALS. Connectors Without a Secondary Lock All examples are shown with the connector lock facing up. The illustrations are examples of connector terminals without a secondary lock; however, the connector you are repairing may vary in size and shape. EXAMPLE A: Page 8330 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 7251 The 1999-00 transmitter is not interchangeable with the 2001-04 transmitter. To tell them apart, look at the FCC ID on the back. 1999-00 - FCC ID: E4EG8DN 2001-04 - FCC ID: OUCG8D-440H-A* Programming the Transmitter NOTES: ^ The system accepts up to three transmitters. The transmitter codes are stored in a stacking-type memory. If a fourth transmitter code is programmed, the code for the first transmitter is erased. ^ Entering the programming mode cancels all learned transmitter codes, so none of the previously programmed transmitters will work. You must reprogram all of the transmitters once you are in the programming mode. You must complete steps 1-6 within 4 seconds of the previous step to keep the system from exiting the programming mode. 1. Turn the ignition switch to ON (II). 2. Press the "Lock" or "Unlock" button on one of the transmitters. (An unprogrammed transmitter can be used for this step.) 3. Turn the ignition switch to LOCK (0). 4. Repeat steps 1, 2, and 3 two more times using the same transmitter used in step 2. 5. Turn the ignition switch to ON (II). 6. Press the "Lock" or "Unlock" button on the same transmitter. Make sure the power door locks cycle to confirm that the system is in programming mode. 7. Within 10 seconds, press the "Lock" or "Unlock" button on each transmitter. Make sure the power door locks cycle after you press each transmitter button to confirm that the system accepted the transmitter's code. 8. Turn the ignition switch to LOCK (0) to exit the programming mode. Ordering a Transmitter Transmitters can be ordered only by authorized Honda dealers. Order them from American Honda using normal parts ordering procedures. Batteries for the Transmitter The battery number is CR2025. Each transmitter uses one battery. 99-01 Prelude With Factory-Installed Keyless Entry System 1999-01 Prelude with factory-installed keyless entry system Page 2841 8. Put the splice connector in the proper size slot in the Crimper Tool, slide it to one end (where the flare begins), and close the crimper handles far enough to hold it in place. To release the ratchet mechanism at any point after the first click, squeeze the handles slightly and push the release lever, then let the handles open. 9. Insert one of the bare wires into the splice connector end that is in the crimper jaws. Push the wire all the way into the splice connector, and squeeze the crimper handles. Keep squeezing until the jaws touch, and hold it at that position until the ratchet clicks again. 10. Crimp the other wire in the same way into the other end of the splice connector. 11. After crimping, gently pull on the wires in the opposite directions to make sure they are secure in the connector. 12. Separate the other wires in the harness from the repaired wire(s), and shield them with nonflammable material. Page 689 Camshaft Position Sensor: Description and Operation Camshaft Position (CMP) Sensor (Top Dead Center (TDC) Sensor) The CMP (TDC) sensor detects the position of the No.1 cylinder as a reference for sequential fuel injection to each cylinder. Page 6156 12. Check for continuity between PSP switch 2P connector terminal No.2 and body ground. Is there continuity? YES - Repair open in the wire between the PSP switch and ECM/PCM (E16). NO - Repair open in the wire between the PSP switch and G201. 13. Turn the ignition switch OFF. 14. Disconnect the PSP switch 2P connector. 15. Turn the ignition switch ON (II). 16. Measure voltage between ECM/PCM connector terminals A24 and E16. Is there battery voltage? YES - Replace the PSP switch. NO - Go to step 17. 17. Turn the ignition switch OFF. 18. Disconnect ECM/PCM connector E (31P). 19. Check for continuity between body ground and ECM/PCM connector terminal E16. Is there continuity? YES - Repair short in the wire between ECM/PCM (E16) and the PSP switch. NO - Update the ECM/PCM if it does not have the latest software, or substitute a known-good ECM/PCM, then recheck. If the Locations Combination Switch: Locations Exterior Lights Component Location Index Page 4386 2. Remove the terminal (same procedure for male and female). 3. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE E: 1. Remove the secondary locks. 2. Remove the terminal (same procedure for male and female). 3. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE F: Page 4225 1. Remove the secondary locks. 2. Remove the terminal from the female half. 3. Remove the terminal from the male half. 4. Go to HOW TO INSTALL NEW TERMINALS. Connectors Without a Secondary Lock All examples are shown with the connector lock facing up. The illustrations are examples of connector terminals without a secondary lock; however, the connector you are repairing may vary in size and shape. EXAMPLE A: Page 5187 1. Remove and discard the plastic cover from the ignition switch key interlock solenoid. 2. Note the position of the interlock solenoid plunger; you'll need to install it the same way. 3. Remove the screw from the solenoid, but keep the solenoid attached to its electrical connector. Discard the screw. NOTE: ^ Be careful not to lose the solenoid plunger; it slides out easily. ^ Keep the plunger free of dirt and grease while it's removed from the solenoid. 4. Note the position of the interlock lever spring; you'll need to install the new spring the same way. Locations Windshield Washer Switch: Locations Wiper/Washer Component Location Index 55. In Steering Column Cover Page 7661 6. Disconnect the trunk lid opener cable (A) from the trunk lid latch (B). 7. Using a clip remover, detach the clip (C) from the trunk lid, and detach the clips (D) from the trunk lid hinge. 8. Remove the trunk lid opener/fuel fill door opener cable from the vehicle. Take care not to kink the cable. 9. Install the cable in the reverse order of removal, and note these items: - Align the alignment mark of the cable to the clip on the bottom portion of the trunk lid hinge. - Replace any damaged clips. Page 1652 - Turn off the engine. It is best to tow the vehicle no farther than 50 miles (80 km), and keep the speed below 35 mph (55 km/h). NOTE: - Improper towing preparation will damage the transmission. Follow the above procedure exactly. If you cannot shift the transmission or start the engine (automatic transmission), the vehicle must be transported on a flat-bed. - Trying to lift or tow the vehicle by the bumpers will cause serious damage. The bumpers are not designed to support the vehicle's weight. Front Page 9781 Power Window Relay: Testing and Inspection Power Relay Test Use this chart to identify the type of relay, then do the test listed for it. NOTE: See the turn signal/hazard relay input test. Normally-open type A: Page 9573 Hazard Warning Switch: Testing and Inspection Hazard Warning Switch Test 1. Remove the center panel. 2. Disconnect the 10P connector (A) from the hazard warning switch (B). 3. Push out the hazard warning switch from behind the center panel (C). 4. Check for continuity between the terminals in each switch position according to the table. 5. If the continuity is not as specified, replace the illumination bulb (D) or the switch. Page 9439 PGM-F1 Main Relay 1, 2 Type 1, 2 Check for continuity between the terminals. - There should be continuity between the No.1 and No.2 terminals when power and ground are connected to the No.3 and No.4 terminals. - There should be no continuity between the No.1 and No.2 terminals when power is disconnected. Normally-open type B: Rear Window Defogger Relay Page 297 Engine Control Module: Service and Repair ECM/PCM Idle Learn Procedure ECM/PCM Idle Learn Procedure The idle learn procedure must be done so the ECM/PCM can learn the engine idle characteristics. Do the idle learn procedure whenever you do any of these actions: - Disconnect the battery. - Replace the ECM/PCM or disconnect its connector. - Reset the ECM/PCM. NOTE: Erasing DTCs with the Honda PGM Tester does not require you to do the idle learn procedure. - Remove the No.6 ECU (ECM/PCM) (15A) fuse from the under-hood fuse/relay box. - Remove the No.19 battery (80A) fuse from the under-hood fuse/relay box. - Remove PGM-FI main relay 1. - Remove any of the wires from the under-hood fuse/relay box. - Disconnect any of the connectors from the under-hood fuse/relay box. - Disconnect the connector between the engine compartment wire harness and ECM/PCM wire harness. - Disconnect the G2 terminal from the transmission housing. - Disconnect the G1 terminal from the body. - Disconnect the G101 terminal from the water passage. Procedure: 1. Make sure all electrical items (A/C, audio, rear defogger, lights, etc.) are off. 2. Start the engine, and hold it at 3,000 rpm with no load (in Park or neutral) until the radiator fan comes on, or until the engine coolant temperature reaches 194 °F (90 °C). 3. Let the engine idle for about 5 minutes with the throttle fully closed. NOTE: If the radiator fan comes on, do not include its running time in the 5 minutes Page 9102 8. Put the splice connector in the proper size slot in the Crimper Tool, slide it to one end (where the flare begins), and close the crimper handles far enough to hold it in place. To release the ratchet mechanism at any point after the first click, squeeze the handles slightly and push the release lever, then let the handles open. 9. Insert one of the bare wires into the splice connector end that is in the crimper jaws. Push the wire all the way into the splice connector, and squeeze the crimper handles. Keep squeezing until the jaws touch, and hold it at that position until the ratchet clicks again. 10. Crimp the other wire in the same way into the other end of the splice connector. 11. After crimping, gently pull on the wires in the opposite directions to make sure they are secure in the connector. 12. Separate the other wires in the harness from the repaired wire(s), and shield them with nonflammable material. Page 5913 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. Test Equipment 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. Locations Throttle Position Sensor: Locations PGM-FI System - Component Location Index Ceiling Light/Spotlight Test/Replacement Dome Lamp: Service and Repair Ceiling Light/Spotlight Test/Replacement Ceiling Light/Spotlights Test/Replacement - With Moonroof 1. Turn the ceiling light/spotlights switches OFF. 2. Carefully pry off the lens (A) with a small screwdriver. 3. Remove the two screws and the housing (B). 4. Disconnect the 4P connector (C) from the housing. 5. Check the bulbs. If the bulbs are OK, check for continuity between the terminals in each switch position according to the table. 6. If the continuity is not as specified, replace the ceiling light. Primary HO2S and A/F Sensor Replacement Oxygen Sensor: Service and Repair Primary HO2S and A/F Sensor Replacement Primary HO2S and A/F Sensor Replacement Special Tools Required O2 sensor wrench, Snap-on YA8875, SP Tools 93750, or equivalent, commercially available 1. Disconnect the primary HO2S or A/F sensor 4P connector (A), then remove the primary HO2S or A/F sensor (B). 2. Install the primary HO2S or A/F sensor in the reverse order of removal. Page 1756 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 Locater) 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. Troubleshooting Precautions Troubleshooting Precautions Before Troubleshooting 1. Check the main fuse and the fuse 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, or you will damage the alternator diodes. - Do not attempt to crank the engine with the ground cable disconnected 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. Page 3557 159. Left Side Of Engine Compartment Page 4596 107. Behind A/T Shift Lever (except M/T) Page 6359 4. Install the washer (A) and a new self-locking nut (B) on the damper shaft. 5. Hold the damper shaft with a hex wrench (C), and tighten the self-locking nut to the specified torque. Installation 1. Position the damper assembly in the body. Note the direction of the damper mounting base so that the small hole dot on it is toward the front and inside of the vehicle. 2. Loosely install the flange nuts (A) onto the top of the damper. Specifications Brake Fluid: Specifications Geniune Honda Brake Fluid ................................................................................................................ ...................................................................... Dot 3 Page 3552 Camshaft Position Sensor: Description and Operation Camshaft Position (CMP) Sensor (Top Dead Center (TDC) Sensor) The CMP (TDC) sensor detects the position of the No.1 cylinder as a reference for sequential fuel injection to each cylinder. Page 4514 Pressure Plate: Service and Repair Clutch Disc and Pressure Plate Installation Clutch Replacement Special Tools Required ^ Clutch alignment shaft 07LAF-PT00110 ^ Clutch alignment disc 07JAF-PM7011A ^ Remover handle 07936-3710100 ^ Ring gear holder 07LAB-PV00100 or 07924-PD20003 ^ Attachment, 57 x 40 mm 07746-0010200 ^ Driver 077 49-0010000 Clutch Disc and Pressure Plate Installation 1. Install the ring gear holder. 2. Apply super high temp urea grease (P/N 08798-9002) to the splines (A) of the clutch disc (B), then install the clutch disc using the special tools. 3. Install the pressure plate (A) and the mounting bolts (B) finger-tight. 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 8267 Disclaimer Cutting Procedure - By Copying 1. Press the ON/OFF button in the middle of the setting unit keypad. (This powers up the keypad.) 2. Turn the clamp unit lock lever to the left to release the clamp unit, and slide it all the way to the left until it stops. Turn the lever to the right to lock the clamp unit in place. 3. Use the clamp carriage lever to position the clamp unit so the tracer and cutter bit are centered directly over the base of the center and right jaws. 4. Pull the vertical carriage lever toward you until the tracer and the cutter bit just touch the base of each fixed jaw. Watch the arrows on the keypad: ^ If the double-headed arrow in the middle of the keypad lights green, the tracer and cutter bit are properly aligned. ^ If the arrow on the left of the keypad lights red, the cutter bit is not touching the fixed jaw. Turn the micrometric ring nut above the tracer to the left until the double-headed arrow lights green. ^ If the arrow on the right of the keypad lights red, the tracer is not touching the fixed jaw. Turn the micrometric ring nut above the tracer to the right until the double-headed arrow lights green. *5. Turn the micrometric ring nut to the right three clicks so the cutter bit is slightly higher than the tracer. The arrow on the left should light red. Raise the vertical carriage. NOTE: Setting the tracer three clicks lower than the cutter bit has the effect of making the cutter bit cut the duplicated key a little shallower. This will protect the locking jaws from being damaged.* 6. Optional: Loosen the setscrew, and adjust the hand rest to a comfortable position. Tighten the screw. 7. Pull the clamp carriage lever toward you until the clamp carriage clicks into its end-of-run position. Tighten both the lateral and spring tension adjustment knobs. 8. Make sure the center and right jaws are free of any metal shavings or debris. (A soft-bristle toothbrush is ideal for this purpose.) Locations Oxygen Sensor Relay: Locations PGM-FI System - Component Location Index Page 4094 Diodes Light Emitting Diode (LED) Motor Pressure Sensor Page 3978 72. Shift Lock Solenoid (A/T) Page 4489 Clutch Switch: Testing and Inspection Clutch Interlock Switch Test 1. Disconnect the clutch interlock switch 2P connector. 2. Remove the clutch interlock switch (A). 3. Check for continuity between the terminals according to the table. - If the continuity is not as specified, replace the clutch interlock switch. - If OK, install clutch interlock switch and adjust the pedal height. Page 5970 Fuse Block: Connector Locations 71. Under Left Side Of Dash 70. Under Left Side Of Dash Environmental Impact Information Refrigerant: Environmental Impact Information Service Procedures The Ozone Layer A thin layer of ozone molecules, located 10 to 30 miles above the earth, form a protective cover by absorbing a portion of the ultraviolet (UV) radiation emitted from the Sun. Ozone Depletion Scientific research performed over the past 15 years links the release of chlorofluorocarbons (CFC)s, also know by the trade name Freon) into the atmosphere to ozone depletion. When CFC's are released into the atmosphere, they eventually reach the ozone layer located in the stratosphere where they react with and destroy ozone molecules. Harmful Effects Ozone depletion and the corresponding increase in UV radiation has been shown to lead to higher incidents of cancer as well as global warming. When viewed from a global perspective, ozone depletion holds an enormous potential for damage. Upper Level vs. Ground Level Ozone Confusion often arises when we hear about the necessity of the ozone layer and ground level ozone. The ozone layer existing high above the earth is beneficial but the same compound, when located at ground level, is harmful to humans, animals, crops and vegetation. Ground level ozone is a component of smog and forms when hydrocarbons (HC) react with nitrogen oxides (NOx) in the presence of sunlight and heat. Montreal Protocol In response to the growing body of evidence demonstrating the detrimental effects of (CFC)s, 24 countries and the European community met in Montreal, Canada, in 1987 to establish standards for the control of (CFC)s. Since that time, a total of 132 countries have become signatories to this agreement leading to an end of production of R12 in December, 1995, in all developed countries. As established by the Montreal Protocol, R12 production in developed countries has ceased. Clean Air Act The United States Congress, acting in response to the Montreal Protocol, banned production of (CFC)s by the year 2000. Congress also amended the Clean Air Act in an effort to control both the production and use of (CFC)s for refrigerant applications including mobile vehicle air conditioning systems. Alternative Refrigerants The introduction of alternative refrigerants, primarily the hydrofluorocarbon (HFC) 134a, aims at preventing further ozone layer depletion. Because 134a is chlorine free, it is deemed ozone safe. Technician Certification Organizations providing technician refrigerant recovery and recycling certification include: National Institute for Automotive Service Excellence (ASE) 13505 Dulles Technology Drive, Suite 2 Herndon, VA 22071-3421 Phone: (703) 713-3800 Fax: (703) 713-0727 http://www.asecert.org/ International Mobile Air Conditioning Association (IMACA) P.O. Box 9000 Fort Worth, TX 76147-2000 Phone: (817) 338-1100 Fax: (817) 338-1451 Mobile Air Conditioning Society (MACS) Worldwide P.O. Box 100 East Greenville, PA 18041 Phone: 215-679-2220 Fax: 215-541-4635 http://www.macsw.org/ Page 3520 Throttle Body: Description and Operation Throttle Body The throttle body is a single-barrel down draft type. The side portion of the idle air control (IAC) valve is heated by engine coolant from the cylinder head. Page 8904 Malfunction Indicator Lamp: Description and Operation Malfunction Indicator Lamp (MIL) Indication (In relation to Readiness Codes) The vehicle has certain "readiness codes" that are part of the on-board diagnostics for the emissions systems. If the vehicle's battery has been disconnected or gone dead, if the DTCs have been cleared, or if the ECM/PCM has been reset, these codes are reset. In some states, part of the emissions testing is to make sure these codes are set to complete. If all of them are not set to complete, the vehicle may fail the test or the test cannot be finished. To check if the readiness codes are set to complete, turn the ignition switch ON (II), but do not start the engine. The MIL will come on for 15 - 20 seconds. If it then goes off, the readiness codes are set. If it blinks several times, one or more readiness codes are not set to complete. To set each code, drive the vehicle or run the engine as described in the procedures to set them in this section. Page 4923 1. Remove and discard the plastic cover from the ignition switch key interlock solenoid. 2. Note the position of the interlock solenoid plunger; you'll need to install it the same way. 3. Remove the screw from the solenoid, but keep the solenoid attached to its electrical connector. Discard the screw. NOTE: ^ Be careful not to lose the solenoid plunger; it slides out easily. ^ Keep the plunger free of dirt and grease while it's removed from the solenoid. 4. Note the position of the interlock lever spring; you'll need to install the new spring the same way. Page 7123 28. Antenna Module (Coupe) Page 4366 Connectors - "C" Page 8278 WARRANTY CLAIM INFORMATION In warranty: The normal warranty applies. Failed Part: P/N 68500-S5P-A90ZZ H/C 6528640 *Defect Code: 07406* Symptom Code: 03220 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 A 1. Check the side-to-side alignment of the trunk lid latch to the striker: ^ Refer to page 20-132 of the 2001-04 Civic Service Manual. ^ In ISIS, use the keyword TRUNK ADJUST, and select Trunk Lid Adjustment from the list. 2. Make sure the gaps of the trunk lid are even on all sides. ^ If the trunk is misaligned, go to step 3. ^ If the trunk lid is properly aligned on all sides, go to REPAIR PROCEDURE B. 3. Adjust the trunk lid hinges: ^ Refer to page 20-132 of the 2001-04 Civic Service Manual. ^ In ISIS, use the keyword TRUNK ADJUST, and select Trunk Lid Adjustment from the list. 4. Check the trunk operation: ^ If the trunk opens and closes smoothly and is properly aligned, return the vehicle to the customer. ^ If the trunk lid is still difficult to close, go to REPAIR PROCEDURE B. REPAIR PROCEDURE B Page 4378 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 Locater) 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. Troubleshooting Precautions Troubleshooting Precautions Before Troubleshooting 1. Check the main fuse and the fuse 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, or you will damage the alternator diodes. - Do not attempt to crank the engine with the ground cable disconnected 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. Page 2860 160. Left Side Of Engine Compartment (except GX) Capacity Specifications Refrigerant: Capacity Specifications Refrigerant Capacity or system .............................................................................................................................. ................................... 500 - 550 g (17.6 - 19.4 oz) Page 7244 1991-93 Accord 5-door EX with factory-installed keyless entry or dealer-installed security system Programming the Transmitter The transmitter is not programmable. Ordering a Transmitter Transmitters can be ordered only by authorized Honda dealers. To order a transmitter, you need the vehicle's VIN, the code number from the power door lock control unit, and the ignition key code number. The power door lock code number is a five-digit number etched into the plastic case of the control unit (mounted under the driver's seat). The ignition key code number is a four-digit number stamped on the metal shank of all five original keys delivered with the car. Replacement transmitters are manufactured to match the code of the keyless entry system. The new ignition key is cut to match the vehicle's ignition switch, front door locks, tailgate lock, and glove compartment lock. To order this transmitter, use the controlled parts ordering screen on the iN system. The transmitters are manufactured in Japan; delivery takes 4 to 6 weeks. Batteries for the Transmitter The battery is not replaceable. 91-93 Accord 5-Door LX 1991-93 Accord 5-door LX with dealer-installed security system Programming the Transmitter This transmitter is not programmable. Ordering a Transmitter Transmitters can be ordered directly from Kenwood USA only by authorized Honda dealers. Send a completed order form (copy it from the Accessory Replacement Parts section of the Dealer Parts Price List) along with a dealer check for $30.00 (payable to Kenwood U.S.A. Corp.) to this address: Kenwood Service Corp. P.O. Box 22745 Long Beach, CA 90501-5745 Page 6548 43. Evapoator Temperature Sensor Page 5870 Power Windows Component Location Index Page 9011 Shift Indicator: Diagnostic Aids General Troubleshooting Information General Troubleshooting Information Tips and Precautions Before Troubleshooting 1. Check applicable fuses in the appropriate fuse/relay box. 2. Check the battery for damage, state of charge, and clean and tight connections. NOTE: 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. Handling Connectors - Make sure the connectors are clean and have no loose wire terminals. - Make sure multiple cavity connectors are packed with dielectric grease (except watertight connectors). - All connectors have push-down release type locks (A). - Some connectors have a clip on their side used to attach them to a mount bracket on the body or on another component. This clip has a pull type lock. - Some mounted connectors cannot be disconnected unless you first release the lock and remove the connector from its mount bracket (A). - Never try to disconnect connectors by pulling on their wires; pull on the connector halves instead. - Always reinstall plastic covers. Page 7656 ^ Incorrect: "If a Master Key is to be cut, put a five (5) in the blank space. Use a two (2) if a valet key is needed." ^ Correct: "If a Master Key is to be cut, put an M in the blank space. Use an S if a valet key is needed." Page 2, legend at the bottom: ^ Incorrect: "C. If a Master key is desired, then the number five (5) should be placed in the M/S position. Place the number two (2) in the M/S column if a Sub (Valet) key is needed." ^ Correct: "C. If a Master Key is desired, then an M should be placed in the M/S position. Place an S in the MIS column if a Sub (Valet) key is needed." M/T - Clicking Noise Driving in 2nd Gear Synchronizer Hub: All Technical Service Bulletins M/T - Clicking Noise Driving in 2nd Gear 03-009 June 10, 2003 Applies To: 2001-03 Civic DX, LX, HX, EX with M/T - ALL 2003 Civic Hybrid - From VIN JHMES95..3S000001 thru JHMES95..3S018631 Clicking Noise While Driving in 2nd (Supersedes 03-009, dated April 1, 2003) Updated information is shown with asterisks. SYMPTOM * While driving in 2nd gear, a clicking noise occurs when turning right (DX, LX, HX, and EX) or when turning left (Civic Hybrid).* PROBABLE CAUSE The reverse idler gear is contacting the 1st/2nd hub sleeve set. CORRECTIVE ACTION Replace the reverse idler gear, the 1st/2nd synchro hub/sleeve set, and the reverse gear holder. REQUIRED MATERIALS Honda Manual Transmission Fluid (1.7 quarts required): P/N 08798-9016, H/C 4928271 Liquid Gasket: P/N 08718-0001, H/C 2963817 PARTS INFORMATION WARRANTY CLAIM INFORMATION In warranty: The normal warranty applies. Operation Number: 213110 Page 820 2. Remove the terminal (same procedure for male and female). 3. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE E: 1. Remove the secondary locks. 2. Remove the terminal (same procedure for male and female). 3. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE F: Page 309 Main Relay (Computer/Fuel System): Description and Operation PGM-FI Main Relay 1 and 2 The PGM-FI relay consists of two separate relays. PGM-FI main relay 1 is energized whenever the ignition switch is ON (II) which supplies battery voltage to ECM/PCM, power to the injectors, and power for PGM-FI main relay 2. PGM-FI main relay 2 is energized to supply power to the fuel pump for 2 seconds when the ignition switch is turned ON (II), and when the engine is running. Page 1761 Use the tools from Pin Tool Set. First, check the connector that you are about to repair. - If it has a secondary terminal lock, go to Connectors With a Secondary Lock. A secondary lock, found on most connectors on some models, is an additional locking device on the connector housing as a backup for the primary lock on the terminal. - If the connector does not have a secondary lock, go to Connectors Without a Secondary Lock. Connectors With a Secondary Lock All examples are shown with the connector lock facing up. The illustrations are examples of the secondary terminal locks; however, the connector you are repairing may vary in size. Identify the connector by the type of secondary lock, not by the number of terminal cavities. EXAMPLE A: 1. Release the secondary lock. 2. Remove the terminal. 3. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE B: Page 1949 5. If 8 numbers (1 to 8) are printed around the outside of the filter, use the following procedure to tighten the filter. ^ Spin the filter on until its seal lightly seats against the block, and note which number is at the bottom. ^ Tighten the filter by turning it clockwise 7 numbers from the one you noted. For example, if number 2 is at the bottom when the seal is seated, tighten the filter until the number 1 comes around the bottom. 6. After installation, fill the engine with oil up to the specified level, run the engine for more than 3 minutes, then check for oil leakage. Page 5531 162. Right Side Of Engine Compartment 165. Under Left Side Of Floor (EX) Page 282 ECM/PCM Inputs And Outputs At Connector C (22P) Locations Control Module: Locations Electronic Controls Location Page 6974 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 3496 Blower Motor Relay Type 1, Type 2 Check for continuity between the terminals. - There should be continuity between the No.1 and No.3 terminals when power and ground are connected to the No.2 and No.4 terminals. - There should be no continuity between the No.1 and No.3 terminals when power is disconnected. Five-terminal type Check for continuity between the terminals. - There should be continuity between the No.1 and No.2 terminals when power and ground are connected to the No.3 and No.5 terminals. - There should be continuity between the No.1 and No.4 terminals when power is disconnected. Page 4622 Transmission Speed Sensor: Diagrams 105. CVT Drive Pulley Speed Sensor 106. CVT Driven Pulley Speed Sensor 107. CVT Speed Sensor 1 108. CVT Speed Sensor 2 Page 3254 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. Circuits must be operating when checking voltage drop. 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. 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 off, 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 Self-Powered Test Light or DVOM 1. Remove the blown fuse and disconnect the battery and load. Component Locations Shift Interlock Switch: Component Locations Component Location Index Page 381 1. On Accords and Pilots, remove the front passenger's seat-back panel by prying out the bottom. Replace the two lower clips. 2. On all models except Accords and Pilots, unzip the two seat cover zippers on the back of the front passenger's seat. 3. Pull back the seat-back cover from the left side bolster to access the OPDS unit cover. 4. Remove the OPDS unit cover from the seat frame. 5. Check the part number of the installed OPDS unit. Page 9350 License Plate Lamp: Diagnostic Aids General Troubleshooting Information General Troubleshooting Information Tips and Precautions Before Troubleshooting 1. Check applicable fuses in the appropriate fuse/relay box. 2. Check the battery for damage, state of charge, and clean and tight connections. NOTE: 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. Handling Connectors - Make sure the connectors are clean and have no loose wire terminals. - Make sure multiple cavity connectors are packed with dielectric grease (except watertight connectors). - All connectors have push-down release type locks (A). - Some connectors have a clip on their side used to attach them to a mount bracket on the body or on another component. This clip has a pull type lock. - Some mounted connectors cannot be disconnected unless you first release the lock and remove the connector from its mount bracket (A). - Never try to disconnect connectors by pulling on their wires; pull on the connector halves instead. - Always reinstall plastic covers. Locations 12. Middle of Engine Alignment Alignment: Specifications Alignment Wheel alignment Camber Front .................................................................................................................................................... ....................................................... 0°00' ± 45' Rear ........................................................................... ................................................................................................................................ -0°45' ± 45' Caster, Front '01-02 models ...................................................................................................................................... ......................................................... 1°33' ± 1° '03-04 models ........................................................... .................................................................................................................................... 2°14' ± 1° Total toe Front .................................................................................................................................................... ............................. 0 ± 3 mm (0 ± 0.12 inch) Rear ............................................................................... .................................................................................. IN 2 [2/1] mm (0.08 [0.08/0.04] inch) Front wheel turning angle Inside wheel w/o P195/60R15 tire.............................................................. ...................................................................................................... 40°00' ± 2° Inside wheel w P195/60R15 tire.................................................................................................................................... ................................... 38°00' ± 2° Outside wheel w/o P195/60R15 tire ................................................................................................................................................... 31°00' (Reference) Outside wheel w P195/60R15 tire ...................................................................................................................................................... 30°00' (Reference) ECM/PCM Terminal Values Engine Control Module: Testing and Inspection ECM/PCM Terminal Values ECM/PCM Inputs And Outputs At Connector A (31P) Page 3970 Page 9015 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 Locater) 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. Troubleshooting Precautions Troubleshooting Precautions Before Troubleshooting 1. Check the main fuse and the fuse 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, or you will damage the alternator diodes. - Do not attempt to crank the engine with the ground cable disconnected 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. Page 8862 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 6299 3. Install the special tool as shown. Insert the jaws carefully, making sure not to damage the ball joint boot. Adjust the jaw spacing by turning the pressure bolt (B). 4. After adjusting the adjusting bolt, make sure the head of the adjusting bolt (A) is in the position shown to allow the jaw (C) to pivot. 5. With a wrench, tighten the pressure bolt until the ball joint pin pops loose from the steering arm or knuckle. If necessary, apply penetrating type lubricant to loosen the ball joint pin. 6. Remove the tool, then remove the nut from the end of the ball joint pin, and pull the ball joint out of the steering arm or knuckle. Inspect the ball joint boot, and replace it if damaged. Body Paint Paint: Service and Repair Body Paint General General The 3-coat-3-bake (3C.3B) paint finishes gives the Civic a deep gloss and stunning finish. This manual provides information on paint defects, repair, and refinishing. Throughout, the objective is to explain in a simple yet comprehensive manner the basic items you should know about paint repairs. Select the correct material for the defect, and repaint or refinish in the correct manner as described. WARNING: - Most paints contain substances that are harmful if inhaled or swallowed. Read the paint label before opening the container. Spray paint only in a well ventilated area. - Cover spilled paint with sand, or wipe it up at once. - Wear an approved respirator, gloves, eye protection, and appropriate clothing when painting. Avoid contact with skin. - If paint gets in your mouth or on your skin, rinse or wash thoroughly with water. If paint gets in your eyes, flush with water and get prompt medical attention. - Paint is flammable. Store it in a safe place, and keep it away from sparks, flames, or cigarettes. Basic Rules for Repairing a Paint Finish To repair paint damage, always use the 2-part acrylic urethane paints designated; polish and bake each of the three coats, as in production, to maintain the original film thickness, and to assure the same quality as the original finish. Outline of Factory Painting Process: Features in Each Work Process 1. Pretreatment and Electrodeposition In the pretreatment process, the entire body is degreased, cleaned, and coated with zinc phosphate by dipping. After the body has been cleaned with pure water, it is placed in an electrolytic bath of soluble primer (Cationic Electrodeposition) This produces a thorough corrosion inhibiting coating on the inner surface and corners of the body, pillars, sills, and panel joints. Chipping primer is then applied to the most susceptible areas. 2. Intermediate coat The intermediate coat is applied to the prepared surface for further protection against damage. 3. Top Coat Enamel paint and either polyester or acrylic resin paint are used in the top coat for higher solidity, smoothness, brightness, and weather resistance. Sectional View of Paint Coats: Refinishing Processes Refinishing Processes Page 7169 6. Disconnect the M, P, K, and J connectors from the under-dash fuse/relay box, and make these input tests at the connectors. - If any test indicates a problem, find and correct the cause, then recheck the system. - If all the input tests prove OK, the multiplex control unit must be faulty. Replace the under-dash fuse/relay box assembly. Page 1667 Terminals - "T" Shielding Switches Fuses Page 6685 Air Bag(s) Arming and Disarming: Description and Operation SRS Operation SRS Operation The main circuit in the SRS unit senses and judges the force of impact and, if necessary, ignites the inflator charges. 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: Seat Belt Tensioners and Seat Belt Buckle Tensioners 1. A front impact sensor must activate and send electric signals to the microprocessor. 2. The microprocessor must compute the signals and send them to the tensioners. 3. The charges must ignite and deploy the tensioners. Driver's and Front Passenger's Airbag(s) 1. A front impact sensor must activate, and send electric signals to the microprocessor. 2. The microprocessor must compute the signals, and depending on the severity of the collision and whether the seat belt buckle switch is ON or OFF, it sends the appropriate signals to the airbag inflator(s). 3. The inflators that received signals must ignite and deploy the airbags. Side Airbag(s) 1. Aside impact sensor must activate, and send electric signals to the microprocessor. 2. The microprocessor must compute the signals and send them to the side airbag inflator(s). However, the microprocessor cuts off the signals to the front passenger's side airbag if the OPDS unit determines that the front passenger's head is in the deployment path of the side airbag. 3. The inflator that received the signal must ignite and deploy the side airbag. Self-diagnosis System A self-diagnosis circuit is built into the SRS unit; when the ignition switch is turned ON (II), the SRS indicator comes on and goes off after about 6 seconds if the SRS is operating normally. If the indicator does not come on, or does not go off after 6 seconds, or if it comes on while driving, it indicates an abnormality in the SRS. The SRS must be inspected and repaired as soon as possible. For better serviceability, the SRS unit memory stores a DTC that relates to the cause of the malfunction, and the unit is connected to the data link circuit. This information can be read with the Honda PGM Tester when it is connected to the data link connector (DLC). Technician Safety Information Air Bag(s) Arming and Disarming: Technician Safety Information Technician Safety Information Page 2494 65. PSP Switch Page 4513 5. Align the hole in the flywheel with the crankshaft dowel pin, and install the flywheel. Install the mounting bolts finger-tight. 6. Install the special tool, then torque the flywheel mounting bolts in a crisscross pattern in several steps. 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 9511 2. Insert the terminal tool into the female terminal, and then remove the terminal tool. NOTE: Make sure you do not select a terminal tool that is larger than the mating male terminal because it would spread the female terminal and cause a loose fit. 3. Compare the drag to the other terminals in the connector. If the drag is less, replace the terminal with a replacement terminal from the appropriate terminal repair kit. Page 5545 Clutch Switch: Adjustments Clutch Pedal, Clutch Pedal Position Switch, and Clutch Interlock Switch Adjustment NOTE: ^ To check the clutch pedal position switch. ^ To check the clutch interlock switch. ^ Remove the driver's side floor mat before adjusting the clutch pedal. ^ The clutch is self-adjusting to compensate for wear. ^ If there is no clearance between the master cylinder piston and push rod, the release bearing is held against the diaphragm spring, which can result in clutch slippage or other clutch problems. 1. Loosen locknut (A), and back off the clutch pedal position switch (B) (or adjusting bolt) until it no longer touches the clutch pedal (C). 2. Loosen locknut (D), and turn the push rod (E) in or out to get the specified height (F) and stroke (G) at the clutch pedal. Clutch Pedal Stroke: 130 - 140 mm (5.1 - 5.5 inch) Clutch Pedal Height: 198 mm (7.8 inch) 3. Tighten locknut (D). 4. With the clutch pedal released, turn the clutch pedal position switch (B) in until it contacts the clutch pedal (C).. 5. Turn the clutch pedal position switch (B) in an additional 3/4 to 1 turn. 6. Tighten locknut (A). 7. Loosen locknut (H) and the clutch interlock switch (1) 8. Press the clutch pedal to the floor. 9. Release the clutch pedal 15 - 20 mm (0.59 - 0.79 inch) from the fully depressed position, and hold it there. Adjust the position of the clutch interlock switch (1) so that the engine will start with the clutch pedal in this position. 10. Tighten locknut (H). Page 6591 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 7025 8. Install the buckle in the reverse order of removal, and note these items: - Assemble the washers on the center anchor bolt as shown. - Apply liquid thread lock to the center anchor bolt before reinstallation. - If the seat belt tensioner has been deployed, replace the front seat belt protector with a new one. - Apply liquid thread lock to the seat mounting bolts before reinstallation. - Reconnect the negative cable to the battery. - Enter the anti-theft code for the radio, then enter the customer's radio station presets. - Reset the clock. - Do the ECM idle learn procedure. Page 4030 Shift Interlock Solenoid: Testing and Inspection Shift Lock Solenoid Test 1. Remove the center console panel and center console. 2. Disconnect the shift lock solenoid connector (2P). 3. Connect the No. 1 terminal of the shift lock solenoid connector (2P) to the battery positive terminal, and connect the No. 2 terminal to the battery negative terminal. 4. Check that the shift lever can be moved from the P position. Release the battery terminals from the shift lock solenoid connector. Move the shift lever back to the P position, and make sure it locks. NOTE: Do not connect power to the No. 2 terminal (reverse polarity) or you will damage the diode inside the solenoid. 5. Check that the shift lock releases when the shift lock release is pushed, and check that it locks when the shift lock release is released. 6. If the shift lock solenoid does not work properly, replace it. Page 8088 80. Under Middle Of Dash Page 7104 12. Watch the SRS indicator: ^ If the indicator blinks twice and then goes off, the OPDS unit is initialized. Turn the ignition switch to LOCK (0), and disconnect the HDS. ^ If the indicator blinks twice and then stays on, the OPDS unit is initialized, but SRS DTCs need to be cleared. Go to step 13. ^ If the indicator stays on without first blinking, the OPDS unit is not initialized. Repeat steps 3 thru 12. 13. Turn the ignition switch to LOCK (0), then disconnect the HDS. 14. Reconnect the SCS service connector to the MES connector. Do not use a jumper wire. 15. Turn the ignition switch to ON (II). 16. Watch the SRS indicator. (It comes on for about 6 seconds and then goes off.) Disconnect the SCS service connector from the MES connector within 4 seconds after the indicator goes off. 17. When the SRS indicator comes on again, connect the SCS service connector to the MES connector within 4 seconds after the indicator comes on. 18. When the SRS indicator goes off, disconnect the SCS service connector from the MES connector within 4 seconds. (The SRS indicator blinks twice to indicate that the memory has been cleared.) 19. Turn the ignition switch to LOCK (0), and wait for 10 seconds. 20. Turn the ignition switch to ON (II). (The SRS is OK if the SRS indicator comes on for 6 seconds and then goes off.) If the DTC clearing fails, repeat the process two more times. If the DTC clearing fails again, check for set SRS DTCs, and troubleshoot them with the appropriate service manual. REPAIR PROCEDURE B: OPDS SENSOR REPLACEMENT 1. Remove the seat-back cover from the front passenger's seat: ^ Using the appropriate service manual, go to section 20 (Body), and do the removal steps under Front Seat Cover Replacement, or ^ Online, enter keyword SEAT COVER, then select Front Seat Cover Replacement from the list, and do the removal steps in the procedure. 2. Slide the seat-back cushion (foam) off the seat-back frame. (The OPDS sensor is built into the seat-back cushion.) 3. Slide a new seat-back cushion over the seat-back frame. Make sure the cushion is centered. 4. Install the seat-back cover: ^ Using the appropriate service manual, go to section 20 (Body), and do the installation step under Front Seat Cover Replacement, or ^ Online, enter keyword SEAT COVER, then select Front Seat Cover Replacement from the list, and do the installation step in the procedure. 5. Initialize the OPDS unit: ^ To initialize with the HDS, go to Initializing the OPDS Unit: HDS Method in this service bulletin. ^ To initialize with the SCS service connector, go to Initializing the OPDS Unit: Manual Mode in this service bulletin. Disclaimer Page 2758 DTC P2240 thru U0073 Page 8361 NOTE: Use a spray gun to apply the paint. Do not use a brush. Drying Time: Force dry the intermediate coat and top coat. NOTE: Mix only an amount that can be used before it hardens. Page 2095 Air Filter Element: Service and Repair Air Cleaner Element Replacement 1. Open the air cleaner housing cover (A). 2. Remove the air cleaner (B) from the air cleaner housing (C). 3. Install in the reverse order of removal. Body - Door Lock Cylinders Bind Trunk / Liftgate Lock Cylinder: Customer Interest Body - Door Lock Cylinders Bind 03-068 October 29, 2004 Applies To: See VEHICLES AFFECTED Door Lock Cylinder Binds (Supersedes 03-068, dated April 20, 2004) Updated information is shown with asterisks and black bars. SYMPTOM The key will not go into the door lock cylinder, or if it goes in, it will not turn. PROBABLE CAUSE The door lock tumblers are damaged or worn. VEHICLES AFFECTED CORRECTIVE ACTION Remove the door lock cylinder, and replace the inner cylinder, springs, and tumblers. Page 4726 3. Remove the brake hose bracket mounting bolt (A). 4. Remove the caliper bracket mounting bolts (B), and remove the caliper assembly (C) from the knuckle. To prevent damage to the caliper assembly or brake hose, use a short piece of wire to hang the caliper assembly from the undercarriage. Do not twist the brake hose with force. 5. Raise the stake (A), and remove the spindle nut (B), then remove and discard the nut. 6. Remove the brake disc retaining flat screws (A). 7. Screw two 8 x 1.25 mm bolts (B) into the disc to push it away from the hub. Turn each bolt 2 turns at a time to prevent cocking the disc excessively. Capacity Specifications Engine Oil: Capacity Specifications Engine Oil D17A2, D1746 engines: For engine overhaul ............................................................................................................................. .............................................................. 4.2L (4.4 Qt) For oil change, including filter .............................................................................................................. ............................................................ 3.5L (3.7 Qt) For oil change, without filter ................................................................................................................. ............................................................ 3.3L (3.5 Qt) D17A1 engine: For engine overhaul ............................................................................................................................. .............................................................. 4.2L (4.4 Qt) For oil change, including filter .............................................................................................................. ............................................................ 3.2L (3.4 Qt) For oil change, without filter ................................................................................................................. ............................................................ 3.0L (3.2 Qt) Page 144 Headlamp Relay: Testing and Inspection Power Relay Test Use this chart to identify the type of relay, then do the test listed for it. NOTE: See the turn signal/hazard relay input test. Normally-open type A: Page 4975 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. Below most connector numbers and component names are PHOTO and VIEW numbers. The PHOTO number refers to a photo in the back of the book that shows the connector's location on the car. The VIEW number refers to an illustration in the back of the book that shows the connector terminals, wire colors, connector cavity numbers, and other details. The connector cavity numbering sequence begins at the top left corner of the connector as seen from either of the viewpoints shown on diagram [8] . Except for the DLC (data link 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 C554, for example, means those terminals join in cavity 2 of connector C554. Power Distribution Schematics Power Distribution Schematics Page 7269 Wires Page 3399 Fuel: Vehicle Damage Warnings CAUTION: Your vehicle must use unleaded fuel only. Using leaded fuel will damage the catalytic converter and affect the warranty coverage validity. Page 3269 13. Plug in the heat gun, and turn it on. Start at the middle of the splice connector, and move the gun toward the ends as the tube shrinks. Apply heat evenly by rotating the curved heat spreader around the splice connector. Shrinking is complete when a small amount of sealant appears at each end of the tube. Pigtail Terminal Selection Chart PIGTAIL TERMINAL SELECTION CHART Select the proper size pigtail terminal by matching the replacement terminal part number and the wire size being repaired to the corresponding pigtail terminal part number. Then use the color (size) splice connector listed. In some instances you may also have to match the wire seal style to select the proper pigtail terminal. Pigtail terminals are available through your parts department, in quantities of 10, using normal parts ordering procedures. Checking For Poor Fir of Terminals CHECKING FOR POOR FIT OF TERMINALS Loose terminal fit can cause a number of intermittent problems in electrical circuits. By using the Terminal Inspection Feeler Tool Set you can inspect the terminal fit between the two matching connectors without removing the terminals from the connector body. 1. Find the terminal tool that best matches the male terminal in the mating connector. Page 7227 6. Press and hold the green programming button on the side of the control unit until the LED on the instrument panel begins to flash, then release the button. (Steps 6 and 7 must be done within 5 seconds of each other.) 7. Press and release the bottom button on the transmitter. Verify that the LED goes out, the siren chirps twice, and the front sidemarker lights flash twice to confirm that the transmitter's code was accepted by the control unit. 8. Turn the ignition switch to LOCK. Test the transmitter you just programmed. If it doesn't work repeat steps 2 thru 7. 9. If you have another transmitter to program, repeat steps 2 thru 7. Ordering a Transmitter Transmitters can be ordered only by authorized Honda dealers. Order them from American Honda using normal parts ordering procedures. Batteries for the Transmitter The battery number is CR2025. Each transmitter uses one battery. 98-02 Passport With Factory-Installed Security System 1998-02 Passport with factory-installed security system Programming the Transmitter To program the transmitters, use one of these two procedures: ^ Procedure One cancels all learned transmitter codes and adds one new transmitter. None of the previously programmed transmitters will work. Use this programming procedure only if all transmitters were lost or stolen, or if a new control unit has been installed. ^ Procedure Two adds additional transmitters without cancelling any of the previously learned codes. The system will accept up to four transmitters. Procedure One (cancels all codes, adds one new transmitter) 1. Open the driver's door. 2. Turn the ignition switch to the ACC position and then to the LOCK position three times. (This step must be completed within 10 seconds, or the system will not enter the programming mode.) 3. Within 10 seconds, close and open the door two times. 4. Turn the ignition switch to the ACC position and then to the LOCK position five times. Close and open the door. (Complete this process within 10 seconds.) Verify that the power door locks cycle once to confirm that the system is in programming mode. 5. Within 20 seconds, press the "LOCK" button on the transmitter you are programming. Verify that the door locks cycle once. 6. Within 20 seconds, press the "UNLOCK" button on the transmitter. Verify that the door locks cycle once to confirm that the system has accepted the transmitter's code. Procedure Two (adds transmitters) 1. Open the driver's door. 2. Turn the ignition switch to the ACC position and then to the LOCK position three times. (This step must be completed within 10 seconds, or the Page 9826 Power Window Switch: Testing and Inspection Passenger's Window Switch Input Test Passenger's Switch Input Test 1. Remove the switch panel. 2. Disconnect the 5P connector (A) from the switch (B). 3. Inspect the connector and socket terminals to be sure they are all making good contact. - If the terminals are bent, loose or corroded, repair them as necessary, and recheck the system. - If the terminals look OK, go to step 4. Page 1728 5. Inspect the rocker arm piston (A). Push it manually. If it does not move smoothly, replace the rocker arm set. NOTE: ^ When reassembling the primary rocker arm (B), carefully apply air pressure to its oil passage. ^ Apply oil to the pistons when reassembling. Page 8563 Spoiler: Service and Repair Trunk Lid Spoiler Replacement For Some '03-05 Models 1. On the inside of the trunk lid, disconnect the high mount brake light connector (A), and remove the nuts (2-door) or bolts (4-door). 2. Lift up on the trunk lid spoiler (B), and on the 4-door, release the pins (C) from both grommets (D). Remove the wire harness grommet (E), then pull out the spoiler subharness (F) through the hole in the trunk lid, and remove the spoiler. 3. Install the spoiler in the reverse order of removal, and note these items: - Replace any damaged seals (G). - Before installing the seal, clean the spoiler and bracket surfaces with a sponge dampend in alcohol. - Make sure the high mount brake light connector is connected properly. - 4-door: Apply liquid thread lock to the spoiler mounting bolts before reinstallation. Page 1682 Use the tools from Pin Tool Set. First, check the connector that you are about to repair. - If it has a secondary terminal lock, go to Connectors With a Secondary Lock. A secondary lock, found on most connectors on some models, is an additional locking device on the connector housing as a backup for the primary lock on the terminal. - If the connector does not have a secondary lock, go to Connectors Without a Secondary Lock. Connectors With a Secondary Lock All examples are shown with the connector lock facing up. The illustrations are examples of the secondary terminal locks; however, the connector you are repairing may vary in size. Identify the connector by the type of secondary lock, not by the number of terminal cavities. EXAMPLE A: 1. Release the secondary lock. 2. Remove the terminal. 3. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE B: Component Locations Heating Component Location Index Page 9813 (Coupe Except DX, HX) 167. Power Window Switch, Front Passenger's (Sedan Except DX) 168. Power Window Switch, Left Rear Or Right Rear (Sedan Except DX) Page 3882 7. Align the cutouts (A) on the rotary-frame with the neutral positioning cutouts (B) on the transmission range switch, then put a 2.0 mm (0.08 inch) feeler gauge blade (C) in the cutouts to hold it in the N Position. NOTE: Be sure to use a 2.0 mm (0.08 inch) blade or equivalent to hold the switch in the N position. 8. Install the transmission range switch (A) gently on the control shaft (B) while holding it in the N position with the 2.0 mm (0.08 inch) blade (C). 9. Tighten the bolts on the transmission range switch while you continue to hold the N position. Do not move the transmission range switch when tightening the bolts. Remove the feeler gauge. Key Beeper, Light Chime & Ceiling Light Don't Work Door Switch: Technical Service Bulletins Key Beeper, Light Chime & Ceiling Light Don't Work SOURCE: Honda Service News April 2003 TITLE: Key Beeper, Light Chime, Ceiling Light Don't Work APPLIES TO: 2001-03 Civic, 2002-03 CR-V SERVICE TIP: If the ignition key-in beeper, the headlights-on chime, the ceiling light, and the driver's-dooropen indicator are all on the fritz check the driver's door switch in the doorjamb. A faulty door switch can cause all of these symptoms. Page 3825 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. Circuits must be operating when checking voltage drop. 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. 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 off, 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 Self-Powered Test Light or DVOM 1. Remove the blown fuse and disconnect the battery and load. Page 8091 Keyless Entry Receiver: Diagrams 163. Keyless Receiver Unit (EX; '04-'05: LX, GX) 164. Keyless Receiver Unit (Honda Accessory) ECM/PCM Terminal Values Engine Control Module: Testing and Inspection ECM/PCM Terminal Values ECM/PCM Inputs And Outputs At Connector A (31P) Page 6757 2. Connect the cable reel to the driver's airbag 4P connector (A), then install the access panel (B) on the steering wheel. 3. Connect the battery negative cable. 4. After installing the airbag, confirm proper system operation: - Turn the ignition switch ON (II); the SRS indicator should come on for about 6 seconds and then go off. - Make sure the horn works. Page 5263 2. Insert the terminal tool into the female terminal, and then remove the terminal tool. NOTE: Make sure you do not select a terminal tool that is larger than the mating male terminal because it would spread the female terminal and cause a loose fit. 3. Compare the drag to the other terminals in the connector. If the drag is less, replace the terminal with a replacement terminal from the appropriate terminal repair kit. Page 4428 Clutch Disc: Service and Repair Clutch Disc and Pressure Plate Installation Clutch Replacement Special Tools Required ^ Clutch alignment shaft 07LAF-PT00110 ^ Clutch alignment disc 07JAF-PM7011A ^ Remover handle 07936-3710100 ^ Ring gear holder 07LAB-PV00100 or 07924-PD20003 ^ Attachment, 57 x 40 mm 07746-0010200 ^ Driver 077 49-0010000 Clutch Disc and Pressure Plate Installation 1. Install the ring gear holder. 2. Apply super high temp urea grease (P/N 08798-9002) to the splines (A) of the clutch disc (B), then install the clutch disc using the special tools. 3. Install the pressure plate (A) and the mounting bolts (B) finger-tight. Page 171 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 Locater) 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. Troubleshooting Precautions Troubleshooting Precautions Before Troubleshooting 1. Check the main fuse and the fuse 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, or you will damage the alternator diodes. - Do not attempt to crank the engine with the ground cable disconnected 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. Page 9512 Interior Lighting Module: Electrical Diagrams Diagram 115-0 (except EX) Page 1878 NOTE: ^ Identify parts as they are removed to ensure reinstallation in original location. ^ Inspect the rocker shafts and rocker arms. ^ The rocker arms must be installed in the same positions if reused. ^ When removing or installing the rocker arm assembly, do not remove the camshaft holder bolts. The bolts will keep the holders, springs and rocker arms on the shaft. ^ Prior to reassembling, clean all the parts in solvent, dry them, and apply lubricant to any contact points. Page 8381 Sunroof / Moonroof Relay: Testing and Inspection Power Relay Test Use this chart to identify the type of relay, then do the test listed for it. NOTE: See the turn signal/hazard relay input test. Five-terminal type Check for continuity between the terminals. - There should be continuity between the No.1 and No.2 terminals when power and ground are connected to the No.3 and No.5 terminals. - There should be continuity between the No.1 and No.4 terminals when power is disconnected. Testing and Inspection Timing Belt: Testing and Inspection Inspection 1. Remove the ignition coil cover, then remove the four ignition coils. 2. Remove the throttle cable clamps and harness holder mounting bolts. 3. Remove the cylinder head cover. 4. Inspect the timing belt for cracks and oil or coolant soaking. Replace the belt if it is oil or coolant soaked. Remove any oil or solvent that gets on the belt. 5. After inspecting, retorque the crankshaft pulley bolt. Page 4008 Shift Solenoid: Service and Repair Shift Solenoid Valves A and B Replacement NOTE: Shift solenoid valves A and B must be removed/ replaced as an assembly. 1. Remove the harness clamp (c) form the clamp bracket (D). 2. Remove the mounting bolts and the shift solenoid valves A and B. 3. Clean the mounting surface and fluid passage. 4. Install a new shift solenoid valves A and B with a new filter/gasket (E), and install the harness clamp on the clamp bracket. 5. Check the connector for rust, dirt, or oil, then reconnect the connector securely. Page 3593 Crankshaft Position Sensor: Service and Repair CKP Sensor Replacement 1. Remove the grommet (A) from the upper cover, and disconnect the camshaft position (CMP) (top dead center (TDC)) sensor connector (B). 2. Remove the upper cover (C) and lower cover (D). 3. Disconnect the crankshaft position (CKP) sensor connector, then remove the CKP sensor from the oil pump. 4. Install the CKP sensor in reverse order of removal. Page 8226 1. Check the depth adjustment of the trunk lid: ^ Refer to page 20-132 of the 2001-04 Civic Service Manual. ^ In ISIS, use the keyword TRUNK ADJUST, and select Trunk Lid Adjustment from the list. 2. Make sure the trunk lid is flush on all sides and corners. ^ If the trunk is misaligned, go to step 3. ^ If the trunk lid is properly aligned on all sides and corners, go to REPAIR PROCEDURE C. 3. Adjust the striker depth position and the trunk lid edge cushions: ^ Refer to page 20-132 of the 2001-04 Civic Service Manual. ^ In ISIS, use the keyword TRUNK ADJUST, and select Trunk Lid Adjustment from the list. 4. Check the trunk operation: ^ If the trunk opens and closes smoothly, return the vehicle to the customer. ^ If the trunk lid is still difficult to close, go to REPAIR PROCEDURE C. REPAIR PROCEDURE C 1. Use a small screwdriver to manually set and release the trunk lid latch. Check the operation of the latch: ^ If the latch is difficult to set or release, go to step 2. ^ If the latch operates properly, go to REPAIR PROCEDURE D. 2. Replace the trunk lid latch: ^ Refer to page 20-157 of the 2001-04 Civic Service Manual. ^ In ISIS, use the keyword LID LATCH, and select Trunk Lid Latch Replacement from the list. 3. Check the trunk operation: ^ If the trunk opens and closes smoothly, return the vehicle to the customer. ^ If the trunk lid is still difficult to close, go to REPAIR PROCEDURE D. REPAIR PROCEDURE D 1. Disconnect the trunk lid opener cable from the trunk lid latch. Check the cable operation: ^ Refer to page 20-157 of the 2001-04 Civic Service Manual. ^ In ISIS, use the keyword LID LATCH, and select Trunk Lid Latch Replacement from the list. 2. Check that there is no friction or binding of the cable by holding the outside casing and pulling back and forth on the inner cable: ^ If the cable is difficult to move or binds, go to step 3. ^ If the cable operates smoothly, go to REPAIR PROCEDURE E. 3. Replace the trunk lid opener cable: ^ Refer to page 20-151 of the 2001-04 Civic Service Manual. ^ In ISIS, use the keyword LID OPEN, and select Trunk Lid Opener/Fuel Fill Door Opener Cable Replacement from the list. 4. Check the trunk operation: Page 4758 Flywheel: Service and Repair Release Bearing Replacement Clutch Replacement Special Tools Required ^ Clutch alignment shaft 07LAF-PT00110 ^ Clutch alignment disc 07JAF-PM7011A ^ Remover handle 07936-3710100 ^ Ring gear holder 07LAB-PV00100 or 07924-PD20003 ^ Attachment, 57 x 40 mm 07746-0010200 ^ Driver 07749-0010000 Release Bearing Replacement 1. Remove the release fork boot (A) from the clutch housing (B). 2. Remove the release fork (C) from the clutch housing (B) by squeezing the release fork set spring (D) with pliers. Remove the release bearing (E). 3. Check the release bearing for play by spinning it by hand. If there is excessive play, replace the release bearing with a new one. NOTE: The release bearing is packed with grease. Do not wash it in solvent. Page 659 72. Behind Hazard Warning Switch Page 789 48. Middle Of Engine (except GX) 49. Middle Of Engine (GX) Page 334 Blower Motor Relay Type 1, Type 2 Check for continuity between the terminals. - There should be continuity between the No.1 and No.3 terminals when power and ground are connected to the No.2 and No.4 terminals. - There should be no continuity between the No.1 and No.3 terminals when power is disconnected. Five-terminal type Check for continuity between the terminals. - There should be continuity between the No.1 and No.2 terminals when power and ground are connected to the No.3 and No.5 terminals. - There should be continuity between the No.1 and No.4 terminals when power is disconnected. Locations Power Mirrors Component Location Index Page 1303 Air Filter Element: Service and Repair Air Cleaner Element Replacement 1. Open the air cleaner housing cover (A). 2. Remove the air cleaner (B) from the air cleaner housing (C). 3. Install in the reverse order of removal. Page 6972 - 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. - Refer to the scrapping procedures for disposal of the damaged airbag. 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. 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. Page 9827 4. Reconnect the connector, and make these input tests at the connector. If any test indicates a problem, find and correct the cause, then recheck the system. Page 8860 Air Bag(s) Arming and Disarming: Description and Operation SRS Operation SRS Operation The main circuit in the SRS unit senses and judges the force of impact and, if necessary, ignites the inflator charges. 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: Seat Belt Tensioners and Seat Belt Buckle Tensioners 1. A front impact sensor must activate and send electric signals to the microprocessor. 2. The microprocessor must compute the signals and send them to the tensioners. 3. The charges must ignite and deploy the tensioners. Driver's and Front Passenger's Airbag(s) 1. A front impact sensor must activate, and send electric signals to the microprocessor. 2. The microprocessor must compute the signals, and depending on the severity of the collision and whether the seat belt buckle switch is ON or OFF, it sends the appropriate signals to the airbag inflator(s). 3. The inflators that received signals must ignite and deploy the airbags. Side Airbag(s) 1. Aside impact sensor must activate, and send electric signals to the microprocessor. 2. The microprocessor must compute the signals and send them to the side airbag inflator(s). However, the microprocessor cuts off the signals to the front passenger's side airbag if the OPDS unit determines that the front passenger's head is in the deployment path of the side airbag. 3. The inflator that received the signal must ignite and deploy the side airbag. Self-diagnosis System A self-diagnosis circuit is built into the SRS unit; when the ignition switch is turned ON (II), the SRS indicator comes on and goes off after about 6 seconds if the SRS is operating normally. If the indicator does not come on, or does not go off after 6 seconds, or if it comes on while driving, it indicates an abnormality in the SRS. The SRS must be inspected and repaired as soon as possible. For better serviceability, the SRS unit memory stores a DTC that relates to the cause of the malfunction, and the unit is connected to the data link circuit. This information can be read with the Honda PGM Tester when it is connected to the data link connector (DLC). Page 5004 Transmission Position Switch/Sensor: Service and Repair Transmission Range Switch Replacement 1. Raise the vehicle, and make sure it is securely supported. 2. Shift to the N position. 3. Remove the transmission range switch cover (A). 4. Disconnect the transmission range switch connector (B). 5. Remove the old transmission range switch, and install the new switch. 6. Make sure that the control shaft is in the N position. If necessary, move the shift lever to the N position. Page 5920 1. Remove the secondary lock from the male terminal half. 2. Remove the secondary lock from the female terminal half. 3. Remove the terminal (same procedure for male and female). 4. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE C: 1. Remove the secondary lock. 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 7822 Disclaimer Cutting Procedure - By Copying 1. Press the ON/OFF button in the middle of the setting unit keypad. (This powers up the keypad.) 2. Turn the clamp unit lock lever to the left to release the clamp unit, and slide it all the way to the left until it stops. Turn the lever to the right to lock the clamp unit in place. 3. Use the clamp carriage lever to position the clamp unit so the tracer and cutter bit are centered directly over the base of the center and right jaws. 4. Pull the vertical carriage lever toward you until the tracer and the cutter bit just touch the base of each fixed jaw. Watch the arrows on the keypad: ^ If the double-headed arrow in the middle of the keypad lights green, the tracer and cutter bit are properly aligned. ^ If the arrow on the left of the keypad lights red, the cutter bit is not touching the fixed jaw. Turn the micrometric ring nut above the tracer to the left until the double-headed arrow lights green. ^ If the arrow on the right of the keypad lights red, the tracer is not touching the fixed jaw. Turn the micrometric ring nut above the tracer to the right until the double-headed arrow lights green. *5. Turn the micrometric ring nut to the right three clicks so the cutter bit is slightly higher than the tracer. The arrow on the left should light red. Raise the vertical carriage. NOTE: Setting the tracer three clicks lower than the cutter bit has the effect of making the cutter bit cut the duplicated key a little shallower. This will protect the locking jaws from being damaged.* 6. Optional: Loosen the setscrew, and adjust the hand rest to a comfortable position. Tighten the screw. 7. Pull the clamp carriage lever toward you until the clamp carriage clicks into its end-of-run position. Tighten both the lateral and spring tension adjustment knobs. 8. Make sure the center and right jaws are free of any metal shavings or debris. (A soft-bristle toothbrush is ideal for this purpose.) Body - Trunk Lid Hard to Close Trunk / Liftgate Lock Cylinder: Customer Interest Body - Trunk Lid Hard to Close 02-061 November 5, 2004 Applies To: See VEHICLES AFFECTED Trunk Lid is Difficult to Close (Supersedes 02-061, dated July 23, 2004) Updated information is shown with asterisks. SYMPTOM The trunk lid may be difficult to close or won't latch closed. PROBABLE CAUSE The trunk lid may be misaligned, and the trunk lid opener cable, trunk lid latch, lock cylinder, lock rod, and/or the trunk lid latch striker may need adjustment or replacement. VEHICLES AFFECTED CORRECTIVE ACTION Adjust the trunk lid and/or the trunk lid latch, or replace components as needed. PARTS INFORMATION Page 4729 16. Remove the snap ring (A) and the splash guard (B) from the knuckle (C). 17. Press the wheel bearing (A) out of the knuckle (B) using the special tool and a press. 18. Wash the knuckle and hub thoroughly in high flash point solvent before reassembly. 19. Press a new wheel bearing (A) into the knuckle (B) using the old bearing (C), a steel plate (D), the special tool, and a press. Place the wheel bearing on the knuckle with the pack seal side facing (metal color) toward the inside. Be careful not to damage the sleeve of the pack seal. 20. Install the snap ring (A) securely in the knuckle (B). 21. Install the splash guard (C), and tighten the screws (D) to the specified torque. Page 1698 5. If the filter is not clogged, push the VTEC solenoid valve with your finger and check its movement. If the VTEC solenoid valve moves, check the engine oil pressure. Page 4793 1. Remove the terminal. 2. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE B: 1. Remove the terminal. 2. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE C: 1. Remove the terminal. 2. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE D: Page 6168 22. Press a new hub bearing unit (A) into the hub (B) using the special tools and a press. 23. Install the knuckle/hub/hub bearing unit in the reverse order of removal, and note these items: ^ Be careful not to damage the ball joint boot when installing the knuckle. ^ Tighten all mounting hardware to the specified torque values. ^ Torque the castle nut to the lower torque specification, then tighten it only far enough to align the slot with the ball joint pin hole. Do not align the castle nut by loosening it. ^ Install a new lock pin on the castle nut after torquing. ^ Use a new spindle nut on reassembly. ^ Before installing the new spindle nut, apply a small amount of engine oil to the seating surface of the nut. After tightening, use a drift to stake the spindle nut shoulder against the driveshaft. ^ Before installing the brake disc, clean the mating surface of the front hub and the inside of the brake disc. ^ Before installing the wheel, clean the mating surface of the brake disc and the inside of the wheel. ^ Check the front wheel alignment, and adjust it if necessary. Page 5239 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. Below most connector numbers and component names are PHOTO and VIEW numbers. The PHOTO number refers to a photo in the back of the book that shows the connector's location on the car. The VIEW number refers to an illustration in the back of the book that shows the connector terminals, wire colors, connector cavity numbers, and other details. The connector cavity numbering sequence begins at the top left corner of the connector as seen from either of the viewpoints shown on diagram [8] . Except for the DLC (data link 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 C554, for example, means those terminals join in cavity 2 of connector C554. Power Distribution Schematics Power Distribution Schematics Component Tests and General Diagnostics Control Assembly: Component Tests and General Diagnostics Heater Control Power and Ground Circuits Troubleshooting 1. Check the No.14 (10 A) fuse in the under-dash fuse/relay box. Is the fuse OK? YES - Go to step2. NO - Replace the fuse, and recheck. 2. Disconnect heater control panel connector A (14P). 3. Turn the ignition switch ON (II). 4. Measure the voltage between the No.14 terminal of heater control panel connector A (14P) and body ground. Is there battery voltage? YES - Go to step 5. NO - Repair open in the wire between the No.14 fuse in the under-dash fuse/relay box and the heater control panel. 5. Turn the ignition switch OFF. 6. Check for continuity between the No.13 terminal of heater control panel connector A (14P) and body ground. Is there continuity? YES - Check for loose wires or poor connections at heater control panel connector A (14P). If the connections are good, substitute a known-good heater control panel, and recheck. If the symptom/indication goes away, replace the original heater control panel. NO - Check for an open in the wire between the heater control panel and body ground. If the wire is OK, check for poor ground at G502. Page 9264 Blower Motor Relay Type 1, Type 2 Check for continuity between the terminals. - There should be continuity between the No.1 and No.3 terminals when power and ground are connected to the No.2 and No.4 terminals. - There should be no continuity between the No.1 and No.3 terminals when power is disconnected. Five-terminal type Check for continuity between the terminals. - There should be continuity between the No.1 and No.2 terminals when power and ground are connected to the No.3 and No.5 terminals. - There should be continuity between the No.1 and No.4 terminals when power is disconnected. Page 3175 20. Transmission Housing Page 7456 2. Remove the terminal from the female half. 3. Remove the terminal from the male half. 4. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE D: 1. Remove the secondary locks. Page 5454 31. Brake Fluid Level Switch Diagram Information and Instructions Shift Indicator: Diagram Information and Instructions Terminal Numbering System Terminal Numbering System Connector terminals are numbered according to the cavities they're in. The cavities are numbered starting from the upper left, looking at the male terminals from the terminal side or looking at the female terminals from the wire side. Both views are in the same direction so the numbers are the same. All actual cavities are numbered, even if they have no wire terminals in them. NOTE: Data Link Connector (DLC) terminals are numbered according 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 below is #6. Page 3259 2. Remove the terminal from the female half. 3. Remove the terminal from the male half. 4. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE D: 1. Remove the secondary locks. Page 3690 Wires Page 476 142. Moonroof Limit Switch (EX) A/C - Refrigerant Leak Detection Refrigerant: Technical Service Bulletins A/C - Refrigerant Leak Detection 07-030 October 12, 2007 Applies To: ALL Vehicles With Conventional A/C Compressors A/C Leak Detection (Supersedes 07-030, dated June 15, 2007, to update the information marked by asterisks) The OPTIMAX Jr. (TM)A/C Leak Detection Kit for Honda vehicles, P/N TRP124893, is a new required tool. The kit is used to add small amounts of dye to A/C systems to help locate smaller leaks that an electronic leak detector might not find. When searching for leaks, always begin by using an electronic leak detector. Refer to Service Bulletin 97-027, Denso HLD-100 Halogen Leak Detector; for tips on using this tool, then follow up with the OPTIMAX Jr. This new detection kit complements but does not replace the electronic detector. The kit contains: ^ TRP8640CS, OPTIMAX Jr. (TM) cordless, fluorescent leak detection flashlight lamp (includes 3 standard AA batteries) ^ TRP38600601, (6) 0.06 oz. (1.7 g) Tracer-Stick(R) R134a/PAG A/C dye capsules with ID labels ^ TRP3887, R-134a Universal Connect Set(TM) ^ TRP120884, GLO-AWAY(TM) dye cleaner ^ TRP9940, fluorescence-enhancing glasses ^ TRP1143, (1) empty Tracer-Stick dye capsule ORDERING INFO *One OPTIMAX Jr. A/C Leak Detection Kit was shipped to each current dealer as a required special tool. Additional kits and replacement capsules may be ordered through the Honda Tool and Equipment Program. On the iN, click on Service, Service Bay, Tool and Equipment Program, Online Catalog tab, and Air Conditioning Equipment, or call.* NOTICE ^ Do not use leak-trace dye in any Honda hybrid vehicle equipped with a dual-scroll compressor This can increase the chance of electric shock. The compressor is easily identified by the orange high-voltage cable that is connected to the compressor body. ^ Only Tracer-Stick single-dose fluorescent dye capsules from Tracer Products (Tracerline(R)) are approved for use in Honda vehicles. Other dyes contain solvents that may contaminate the system's refrigerant oil, leading to component failure. ^ Adding excessive amounts of dye can lead to compressor damage and failure. USING THE OPTIMAX JR. Page 850 Vehicle Speed Sensor: Description and Operation Vehicle Speed Sensor (VSS) The VSS is driven by the differential. It generates a pulsed signal from an input of 1 volts. The number of pulses per minute increases/decreases with the speed of the vehicle. Page 7836 4. Install the torsion bars in the reverse order of removal, and note these items: - The shape of the right torsion bar (A) and left torsion bar (B) are shown. Install the torsion bars properly. - Adjust the torsion bars forward or rearward with the torsion bar assembly tool. - Make sure the trunk lid opens properly and locks securely. Page 2605 9. Open the jaws with the jaws knob, and slide the original key with its flat side down into the center jaw up to the key stop. Slide the key blank with its flat side down into the right jaw up to the key stop. Close the jaws with the jaws knob to lock the keys into place. Visually inspect both keys for proper alignment in the jaws. 10. Loosen the lateral and spring tension adjustment knobs on the clamp carriage. With the clamp carriage lever, adjust the clamp carriage to position the tracer and the cutter bit over the middle of the two locked key blades. Tighten only the spring tension knob when done. NOTE: The clamp carriage has a spring system that puts lateral pressure on the tracer and cutting bit to make it easier to cut sidewinder-type keys. Do not tighten the lateral tension adjustment knob. This knob should be left loose. 11. Turn on the cutter motor with the motor start switch. [NOTICE] ^ To avoid damaging the locking jaws while cutting, keep your hand off the vertical carriage lever. Pressure on the lever will change the cutting depth. * ^ To avoid breaking the cutter bit, never back up while cutting.* ^ Wear proper eye protection (safety glasses, goggles, etc.) Page 4189 107. Behind A/T Shift Lever (except M/T) Page 3438 Fuel Pump Relay: Testing and Inspection Power Relay Test Use this chart to identify the type of relay, then do the test listed for it. NOTE: See the turn signal/hazard relay input test. Normally-open type A: Page 2530 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. How to Replace Connector Terminals Terminal Replacement Procedure HOW TO REPLACE CONNECTOR TERMINALS The terminal repair kits provide necessary tools and materials (terminals, wire seals, and splice connectors) to repair many damaged or faulty connector terminals. However, not all terminals for all connectors are available. Refer to the labels on the lids of the repair kits for replacement terminal availability. IMPORTANT SAFETY INFORMATION: On some models, the SRS wires are in a separate harness. If the SRS harness is damaged, replace the harness; do not repair it. On other models, wire harnesses include yellow SRS wires. If any SRS wire is damaged, replace the entire harness; do not repair it. Before you begin, inspect the wire you are about to repair for damage and length. Make sure the wire will be long enough to make a terminal repair without stretching it when you reinstall the terminal in the connector. If the wire is too short, or if access to the connector is too restricted to make a terminal repair, you may need to install a pigtail terminal (a short length of wire with a factory-crimped terminal on it). Refer to HOW TO INSTALL PIGTAIL TERMINALS. Removing the Terminal Page 2308 DTC P0A94 thru P0157 Page 5139 8. Inspect the quality of the wire crimp. If it has any of the following NO GOOD crimps, cut it off and start over. 9. Insert the terminal into the connector. Make sure the wire seals are pushed all the way into the connector. Lightly pull on the wires to make sure the terminal is locked into place. 10. Close or insert the secondary terminal lock, if applicable, and reconnect the connector. How to Install Pigtail Terminals HOW TO INSTALL PIGTAIL TERMINALS Pigtail terminals (short pieces of wire with a factory crimped terminal) are used when the wire is too short or when access to the connector is too restricted to make a terminal repair. NOTE: To replace just a connector terminal, go to How to Replace Connector Terminals. IMPORTANT SAFETY INFORMATION: On some models, the SRS wires are in a separate harness. If the SRS harness is damaged, replace the harness; do not repair it. On other models, wire harnesses include yellow SRS wires. If any SRS wire is damaged, replace the entire harness; do not repair it. 1. Remove the damaged or faulty terminal from the connector. Use the proper removal tool from Pin Tool Set. Page 8250 PARTS INFORMATION REQUIRED MATERIALS WARRANTY CLAIM INFORMATION In warranty: The normal warranty applies. Failed Part: P/N 72185-S9A-003 H/C 6896716 Defect Code: 00503 Symptom Code: 07902 Skill Level: Repair Technician Page 6722 administrative office for Fed Ex Air shipping documents and instructions; do not use the documentation included in the airbag inflator kit. WARRANTY CLAIM INFORMATION NOTE: ^ To avoid non-payment of warranty claims, the 13- digit serial number on the box of the new airbag inflator must be entered in the Diagnostic Trouble Codes field on each warranty claim. For more information, refer to step 1 of REPAIR PROCEDURE. ^ To avoid a warranty claim being charged back to your dealership, the original, undeployed inflator must be returned to its supplier. For more information, refer to INFLATOR PACKING AND GROUND SHIPPING INSTRUCTIONS: DEALERS IN THE 48 CONTIGUOUS STATES or INFLATOR PACKING AND AIR SHIPPING INSTRUCTIONS: DEALERS IN ALASKA AND HAWAII. Operation Number: 7521F4 Flat Rate Time: 0.5 hour Failed Part: P/N 06770-S84-A11ZA H/C 6556476 Defect Code: 55Z00 Symptom Code: Q9600 Skill Level: Repair Technician REPAIR PROCEDURE - ACCORD ONLY NOTE: Be careful not to damage any parts when replacing the inflator, and follow the procedure exactly. 1. Write down the 13-digit serial number located on the right side of the new inflator's box. For the warranty claim to be paid, your warranty clerk must enter this 13-digit serial number in the Diagnostic Trouble Codes field on the warranty claim. 2. Remove the driver's airbag: ^ Refer to page 23-278 of the 1998-2002 Accord Service Manual, or ^ Online, enter keywords DRIVER AIR, and select Driver's Airbag Replacement from the list. 3. Place the airbag, face down, on a clean shop towel. Page 5333 223. ABS Modulator-Control Unit (EX, GX) Page 7896 - Cut and remove the wheelhouse upper member, and replace the front wheelhouse. - Check the front damper extension and damper housing position, and check for damage. If necessary, remove the wheelhouse upper member, and replace the damper housing and front damper extension as an assembly, if possible. Page 3785 7. Apply a small amount of Permalube grease to the base of the new lever. Then attach the slide hammer to the new lever pin, insert the lever into the ignition switch, and seat the pin with the slide hammer. 8. Check the installed height of the pin with vernier calipers. If the height is more than 5.0 mm, the pin is not seated. If needed, reattach the slide hammer, and seat the pin. NOTE: It's normal for the interlock lever to be loose, even when the pin is fully seated. 9. Install a new spring on the lever. Make sure you attach the ends of the spring correctly: ^ The right end goes into the slot on the ignition switch. Page 9116 Center Mounted Brake Lamp: Service and Repair High Mount Brake Light Replacement 1. Open the trunk lid and disconnect the 2P connectors (A) from the high mount brake light (B). 2. Carefully remove the rear shelf and high mount brake light. 3. Install the light in the reverse order of removal. Locations 142. Middle of Rear Shelf (Sedan) Ceiling Light/Spotlights Test/Replacement - With Moonroof Map Light: Testing and Inspection Ceiling Light/Spotlights Test/Replacement - With Moonroof Ceiling Light/Spotlights Test/Replacement - With Moonroof 1. Turn the ceiling light/spotlights switches OFF. 2. Carefully pry off the lens (A) with a small screwdriver. 3. Remove the two screws and the housing (B). 4. Disconnect the 4P connector (C) from the housing. 5. Check the bulbs. If the bulbs are OK, check for continuity between the terminals in each switch position according to the table. 6. If the continuity is not as specified, replace the ceiling light. Page 9322 2. Insert the terminal tool into the female terminal, and then remove the terminal tool. NOTE: Make sure you do not select a terminal tool that is larger than the mating male terminal because it would spread the female terminal and cause a loose fit. 3. Compare the drag to the other terminals in the connector. If the drag is less, replace the terminal with a replacement terminal from the appropriate terminal repair kit. Component Locations Shift Solenoid: Component Locations Electronic Controls Location Page 352 brackets. 2. Reinstall the dashboard center lower cover. 3. Reconnect the driver's and front passenger's airbag connectors. 4. Reconnect the side airbag connectors. 5. Reconnect both seat belt tensioner connectors and both seat belt buckle tensioner connectors. 6. Reconnect the battery negative cable. 7. Initialize the OPDS unit. 8. After installing the SRS unit, confirm proper system operation: Turn the ignition switch ON (II); the SRS indicator should come on for about 6 seconds and then go off. Page 8158 (Not interchangeable with CR-V and S2000 remote transmitter) Transmitter Identification The transmitter for the 1995-99 Accord and the 2000-02 Accord look identical, but they are not interchangeable. The 1995-99 transmitter works the doors of a 2000-02 Accord, but it does not open the trunk. If you are not sure which transmitter you have, press and hold the trunk release button while looking at the LED. The LED on the 1995-99 transmitter comes on in about 1.1 seconds. The LED on the 2000-02 transmitter comes on in about 0.5 second. Programming the Transmitter NOTES: ^ The system accepts up to three transmitters. The transmitter codes are stored in a stacking-type memory. If a fourth transmitter code is programmed, the code for the first transmitter is erased. ^ Entering the programming mode cancels all learned transmitter codes, so none of the previously programmed transmitters will work. You must reprogram all of the transmitters once you are in the programming mode. ^ You must complete steps 1-6 within 4 seconds of the previous step to keep the system from exiting the programming mode. 1. Turn the ignition switch to ON (II). 2. Press the "Lock" or "Unlock" button on one of the transmitters. (An unprogrammed transmitter can be used for this step.) 3. Turn the ignition switch to LOCK (0). 4. Repeat steps 1 2, and 3 two more times using the same transmitter used in step 2. 5. Turn the ignition switch to ON (II). 6. Press the "Lock" or "Unlock" button on the same transmitter. Make sure the power door locks cycle to confirm that the system is in programming mode. 7. Within 10 seconds, press the "Lock" or "Unlock" button on each transmitter. Make sure the power door locks cycle after you press each transmitter button to confirm that the system accepted the transmitter's code. 8. Turn the ignition switch to LOCK (0) to exit the programming mode. Ordering a Transmitter Transmitters can be ordered only by authorized Honda dealers. Order them from American Honda using normal parts ordering procedures. Batteries for the Transmitter The battery number is CR2025. Each transmitter uses one battery. 03-04 Accord LX and EX 2003-04 Accord LX and EX with factory-installed keyless entry system Page 1140 Transmission Speed Sensor: Diagrams 105. CVT Drive Pulley Speed Sensor 106. CVT Driven Pulley Speed Sensor 107. CVT Speed Sensor 1 108. CVT Speed Sensor 2 Locations 40. Left Side Of Engine Compartment (EX, GX) Page 6053 Power Windows Component Location Index Page 29 28. Antenna Module (Coupe) Page 2019 19. Install the harness holder (A) and throttle cable clamps (B). 20. Install the ignition coils. 21. Loosely install the alternator. 22. Adjust the alternator belt tension or the alternator-compressor belt tension. 23. Loosely install the power steering (P/S) pump belt and pump. 24. Adjust the P/S pump belt. 25. Install the splash shield. 26. Install the front tires/wheels. 27. Clean the battery posts and cable terminals with sandpaper. Connect the negative cable, then positive cable and apply grease to prevent corrosion. 28. Enter the anti-theft code for the radio, then enter the customer's radio station presets. Maintenance Required Indicator Doesn't Reset Maintenance Required Lamp/Indicator: Technical Service Bulletins Maintenance Required Indicator Doesn't Reset SOURCE: Honda Service News February 2003 TITLE: Maintenance Required Indicator Doesn't Reset APPLIES TO: 2001-03 Civics, 2002-03 Civic Sis, 2003 Civic Hybrids, 2002-03 CR-Vs, and 2003 Elements. SERVICE TIP: Are customers complaining that they can't reset the maintenance required indicator (MAINT REQ'D) on the instrument panel? Find out if the headlights, parking lights, or both were turned on when they tried to reset it. The maintenance required indicator can't be reset if any of these lights are on. In fact, some aftermarket daytime running light devices designed to turn on the headlights, parking lights, or both as soon as you turn the ignition switch to ON (II), must be disabled before the indicator can be reset. 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 5957 Exterior Lights Component Location Index Page 1722 8. Tighten each bolt two turns at a time, in the sequence shown below, to ensure that the rockers do not bind on the valves. Specified torque 8 mm bolts: 20 Nm (2.0 kgf-cm, 14 ft. lbs.) Apply engine oil to the bolt threads. 6 mm bolts: 12 Nm (1.2 kgf-cm, 8.7 ft. lbs.) Apply engine oil to the bolt threads. 6 mm bolts: (11), (12), (13), (14) 9. Align the marks (A) on the new cylinder head plug (B) with the top edge of the head, then install the cylinder head plug in the cylinder head. Page 6378 4. Install the washer (A) and a new self-locking nut (B) on the damper shaft. 5. Hold the damper shaft with a hex wrench (C), and tighten the self-locking nut to the specified torque. Installation 1. Position the damper assembly in the body. Note the direction of the damper mounting base so that the small hole dot on it is toward the front and inside of the vehicle. 2. Loosely install the flange nuts (A) onto the top of the damper. Page 4101 - Remove clips carefully; don't damage their locks (A). - Slip pliers (A) under the clip base and through the hole at an angle, then squeeze the expansion tabs to release the clip. - After installing harness clips, make sure the harness doesn't interfere with any moving parts. - Keep wire harnesses away from exhaust pipes and other hot parts, from sharp edges of brackets and holes, and from exposed screws and bolts. - Seat grommets in their grooves properly (A). Do not leave grommets distorted (B). Testing and Repairs - Do not use wires or harnesses with broken insulation. Replace them or repair them by wrapping the break with electrical tape. - After installing parts, make sure that no wires are pinched under them. - When using electrical test equipment, follow the manufacturer's instructions and those described. - If possible, insert the probe of the tester from the wire side (except waterproof connector). - Use back probe adaptor 07TAZ-001020A. - Refer to the instructions in the Honda Terminal Kit for identification and replacement of connector terminals. Five-Step Troubleshooting Five-Step Troubleshooting 1. Verify The Complaint Page 5822 13. Plug in the heat gun, and turn it on. Start at the middle of the splice connector, and move the gun toward the ends as the tube shrinks. Apply heat evenly by rotating the curved heat spreader around the splice connector. Shrinking is complete when a small amount of sealant appears at each end of the tube. Removal and Installation Steering Gear: Service and Repair Removal and Installation Steering Gearbox Removal Special Tools Required Ball joint remover, 28 mm 07MAC-SL00200 Note these items during removal: ^ Using solvent and a brush, wash any oil and dirt off the valve body unit, its lines, and the end of the gearbox. Blow dry with compressed air. ^ Be sure to remove the steering wheel before disconnecting the steering joint. Damage to the cable reel can occur. 1. Raise the front of vehicle, and make sure it is securely supported. 2. Remove the front wheels. 3. Remove the driver's airbag and the steering wheel. 4. Remove the driver's dashboard lower covers. 5. Remove the steering joint bolts, and disconnect the steering joint by moving the steering joint (A) toward the column. 6. Remove the air cleaner (A) and resonator (B). 7. Open the heater valve cable clamp, and disconnect the heater valve cable. Remove the heater valve (A) from the bulkhead, and move it aside. Page 3702 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. Test Equipment 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. Page 6704 administrative office for Fed Ex Air shipping documents and instructions; do not use the documentation included in the airbag inflator kit. WARRANTY CLAIM INFORMATION NOTE: ^ To avoid non-payment of warranty claims, the 13- digit serial number on the box of the new airbag inflator must be entered in the Diagnostic Trouble Codes field on each warranty claim. For more information, refer to step 1 of REPAIR PROCEDURE. ^ To avoid a warranty claim being charged back to your dealership, the original, undeployed inflator must be returned to its supplier. For more information, refer to INFLATOR PACKING AND GROUND SHIPPING INSTRUCTIONS: DEALERS IN THE 48 CONTIGUOUS STATES or INFLATOR PACKING AND AIR SHIPPING INSTRUCTIONS: DEALERS IN ALASKA AND HAWAII. Operation Number: 7521F4 Flat Rate Time: 0.5 hour Failed Part: P/N 06770-S84-A11ZA H/C 6556476 Defect Code: 55Z00 Symptom Code: Q9600 Skill Level: Repair Technician REPAIR PROCEDURE - ACCORD ONLY NOTE: Be careful not to damage any parts when replacing the inflator, and follow the procedure exactly. 1. Write down the 13-digit serial number located on the right side of the new inflator's box. For the warranty claim to be paid, your warranty clerk must enter this 13-digit serial number in the Diagnostic Trouble Codes field on the warranty claim. 2. Remove the driver's airbag: ^ Refer to page 23-278 of the 1998-2002 Accord Service Manual, or ^ Online, enter keywords DRIVER AIR, and select Driver's Airbag Replacement from the list. 3. Place the airbag, face down, on a clean shop towel. Page 6726 8. Reinstall the driver's airbag using new Torx bolts: ^ Refer to the appropriate service manual, or ^ Online, enter keywords DRIVER AIR, and select Driver's Airbag Replacement from the list. 9. Center-punch a completion mark below the third character of the engine compartment VIN: 10. Give your warranty clerk the 13-digit inflator serial number you wrote down in step 1. For the warranty claim to be paid, your warranty clerk must enter the appropriate 13-digit serial number in the Diagnostic Trouble Codes field on the warranty claim. INFLATOR PACKING AND GROUND SHIPPING INSTRUCTIONS: DEALERS IN THE 48 CONTIGUOUS STATES NOTE: ^ Do not deploy the original inflator. Claims for deployed inflators will be charged back to your dealership. ^ There is a 48-hour return shipment objective for the inflator. ^ The following ground shipping instructions are also in the return shipping box (the box the new inflator came in) from kit P/N 04770-55A-308. If you're a dealer in Alaska or Hawaii, call the WPI administrative office for FedEx Air shipping documents and instructions. 1. Carefully insert the original inflator into the round opening in the return shipping box (the box that the new inflator came in). Also place a copy of the repair order in the box. 2. Close the top flap on the box, then double-tape the the box closed with 2-inch clear packing tape on the entire front seam and the side seams. Press down on the tape for good adhesion. 3. Fill out the Fed Ex Ground paperwork, and handle it as indicated below: ^ OP-950 Hazardous Materials Certification form: - At the top, fill in the shipper name, address, and date. - At the bottom, sign your name on the signature line. - List the Tracking ID on the right side column of both copies. (The 15-digit Tracking ID is found on the PRP Shipping Label beneath the large bar code to the right of the parenthesis.) - Keep one copy for dealer records and retain it for 1 year; give the second copy to the Fed Ex Ground driver. ^ FedEx Ground PRP Shipping Label: - Complete all fields in the upper section of the label. (The RA number is not required.) - Review the instructions on the back and, when the shipment is ready, call for Fed Ex Ground pick up for business locations at 888-777-6040. ^ OP-900 Hazardous Materials form: - This form requires no further completion; attach the six-part label to the box. 4. Prepare the box and the labels: ^ Remove or black-out any old shipping labels, including the original bar code. Do not remove or black-out any of the hazard marks or labels. ^ Remove the adhesive backing from the PRP and the OP-900 labels, and attach them firmly to the box. Do not cover any of the hazard marks or labels. Body - Windshield Moulding Warped/Deformed Windshield Moulding / Trim: All Technical Service Bulletins Body - Windshield Moulding Warped/Deformed 00-064 March 17, 2009 Applied Vehicles Deformed Windshield Molding (Supersedes 00-064, dated November 13, 2007, to update the information marked by the black bars) REVISION SUMMARY SYMPTOM The windshield molding is warped or deformed. PROBABLE CAUSE The inner lip is folded, causing a poor fit against the body. CORRECTIVE ACTION Remove the entire inner lip, and fill the channel between the molding and the body with silicone sealant. REQUIRED MATERIALS WARRANTY CLAIM INFORMATION In warranty: The normal warranty applies. Operation Number: 831004 Flat Rate Time: 0.7 hour Failed Part: P/N 73150-S84-A01 H/C 5443387 Defect Code: 00401 Symptom Code: 00101 Template ID: 00-064A Skill Level: Repair Technician Page 2047 - Remove clips carefully; don't damage their locks (A). - Slip pliers (A) under the clip base and through the hole at an angle, then squeeze the expansion tabs to release the clip. - After installing harness clips, make sure the harness doesn't interfere with any moving parts. - Keep wire harnesses away from exhaust pipes and other hot parts, from sharp edges of brackets and holes, and from exposed screws and bolts. - Seat grommets in their grooves properly (A). Do not leave grommets distorted (B). Testing and Repairs - Do not use wires or harnesses with broken insulation. Replace them or repair them by wrapping the break with electrical tape. - After installing parts, make sure that no wires are pinched under them. - When using electrical test equipment, follow the manufacturer's instructions and those described. - If possible, insert the probe of the tester from the wire side (except waterproof connector). - Use back probe adaptor 07TAZ-001020A. - Refer to the instructions in the Honda Terminal Kit for identification and replacement of connector terminals. Five-Step Troubleshooting Five-Step Troubleshooting 1. Verify The Complaint Page 3075 160. Left Side Of Engine Compartment (except GX) Page 6057 Under-dash Fuse/Relay Box (4-door) Page 208 Blower Motor Relay Type 1, Type 2 Check for continuity between the terminals. - There should be continuity between the No.1 and No.3 terminals when power and ground are connected to the No.2 and No.4 terminals. - There should be no continuity between the No.1 and No.3 terminals when power is disconnected. Five-terminal type Check for continuity between the terminals. - There should be continuity between the No.1 and No.2 terminals when power and ground are connected to the No.3 and No.5 terminals. - There should be continuity between the No.1 and No.4 terminals when power is disconnected. Page 1195 3. Check for continuity between the terminals in each switch position according to the tables. Driver's Switch: The driver's switch is combined with the control unit so you cannot isolate the switch to test it. Instead, run the master switch input test procedures. If the tests are normal, the driver's switch must be faulty. Replace the switch. 4. If the continuity is not as specified, remove the driver's door panel. 5. Remove the armrest from the door panel. Page 9651 1. Remove the secondary locks. 2. Remove the terminal from the female half. 3. Remove the terminal from the male half. 4. Go to HOW TO INSTALL NEW TERMINALS. Connectors Without a Secondary Lock All examples are shown with the connector lock facing up. The illustrations are examples of connector terminals without a secondary lock; however, the connector you are repairing may vary in size and shape. EXAMPLE A: Page 5534 Wheel Speed Sensor: Description and Operation Wheel Sensors The wheel sensors are the magnetic contact less type. As the gear purser teeth rotate past the wheel sensor's magnetic coil, AC current is generated. The AC frequency changes in accordance with the wheel speed. The ABS control unit detects the wheel sensor signal frequency and thereby detects the wheel speed. When the wheel speed drops sharply below the vehicle speed, the outlet valve opens momentarily to reduce the caliper fluid pressure. The pump motor starts at this time. As the wheel speed is restored, the inlet valve opens momentarily to increase the caliper fluid pressure. Locations 134. Right C Pillar (Coupe) Page 4986 Use the tools from Pin Tool Set. First, check the connector that you are about to repair. - If it has a secondary terminal lock, go to Connectors With a Secondary Lock. A secondary lock, found on most connectors on some models, is an additional locking device on the connector housing as a backup for the primary lock on the terminal. - If the connector does not have a secondary lock, go to Connectors Without a Secondary Lock. Connectors With a Secondary Lock All examples are shown with the connector lock facing up. The illustrations are examples of the secondary terminal locks; however, the connector you are repairing may vary in size. Identify the connector by the type of secondary lock, not by the number of terminal cavities. EXAMPLE A: 1. Release the secondary lock. 2. Remove the terminal. 3. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE B: Locations Relay And Control Unit Locations - Dashboard Page 1514 Under-hood Fuse/Relay Box (2-door) Page 4276 Page 8462 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. Make sure you have the anti-theft code for the radio, then write down the frequencies for the preset buttons. 2. Disconnect the negative cable from the battery, and wait at least 3 minutes before beginning work. 3. Remove the driver's seat from the vehicle. Refer to page 20-109 of the 2001-05 Civic Service Manual. 4. Remove the recline handle by pulling it forward. 5. Remove the center cap from the height knob. Remove the C-clip that holds the height knob. Then remove the knob. 6. Remove the screw and clips from the recline cover. Remove the recline cover. Page 6839 Page 8765 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. How to Replace Connector Terminals Terminal Replacement Procedure HOW TO REPLACE CONNECTOR TERMINALS The terminal repair kits provide necessary tools and materials (terminals, wire seals, and splice connectors) to repair many damaged or faulty connector terminals. However, not all terminals for all connectors are available. Refer to the labels on the lids of the repair kits for replacement terminal availability. IMPORTANT SAFETY INFORMATION: On some models, the SRS wires are in a separate harness. If the SRS harness is damaged, replace the harness; do not repair it. On other models, wire harnesses include yellow SRS wires. If any SRS wire is damaged, replace the entire harness; do not repair it. Before you begin, inspect the wire you are about to repair for damage and length. Make sure the wire will be long enough to make a terminal repair without stretching it when you reinstall the terminal in the connector. If the wire is too short, or if access to the connector is too restricted to make a terminal repair, you may need to install a pigtail terminal (a short length of wire with a factory-crimped terminal on it). Refer to HOW TO INSTALL PIGTAIL TERMINALS. Removing the Terminal Page 2895 120. MAP Sensor Page 2884 41. Check for continuity between PGM-FI main relay 1 4P connector terminal No.3 and ECM/PCM connector terminal E7. Is there continuity? YES - Test PGM-FI main relay 1. If the relay is OK, update the ECM/PCM if it does not have the latest software, or substitute a known good ECM/PCM, then recheck. If the symptom/indication goes away with a known-good ECM/PCM, replace the original ECM/PCM. NO - Repair open in the wire between PGM-FI main relay 1 and the ECM/PCM (E7). 42. Reconnect ECM/PCM connector E (31P). 43. Turn the ignition switch ON (II). 44. Measure voltage between body ground and ECM/PCM connector terminals A2 and A3 individually. Is there battery voltage? YES - Go to step 51. NO - Go to step 45. 45. Turn the ignition switch OFF. 46. Remove PGM-FI main relay 1 (A). 47. Turn the ignition switch ON (II). Page 8916 YES - Replace the sensor that restored about 5 V when disconnected. NO - Go to step 62. 62. Turn the ignition switch OFF. 63. Disconnect the 3P connectors from the following sensors. - Exhaust gas recirculation (EGR) valve position sensor - Knock sensor - Throttle position (TP) sensor - CVT drive pulley speed sensor (CVT) - CVT speed sensor 2 (CVT) 64. Disconnect ECM/PCM connector A (31P). 65. Check for continuity between ECM/PCM connector terminal A20 and body ground. Is there continuity? YES - Repair short in the wire between the ECM/PCM (A20) and the EGR valve position sensor, knock sensor, TP sensor, CVT drive pulley speed sensor (CVT), or CVT speed sensor 2 (CVT), or repair short in the wire between the ECM/PCM (A8) and the knock sensor. NO - Update the ECM/PCM if it does not have the latest software, or substitute a known-good ECM/PCM, then recheck. If the symptom/indication goes away with a known-good ECM/PCM, replace the original ECM/PCM. 66. Measure voltage between body ground and ECM/PCM connector terminal E5. Is there about 5 V? YES - Update the ECM/PCM if it does not have the latest software, or substitute a known-good ECM/PCM, then recheck. If the symptom/indication goes away with a known-good ECM/PCM, replace the original ECM/PCM. NO - Go to step 67. 67. Turn the ignition switch OFF. 68. Disconnect the fuel tank pressure (FTP) sensor 3P connector. 69. Turn the ignition switch ON (II). Page 667 Horn Switch: Testing and Inspection Horn Switch Test 1. Remove the steering column covers. 2. Disconnect the dashboard wire harness B 5P connector (A) from the cable reel (B). 3. Using a jumper wire, connect the dashboard wire harness B 5P connector (A) No.2 terminal to body ground. - If the horn sounds, go to step 4. - If the horn does not sound, check these items: horn relay - No.7 (15 A) fuse in the under-hood fuse/relay box - Horn. - An open in the wire. 4. Reconnect the dashboard wire harness B 5P connector (A), and disconnect the horn switch positive 1P connector (B). 5. Using a jumper wire, connect the horn switch positive 1P connector (B) to ground. - If the horn sounds, go to step 6. - If the horn does not sound, replace the cable reel. 6. Reconnect the horn switch positive connector (B). Master Switch Test/Replacement Power Window Switch: Testing and Inspection Master Switch Test/Replacement Master Switch Test/Replacement 4-door 1. Remove the door grip cover. 2. Disconnect the 20P connector from the power window master switch. Page 1715 10. Install the back cover (A), then install the camshaft pulley (B). Page 5918 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. How to Replace Connector Terminals Terminal Replacement Procedure HOW TO REPLACE CONNECTOR TERMINALS The terminal repair kits provide necessary tools and materials (terminals, wire seals, and splice connectors) to repair many damaged or faulty connector terminals. However, not all terminals for all connectors are available. Refer to the labels on the lids of the repair kits for replacement terminal availability. IMPORTANT SAFETY INFORMATION: On some models, the SRS wires are in a separate harness. If the SRS harness is damaged, replace the harness; do not repair it. On other models, wire harnesses include yellow SRS wires. If any SRS wire is damaged, replace the entire harness; do not repair it. Before you begin, inspect the wire you are about to repair for damage and length. Make sure the wire will be long enough to make a terminal repair without stretching it when you reinstall the terminal in the connector. If the wire is too short, or if access to the connector is too restricted to make a terminal repair, you may need to install a pigtail terminal (a short length of wire with a factory-crimped terminal on it). Refer to HOW TO INSTALL PIGTAIL TERMINALS. Removing the Terminal Page 824 1. Remove the terminal. 2. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE G: 1. Remove the terminal. 2. Go to HOW TO INSTALL NEW TERMINALS. How to Install New Terminals HOW TO INSTALL NEW TERMINALS 1. Carefully match the old terminal with a new one from the terminal repair kit. Choose the correct replacement terminal based on the wire size range the terminal will accommodate. NOTE: If the replacement terminal quantities are low, reorder them by using the terminal part number listed on the inside lid of the terminal repair kit. Replacement terminals are available through your parts department using normal parts ordering procedures. 2. Depending on the size of the wire you are repairing, use the proper size slot in the crimping tool. Page 8121 The battery number is CR2025. Each transmitter uses one battery. 94-95 Accord, Civic, Del SOL, Prelude & 95 Odyssey 1994-95 Accord with dealer-installed security system 1994-95 Civic with dealer-installed security system 1994-95 del Sol with dealer-installed security system 1994-95 Prelude with dealer-installed security system 1995 Odyssey with dealer-installed security system Programming the Transmitter NOTES: ^ The system uses a stacking-type memory that accepts up to four transmitters. If you program a fifth transmitter, the system's memory for the first transmitter is pushed out, and it will no longer work. ^ To clear a lost or stolen transmitter from the system's memory, program a transmitter four times. This will remove the missing transmitter from memory, since only four transmitter codes can be accepted. ^ Another way to clear a lost or stolen transmitter is to erase all transmitter codes, and then reprogram them. To do this, refer to the security system owner's manual. 1. Turn the ignition switch to ON (II). 2. Press and hold the Valet-Disarm button on the dashboard lower cover. (Continue to hold the button during this procedure, or programming will be cancelled.) The LED on the upper steering column cover flashes when the system is in programming mode. 3. Press the top button on the transmitter. Check that the parking lights flash to confirm that the transmitter's code was accepted. 4. Press the top button on each of the remaining transmitters. Check that the parking lights flash after each transmitter code is accepted. 5. Release the Valet-Disarm button to exit the programming mode. Ordering a Transmitter Transmitters can be ordered only by authorized Honda dealers. Order them from American Honda using normal parts ordering procedures. Batteries for the Transmitter The battery number is CR2025. Each transmitter uses one battery. 96-98 Civic EX & Except EX, Civic 1996-98 Civic EX with factory-installed keyless entry system 1996-98 Civic (except EX) with dealer-installed keyless entry system 1996-98 Civic with dealer-installed security system Page 9123 Wires Page 6920 SRS Component Location Index Page 8488 Seat Cover: Service and Repair Rear Seat Side Bolster Cover Replacement Rear Seat Side Bolster Cover Replacement 4-door 1. Remove the seat side bolster. 2. Release all the hook strips (A), and fold back the seat side bolster cover (B), and release the cover from the hooks (C) to remove it. 3. Install the cover in the reverse order of removal, and to prevent wrinkles, make sure the material is stretched evenly over the pad before securing the hook strips. Page 8355 Shallow Scratch: Use a flexible block and #240 - #400 - #600 sandpaper. Hole/Deep Gouge: Cut out and make any torn or burred area flat. Use a knife, flexible block, and #180 - #240 sandpapers. 2. Air blowing/degreasing Clean the damaged area throughly. Use alcohol, and wax and grease remover. Undercoating Undercoating 1. Spraying primer Primer is used to fill cavities in the putty and primer surfacer. - Spray primer on the exposed area. - Spray the 2 - 3 coats of primer on 2 - 3 coats over the area you applied puny. - Apply primer to the back of the bumper if the damage is a tear or hole. - Bumper primer - Warm the primer if the ambient temperature is below 50 degrees F (10 degrees C). - Follow the bumper primer manufacturer's instructions. - Use a spray gun and a brush. Drying NOTE: Take care not to let the heat lamp deform the bumper during the drying process. Dry the bumper primer thoroughly with an infrared dryer or other suitable method. Drying Time: Page 3667 23. Transmission Housing (A/T) Page 8375 6. Disconnect the M, P, K, and J connectors from the under-dash fuse/relay box, and make these input tests at the connectors. - If any test indicates a problem, find and correct the cause, then recheck the system. - If all the input tests prove OK, the multiplex control unit must be faulty. Replace the under-dash fuse/relay box assembly. Service and Repair Trunk / Liftgate Weatherstrip: Service and Repair Trunk Lid Weatherstrip Replacement 1. Remove the trunk lid weatherstrip (A) by pulling it off. 2. Locate the painted alignment mark (B or C) on the trunk lid weatherstrip. Align the painted mark with the alignment tab in the center of the trunk, and install the weatherstrip. Make sure it's seated completely and facing in the direction shown. Make sure there are no wrinkles in the weatherstrip. 3. Check for water leaks. Page 4209 Circuit Schematics Each schematic represents one circuit. A circuit's wires and components are arranged to show current flow from power at the top of the diagram 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 Page 3922 3. Turn the ignition switch to ON (II), and connect the DLC cable to the vehicle's DLC. In the Updating Honda Control Modules screen, click on the check mark. Each updatable vehicle system is checked to make sure it is current. Any systems needing an update are listed on the screen. Highlight the system you want to update, then click on the check mark to continue. NOTE: Update the Systems one at a time. 4. Verify that the Program ID and the Program Part No. are correct, then click on the check mark. Page 6264 23. Carefully pry the piston seal ring (A) and O-ring (B) off the rack piston. Be careful not to damage the inside of the seal ring groove and piston edges when removing the seal ring. 24. Before removing the valve housing (A), apply vinyl tape (B) to the splines on the pinion shaft. 25. Separate the valve housing from the pinion shaft/ valve using a press. 26. With your finger, check the inner wall of the valve housing where the seal ring slides. If there is a step in the wall, the housing is worn. Replace it. NOTE: There may be sliding marks from the seal ring on the wall of the valve housing. Replace the valve housing only if the wall is stepped. 27. Check for wear, burrs, and other damage to the edges of the grooves in the sleeve. NOTE: The pinion shaft and sleeve are a precision matched set. If either the pinion shaft or sleeve must be replaced, replace both parts as a set. Page 6252 13. Remove the engine wire harness (A) from the harness bracket (B). 14. Remove the steering rack guard (C) by removing the three clips. 15. Remove the steering gearbox attaching nut and washer on the right gearbox mounting bracket. 16. Remove the steering gearbox attaching bolts and washers on the left gearbox mounting bracket. Page 8050 NOTE: You need to make the corrections listed in CODE BOOK CORRECTIONS at the end of this service bulletin. TRACER AND CUTTER BIT INSTALLATION 1. Turn the power switch on the back of the machine to ON. (This turns on the built-in work light.) 2. Use the Allen wrench from the built-in tool drawer to loosen the setscrew on the left sleeve of the vertical carriage. Slide the tracer all the way into the sleeve, and tighten the screw. 3. Turn the plastic shield on the right sleeve of the vertical carriage so you can access the setscrew on the sleeve. Use the Allen wrench to loosen the screw. Slide the cutter bit all the way into the sleeve, and tighten the screw. Turn the plastic shield so the open side is in the back. MACHINE COMPONENTS Page 6262 14. Set the special tool (A) on the lock washer (B) securely, then loosen and remove the lock washer from inside of the gearbox housing (C). 15. Remove the special tool. 16. Pull on the cylinder to remove it from the gearbox housing. Remove boot A and the slider guide (B) from the cylinder. 17. Check the slider guide for damage and cracks. Using vernier calipers to measure the thickness of the slider guide. If the thickness is less than the service limit, replace the slider guide. 18. Remove and discard the stop ring (A) on the cylinder by expanding it with snap ring pliers. Remove and discard the lock washer (B). Locations Cruise Control Switch: Locations Cruise Control Component Location Index Page 1266 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 4802 Shift Indicator: Electrical Diagrams Automatic Transmission Circuit Diagram Continuously Variable Transmission Page 4658 Shift Solenoid: Testing and Inspection Solenoid Valve Test - Continuously Variable Transmission Solenoid Valve Test 1. Disconnect solenoid harness connector (BP). 2. Measure CVT speed change control valve assembly resistance between solenoid harness connector terminals No. 3 and No. 7. STANDARD: 3.8 - 6.8 Ohms 3. Measure CVT pulley pressure control valve assembly resistance between terminals No. 2 and No. 6. STANDARD: 3.8 - 6.8 Ohms 4. Measure CVT start clutch pressure control valve assembly resistance between terminals No. 4 and No. 8. STANDARD: 3.8 - 6.8 Ohms 5. Measure the inhibitor solenoid resistance between terminal No. 5 and body ground. STANDARD: 11.7 - 21.0 Ohms 6. Replace the CVT speed change control valve assembly or CVT start clutch pressure control valve assembly, if the measurements are out of standard. Replace the lower valve body assembly, if the measurements of CVT pulley pressure control valve assembly or inhibitor solenoid are out of standard. 7. If all of the resistance are within the standard, a clicking sound should be heard when connecting the battery terminals to the solenoid harness connector terminals below. ^ CVT speed change control valve assembly No. 3 to battery positive terminal No. 7 to battery negative terminal ^ CVT pulley pressure control valve assembly No. 2 to battery positive terminal No. 6 to battery negative terminal ^ CVT start clutch pressure control valve assembly No. 4 to battery positive terminal No. 8 to battery negative terminal ^ Inhibitor solenoid No.5 to battery positive terminal and body ground to negative terminal 8. If no clicking sound is heard, remove the lower valve body assembly, and check the solenoid. Page 2742 Electric Load Sensor: Description and Operation Electrical Load Detector (ELD) Since the early 1990's, 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's 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. Recall - Ignition/Shift Interlock Defect Technical Service Bulletin # 10-059 Date: 101001 Recall - Ignition/Shift Interlock Defect 10-059 October 1, 2010 Applies To: See VEHICLES AFFECTED Safety Recall: Accord, Civic, and Element Ignition Switch Key Interlock BACKGROUND Under certain conditions, the interlock lever of the ignition switch may unexpectedly deform. The interlock ensures the transmission is in Park before the ignition key can be removed. Interlock failure may allow the ignition key to be removed when the shift lever is not in Park. If the driver fails to engage the parking brake, the vehicle could roll away, increasing the risk of a crash. VEHICLES AFFECTED Not all vehicles within the VIN ranges are affected by this recall. Before beginning work on a vehicle, verify its eligibility by checking at least one of these items: ^ The customer has a notification letter. Page 1568 Relay And Control Unit Locations - Engine Compartment Page 9200 2. Remove the terminal (same procedure for male and female). 3. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE E: 1. Remove the secondary locks. 2. Remove the terminal (same procedure for male and female). 3. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE F: Page 2285 D17A1, D17A6 engines Page 9355 - 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. Troubleshooting Tests 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 test 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 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. 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 Drop Page 8323 Power Mirror Switch: Testing and Inspection Power Mirror Switch Test 1. Remove the driver's pocket. 2. Disconnect the 13P connector (A) from the switch. 3. Remove the power mirror switch (B). 4. Check for continuity between the terminals in each switch position according to the table. 5. If the continuity is not as specified, replace the power mirror switch. Lighting - Interior Spot Light Lenses Stick Map Lamp: Customer Interest Lighting - Interior Spot Light Lenses Stick 00-085 April 22, 2003 * Applies To: * 2001-03 Civic LX - ALL * Spotlight Lens Sticks (Supersedes 00-085, dated October 31, 2000) Updated information is shown with asterisks. SYMPTOM When you push on either spotlight lens to turn on the light, the lens doesn't pop back out. PROBABLE CAUSE Headliner material interferes with the lens, preventing the lens from moving freely. CORRECTIVE ACTION Reposition the spotlight assembly. If needed, remove some of the headliner material. WARRANTY CLAIM INFORMATION In warranty: The normal warranty applies. Operation Number: 715012 Flat Rate Time: 0.2 hour Failed Part: P/N 34403-S5A-003ZB H/C 6569792 Defect Code: 030 Contention Code: B02 Template ID: 00-085A 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. Remove each spotlight lens by carefully prying on the inside edge with a small screwdriver. 2. Loosen the spotlight assembly mounting screws. Page 2844 Information Bus: Electrical Diagrams Wiring Diagrams Diagram 50 Diagrams: Other diagrams referred to by number (See Diagram ##-#, etc.)within these diagrams can be found at Diagrams by Number. See: Diagrams/Electrical Diagrams/Diagrams By Number Locations: Location photographs (references to PHOTOS) referred to within these diagrams can be found at Locations by Photo Number. See: Locations/Component Locations/Locations By Photo Number Mainshaft Speed Sensor Replacement Transmission Speed Sensor: Service and Repair Mainshaft Speed Sensor Replacement Mainshaft Speed Sensor Replacement 1. Disconnect the mainshaft speed sensor connector. 2. Remove the mainshaft speed sensor (A). 3. Install the new mainshaft speed sensor with the new O-ring (B) and mainshaft speed sensor washer (C). NOTE: The mainshaft speed sensor washer is equipped on the SLXA automatic transmission; the BMXA does not have it. 4. Check the mainshaft speed sensor connector for rust, dirt, or oil, then connect the connector securely. Page 289 ECM/PCM Inputs And Outputs At Connector B (24P) Page 5384 1. Remove the terminal. 2. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE E: 1. Remove the terminal. 2. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE F: Page 9352 - Remove clips carefully; don't damage their locks (A). - Slip pliers (A) under the clip base and through the hole at an angle, then squeeze the expansion tabs to release the clip. - After installing harness clips, make sure the harness doesn't interfere with any moving parts. - Keep wire harnesses away from exhaust pipes and other hot parts, from sharp edges of brackets and holes, and from exposed screws and bolts. - Seat grommets in their grooves properly (A). Do not leave grommets distorted (B). Testing and Repairs - Do not use wires or harnesses with broken insulation. Replace them or repair them by wrapping the break with electrical tape. - After installing parts, make sure that no wires are pinched under them. - When using electrical test equipment, follow the manufacturer's instructions and those described. - If possible, insert the probe of the tester from the wire side (except waterproof connector). - Use back probe adaptor 07TAZ-001020A. - Refer to the instructions in the Honda Terminal Kit for identification and replacement of connector terminals. Five-Step Troubleshooting Five-Step Troubleshooting 1. Verify The Complaint Page 4044 Torque Converter Clutch Solenoid: Testing and Inspection Torque Converter Clutch Solenoid Valve Test 1. Disconnect the torque converter clutch solenoid valve connector. 2. Measure the resistance between the No. 1 and No. 2 terminals of the torque converter solenoid valve connector. STANDARD: 12 - 25 Ohms 3. Replace the torque converter clutch solenoid valve if the resistance is out of standard. 4. If the resistance is within the standard, connect the No. 2 terminal to the battery positive terminal, and connect the No. 1 terminal to the battery negative terminal. A clicking sound should be heard. Replace the torque converter clutch solenoid valve if no sound is heard when connecting the battery positive terminal. Locations Gasoline Page 9244 Under-dash Fuse/Relay Box Service and Repair Rear Door Window Glass Weatherstrip: Service and Repair Rear Door Glass Outer Weatherstrip Replacement 4-door NOTE: - Put on gloves to protect your hands. - Take care not to scratch the door. 1. Starting at the front, pry the door glass outer weatherstrip (A) up to detach the clips (B, C, D), then remove the weatherstrip. 2. Install the weatherstrip in the reverse order of removal, and replace any damaged clips. Page 8580 PARTS INFORMATION REQUIRED MATERIALS WARRANTY CLAIM INFORMATION In warranty: The normal warranty applies. Failed Part: P/N 72185-S9A-003 H/C 6896716 Defect Code: 00503 Symptom Code: 07902 Skill Level: Repair Technician Page 3928 13. The green No.1 LED stays on, and the yellow No. 2 LED blinks. This indicates that the control uniti module is being updated. NOTE: To avoid control unit/module damage, do not interrupt the update. 14. When the yellow No.2 LED stays on, turn the ignition switch to LOCK (0). 15. Turn the ignition switch to ON (II). When the green No.1 and the yellow No.2 LEDs stay on, the control unit/module is updated. 16. Turn the ignition switch to LOCK (0), and disconnect the HIM from the vehicle. To do the same update on an identical vehicle, repeat steps 11 thru 16. Diagnosing HIM Error Codes If the red No.3 LED on the HIM came on or was flashing during the update, do this: 1. Leave the ignition switch in ON (II) while you disconnect the HIM from the vehicle's DLC. 2. If not already done, load the latest HDS sofiware onto the iN workstation. 3. Connect the HIM to the iN workstation. Connect the small end of the PC interface cable to the PC port on the HIM. 4. If not already done, connect the PC end of the blue PC interface cable to the 9P serial port on the iN workstation. 5. Connect the 110 VACIl 2 VDC power supply to the HIM and to a wall outlet. 6. Restart the CM Update application on the iN workstation. 7. On the right side of the screen, click on the view error button. 8. Click on View Error at the bottom of the screen to display the problem encountered while the HIM was connected to the vehicle. ^ If you get a Code 40 error message (usually caused by a communication error between the HIM and the workstation), do this: - Do the HIM self-test procedure (see HIM Self-Test). - Move the blue PC interface cable to another communication port on the back of the computer. - If one of the communication ports on the back of the computer has another cable connected to it, disconnect that cable, leave it disconnected during the HIM procedure, and connect the blue PC interface cable to that port. - Connect the HIM to another computer. (Some iN workstations require an internal communication port setup procedure. For help, call the iN Support Center) ^ If you get a Code 50 error message (usually caused by a communications error between the HIM and the vehicle's DLC), do this: - Diagnose and clear any DTCs. (The control unit/module must be free of DTCs before you can update it.) - Make sure there's a good connection between the HIM and the DLC. - Retry the update using the procedures in this service bulletin or on the back of the HIM. - If needed, call Tech Line for further help. HIM Self-Test If you suspect there's a problem with the HIM, review the instructions in this service bulletin to make sure you are using it correctly. If you still think there's a problem, do this self-test: Page 2439 ^ Start the engine and let it warm up to its normal operating temperature (the cooling fans cycle twice). ^ Let the engine idle (throttle closed and all electrical items off) for 10 minutes. 17. CR-V only: Reset the power window control unit: ^ Turn the ignition switch to ON (II). ^ Make sure the driver's window is fully closed. ^ Push down and hold the window switch until the window goes all the way down. ^ Pull back and hold the window switch until the window goes all the way up, then hold the switch for at least 2 more seconds. 18. Enter the audio unit anti-theft code, and set the clock. Enter the audio presets. Disclaimer Page 431 PGM-F1 Main Relay 1, 2 Type 1, 2 Check for continuity between the terminals. - There should be continuity between the No.1 and No.2 terminals when power and ground are connected to the No.3 and No.4 terminals. - There should be no continuity between the No.1 and No.2 terminals when power is disconnected. Normally-open type B: Rear Window Defogger Relay Page 367 12. On Accords and Pilots, install the new seat-back clips on the seat-back panel. Turn the clips so their retaining tabs are horizontal. 13. On Accords and Pilots, install the seat-back panel. 14. On all models except Accords and Pilots, zip the seat-back cover closed. 15. Initialize the OPDS unit. ^ To initialize with the HDS, go to Initializing the OPDS Unit: HDS Method. ^ To initialize with the SCS service connector, go to Initializing the OPDS Unit: Manual Mode. Initializing the OPDS Unit: HDS Method NOTE: Non-Honda seat covers will interfere with the performance of the OPDS and are not recommended. 1. Adjust the front passenger's seat-back to an upright position, then remove anything on or near the seat. 2. Turn the ignition switch to LOCK (0). 3. Connect the HDS to the vehicle's DLC (data link connector). 4. Turn the ignition switch to ON (II), then turn on the HDS. 5. At the screen prompts, enter the VIN and the odometer reading. Also verify the correct date and time. 6. From the System Selection menu, select SRS. M/T Mainshaft Reassembly Manual Revision Mainshaft: Technical Service Bulletins M/T Mainshaft Reassembly Manual Revision SOURCE: Honda Service News January 2004 TITLE: S/M Fix: M/T Mainshaft Reassembly APPLIES TO: 2001-04 Civic SERVICE TIP: The synchro ring order for 5th gear is wrong in the Exploded View on page 13-28. It shows the synchro ring with nine teeth per segment mating to 5th gear and the synchro ring with four teeth per segment mating to the tapered cone ring. If you install the synchro rings in this order, the M/T locks up in 5th gear. To ensure proper reassembly of 5th gear, refer to this exploded view. Locations Shift Interlock Solenoid: Locations 107. Behind A/T Shift Lever (except M/T) Page 4754 Flywheel: Service and Repair Flywheel Replacement Clutch Replacement Special Tools Required ^ Clutch alignment shaft 07LAF-PT00110 ^ Clutch alignment disc 07JAF-PM7011A ^ Remover handle 07936-3710100 ^ Ring gear holder 07LAB-PV00100 or 07924-PD20003 ^ Attachment, 57 x 40 mm 07746-0010200 ^ Driver 077 49-0010000 Flywheel Replacement NOTE: Do not disassemble the flexible plate from the flywheel. 1. Install the special tool. 2. Remove the flywheel mounting bolts in a crisscross pattern in several steps, then remove the flywheel. 3. Remove the pilot bearing (A) from the flywheel (B). 4. Drive the new bearing into the flywheel using the special tools as shown. Apply a light coat of oil to the outside of the bearing surface. Page 5726 Auxiliary Power Outlet: Diagnostic Aids General Troubleshooting Information General Troubleshooting Information Tips and Precautions Before Troubleshooting 1. Check applicable fuses in the appropriate fuse/relay box. 2. Check the battery for damage, state of charge, and clean and tight connections. NOTE: 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. Handling Connectors - Make sure the connectors are clean and have no loose wire terminals. - Make sure multiple cavity connectors are packed with dielectric grease (except watertight connectors). - All connectors have push-down release type locks (A). - Some connectors have a clip on their side used to attach them to a mount bracket on the body or on another component. This clip has a pull type lock. - Some mounted connectors cannot be disconnected unless you first release the lock and remove the connector from its mount bracket (A). - Never try to disconnect connectors by pulling on their wires; pull on the connector halves instead. - Always reinstall plastic covers. Page 9496 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 Short Circuit Locator (Short Finder) 1. Remove the blown fuse. Leave the battery connected. Page 8349 4. Polishing Check that the primer surfacer has dried thoroughly, then sand the primer surfacer. Use the double action sander and #32O - #4OO - #6OO disc papers. 5. Air blowing/degreasing Use alcohol, and wax and grease remover. Also clean and degrease the surfaces where masking tape will be attached. Intermediate Coating Intermediate Coating 1. Masking Mask the area surrounding the damage to protect it from the intermediate coat overspray. Use masking tape and paper. 2. Spraying top coat enamel Spray the top coat enamel over the surface until the primer surfacer is fully covered. Use the 2-part polyester urethane top coat enamel and a spray gun. - Mix the top coat enamel with the additive and solvent in the correct ratio. - Follow the top coat manufacturer's instructions. 3. Drying After spraying top coat enamel, allow for 5-10 minutes of normal drying time, then force dry it with infrared lamps or other industrial dryer. NOTE: Follow the top coat manufacturer's instruction for drying time. Page 8255 17. Using a small screwdriver, push down on the tip of the last tumbler to release it, then remove the cylinder from the housing, being careful not to drop any tumblers and springs. Use your thumb and forefinger to hold the tumblers in place. Then go to step 20. 18. While turning the key left and right and pushing on the rear of the inner cylinder to release the spring, slowly remove the cylinder from the housing. Page 9099 3. Strip the insulation off the end of the wire so the wire fits in the new terminal as shown. (If the wire has a wire seal, replace it with a new one from the kit.) NOTE: After stripping the end of the wire, make sure you did not cut any wire strands. If you did, cut the wire off even with the insulation, and strip it again. 4. Position the terminal in the crimping tool slot with the solid portion of the terminal toward the anvil and the open section toward the former. 5. Insert the wire in the terminal to the position shown in step 3. 6. Squeeze the tool with both hands until the stops make contact. 7. Crimp the insulation crimp. - If you do not have a wire seal, then use the next larger size crimp slot. Position the crimping tool over the insulation crimp section of the terminal, then squeeze the tool with both hands until the stops make contact. - If you have a wire seal, position the insulation crimp in the 5.5 crimping slot, then carefully squeeze the crimp closed until its ends are touching and making a full-circle shape. Continuously Variable Transmission Transmission Position Switch/Sensor: Testing and Inspection Continuously Variable Transmission Transmission Range Switch Test 1. Disconnect the transmission range switch connector. 2. Check for continuity between terminals at the switch connector. There should be continuity between terminals below listed for each switch position. 3. If there is no continuity between any terminals, adjust the transmission range switch installation. If the transmission range switch installation is OK, replace the transmission range switch. 4. If the transmission range switch continuity check was OK, replace the faulty transmission harness. Interior - Driver's Seat Rocks Back & Forth Seat Bottom Frame: All Technical Service Bulletins Interior - Driver's Seat Rocks Back & Forth 01-057 February 22, 2005 Applies To: 2001-02 Civic EX - ALL 2003-04 Civic EX and LX - ALL Updated information is shown by a black bar. Driver's Seat Rocks (Supersedes 01-057, dated November 9, 2004) SYMPTOM The driver's seat rocks back and forth during normal driving. PROBABLE CAUSE Worn bushings in the height adjustment mechanism. CORRECTIVE ACTION Install new seat bushings, nuts, and spacers. PARTS INFORMATION Seat Link Bushing (six required): P/N 90502-S3N-013, H/C 6690440 8/18 mm Nut Washer (six required): P/N 90321-SCV-A11, H/C 7952138 Spacer (four required): P/N 90503-53N-003, H/C 6852578 WARRANTY CLAIM INFORMATION In warranty: The normal warranty applies. Failed Part: P/N 81536-55P-A71 H/C 6526230 Defect Code: 00503 Symptom Code: 07302 Template ID: 01-057A Skill Level: Repair Technician Page 1997 Oil Pressure Sender: Testing and Inspection Oil Pressure Switch Test 1. Remove the YEL/RED wire (A) from the engine oil pressure switch (B). 2. Check for continuity between the positive terminal (C) and the engine (ground). There should be continuity with the engine stopped. There should be no continuity with the engine running. 3. If the switch fails to operate, check the engine oil level. If the engine oil level is OK, check the engine oil pressure. If the oil pressure is OK, replace the oil pressure switch. Page 102 Blower Motor Relay Type 1, Type 2 Check for continuity between the terminals. - There should be continuity between the No.1 and No.3 terminals when power and ground are connected to the No.2 and No.4 terminals. - There should be no continuity between the No.1 and No.3 terminals when power is disconnected. Five-terminal type Check for continuity between the terminals. - There should be continuity between the No.1 and No.2 terminals when power and ground are connected to the No.3 and No.5 terminals. - There should be continuity between the No.1 and No.4 terminals when power is disconnected. Page 5121 Shift Indicator: Diagnostic Aids General Troubleshooting Information General Troubleshooting Information Tips and Precautions Before Troubleshooting 1. Check applicable fuses in the appropriate fuse/relay box. 2. Check the battery for damage, state of charge, and clean and tight connections. NOTE: 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. Handling Connectors - Make sure the connectors are clean and have no loose wire terminals. - Make sure multiple cavity connectors are packed with dielectric grease (except watertight connectors). - All connectors have push-down release type locks (A). - Some connectors have a clip on their side used to attach them to a mount bracket on the body or on another component. This clip has a pull type lock. - Some mounted connectors cannot be disconnected unless you first release the lock and remove the connector from its mount bracket (A). - Never try to disconnect connectors by pulling on their wires; pull on the connector halves instead. - Always reinstall plastic covers. Page 8495 3. Remove the screws, then remove the seat-back lock cylinder (A) and cylinder rods (B). 4. Install the lock cylinder in the reverse order of removal, and note these items: - Make sure the cylinder rod is connected securely. - Make sure the seat-back opens properly. Page 3919 NOTE: If the latest sofiware is not loaded and you do a control unit/module update, the software may indicate the vehicle has the latest update when it doesn't. Updates not done with the latest software are not covered under warranty. 2. From the iN workstation desktop, select CM Update (ECU Rewrite). 3. Click on the Tools button on the right side of the screen, and make sure the interface device is set to GNA600. 4. Return to the Updating Honda Control Modules main screen, then click on Storage Mode and follow the on-screen instructions. 5. Take the GNA600 to the vehicle. Connect the DLC cable to the GNA600 and to the vehicle's DLC. 6. Turn the ignition switch to ON (II), and wait until the green No.2 LED on the GNA6OO stays on. Turn the ignition switch to LOCK (0), and disconnect the DLC cable from the vehicle. 7. Connect the USB PC interface cable to the iN workstation and to the GNA6OO. Connect the power supply unit and power supply cord to the GNA600. The GNA600 does a self-check and, after about 30 seconds, its yellow No.1 and green No.2 LEDs flash. Each updatable vehicle system is checked to make sure it is current. Any systems needing an update are listed on the screen. Highlight the system you want to update, then click on the check mark to continue. NOTE: Update the systems one at a time. Page 2975 ECM/PCM Inputs And Outputs At Connector C (22P) Page 8055 ^ Going from front to back, use the middle lock pin to set the first cam to the appropriate key code number in the code book. (The cam is properly set when the number on the cam lines up with the red scribe mark on the clamp unit.) ^ Slide the lock pin through the notch in the cam. (This locks the cam in place.) ^ Keep doing this for each of the remaining cams in the set until all the cams are set and locked, then push the lock pin all the way in. Repeat this process to set and lock the cams for the right cam set. NOTE: Make sure you set the MIS cam in the right cam set for the type of key you are cutting. For a master key, set the cam to M; for a valet key, set it to S. When you are done, push all the cam blades to the left until they touch the cams in the left cam set. 10. Pull the vertical carriage lever toward you until the tracer touches the flat surface on the right side at the front of the cams. Gently twist the lever clockwise to lock the vertical carriage at this height. Do not overtighten the lever. 11. Turn on the cutter motor with the motor start switch. [NOTICE] ^ To avoid damaging the locking jaws while cutting, keep your hand off the vertical carriage lever. Pressure on the lever will change the cutting depth. * ^ To avoid breaking the cutter bit, never back up while cutting.* ^ Wear proper eye protection (safety glasses, goggles, etc.) 12. Use the clamp carriage lever and the tracer to follow the contours of the cam blades from front to back. (The cutter bit cuts the same contours into the right edge of the key blank, from head to tip.) Page 4497 Clutch Release Bearing: Service and Repair Flywheel Inspection Clutch Replacement Special Tools Required ^ Clutch alignment shaft 07LAF-PT00110 ^ Clutch alignment disc 07JAF-PM7011A ^ Remover handle 07936-3710100 ^ Ring gear holder 07LAB-PV00100 or 07924-PD20003 ^ Attachment, 57 x 40 mm 07746-0010200 ^ Driver 077 49-0010000 Flywheel Inspection 1. Inspect the ring gear teeth for wear and damage. 2. Inspect the clutch disc mating surface on the flywheel for wear, cracks and burning. 3. Measure the flywheel (A) runout using a dial indicator (B) through at least two full turns with the engine installed. Push against the flywheel each time you turn it to take up the crankshaft thrust washer clearance. If the runout is more than the service limit, replace the flywheel and recheck the runout. Standard (New): 0.06 mm (0.002 inch) max. Service Limit: 0.15 mm (0.006 inch) 4. Turn the inner race of the pilot bearing (A) with your finger. The bearing should turn smoothly and quietly. Check that the bearing outer race fits tightly in the flywheel. If the race does not turn smoothly, quietly, or fit tight in the flywheel, replace the bearing. Page 3880 3. If there is no continuity between any terminal, remove the transmission range switch cover, and disconnect the connector (A) at the switch (B). 4. Check for continuity between terminals at the switch connector (c). There should be continuity between the terminals listed for each position. In the P position, between terminals: ^ No. 4 and No. 5 ^ No. 4 and No. 6 ^ No. 5 and No. 6 In the R position, between terminals: ^ No. 1 and No. 4 In the N position, between terminals: ^ No. 4 and No. 5 ^ No. 4 and No. 7 ^ No.5 and No.7 In the D position, between terminals: ^ No.2 and No.4 ^ No. 2 and No. 10 ^ No. 4 and No. 10 In the D3 position, between terminals: ^ No. 4 and No. 8 ^ No. 4 and No. 10 ^ No. 8 and No. 10 In the 2 position, between terminals: ^ No.3 and No.4 5. If there is no continuity between any terminals, adjust the transmission range switch installation. If the transmission range switch installation is OK, replace the switch. 6. If the transmission range switch continuity check was OK, replace the faulty transmission range switch harness. Page 2823 - Remove clips carefully; don't damage their locks (A). - Slip pliers (A) under the clip base and through the hole at an angle, then squeeze the expansion tabs to release the clip. - After installing harness clips, make sure the harness doesn't interfere with any moving parts. - Keep wire harnesses away from exhaust pipes and other hot parts, from sharp edges of brackets and holes, and from exposed screws and bolts. - Seat grommets in their grooves properly (A). Do not leave grommets distorted (B). Testing and Repairs - Do not use wires or harnesses with broken insulation. Replace them or repair them by wrapping the break with electrical tape. - After installing parts, make sure that no wires are pinched under them. - When using electrical test equipment, follow the manufacturer's instructions and those described. - If possible, insert the probe of the tester from the wire side (except waterproof connector). - Use back probe adaptor 07TAZ-001020A. - Refer to the instructions in the Honda Terminal Kit for identification and replacement of connector terminals. Five-Step Troubleshooting Five-Step Troubleshooting 1. Verify The Complaint Locations Keyless/Power Door Lock System Component Location Index Page 1103 Transmission Speed Sensor: Locations 22. Transmission Housing (A/T Except CVT) 19. Transmission Housing (A/T Except CVT) Page 1632 8. Remove the flange bolt (A) and wheel sensor (B) from the knuckle. Do not disconnect the wheel sensor connector. 9. Remove the flange nut (A) while holding the joint pin (B) with a hex wrench (C), and disconnect the stabilizer link (D) from the lower arm (E). 10. Remove the lock pin (A) from the lower arm ball joint, and remove the castle nut (B). NOTE: During installation, insert the lock pin into the ball joint pin in the range of 180 degrees or below from the inside of the vehicle. Insert the lock pin from the inside to the outside of the vehicle. 11. Disconnect the lower arm from the knuckle using the special too. Page 2498 symptom/indication goes away with a known-good ECM/PCM, replace the original ECM/PCM. Page 1666 Splices Components Ground - "G" Page 515 162. Right Side Of Engine Compartment 165. Under Left Side Of Floor (EX) Engine Controls - DTC P0171 Set Absolute Pressure Sensor: Technical Service Bulletins Engine Controls - DTC P0171 Set SOURCE: Honda Service News TITLE: Got a DTC P0171? Check the Short-Term Fuel Trim APPLIES TO: 03-04 Accord 01-04 Civic 02-04 CR-V 03-04 Element 02-04 Odyssey 03-04 Pilot SERVICE TIP: Got a vehicle in your shop that purrs like a kitten but it sets a DTC P0171 (fuel system too lean)? Check the short-term fuel trim (ST FUEL TRIM B1). If the value reads higher than 1.05, then check the MAP SENSOR value with the engine turned off and the ignition switch turned to ON (II). - If the MAP SENSOR and BARO SENSOR values match, the MAP sensor is working OK. Do the normal troubleshooting for DTC P0171. - If the MAP SENSOR and BARO SENSOR values don't match, install a known-good MAP sensor, and retest. If the sensor values now match, clear the DTC, and make sure the ST FUEL TRIM B1 value is normal (it reads about 1.0). Page 9320 8. Put the splice connector in the proper size slot in the Crimper Tool, slide it to one end (where the flare begins), and close the crimper handles far enough to hold it in place. To release the ratchet mechanism at any point after the first click, squeeze the handles slightly and push the release lever, then let the handles open. 9. Insert one of the bare wires into the splice connector end that is in the crimper jaws. Push the wire all the way into the splice connector, and squeeze the crimper handles. Keep squeezing until the jaws touch, and hold it at that position until the ratchet clicks again. 10. Crimp the other wire in the same way into the other end of the splice connector. 11. After crimping, gently pull on the wires in the opposite directions to make sure they are secure in the connector. 12. Separate the other wires in the harness from the repaired wire(s), and shield them with nonflammable material. Page 6861 Page 5000 195. Tranmission Range Switch Page 6818 WARRANTY CLAIM INFORMATION Out of warranty: Any repairs to the SRS system for problems other than the 15-1, 15-2, and 15-3 DTCs that are done 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. INSPECTION PROCEDURE NOTE: ^ When you check for SRS DTCs with the HDS, codes other than 15-1, 15-2, and 15-3 are not covered by this warranty extension bulletin. ^ If the vehicle is covered by warranty, repair it using the normal warranty repair procedures. If the vehicle's warranty is expired, give your customer an estimate for the cost of the repair. Do the appropriate inspection, based on the DTC. SRS DTC 15-1 Clear the DTC with the HDS. ^ If DTC 15-1 does not set again, go to REPAIR PROCEDURE A: OPDS UNIT REPLACEMENT. ^ If DTC 15-1 sets again, continue with normal troubleshooting. ^ If the OPDS unit causes DTC 15-1 to set repeatedly, yet passes the other troubleshooting steps, go to REPAIR PROCEDURE A: OPDS UNIT REPLACEMENT. SRS DTC 15-2 1. Inspect the connections and the wiring in the side airbag cutoff indicator circuit. ^ If all the connections and the wiring are OK, go to step 2. ^ If any of the connections or the wiring are faulty, repair the circuit, then go to step 2. 2. Clear the DTC with the HDS. ^ If DTC 15-2 does not set again, go to REPAIR PROCEDURE A: OPDS UNIT REPLACEMENT. ^ If DTC 15-2 sets again, continue with normal troubleshooting. ^ If the OPDS unit causes DTC 15-2 to set repeatedly, yet passes the other troubleshooting steps, go to REPAIR PROCEDURE A: OPDS UNIT REPLACEMENT. SRS DTC 15-3 1. Clear the DTC with the HDS. ^ If DTC 15-3 does not set again, go to step 2. ^ If DTC 15-3 sets again, continue with normal troubleshooting. 2. Ask your customer if electrical devices such as a laptop computer or a fluorescent map light are ever used near the front passenger's seat-back. (Some electrical devices that plug into the vehicle's accessory power socket, especially those using a power inverter/converter, can interfere with the seat-back sensors and cause SRS DTC 15-3 to set.) ^ If your customer uses any of these devices operate the device near the front passenger's seat-back. If DTC 15-3 sets again, clear it, then return the vehicle to the customer. Advise the customer to avoid using the device near the front passenger's seat-back. ^ If your customer does not use any of these devices and DTC 15-3 does not set again, go to REPAIR PROCEDURE A: OPDS UNIT REPLACEMENT. REPAIR PROCEDURE A: OPDS UNIT REPLACEMENT Page 2978 ECM/PCM Inputs And Outputs At Connector E (31P) Page 8867 6. Disconnect both seat belt buckle tensioner 4P connectors (A). Page 6822 7. From the Mode menu, select Miscellaneous Test. 8. From the Miscellaneous Test menu, select OPDS Initialization. 9. Follow the remaining screen prompts to complete the OPDS initialization. If the initialization fails repeat the process two more times. If the initialization fails again, check for SRS DTCs, then troubleshoot them using the appropriate service manual. Initializing the OPDS Unit: Manual Mode NOTE: Non-Honda seat covers will interfere with the performance of the OPDS and are not recommended. 1. Adjust the front passenger's seat-back to an upright position, then remove anything on or near the seat. 2. Turn the ignition switch to LOCK (0). 3. Connect the HDS to the vehicle's DLC (data link connector). 4. Keep the ignition switch at LOCK (0), and turn on the HDS. 5. At the screen prompts, enter the VIN and the odometer reading. 6. From the Select Mode screen, select SCS, and follow the screen prompts. Page 7005 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 9239 160. Fog Light Switch (Honda Accessory) Page 8748 Wires Page 3705 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. Circuits must be operating when checking voltage drop. 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. 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 off, 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 Self-Powered Test Light or DVOM 1. Remove the blown fuse and disconnect the battery and load. Page 8463 7. Remove and discard the three nuts, and remove the washers from the outboard link and from the outboard seat track. 8. 2001-02 Models: Remove and discard the spacer from the outboard link. 9. Remove and discard the old bushings. 10. Install the new bushings, and add one spacer as shown. 11. Reassemble the outboard side of the seat track in the reverse order of removal using new nuts. Torque the nuts to 24 N.m (17 lb-ft). 12. Install the recline cover, height knob, and recline handle. 13. Remove the seat belt buckle. Page 3253 - 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. Troubleshooting Tests 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 test 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 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. 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 Drop Page 4906 Control Module: Service and Repair Updating the ECM/PCM PCM Updating and Substitution for Testing Special Tools Required Honda Interface Module (HIM) P/N EQS05A35570 Use this procedure when you have to substitute a known-good PCM in a troubleshooting procedure. Update the PCM only if the PCM does not already have the latest software loaded. NOTE: Do not turn the ignition switch OFF while updating; the PCM can be damaged. How to Update the PCM NOTE: To ensure the latest program is installed, do an PCM update whenever the PCM is substituted or replaced. - Before you update the PCM, make sure the vehicle's battery is fully charged. - To prevent PCM damage, do not operate anything electrical (audio system, brakes, A/C, power windows, moon roof, door locks, etc.) during the update. - If you need to diagnose the Honda Interface Module (HIM) because the HIM's red (#3) light came on or was flashing during the update, leave the ignition switch in the ON (II) position when you disconnect the HIM from the Data Link Connector (DLC). This will prevent PCM damage. 1. Turn the ignition switch ON (II). Do not start the engine. 2. Connect the HIM to the DLC (A) located under the driver's side of dashboard. 3. Do the PCM update procedure as described on the HIM label and in the PCM update system. If the software in the PCM is the latest version, replace the PCM. How to End a Troubleshooting Session This procedure must be done after any troubleshooting. 1. Clear the DTC(s) with the Scan Tool or HDS, or reset the PCM by removing the No. 6 (PCM) fuse in the under-hood fuse/relay box for more than 10 seconds. 2. Turn the ignition switch ON (II). 3. Start the engine in the P or N position, and warm it up to normal operating temperature (the radiator fans come on). 4. To verify that the problem is repaired, test-drive the vehicle for several minutes at speeds over 30 mph (50 km/h) or in freeze data range. Page 9303 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. Test Equipment 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. Page 9006 Diodes Light Emitting Diode (LED) Motor Pressure Sensor Page 6604 Refrigerant: Service and Repair System Evacuation System Evacuation CAUTION: - Air conditioning refrigerant or lubricant vapor can irritate your eyes, nose, or throat. - Be careful when connecting service equipment. - Do not breathe refrigerant or vapor. Use only service equipment that is U.L.-listed and is certified to meet the requirements of SAE J221 0 to remove HFC-134a (R-134a) from the air conditioning system. If accidental system discharge occurs, ventilate work area before resuming service. Additional health and safety information may be obtained from the refrigerant and lubricant manufacturers. 1. When an A/C system has been opened to the atmosphere, such as during installation or repair, it must be evacuated using a R-134a refrigerant recovery/recycling/charging station (If the system has been open for several days, the receiver/dryer should be replaced, and the system should be evacuated for several hours.) 2. Connect a R-134a refrigerant recovery/recycling/charging station (A) to the high-pressure service port (B) and the low-pressure service port (C), as shown, following the equipment manufacturer's instructions. Evacuate the system. 3. If the low-pressure does not reach more than 93.3 kPa (700 mmHg, 27.6 in.Hg) in 15 minutes, there is probably a leak in the system. Partially charge the system, and check for leaks. Page 4335 87. TCC Solenoid Valve (A/T Except CVT) Page 1573 71. Under Left Side Of Dash Under-hood Fuse/Relay Box Page 7628 ^ Incorrect: "If a Master Key is to be cut, put a five (5) in the blank space. Use a two (2) if a valet key is needed." ^ Correct: "If a Master Key is to be cut, put an M in the blank space. Use an S if a valet key is needed." Page 2, legend at the bottom: ^ Incorrect: "C. If a Master key is desired, then the number five (5) should be placed in the M/S position. Place the number two (2) in the M/S column if a Sub (Valet) key is needed." ^ Correct: "C. If a Master Key is desired, then an M should be placed in the M/S position. Place an S in the MIS column if a Sub (Valet) key is needed." Page 4108 Use the tools from Pin Tool Set. First, check the connector that you are about to repair. - If it has a secondary terminal lock, go to Connectors With a Secondary Lock. A secondary lock, found on most connectors on some models, is an additional locking device on the connector housing as a backup for the primary lock on the terminal. - If the connector does not have a secondary lock, go to Connectors Without a Secondary Lock. Connectors With a Secondary Lock All examples are shown with the connector lock facing up. The illustrations are examples of the secondary terminal locks; however, the connector you are repairing may vary in size. Identify the connector by the type of secondary lock, not by the number of terminal cavities. EXAMPLE A: 1. Release the secondary lock. 2. Remove the terminal. 3. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE B: Page 4770 Wires Page 8434 7. To remove a rear drain valve (A) from the trunk compartment, remove these parts, 2-door, 4-door: - Trunk floor mat and trunk floor - Trunk rear trim panel Pull back the trunk side trim panel and release the rear drain tube (B) from the clip (C), and pull the drain tube out through the hole in the pillar. 8. From inside: Release the rear drain tube (A) from the inside of the vehicle by releasing the clips (B). Remove the rear drain tube. 9. Install the frame and drain tube in the reverse order of removal, and note these items: - Before installing the frame, clear the drain tubes and drain valves using compressed air. - Check the frame seal. - Clean the surface of the frame. - When installing the frame, first attach the rear hooks into the body holes. - Make sure the connectors are plugged in properly. - When installing the rear drain tube to the body at the C-pillar, align the cushion of the tube to the hole in the body, and align the alignment mark of the tube to the clip of the upper portion. - When connecting the drain tube, slide it over the frame nozzle at least 10 mm (0.39 in). - Install the tube clip (A) on the drain tube (B) as shown. 10. Check for water leaks. Let the water run freely from a hose without a nozzle. Do not use a high-pressure spray. Page 7779 24. Remove the key. Reinstall the retainer clip in the door handle, and push the lock cylinder into place. 25. Civic: Reconnect the cylinder rod. 26. CR-V: Reconnect the cylinder rod, the outer handle rod, and the rod protector. 27. Element: Reconnect the cylinder rod, the outer handle rod, and the access seal. Reinstall the lower run channel. 28. Reinstall the plastic covering, and lower the window glass. Install the door panel. 29. Check that the door lock and handle operate smoothly. Disclaimer Page 7907 5. Install the gusset in the reverse order of removal, and note these items: - When installing the mounting bolts for the middle cross-member gusset (A), torque the mounting hardware in the sequence shown. If the mounting bolts are not torqued in this sequence, damage to the quarter panel will occur. - Replace the damaged cushion tape (P/N 91902-SB2-003). Page 4964 162. Right Side Of Engine Compartment Locations Pressure Regulating Solenoid: Locations Electronic Controls Location Locations Transmission Position Switch/Sensor: Locations Electronic Controls Location, CVT 25. Transmission Housing (CVT) Electrical - DTC P1298 Stored in ECM/PCM Electric Load Sensor: All Technical Service Bulletins Electrical - DTC P1298 Stored in ECM/PCM 05-006 May 6, 2005 Updated information is noted by asterisks. Applies To: 2001-05 Civic - ALL *2002-04 CR-V - ALL* DTC P1298 Is Stored in the ECM/PCM (Supersedes 05-006, dated February 25, 2005, to change the CR-V model-year range) SYMPTOM DTC P1298 (electrical load detector (ELD) circuit high voltage) is stored in the ECM/PCM. PROBABLE CAUSE The electronic load detector (ELD) has a faulty solder joint. CORRECTIVE ACTION Replace the ELD. NOTE: Previously, if an ELD required replacement, you had to replace the under-hood fuse/relay box. To reduce repair costs, replacement ELDs are now available. PARTS INFORMATION Electronic Load Detector: P/N 38255-S5A-003, H/C 7987571 WARRANTY CLAIM INFORMATION In warranty: The normal warranty applies. Operation Number: 121195 Flat Rate Time: 0.4 hour Failed Part: Civic P/N 38250-S5A-A03 H/C 7472277 CR-V P/N 38250-S9A-A01 H/C 6890594 Defect Code: 06402 Symptom Code: 01201 Template ID: 05-006A 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 5991 220. C103 (Junction Connector) 221. C104 (Junction Connector) Page 7345 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 1557 Air Conditioning Component Location Index Page 1279 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. Body - Door Lock Cylinders Bind Trunk / Liftgate Lock Cylinder: All Technical Service Bulletins Body - Door Lock Cylinders Bind 03-068 October 29, 2004 Applies To: See VEHICLES AFFECTED Door Lock Cylinder Binds (Supersedes 03-068, dated April 20, 2004) Updated information is shown with asterisks and black bars. SYMPTOM The key will not go into the door lock cylinder, or if it goes in, it will not turn. PROBABLE CAUSE The door lock tumblers are damaged or worn. VEHICLES AFFECTED CORRECTIVE ACTION Remove the door lock cylinder, and replace the inner cylinder, springs, and tumblers. Page 2623 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 3129 Terminals - "T" Shielding Switches Fuses Page 8008 8. Release the clip, detach the hook, and remove the lock rod protector. 9. Disconnect the outer handle rod and cylinder rod. Diagrams Rear Defogger: Diagrams (Coupe) (Sedan) Page 8303 9. Open the jaws with the jaws knob, and slide the original key with its flat side down into the center jaw up to the key stop. Slide the key blank with its flat side down into the right jaw up to the key stop. Close the jaws with the jaws knob to lock the keys into place. Visually inspect both keys for proper alignment in the jaws. 10. Loosen the lateral and spring tension adjustment knobs on the clamp carriage. With the clamp carriage lever, adjust the clamp carriage to position the tracer and the cutter bit over the middle of the two locked key blades. Tighten only the spring tension knob when done. NOTE: The clamp carriage has a spring system that puts lateral pressure on the tracer and cutting bit to make it easier to cut sidewinder-type keys. Do not tighten the lateral tension adjustment knob. This knob should be left loose. 11. Turn on the cutter motor with the motor start switch. [NOTICE] ^ To avoid damaging the locking jaws while cutting, keep your hand off the vertical carriage lever. Pressure on the lever will change the cutting depth. * ^ To avoid breaking the cutter bit, never back up while cutting.* ^ Wear proper eye protection (safety glasses, goggles, etc.) How to Remove the PCM Control Module: Service and Repair How to Remove the PCM How to Remove the PCM for Testing 1. Remove the passenger's dashboard lower cover, the right kick panel, and the glove box. 2. Remove the bolt. Cut the plastic cross brace in the glove box opening with diagonal cutters in the area shown, and discard it. 3. Remove the relays (A), then remove the bolts and the glove box frame (B). 4. Remove the gray 20P PCM wire harness connector from the PCM mounting bracket. Remove the PCM mounting bolt (A) and the bracket. 5. Remove the nuts, then remove the PCM (B). 6. Install the PCM in the reverse order of removal. Page 8011 17. Using a small screwdriver, push down on the tip of the last tumbler to release it, then remove the cylinder from the housing, being careful not to drop any tumblers and springs. Use your thumb and forefinger to hold the tumblers in place. Then go to step 20. 18. While turning the key left and right and pushing on the rear of the inner cylinder to release the spring, slowly remove the cylinder from the housing. Page 4121 2. Insert the terminal tool into the female terminal, and then remove the terminal tool. NOTE: Make sure you do not select a terminal tool that is larger than the mating male terminal because it would spread the female terminal and cause a loose fit. 3. Compare the drag to the other terminals in the connector. If the drag is less, replace the terminal with a replacement terminal from the appropriate terminal repair kit. Page 7311 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 9673 Heated Glass Element Switch: Diagrams 194. Recirc - A/C - Defogger Switch Assembly Page 1139 Page 9295 Diodes Light Emitting Diode (LED) Motor Pressure Sensor Page 1783 Numbers have been stamped on the side of each connecting rod as a code for the size of the big end. Use them, and the letters stamped on the crank (codes for rod journal size), to choose the correct bearings. If the codes are indecipherable because of an accumulation of dirt and dust, do not scrub them with a wire brush or scraper. Clean them only with solvent or detergent. Connecting Rod Journal Code Locations (Letters) Page 2524 - Remove clips carefully; don't damage their locks (A). - Slip pliers (A) under the clip base and through the hole at an angle, then squeeze the expansion tabs to release the clip. - After installing harness clips, make sure the harness doesn't interfere with any moving parts. - Keep wire harnesses away from exhaust pipes and other hot parts, from sharp edges of brackets and holes, and from exposed screws and bolts. - Seat grommets in their grooves properly (A). Do not leave grommets distorted (B). Testing and Repairs - Do not use wires or harnesses with broken insulation. Replace them or repair them by wrapping the break with electrical tape. - After installing parts, make sure that no wires are pinched under them. - When using electrical test equipment, follow the manufacturer's instructions and those described. - If possible, insert the probe of the tester from the wire side (except waterproof connector). - Use back probe adaptor 07TAZ-001020A. - Refer to the instructions in the Honda Terminal Kit for identification and replacement of connector terminals. Five-Step Troubleshooting Five-Step Troubleshooting 1. Verify The Complaint Page 1749 Circuit Schematics Each schematic represents one circuit. A circuit's wires and components are arranged to show current flow from power at the top of the diagram 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 Page 5792 234. Under-dash Fuse/Relay Box Part 2 Page 6564 Heater Core: Service and Repair Heater Unit/Core Replacement SRS components are located in this area. Review the SRS component locations, and precautions and procedures in the SRS section before performing repairs or service. 1. Make sure you have the anti-theft code for the radio, then write down the frequencies for the radio's preset buttons. 2. Disconnect the negative cable from the battery. 3. With air conditioning; disconnect the suction and receiver lines from the evaporator core. 4. From under the hood, open the cable clamp (A), then disconnect the heater valve cable (B) from the heater valve arm (C). Turn the heater valve arm to the fully opened position as shown. 5. When the engine is cool, drain the engine coolant from the radiator. 6. Slide the hose clamps (A) back, then disconnect the inlet heater hose (B) and the outlet heater hose (C) from the heater core. Engine coolant will run out when the hoses are disconnected; drain it into a clean drip pan. Be sure not to let coolant spill on the electrical parts or the painted surfaces. If any coolant spills, rinse it off immediately. 7. Remove the mounting bolt and the heater valve as shown. Page 2565 Vehicle Speed Sensor: Testing and Inspection Vehicle Speed Signal Circuit Troubleshooting Special Tools Required: Test Harness 07LAJ-PT3020A Before testing, inspect the No.4 (10 A) and No.10 (7.5 A) fuses in the under-dash fuse/relay box. 1. Disconnect the 3P connector from the vehicle speed sensor (VSS) (A). 2. Connect the test harness only to the engine wire harness. 3. Connect the RED test harness clip (B) to the positive probe of an ohmmeter. Cover the white (C) and green (D) test harness leads with protective tape (E). 4. Check for continuity between the RED test harness clip and body ground. Is there continuity? YES - Go to step 5. NO - Repair open in the BLK wire between the VSS and G101. 5. Connect the WHT test harness clip (B) to the positive probe of a voltmeter, and connect the RED test harness clip (C) to the negative probe. 6. Turn the ignition switch ON (II). Is there battery voltage? YES - Go to step 7. NO - Repair open in the BLK/YEL wire between the VSS and the under-dash fuse/relay box. 7. Disconnect the WHT test harness clip (B). Page 1631 3. Remove the brake hose bracket mounting bolt (A). 4. Remove the caliper bracket mounting bolts (B), and remove the caliper assembly (C) from the knuckle. To prevent damage to the caliper assembly or brake hose, use a short piece of wire to hang the caliper assembly from the undercarriage. Do not twist the brake hose with force. 5. Raise the stake (A), and remove the spindle nut (B), then remove and discard the nut. 6. Remove the brake disc retaining flat screws (A). 7. Screw two 8 x 1.25 mm bolts (B) into the disc to push it away from the hub. Turn each bolt 2 turns at a time to prevent cocking the disc excessively. Page 7245 On the order form, you must include the serial number of the keyless control unit or the number from one of the original transmitters. If you need a transmitter shipped overnight, fill out the order form, then call Kenwood at (500) 552-4690, or fax them at (310) 595-1029 (weekdays from 5:30A.M. thru 4:00 P.M. Pacific time). You will need to give the information on the order form to the Kenwood representative. The transmitter will be sent to your dealership COD. Additional shipping and handling charges will be applied to the order. Batteries for the Transmitter The battery number is CR1220. Each transmitter uses two batteries. 94-97 Accord 5-Door EX, 95-98 Odyssey EX 1994-97 Accord 5-door EX with factory-installed keyless entry system 1995-98 Odyssey EX with factory-installed keyless entry system Programming the Transmitter NOTE: ^ The system accepts up to two transmitters. ^ Entering the programming mode cancels all learned transmitter codes, so none of the previously programmed transmitters will work. You must reprogram all of the transmitters once you are in the programming mode. 1. Open the driver's door. 2. Push the driver's power door lock switch to the unlock position and hold it. (Continue to hold the switch during this procedure.) 3. Insert the key into the ignition switch, then remove it. Repeat this four more times (five times total) within 10 seconds. (You must complete steps 3 and 4 within 10 seconds or the system will exit the programming mode.) 4. Insert the key into the ignition switch. After you insert the key, make sure the power door locks cycle to confirm that the system is in the programming mode. 5. Press the "LOCK" or "UNLOCK" button on the transmitter. All the power door locks (except the driver's door) should cycle to confirm that the system accepted the transmitter's code. 6. To program a second transmitter, press its "LOCK" or "UNLOCK" button within 10 seconds of programming the first transmitter. 7. Release the master power door lock switch to exit the programming mode. Ordering a Transmitter Transmitters can be ordered only by authorized Honda dealers. Order them from American Honda using normal parts ordering procedures. Batteries for the Transmitter The battery number is CR2016. Each transmitter uses two batteries. 96-04 Accord, CRV, DelSOL, Ody., Prelude, S2000, Insight, Pilot 1996-02 Accord with dealer-installed security system 1998-02 Accord DX & LX with dealer-installed keyless entry system Page 7026 Seat Belt Buckle: Service and Repair Rear Seat Belt Buckle Rear Seat Belt Replacement NOTE: Check the rear seat belts for damage, and replace them if necessary. Be careful not to damage them during removal and installation. Center Belt and Seat Belt Buckles 1. Remove the rear seat cushion, 2-door, 4-door. 2. Remove the center anchor bolts (A), and remove the seat belt buckles (B). 3. Remove the rear shelf, 2-door, 4-door. 4. Remove the retractor mounting self-tapping ET screw (A), and the retractor bolt (B), then remove the center belt (C) and retractor (D). 5. Remove the protector (A). Page 1073 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 Locater) 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. Troubleshooting Precautions Troubleshooting Precautions Before Troubleshooting 1. Check the main fuse and the fuse 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, or you will damage the alternator diodes. - Do not attempt to crank the engine with the ground cable disconnected 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. Locations Impact Sensor: Locations SRS Component Location Index Page 2934 Power Steering Pressure Switch: Testing and Inspection PSP Switch Signal Circuit Troubleshooting 1. Turn the ignition switch ON (II). 2. Measure voltage between ECM/PCM connector terminals A24 and E16. Is there less than 1.0 V? YES - Go to step 3. NO - Go to step 6. 3. Start the engine. 4. Turn the steering wheel to the full lock position. 5. Measure voltage between ECM/PCM connector terminals A24 and E16. Is there battery voltage? YES - The PSP switch signal is OK. NO - Go to step 13. 6. Turn the ignition switch OFF. 7. Disconnect the PSP switch 2P connector. 8. Turn the ignition switch ON (II). 9. At the harness side, connect the PSP switch 2P connector terminals No.1 and No.2 with a jumper wire. 10. Measure voltage between ECM/PCM connector terminals A24 and E16. Is there less than 1.0 V? YES - Replace the PSP switch. NO - Go to step 11. 11. Turn the ignition switch OFF. Under-Dash Fuse/Relay Box Under-dash Fuse/Relay Box Page 6372 6. Remove the flange nuts (A) from the top of the damper. 7. Lower the lower arm, and remove the damper assembly (B). Disassembly/Inspection 1. Compress the damper spring with a commercially available strut spring compressor (A) according to the manufacturer's instructions, then remove the self-locking nut (B) while holding the damper shaft (C) with a hex wrench (D). Do not compress the spring more than necessary to remove the nut. 2. Release the pressure from the strut spring compressor, then disassemble the damper as shown in the Exploded View. 3. Reassemble all the parts, except for the spring. 4. Compress the damper assembly by hand, and check for smooth operation through a full stroke, both compression and extension. The damper should extend smoothly and constantly when compression is released. If it does not, the gas is leaking and the damper should be replaced. 5. Check for oil leaks, abnormal noises, and binding during these tests. Reassembly Page 8983 Key Reminder Switch: Locations Entry Light Control System Component Location Index Page 6174 Power Steering Fluid: Fluid Type Specifications Power Steering Fluid Type ........................................................................................................................................................ Honda Power Steering Fluid Do not use ATF Page 4873 8. Reassemble the transmission; see page 13-43 (13-59 for Hybrid) of the service manual. 9. Install the new shift fork holder. Check the reverse shift fork clearance; see page 13-19 (13-34 for Hybrid) of the service manual. 10. Reinstall the transmission; see page 13-9 (13-23 for Hybrid) of the service manual. 11. Fill the transmission with MTF. 12. * Test-drive the car; make several right turns (left turns for Hybrid), and check that the clicking noise is gone.* Disclaimer Page 4782 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. Test Equipment 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. Page 6026 Relay And Control Unit Locations - Engine Compartment Page 3954 8. Verify that the Program ID and the Program Part No. are correct, then click on the check mark. 9. Confirm the control module update by Program ID and Program Part No. Make sure this corresponds with any information provided in the service bulletin for the update you are doing. Click on Yes to continue. Within a few seconds, the CM Update software loads the program file onto the GNA600. 10. Disconnect the GNA600 from the USB PC interface cable, then connect the trigger switch adapter block (yellow) and the trigger switch to the GNA600 as shown below. (The DLC cable should still be connected to the GNA600.) 11. Reconnect the DLC cable to the vehicle's DLC. 12. Turn the ignition switch to ON (II), and wait until the green No.2 LED on the GNA600 stays on. Press and release the trigger switch button. 13. The yellow No.1 LED blinks, and the green No.2 LED stays on. This indicates that the control uniti module is being updated. Page 6126 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 Removal and Installation Brake Caliper: Service and Repair Removal and Installation Front Inspection and Replacement CAUTION: Frequent inhalation of brake pad dust, regardless of material composition, could be hazardous to your health. ^ Avoid breathing dust particles. ^ Never use an air hose or brush to clean brake assemblies. Use an OSHA-approved vacuum cleaner. Replacement 1. Remove the bolt (B), and pivot the caliper (C) up out of the way. Check the hose and pin boots for damage and deterioration. 2. Remove the pad shim (A) and pads (B). 3. Remove the pad retainers (A). 4. Clean the caliper thoroughly; remove any rust, and check for grooves and cracks. 5. Check the brake disc for damage and cracks. 6. Apply Dow Corning Molykote M77 grease to the retainers on their mating surfaces against the caliper bracket. 7. Install the pad retainers. Wipe excess grease off the retainers. Contaminated brake discs and pads reduce stopping ability. Keep grease off the discs and pads. Page 284 ECM/PCM Inputs And Outputs At Connector E (31P) Page 6842 Page 5246 - 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. Troubleshooting Tests 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 test 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 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. 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 Drop Page 7478 Body Control Systems: Testing and Inspection Multiplex Control Unit Input Test Multiplex Control Unit Input Test 1. Remove the dashboard lower cover. 2. Unbolt the under-dash fuse/relay box and pull it down. NOTE: All connectors are wire side of female terminals. 3. Inspect the connector and socket terminals to be sure they are all making good contact. - If the terminals are bent, loose or corroded, repair them as necessary, and recheck the system. - If the terminals look OK, go to step 4. 4. With the connectors still disconnected, make these input tests at the connector. - If any test indicates a problem, find and correct the cause, then recheck the system. - If all the input tests prove OK, go to step 5. Page 2705 Crankshaft Position Sensor: Service and Repair CKP Sensor Replacement 1. Remove the grommet (A) from the upper cover, and disconnect the camshaft position (CMP) (top dead center (TDC)) sensor connector (B). 2. Remove the upper cover (C) and lower cover (D). 3. Disconnect the crankshaft position (CKP) sensor connector, then remove the CKP sensor from the oil pump. 4. Install the CKP sensor in reverse order of removal. Page 8286 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. Obtain the customer's key code from the iN (Key Code Inquiry). Refer to the Honda High Security key Codes book that comes with the Matrix H key cutting machine. Write down the applicable cutting code for the key code number. Make sure the corrections to the code book listed in Service Bulletin 01-077, Cutting Sidewinder-Type keys With the Matrix H key Cutting Machine, have been made. 2. Use the chart shown to write down the numbers found in the key code book. 3. Remove the door panel. Refer to the appropriate service manual or use ISIS keyword Door Panel. 4. Remove the plastic cover as necessary. 5. Raise the window glass fully. 6. Remove the lock cylinder. ^ For Civic, go to step 7. ^ For CR-V, go to step 8. ^ For Element, go to step 11. 7. Pull down on the retainer clip with a hook-shaped tool. Remove the lock cylinder and disconnect the cylinder rod. Then go to step 14. Service and Repair Cowl Moulding / Trim: Service and Repair Cowl Cover Replacement 1. Remove the windshield wiper arms. 2. Using a clip remover, detach the clips (A), then remove the hood rear seal (B), and detach the clips (C) from the cowl covers. Take care not to scratch the cowl covers. 3. Detach the clip (D) or clip (E), and clips (F, G), and release the hook (H) by carefully pulling the passenger's cowl cover (I) upward, and pull the cover forward to release the hooks (J), then remove the cover. Take care not to scratch the body. 4. Detach the clips (D) or clips (E), and clips (F, G) by carefully pulling the driver's cowl cover (K) upward, and pull the cover forward to release the hooks (L), then remove the cover. Take care not to scratch the body. 5. Install the cover in the reverse order of removal, and note these items: - Replace any damaged clips. - Push the clip portions into place securely. Page 3379 Fuel Pressure: Testing and Inspection Fuel Pressure Test Special Tools Required - Fuel pressure gauge 07406-004000A - Fuel pressure gauge set 07ZAJ-S5A0100 1. Relieve the fuel pressure. 2. Disconnect the quick-connect fitting (A). Attach the fuel pressure gauge set and fuel pressure gauge. 3. Start the engine and let it idle. - If the engine starts, go to step 5. - If the engine does not start, go to step 4. 4. Check to see if the fuel pump is running: listen to the fuel fill port with the fuel fill cap removed. The fuel pump should run for 2 seconds when the ignition switch is first turned on. If the pump runs, step 5. - If the pump does not run, perform the fuel pump circuit troubleshooting. 5. Read the pressure gauge. The pressure should be 270 - 320 kPa (2.8 - 3.3 kgf/sq.cm, 40 - 47 psi) - If the pressure is OK, the test is complete. - If the pressure is out of specification, replace the fuel pressure regulator and the fuel filter, then recheck the fuel pressure. Page 4776 Circuit Schematics Each schematic represents one circuit. A circuit's wires and components are arranged to show current flow from power at the top of the diagram 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 Page 9025 1. Remove the terminal. 2. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE B: 1. Remove the terminal. 2. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE C: 1. Remove the terminal. 2. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE D: Page 7711 ^ If the trunk opens and closes smoothly, return the vehicle to the customer. ^ If the trunk lid is still difficult to close, go to REPAIR PROCEDURE E. REPAIR PROCEDURE E 1. Look at the back of the lock cylinder while you turn the key from lock to unlock. ^ Refer to page 20-158 of the 2001-04 Civic Service Manual. ^ In ISIS, use the keyword LID LOCK, and select Trunk Lid Lock Cylinder Replacement from the list. 2. Check the operation of the trunk lid lock cylinder: ^ If the lock cylinder is difficult to turn or binds, go to step 3. ^ If the lock cylinder operates properly, and the trunk lid is still difficult to close, refer to the appropriate body repair manual, and check for body inaccuracies. 3. Replace the lock cylinder, and re-key the cylinder to the customer's original key; on 2-door Civics, replace the lock cylinder and the lock cylinder rod: ^ Refer to page 20-158 of the 2001-04 Civic Service Manual. ^ In ISIS, use the keyword LID LOCK, and select Trunk Lid Lock Cylinder Replacement from the list. 4. Check the trunk operation, and return the vehicle to the customer. Disclaimer Page 9523 PGM-F1 Main Relay 1, 2 Type 1, 2 Check for continuity between the terminals. - There should be continuity between the No.1 and No.2 terminals when power and ground are connected to the No.3 and No.4 terminals. - There should be no continuity between the No.1 and No.2 terminals when power is disconnected. Normally-open type B: Rear Window Defogger Relay Page 7785 *T-5 Sidewinder Key Applications ^ 2003-05 Civic ^ 2004-05 Civic Hybrid ^ 2003-05 Civic GX (CNG) ^ 2004-05 S2000 ^ 2002-06 CR-V ^ 2003-06 Element ^ 2003-04 Odyssey ^ 2003-04 Pilot Ordering Honda key blanks through normal parts ordering channels: Refer to the parts catalog for correct key(s) for your application. PROGRAMMING KEYS Depending on the type of key blank you use, do this: ^ If you have used a T-5 programmable key blank ("T-5" stamped on the shank), you must code the key's transponder with the Ilco Immobilizer Key Code Duplicator (see S/B 99-053, Ilco Immobilizer key Code Duplicator). ^ If you have used a Honda key blank, add the* transponder code of the new key to the immobilizer system with the Honda Diagnostic System (HDS). ORDERING INFORMATION *To order the MATRIX H Key Cutting Machine, replacement cutter bits, fixed jaws and mobile jaws, T-5 programmable key blanks, and practice key blanks, contact the Honda Tool and Equipment Program by calling 888-424-6857 or using the fax order form provided in your Honda Tool and Equipment Program Catalog.* Order Honda key blanks through normal parts ordering channels. WARRANTY CLAIM INFORMATION None. This service bulletin is for information only. *DETERMINING WHICH KEY TO USE T-5 keys require less time to program and should be the first choice. They can be used as long as the following requirements are met: ^ Do you have the customer's operating key? ^ Does the vehicle fall within the T-5 Sidewinder Key Applications? ^ Does your dealership have an Ilco Immobilizer Key Code Duplicator? If the answer to all three questions on the above is yes, the 1-5 key option is the easier procedure. If you answered no to any of the questions, you should order the key(s) from the parts catalogue, and program it using the HDS.* BEFORE YOU START CUTTING 1. Get the original key or the key number from your customer or from the iN. 2. Get the applicable key blank. 3. If cutting by code, look up the applicable 9-digit cutting code for the key number. Refer to the code book Honda High Security key Codes that comes with the machine. Application and ID Hazard Warning Flasher: Application and ID PLEASE NOTE: The flasher function for this vehicle is provided by the Turn Signal/Hazard Relay. Page 553 53. Steering Wheel (Airbag Inflators Removed) 57. Under Left Side Of Dash Page 9485 Resistor Variable Sensor Solenoid Transistors Circuit Schematics Page 9408 1. Remove the terminal. 2. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE G: 1. Remove the terminal. 2. Go to HOW TO INSTALL NEW TERMINALS. How to Install New Terminals HOW TO INSTALL NEW TERMINALS 1. Carefully match the old terminal with a new one from the terminal repair kit. Choose the correct replacement terminal based on the wire size range the terminal will accommodate. NOTE: If the replacement terminal quantities are low, reorder them by using the terminal part number listed on the inside lid of the terminal repair kit. Replacement terminals are available through your parts department using normal parts ordering procedures. 2. Depending on the size of the wire you are repairing, use the proper size slot in the crimping tool. Page 9468 Blower Motor Relay Type 1, Type 2 Check for continuity between the terminals. - There should be continuity between the No.1 and No.3 terminals when power and ground are connected to the No.2 and No.4 terminals. - There should be no continuity between the No.1 and No.3 terminals when power is disconnected. Five-terminal type Check for continuity between the terminals. - There should be continuity between the No.1 and No.2 terminals when power and ground are connected to the No.3 and No.5 terminals. - There should be continuity between the No.1 and No.4 terminals when power is disconnected. Page 5776 Power Windows Component Location Index Locations 162. Right Side Of Engine Compartment Locations VTEC - Component Location Index Page 9012 - Before connecting connectors, make sure the terminals (A) are in place and not bent. - Check for loose retainer (A) and rubber seals (B). - The backs of some connectors are packed with dielectric grease. Add grease if necessary. If the grease is contaminated, replace it. - Insert the connector all the way and make sure it is securely locked. - Position wires so that the open end of the cover faces down. Handling Wires and Harnesses - Secure wires and wire harnesses to the frame with their respective wire ties at the designated locations. Page 3560 Crankshaft Position Sensor: Service and Repair CKP Sensor Replacement 1. Remove the grommet (A) from the upper cover, and disconnect the camshaft position (CMP) (top dead center (TDC)) sensor connector (B). 2. Remove the upper cover (C) and lower cover (D). 3. Disconnect the crankshaft position (CKP) sensor connector, then remove the CKP sensor from the oil pump. 4. Install the CKP sensor in reverse order of removal. Page 9817 3. Check for continuity between the terminals in each switch position according to the tables. Driver's Switch: The driver's switch is combined with the control unit so you cannot isolate the switch to test it. Instead, run the master switch input test procedures. If the tests are normal, the driver's switch must be faulty. Replace the switch. 4. If the continuity is not as specified, remove the driver's door panel. 5. Remove the armrest from the door panel. Page 6946 7. Connect the SCS service connector to the 2P MES (memory erase signal) connector, as shown. Do not use a jumper wire. 8. Turn the ignition switch to ON (II). 9. Watch the SRS indicator. (It comes on for about 6 seconds and then goes off.) Disconnect the SCS service connector from the MES connector within 4 seconds after the indicator goes off. 10. When the SRS indicator comes on again, connect the SCS service connector to the MES connector within 4 seconds after the indicator comes on. 11. When the SRS indicator goes off, disconnect the SCS service connector from the MES connector within 4 seconds. Page 4061 1. Install the 80 mm set ring (A) in the transmission housing (B). 2. Install the differential assembly (A) in the torque converter housing (B) using the special tool. 3. Align the spring pin (A) on the control shaft with the transmission housing groove (B) by turning the control shaft (C). NOTE: Be careful not to squeeze the end of the control shaft tips together when turning the shaft. If the tips are squeezed together it will cause a faulty signal or position due to the play between the control shaft and the switch. Page 1743 Wires Page 2695 Camshaft Position Sensor: Service and Repair CMP (TDC) Sensor Replacement 1. Remove the grommet (A) from the upper cover, and disconnect the camshaft position (CMP) (top dead center (TDC)) sensor connector (B). 2. Remove the upper cover (C). 3. Remove the CMP (TDC) sensor from the cylinder head. 4. Install the CMP (TDC) sensor in reverse order of removal. Page 1564 67. Under Left Side Of Dash Page 1562 Power Windows Component Location Index Page 516 Wheel Speed Sensor: Diagrams 95. Wheel Speed Sensor, Left Front (EX, GX) 96. Wheel Speed Sensor, Left Rear (EX, GX) 97. Wheel Speed Sensor, Right Front (EX, GX) Page 1132 7. Align the cutouts (A) on the rotary-frame with the neutral positioning cutouts (B) on the transmission range switch, then put a 2.0 mm (0.08 inch) feeler gauge blade (C) in the cutouts to hold it in the N Position. NOTE: Be sure to use a 2.0 mm (0.08 inch) blade or equivalent to hold the switch in the N position. 8. Install the transmission range switch (A) gently on the control shaft (B) while holding it in the N position with the 2.0 mm (0.08 inch) blade (C). 9. Tighten the bolts on the transmission range switch while you continue to hold the N position. Do not move the transmission range switch when tightening the bolts. Remove the feeler gauge. Page 5708 16. Starter Solenoid Page 6368 Page 5385 1. Remove the terminal. 2. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE G: 1. Remove the terminal. 2. Go to HOW TO INSTALL NEW TERMINALS. How to Install New Terminals HOW TO INSTALL NEW TERMINALS 1. Carefully match the old terminal with a new one from the terminal repair kit. Choose the correct replacement terminal based on the wire size range the terminal will accommodate. NOTE: If the replacement terminal quantities are low, reorder them by using the terminal part number listed on the inside lid of the terminal repair kit. Replacement terminals are available through your parts department using normal parts ordering procedures. 2. Depending on the size of the wire you are repairing, use the proper size slot in the crimping tool. Page 2413 Crankshaft Position Sensor: Description and Operation Crankshaft Position (CKP) Sensor The CKP sensor detects engine speed, and is used by the ECM/PCM to determine ignition timing and timing for fuel injection of each cylinder. Page 5124 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. Test Equipment 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. Component Locations Sunroof / Moonroof Switch: Component Locations Moonroof Component Location Index 57. Under Left Side Of Dash Page 2414 Crankshaft Position Sensor: Service and Repair CKP Sensor Replacement 1. Remove the grommet (A) from the upper cover, and disconnect the camshaft position (CMP) (top dead center (TDC)) sensor connector (B). 2. Remove the upper cover (C) and lower cover (D). 3. Disconnect the crankshaft position (CKP) sensor connector, then remove the CKP sensor from the oil pump. 4. Install the CKP sensor in reverse order of removal. Pressure Plate and Clutch Disc Removal Flywheel: Service and Repair Pressure Plate and Clutch Disc Removal Clutch Replacement Special Tools Required ^ Clutch alignment shaft 07LAF-PT00110 ^ Clutch alignment disc 07JAF-PM7011A ^ Remover handle 07936-3710100 ^ Ring gear holder 07LAB-PV00100 or 07924-PD20003 ^ Attachment, 57 x 40 mm 07746-0010200 ^ Driver 077 49-0010000 Pressure Plate and Clutch Disc Removal 1. Check the diaphragm spring fingers for height using the special tools and a feeler gauge (A). If the height is more than the service limit, replace the pressure plate. Standard (New): 0.6 mm (0.02 inch) max. Service Limit: 1.0 mm (0.04 inch) 2. Install the special tools. 3. To prevent warping, unscrew the pressure plate mounting bolts (A) in a crisscross pattern in several steps, then remove the pressure plate (B). Page 1766 1. Remove the terminal. 2. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE B: 1. Remove the terminal. 2. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE C: 1. Remove the terminal. 2. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE D: Page 9312 2. Remove the terminal (same procedure for male and female). 3. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE E: 1. Remove the secondary locks. 2. Remove the terminal (same procedure for male and female). 3. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE F: Diagram Information and Instructions Vanity Lamp: Diagram Information and Instructions Terminal Numbering System Terminal Numbering System Connector terminals are numbered according to the cavities they're in. The cavities are numbered starting from the upper left, looking at the male terminals from the terminal side or looking at the female terminals from the wire side. Both views are in the same direction so the numbers are the same. All actual cavities are numbered, even if they have no wire terminals in them. NOTE: Data Link Connector (DLC) terminals are numbered according 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 below is #6. Page 5823 Multiple Junction Connector: Service and Repair Pigtail Terminal Selection Chart PIGTAIL TERMINAL SELECTION CHART Select the proper size pigtail terminal by matching the replacement terminal part number and the wire size being repaired to the corresponding pigtail terminal part number. Then use the color (size) splice connector listed. In some instances you may also have to match the wire seal style to select the proper pigtail terminal. Pigtail terminals are available through your parts department, in quantities of 10, using normal parts ordering procedures. Page 8625 Disclaimer Cutting Procedure - By Copying 1. Press the ON/OFF button in the middle of the setting unit keypad. (This powers up the keypad.) 2. Turn the clamp unit lock lever to the left to release the clamp unit, and slide it all the way to the left until it stops. Turn the lever to the right to lock the clamp unit in place. 3. Use the clamp carriage lever to position the clamp unit so the tracer and cutter bit are centered directly over the base of the center and right jaws. 4. Pull the vertical carriage lever toward you until the tracer and the cutter bit just touch the base of each fixed jaw. Watch the arrows on the keypad: ^ If the double-headed arrow in the middle of the keypad lights green, the tracer and cutter bit are properly aligned. ^ If the arrow on the left of the keypad lights red, the cutter bit is not touching the fixed jaw. Turn the micrometric ring nut above the tracer to the left until the double-headed arrow lights green. ^ If the arrow on the right of the keypad lights red, the tracer is not touching the fixed jaw. Turn the micrometric ring nut above the tracer to the right until the double-headed arrow lights green. *5. Turn the micrometric ring nut to the right three clicks so the cutter bit is slightly higher than the tracer. The arrow on the left should light red. Raise the vertical carriage. NOTE: Setting the tracer three clicks lower than the cutter bit has the effect of making the cutter bit cut the duplicated key a little shallower. This will protect the locking jaws from being damaged.* 6. Optional: Loosen the setscrew, and adjust the hand rest to a comfortable position. Tighten the screw. 7. Pull the clamp carriage lever toward you until the clamp carriage clicks into its end-of-run position. Tighten both the lateral and spring tension adjustment knobs. 8. Make sure the center and right jaws are free of any metal shavings or debris. (A soft-bristle toothbrush is ideal for this purpose.) Page 2956 Engine Control Module: Technical Service Bulletins Engine Controls - Replace ECM/PCM For DTC P1607 SOURCE: Honda Service News May 2003 TITLE: Replace ECM/PCM for DTC P1607 APPLIES TO: 2002-03 Civic SERVICE TIP If you've got a DTC P1607 (ECM/PCM internal circuit malfunction) set, you need to replace the ECM/PCM. These units may have defective printed circuit boards. Page 3201 Circuit Schematics Each schematic represents one circuit. A circuit's wires and components are arranged to show current flow from power at the top of the diagram 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 Page 6658 Evaporator Temperature Sensor / Switch: Description and Operation How the Circuit Works The heater control panel controls the blower controls, air delivery, and A/C compressor controls automatically. With the ignition switch in ON (II), battery voltage is supplied through fuse 14. The control unit is grounded at G502. Evaporator Temperature Sensor The evaporator temperature sensor is located on the evaporator housing. If the temperature at the evaporator gets too cold, the evaporator temperature sensor sends a signal to the heater control panel to turn off the A/C compressor clutch. This prevents condensation from freezing on the evaporator fins and blocking air delivery into the passenger compartment. Page 2035 Wire Color Abbreviations 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. Specifications Idle Speed: Specifications Idle Speed With no-load conditions: USA model: M/T .................................................................................................................................. .................................................................................. 700 ± 50 rpm A/T, CVT .................................... ....................................................................................................................................... 700 ± 50 rpm (in Park or neutral) Canada model: M/T .............................................................................................. ...................................................................................................................... 720 ± 50 rpm A/T .......... .............................................................................................................................................................. ............. 720 ± 50 rpm (in Park or neutral) With load conditions: M/T ...................................................................................................................................................... .............................................................. 720 ± 50 rpm A/T, CVT ........................................................ ................................................................................................................... 720 ± 50 rpm (in Park or neutral) Page 8332 Specifications Fuel: Specifications Fuel required ....................................................................................................................... UNLEADED gasoline with 86 pump octane number or higher Page 3148 1. Remove the secondary locks. 2. Remove the terminal from the female half. 3. Remove the terminal from the male half. 4. Go to HOW TO INSTALL NEW TERMINALS. Connectors Without a Secondary Lock All examples are shown with the connector lock facing up. The illustrations are examples of connector terminals without a secondary lock; however, the connector you are repairing may vary in size and shape. EXAMPLE A: Locations Condenser Fan Motor Relay: Locations Under-hood Fuse/Relay Box Page 2358 166. PGM-FI Main Relays 1 And 2 Page 5080 Torque Converter Clutch Solenoid: Service and Repair Torque Converter Clutch Solenoid Valve Replacement 1. Remove the mounting bolt and the torque converter clutch solenoid valve (A). 2. Install a new torque converter clutch solenoid valve with new O-rings (B). While installing the valve, do not allow dust or other foreign particles to enter the transmission. 3. Check the connector for rust, dirt, or oil, then connect the connector securely. Page 7101 7. From the Mode menu, select Miscellaneous Test. 8. From the Miscellaneous Test menu, select OPDS Initialization. 9. Follow the remaining screen prompts to complete the OPDS initialization. If the initialization fails repeat the process two more times. If the initialization fails again, check for SRS DTCs, then troubleshoot them using the appropriate service manual. Initializing the OPDS Unit: Manual Mode NOTE: Non-Honda seat covers will interfere with the performance of the OPDS and are not recommended. 1. Adjust the front passenger's seat-back to an upright position, then remove anything on or near the seat. 2. Turn the ignition switch to LOCK (0). 3. Connect the HDS to the vehicle's DLC (data link connector). 4. Keep the ignition switch at LOCK (0), and turn on the HDS. 5. At the screen prompts, enter the VIN and the odometer reading. 6. From the Select Mode screen, select SCS, and follow the screen prompts. Page 8452 4. Repeat steps 2 and 3 as needed for additional buttons. 5. Install the seat-back cover in the reverse order of removal. Disclaimer Page 1249 ^ 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 266 DTC P1586 thru P1678 Page 5958 Rear Window Defogger Component Location Index Page 8891 Page 9026 1. Remove the terminal. 2. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE E: 1. Remove the terminal. 2. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE F: Page 7750 2. Replace the trunk lid latch: ^ Refer to page 20-157 of the 2001-04 Civic Service Manual. ^ In ISIS, use the keyword LID LATCH, and select Trunk Lid Latch Replacement from the list. 3. Check the trunk operation: ^ If the trunk opens and closes smoothly, return the vehicle to the customer. ^ If the trunk lid is still difficult to close, go to REPAIR PROCEDURE D. REPAIR PROCEDURE D 1. Disconnect the trunk lid opener cable from the trunk lid latch. Check the cable operation: ^ Refer to page 20-157 of the 2001-04 Civic Service Manual. ^ In ISIS, use the keyword LID LATCH, and select Trunk Lid Latch Replacement from the list. 2. Check that there is no friction or binding of the cable by holding the outside casing and pulling back and forth on the inner cable: ^ If the cable is difficult to move or binds, go to step 3. ^ If the cable operates smoothly, go to REPAIR PROCEDURE E. 3. Replace the trunk lid opener cable: ^ Refer to page 20-151 of the 2001-04 Civic Service Manual. ^ In ISIS, use the keyword LID OPEN, and select Trunk Lid Opener/Fuel Fill Door Opener Cable Replacement from the list. 4. Check the trunk operation: ^ If the trunk opens and closes smoothly, return the vehicle to the customer. ^ If the trunk lid is still difficult to close, go to REPAIR PROCEDURE E. REPAIR PROCEDURE E 1. Look at the back of the lock cylinder while you turn the key from lock to unlock. ^ Refer to page 20-158 of the 2001-04 Civic Service Manual. ^ In ISIS, use the keyword LID LOCK, and select Trunk Lid Lock Cylinder Replacement from the list. 2. Check the operation of the trunk lid lock cylinder: ^ If the lock cylinder is difficult to turn or binds, go to step 3. ^ If the lock cylinder operates properly, and the trunk lid is still difficult to close, refer to the appropriate body repair manual, and check for body inaccuracies. 3. Replace the lock cylinder, and re-key the cylinder to the customer's original key; on 2-door Civics, replace the lock cylinder and the lock cylinder rod: ^ Refer to page 20-158 of the 2001-04 Civic Service Manual. ^ In ISIS, use the keyword LID LOCK, and select Trunk Lid Lock Cylinder Replacement from the list. 4. Check the trunk operation, and return the vehicle to the customer. Page 6429 Wheel Bearing: Service and Repair Rear Hub Bearing Unit Replacement 1. Raise the rear of the vehicle, and support it with safety stands in the proper locations. 2. Remove the wheel cap, wheel nuts, and rear wheel. Page 5412 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 6455 Air Door Actuator / Motor: Testing and Inspection Recirculation Control Motor Test Recirculation Control Motor Test 1. Disconnect the 7P connector from the recirculation control motor. NOTE: Incorrectly applying power and ground to the recirculation control motor will damage it. Follow the instructions carefully. 2. Connect battery power to the No.1 terminal of the recirculation control motor, and ground the No.5 and No.7 terminals; the recirculation control motor should run smoothly. To avoid damaging the recirculation control motor, do not reverse power and ground. Disconnect the No.5 or No.7 terminals from ground; the recirculation control motor should stop at Fresh or Recirculate. Don't cycle the recirculation control motor for a long time. 3. If the recirculation control motor does not run in step 2, remove it, then check the recirculation control linkage and doors for smooth movement. - If the linkage and doors move smoothly, replace the recirculation control motor. - If the linkage or doors stick or bind, repair them as needed. Page 5696 9. Place the armature (A) on an armature tester (B). Hold a hacksaw blade (C) on the armature core. If the blade is attracted to the core or vibrates while the core is turned, the armature is shorted. Replace the armature. 10. Check with an ohmmeter that no continuity exists between the commutator (A) and armature coil core (B), and between the commutator and armature shaft (C). If continuity exists, replace the armature. Starter Brush Inspection 11. Measure the brush length. If it is not within the service limit, replace the armature housing assembly (M/T, CVT), or the brush holder assembly (A/T). Starter Field Winding Test (M/T, CVT) Recall 10V364000: Ignition Interlock Defect Shift Interlock Switch: All Technical Service Bulletins Recall 10V364000: Ignition Interlock Defect VEHICLE MAKE/MODEL: MODEL YEAR(S): Honda/Accord 2003 Honda/Civic 2003 Honda/Element 2003-2004 MANUFACTURER: Honda (American Honda Motor Co.) MFR'S REPORT DATE: August 04, 2010 NHTSA CAMPAIGN ID NUMBER: 10V364000 NHTSA ACTION NUMBER: EA09001 COMPONENT: Electrical System: Ignition POTENTIAL NUMBER OF UNITS AFFECTED: 384220 SUMMARY: Honda is recalling certain model year 2003 Honda Accord, Civic two and four door, and model year 2003-2004 Honda Element vehicles. The interlock lever of the ignition switch may unexpectedly deform, which can allow the interlock function of a vehicle with an automatic transmission to be defeated. CONSEQUENCE: Removal of the ignition key when the gear selector of a vehicle with an automatic transmission has not been shifted to the park position can allow the vehicle to roll away, increasing the risk of a crash. REMEDY: Dealers will remove the original interlock pin and lever within the ignition switch, and replace them with newly, designed components. This service will be performed free of charge. The safety recall is expected to begin on or about September 29, 2010. Owners may contact Honda at 1-800-999-1009. NOTES: Honda safety recall No. R44. 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 4708 Valve Body: Service and Repair CVT Lower Valve Body Assembly Removal 1. Raise the front of the vehicle, and make sure it is securely supported. 2. Set the parking brake, and block rear wheels securely. 3. Disconnect the solenoid harness connector (8P). 4. Remove the drain plug (A), and drain the automatic transmission fluid (ATF). Reinstall the drain plug with a new sealing washer (B). 5. Remove the ATF pan (A) (14 bolts). Page 4536 107. Behind A/T Shift Lever (except M/T) Page 2361 PGM-F1 Main Relay 1, 2 Type 1, 2 Check for continuity between the terminals. - There should be continuity between the No.1 and No.2 terminals when power and ground are connected to the No.3 and No.4 terminals. - There should be no continuity between the No.1 and No.2 terminals when power is disconnected. Normally-open type B: Rear Window Defogger Relay Page 7545 Front Door Window Glass Weatherstrip: Service and Repair Door Glass Outer Weatherstrip Replacement Door Glass Outer Weatherstrip Replacement 2-door NOTE: - Put on gloves to protect your hands. - Take care not to scratch the door. 1. Remove the mirror. 2. Starting at the front, pry the door glass outer weatherstrip (A) up to detach the clips (B), and release the weatherstrip from the door sash trim (C), then remove the weatherstrip. 3. Install the weatherstrip in the reverse order of removal, and replace any damaged clips. Page 5504 Electronic Brake Control Module: Description and Operation ABS Control Unit Main Control The ABS control unit detects the wheel speed based on the wheel sensor signal it received, then it calculates the vehicle speed based on the detected wheel speed. The control unit detects the vehicle speed during deceleration based on the rate of deceleration. The ABS control unit calculates the slip rate of each wheel and transmits the control signal to the modulator unit solenoid valve when the slip rate is high. The pressure reduction control has three modes: pressure reducing, pressure retaining, and pressure intensifying. Self-diagnosis Function 1. The ABS control unit is equipped with a main CPU and a sub-CPU. Each CPU checks the other for problems. 2. The CPUs check the circuit of the system. 3. The ABS control unit turns on the ABS indicator when the unit detects a problem and the unit stops the system. 4. The self-diagnosis can be classified into these two categories: ^ Initial diagnosis ^ Regular diagnosis On-board Diagnosis Function The ABS can be diagnosed with the Honda PGM Tester. The ALB Checker cannot be used with this system. For air bleeding and checking wheel sensor signals, use the Honda PGM Tester. See the Honda PGM Tester user's manual for specific operating instructions. Page 4924 5. Attach the slide hammer to the interlock lever pin, and tighten the slide hammer clamping bolt. Then use the slide hammer to remove the pin. Discard the pin, the lever, and the spring. 6. Wipe off any debris from the lever's sliding surface on the ignition switch with a clean cloth or a cotton swab. NOTE: To keep debris out of the ignition switch, do not clean it with compressed air. Page 8134 Programming the Transmitter NOTES: ^ The system accepts up to three transmitters. The transmitter codes are stored in a stacking-type memory. If a fourth transmitter code is programmed, the code for the first transmitter is erased. ^ Entering the programming mode cancels all learned transmitter codes, so none of the previously programmed transmitters will work. You must reprogram all of the transmitters once you are in the programming mode. ^ You must complete steps 1-6 within 4 seconds of the previous step to keep the system from exiting the programming mode. 1. Turn the ignition switch to ON (II). 2. Press the "Lock" or "Unlock" button on one of the transmitters. (An unprogrammed transmitter can be used for this step.) 3. Turn the ignition switch to LOCK (0). 4. Repeat steps 1 2, and 3 two more times using the same transmitter used in step 2. 5. Turn the ignition switch to ON (II). 6. Press the "Lock" or "Unlock" button on the same transmitter. Make sure the power door locks cycle to confirm that the system is in programming mode. 7. Within 10 seconds, press the "Lock" or "Unlock" button on each transmitter. Make sure the power door locks cycle after you press each transmitter button to confirm that the system accepted the transmitter's code. 8. Turn the ignition switch to LOCK (0) to exit the programming mode. Ordering a Transmitter Transmitters can be ordered only by authorized Honda dealers. Order them from American Honda using normal parts ordering procedures. Batteries for the Transmitter The battery number is CR2025. Each transmitter uses one battery. 94-95 Passport (Except 1995-1/2) 1994-95 Passport (except 19951A) with dealer-installed security system NOTES: ^ The system uses a stacking-type memory that accepts up to four transmitters. If you program a fifth transmitter, the memory for the first transmitter is pushed out, and it will no longer work. ^ To clear a lost or stolen transmitter from the system's memory, program a transmitter four times. This will remove the missing transmitter from memory, since only four transmitters can be accepted. Page 4156 ^ The vehicle is shown as eligible on a VIN status inquiry. In addition, check for a punch mark above the seventh character of the engine compartment VIN. A punch mark in that location means the ignition switch key interlock has already been inspected/repaired. 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 a VIN status inquiry before selling it. CUSTOMER NOTIFICATION All owners of affected vehicles will be sent a notification of this campaign. An example of the customer notification is at the end of this service bulletin. CORRECTIVE ACTION Inspect the ignition switch and, if needed, install a Key Interlock Repair Kit. PARTS INFORMATION Key Interlock Repair Kit: P/N 06351-SDA-000 REQUIRED SPECIAL TOOLS Interlock Slide Hammer: T/N 07AAC-S84A100 NOTE: ^ An initial quantity of Permalube grease to lubricate the sliding surface of the interlock lever is included with the slide hammer. To order more Permalube, use P/N 08734-0030. ^ To order a replacement clamping bolt for the slide hammer, use T/N 07AAC-S84A400. WARRANTY CLAIM INFORMATION Failed Part: P/N 35100-SDA-A31 Defect Code: 5GC00 Symptom Code: R4400 Page 5935 Auxiliary Power Outlet: Testing and Inspection Test/Replacement 1. Carefully pry the accessory power socket (A) out from the center lower cover. 2. Disconnect the 2P connector (B) from the socket. 3. Inspect the connector terminals to be sure they are all making good contact. - If the terminals are bent, loose or corroded, repair them as necessary, and recheck the system. - If the terminals look OK, go to step 4. 4. Turn the ignition switch ACC (I), and check for voltage between the No.1 and No.2 terminals. - There should be battery voltage. - If there is no battery voltage, check for: poor ground (G502). - an open in the wire. - blown No.18 (15 A) fuse in the under-dash fuse/relay box. Page 2890 NO - Go to step 77. 77. Turn the ignition switch OFF. 78. Disconnect ECM/PCM connector E (31P). 79. Check for continuity between ECM/PCM connector terminal E29 and body ground. Is there continuity? YES - Repair short in the wire between the DLC and the ECM/PCM (E29). NO - Update the ECM/PCM if it does not have the latest software, or substitute a known-good ECM/PCM, then recheck. If the symptom/indication goes away with a known-good ECM/PCM, replace the original ECM/PCM. 80. Turn the ignition switch OFF. 81. Disconnect ECM/PCM connector E (31P). 82. Turn the ignition switch ON (II). Is the MIL on? YES - Repair short in the wire between the gauge assembly and the ECM/PCM (E31). If the wires are OK, replace the gauge assembly. NO - Update the ECM/PCM if it does not have the latest software, or substitute a known-good ECM/PCM, then recheck. If the symptom/indication goes away with a known-good ECM/PCM, replace the original ECM/PCM. Under-Dash Fuse/Relay Box Under-dash Fuse/Relay Box Page 2185 10. Middle Of Engine Page 1990 7. Lightly tap the end of each valve stem two or three times with a plastic mallet (A) to ensure proper seating of the valve and valve keepers. Tap the valve stem only along its axis so you do not bend the stem. Page 6349 Page 6008 Multiple Junction Connector: Service and Repair Checking For Poor Fir of Terminals CHECKING FOR POOR FIT OF TERMINALS Loose terminal fit can cause a number of intermittent problems in electrical circuits. By using the Terminal Inspection Feeler Tool Set you can inspect the terminal fit between the two matching connectors without removing the terminals from the connector body. 1. Find the terminal tool that best matches the male terminal in the mating connector. 2. Insert the terminal tool into the female terminal, and then remove the terminal tool. NOTE: Make sure you do not select a terminal tool that is larger than the mating male terminal because it would spread the female terminal and cause a loose fit. 3. Compare the drag to the other terminals in the connector. If the drag is less, replace the terminal with a replacement terminal from the appropriate terminal repair kit. Page 2839 8. Inspect the quality of the wire crimp. If it has any of the following NO GOOD crimps, cut it off and start over. 9. Insert the terminal into the connector. Make sure the wire seals are pushed all the way into the connector. Lightly pull on the wires to make sure the terminal is locked into place. 10. Close or insert the secondary terminal lock, if applicable, and reconnect the connector. How to Install Pigtail Terminals HOW TO INSTALL PIGTAIL TERMINALS Pigtail terminals (short pieces of wire with a factory crimped terminal) are used when the wire is too short or when access to the connector is too restricted to make a terminal repair. NOTE: To replace just a connector terminal, go to How to Replace Connector Terminals. IMPORTANT SAFETY INFORMATION: On some models, the SRS wires are in a separate harness. If the SRS harness is damaged, replace the harness; do not repair it. On other models, wire harnesses include yellow SRS wires. If any SRS wire is damaged, replace the entire harness; do not repair it. 1. Remove the damaged or faulty terminal from the connector. Use the proper removal tool from Pin Tool Set. Page 9593 Blower Motor Relay Type 1, Type 2 Check for continuity between the terminals. - There should be continuity between the No.1 and No.3 terminals when power and ground are connected to the No.2 and No.4 terminals. - There should be no continuity between the No.1 and No.3 terminals when power is disconnected. Five-terminal type Check for continuity between the terminals. - There should be continuity between the No.1 and No.2 terminals when power and ground are connected to the No.3 and No.5 terminals. - There should be continuity between the No.1 and No.4 terminals when power is disconnected. Page 7363 2. Remove the three mounting screws, then disconnect the 2P connector (A) from the speaker (B). Rear Speaker: 2-door 1. Remove the rear shelf. 2. Remove the four screws, and disconnect the 2P connector (A) from the speaker (B). Page 1277 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 4191 Shift Interlock Switch: Testing and Inspection Park Pin Switch Test 1. Remove the center console panel and center console. 2. Disconnect the park pin switch connector (4P). 3. Shift to the P position, then check for continuity between the No. 3 and No. 4 terminals. There should be no continuity. 4. Shift out of the P position, and check for continuity between terminals No. 3 and No. 4. There should be continuity. 5. If the park pin switch is faulty, replace it. Page 3042 7. Remove the four screws that hold the two fuses, and remove the fuses. 8. Release the tab that holds the ELD, and pull up on the ELD to remove it. 9. Remove the bus bar from the ELD, and insert the bar into the new ELD. 10. Install the new ELD and bus bar into the fuse/relay box. 11. Reinstall the two fuses. 12. Reinstall the 3P ELD connector and the lower fusel relay box cover. 13. Reinstall the fuse/relay box onto its holder. CR-V only: Reinstall the wire harness clip onto the holder. 14. Reinstall the fuse/relay box cover. 15. Reconnect the negative battery cable. 16. Do the idle learn procedure: ^ Make sure all electrical items (A/C, audio unit, defogger, lights, etc.) are off. Page 9088 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. Circuits must be operating when checking voltage drop. 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. 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 off, 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 Self-Powered Test Light or DVOM 1. Remove the blown fuse and disconnect the battery and load. Component Locations Relay Box: Component Locations Relay Box Locations Starting System Component Location Index Page 8914 52. Measure voltage between body ground and ECM/PCM connector terminal A21. Is there about 5 V? YES - Go to step 59. NO - Go to step 53. 53. Turn the ignition switch OFF. 54. Disconnect the 3P connector from each of these sensors, one at a time, and measure voltage between body ground and ECM/PCM connector terminal A21 with the ignition switch ON (II). Manifold absolute pressure (MAP) sensor - CVT driven pulley speed sensor (CVT) - CVT speed sensor 1 (CVT) Is there about 5 V? YES - Replace the sensor that restored 5 V when disconnected. NO - Go to step 55. 55. Turn the ignition switch OFF. 56. Disconnect the 3P connector from the following sensors. - Manifold absolute pressure (MAP) sensor - CVT driven pulley speed sensor (CVT) - CVT speed sensor 1 57. Disconnect ECM/PCM connector A (31P). Page 1398 Brake Fluid: Service Precautions SAFETY PRECAUTIONS WARNING: Brake fluid may be irritating to the skin or eyes. In case of contact, take the following actions: * Eye Contact - rinse eyes thoroughly with water. * Skin Contact - wash skin with soap and water. Page 7497 Cabin Ventilation Duct: Removal and Replacement Rear Air Outlet Replacement 1. Remove the rear bumper. 2. Detach the hooks (A), then remove the rear air outlet (B) Take care not to scratch the body. 3. Install the air outlet by pushing on the hook portions until the hooks snap into place. Page 323 Fuel Pump Relay: Testing and Inspection Power Relay Test Use this chart to identify the type of relay, then do the test listed for it. NOTE: See the turn signal/hazard relay input test. Normally-open type A: Page 8690 6. Check the operation of the actuator motor in each output linkage position according to the table. You should be able to hear the motor. Locations Page 6498 5. Connect the No.1 and No.2 terminals of the compressor clutch relay 4P socket with a jumper wire. Does the compressor clutch click ? YES - Go to step 6. NO - 01 Model: Go to step 14. 02-04 Model: Go to step 17. 6. Disconnect the jumper wire. 7. Turn the ignition switch ON (II). 8. Measure the voltage between the No.3 terminal of the compressor clutch relay 4P socket and body ground. Is there battery voltage? YES - Go to step 9. NO - Repair open in the wire between the No.14 fuse in the under-dash fuse/relay box and the compressor clutch relay. 9. Turn the ignition switch OFF. 10. Reinstall the compressor clutch relay. 11. Make sure the A/C switch is OFF. 12. Turn the ignition switch ON (II). 13. Using the Backprobe Set, measure the voltage between the No.18 terminal of ECM/PCM connector E (31P) and body ground with the ECM/PCM Page 5016 Transmission Speed Sensor: Service and Repair Countershaft Speed Sensor Replacement Countershaft Speed Sensor Replacement 1. Disconnect the countershaft speed sensor connector. 2. Remove the countershaft speed sensor (A). 3. Install the new countershaft speed sensor with the new O-ring (B). 4. Check the countershaft speed sensor connector for rust, dirt, or oil, then connect the connector securely. Pressure Plate and Clutch Disc Removal Clutch Disc: Service and Repair Pressure Plate and Clutch Disc Removal Clutch Replacement Special Tools Required ^ Clutch alignment shaft 07LAF-PT00110 ^ Clutch alignment disc 07JAF-PM7011A ^ Remover handle 07936-3710100 ^ Ring gear holder 07LAB-PV00100 or 07924-PD20003 ^ Attachment, 57 x 40 mm 07746-0010200 ^ Driver 077 49-0010000 Pressure Plate and Clutch Disc Removal 1. Check the diaphragm spring fingers for height using the special tools and a feeler gauge (A). If the height is more than the service limit, replace the pressure plate. Standard (New): 0.6 mm (0.02 inch) max. Service Limit: 1.0 mm (0.04 inch) 2. Install the special tools. 3. To prevent warping, unscrew the pressure plate mounting bolts (A) in a crisscross pattern in several steps, then remove the pressure plate (B). Page 8793 Air Bag(s) Arming and Disarming: Description and Operation SRS Components SRS Components Airbags The SRS is a safety device which, when used 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 (A), the cable reel (B), the driver's airbag (C), the front passenger's airbag (D), seat belt tensioners (I), seat belt buckle tensioners (J), and front impact sensors (K). Since the driver's and front passenger's airbags use the same sensors, both normally inflate at the same time. However, it is possible for only one airbag to inflate. This can occur when the severity of a collision is at the margin, or threshold, that determines whether or not the airbags will deploy. In such cases, the seat belt will provide sufficient protection, and the supplemental protection offered by the airbag would be minimal. Side Airbags The side airbags (E) are in each front seat-back. They help protect the upper torso of the driver or front seat passenger during a moderate to severe side impact. Side impact sensors (F) in each door sill and in the SRS unit detect such an impact and instantly inflate the driver's or the passenger's side airbag. Only one side airbag will deploy during a side impact. If the impact is on the passenger's side, the passenger's side airbag will deploy even if there is no passenger. 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. OPDS The side airbag system also includes an occupant position detection system (OPDS). This system consists of sensors (G) and a OPDS unit (H) in the front passenger's seat-back. The OPDS unit sends occupant height and position data to the SRS unit. If the OPDS unit determines that the front passenger is of small stature (for example, a child) and the front passenger is leaning into the side airbag deployment path, the SRS unit will automatically disable the passenger's side airbag. The SRS unit will also disable the airbag when the OPDS detects certain objects on the seat. When the side airbag is disabled, the side airbag cutoff indicator on the instrument panel alerts the driver that the passenger's side airbag will not deploy in a side impact. When the object is removed, or the passenger sits upright, the Side Airbag Cutoff indicator will go off after a few seconds, alerting the driver that the passenger's side airbag will deploy in a side impact. Page 4927 13. Remove the solenoid cover, and make sure the solenoid plunger groove is installed in the fork on the lever. ^ If needed, correct the position of the solenoid plunger, then go to step 14. ^ If the solenoid plunger is correctly installed, there is an electrical problem with the key interlock system; refer to the Automatic Transmission section of the appropriate service manual for troubleshooting information. Once the key interlock is working normally, go to step 14. 14. Install the solenoid cover. 15. Reinstall the steering column covers. 16. Center-punch a completion mark above the seventh character of the engine compartment VIN. Disclaimer Page 5660 ^ Refer to page 11-199 of the 2001-2005 Civic Service Manual, or ^ Online, enter keyword RESONATOR, and select Resonator Removal/Replacement from the list. 4. Disconnect the female terminal (BLK/WHT wire) from the S terminal of the starter solenoid. NOTE: A/T is shown. M/T is similar 5. Pull the boot back from the female S terminal, and check the terminal for signs of arcing. 6. Check the male S terminal at the starter for signs of arcing. 7. If either terminal has signs of arcing, go to REPAIR PROCEDURE. If neither terminal has signs of arcing, continue your diagnosis using the appropriate service manual. REPAIR PROCEDURE Page 2451 Fuel Tank Pressure Sensor: Description and Operation The FTP sensor converts fuel tank absolute pressure into an electrical input to the ECM/PCM. Page 4176 1. Remove and discard the plastic cover from the ignition switch key interlock solenoid. 2. Note the position of the interlock solenoid plunger; you'll need to install it the same way. 3. Remove the screw from the solenoid, but keep the solenoid attached to its electrical connector. Discard the screw. NOTE: ^ Be careful not to lose the solenoid plunger; it slides out easily. ^ Keep the plunger free of dirt and grease while it's removed from the solenoid. 4. Note the position of the interlock lever spring; you'll need to install the new spring the same way. Page 6906 NOTE: For color information, refer to PIB A05-0005, Child Seat Anchor Buttons. Click PARTS, then click PARTS LIBRARY, then click Parts Bulletins. Select Child Seat Anchor Buttons from the list. (Each part contains fabric washers, button posts, and back portions.) WARRANTY CLAIM INFORMATION In warranty: The normal warranty applies. Failed Part: 82123-SDA-305ZA Defect Code: 07801 Symptom Code: 03220 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. Remove the rear seat-back cover just enough to allow access to the opening where the button will be attached: ^ Refer to Section 20, Rear Seat-back Cover Replacement, in the appropriate service manual, or ^ Online, enter keyword SEAT COVER, and select the appropriate Rear Seat-back Cover Replacement procedure from the list. 2. Select the appropriate button from the Child Seat Anchor Service Set. 3. Attach the button to the rear seat-back cover: ^ Place a fabric washer over the button post. ^ Insert the post through the opening in the cover. ^ Snap the back portion onto the post. Page 5413 3. Attach the driveshaft on the drive motor assembly to the mounting yoke, making sure the center line of the driveshaft is level with the spindle nut on the wheel hub. 4. Set the lower toggle switch on the drive motor assembly to FWD (counterclockwise rotation) or REV (clockwise rotation). Setting Up and Adjusting the Brake Lathe Use Kwik-Way cutting bits, P/N KWY-109109223, and the holding screws that come with them. These bits are stamped KW and are available through the Honda Tool and Equipment Program (see ORDERING INFORMATION). Before you use the brake lathe, inspect the tips of the cutting bits with a magnifying glass to make sure the tips are not worn out. Each bit has three tips. If a tip is worn, rotate the bit, and use a new tip. A worn tip produces a poor finish and may cause chattering. Page 8747 Wire Color Abbreviations Page 5892 Under-hood Fuse/Relay Box Page 4045 Torque Converter Clutch Solenoid: Service and Repair Torque Converter Clutch Solenoid Valve Replacement 1. Remove the mounting bolt and the torque converter clutch solenoid valve (A). 2. Install a new torque converter clutch solenoid valve with new O-rings (B). While installing the valve, do not allow dust or other foreign particles to enter the transmission. 3. Check the connector for rust, dirt, or oil, then connect the connector securely. Page 6036 234. Under-dash Fuse/Relay Box Part 5 Locations Power Steering Pressure Switch: Locations Idle Control System - Component Location Index 34. Left Side Of Engine Compartment Page 4779 Shift Indicator: Diagnostic Aids General Troubleshooting Information General Troubleshooting Information Tips and Precautions Before Troubleshooting 1. Check applicable fuses in the appropriate fuse/relay box. 2. Check the battery for damage, state of charge, and clean and tight connections. NOTE: 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. Handling Connectors - Make sure the connectors are clean and have no loose wire terminals. - Make sure multiple cavity connectors are packed with dielectric grease (except watertight connectors). - All connectors have push-down release type locks (A). - Some connectors have a clip on their side used to attach them to a mount bracket on the body or on another component. This clip has a pull type lock. - Some mounted connectors cannot be disconnected unless you first release the lock and remove the connector from its mount bracket (A). - Never try to disconnect connectors by pulling on their wires; pull on the connector halves instead. - Always reinstall plastic covers. Page 9421 Map Light: Testing and Inspection Spotlights Test/Replacement - Without Moonroof Spotlights Test/Replacement - Without Moonroof 1. Turn the light switch OFF. 2. Carefully pry off the lenses (A) with a small screwdriver. 3. Remove the two mounting screws. 4. Disconnect the 2P connector (B) from the housing (c). 5. Check the bulbs. If the bulbs are OK,check for continuity between the terminals in each switch position according to the table. 6. If the continuity is not as specified, replace the spotlights. Page 8749 Connectors - "C" Service and Repair Valve Seat: Service and Repair Reconditioning If the valve guides are worn, replace them before cutting the valve seats. 1. Renew the valve seats in the cylinder head using a valve seat cover. -1 Carefully cut a 45°seat, removing only enough material to ensure a smooth and concentric seat. -2 Bevel the upper edge of the seat with the 30° cutter and the lower edge of the seat with the 67.5° cutter (Intake) or 60° cutter (exhaust). Check the width of the seat and adjust accordingly. -3 Make one more very light pass with the 45° cutter to remove any possible burrs caused by the other cutters. Valve Seat Width Intake: Standard (New): 0.85 - 1.15 mm (0.033 - 0.045 inch) Service Limit: 1.60 mm (0.063 inch) Exhaust: Standard (New1: 1.25 - 1.55 mm (0.049 - 0.061 inch) Service Limit:2.00 mm (0.079 inch) 2. After resurfacing the seat, inspect it for even valve seating: Apply Prussian Blue compound (A) to the valve face. Insert the valve in its original location in the head, then lift it and snap it closed against the seat several times. 3. The actual valve seating surface (B), as shown by the blue compound, should be centered on the seat. ^ If it is too high (closer to the valve stem), you must make a second cut with the 67.5° cutter (Intake) or 60° cutter (exhaust) to move it down, then one more cut with the 45° cutter to restore seat width. ^ If it is too low (closer to the valve edge), you must make a second cut with the 30° cutter to move it up, then one more cut with the 45° cutter to restore seat width. NOTE: The final cut should always be made with the 45° cutter. Page 1570 Under-hood Fuse/Relay Box (2-door) Brakes - Brake Disc Refinishing Information Brake Rotor/Disc: Technical Service Bulletins Brakes - Brake Disc Refinishing Information 00-088 July 14, 2010 Applies To: ALL Models Brake Disc Refinishing Guidelines (Supersedes 00-088, dated October 6, 2006, to revise the information marked with the black bars) *REVISION SUMMARY The requirement to refinish new brake discs was removed.* American Honda does not allow replacement of brake discs under warranty unless the brake disc is beyond its service limit for refinishing. If the brake disc is within its service limit, you must refinish it. Maximum refinishing limits may be found in the Conventional Brakes section of the appropriate service manual. *Refinish brake discs only when they are scored or out of specification for runout or parallelism. See the appropriate service manual for the specifications.* American Honda requires refinishing of the front brake discs with an on-car brake lathe that mounts to the steering knuckle. Use of an on-car, steering knuckle- mounted lathe is critical because it corrects runout of the hub and disc as an assembly. Experience has shown that very small amounts of runout, not felt as brake pulsation initially, will grow and become noticeable as the discs are subjected to heat and wear over time and mileage. Two on-car brake lathes are recommended. The Kwik-Lathe, model number KWY-108000501, is supported with automatic shipments of adapters for new models, when required. The Accu-turn On-car Brake Lathe, model ACCHONOCLPKG, is also recommended. A power driver is required for the 82000 and is highly recommended for all other models. The Kwik-Lathe power driver model number is KWY-108012005; the Accu-turn lathe includes a power driver. Here are some advantages of using power drivers: ^ The disc is rotated at the optimum speed for a smooth and consistent cut. ^ There is no need to climb in and out of the vehicle to start and stop the engine or to shift the transmission. ^ Securing the opposite wheel with a tie-down strap is not required. ^ There is no waiting for the engine to return to idle and no concern about engine speed changes that can adversely affect brake disc cut and finish. ^ The Traction Control System (TCS) is not involved. ^ Consistent cutting speed increases cutting tool life. ORDERING INFORMATION Order brake lathes and power drivers through the Honda Tool and Equipment Program. To place an order, call or use the fax order form provided in your Honda Tool and Equipment Program Catalog. Phone lines are open Monday thru Friday from 7:30 a.m. to 7:00 p.m. Central Time. You can also order online through the Interactive Network (iN). Click on Service, Tool and Equipment, and then Online Catalog. Click on Alignment, Wheel, and Brake Equipment, and then On-Car Brake Lathes. WARRANTY CLAIM INFORMATION None, this bulletin is for information only. FRONT BRAKE DISCS The following guidelines show the Kwik-Way lathe setup, the Accu-turn lathe setup is similar. Setting Up the Vehicle Put the transmission in Neutral. If you are not using the power drive system, start the engine, and let it warm up to its normal operating temperature so the idle speed will stabilize to its lowest rpm. Page 5343 Wheel Speed Sensor: Testing and Inspection Inspection 1. Inspect the front and rear pursers for chipped or damaged teeth. 2. Measure the air gap between the wheel sensor and the purser all the way around while rotating the purser. Remove the rear brake disc to measure the gap on the rear wheel sensor. If the gap exceeds 1.0 mm (0.04 inch), check for a bent suspension arm. Standard: Front: 0.4 - 1.0 mm (0.02 - 0.04 inch) Rear: 0.2 - 1.0 mm (0.01 - 0.04 inch) Page 4204 Connectors - "C" Page 5900 Wire Color Abbreviations Page 8258 21. Leave the key in the cylinder. Reinstall the plastic retainer and spring if you removed them in step 16. Hold the plastic retainer and spring on the housing, and insert the inner cylinder. Rotate it left and right to engage the spring to the inner cylinder. Make sure the spring is properly seated to the inner cylinder. 22. Install the arm with a new cylinder rod clip and a new E-clip. 23. Make sure the key can be inserted and removed easily, and that the cylinder turns with the key. Page 8536 Sunroof / Moonroof Switch: Testing and Inspection Switch Test/Replacement 1. Remove the driver's pocket. 2. Disconnect the 6P connector (A) from the moonroof switch (B), and remove the moonroof switch. 3. Check for continuity between the terminals in each switch position according to the table. 4. If the continuity is not as specified, replace the illumination bulb (C) or the moonroof switch. Page 9744 6. Separate the master switch plate (A) from the armrest (B). 7. Remove the three screws and replace the switch. 2-door Page 1364 -Works on most Honda applications Contact AST for pricing Assenmacher Specialty Tools 1 800 525 2943 Locations VTEC - Component Location Index Main Switch Cruise Control Switch: Testing and Inspection Main Switch Main Switch Test/Replacement 1. Carefully pry the switch panel assembly out of the instrument panel. 2. Disconnect the 5P connector (A) from the main switch (B), then remove the switch. 3. Check for continuity between the terminals in each switch position according to the table. If the continuity is not as specified, replace the illumination bulbs (C) or the switch. Page 2666 10. Rotate the crankshaft 180° counterclockwise (camshaft pulley turns 90°). The "UP" mark (A) on the camshaft pulley should be toward the exhaust side of the head. 11. Check and, if necessary, adjust the valve clearance on No. 3 cylinder. 12. Rotate the crankshaft 180° counterclockwise to bring No. 4 piston to TDC. TDC marks (A) are visible again. 13. Check and, if necessary, adjust the valve clearance on No. 4 cylinder. 14. Rotate the crankshaft 180° counterclockwise to bring No. 2 piston to TDC. The "UP" mark (A) should be on the intake side of the head. 15. Check and, if necessary, adjust the valve clearance on No. 2 cylinder. 16. Install the cylinder head cover. Primary HO2S and A/F Sensor Replacement Oxygen Sensor: Service and Repair Primary HO2S and A/F Sensor Replacement Primary HO2S and A/F Sensor Replacement Special Tools Required O2 sensor wrench, Snap-on YA8875, SP Tools 93750, or equivalent, commercially available 1. Disconnect the primary HO2S or A/F sensor 4P connector (A), then remove the primary HO2S or A/F sensor (B). 2. Install the primary HO2S or A/F sensor in the reverse order of removal. Diagram Information and Instructions Transmission Position Switch/Sensor: Diagram Information and Instructions Terminal Numbering System Terminal Numbering System Connector terminals are numbered according to the cavities they're in. The cavities are numbered starting from the upper left, looking at the male terminals from the terminal side or looking at the female terminals from the wire side. Both views are in the same direction so the numbers are the same. All actual cavities are numbered, even if they have no wire terminals in them. NOTE: Data Link Connector (DLC) terminals are numbered according 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 below is #6. Locations Knock Sensor: Locations PGM-FI System - Component Location Index Page 873 Camshaft Position Sensor: Description and Operation Camshaft Position (CMP) Sensor (Top Dead Center (TDC) Sensor) The CMP (TDC) sensor detects the position of the No.1 cylinder as a reference for sequential fuel injection to each cylinder. Page 2300 NOTE: Use new gaskets and self-locking nuts when reassembling. Air Bag Disarming and Arming Air Bag(s) Arming and Disarming: Service and Repair Air Bag Disarming and Arming 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 6724 7. Use shop air to clean any debris that may be on the inflator, then remove the inflator from the airbag. NOTE: ^ Do not allow any debris to enter the inflator opening in the airbag. ^ Do not deploy the inflator. The inflator must be returned to its supplier in the box the new inflator came in (see INFLATOR PACKING AND GROUND SHIPPING INSTRUCTIONS: DEALERS IN THE 48 CONTIGUOUS STATES or INFLATOR PACKING AND AIR SHIPPING INSTRUCTIONS: DEALERS IN ALASKA AND HAWAII). 8. Turn over the airbag (inflator side down), and shake it to remove any debris from the inflator opening. 9. Install the new inflator in the airbag with new locknuts. Torque the locknuts to 3.9 N.m (2.8 lb-ft, 34 lb-in). NOTE: The 55A inflator is slightly taller than the S84 inflator, but they are still interchangeable. 10. Cover the lower two inflator locknuts with new felt tape. 11. Reinstall the horn plate with new felt washers on its mounting bolts. Torque the mounting bolts to 3.4 N.m (2.5 lb-ft, 30 lb-in), then make sure the horn plate moves freely. 12. Reinstall the driver's airbag using new Torx bolts: ^ Refer to page 23-279 of the service manual, or ^ Online, enter keywords DRIVER AIR, and select Driver's Airbag Replacement from the list. 13. Center-punch a completion mark below the third character of the engine compartment VIN: 14. Give your warranty clerk the 13-digit inflator serial number you wrote down in step 1. For the warranty claim to be paid, your w3arranty clerk must enter the appropriate 13-digit serial number in the Diagnostic Trouble Codes field on the warranty claim. *REPAIR PROCEDURE - CIVIC, CR-V, ODYSSEY, AND PILOT* NOTE: Be careful not to damage any parts when replacing the inflator, and follow the procedure exactly. 1. Write down the 13-digit serial number located on the right side of the new inflator's box. For the warranty claim to be paid, your warranty clerk must enter this 13-digit serial number in the Diagnostic Trouble Codes field on the warranty claim. Page 3351 Refueling Control Valve: Service and Repair Fuel Tank Vapor Control Valve Replacement 1. Remove the fuel tank. 2. Remove the fuel tank vapor control valve (A) from the fuel tank (B). 3. Install the fuel tank vapor control valve. 4. Install the fuel tank. Interior - Driver's Seat Rocks Back & Forth Seat Bottom Frame: Customer Interest Interior - Driver's Seat Rocks Back & Forth 01-057 February 22, 2005 Applies To: 2001-02 Civic EX - ALL 2003-04 Civic EX and LX - ALL Updated information is shown by a black bar. Driver's Seat Rocks (Supersedes 01-057, dated November 9, 2004) SYMPTOM The driver's seat rocks back and forth during normal driving. PROBABLE CAUSE Worn bushings in the height adjustment mechanism. CORRECTIVE ACTION Install new seat bushings, nuts, and spacers. PARTS INFORMATION Seat Link Bushing (six required): P/N 90502-S3N-013, H/C 6690440 8/18 mm Nut Washer (six required): P/N 90321-SCV-A11, H/C 7952138 Spacer (four required): P/N 90503-53N-003, H/C 6852578 WARRANTY CLAIM INFORMATION In warranty: The normal warranty applies. Failed Part: P/N 81536-55P-A71 H/C 6526230 Defect Code: 00503 Symptom Code: 07302 Template ID: 01-057A Skill Level: Repair Technician Page 495 34. Left Side Of Engine Compartment Page 7061 Impact Sensor: Diagrams 54. Impact Sensor, Left Front 55. Impact Sensor, Right Front 77. Side Impact Sensor, Driver's Page 7459 1. Remove the terminal. 2. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE B: 1. Remove the terminal. 2. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE C: 1. Remove the terminal. 2. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE D: Page 7463 8. Inspect the quality of the wire crimp. If it has any of the following NO GOOD crimps, cut it off and start over. 9. Insert the terminal into the connector. Make sure the wire seals are pushed all the way into the connector. Lightly pull on the wires to make sure the terminal is locked into place. 10. Close or insert the secondary terminal lock, if applicable, and reconnect the connector. How to Install Pigtail Terminals HOW TO INSTALL PIGTAIL TERMINALS Pigtail terminals (short pieces of wire with a factory crimped terminal) are used when the wire is too short or when access to the connector is too restricted to make a terminal repair. NOTE: To replace just a connector terminal, go to How to Replace Connector Terminals. IMPORTANT SAFETY INFORMATION: On some models, the SRS wires are in a separate harness. If the SRS harness is damaged, replace the harness; do not repair it. On other models, wire harnesses include yellow SRS wires. If any SRS wire is damaged, replace the entire harness; do not repair it. 1. Remove the damaged or faulty terminal from the connector. Use the proper removal tool from Pin Tool Set. Odometer - Does It Rack Up Miles When Towed Odometer: All Technical Service Bulletins Odometer - Does It Rack Up Miles When Towed SOURCE: Honda Service News April 2003 TITLE: Does a Towed Vehicle's Odometer Rack Up Miles? APPLIES TO: All Models SERVICE TIP: If the vehicle has an electronic speedometer (one that isn't cable-driven), the answer is NO. The odometer doesn't rack up mileage as long as the ignition switch is in the LOCK (0) or the ACC (1) position. Page 7240 This system uses ROM chips that match the transmitter to the security system control unit. When replacing a lost or stolen transmitter, you need to use the three ROM chips (provided with the new transmitter) to match the old transmitter with the new transmitter and the control unit. 1. Remove the rear cover from the old transmitter and the new one. 2. Remove the ROM chip from the old transmitter by sliding its socket holder toward the ROM chip. 3. Insert a new ROM chip into the socket holder, then slide the socket holder toward the socket to lock the chip in place. 4. Repeat step 3 to install a ROM chip into the new transmitter. 5. Reinstall the rear covers on the transmitters. 6. Remove the security system control unit from under the driver's seat. 7. Open the access cover on the control unit, and replace the ROM chip. (Use the same procedure as in steps 2 and 3.) 8. Press the reset button next to the ROM chip. 9. Close the access cover, and reinstall the control unit. If you are replacing a damaged transmitter, don't replace the ROM chips in the transmitters and the control unit; just remove the chip from the old transmitter and install it in the new one. Ordering a Transmitter Transmitters can be ordered only by authorized Honda dealers. Order them from American Honda using normal parts ordering procedures. If your customer wants to add a third transmitter to the system, you need to order a four ROM chip set directly from Alpine Electronics of America. The Alpine part number for the four ROM chip set is 5319. This ROM chip set does not come with a transmitter. Order the additional transmitter from American Honda. If you have questions about how to order a four ROM chip set, call Alpine's parts department at (800) 421-2284, extension 8885. Batteries for the Transmitter Specifications Clutch Fluid: Specifications Clutch Fluid ..................................................................................................................................... Genuine Honda DOT 3 Brake Fluid (P/N 08798-9008) Page 8175 Door Lock Cylinder Switch: Testing and Inspection Door Lock Actuator Test Driver's door: 1. Remove the driver's door panel. 2. Disconnect the 2P connector from the actuator. 3. Check actuator operation by connecting power and ground according to the table. To prevent damage to the actuator, apply battery voltage only momentarily. 4. If the actuator does not operate as specified, replace it. Passenger's door: 1. Remove the passenger's door panel. Locations Shift Interlock Solenoid: Locations 107. Behind A/T Shift Lever (except M/T) Page 4926 ^ The left end goes behind the notch on the interlock lever. ^ Once the spring is correctly installed, make sure the lever moves freely and returns properly. 10. Insert the plunger into the interlock solenoid, then install the solenoid using a new screw. Make sure the groove of the solenoid plunger is in the fork on the lever. 11. Install a new plastic cover on the interlock solenoid. 12. Check the operation of the ignition switch key interlock: ^ Set the parking brake, and turn the ignition switch to ON (I I). ^ While pressing the brake pedal, shift the transmission to Neutral. ^ Try turning the ignition switch to LOCK (0) - If you cannot turn the switch to LOCK (0), your repair was successful; go to step 15. - If you can turn the switch to LOCK (0), the interlock is not working; go to step 13. Page 461 Power Door Lock Switch: Diagrams 109. Door Lock Knob Switch, Driver's (except DX) 110. Door Lock Switch, Driver's Page 2342 ECM/PCM Inputs And Outputs At Connector E (31P) Front Door Side Sill Seal Replacement Front Door Weatherstrip: Service and Repair Front Door Side Sill Seal Replacement Front Door Side Sill Seal Replacement NOTE: - Take care not to scratch the door. - Use a clip remover to remove the clips. 1. Detach the clips, then remove the door side sill seal (A). 2. Install the seal in the reverse order of removal, and replace any damaged clips. Page 2750 DTC P0563 thru P0748 Page 5571 Relay And Control Unit Locations - Dashboard Page 9086 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 Locater) 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. Troubleshooting Precautions Troubleshooting Precautions Before Troubleshooting 1. Check the main fuse and the fuse 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, or you will damage the alternator diodes. - Do not attempt to crank the engine with the ground cable disconnected 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. Page 5921 2. Remove the terminal from the female half. 3. Remove the terminal from the male half. 4. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE D: 1. Remove the secondary locks. Page 388 Diagram Information and Instructions Information Bus: Diagram Information and Instructions Terminal Numbering System Terminal Numbering System Connector terminals are numbered according to the cavities they're in. The cavities are numbered starting from the upper left, looking at the male terminals from the terminal side or looking at the female terminals from the wire side. Both views are in the same direction so the numbers are the same. All actual cavities are numbered, even if they have no wire terminals in them. NOTE: Data Link Connector (DLC) terminals are numbered according 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 below is #6. Page 6383 to load it with the vehicle's weight before fully tightening bolts and nuts to the specified torque values. ^ Tighten all the mounting hardware to the specified torque values. ^ Before installing the wheel, clean the mating surface of the brake drum and the inside of the wheel. ^ Check the wheel alignment, and adjust it if necessary. Diagrams 39. ECT Sensor Page 6214 Air Bag(s) Arming and Disarming: Vehicle Damage Warnings 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. - To prevent damage to the airbag assembly, keep free from any oil, grease, detergent, or water. - Store the removed airbag on a secure, fiat surface away from any high heat source (exceeding 200 °F / 93 °C). Page 2563 128. VSS (except CVT) Page 734 Fuel Tank Pressure Sensor: Locations EVAP System - Component Location Index Page 510 13. Parking Brake Switch Page 1354 Drive Belt: Testing and Inspection Alternator Belt Alternator Belt Inspection and Adjustment Special Tools Required Belt tension gauge 07JGG-001010A Belt Tension Gauge Method Inspection 1. Attach the belt tension gauge to the belt and measure the tension. Follow the gauge manufacturer's instructions. If the belt is worn or damaged, replace it. If the belt needs adjustment, go to step 2. Adjustment 2. Loosen the mounting bolt (A), lock bolt (B) and lower bracket mounting bolt (C). 3. Torque the mounting bolt to 20 N.m (2.0 kgf.m, 14 lbf.ft). 4. Turn the adjusting bolt (D) to obtain the proper belt tension, then retighten the lock bolt, mounting bolt and lower bracket mounting bolt. 5. Recheck the belt tension. 6. If you installed a new belt, run the engine for 5 minutes, then readjust the belt to the used belt specification. 7. Check the power steering pump belt adjustment. Deflection Method Inspection Page 1792 3. Measure the piston pin-to-piston clearance. Piston Pin-to-Piston Clearance Standard (New): 0.010 - 0.020 mm (0.0004 - 0.0008 inch) 4. Check the difference between the piston pin diameter and connecting rod small end diameter. Piston Pin-to-Connecting Rod Interference Standard (New): 0.016 - 0.036 mm (0.0006 - 0.0014 inch) Reassembly 1. Assemble the piston and connecting rod with the connecting rod oil hole (A) facing the "IN" mark (B). Page 6855 ^ If the OPDS unit has an original part number, go to step 6. ^ If the OPDS unit has a new part number (refer to PARTS INFORMATION) or higher, go to REPAIR PROCEDURE B: OPDS SENSOR REPLACEMENT. 6. Recline the seat-back to access the OPDS unit mounting screws. 7. Remove the mounting screws from the OPDS unit, and gently pull out the unit. 8. Disconnect the OPDS connectors, then remove the OPDS unit. 9. Install a new OPDS unit, then snap on its cover. 10. Slip the seat-back cover over the OPDS unit. 11. On Accords, check the seat-back clip attachment bosses on the seat-back panel: ^ If the attachment bosses are OK, go to step 12. ^ If the seat-back has a pocket, and the attachment bosses are deformed or damaged, do the repair procedure in S/B 02-010, Seat-Back Panel Is Loose or Detached. Then go to step 12. ^ If the seat-back does not have a pocket, and the attachment bosses are deformed or damaged, replace the seat-back. Then go to step 12. Page 9357 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 Short Circuit Locator (Short Finder) 1. Remove the blown fuse. Leave the battery connected. Page 1184 Power Window Switch: Testing and Inspection Master Switch Input Test Master Switch Input Test 4-door NOTE: The power window control unit is built into the power window master switch, and it only controls the driver's window operations. 1. Remove the door grip cover. 2. Disconnect the 20P connector (A) from the master switch (B). 3. Inspect the connector and socket terminals to be sure they are all making good contact. - If the terminals are bent, loose or corroded, repair them as necessary, and recheck the system. - If the terminals look OK, make the following input tests at the connector. If a test indicates a problem, find and correct the cause, then recheck the system. - If all the input tests prove OK, the power window master switch must be faulty; replace it. Component Locations Relay Box: Component Locations Relay Box Locations Starting System Component Location Index Page 7655 13. After completing the right edge, push all of the cam blades to the right until they touch the cams, then trace the cam blades from back to front. (The cutter bit cuts the same contours into the left edge of the key from tip to head.) Turn off the cutter motor. 14. Release the vertical carriage lever. Push all the cam blades to the left until they touch the cams. Pull the vertical carriage lever towards you until the tracer touches the flat surface on the right side, at the front of the cams. Gently twist the lever clockwise to lock the vertical carriage at this height. Do not overtighten the lever. 15. Turn on the cutter motor, then retrace the cam blades from front to back. Push all the cam blades to the right until they touch the cams, and then retrace the cam blades from back to front (retracing cleans up the cuts on the key). Turn off the cutter motor. 16. Release the vertical carriage lever. Open the jaw and remove the key. Make sure the jaw is free of any metal shavings or debris. Turn the key over so the blank side is up, then slide it into the jaw up to the key stop. Close the jaw to lock the key in place. 17. Push all the cam blades to the left until they touch the cams. Repeat steps 10 through 15 to cut both edges on the other side of the key. 18. When you are done making the required cuts, release the vertical carriage lever. Open the jaw and remove the key. 19. Make sure the key works in the ignition switch and the locks. If the key does not work, recut the key, and try it again. 20. Depending on the type of key, code the key transponder. Equipment Service and Warranty To service the MATRIX H Key Cutting Machine, refer to section 7 of the MATRIX H Operating Manual. It tells you how to replace parts that commonly wear out such as the drive belt, the work light bulb, and the tension spring on the vertical carriage. It also covers checking and replacing fuses and replacing the printed circuit board for the setting unit keypad. If you have technical questions on the equipment, contact the Ilco Technical Assistance Department. Mail: Kaba Ilco Technical Assistance Department 400 Jeffreys Road Rocky Mount, NC 27804 Phone: 800-452-6872 Ext: 200, 384, 323, 398, 356 Fax: 252-446-4702 The MATRIX H Key Cutting Machine comes with a 3-year limited warranty. This warranty does not cover the cutter bit or the work light bulb. CODE BOOK CORRECTIONS In the code book Honda High Security key Codes, correct these errors: Pages 4 thru 51, code headings: ^ Incorrect: J H G F Z X E D C B M/S X ^ Correct: J H G F A X E D C B M/S X Page 2, last paragraph: Locations Main Relay (Computer/Fuel System): Locations Relay And Control Unit Locations - Dashboard Page 6841 12. Watch the SRS indicator: ^ If the indicator blinks twice and then goes off, the OPDS unit is initialized. Turn the ignition switch to LOCK (0), and disconnect the HDS. ^ If the indicator blinks twice and then stays on, the OPDS unit is initialized, but SRS DTCs need to be cleared. Go to step 13. ^ If the indicator stays on without first blinking, the OPDS unit is not initialized. Repeat steps 3 thru 12. 13. Turn the ignition switch to LOCK (0), then disconnect the HDS. 14. Reconnect the SCS service connector to the MES connector. Do not use a jumper wire. 15. Turn the ignition switch to ON (II). 16. Watch the SRS indicator. (It comes on for about 6 seconds and then goes off.) Disconnect the SCS service connector from the MES connector within 4 seconds after the indicator goes off. 17. When the SRS indicator comes on again, connect the SCS service connector to the MES connector within 4 seconds after the indicator comes on. 18. When the SRS indicator goes off, disconnect the SCS service connector from the MES connector within 4 seconds. (The SRS indicator blinks twice to indicate that the memory has been cleared.) 19. Turn the ignition switch to LOCK (0), and wait for 10 seconds. 20. Turn the ignition switch to ON (II). (The SRS is OK if the SRS indicator comes on for 6 seconds and then goes off.) If the DTC clearing fails, repeat the process two more times. If the DTC clearing fails again, check for set SRS DTCs, and troubleshoot them with the appropriate service manual. REPAIR PROCEDURE B: OPDS SENSOR REPLACEMENT 1. Remove the seat-back cover from the front passenger's seat: ^ Using the appropriate service manual, go to section 20 (Body), and do the removal steps under Front Seat Cover Replacement, or ^ Online, enter keyword SEAT COVER, then select Front Seat Cover Replacement from the list, and do the removal steps in the procedure. 2. Slide the seat-back cushion (foam) off the seat-back frame. (The OPDS sensor is built into the seat-back cushion.) 3. Slide a new seat-back cushion over the seat-back frame. Make sure the cushion is centered. 4. Install the seat-back cover: ^ Using the appropriate service manual, go to section 20 (Body), and do the installation step under Front Seat Cover Replacement, or ^ Online, enter keyword SEAT COVER, then select Front Seat Cover Replacement from the list, and do the installation step in the procedure. 5. Initialize the OPDS unit: ^ To initialize with the HDS, go to Initializing the OPDS Unit: HDS Method in this service bulletin. ^ To initialize with the SCS service connector, go to Initializing the OPDS Unit: Manual Mode in this service bulletin. Disclaimer Page 8257 ^ If no key code can be found on the iN or with the Matrix H High Security key Codes Book, remove one tumbler at a time from the old inner cylinder, and match the number stamped on the old tumbler to a new tumbler from the kit. Insert the new tumbler and spring in the appropriate new inner cylinder cavity. ^ Do not use the old inner cylinder, springs, or tumblers. ^ Using your thumb and forefinger, hold the tumblers in place, insert the key in the cylinder and verify that all tumblers are flush with the cylinder. If not, double-check the key number, the cutting key code, the tumbler numbers, and the cavity locations. NOTE: If the key cannot be inserted, check the tumbler in the "J" cavity. It may be out of position. Page 1801 Main Journal Code Locations (Numbers) Page 3923 5. Confirm the control module update by Program ID and Program Part No. Make sure this corresponds with any information provided in the service bulletin for the update you are doing. Click on Yes to continue. Within a few seconds, the CM Update sofiware loads the program file onto the HDS tablet. 6. In the HDS Tablet Programming screen, click on the check mark after programming is completed. 7. In the Updating Honda Control Modules screen, click on the check mark. NOTE: To avoid permanent control module damage, do not turn the ignition switch to LOCK (0) during the update. 8. When updating is complete, follow the screen prompts to turn the ignition switch to LOCK (0), and then to ON (II). To update another system, return to the Updating Honda Control Modules screen by clicking on the exit button on the right side of the screen. UPDATING WITH THE HIM Page 3486 Main Relay (Computer/Fuel System): Testing and Inspection Power Relay Test Use this chart to identify the type of relay, then do the test listed for it. NOTE: See the turn signal/hazard relay input test. Normally-open type A: Page 115 (A/T, CVT) Page 5687 Starter Overhaul For A/T Page 9807 Power Windows Component Location Index 119. Driver's Door (Coupe except DX, HX) Locations 94. Behind Glove Box (except GX) Page 3282 17. VTEC Solenoid Valve (EX, HX) How to Remove the PCM Control Module: Service and Repair How to Remove the PCM How to Remove the PCM for Testing 1. Remove the passenger's dashboard lower cover, the right kick panel, and the glove box. 2. Remove the bolt. Cut the plastic cross brace in the glove box opening with diagonal cutters in the area shown, and discard it. 3. Remove the relays (A), then remove the bolts and the glove box frame (B). 4. Remove the gray 20P PCM wire harness connector from the PCM mounting bracket. Remove the PCM mounting bolt (A) and the bracket. 5. Remove the nuts, then remove the PCM (B). 6. Install the PCM in the reverse order of removal. Diagram Information and Instructions Shift Indicator: Diagram Information and Instructions Terminal Numbering System Terminal Numbering System Connector terminals are numbered according to the cavities they're in. The cavities are numbered starting from the upper left, looking at the male terminals from the terminal side or looking at the female terminals from the wire side. Both views are in the same direction so the numbers are the same. All actual cavities are numbered, even if they have no wire terminals in them. NOTE: Data Link Connector (DLC) terminals are numbered according 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 below is #6. Page 7469 Body Control Systems: Electrical Diagrams Diagram 52-0 (LX-C) Continuously Variable Transmission Shift Interlock Switch: Testing and Inspection Continuously Variable Transmission Park Pin Switch Test 1. Remove the center console panel and center console. 2. Disconnect the park pin switch connector (4P). 3. Shift to the P position, then check for continuity between the No. 3 and No. 4 terminals. There should be no continuity. 4. Shift out of the P position, and check for continuity between terminals No. 3 and No. 4. There should be no continuity. 5. If the park pin switch is faulty, replace it. Page 3910 HDS Tablet: HDS Pocket Tester: Page 2046 - Before connecting connectors, make sure the terminals (A) are in place and not bent. - Check for loose retainer (A) and rubber seals (B). - The backs of some connectors are packed with dielectric grease. Add grease if necessary. If the grease is contaminated, replace it. - Insert the connector all the way and make sure it is securely locked. - Position wires so that the open end of the cover faces down. Handling Wires and Harnesses - Secure wires and wire harnesses to the frame with their respective wire ties at the designated locations. Page 5817 1. Remove the terminal. 2. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE G: 1. Remove the terminal. 2. Go to HOW TO INSTALL NEW TERMINALS. Page 5465 Hydraulic Control Assembly - Antilock Brakes: Description and Operation ABS Modulator The ABS modulator consists of the inlet solenoid valve, outlet solenoid valve, reservoir, pump, pump motor, and the damping chamber. The modulator reduces the caliper fluid pressure directly. It is a circulating-type modulator because the brake fluid circulates through the caliper, reservoir, and the master cylinder. The hydraulic control has three modes: pressure intensifying, pressure retaining, and pressure reducing. The hydraulic circuit is an independent four-channel type, one channel for each wheel. Pressure intensifying mode ................................................................................................................. ................................................................. Inlet valve open, outlet valve closed ............................................................................................................................................................ Master cylinder fluid is pumped out to the caliper. Pressure retaining mode ..................................................................................................................... ........................................................... Inlet valve closed, outlet valve closed .............................................................................................................................................. Caliper fluid is retained by the inlet valve and outlet valve. Pressure reducing mode ..................................... ............................................................................................................................................. Inlet valve closed, outlet valve open ............................................................................................................................................. Caliper fluid flows through the outlet valve to the reservoir. Motor operation mode .................................................................................................................................. When starting the pressure reducing mode, the pump motor is ON. ................................................................................................................................................... When stopping ABS operation, the pump motor is OFF. ........................................................................... The reservoir fluid is pumped out by the pump, through the damping chamber, to the master cylinder. Component Locations Shift Solenoid: Component Locations Electronic Controls Location Page 9033 2. Insert the terminal tool into the female terminal, and then remove the terminal tool. NOTE: Make sure you do not select a terminal tool that is larger than the mating male terminal because it would spread the female terminal and cause a loose fit. 3. Compare the drag to the other terminals in the connector. If the drag is less, replace the terminal with a replacement terminal from the appropriate terminal repair kit. Page 8290 17. Using a small screwdriver, push down on the tip of the last tumbler to release it, then remove the cylinder from the housing, being careful not to drop any tumblers and springs. Use your thumb and forefinger to hold the tumblers in place. Then go to step 20. 18. While turning the key left and right and pushing on the rear of the inner cylinder to release the spring, slowly remove the cylinder from the housing. Page 6133 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 1451 Power Steering Fluid: Service and Repair Replacement Check the reservoir (A) at regular intervals, and add the recommended fluid as necessary. Always use Honda Power Steering Fluid. Using any other type of power steering fluid or automatic transmission fluid can cause increased wear and poor steering in cold weather. 1. Raise the reservoir, then disconnect the return hose (A) to drain the reservoir. Take care not to spill the fluid on the body and parts. Wipe off any spilled fluid at once. 2. Connect a hose (B) of suitable diameter to the disconnected return hose, and put the hose end in a suitable container. 3. Start the engine, let it run at idle, and turn the steering wheel from lock-to-lock several times. When fluid stops running out of the hose, shut off the engine. Discard the fluid. 4. Reinstall the return hose on the reservoir. 5. Fill the reservoir to the upper level line (C). 6. Start the engine and run it at fast idle, then turn the steering from lock-to-lock several times to bleed air from the system. 7. Recheck the fluid level and add more if necessary. Do not fill the reservoir beyond the upper level line. Page 3131 Resistor Variable Sensor Solenoid Transistors Circuit Schematics Capacity Specifications Engine Oil: Capacity Specifications Engine Oil D17A2, D1746 engines: For engine overhaul ............................................................................................................................. .............................................................. 4.2L (4.4 Qt) For oil change, including filter .............................................................................................................. ............................................................ 3.5L (3.7 Qt) For oil change, without filter ................................................................................................................. ............................................................ 3.3L (3.5 Qt) D17A1 engine: For engine overhaul ............................................................................................................................. .............................................................. 4.2L (4.4 Qt) For oil change, including filter .............................................................................................................. ............................................................ 3.2L (3.4 Qt) For oil change, without filter ................................................................................................................. ............................................................ 3.0L (3.2 Qt) Service and Repair Oil Separator: Service and Repair Oil/Air Separator Installation 1. Clean and dry the oil/air separator mating surfaces. 2. Apply liquid gasket, P/N 08718-0001 or 08718-0003, evenly to the block mating surface of the oil/air separator and to the inner threads of the bolt holes. NOTE: Do not install the parts if 5 minutes or more have elapsed since applying liquid gasket. Instead, reapply liquid gasket after removing the old residue. 3. Install the oil/air separator. Capacity Specifications Fluid - A/T: Capacity Specifications ATF Change ................................................................................................................................................ .............................................................. 2.7L (2.9 Qt) Overhaul .......................................................... .................................................................................................................................................. 6.0L (6.3 Qt) CVT fluid Change ................................................................................................................................ .............................................................................. 3.1L (3.3 Qt) Overhaul .......................................... .............................................................................................................................................................. .... 5.6L (6.0 Qt) Locations 25. Transmission Housing (CVT) Service and Repair Body Emblem: Service and Repair Emblem Replacement NOTE: When using dental floss to cut the emblem adhesive, take care not to scratch the body. Page 4392 8. Inspect the quality of the wire crimp. If it has any of the following NO GOOD crimps, cut it off and start over. 9. Insert the terminal into the connector. Make sure the wire seals are pushed all the way into the connector. Lightly pull on the wires to make sure the terminal is locked into place. 10. Close or insert the secondary terminal lock, if applicable, and reconnect the connector. How to Install Pigtail Terminals HOW TO INSTALL PIGTAIL TERMINALS Pigtail terminals (short pieces of wire with a factory crimped terminal) are used when the wire is too short or when access to the connector is too restricted to make a terminal repair. NOTE: To replace just a connector terminal, go to How to Replace Connector Terminals. IMPORTANT SAFETY INFORMATION: On some models, the SRS wires are in a separate harness. If the SRS harness is damaged, replace the harness; do not repair it. On other models, wire harnesses include yellow SRS wires. If any SRS wire is damaged, replace the entire harness; do not repair it. 1. Remove the damaged or faulty terminal from the connector. Use the proper removal tool from Pin Tool Set. Page 9761 1. Remove the screw and passenger's power window switch (A) from the door panel. 2. Disconnect the 5P connector (B) from the switch. 3. Check for continuity between the terminals in each switch position according to the table. 4. If the continuity is not as specified remove the two screws and replace the switch. Page 5127 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. Circuits must be operating when checking voltage drop. 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. 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 off, 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 Self-Powered Test Light or DVOM 1. Remove the blown fuse and disconnect the battery and load. Page 8688 3. With the 12P connector disconnected, make these input tests. 4. If any test indicates a problem, find and correct the cause, then recheck the system. If all the input tests prove OK, the actuator may be faulty. Substitute a known-good control unit and retest. If the system works properly, replace the cruise control actuator. Page 7053 8. Disconnect the 4P connector between the seat belt buckle tensioner (A) and floor wire harness. 9. Pull the seat belt out all the way and cut it. 10. Cutoff each connector, strip the ends of the wires, and connect the deployment tool alligator clips (A) to the wires. Place the deployment tool at least 30 feet (10 meters) away from the vehicle. NOTE: The driver's airbag and the front passenger's airbag has four wires, two yellow and two red. Twist each pair of unlike colored wires together, and connect an alligator clip to each pair. 11. Connect a 12 volt battery to the tool. - If the green light on the tool comes on, the igniter circuit is defective and cannot deploy the component. Go to Disposal of Damaged Components. - If the red light on the tool comes on, the component is ready to be deployed. 12. Push the tool's deployment switch. The airbags and tensioners should deploy (deployment is both highly audible and visible: a loud noise and rapid inflation of the bag, followed by slow deflation). If the components deploy and the green light on the tool comes on, continue with this procedure. - If an component doesn't deploy, yet the green light comes ON, its igniter is defective. Go to Disposal of Damaged Components. - During deployment the airbag can become hot enough to burn you. Wait 30 minutes after deployment before touching the airbag. Page 5821 the same location; the resulting "lump" of splice connectors would interfere with rewrapping the harness. Instead, cut the first pigtail close enough to the terminal so you will have room to make each remaining cut about 20 mm (3/4 inch) farther down on the next pigtail. 7. If you are using a yellow splice connector, strip about 6 mm (1/4 inch) of insulation off the ends of both wires. If you are using a pink or blue splice connector, strip off about 8 mm (5/16 inch) of insulation. 8. Put the splice connector in the proper size slot in the Crimper Tool, slide it to one end (where the flare begins), and close the crimper handles far enough to hold it in place. To release the ratchet mechanism at any point after the first click, squeeze the handles slightly and push the release lever, then let the handles open. 9. Insert one of the bare wires into the splice connector end that is in the crimper jaws. Push the wire all the way into the splice connector, and squeeze the crimper handles. Keep squeezing until the jaws touch, and hold it at that position until the ratchet clicks again. 10. Crimp the other wire in the same way into the other end of the splice connector. 11. After crimping, gently pull on the wires in the opposite directions to make sure they are secure in the connector. 12. Separate the other wires in the harness from the repaired wire(s), and shield them with nonflammable material. Page 1618 ^ 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 5388 2. Cut off the wire about an inch back from where it connects to the damaged or faulty terminal, then strip about half of the insulation off that piece. This will be used to size the wire end of the replacement pigtail terminal. NOTE: If you are not sure of the wire size, start with a large enough hole on the stripper that will not nick or cut off any strands of wires. 3. Select a pigtail terminal that matches the original wire at both ends (same kind of terminal and same diameter bare wire). 4. Select the smallest splice connector (yellow, pink, or blue) that will fit onto the stripped end of the original wire. 5. Insert the pigtail terminal into the connector cavity; push it in until it locks in place. 6. Lay the pigtail and the original wire side-by-side, and cut off both ends at once. If you are making more than one splice, do not cut each pigtail at the same location; the resulting "lump" of splice connectors would interfere with rewrapping the harness. Instead, cut the first pigtail close enough to the terminal so you will have room to make each remaining cut about 20 mm (3/4 inch) farther down on the next pigtail. 7. If you are using a yellow splice connector, strip about 6 mm (1/4 inch) of insulation off the ends of both wires. If you are using a pink or blue splice connector, strip off about 8 mm (5/16 inch) of insulation. Page 7059 105. Left B Pillar (Right Similar) 155. Behind Left Side Of Front Bumper Page 3421 5. To prevent damage and keep foreign matter out, cover the disconnected connector and line end with plastic bags (A). NOTE: The retainer cannot be reused once it has been removed from the pipe. Replace the retainer when replacing the fuel rail. - replacing the fuel feed line. - replacing the fuel pump. - replacing the fuel filter. - replacing the fuel pressure regulator. - replacing the fuel gauge sending unit. - it has been removed from the line. - it is damaged. Fuel Line/Quick-Connect Fittings Installation 1. Check the contact area (A) of the line (B) for dirt and damage, and clean if necessary. 2. Insert a new retainer (A) into the connector (B) if the retainer is damaged, or after - replacing the fuel rail. - replacing the fuel feed line. - replacing the fuel pump. Page 7259 Keyless Entry Transmitter: Testing and Inspection Transmitter Test NOTE: - If the doors unlock or lock with the transmitter, but the LED on the transmitter does not come on, the LED is faulty; replace the transmitter. - If any door is open, you cannot lock the door with the transmitter. - If you unlocked the doors with the transmitter, but do not open any of the doors within 30 seconds, the doors relock automatically. - The doors do not lock or unlock with the transmitter if the ignition key is inserted in the ignition switch. 1. Press the lock or unlock button 5 or 6 times to reset the transmitter. - If the locks work, the transmitter is OK. - If the locks don't work, go to step 2. 2. Open the transmitter and check for water damage. - If you find any water damage, replace the transmitter. - If there is no water damage, go to step 3. 3. Replace the transmitter battery (A) with a new one, and try to lock and unlock the doors with the transmitter by pressing the lock or unlock button 5 or 6 times. If the doors lock and unlock, the transmitter is OK. - If the doors don't lock and unlock, go to step 4. 4. Reprogram the transmitter, then try to lock and unlock the doors. - If the doors lock and unlock, the transmitter is OK. - If the doors don't lock and unlock, replace the transmitter. Page 3718 2. Cut off the wire about an inch back from where it connects to the damaged or faulty terminal, then strip about half of the insulation off that piece. This will be used to size the wire end of the replacement pigtail terminal. NOTE: If you are not sure of the wire size, start with a large enough hole on the stripper that will not nick or cut off any strands of wires. 3. Select a pigtail terminal that matches the original wire at both ends (same kind of terminal and same diameter bare wire). 4. Select the smallest splice connector (yellow, pink, or blue) that will fit onto the stripped end of the original wire. 5. Insert the pigtail terminal into the connector cavity; push it in until it locks in place. 6. Lay the pigtail and the original wire side-by-side, and cut off both ends at once. If you are making more than one splice, do not cut each pigtail at the same location; the resulting "lump" of splice connectors would interfere with rewrapping the harness. Instead, cut the first pigtail close enough to the terminal so you will have room to make each remaining cut about 20 mm (3/4 inch) farther down on the next pigtail. 7. If you are using a yellow splice connector, strip about 6 mm (1/4 inch) of insulation off the ends of both wires. If you are using a pink or blue splice connector, strip off about 8 mm (5/16 inch) of insulation. Page 9506 3. Strip the insulation off the end of the wire so the wire fits in the new terminal as shown. (If the wire has a wire seal, replace it with a new one from the kit.) NOTE: After stripping the end of the wire, make sure you did not cut any wire strands. If you did, cut the wire off even with the insulation, and strip it again. 4. Position the terminal in the crimping tool slot with the solid portion of the terminal toward the anvil and the open section toward the former. 5. Insert the wire in the terminal to the position shown in step 3. 6. Squeeze the tool with both hands until the stops make contact. 7. Crimp the insulation crimp. - If you do not have a wire seal, then use the next larger size crimp slot. Position the crimping tool over the insulation crimp section of the terminal, then squeeze the tool with both hands until the stops make contact. - If you have a wire seal, position the insulation crimp in the 5.5 crimping slot, then carefully squeeze the crimp closed until its ends are touching and making a full-circle shape. Page 7154 Alarm System Transmitter: Service and Repair Transmitter Programming Transmitter Programming Storing transmitter codes: The codes of up to three transmitters can be read into the keyless receiver unit memory. (If a fourth code is stored, the code which was input first will be erased.) NOTE: It is important to maintain the time limits between the steps. Make sure the doors and the trunk are closed. 1. Turn the ignition switch ON (II). 2. Within 1 to 4 sec., push the transmitter lock or unlock button with the transmitter aimed at the receiver in the multiplex control unit behind the driver's side of the dash. 3. Within 1 to 4 sec., turn the ignition switch OFF. 4. Within 1 to 4 sec., turn the ignition switch ON (II). 5. Within 1 to 4 sec., push the transmitter lock or unlock button with the transmitter aimed at the receiver in the multiplex control unit behind the driver's side of the dash. 6. Within 1 to 4 sec., turn the ignition switch OFF. 7. Within 4 sec., turn the ignition switch ON (II). 8. Within 1 to 4 sec., push the transmitter lock or unlock button with the transmitter aimed at the receiver in the multiplex control unit behind the driver's side of the dash. 9. Within 1 to 4 sec., turn the ignition switch OFF. 10. Within 4 sec., turn the ignition switch ON (II). 11. Within 1 to 4 sec., push the transmitter lock or unlock button with the transmitter aimed at the receiver in the multiplex control unit behind the driver's side of the dash. 12. Confirm you can hear the sound of the door lock actuators. Within 1 to 4 sec., push the transmitter lock or unlock button again. 13. Within 10 sec., aim the transmitters (up to two additional ones) whose codes you want to store at the receiver, and press the transmitter lock or unlock buttons. Confirm that you can hear the sound of the door lock actuators after each transmitter code is stored. 14. Turn the ignition switch OFF, and pull out the key. 15. Confirm proper operation of the transmitter. Page 9342 Connectors - "C" Page 5249 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. How to Replace Connector Terminals Terminal Replacement Procedure HOW TO REPLACE CONNECTOR TERMINALS The terminal repair kits provide necessary tools and materials (terminals, wire seals, and splice connectors) to repair many damaged or faulty connector terminals. However, not all terminals for all connectors are available. Refer to the labels on the lids of the repair kits for replacement terminal availability. IMPORTANT SAFETY INFORMATION: On some models, the SRS wires are in a separate harness. If the SRS harness is damaged, replace the harness; do not repair it. On other models, wire harnesses include yellow SRS wires. If any SRS wire is damaged, replace the entire harness; do not repair it. Before you begin, inspect the wire you are about to repair for damage and length. Make sure the wire will be long enough to make a terminal repair without stretching it when you reinstall the terminal in the connector. If the wire is too short, or if access to the connector is too restricted to make a terminal repair, you may need to install a pigtail terminal (a short length of wire with a factory-crimped terminal on it). Refer to HOW TO INSTALL PIGTAIL TERMINALS. Removing the Terminal Page 737 Fuel Tank Pressure Sensor: Description and Operation The FTP sensor converts fuel tank absolute pressure into an electrical input to the ECM/PCM. Capacity Specifications Power Steering Fluid: Capacity Specifications Power steering fluid Capacity For fluid change ................................................................................................................................... ......................................... 0.4 L (0.42 US qt.) For system overhaul .................................................... ................................................................................................................... 1.0 L (1.06 US qt.) Page 124 Daytime Running Lamp Control Unit: Testing and Inspection Daytime Running Lights Control Unit Input Test - Canada The DRL indicator light in the gauge assembly will come on when you turn the ignition switch to ON (II) with the headlight switch off and the parking brake set. If should go off when you turn on the headlight switch, release the parking brake. If it comes on at any other time, do the control unit input test. NOTE: When the daytime running lights are on, the high beam indicator will glow at half its normal intensity. 1. Remove the driver's dashboard lower cover. 2. Disconnect the 14P connector (A) from the daytime running lights control unit (B). 3. Inspect the connector and socket terminals to be sure they are all making good contact. - If the terminals are bent, loose or corroded, repair them as necessary, and recheck the system. - If the terminals look OK, go to step 4. '01-03 models Diagram Information and Instructions Variable Valve Timing Actuator: Diagram Information and Instructions Terminal Numbering System Terminal Numbering System Connector terminals are numbered according to the cavities they're in. The cavities are numbered starting from the upper left, looking at the male terminals from the terminal side or looking at the female terminals from the wire side. Both views are in the same direction so the numbers are the same. All actual cavities are numbered, even if they have no wire terminals in them. NOTE: Data Link Connector (DLC) terminals are numbered according 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 below is #6. Page 4553 2. Install the differential assembly (A) in the transmission housing (B) using the special tool. 3. Install the three dowel pins (A) and the gasket (B) on the transmission housing (C). 4. Place the flywheel housing (D) on the transmission housing. 5. Install the housing bolts (20 bolts), and tighten the bolts in two or more steps to 29 Nm (3.0 kgf-cm, 22 ft. lbs.) in a crisscross pattern. Page 4380 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. Circuits must be operating when checking voltage drop. 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. 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 off, 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 Self-Powered Test Light or DVOM 1. Remove the blown fuse and disconnect the battery and load. Page 9148 1. Remove the terminal. 2. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE G: 1. Remove the terminal. 2. Go to HOW TO INSTALL NEW TERMINALS. How to Install New Terminals HOW TO INSTALL NEW TERMINALS 1. Carefully match the old terminal with a new one from the terminal repair kit. Choose the correct replacement terminal based on the wire size range the terminal will accommodate. NOTE: If the replacement terminal quantities are low, reorder them by using the terminal part number listed on the inside lid of the terminal repair kit. Replacement terminals are available through your parts department using normal parts ordering procedures. 2. Depending on the size of the wire you are repairing, use the proper size slot in the crimping tool. Page 3504 PGM-F1 Main Relay 1, 2 Type 1, 2 Check for continuity between the terminals. - There should be continuity between the No.1 and No.2 terminals when power and ground are connected to the No.3 and No.4 terminals. - There should be no continuity between the No.1 and No.2 terminals when power is disconnected. Normally-open type B: Rear Window Defogger Relay Page 5482 Parking Brake Cable: Service and Repair Replacement 1. Remove the brake drum and shoes, and disconnect the parking brake cable from the brake shoe. 2. Remove the flange bolts (A) and parking brake cable (B) from the backing plate (C). 3. Reinstall the parking brake cable in the reverse order of removal, and note these items: ^ Before installing the brake drum, clean the mating surface of the rear hub and the inside of the brake drum. Before installing the wheel, clean the mating surfaces on the brake drum and inside of the wheel. ^ Adjust the parking brake. Page 7635 8. Release the clip, detach the hook, and remove the lock rod protector. 9. Disconnect the outer handle rod and cylinder rod. Testing and Inspection Power Door Lock Control Module: Testing and Inspection Control Unit Input Test 1. Before testing, troubleshoot the multiplex control system.See: Body and Frame/Body Control Systems/Testing and Inspection 2. Remove the dashboard lower cover. 3. Disconnect the under-dash fuse/relay box connectors. NOTE: All connectors are wire side of female terminals. 4. Inspect the connector and socket terminals to be sure they are all making good contact. - If the terminals are bent, loose or corroded, repair them as necessary, and recheck the system. - If the terminals look OK, go to step 5. Specifications Spark Plug: Specifications NGK ..................................................................................................................................................... ............................................................... PZFR6F-11 DENSO ................................................................................................................................................ ......................................................... PKJ20CR-M11 Gap ...................................................................................................................................................... ................................. 1.0 -1.1 mm (0.039 - 0.043 in) Torque ................................................................................................................................................. ...................................................... 18 N.m (13 lb.ft) Page 8910 32. Reinstall PGM-FI main relay 2 (A). 33. Check for continuity between fuel pump 5P connector terminal No.5 and body ground. Is there continuity? YES - Replace PGM-FI main relay 2. Also replace the No.17 FUEL PUMP (15A) fuse. NO - Check the fuel pump, and replace it as necessary. Also replace the No.17 FUEL PUMP (15A) fuse. 34. Disconnect ECM/PCM connector E (31P). 35. Turn the ignition switch ON (II). 36. Measure voltage between ECM/PCM connector terminals E9 and body ground. Is there battery voltage? YES - Go to step 37. NO - Repair open in the wire between the No.17 FUEL PUMP (15A) fuse and the ECM/PCM (E9). 37. Turn the ignition switch OFF. Page 7747 ^ If the trunk opens and closes smoothly, return the vehicle to the customer. ^ If the trunk lid is still difficult to close, go to REPAIR PROCEDURE E. REPAIR PROCEDURE E 1. Look at the back of the lock cylinder while you turn the key from lock to unlock. ^ Refer to page 20-158 of the 2001-04 Civic Service Manual. ^ In ISIS, use the keyword LID LOCK, and select Trunk Lid Lock Cylinder Replacement from the list. 2. Check the operation of the trunk lid lock cylinder: ^ If the lock cylinder is difficult to turn or binds, go to step 3. ^ If the lock cylinder operates properly, and the trunk lid is still difficult to close, refer to the appropriate body repair manual, and check for body inaccuracies. 3. Replace the lock cylinder, and re-key the cylinder to the customer's original key; on 2-door Civics, replace the lock cylinder and the lock cylinder rod: ^ Refer to page 20-158 of the 2001-04 Civic Service Manual. ^ In ISIS, use the keyword LID LOCK, and select Trunk Lid Lock Cylinder Replacement from the list. 4. Check the trunk operation, and return the vehicle to the customer. Disclaimer Technical Service Bulletin # 02-061 Date: 041105 Body - Trunk Lid Hard to Close 02-061 November 5, 2004 Applies To: See VEHICLES AFFECTED Trunk Lid is Difficult to Close (Supersedes 02-061, dated July 23, 2004) Updated information is shown with asterisks. SYMPTOM The trunk lid may be difficult to close or won't latch closed. PROBABLE CAUSE The trunk lid may be misaligned, and the trunk lid opener cable, trunk lid latch, lock cylinder, lock rod, and/or the trunk lid latch striker may need adjustment or replacement. Locations 151. Middle Of Trunk Lid Diagrams Page 7640 ^ If no key code can be found on the iN or with the Matrix H High Security key Codes Book, remove one tumbler at a time from the old inner cylinder, and match the number stamped on the old tumbler to a new tumbler from the kit. Insert the new tumbler and spring in the appropriate new inner cylinder cavity. ^ Do not use the old inner cylinder, springs, or tumblers. ^ Using your thumb and forefinger, hold the tumblers in place, insert the key in the cylinder and verify that all tumblers are flush with the cylinder. If not, double-check the key number, the cutting key code, the tumbler numbers, and the cavity locations. NOTE: If the key cannot be inserted, check the tumbler in the "J" cavity. It may be out of position. Page 3868 Shift Interlock Switch: Testing and Inspection Park Pin Switch Test Park Pin Switch Test 1. Remove the center console panel and center console. 2. Disconnect the park pin switch connector (4P). 3. Shift to the P position, then check for continuity between the No. 3 and No. 4 terminals. There should be no continuity. 4. Shift out of the P position, and check for continuity between terminals No. 3 and No. 4. There should be continuity. 5. If the park pin switch is faulty, replace it. Page 283 ECM/PCM Inputs And Outputs At Connector E (31P) Page 1565 Under-dash Fuse/Relay Box (4-door) Page 1076 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 Short Circuit Locator (Short Finder) 1. Remove the blown fuse. Leave the battery connected. Page 1607 YES - Replace the sensor that restored about 5 V when disconnected. NO - Go to step 62. 62. Turn the ignition switch OFF. 63. Disconnect the 3P connectors from the following sensors. - Exhaust gas recirculation (EGR) valve position sensor - Knock sensor - Throttle position (TP) sensor - CVT drive pulley speed sensor (CVT) - CVT speed sensor 2 (CVT) 64. Disconnect ECM/PCM connector A (31P). 65. Check for continuity between ECM/PCM connector terminal A20 and body ground. Is there continuity? YES - Repair short in the wire between the ECM/PCM (A20) and the EGR valve position sensor, knock sensor, TP sensor, CVT drive pulley speed sensor (CVT), or CVT speed sensor 2 (CVT), or repair short in the wire between the ECM/PCM (A8) and the knock sensor. NO - Update the ECM/PCM if it does not have the latest software, or substitute a known-good ECM/PCM, then recheck. If the symptom/indication goes away with a known-good ECM/PCM, replace the original ECM/PCM. 66. Measure voltage between body ground and ECM/PCM connector terminal E5. Is there about 5 V? YES - Update the ECM/PCM if it does not have the latest software, or substitute a known-good ECM/PCM, then recheck. If the symptom/indication goes away with a known-good ECM/PCM, replace the original ECM/PCM. NO - Go to step 67. 67. Turn the ignition switch OFF. 68. Disconnect the fuel tank pressure (FTP) sensor 3P connector. 69. Turn the ignition switch ON (II). Page 8162 Programming the Transmitter NOTES: ^ The system accepts up to three transmitters. The transmitter codes are stored in a stacking-type memory. If a fourth transmitter code is programmed, the code for the first transmitter is erased. ^ Entering the programming mode cancels all learned transmitter codes, so none of the previously programmed transmitters will work. You must reprogram all of the transmitters once you are in the programming mode. ^ You must complete steps 1-6 within 4 seconds of the previous step to keep the system from exiting the programming mode. 1. Turn the ignition switch to ON (II). 2. Press the "Lock" or "Unlock" button on one of the transmitters. (An unprogrammed transmitter can be used for this step.) 3. Turn the ignition switch to LOCK (0). 4. Repeat steps 1, 2, and 3 two more times using the same transmitter used in step 2. 5. Turn the ignition switch to ON (II). 6. Press the "Lock" or "Unlock" button on the same transmitter. Make sure the power door locks cycle to confirm that the system is in programming mode. 7. Within 10 seconds, press the "Lock" or "Unlock" button on each transmitter. Make sure the power door locks cycle after you press each transmitter button to confirm that the system accepted the transmitter's code. 8. Turn the ignition switch to LOCK (0) to exit the programming mode. Ordering a Transmitter Transmitters can be ordered only by authorized Honda dealers. Order them from American Honda using normal parts ordering procedures. Batteries for the Transmitter The battery number is CR2025. Each transmitter uses one battery. 88-91 Prelude With Dealer-Installed Security System 1988-91 Prelude with dealer-installed security system Page 9399 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 Short Circuit Locator (Short Finder) 1. Remove the blown fuse. Leave the battery connected. Page 8144 Page 7447 - Remove clips carefully; don't damage their locks (A). - Slip pliers (A) under the clip base and through the hole at an angle, then squeeze the expansion tabs to release the clip. - After installing harness clips, make sure the harness doesn't interfere with any moving parts. - Keep wire harnesses away from exhaust pipes and other hot parts, from sharp edges of brackets and holes, and from exposed screws and bolts. - Seat grommets in their grooves properly (A). Do not leave grommets distorted (B). Testing and Repairs - Do not use wires or harnesses with broken insulation. Replace them or repair them by wrapping the break with electrical tape. - After installing parts, make sure that no wires are pinched under them. - When using electrical test equipment, follow the manufacturer's instructions and those described. - If possible, insert the probe of the tester from the wire side (except waterproof connector). - Use back probe adaptor 07TAZ-001020A. - Refer to the instructions in the Honda Terminal Kit for identification and replacement of connector terminals. Five-Step Troubleshooting Five-Step Troubleshooting 1. Verify The Complaint Page 4349 4. Select the appropriate pair of fittings, and attach them to the radiator, to the hoses, or to the banjo bolts for flow through the ATF cooler cleaner. 5. Connect the red hose to the cooler outlet line (the line that normally goes to the external filter on the transmission). 6. Connect the blue hose to the cooler inlet line. 7. Connect a shop air hose (regulated to 100 to 125 psi) 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. 8. Flip the MOTOR toggle switch to ON; the green indicator above the toggle switch comes on. 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. Always open the valve slowly. At the end of the 5 minutes cleaning period, leave the air purge valve open. NOTE: While the pump is running with the air purge valve open, it is normal to see vapor coming from the filler/breather tube vents. 9. With the air purge valve open, flip the MOTOR toggle switch to OFF; the green indicator goes off. Leave the air purge valve open for at least 15 seconds to purge the lines and hoses of residual ATF, then close the valve. 10. Disconnect the red and blue hoses from the ATF cooler. Now connect the red hose to the cooler inlet line. 11. Now connect the blue hose to the cooler outlet line. 12. 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. Always open the valve slowly. At the end of the 5 minutes cleaning period, leave the air purge valve open. NOTE: While the pump is running with the air purge valve open, it is normal to see vapor coming from the filler/breather tube vents. 13. With the air purge valve open, flip the MOTOR toggle switch to OFF. Leave the air purge valve open for at least 15 seconds to purge the lines and hoses of residual ATF, then close the valve. 14. Disconnect the red and blue hoses from the ATF cooler lines. 15. Connect the red and blue hoses to each other. 16. Disconnect the shop air from the air purge valve. Disconnect and stow the coupler if used. 17. Disconnect and stow the fittings from the ATF cooler inlet and outlet lines. 18. Unplug the cooler cleaner from the 110 V outlet. Tool Maintenance Page 7177 Keyless/Power Door Lock System Component Location Index Front Door Side Sill Seal Replacement Front Door Weatherstrip: Service and Repair Front Door Side Sill Seal Replacement Front Door Side Sill Seal Replacement NOTE: - Take care not to scratch the door. - Use a clip remover to remove the clips. 1. Detach the clips, then remove the door side sill seal (A). 2. Install the seal in the reverse order of removal, and replace any damaged clips. Service and Repair Brake Bleeding: Service and Repair Brake System Bleeding NOTE: ^ Do not spill brake fluid on the vehicle, it may damage the paint; if brake fluid does contact the paint, wash it off immediately with water. ^ The reservoir on the master cylinder must be at the MAX (upper) level mark at the start of the bleeding procedure and checked after bleeding each brake caliper. Add fluid as required. ^ Do not reuse the drained fluid. ^ Always use Honda DOT 3 brake fluid. Non-Honda brake fluid can cause corrosion and shorten the life of the system. ^ Make sure no dirt or other foreign matter is allowed to contaminate the brake fluid. 1. Make sure the brake fluid level in the reservoir is at the MAX (upper) level line (A). 2. Slide a piece of clear plastic hose over the first bleed screw, and submerge the other end in a container of new brake fluid. 3. Have someone slowly pump the brake pedal several times, then apply steady pressure. 4. Starting at the left front, loosen the brake bleed screw to allow air to escape from the system. Then tighten the bleed screw securely. 5. Repeat the procedure for each wheel in the sequence shown until air bubbles no longer appear in the fluid. Page 5218 107. Behind A/T Shift Lever (except M/T) Page 5854 234. Under-dash Fuse/Relay Box Part 7 Page 5334 Hydraulic Control Assembly - Antilock Brakes: Description and Operation ABS Modulator The ABS modulator consists of the inlet solenoid valve, outlet solenoid valve, reservoir, pump, pump motor, and the damping chamber. The modulator reduces the caliper fluid pressure directly. It is a circulating-type modulator because the brake fluid circulates through the caliper, reservoir, and the master cylinder. The hydraulic control has three modes: pressure intensifying, pressure retaining, and pressure reducing. The hydraulic circuit is an independent four-channel type, one channel for each wheel. Pressure intensifying mode ................................................................................................................. ................................................................. Inlet valve open, outlet valve closed ............................................................................................................................................................ Master cylinder fluid is pumped out to the caliper. Pressure retaining mode ..................................................................................................................... ........................................................... Inlet valve closed, outlet valve closed .............................................................................................................................................. Caliper fluid is retained by the inlet valve and outlet valve. Pressure reducing mode ..................................... ............................................................................................................................................. Inlet valve closed, outlet valve open ............................................................................................................................................. Caliper fluid flows through the outlet valve to the reservoir. Motor operation mode .................................................................................................................................. When starting the pressure reducing mode, the pump motor is ON. ................................................................................................................................................... When stopping ABS operation, the pump motor is OFF. ........................................................................... The reservoir fluid is pumped out by the pump, through the damping chamber, to the master cylinder. Service and Repair Steering Column Lock: Service and Repair Steering Lock Replacement 1. Remove the steering column. 2. Center punch each of the two shear bolts, and drill their heads off with a 5 mm (3/16 inch) drill bit. Be careful not to damage the switch body when removing the shear bolts. 3. Remove the shear bolts from the switch body. 4. Install the switch body without the key inserted. 5. Loosely tighten the new shear bolts. 6. Insert the ignition key, and check for proper operation of the steering wheel lock and that the ignition key turns freely. 7. Tighten the shear bolts (A) until the hex heads (B) twist off. Page 1838 4. With the embossed mark facing up, place the piston assembly (A) on the special tool (B). Be sure you position the recessed flat on the piston against the lugs on the base attachment. 5. Press the pin (C) out with the pin driver (D), pilot collar (E) and a hydraulic press. Inspection 1. Measure the diameter of the piston pin. Piston Pin Diameter Standard (New): 18.996 - 19.000 mm (0.7479 - 0.7480 inch) 2. Zero the dial indicator to the piston pin diameter. Page 225 Rear Window Defogger Component Location Index Page 6938 VEHICLES AFFECTED CUSTOMER NOTIFICATION All owners of affected vehicles were mailed a notification of this warranty extension. A example of the customer notification is shown in this service bulletin. CORRECTIVE ACTION Repair the vehicle as indicated by the INSPECTION PROCEDURE. If needed, replace the OPDS unit. In rare cases where an updated OPDS unit was already installed, replace the OPDS sensor. Page 8416 138. Rear of Roof (EX) Page 9466 Headlamp Relay: Testing and Inspection Power Relay Test Use this chart to identify the type of relay, then do the test listed for it. NOTE: See the turn signal/hazard relay input test. Normally-open type A: Recall - Ignition/Shift Interlock Defect Technical Service Bulletin # 10-059 Date: 101001 Recall - Ignition/Shift Interlock Defect 10-059 October 1, 2010 Applies To: See VEHICLES AFFECTED Safety Recall: Accord, Civic, and Element Ignition Switch Key Interlock BACKGROUND Under certain conditions, the interlock lever of the ignition switch may unexpectedly deform. The interlock ensures the transmission is in Park before the ignition key can be removed. Interlock failure may allow the ignition key to be removed when the shift lever is not in Park. If the driver fails to engage the parking brake, the vehicle could roll away, increasing the risk of a crash. VEHICLES AFFECTED Not all vehicles within the VIN ranges are affected by this recall. Before beginning work on a vehicle, verify its eligibility by checking at least one of these items: ^ The customer has a notification letter. Page 620 Key Reminder Switch: Testing and Inspection Ignition Key Switch Test NOTE: For more key-in beeper information, refer to the circuit diagram and input test. When the ignition key is in the ignition switch the multiplex control unit senses ground through the closed ignition key switch. When you open the driver's door, the beeper circuit senses ground through the closed door switch and sounds the beeper. 1. Remove the steering column upper and lower covers. 2. Disconnect the 6P connector. 3. Check for continuity between the No.1 and No.2 terminals. - There should be continuity with the key in the ignition switch. - There should be no continuity with the key removed. 4. If the continuity is not as specified, replace the ignition switch. Page 5793 234. Under-dash Fuse/Relay Box Part 3 Page 9517 Diagram 115-5 (Sedan EX) Diagrams: Other diagrams referred to by number (See Diagram ##-#, etc.)within these diagrams can be found at Diagrams by Number. See: Diagrams/Electrical Diagrams/Diagrams By Number Locations: Location photographs (references to PHOTOS) referred to within these diagrams can be found at Locations by Photo Number. See: Locations/Component Locations/Locations By Photo Number Connector Views: Connector terminal views (references to VIEWS) referred to within these diagrams can be found at Connector Views by View Number. See: Diagrams/Connector Views/Connector Views By View Number Page 475 138. Rear Of Roof (EX) Page 8029 ^ Incorrect: "If a Master Key is to be cut, put a five (5) in the blank space. Use a two (2) if a valet key is needed." ^ Correct: "If a Master Key is to be cut, put an M in the blank space. Use an S if a valet key is needed." Page 2, legend at the bottom: ^ Incorrect: "C. If a Master key is desired, then the number five (5) should be placed in the M/S position. Place the number two (2) in the M/S column if a Sub (Valet) key is needed." ^ Correct: "C. If a Master Key is desired, then an M should be placed in the M/S position. Place an S in the MIS column if a Sub (Valet) key is needed." Page 9062 Blower Motor Relay Type 1, Type 2 Check for continuity between the terminals. - There should be continuity between the No.1 and No.3 terminals when power and ground are connected to the No.2 and No.4 terminals. - There should be no continuity between the No.1 and No.3 terminals when power is disconnected. Five-terminal type Check for continuity between the terminals. - There should be continuity between the No.1 and No.2 terminals when power and ground are connected to the No.3 and No.5 terminals. - There should be continuity between the No.1 and No.4 terminals when power is disconnected. Lighting - Interior Spot Light Lenses Stick Map Lamp: All Technical Service Bulletins Lighting - Interior Spot Light Lenses Stick 00-085 April 22, 2003 * Applies To: * 2001-03 Civic LX - ALL * Spotlight Lens Sticks (Supersedes 00-085, dated October 31, 2000) Updated information is shown with asterisks. SYMPTOM When you push on either spotlight lens to turn on the light, the lens doesn't pop back out. PROBABLE CAUSE Headliner material interferes with the lens, preventing the lens from moving freely. CORRECTIVE ACTION Reposition the spotlight assembly. If needed, remove some of the headliner material. WARRANTY CLAIM INFORMATION In warranty: The normal warranty applies. Operation Number: 715012 Flat Rate Time: 0.2 hour Failed Part: P/N 34403-S5A-003ZB H/C 6569792 Defect Code: 030 Contention Code: B02 Template ID: 00-085A 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. Remove each spotlight lens by carefully prying on the inside edge with a small screwdriver. 2. Loosen the spotlight assembly mounting screws. Camshaft, Rocker Arm, Camshaft Seal and Pulley Installation Rocker Arm Assembly: Service and Repair Camshaft, Rocker Arm, Camshaft Seal and Pulley Installation Camshaft, Rocker Arm, Camshaft Seal and Pulley Installation NOTE: To prevent the rocker arm assembly from coming apart, leave the camshaft holder bolts in the holes. 1. After wiping down the camshaft and the journals in the cylinder head, lubricate both surfaces and install the camshaft. 2. Clean and install the oil control orifice (A) with a new O-ring (B) (D17A2, D17A6 engines). 3. Clean and install the oil control orifice (C) (D17A1 engine). 4. Turn the camshaft until its keyway (D) is facing up (No.1 piston TDC). 5. Loosen all the valve adjusting screws. 6. Apply liquid gasket to the head mating surface (shaded areas) of the No. 1 and No. 5 camshaft holders. 7. Set the rocker arm assembly in place and loosely install the bolts. Make sure that the rocker arms are properly positioned on the valve stems. Page 5824 Multiple Junction Connector: Service and Repair Checking For Poor Fir of Terminals CHECKING FOR POOR FIT OF TERMINALS Loose terminal fit can cause a number of intermittent problems in electrical circuits. By using the Terminal Inspection Feeler Tool Set you can inspect the terminal fit between the two matching connectors without removing the terminals from the connector body. 1. Find the terminal tool that best matches the male terminal in the mating connector. 2. Insert the terminal tool into the female terminal, and then remove the terminal tool. NOTE: Make sure you do not select a terminal tool that is larger than the mating male terminal because it would spread the female terminal and cause a loose fit. 3. Compare the drag to the other terminals in the connector. If the drag is less, replace the terminal with a replacement terminal from the appropriate terminal repair kit. Page 9093 2. Remove the terminal from the female half. 3. Remove the terminal from the male half. 4. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE D: 1. Remove the secondary locks. Page 1669 Resistor Variable Sensor Solenoid Transistors Circuit Schematics Page 1360 1. Apply a force of 98 N (10 kgf, 22 lbf), and measure the deflection at the mid point (A) between the alternator and crankshaft pulley. If the belt is worn or damaged, replace it. If the belt needs adjustment, go to step 2. Adjustment 2. Loosen the mounting bolt (B), lock bolt (C) and lower bracket mounting bolt (D). 3. Torque the mounting bolt to 20 N.m (2.0 kgf.m, 14 lbf.ft). 4. Turn the adjusting bolt (E) to obtain the proper belt tension, then retighten the lock bolt, mounting bolt and lower bracket mounting bolt. 5. Recheck the belt tension. 6. If you installed a new belt, run the engine for 5 minutes, then readjust the belt to the used belt specification. 7. Check the power steering pump belt adjustment. Page 2556 Variable Valve Timing Pressure Switch: Service and Repair VTEC Oil Pressure Switch Replacement 1. Remove the resonator (see step 5). 2. Remove the bolt (A) and loosen the bolt (B) securing the VTEC solenoid valve, then remove the harness bracket (C) from the VTEC solenoid valve. 3. Remove the harness clamp (D) from the connecting pipe. 4. Disconnect the VTEC oil pressure switch connector, then remove the VTEC oil Pressure switch (A). 5. Install the VTEC oil pressure switch using a new O-ring (B). Page 6394 12. Loosen the damper pinch bolts (A) while holding the nuts (B), and remove the bolts and nuts. 13. Remove the driveshaft outboard joint (C) from the knuckle (D) by tapping the driveshaft end (E) with a plastic hammer while pulling the knuckle outward, then remove the knuckle. NOTE: Do not pull the driveshaft end outward. The driveshaft joint may come off. 14. Separate the hub (A) from the knuckle (B) using the special tool and a hydraulic press. Be careful not to deform the splash guard. Hold onto the hub to keep it from falling when pressed clear. 15. Press the wheel bearing inner race (A) out of the hub (B) using the special tool, a commercially available bearing separator (C), and a press. Page 5157 Control Module: Service and Repair How to Substitute the PCM How to Substitute the PCM 1. Remove the PCM from the vehicle. 2. Install a known-good PCM in the vehicle. 3. Rewrite the immobilizer code with the PCM replacement procedure in the Honda PGM Tester; It allows you to start the engine. 4. After completing your tests, reinstall the original PCM and rewrite the immobilizer code with the PCM replacement procedure in the HDS Tester again. Page 949 ^ If the OPDS unit has an original part number, go to step 6. ^ If the OPDS unit has a new part number (refer to PARTS INFORMATION) or higher, go to REPAIR PROCEDURE B: OPDS SENSOR REPLACEMENT. 6. Recline the seat-back to access the OPDS unit mounting screws. 7. Remove the mounting screws from the OPDS unit, and gently pull out the unit. 8. Disconnect the OPDS connectors, then remove the OPDS unit. 9. Install a new OPDS unit, then snap on its cover. 10. Slip the seat-back cover over the OPDS unit. 11. On Accords, check the seat-back clip attachment bosses on the seat-back panel: ^ If the attachment bosses are OK, go to step 12. ^ If the seat-back has a pocket, and the attachment bosses are deformed or damaged, do the repair procedure in S/B 02-010, Seat-Back Panel Is Loose or Detached. Then go to step 12. ^ If the seat-back does not have a pocket, and the attachment bosses are deformed or damaged, replace the seat-back. Then go to step 12. Page 9446 Daytime Running Lamp Control Unit: Testing and Inspection Daytime Running Lights Control Unit Input Test - Canada The DRL indicator light in the gauge assembly will come on when you turn the ignition switch to ON (II) with the headlight switch off and the parking brake set. If should go off when you turn on the headlight switch, release the parking brake. If it comes on at any other time, do the control unit input test. NOTE: When the daytime running lights are on, the high beam indicator will glow at half its normal intensity. 1. Remove the driver's dashboard lower cover. 2. Disconnect the 14P connector (A) from the daytime running lights control unit (B). 3. Inspect the connector and socket terminals to be sure they are all making good contact. - If the terminals are bent, loose or corroded, repair them as necessary, and recheck the system. - If the terminals look OK, go to step 4. '01-03 models Page 3070 Intake Air Temperature Sensor: Description and Operation Intake Air Temperature (IAT) Sensor The IAT sensor is a temperature dependent resistor (thermistor). The resistance of the thermistor decreases as the intake air temperature increases. Connector Views Engine Control Module: Connector Views 228. ECM/PCM Part 1 228. ECM/PCM Part 2 Page 2066 13. Plug in the heat gun, and turn it on. Start at the middle of the splice connector, and move the gun toward the ends as the tube shrinks. Apply heat evenly by rotating the curved heat spreader around the splice connector. Shrinking is complete when a small amount of sealant appears at each end of the tube. Pigtail Terminal Selection Chart PIGTAIL TERMINAL SELECTION CHART Select the proper size pigtail terminal by matching the replacement terminal part number and the wire size being repaired to the corresponding pigtail terminal part number. Then use the color (size) splice connector listed. In some instances you may also have to match the wire seal style to select the proper pigtail terminal. Pigtail terminals are available through your parts department, in quantities of 10, using normal parts ordering procedures. Checking For Poor Fir of Terminals CHECKING FOR POOR FIT OF TERMINALS Loose terminal fit can cause a number of intermittent problems in electrical circuits. By using the Terminal Inspection Feeler Tool Set you can inspect the terminal fit between the two matching connectors without removing the terminals from the connector body. 1. Find the terminal tool that best matches the male terminal in the mating connector. 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 7749 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 A 1. Check the side-to-side alignment of the trunk lid latch to the striker: ^ Refer to page 20-132 of the 2001-04 Civic Service Manual. ^ In ISIS, use the keyword TRUNK ADJUST, and select Trunk Lid Adjustment from the list. 2. Make sure the gaps of the trunk lid are even on all sides. ^ If the trunk is misaligned, go to step 3. ^ If the trunk lid is properly aligned on all sides, go to REPAIR PROCEDURE B. 3. Adjust the trunk lid hinges: ^ Refer to page 20-132 of the 2001-04 Civic Service Manual. ^ In ISIS, use the keyword TRUNK ADJUST, and select Trunk Lid Adjustment from the list. 4. Check the trunk operation: ^ If the trunk opens and closes smoothly and is properly aligned, return the vehicle to the customer. ^ If the trunk lid is still difficult to close, go to REPAIR PROCEDURE B. REPAIR PROCEDURE B 1. Check the depth adjustment of the trunk lid: ^ Refer to page 20-132 of the 2001-04 Civic Service Manual. ^ In ISIS, use the keyword TRUNK ADJUST, and select Trunk Lid Adjustment from the list. 2. Make sure the trunk lid is flush on all sides and corners. ^ If the trunk is misaligned, go to step 3. ^ If the trunk lid is properly aligned on all sides and corners, go to REPAIR PROCEDURE C. 3. Adjust the striker depth position and the trunk lid edge cushions: ^ Refer to page 20-132 of the 2001-04 Civic Service Manual. ^ In ISIS, use the keyword TRUNK ADJUST, and select Trunk Lid Adjustment from the list. 4. Check the trunk operation: ^ If the trunk opens and closes smoothly, return the vehicle to the customer. ^ If the trunk lid is still difficult to close, go to REPAIR PROCEDURE C. REPAIR PROCEDURE C 1. Use a small screwdriver to manually set and release the trunk lid latch. Check the operation of the latch: ^ If the latch is difficult to set or release, go to step 2. ^ If the latch operates properly, go to REPAIR PROCEDURE D. Page 4496 9. Measure the clutch disc thickness. If the thickness is less than the service limit, replace the clutch disc. Standard (New): '01 model: 8.3 - 9.0 mm (0.33 - 0.35 inch) max. '02-03 models: 8.5 - 9.1 mm (0.34 - 0.36 inch) max. Service Limit: '01 model: 5.7 mm (0.22 inch) '02-03 models: 5.8 mm (0.23 inch) 10. Measure the rivet depth from the clutch disc lining surface (A) to the rivets (B) on both sides. If the rivet depth is less than the service limit, replace the clutch disc. Standard (New): 1.65 - 2.25 mm (0.065 - 0.089 inch) max. Service Limit: 0.8 mm (0.03 inch) Page 8183 128. Left Rear Door (Sedan Except DX) (Right Similar) Campaign - OPDS Unit Warranty Extension Technical Service Bulletin # 06-009 Date: 080205 Campaign - OPDS Unit Warranty Extension 06-009 February 5, 2008 Applies To: See VEHICLES AFFECTED Warranty Extension: OPDS Unit or OPDS Sensor Triggers SRS DTC(s) 15-1, 15-2, 15-3 (Supersedes 06-009, dated September 21, 2007) Updated information is shown with asterisks. BACKGROUND *NOTE: Because of a class action settlement, the warranty extension coverage for the OPDS unit and the OPDS sensor on 2002 Accords, 2002-04 Civics, 2003-04 Civic Hybrids, 2002-04 CR-Vs, 2003 Elements, 2002 Odysseys, and 2003-04 Pilots purchased or leased between April 13, 2002, and November 7, 2006, is now 10 years or 157,500 miles, whichever occurs first. For more information, refer to Service Bulletin 06-085, Warranty Extension: Vehicle Warranty Mileage.* Several vehicle models may have a problem with the OPDS (occupant position detection system) that causes the SRS indicator to stay on. Typically, one or more of these DTCs will be set: ^ SRS DTC 15-1 (faulty OPDS unit or OPDS not initialized) ^ SRS DTC 15-2 (faulty side airbag indicator circuit) ^ SRS DTC 15-3 (faulty OPDS sensor) To ensure continued reliability with the OPDS, American Honda is extending the warranty on the OPDS unit and the OPDS sensor to 10 years or 150,000 miles, whichever occurs first. This warranty extension does not apply to any vehicle that has ever been declared a total loss, or any that has been issued a salvage, branded, or similar title under any state's law. To check for vehicle eligibility, you must do a VIN status inquiry Page 5219 143. Park Pin/Shift Switch (A/T) Page 9305 - 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. Troubleshooting Tests 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 test 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 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. 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 Drop Page 6395 16. Remove the snap ring (A) and the splash guard (B) from the knuckle (C). 17. Press the wheel bearing (A) out of the knuckle (B) using the special tool and a press. 18. Wash the knuckle and hub thoroughly in high flash point solvent before reassembly. 19. Press a new wheel bearing (A) into the knuckle (B) using the old bearing (C), a steel plate (D), the special tool, and a press. Place the wheel bearing on the knuckle with the pack seal side facing (metal color) toward the inside. Be careful not to damage the sleeve of the pack seal. 20. Install the snap ring (A) securely in the knuckle (B). 21. Install the splash guard (C), and tighten the screws (D) to the specified torque. Page 4517 4. Apply super high temp urea grease (P/N 08798-9002) to the release fork (A), the release fork bolt (B), the release bearing (C), and the release bearing guide (D) in the shaded areas. 5. With the release fork slid between the release bearing pawls, install the release bearing on the mainshaft while inserting the release fork through the hole in the clutch housing. 6. Align the detent of the release fork with the release fork bolt, then press the release fork over the release fork bolt squarely. 7. Install the release fork boot (E), make sure the boot seals around the release fork and clutch housing. 8. Move the release fork (A) right and left to make sure that it fits properly against the release bearing (B), and that the release bearing slides smoothly. Page 2755 DTC P1586 thru P1678 Locations Transmission Position Switch/Sensor: Locations Electronic Controls Location, CVT 25. Transmission Housing (CVT) Page 8345 Paint damage can appear in any form. Before making a repair, check the damaged area carefully, and determine the best procedure for repairing the damage. The following shows you refinishing methods for various types of paint damage or defects. Preprocessing of Painting Preprocessing of Painting 1. Featheredging NOTE: The paint film damaged area should be sanded flat and smooth. - If this is not done correctly the end results will not be acceptable. Damage to metal surface: - Sand the damaged area flat and smooth. Use the disc sander and #60-#80 disc paper. Environmental Impact Information Refrigerant: Environmental Impact Information Service Procedures The Ozone Layer A thin layer of ozone molecules, located 10 to 30 miles above the earth, form a protective cover by absorbing a portion of the ultraviolet (UV) radiation emitted from the Sun. Ozone Depletion Scientific research performed over the past 15 years links the release of chlorofluorocarbons (CFC)s, also know by the trade name Freon) into the atmosphere to ozone depletion. When CFC's are released into the atmosphere, they eventually reach the ozone layer located in the stratosphere where they react with and destroy ozone molecules. Harmful Effects Ozone depletion and the corresponding increase in UV radiation has been shown to lead to higher incidents of cancer as well as global warming. When viewed from a global perspective, ozone depletion holds an enormous potential for damage. Upper Level vs. Ground Level Ozone Confusion often arises when we hear about the necessity of the ozone layer and ground level ozone. The ozone layer existing high above the earth is beneficial but the same compound, when located at ground level, is harmful to humans, animals, crops and vegetation. Ground level ozone is a component of smog and forms when hydrocarbons (HC) react with nitrogen oxides (NOx) in the presence of sunlight and heat. Montreal Protocol In response to the growing body of evidence demonstrating the detrimental effects of (CFC)s, 24 countries and the European community met in Montreal, Canada, in 1987 to establish standards for the control of (CFC)s. Since that time, a total of 132 countries have become signatories to this agreement leading to an end of production of R12 in December, 1995, in all developed countries. As established by the Montreal Protocol, R12 production in developed countries has ceased. Clean Air Act The United States Congress, acting in response to the Montreal Protocol, banned production of (CFC)s by the year 2000. Congress also amended the Clean Air Act in an effort to control both the production and use of (CFC)s for refrigerant applications including mobile vehicle air conditioning systems. Alternative Refrigerants The introduction of alternative refrigerants, primarily the hydrofluorocarbon (HFC) 134a, aims at preventing further ozone layer depletion. Because 134a is chlorine free, it is deemed ozone safe. Technician Certification Organizations providing technician refrigerant recovery and recycling certification include: National Institute for Automotive Service Excellence (ASE) 13505 Dulles Technology Drive, Suite 2 Herndon, VA 22071-3421 Phone: (703) 713-3800 Fax: (703) 713-0727 http://www.asecert.org/ International Mobile Air Conditioning Association (IMACA) P.O. Box 9000 Fort Worth, TX 76147-2000 Phone: (817) 338-1100 Fax: (817) 338-1451 Mobile Air Conditioning Society (MACS) Worldwide P.O. Box 100 East Greenville, PA 18041 Phone: 215-679-2220 Fax: 215-541-4635 http://www.macsw.org/ Page 3501 166. PGM-FI Main Relays 1 And 2 Page 5262 13. Plug in the heat gun, and turn it on. Start at the middle of the splice connector, and move the gun toward the ends as the tube shrinks. Apply heat evenly by rotating the curved heat spreader around the splice connector. Shrinking is complete when a small amount of sealant appears at each end of the tube. Pigtail Terminal Selection Chart PIGTAIL TERMINAL SELECTION CHART Select the proper size pigtail terminal by matching the replacement terminal part number and the wire size being repaired to the corresponding pigtail terminal part number. Then use the color (size) splice connector listed. In some instances you may also have to match the wire seal style to select the proper pigtail terminal. Pigtail terminals are available through your parts department, in quantities of 10, using normal parts ordering procedures. Checking For Poor Fir of Terminals CHECKING FOR POOR FIT OF TERMINALS Loose terminal fit can cause a number of intermittent problems in electrical circuits. By using the Terminal Inspection Feeler Tool Set you can inspect the terminal fit between the two matching connectors without removing the terminals from the connector body. 1. Find the terminal tool that best matches the male terminal in the mating connector. Page 5265 Transmission Position Switch/Sensor: Electrical Diagrams Circuit Diagram Locations Fuel Supply System - Component Location Index Page 4675 Transmission Cooler: Technical Service Bulletins A/T - Avoiding Fluid Contamination SOURCE: Honda Service News TITLE: Avoiding Comebacks From A/T Contamination APPLIES TO: All models SERVICE TIP: Installing a reman A/T? Here are some important tips to keep in mind to ensure a first-time fix and to avoid any come-backs: - If the vehicle has an ATF cooler, make sure you clean the cooler with the ATF Cooler Cleaner (P/N GHTTTCF6H). See S/B 89-022, ATF Cooler Cleaner, for details. - If the reman A/T kit includes an in-line filter, don't forget to install it. If the vehicle already has an in-line filter from an earlier A/T replacement, then remove the existing filter, and install the new one. - Spray the driveshaft splines with solvent and compressed air before installing them in the reman A/T. If the failed A/T had a speed sensor, make sure it's clean before you install it. Debris from the failed A/T can catch in the driveshaft splines or on the speed sensor and contaminate the reman A/T. - If the reman A/T comes with a heater/cooler, make sure you install the reman A/T with that heater/cooler. Never install the heater/cooler from the failed A/T; you could contaminate the reman A/T. Page 4056 Differential: Service and Repair A/T Differential Backlash Inspection 1. Install both axles in the differential, and place the differential assembly on V-blocks (A). 2. Check the backlash of the pinion gears (B) with a dial indicator (C). STANDARD: 0.05 - 0.15 mm (0.002 - 0.006 inch) 3. If the backlash is out of standard, replace the differential carrier. Page 6122 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 2925 Power Steering Pressure Signal: Testing and Inspection PSP Switch Signal Circuit Troubleshooting 1. Turn the ignition switch ON (II). 2. Measure voltage between ECM/PCM connector terminals A24 and E16. Is there less than 1.0 V? YES - Go to step 3. NO - Go to step 6. 3. Start the engine. 4. Turn the steering wheel to the full lock position. 5. Measure voltage between ECM/PCM connector terminals A24 and E16. Is there battery voltage? YES - The PSP switch signal is OK. NO - Go to step 13. 6. Turn the ignition switch OFF. 7. Disconnect the PSP switch 2P connector. 8. Turn the ignition switch ON (II). 9. At the harness side, connect the PSP switch 2P connector terminals No. 1 and No. 2 with a Jumper wire. 10. Measure voltage between ECM/PCM connector terminals A24 and E16. Is there less than 1.0 V? YES - Replace the PSP switch. NO - Go to step 11. 11. Turn the ignition switch OFF. Service and Repair Trailing Arm: Service and Repair Removal/Installation 1. Raise the rear of the vehicle, and support it with safety stands in the proper locations. Remove the rear wheels. 2. Remove the knuckle. 3. Place the floor jack under the trailing arm (A) to support it. 4. Remove the flange nut (B), and disconnect the stabilizer link (C) from the trailing arm. 5. Remove the flange bolt (D), and disconnect the damper (E) from the trailing arm. 6. Remove the trailing arm front mounting bolts (A). 7. Remove the trailing arm rear mounting bolt (A). Note: Do not loosen the special bolts (B) on the trailing arm. 8. Lower the jack, and remove the trailing arm. 9. Install the trailing arm in the reverse order of removal, and note these items: ^ First install all the suspension components and lightly tighten bolts and nuts, then place a jack under the trailing arm, and raise the suspension Locations Sunroof / Moonroof Relay: Locations Relay And Control Unit Locations - Door, Roof And Seat Page 9687 Power Window Relay: Testing and Inspection Power Relay Test Use this chart to identify the type of relay, then do the test listed for it. NOTE: See the turn signal/hazard relay input test. Normally-open type A: Page 4248 Transmission Speed Sensor: Diagrams 34. Output Shaft (Countershaft) Speed Sensor (A/T Except CVT) 57. Input Shaft (Mainshaft) Speed Sensor (A/T Except CVT) Page 6442 Air Conditioning Switch: Service and Repair Heater Control Panel and Push Switch Assembly Removal and Installation 1. Remove the center panel. 2. Remove the dials (A), then remove the self-tapping screws and the heater control panel (B) from the center panel (C). Remove the self-tapping screws and the push switch assembly (D) from the center panel. 3. Install the control panel and the push switch assembly in the reverse order of removal. After installation, operate the control panel controls to see whether it works properly. 4. Run the self-diagnosis function to confirm that there are no problems in the system. Locations Crankshaft Position Sensor: Locations PGM-FI System - Component Location Index Page 1173 119. Driver's Door (Coupe Except DX, HX) 120. Driver's Door (Sedan Except DX) Page 2665 7. Insert the feeler gauge (A) between the adjusting screw (B) and the end of the valve stem and slide it back and forth; you should feel a slight amount of drag. 8. If you feel too much or too little drag, loosen the locknut (A), and turn the adjusting screw (B) until the drag on the feeler gauge is correct. 9. Tighten the locknut and recheck the clearance. Repeat the adjustment, if necessary. Page 449 Door Lock Cylinder Switch: Testing and Inspection Door Lock Actuator Test Driver's door: 1. Remove the driver's door panel. 2. Disconnect the 2P connector from the actuator. 3. Check actuator operation by connecting power and ground according to the table. To prevent damage to the actuator, apply battery voltage only momentarily. 4. If the actuator does not operate as specified, replace it. Passenger's door: 1. Remove the passenger's door panel. Page 8021 *T-5 Sidewinder Key Applications ^ 2003-05 Civic ^ 2004-05 Civic Hybrid ^ 2003-05 Civic GX (CNG) ^ 2004-05 S2000 ^ 2002-06 CR-V ^ 2003-06 Element ^ 2003-04 Odyssey ^ 2003-04 Pilot Ordering Honda key blanks through normal parts ordering channels: Refer to the parts catalog for correct key(s) for your application. PROGRAMMING KEYS Depending on the type of key blank you use, do this: ^ If you have used a T-5 programmable key blank ("T-5" stamped on the shank), you must code the key's transponder with the Ilco Immobilizer Key Code Duplicator (see S/B 99-053, Ilco Immobilizer key Code Duplicator). ^ If you have used a Honda key blank, add the* transponder code of the new key to the immobilizer system with the Honda Diagnostic System (HDS). ORDERING INFORMATION *To order the MATRIX H Key Cutting Machine, replacement cutter bits, fixed jaws and mobile jaws, T-5 programmable key blanks, and practice key blanks, contact the Honda Tool and Equipment Program by calling 888-424-6857 or using the fax order form provided in your Honda Tool and Equipment Program Catalog.* Order Honda key blanks through normal parts ordering channels. WARRANTY CLAIM INFORMATION None. This service bulletin is for information only. *DETERMINING WHICH KEY TO USE T-5 keys require less time to program and should be the first choice. They can be used as long as the following requirements are met: ^ Do you have the customer's operating key? ^ Does the vehicle fall within the T-5 Sidewinder Key Applications? ^ Does your dealership have an Ilco Immobilizer Key Code Duplicator? If the answer to all three questions on the above is yes, the 1-5 key option is the easier procedure. If you answered no to any of the questions, you should order the key(s) from the parts catalogue, and program it using the HDS.* BEFORE YOU START CUTTING 1. Get the original key or the key number from your customer or from the iN. 2. Get the applicable key blank. 3. If cutting by code, look up the applicable 9-digit cutting code for the key number. Refer to the code book Honda High Security key Codes that comes with the machine. Page 8528 Sunroof / Moonroof Limit Switch: Testing and Inspection Limit Switch Test 1. Remove the headliner. 2. Disconnect the 4P connector from the moonroof limit switch. 3. Check for continuity between the terminals in each switch position according to the table. NOTE: Turn the motor by hand with the wrench. 4. If the continuity is not as specified, replace the moonroof limit switch. Page 4133 Pressure Regulating Solenoid: Testing and Inspection A/T Clutch Pressure Control Solenoid Valves A and B Test 1. Disconnect the connectors from the A/T clutch pressure control solenoid valves A and B. 2. Measure the resistance of the A/T clutch pressure control solenoid valves A and B between the No. 1 and No. 2 terminals of each connector. STANDARD: About 5.0 Ohms 3. If the resistance of either A/T clutch pressure control solenoid is out of standard, replace the A/T clutch pressure control solenoid valves A and B. 4. Connect the No. 1 terminal of the A/T clutch pressure control solenoid valve A (and B) to the battery positive terminal, and connect the No. 2 terminal to the battery negative terminal. A clicking sound should be heard. 5. If no sound is heard, remove the A/T clutch pressure control solenoid valves A and B. 6. Check the fluid passage of the A/T clutch pressure control solenoid valve for dust and dirt. 7. Connect the No. 1 terminal of the A/T clutch pressure control solenoid valves A and B to the battery positive terminal, and connect the No. 2 terminal to the battery negative terminal. Make sure the A/T clutch pressure control solenoid valves A and B move. 8. Disconnect one of the battery terminal and check valve movement. NOTE: You can see valve movement through the fluid passage in the mounting surface of the A/T clutch pressure control solenoid valves A and B body (c). 9. If either valve binds or moves sluggishly, or if the A/T clutch pressure control solenoid does not operate, replace the A/T clutch pressure control solenoid valves A and B. Page 9735 119. Driver's Door (Coupe Except DX, HX) 120. Driver's Door (Sedan Except DX) Page 7051 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, 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 come 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" 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) Airbag Disposal Special Tool Required Deployment tool 07HAZ-SG00500 Before scrapping any airbags, side airbags, seat belt tensioners or seat belt buckle tensioners (including those in a whole vehicle to be scrapped), the airbags, side airbags, seat belt tensioners or seat belt buckle tensioners must be deployed. If the vehicle is still within the warranty period, the Honda District Service Manager must give approval and/or special instruction before deploying the airbags, side airbags, seat belt tensioners or seat belt buckle tensioners. Only after the airbags, side airbags, seat belt tensioners or seat belt buckle tensioners have been deployed (as the result of vehicle collision, for example), can they be scrapped. If the airbags, side airbags, seat belt tensioners and seat belt buckle tensioners appear intact (not deployed), treat them with extreme caution. Follow this procedure. Deploying Airbags In the vehicle If an SRS equipped vehicle is to be entirely scrapped, its airbags, side airbags, seat belt tensioners and seat belt buckle tensioners should be deployed while still in the vehicle. The airbags, side airbags, seat belt tensioners and seat belt buckle tensioners should not be considered as salvageable parts and should never be installed in another vehicle. 1. Turn the ignition switch OFF, then disconnect the battery negative cable, and wait at least 3 minutes. 2. Confirm that each airbag, side airbag, and seat belt tensioner is securely mounted. 3. Confirm that the special tool is functioning properly by following the check procedure on the tool label. Driver's Airbag: Page 5241 Transmission Position Switch/Sensor: Diagnostic Aids General Troubleshooting Information General Troubleshooting Information Tips and Precautions Before Troubleshooting 1. Check applicable fuses in the appropriate fuse/relay box. 2. Check the battery for damage, state of charge, and clean and tight connections. NOTE: 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. Handling Connectors - Make sure the connectors are clean and have no loose wire terminals. - Make sure multiple cavity connectors are packed with dielectric grease (except watertight connectors). - All connectors have push-down release type locks (A). - Some connectors have a clip on their side used to attach them to a mount bracket on the body or on another component. This clip has a pull type lock. - Some mounted connectors cannot be disconnected unless you first release the lock and remove the connector from its mount bracket (A). - Never try to disconnect connectors by pulling on their wires; pull on the connector halves instead. - Always reinstall plastic covers. Under-Dash Fuse/Relay Box Fuse: Application and ID Under-Dash Fuse/Relay Box Under-dash Fuse/Relay Box Page 5026 Shift Interlock Switch: Testing and Inspection Park Pin Switch Test Park Pin Switch Test 1. Remove the center console panel and center console. 2. Disconnect the park pin switch connector (4P). 3. Shift to the P position, then check for continuity between the No. 3 and No. 4 terminals. There should be no continuity. 4. Shift out of the P position, and check for continuity between terminals No. 3 and No. 4. There should be continuity. 5. If the park pin switch is faulty, replace it. Page 6215 - 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. - Refer to the scrapping procedures for disposal of the damaged airbag. 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. 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. Page 6928 brackets. 2. Reinstall the dashboard center lower cover. 3. Reconnect the driver's and front passenger's airbag connectors. 4. Reconnect the side airbag connectors. 5. Reconnect both seat belt tensioner connectors and both seat belt buckle tensioner connectors. 6. Reconnect the battery negative cable. 7. Initialize the OPDS unit. 8. After installing the SRS unit, confirm proper system operation: Turn the ignition switch ON (II); the SRS indicator should come on for about 6 seconds and then go off. Page 2927 goes away with a known-good ECM/PCM, replace the original ECM/PCM. Page 9823 5. Disconnected the 14Pconnecter and, make these in put tests at the connector. Page 937 7. Connect the SCS service connector to the 2P MES (memory erase signal) connector, as shown. Do not use a jumper wire. 8. Turn the ignition switch to ON (II). 9. Watch the SRS indicator. (It comes on for about 6 seconds and then goes off.) Disconnect the SCS service connector from the MES connector within 4 seconds after the indicator goes off. 10. When the SRS indicator comes on again, connect the SCS service connector to the MES connector within 4 seconds after the indicator comes on. 11. When the SRS indicator goes off, disconnect the SCS service connector from the MES connector within 4 seconds. Page 7734 1. Check the depth adjustment of the trunk lid: ^ Refer to page 20-132 of the 2001-04 Civic Service Manual. ^ In ISIS, use the keyword TRUNK ADJUST, and select Trunk Lid Adjustment from the list. 2. Make sure the trunk lid is flush on all sides and corners. ^ If the trunk is misaligned, go to step 3. ^ If the trunk lid is properly aligned on all sides and corners, go to REPAIR PROCEDURE C. 3. Adjust the striker depth position and the trunk lid edge cushions: ^ Refer to page 20-132 of the 2001-04 Civic Service Manual. ^ In ISIS, use the keyword TRUNK ADJUST, and select Trunk Lid Adjustment from the list. 4. Check the trunk operation: ^ If the trunk opens and closes smoothly, return the vehicle to the customer. ^ If the trunk lid is still difficult to close, go to REPAIR PROCEDURE C. REPAIR PROCEDURE C 1. Use a small screwdriver to manually set and release the trunk lid latch. Check the operation of the latch: ^ If the latch is difficult to set or release, go to step 2. ^ If the latch operates properly, go to REPAIR PROCEDURE D. 2. Replace the trunk lid latch: ^ Refer to page 20-157 of the 2001-04 Civic Service Manual. ^ In ISIS, use the keyword LID LATCH, and select Trunk Lid Latch Replacement from the list. 3. Check the trunk operation: ^ If the trunk opens and closes smoothly, return the vehicle to the customer. ^ If the trunk lid is still difficult to close, go to REPAIR PROCEDURE D. REPAIR PROCEDURE D 1. Disconnect the trunk lid opener cable from the trunk lid latch. Check the cable operation: ^ Refer to page 20-157 of the 2001-04 Civic Service Manual. ^ In ISIS, use the keyword LID LATCH, and select Trunk Lid Latch Replacement from the list. 2. Check that there is no friction or binding of the cable by holding the outside casing and pulling back and forth on the inner cable: ^ If the cable is difficult to move or binds, go to step 3. ^ If the cable operates smoothly, go to REPAIR PROCEDURE E. 3. Replace the trunk lid opener cable: ^ Refer to page 20-151 of the 2001-04 Civic Service Manual. ^ In ISIS, use the keyword LID OPEN, and select Trunk Lid Opener/Fuel Fill Door Opener Cable Replacement from the list. 4. Check the trunk operation: Page 2018 15. Check the camshaft pulley marks (A) - If the camshaft pulley marks are also at TDC, go to step 15. - If the camshaft pulley marks are not at TDC, remove the timing belt and repeat steps 2 through 11. 16. Install the upper cover (A), then connect the camshaft position (CMP) (top dead center (TDC)) sensor connector (B), and install the grommet (C). 17. Install the upper bracket (A), then tighten the nuts in the numbered sequence shown. 18. Install the cylinder head cover. Page 9080 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. Below most connector numbers and component names are PHOTO and VIEW numbers. The PHOTO number refers to a photo in the back of the book that shows the connector's location on the car. The VIEW number refers to an illustration in the back of the book that shows the connector terminals, wire colors, connector cavity numbers, and other details. The connector cavity numbering sequence begins at the top left corner of the connector as seen from either of the viewpoints shown on diagram [8] . Except for the DLC (data link 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 C554, for example, means those terminals join in cavity 2 of connector C554. Power Distribution Schematics Power Distribution Schematics Locations SRS Component Location Index Page 7247 1997 Accord SE With Factory-Installed Security System 1997 Accord SE with factory-installed security system Programming the Transmitter NOTES: ^ The system accepts up to three transmitters. The transmitter codes are stored in a stacking-type memory. If a fourth transmitter code is programmed, the code for the first transmitter is erased. ^ Entering the programming mode cancels all learned transmitter codes, so none of the previously programmed transmitters will work. You must reprogram all of the transmitters once you are in the programming mode. ^ You must complete steps 1-6 within 4 seconds of the previous step to keep the system from exiting the programming mode. 1. Turn the ignition switch to ON (II). 2. Press the "Lock" or "Unlock" button on one of the transmitters. (An unprogrammed transmitter can be used for this step.) 3. Turn the ignition switch to LOCK (0). 4. Repeat steps 1, 2, and 3 two more times using the same transmitter used in step 2. 5. Turn the ignition switch to ON (II). 6. Press the "Lock" or "Unlock" button on the same transmitter. Make sure the power door locks cycle to confirm that the system is in programming mode. 7. Within 10 seconds, press the "Lock" or "Unlock" button on each transmitter. Make sure the power door locks cycle after you press each transmitter button to confirm that the system accepted the transmitter's code. 5. Turn the ignition switch to LOCK (0) to exit the programming mode. Ordering a Transmitter Transmitters can be ordered only by authorized Honda dealers. Order them from American Honda using normal parts ordering procedures. Batteries for the Transmitter The battery number is CR2025. Each transmitter uses one battery. 98-02 Accord EX & 00-02 Accord SE 1998-02 Accord EX with factory-installed security system 2000 and 2002 Accord SE with factory-installed security system Page 6021 Wiper/Washer Component Location Index Page 4870 Flat Rate Time: 4.0 hours Failed Part: P/N 24230-PLW-000 H/C 6568653 Defect Code: 042 Contention Code: B07 Template ID: 03-009A (DX, LX, EX) 03-009B (HX) 03-009C (Hybrid) 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. * Remove the transmission. See page 13-4 of the 2001-2003 Civic Service Manual; for the Hybrid, see page 13-18. Then remove the housing. See page 13-16 of the 2001-2003 Civic Service Manual; for the Hybrid, see page 13-32.* 2. * Remove the reverse idler shaft and the reverse idler gear; discard the gear. See page 13-17 (13-32 for Hybrid) of the service manual.* Page 6954 VEHICLES AFFECTED CUSTOMER NOTIFICATION All owners of affected vehicles were mailed a notification of this warranty extension. A example of the customer notification is shown in this service bulletin. CORRECTIVE ACTION Repair the vehicle as indicated by the INSPECTION PROCEDURE. If needed, replace the OPDS unit. In rare cases where an updated OPDS unit was already installed, replace the OPDS sensor. Page 8998 Shift Indicator: Locations Continuously Variable Transmission Component Location Index Specifications Page 6721 Owners of affected vehicles have or will receive a notification of this campaign. An example of the customer notification is at the end of this service bulletin. CORRECTIVE ACTION Install a driver's airbag inflator kit, then return the original, undeployed inflator to its supplier, ideally within 48 hours of the repair. NOTE: If the original, undeployed inflator is not returned, the warranty claim for that vehicle will be charged back to your dealership. PARTS INFORMATION Driver's Airbag Inflator Kit: P/N 04770-S5A-308(*) Includes inflator with wire harness, locknuts (4), felt tape, felt washers (4), Torx bolts (2), and shipping instructions. NOTE: ^ The felt tape and the felt washers are used only on Accords. ^ The inflator kit box must be used to return the old inflator to its supplier. Be careful not to damage the inflator kit box. (*)The kit contains Fed Ex Ground shipping documents and instructions for the airbag inflator. If you are a dealer in Alaska or Hawaii, call the WPI Page 834 3. If there is no continuity between any terminal, remove the transmission range switch cover, and disconnect the connector (A) at the switch (B). 4. Check for continuity between terminals at the switch connector (c). There should be continuity between the terminals listed for each position. In the P position, between terminals: ^ No. 4 and No. 5 ^ No. 4 and No. 6 ^ No. 5 and No. 6 In the R position, between terminals: ^ No. 1 and No. 4 In the N position, between terminals: ^ No. 4 and No. 5 ^ No. 4 and No. 7 ^ No.5 and No.7 In the D position, between terminals: ^ No.2 and No.4 ^ No. 2 and No. 10 ^ No. 4 and No. 10 In the D3 position, between terminals: ^ No. 4 and No. 8 ^ No. 4 and No. 10 ^ No. 8 and No. 10 In the 2 position, between terminals: ^ No.3 and No.4 5. If there is no continuity between any terminals, adjust the transmission range switch installation. If the transmission range switch installation is OK, replace the switch. 6. If the transmission range switch continuity check was OK, replace the faulty transmission range switch harness. Page 2309 DTC P0158 thru P0400 Page 3350 - If fuel runs out of the hoses at either location, replace the fuel tank vapor control valve. - If the fuel does not run out of the hoses, the fuel tank vapor system function is normal. 10. Disconnect the fuel tank vapor quick disconnect from the EVAP canister, then plug the port on the canister. Reapply vacuum (80 pumps). - If the vacuum holds, replace the fuel tank control valve. - If the vacuum does not hold, inspect the EVAP canister vent shut valve O-ring. If the O-ring is OK, replace the EVAP canister and repeat step 4. Locations Brake Fluid Level Sensor/Switch: Locations Gauges Component Location Index (Part 1 Of 4) Page 2349 ECT at 140 °F (60 °C) or higher. Procedure 1. Connect the scan tool to the vehicle's data link connector (DLC), and bring up the tool's generic OBD II mode. 2. Start the engine. 3. Test-drive the vehicle under stop-and-go conditions with short periods of steady cruise. During the drive, decelerate (with the throttle fully closed) for 5 seconds. After about 3.5 miles (5.6 km), the readiness code should switch from incomplete to complete. 4. If the readiness code is still set to incomplete, check for a temporary DTC. If there is no DTC, the enable criteria was probably not met; repeat the procedure. Air/Fuel Ratio (A/F) Sensor Heater Monitor Readiness Code NOTE: All readiness codes are cleared when the battery is disconnected or when the ECM/PCM is cleared with the OBD II scan tool or Honda PGM Tester. Procedure 1. Connect the scan tool to the vehicle's data link connector (DLC), and bring up the tool's generic OBD II mode. 2. Start the engine, and let it idle for 1 minute. The readiness code should switch from incomplete to complete. 3. If the readiness code is still set to incomplete, check for a temporary DTC. If there is no DTC, repeat the procedure. Misfire Monitor and Readiness Code - This readiness code is always set to available because misfiring is continuously monitored. - Monitoring pauses, and the misfire counter resets, if the vehicle is driven over a rough road. - Monitoring also pauses, and the misfire counter holds at its current value, if the throttle position changes more than a predetermined value, or if driving conditions fall outside the range of any related enable criteria. Fuel System Monitor and Readiness Code - This readiness code is always set to available because the fuel system is continuously monitored during closed loop operation. - Monitoring pauses when the catalytic converter, EVAP control system, and A/F sensor monitors are active. - Monitoring also pauses when any related enable criteria are not being met. Monitoring resumes when the enable criteria is again being met. Comprehensive Component Monitor and Readiness Code This readiness code is always set to available because the comprehensive component monitor is continuously running whenever the engine is cranking or running. EGR Monitor and Readiness Code NOTE: - Do not turn the ignition switch off during the procedure. - All readiness Codes are cleared when the battery is disconnected or when the ECM/PCM is cleared with the OBD II scan tool or Honda PGM Tester. Enable Criteria - ECT at 176 °F (80 °C) or higher Procedure 1. Connect the scan tool to the vehicle's data link connector (DLC), and bring up the tool's generic OBD II mode. 2. Start the engine. 3. Drive at a steady speed with the CVT and A/T in D position or M/T in 4th gear, 50 - 62mph (80 - 100 km/h) or above for more than 10 seconds. 4. With the CVT and A/Tin D position or M/T in 4th gear, decelerate from 62 mph (100km/h) or above by completely releasing the throttle for at least 5 seconds. If the engine is stopped during this procedure, go to step 3 and do the procedure again. 5. If the readiness code is still set to incomplete, check for a temporary DTC. If there is no DTC, the enable criteria was probably not met; repeat the procedure. Page 7084 12. On Accords and Pilots, install the new seat-back clips on the seat-back panel. Turn the clips so their retaining tabs are horizontal. 13. On Accords and Pilots, install the seat-back panel. 14. On all models except Accords and Pilots, zip the seat-back cover closed. 15. Initialize the OPDS unit. ^ To initialize with the HDS, go to Initializing the OPDS Unit: HDS Method. ^ To initialize with the SCS service connector, go to Initializing the OPDS Unit: Manual Mode. Initializing the OPDS Unit: HDS Method NOTE: Non-Honda seat covers will interfere with the performance of the OPDS and are not recommended. 1. Adjust the front passenger's seat-back to an upright position, then remove anything on or near the seat. 2. Turn the ignition switch to LOCK (0). 3. Connect the HDS to the vehicle's DLC (data link connector). 4. Turn the ignition switch to ON (II), then turn on the HDS. 5. At the screen prompts, enter the VIN and the odometer reading. Also verify the correct date and time. 6. From the System Selection menu, select SRS. Page 9383 Wires Page 9199 2. Remove the terminal from the female half. 3. Remove the terminal from the male half. 4. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE D: 1. Remove the secondary locks. Diagrams 194. Recirc - A/C - Defogger Switch Assembly Page 5977 234. Under-dash Fuse/Relay Box Part 3 Component Locations Keyless Entry Receiver: Component Locations Relay And Control Unit Locations - Dashboard Page 3980 Shift Interlock Solenoid: Service and Repair Shift Lock Solenoid Replacement 1. Remove the center console panel and center console. 2. Disconnect the shift lock solenoid connector (2P), and remove it from the shift lever bracket base. 3. Push the lock tab (A), pry the shift lock solenoid (B) to clear the projected tips (C) with a screwdriver, and remove the shift lock solenoid. 4. Install the shift lock solenoid plunger (D) and plunger spring (E) in the new shift lock solenoid. 5. Install the shift lock solenoid by aligning the joint (F) of the shift lock solenoid plunger with the tip (G) of the shift lock stop. 6. Connect the shift lock solenoid connector, and install it on the shift lever bracket base. 7. Install the center console and console panel. Service and Repair Oil Filter: Service and Repair Engine Oil Filter Replacement Special Tools Required ^ Oil filter wrench 07HAA-PJ70100 3/4-turn type 1. Remove the oil filter with the special oil filter wrench. 2. Inspect the threads (A) and rubber seal (B) on the new filter. Wipe off the seat on the engine block, then apply a light coat of oil to the filter rubber seal. Use only filters with a built-in bypass system. 3. Install the oil filter by hand. 4. After the rubber seal seats, tighten the oil filter clockwise with the special tool. Tighten:3/4 turn clockwise. Tightening torque: 12 Nm (1.2 kgf-cm, 8.7 ft. lbs.) Page 9066 29. Back-up Light Switch (M/T) Specifications Oil Pan: Specifications Aluminum Oil Pan Tighten the bolts in two or three steps. In the final step, tighten all bolts, in sequence to 12 Nm (1.2 kgf-cm, 8.7 ft. lbs.). Note: After assembly, wait at least 30 minutes before filling the engine with oil. Steel Oil Pan Tighten the bolts and nuts finger tight at six points as shown. Tighten all bolts and nuts, starting from nut (1), clockwise in 3 steps. In the final step, tighten all bolts, in sequence to 12 Nm (1.2 kgf-cm, 8.7 ft. lbs.). Note: After assembly, wait at least 30 minutes before filling the engine with oil. Page 3837 8. Inspect the quality of the wire crimp. If it has any of the following NO GOOD crimps, cut it off and start over. 9. Insert the terminal into the connector. Make sure the wire seals are pushed all the way into the connector. Lightly pull on the wires to make sure the terminal is locked into place. 10. Close or insert the secondary terminal lock, if applicable, and reconnect the connector. How to Install Pigtail Terminals HOW TO INSTALL PIGTAIL TERMINALS Pigtail terminals (short pieces of wire with a factory crimped terminal) are used when the wire is too short or when access to the connector is too restricted to make a terminal repair. NOTE: To replace just a connector terminal, go to How to Replace Connector Terminals. IMPORTANT SAFETY INFORMATION: On some models, the SRS wires are in a separate harness. If the SRS harness is damaged, replace the harness; do not repair it. On other models, wire harnesses include yellow SRS wires. If any SRS wire is damaged, replace the entire harness; do not repair it. 1. Remove the damaged or faulty terminal from the connector. Use the proper removal tool from Pin Tool Set. Page 9126 Terminals - "T" Shielding Switches Fuses Page 3146 2. Remove the terminal from the female half. 3. Remove the terminal from the male half. 4. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE D: 1. Remove the secondary locks. Page 7205 Page 9474 Blower Motor Relay Type 1, Type 2 Check for continuity between the terminals. - There should be continuity between the No.1 and No.3 terminals when power and ground are connected to the No.2 and No.4 terminals. - There should be no continuity between the No.1 and No.3 terminals when power is disconnected. Five-terminal type Check for continuity between the terminals. - There should be continuity between the No.1 and No.2 terminals when power and ground are connected to the No.3 and No.5 terminals. - There should be continuity between the No.1 and No.4 terminals when power is disconnected. Page 7012 10. Install the belt in the reverse order of removal, and note these items: - Apply liquid thread lock to the anchor bolts before reinstallation. - Check that the retractor locking mechanism functions. - Assemble the washers, collars, and bushing on the upper and lower anchor bolts as shown. - If the seat belt tensioner has been deployed, replace the front seat belt protector with a new one. - Before installing the anchor bolts, make sure there are no twists or kinks in the front seat belt. - Make sure the seat belt tensioner connector is plugged in properly. - Reconnect the negative cable to the battery. - Enter the anti-theft code for the radio, then enter the customer's radio station presets. - Reset the clock. - Do the ECM idle learn procedure. Front Seat Belt-4-door 1. Make sure you have the anti-theft code for the radio, then write down the frequencies for the preset buttons. 2. Disconnect the negative cable from the battery, and wait at least 3 minutes before beginning work. 3. Slide the front seat forward fully. Page 3305 Catalytic Converter: Description and Operation Catalytic Converter System NOX Adsorptive Three Way Catalyst (NOX Adsorptive TWC) (D17A6 engine) The NOx adsorptive TWC absorbs NOx created during lean burn running when the oxygen concentration is high. Then the engine is put into a richer running mode where the oxygen concentration and NOx levels are low, and the absorbed NOx is released, keeping the average NOx emissions low. Three Way Catalytic Converter (TWC) The TWC converts hydrocarbons (HC), carbon monoxide (CO), and oxides of nitrogen (NOx) in the exhaust gas to carbon dioxide (CO2), dinitrogen (N2), and water vapor. Page 9860 12. With a sponge, apply a light coat of glass primer to the inside face of the quarter glass (A) as shown, then lightly wipe it off with gauze or cheesecloth: Do not apply body primer to the quarter glass, and do not get body and glass primer sponges mixed up. - Never touch the primed surfaces with your hands. If you do the adhesive may not bond to the quarter glass properly, causing a leak after the quarter glass is installed. - Keep water, dust, and abrasive materials away from the primed surfaces. 13. With a sponge, carefully apply a light coat of body primer to any exposed paint or metal around the flange where new adhesive will be applied. Let the primer dry for at least 10 minutes: Do NOT apply body primer to any remaining original adhesive on the flange. - Be careful not to mix up the body and glass primer sponges. - Never touch the primed surfaces with your hands. 14. Cut a "V" in the end of the nozzle (A) on the adhesive cartridge as shown. Page 6960 7. From the Mode menu, select Miscellaneous Test. 8. From the Miscellaneous Test menu, select OPDS Initialization. 9. Follow the remaining screen prompts to complete the OPDS initialization. If the initialization fails repeat the process two more times. If the initialization fails again, check for SRS DTCs, then troubleshoot them using the appropriate service manual. Initializing the OPDS Unit: Manual Mode NOTE: Non-Honda seat covers will interfere with the performance of the OPDS and are not recommended. 1. Adjust the front passenger's seat-back to an upright position, then remove anything on or near the seat. 2. Turn the ignition switch to LOCK (0). 3. Connect the HDS to the vehicle's DLC (data link connector). 4. Keep the ignition switch at LOCK (0), and turn on the HDS. 5. At the screen prompts, enter the VIN and the odometer reading. 6. From the Select Mode screen, select SCS, and follow the screen prompts. Page 8581 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. Obtain the customer's key code from the iN (Key Code Inquiry). Refer to the Honda High Security key Codes book that comes with the Matrix H key cutting machine. Write down the applicable cutting code for the key code number. Make sure the corrections to the code book listed in Service Bulletin 01-077, Cutting Sidewinder-Type keys With the Matrix H key Cutting Machine, have been made. 2. Use the chart shown to write down the numbers found in the key code book. 3. Remove the door panel. Refer to the appropriate service manual or use ISIS keyword Door Panel. 4. Remove the plastic cover as necessary. 5. Raise the window glass fully. 6. Remove the lock cylinder. ^ For Civic, go to step 7. ^ For CR-V, go to step 8. ^ For Element, go to step 11. 7. Pull down on the retainer clip with a hook-shaped tool. Remove the lock cylinder and disconnect the cylinder rod. Then go to step 14. Diagrams 194. Recirc - A/C - Defogger Switch Assembly Page 9328 Diagram 115-5 (Sedan EX) Diagrams: Other diagrams referred to by number (See Diagram ##-#, etc.)within these diagrams can be found at Diagrams by Number. See: Diagrams/Electrical Diagrams/Diagrams By Number Locations: Location photographs (references to PHOTOS) referred to within these diagrams can be found at Locations by Photo Number. See: Locations/Component Locations/Locations By Photo Number Connector Views: Connector terminal views (references to VIEWS) referred to within these diagrams can be found at Connector Views by View Number. See: Diagrams/Connector Views/Connector Views By View Number Page 3027 Crankshaft Position Sensor: Service and Repair CKP Sensor Replacement 1. Remove the grommet (A) from the upper cover, and disconnect the camshaft position (CMP) (top dead center (TDC)) sensor connector (B). 2. Remove the upper cover (C) and lower cover (D). 3. Disconnect the crankshaft position (CKP) sensor connector, then remove the CKP sensor from the oil pump. 4. Install the CKP sensor in reverse order of removal. Page 879 104. CKP Sensor Page 8215 ^ If the trunk opens and closes smoothly, return the vehicle to the customer. ^ If the trunk lid is still difficult to close, go to REPAIR PROCEDURE E. REPAIR PROCEDURE E 1. Look at the back of the lock cylinder while you turn the key from lock to unlock. ^ Refer to page 20-158 of the 2001-04 Civic Service Manual. ^ In ISIS, use the keyword LID LOCK, and select Trunk Lid Lock Cylinder Replacement from the list. 2. Check the operation of the trunk lid lock cylinder: ^ If the lock cylinder is difficult to turn or binds, go to step 3. ^ If the lock cylinder operates properly, and the trunk lid is still difficult to close, refer to the appropriate body repair manual, and check for body inaccuracies. 3. Replace the lock cylinder, and re-key the cylinder to the customer's original key; on 2-door Civics, replace the lock cylinder and the lock cylinder rod: ^ Refer to page 20-158 of the 2001-04 Civic Service Manual. ^ In ISIS, use the keyword LID LOCK, and select Trunk Lid Lock Cylinder Replacement from the list. 4. Check the trunk operation, and return the vehicle to the customer. Disclaimer Page 2870 Main Relay (Computer/Fuel System): Testing and Inspection Power Relay Test Use this chart to identify the type of relay, then do the test listed for it. NOTE: See the turn signal/hazard relay input test. Normally-open type A: Page 5876 Relay And Control Unit Locations - Engine Compartment Page 1791 4. With the embossed mark facing up, place the piston assembly (A) on the special tool (B). Be sure you position the recessed flat on the piston against the lugs on the base attachment. 5. Press the pin (C) out with the pin driver (D), pilot collar (E) and a hydraulic press. Inspection 1. Measure the diameter of the piston pin. Piston Pin Diameter Standard (New): 18.996 - 19.000 mm (0.7479 - 0.7480 inch) 2. Zero the dial indicator to the piston pin diameter. Page 697 159. Left Side Of Engine Compartment Page 9155 Courtesy Lamp: Electrical Diagrams Interior Lights - Circuit Diagram With Moonroof Part 1 Page 2945 DTC P0401 thru P0562 Page 9187 Power Distribution schematics show how power is supplied from the positive battery terminal to various circuits in the vehicle. Refer to the Power Distribution diagram set to get a more detailed understanding of how picture is supplied to the circuit you're working on. Individual circuit schematics begin with a fuse. So 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 Ground Distribution Schematics This sample Ground Distribution schematic shows all of the components that share the same ground point. Page 457 Doors - Component Location Index - 4-door Front Door Component Locations SRS Component Location Index Page 3574 Knock Sensor: Service and Repair Replacement 1. Remove the oil filter with the special oil filter wrench. 2. Disconnect the knock sensor connector, then remove the knock sensor. 3. Install the knock sensor and oil filter. Page 5220 Shift Interlock Switch: Testing and Inspection Park Pin Switch Test 1. Remove the center console panel and center console. 2. Disconnect the park pin switch connector (4P). 3. Shift to the P position, then check for continuity between the No. 3 and No. 4 terminals. There should be no continuity. 4. Shift out of the P position, and check for continuity between terminals No. 3 and No. 4. There should be continuity. 5. If the park pin switch is faulty, replace it. Page 9505 1. Remove the terminal. 2. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE G: 1. Remove the terminal. 2. Go to HOW TO INSTALL NEW TERMINALS. How to Install New Terminals HOW TO INSTALL NEW TERMINALS 1. Carefully match the old terminal with a new one from the terminal repair kit. Choose the correct replacement terminal based on the wire size range the terminal will accommodate. NOTE: If the replacement terminal quantities are low, reorder them by using the terminal part number listed on the inside lid of the terminal repair kit. Replacement terminals are available through your parts department using normal parts ordering procedures. 2. Depending on the size of the wire you are repairing, use the proper size slot in the crimping tool. Page 8818 4. Remove the three mounting screws from the gauge assembly, and gently pull it away from the dashboard. Unplug the blue and green 22P connectors from the top of the assembly, then remove the gauge assembly. 5. Install the appropriate new gauge assembly listed under PARTS INFORMATION. NOTE: ^ Laws governing odometer repair, replacement, or servicing may vary from state to state. Questions concerning state law should be directed to your applicable state agency, DMV office, or an attorney. ^ Refer to the Honda Service Operations Manual (Section 2.24) for warranty policies and procedures regarding odometer servicing and replacement. 6. Reinstall all removed parts. Disclaimer Page 9125 Splices Components Ground - "G" Page 911 Impact Sensor: Diagrams 54. Impact Sensor, Left Front 55. Impact Sensor, Right Front 77. Side Impact Sensor, Driver's Page 3814 Diodes Light Emitting Diode (LED) Motor Pressure Sensor Page 1875 8. Tighten each bolt two turns at a time, in the sequence shown below, to ensure that the rockers do not bind on the valves. Specified torque 8 mm bolts: 20 Nm (2.0 kgf-cm, 14 ft. lbs.) Apply engine oil to the bolt threads. 6 mm bolts: 12 Nm (1.2 kgf-cm, 8.7 ft. lbs.) Apply engine oil to the bolt threads. 6 mm bolts: (11), (12), (13), (14) 9. Align the marks (A) on the new cylinder head plug (B) with the top edge of the head, then install the cylinder head plug in the cylinder head. Description and Operation Brake Signal: Description and Operation Brake Pedal Position Switch The brake pedal position switch signals the ECM/PCM when the brake pedal is pressed. Page 8670 64. Under Left Side Of Dash (M/T) Page 237 Relay Box: Connector Locations Under-dash Fuse/Relay Box Page 1141 Transmission Speed Sensor: Service and Repair Speed Sensors Replacement 1. Disconnect connectors from the drive pulley speed sensor (A), driven pulley speed sensor (B), CVT speed sensor (C), and CVT speed sensor 2 (D). 2. Remove the 6 mm bolts, then remove the speed sensors. Remove the sensor washer (E) from the vehicle speed sensor (C). 3. Replace the O-rings (F) with new ones before installing the speed sensors. 4. Install the sensor washer on the CVT speed sensor 2, and install them. 5. Install the drive pulley speed sensor, driven pulley speed sensor, and CVT speed sensor. 6. Check the speed sensor connectors for rust, dirt, or oil, then connect the connectors securely. Page 1603 41. Check for continuity between PGM-FI main relay 1 4P connector terminal No.3 and ECM/PCM connector terminal E7. Is there continuity? YES - Test PGM-FI main relay 1. If the relay is OK, update the ECM/PCM if it does not have the latest software, or substitute a known good ECM/PCM, then recheck. If the symptom/indication goes away with a known-good ECM/PCM, replace the original ECM/PCM. NO - Repair open in the wire between PGM-FI main relay 1 and the ECM/PCM (E7). 42. Reconnect ECM/PCM connector E (31P). 43. Turn the ignition switch ON (II). 44. Measure voltage between body ground and ECM/PCM connector terminals A2 and A3 individually. Is there battery voltage? YES - Go to step 51. NO - Go to step 45. 45. Turn the ignition switch OFF. 46. Remove PGM-FI main relay 1 (A). 47. Turn the ignition switch ON (II). Page 7089 Page 5741 1. Remove the terminal. 2. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE E: 1. Remove the terminal. 2. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE F: Automatic Transmission Shift Indicator: Locations Automatic Transmission Component Location Index Page 7512 installation, then tighten the handle bolts. - Install the lock cylinder retaining clip on the handle, then install the lock cylinder in the door. Be sure the clip is fully seated in the slot on the lock cylinder. - When reinstalling the door panel, make sure the plastic cover is installed properly and sealed around its outside perimeter to seal out water. Page 2854 3. Operate the switches listed. If the circuit is ok, the spotlight and ceiling lights will blink once. If the circuit is faulty, the lights will not blink. Tip: Operate the switches most closely related to the problem you are diagnosing is a quick way of testing the circuits integrity. 4. If all inputs were confirmed, or multiple circuits failed at the same time in mode 2, go to the multiplex sleep mode test. If a single switch fails in mode 2, troubleshoot its circuit. Multiplex Sleep Mode Test 1. Connect the positive lead of a voltmeter to terminal 10 of the under-dash fuse/relay box connector E (YEL) or K (WHT/GRN) and the negative lead to body ground. 2. Connect ammeter between the negative battery cable and the negative battery post. 3. Remove the special tool from the multiplex inspection connector. 4. Close the doors, the hatch, turn the headlights off, turn off the ignition switch and remove the key. 5. Within 1 minute the voltage on the communication wire (E10 or K10) should change from approx 4 - 10 V to battery voltage and the amperage at the negative battery terminal should drop from approx. 70 - 80 mA to less than 10 mA. 6. Record your findings and go to the Multiplex Wake-up Test. Multiplex Wake-up Test 1. From the sleep mode. Wake-up the multiplex system by performing one of the following operations: 2. As the system shifts to its active (wake-up) mode, communication wire voltage will return to 4 - 10 V and the battery terminal current will return to 70 - 80 mA. 3. If the system does not go into sleep mode or wake-up properly, perform the Multiplex Control Unit Input Test. NOTE: If multiple circuits fail to respond in the mode 2 tests and/or the multiplex circuit fails to go into sleep mode or wake-up, it may mean that a control unit failed without triggering a DTC in mode 1. Perform the Multiplex Control Unit Input Test. If the input test confirms that all the inputs are working properly, substitute a known-good multiplex control unit, gauge assembly or ECM one at a time. If after swapping one of the above components the system works properly, replace the original component, it is faulty. Page 91 Air Conditioning Component Location Index Page 9343 Splices Components Ground - "G" Page 548 33. Clutch Pedal Position Switch (M/T) Testing and Inspection Wheels: Testing and Inspection Wheel Runout Inspection 1. Raise the vehicle, and support it with safety stands in the proper locations. 2. Check for a bent or deformed wheel. 3. Set up the dial gauge as shown, and measure the axial runout by turning the wheel. Front and Rear Wheel axial runout: Standard: Aluminum Wheel: 0 - 0.7 mm (0 - 0.03 inch) Steel Wheel: 0 - 1.0 mm (0 - 0.04 inch) Service limit: 2.0 mm (0.08 inch) 4. Reset the dial gauge to the position shown, and measure the radial runout. Front and Rear Wheel radial runout: Standard: Aluminum Wheel: 0 - 0.7 mm (0 - 0.03 inch) Steel Wheel: 0 - 1.0 mm (0 - 0.04 inch) Service limit: 1.5 mm (0.06 inch) 5. If the wheel runout is not within the specification, cheek the wheel bearing end play. 6. If the bearing end play is within the specification but the wheel runout is more than the service limit, replace the wheel. Page 9324 Diagram 115-1 (except EX) Page 3484 166. PGM-FI Main Relays 1 And 2 Page 293 ECM/PCM Inputs And Outputs At Connector E (31P) Page 9332 173. Ignition Key Swithc/key Light Page 5329 Electronic Brake Control Module: Service and Repair ABS Modulator-Control Unit Removal and Installation NOTE: ^ Do not spill brake fluid on the vehicle; it may damage the paint; if brake fluid gets on the paint, wash it off immediately with water. ^ Be careful not to damage or deform the brake lines during removal and installation. ^ To prevent the brake fluid from flowing, plug and cover the hose ends and joints with a shop towel or equivalent material. Removal 1. Pull up the lock (C) of the ABS control unit 31P connector (B), then disconnect the connector. 2. Disconnect the six brake lines. 3. Remove the two 8 mm nuts. 4. Remove the ABS modulator-control unit (A). Installation 1. Install the ABS modulator-control unit, then tighten the two 8 mm nuts. 2. Align the connecting surface of the ABS control unit 31P connector. 3. Push in the lock of the ABS control unit 31P connector until you hear it click into place, then connect the connector. 4. Bleed the brake system, starting with the front wheels. 5. Start the engine, and check that the ABS indicator goes off. 6. Test-drive the vehicle, and check that the ABS indicator does not come on. Page 9079 Circuit Schematics Each schematic represents one circuit. A circuit's wires and components are arranged to show current flow from power at the top of the diagram 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 Page 3925 NOTE: Update the systems one at a time. 7. Verify that the Program ID and the Program Part No. are for the vehicle you are updating, then click on the check mark. 8. Confirm the control module update by Program ID and Program Part No. Make sure this corresponds with any information provided in the service bulletin for the update you are doing. Click on Yes to continue. Within a few seconds, the CM Update sofiware loads the program file onto the HIM. Page 333 PGM-F1 Main Relay 1, 2 Type 1, 2 Check for continuity between the terminals. - There should be continuity between the No.1 and No.2 terminals when power and ground are connected to the No.3 and No.4 terminals. - There should be no continuity between the No.1 and No.2 terminals when power is disconnected. Normally-open type B: Rear Window Defogger Relay Page 4472 ^ If the noise is still present, look for other causes. 7. Test-drive the vehicle to check for proper clutch operation. Disclaimer Page 6471 Blower Motor: Description and Operation How the Circuit Works The heater control panel controls the blower controls, air delivery, and A/C compressor controls automatically. With the ignition switch in ON (II), battery voltage is supplied through fuse 14. The control unit is grounded at G502. Blower Controls You can manually select the fan speed by turning the fan control dial clockwise, from the OFF position. Turning the dial further clockwise increases the fan's speed, which increases air flow. Battery voltage is applied through fuse 14 to the blower motor relay contacts at all times. With the ignition switch ON (II), the blower motor relay in the under-hood fuse/relay box is energized which feeds battery voltage to the blower motor. The blower power transistor controls the blower motor in all speeds except HIGH. The blower power transistor is controlled by the heater control panel. When the control panel requests HIGH blower speed, the blower power transistor grounds the blower motor which connects it directly to ground, making the blower run at high speed. Page 9412 8. Put the splice connector in the proper size slot in the Crimper Tool, slide it to one end (where the flare begins), and close the crimper handles far enough to hold it in place. To release the ratchet mechanism at any point after the first click, squeeze the handles slightly and push the release lever, then let the handles open. 9. Insert one of the bare wires into the splice connector end that is in the crimper jaws. Push the wire all the way into the splice connector, and squeeze the crimper handles. Keep squeezing until the jaws touch, and hold it at that position until the ratchet clicks again. 10. Crimp the other wire in the same way into the other end of the splice connector. 11. After crimping, gently pull on the wires in the opposite directions to make sure they are secure in the connector. 12. Separate the other wires in the harness from the repaired wire(s), and shield them with nonflammable material. Page 852 8. Connect the GRN test harness clip (D) to the positive probe of a voltmeter. Is there 5 V or more? YES - Go to step 9. NO - Repair short or open in the BLU/WHT or WHT/GRN wire between the VSS and the cruise control unit, or the ECM/PCM. 9. Turn the ignition switch OFF. 10. Connect the other test harness connector (A) to the VSS(B). 11. Raise the front of the vehicle, and make sure it is securely supported. 12. Put the vehicle in neutral with the ignition switch ON (II). 13. Slowly rotate one wheel with the other wheel blocked. Does voltage pulse from 0 to about 5 V or more? YES - Go to step 14. NO - Replace the VSS. Page 2835 1. Remove the terminal. 2. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE B: 1. Remove the terminal. 2. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE C: 1. Remove the terminal. 2. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE D: Page 4431 4. Apply super high temp urea grease (P/N 08798-9002) to the release fork (A), the release fork bolt (B), the release bearing (C), and the release bearing guide (D) in the shaded areas. 5. With the release fork slid between the release bearing pawls, install the release bearing on the mainshaft while inserting the release fork through the hole in the clutch housing. 6. Align the detent of the release fork with the release fork bolt, then press the release fork over the release fork bolt squarely. 7. Install the release fork boot (E), make sure the boot seals around the release fork and clutch housing. 8. Move the release fork (A) right and left to make sure that it fits properly against the release bearing (B), and that the release bearing slides smoothly. Page 6157 symptom/indication goes away with a known-good ECM/PCM, replace the original ECM/PCM. 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. Locations Under-dash Fuse/Relay Box Page 6629 Compressor Clutch Relay: Description and Operation Air Conditioning (A/C) Compressor Clutch Relay When the ECM/PCM receives a demand for cooling from the A/C system, it delays the compressor from being energized, and enriches the mixture to assure smooth transition to the A/C mode. Page 7281 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. Test Equipment 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. Locations Intake Air System - Component Location Index Diagrams (Honda Accessory) Page 2548 3. If there is no continuity between any terminal, remove the transmission range switch cover, and disconnect the connector (A) at the switch (B). 4. Check for continuity between terminals at the switch connector (c). There should be continuity between the terminals listed for each position. In the P position, between terminals: ^ No. 4 and No. 5 ^ No. 4 and No. 6 ^ No. 5 and No. 6 In the R position, between terminals: ^ No. 1 and No. 4 In the N position, between terminals: ^ No. 4 and No. 5 ^ No. 4 and No. 7 ^ No.5 and No.7 In the D position, between terminals: ^ No.2 and No.4 ^ No. 2 and No. 10 ^ No. 4 and No. 10 In the D3 position, between terminals: ^ No. 4 and No. 8 ^ No. 4 and No. 10 ^ No. 8 and No. 10 In the 2 position, between terminals: ^ No.3 and No.4 5. If there is no continuity between any terminals, adjust the transmission range switch installation. If the transmission range switch installation is OK, replace the switch. 6. If the transmission range switch continuity check was OK, replace the faulty transmission range switch harness. Page 4925 7. Apply a small amount of Permalube grease to the base of the new lever. Then attach the slide hammer to the new lever pin, insert the lever into the ignition switch, and seat the pin with the slide hammer. 8. Check the installed height of the pin with vernier calipers. If the height is more than 5.0 mm, the pin is not seated. If needed, reattach the slide hammer, and seat the pin. NOTE: It's normal for the interlock lever to be loose, even when the pin is fully seated. 9. Install a new spring on the lever. Make sure you attach the ends of the spring correctly: ^ The right end goes into the slot on the ignition switch. Page 7243 2003-04 Accord DX with dealer-installed security system 2003-04 Element with dealer-installed keyless entry system or security system 2004 Element EX with factory-installed keyless entry system or dealer-installed security system 2003-04 Pilot EX models with factory-installed security system* Programming the Transmitter NOTES: ^ The system accepts up to three transmitters. The transmitter codes are stored in a stacking-type memory. If a fourth transmitter code is programmed, the code for the first transmitter is erased. ^ Entering the programming mode cancels all learned transmitter codes, so none of the previously programmed transmitters will work. You must reprogram all of the transmitters once you are in the programming mode. ^ You must complete steps 1-6 within 4 seconds of the previous step to keep the system from exiting the programming mode. 1. Turn the ignition switch to ON (II). 2. Press the "Lock" or "Unlock" button on one of the transmitters. (An unprogrammed transmitter can be used for this step.) 3. Turn the ignition switch to LOCK (0). 4. Repeat steps 1, 2, and 3 two more times using the same transmitter used in step 2. 5. Turn the ignition switch to ON (II). 6. Press the "Lock" or "Unlock" button on the same transmitter. Make sure the power door locks cycle to confirm that the system is in programming mode. 7. Within 10 seconds, press the "Lock" or "Unlock" button on each transmitter. Make sure the power door locks cycle after you press each transmitter button to confirm that the system accepted the transmitter's code. 8. Turn the ignition switch to LOCK (0) to exit the programming mode. Ordering a Transmitter Transmitters can be ordered only by authorized Honda dealers. Order them from American Honda using normal parts ordering procedures. Batteries for the Transmitter The battery number is CR2025. Each transmitter uses one battery. 91-93 Accord 5-D00R EX Service and Repair Parking Light Bulb: Service and Repair Front Turn Signal / Side Marker Lights: Parking Light: 1. Remove the inner fender. 2. Disconnect the connectors (A) from the lights. 3. Turn the bulb sockets (B) 45 ° counterclockwise to remove them from the headlight housing. 4. Install the new bulb(s) in the reverse order of removal. Page 3422 - replacing the fuel filter. - replacing the fuel pressure regulator. - replacing the fuel gauge sending unit. - removing the retainer from the line. 3. Before connecting a new fuel line/quick-connect fitting assembly (A), remove the old retainer from the mating line. Page 7790 3. Use the clamp carriage lever to position the clamp unit so the tracer is directly over the flat surface of the code device, just ahead of the cam blades. 4. Pull the vertical carriage lever toward you until the tracer just touches the flat surface ahead of the cam blades. Watch the arrows on the keypad: ^ If the double-headed arrow in the middle of the keypad lights green, the tracer and cutter bit are properly aligned. ^ If the arrow on the left of the keypad lights red, the cutter bit is not touching the jaw. Turn the micrometric ring nut above the tracer to the left until the double-headed arrow lights green. ^ If the vertical arrow on the right of the keypad lights red, the tracer is not touching the jaw. Turn the micrometric ring nut above the tracer to the right until the double-headed arrow lights green. *5. Turn the micrometric ring nut to the right five clicks so the cutter bit is slightly higher than the tracer. The arrow on the left should light red. Raise the vertical carriage. NOTE: Setting the tracer five clicks lower than the cutter bit at this point has the effect of making the cutter bit cut the duplicated key a little shallower. This will protect the locking jaws from being damaged.* 6. Optional: Loosen the set screw, and adjust the hand rest to a comfortable position. Tighten the screw. 7. Pull the clamp carriage lever toward you until the clamp carriage clicks into its end-of-run position. 8. Clean any metal shavings or debris out of the center jaw. (A soft-bristle toothbrush is ideal for this purpose.) Then open the jaws with the jaws knob, and slide the key blank with its flat side down into the jaw up to the key stop. Close the jaw with the jaws knob to lock the key blank into place. Visually inspect the key for proper alignment in the jaw. 9. Set and lock the cam sets on the code device. ^ Starting with the left cam set, make sure the lock pin is pulled all the way out. (This releases the cams.) Specifications Fuel Pressure: Specifications Fuel Pressure at idle .................................................................................................................................... 270 - 320 kPa (2.8 - 3.3 kgf/sq.cm, 40 - 47 psi) Page 371 12. Watch the SRS indicator: ^ If the indicator blinks twice and then goes off, the OPDS unit is initialized. Turn the ignition switch to LOCK (0), and disconnect the HDS. ^ If the indicator blinks twice and then stays on, the OPDS unit is initialized, but SRS DTCs need to be cleared. Go to step 13. ^ If the indicator stays on without first blinking, the OPDS unit is not initialized. Repeat steps 3 thru 12. 13. Turn the ignition switch to LOCK (0), then disconnect the HDS. 14. Reconnect the SCS service connector to the MES connector. Do not use a jumper wire. 15. Turn the ignition switch to ON (II). 16. Watch the SRS indicator. (It comes on for about 6 seconds and then goes off.) Disconnect the SCS service connector from the MES connector within 4 seconds after the indicator goes off. 17. When the SRS indicator comes on again, connect the SCS service connector to the MES connector within 4 seconds after the indicator comes on. 18. When the SRS indicator goes off, disconnect the SCS service connector from the MES connector within 4 seconds. (The SRS indicator blinks twice to indicate that the memory has been cleared.) 19. Turn the ignition switch to LOCK (0), and wait for 10 seconds. 20. Turn the ignition switch to ON (II). (The SRS is OK if the SRS indicator comes on for 6 seconds and then goes off.) If the DTC clearing fails, repeat the process two more times. If the DTC clearing fails again, check for set SRS DTCs, and troubleshoot them with the appropriate service manual. REPAIR PROCEDURE B: OPDS SENSOR REPLACEMENT 1. Remove the seat-back cover from the front passenger's seat: ^ Using the appropriate service manual, go to section 20 (Body), and do the removal steps under Front Seat Cover Replacement, or ^ Online, enter keyword SEAT COVER, then select Front Seat Cover Replacement from the list, and do the removal steps in the procedure. 2. Slide the seat-back cushion (foam) off the seat-back frame. (The OPDS sensor is built into the seat-back cushion.) 3. Slide a new seat-back cushion over the seat-back frame. Make sure the cushion is centered. 4. Install the seat-back cover: ^ Using the appropriate service manual, go to section 20 (Body), and do the installation step under Front Seat Cover Replacement, or ^ Online, enter keyword SEAT COVER, then select Front Seat Cover Replacement from the list, and do the installation step in the procedure. 5. Initialize the OPDS unit: ^ To initialize with the HDS, go to Initializing the OPDS Unit: HDS Method in this service bulletin. ^ To initialize with the SCS service connector, go to Initializing the OPDS Unit: Manual Mode in this service bulletin. Disclaimer Page 8306 ^ Going from front to back, use the middle lock pin to set the first cam to the appropriate key code number in the code book. (The cam is properly set when the number on the cam lines up with the red scribe mark on the clamp unit.) ^ Slide the lock pin through the notch in the cam. (This locks the cam in place.) ^ Keep doing this for each of the remaining cams in the set until all the cams are set and locked, then push the lock pin all the way in. Repeat this process to set and lock the cams for the right cam set. NOTE: Make sure you set the MIS cam in the right cam set for the type of key you are cutting. For a master key, set the cam to M; for a valet key, set it to S. When you are done, push all the cam blades to the left until they touch the cams in the left cam set. 10. Pull the vertical carriage lever toward you until the tracer touches the flat surface on the right side at the front of the cams. Gently twist the lever clockwise to lock the vertical carriage at this height. Do not overtighten the lever. 11. Turn on the cutter motor with the motor start switch. [NOTICE] ^ To avoid damaging the locking jaws while cutting, keep your hand off the vertical carriage lever. Pressure on the lever will change the cutting depth. * ^ To avoid breaking the cutter bit, never back up while cutting.* ^ Wear proper eye protection (safety glasses, goggles, etc.) 12. Use the clamp carriage lever and the tracer to follow the contours of the cam blades from front to back. (The cutter bit cuts the same contours into the right edge of the key blank, from head to tip.) Page 1065 Resistor Variable Sensor Solenoid Transistors Circuit Schematics Page 8992 13. Parking Brake Switch Page 4941 1. Remove and discard the plastic cover from the ignition switch key interlock solenoid. 2. Note the position of the interlock solenoid plunger; you'll need to install it the same way. 3. Remove the screw from the solenoid, but keep the solenoid attached to its electrical connector. Discard the screw. NOTE: ^ Be careful not to lose the solenoid plunger; it slides out easily. ^ Keep the plunger free of dirt and grease while it's removed from the solenoid. 4. Note the position of the interlock lever spring; you'll need to install the new spring the same way. Page 1745 Splices Components Ground - "G" Page 4470 VEHICLES AFFECTED CORRECTIVE ACTION Replace the master cylinder, and apply a thin film of silicone grease to the clutch line fitting. REQUIRED MATERIALS Silicone Grease: P/N 08C30-B0234M, H/C 6110928 Brake Fluid: P/N 08798-9008, H/C 4423802 PARTS INFORMATION Civic/Civic Hybrid Master Cylinder: P/N 46920-S5A-G04, H/C 7569452 Accord/Civic Si/CR-V/Element Master Cylinder: P/N 46920-57A-A02, H/C 7604507 WARRANTY CLAIM INFORMATION In warranty: The normal warranty applies. Operation Number: 211101 Flat Rate Time: 0.6 hour (All Civics) 0.8 hour (Accord/CR-V/Element) Failed Part: Civic/Civic Hybrid: P/N 46920-55A-G01 H/C 6571103 Accord/Civic Si/CR-V/Element: P/N 46920-S7A-A01 H/C 6729031 Defect Code: 03214 Symptom Code: 04201 Page 625 13. Parking Brake Switch Page 4795 1. Remove the terminal. 2. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE G: 1. Remove the terminal. 2. Go to HOW TO INSTALL NEW TERMINALS. How to Install New Terminals HOW TO INSTALL NEW TERMINALS 1. Carefully match the old terminal with a new one from the terminal repair kit. Choose the correct replacement terminal based on the wire size range the terminal will accommodate. NOTE: If the replacement terminal quantities are low, reorder them by using the terminal part number listed on the inside lid of the terminal repair kit. Replacement terminals are available through your parts department using normal parts ordering procedures. 2. Depending on the size of the wire you are repairing, use the proper size slot in the crimping tool. Page 5963 67. Under Left Side Of Dash Page 4585 Control Module: Service and Repair How to Substitute the PCM How to Substitute the PCM 1. Remove the PCM from the vehicle. 2. Install a known-good PCM in the vehicle. 3. Rewrite the immobilizer code with the PCM replacement procedure in the Honda PGM Tester; It allows you to start the engine. 4. After completing your tests, reinstall the original PCM and rewrite the immobilizer code with the PCM replacement procedure in the HDS Tester again. Page 5728 - Remove clips carefully; don't damage their locks (A). - Slip pliers (A) under the clip base and through the hole at an angle, then squeeze the expansion tabs to release the clip. - After installing harness clips, make sure the harness doesn't interfere with any moving parts. - Keep wire harnesses away from exhaust pipes and other hot parts, from sharp edges of brackets and holes, and from exposed screws and bolts. - Seat grommets in their grooves properly (A). Do not leave grommets distorted (B). Testing and Repairs - Do not use wires or harnesses with broken insulation. Replace them or repair them by wrapping the break with electrical tape. - After installing parts, make sure that no wires are pinched under them. - When using electrical test equipment, follow the manufacturer's instructions and those described. - If possible, insert the probe of the tester from the wire side (except waterproof connector). - Use back probe adaptor 07TAZ-001020A. - Refer to the instructions in the Honda Terminal Kit for identification and replacement of connector terminals. Five-Step Troubleshooting Five-Step Troubleshooting 1. Verify The Complaint Page 6947 12. Watch the SRS indicator: ^ If the indicator blinks twice and then goes off, the OPDS unit is initialized. Turn the ignition switch to LOCK (0), and disconnect the HDS. ^ If the indicator blinks twice and then stays on, the OPDS unit is initialized, but SRS DTCs need to be cleared. Go to step 13. ^ If the indicator stays on without first blinking, the OPDS unit is not initialized. Repeat steps 3 thru 12. 13. Turn the ignition switch to LOCK (0), then disconnect the HDS. 14. Reconnect the SCS service connector to the MES connector. Do not use a jumper wire. 15. Turn the ignition switch to ON (II). 16. Watch the SRS indicator. (It comes on for about 6 seconds and then goes off.) Disconnect the SCS service connector from the MES connector within 4 seconds after the indicator goes off. 17. When the SRS indicator comes on again, connect the SCS service connector to the MES connector within 4 seconds after the indicator comes on. 18. When the SRS indicator goes off, disconnect the SCS service connector from the MES connector within 4 seconds. (The SRS indicator blinks twice to indicate that the memory has been cleared.) 19. Turn the ignition switch to LOCK (0), and wait for 10 seconds. 20. Turn the ignition switch to ON (II). (The SRS is OK if the SRS indicator comes on for 6 seconds and then goes off.) If the DTC clearing fails, repeat the process two more times. If the DTC clearing fails again, check for set SRS DTCs, and troubleshoot them with the appropriate service manual. REPAIR PROCEDURE B: OPDS SENSOR REPLACEMENT 1. Remove the seat-back cover from the front passenger's seat: ^ Using the appropriate service manual, go to section 20 (Body), and do the removal steps under Front Seat Cover Replacement, or ^ Online, enter keyword SEAT COVER, then select Front Seat Cover Replacement from the list, and do the removal steps in the procedure. 2. Slide the seat-back cushion (foam) off the seat-back frame. (The OPDS sensor is built into the seat-back cushion.) 3. Slide a new seat-back cushion over the seat-back frame. Make sure the cushion is centered. 4. Install the seat-back cover: ^ Using the appropriate service manual, go to section 20 (Body), and do the installation step under Front Seat Cover Replacement, or ^ Online, enter keyword SEAT COVER, then select Front Seat Cover Replacement from the list, and do the installation step in the procedure. 5. Initialize the OPDS unit: ^ To initialize with the HDS, go to Initializing the OPDS Unit: HDS Method in this service bulletin. ^ To initialize with the SCS service connector, go to Initializing the OPDS Unit: Manual Mode in this service bulletin. Disclaimer Page 1826 2. Install the crankshaft pulley, and tighten bolt to 200 Nm (148 lb.ft.). Do not use an impact wrench. Hold the pulley with holder handle (A) and holder attachment (B). Tighten the bolt with a torque wrench and 19 mm socket (C). Page 5079 Torque Converter Clutch Solenoid: Testing and Inspection Torque Converter Clutch Solenoid Valve Test 1. Disconnect the torque converter clutch solenoid valve connector. 2. Measure the resistance between the No. 1 and No. 2 terminals of the torque converter solenoid valve connector. STANDARD: 12 - 25 Ohms 3. Replace the torque converter clutch solenoid valve if the resistance is out of standard. 4. If the resistance is within the standard, connect the No. 2 terminal to the battery positive terminal, and connect the No. 1 terminal to the battery negative terminal. A clicking sound should be heard. Replace the torque converter clutch solenoid valve if no sound is heard when connecting the battery positive terminal. Page 7751 Disclaimer Technical Service Bulletin # 02-061 Date: 041105 Body - Trunk Lid Hard to Close 02-061 November 5, 2004 Applies To: See VEHICLES AFFECTED Trunk Lid is Difficult to Close (Supersedes 02-061, dated July 23, 2004) Updated information is shown with asterisks. SYMPTOM The trunk lid may be difficult to close or won't latch closed. PROBABLE CAUSE The trunk lid may be misaligned, and the trunk lid opener cable, trunk lid latch, lock cylinder, lock rod, and/or the trunk lid latch striker may need adjustment or replacement. VEHICLES AFFECTED CORRECTIVE ACTION Adjust the trunk lid and/or the trunk lid latch, or replace components as needed. PARTS INFORMATION Page 4397 195. Tranmission Range Switch Page 3699 Shift Indicator: Diagnostic Aids General Troubleshooting Information General Troubleshooting Information Tips and Precautions Before Troubleshooting 1. Check applicable fuses in the appropriate fuse/relay box. 2. Check the battery for damage, state of charge, and clean and tight connections. NOTE: 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. Handling Connectors - Make sure the connectors are clean and have no loose wire terminals. - Make sure multiple cavity connectors are packed with dielectric grease (except watertight connectors). - All connectors have push-down release type locks (A). - Some connectors have a clip on their side used to attach them to a mount bracket on the body or on another component. This clip has a pull type lock. - Some mounted connectors cannot be disconnected unless you first release the lock and remove the connector from its mount bracket (A). - Never try to disconnect connectors by pulling on their wires; pull on the connector halves instead. - Always reinstall plastic covers. Page 8119 Remote Transmitter Quick Reference Guide 90-93 Accord, 92-93 Civic & Prelude, 93 Del SOL 1990-93 Accord (2-door and 4-door) with dealer-installed security system 1992-93 Civic with dealer-installed security system 1993 del Sol with dealer-installed security system 1992-93 Prelude with dealer-installed security system Programming the Transmitter NOTE: Page 967 64. Under Left Side Of Dash (M/T) Page 7276 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. Below most connector numbers and component names are PHOTO and VIEW numbers. The PHOTO number refers to a photo in the back of the book that shows the connector's location on the car. The VIEW number refers to an illustration in the back of the book that shows the connector terminals, wire colors, connector cavity numbers, and other details. The connector cavity numbering sequence begins at the top left corner of the connector as seen from either of the viewpoints shown on diagram [8] . Except for the DLC (data link 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 C554, for example, means those terminals join in cavity 2 of connector C554. Power Distribution Schematics Power Distribution Schematics 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 1001 symptom/indication goes away with a known-good ECM/PCM, replace the original ECM/PCM. Page 4303 Shift Interlock Switch: Testing and Inspection Park Pin Switch Test 1. Remove the center console panel and center console. 2. Disconnect the park pin switch connector (4P). 3. Shift to the P position, then check for continuity between the No. 3 and No. 4 terminals. There should be no continuity. 4. Shift out of the P position, and check for continuity between terminals No. 3 and No. 4. There should be continuity. 5. If the park pin switch is faulty, replace it. Page 1091 2. Insert the terminal tool into the female terminal, and then remove the terminal tool. NOTE: Make sure you do not select a terminal tool that is larger than the mating male terminal because it would spread the female terminal and cause a loose fit. 3. Compare the drag to the other terminals in the connector. If the drag is less, replace the terminal with a replacement terminal from the appropriate terminal repair kit. Page 4871 3. Remove and discard the shift fork. 4. Apply vinyl tape to the mainshaft splines to protect the seal, then remove the mainshaft and shift forks as an assembly from the clutch housing. 5. Disassemble the countershaft assembly; see page 13-32 (13-45 for Hybrid) of the service manual. Page 3098 Oxygen Sensor: Description and Operation Secondary Heated Oxygen Sensor (Secondary HO2S) Secondary Heated Oxygen Sensor (Secondary HO2S) The secondary HO2S detects the oxygen content in the exhaust gas downstream of the TWC and sends signals to the ECM/PCM which checks the efficiency of the TWC. To stabilize its output, the sensor has an internal heater. The secondary HO2S is installed in the TWC. Page 3263 1. Remove the terminal. 2. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE E: 1. Remove the terminal. 2. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE F: Page 8301 NOTE: You need to make the corrections listed in CODE BOOK CORRECTIONS at the end of this service bulletin. TRACER AND CUTTER BIT INSTALLATION 1. Turn the power switch on the back of the machine to ON. (This turns on the built-in work light.) 2. Use the Allen wrench from the built-in tool drawer to loosen the setscrew on the left sleeve of the vertical carriage. Slide the tracer all the way into the sleeve, and tighten the screw. 3. Turn the plastic shield on the right sleeve of the vertical carriage so you can access the setscrew on the sleeve. Use the Allen wrench to loosen the screw. Slide the cutter bit all the way into the sleeve, and tighten the screw. Turn the plastic shield so the open side is in the back. MACHINE COMPONENTS Adjustments Front Door Striker: Adjustments Front and Rear Door Striker Adjustment Make sure the door latches securely without slamming it. If necessary, adjust the striker (A): The striker nuts are fixed, but the striker can be adjusted slightly up or down, and in or out. 1. Loosen the screws (B), then insert a shop towel (C) between the body and striker. 2. Lightly tighten the screws. 3. Wrap the striker with a shop towel, then adjust the striker by tapping it with a plastic hammer (D). Do not tap the striker too hard. 4. Loosen the screws, and remove the shop towel. 5. Lightly tighten the screws. 6. Hold the outer handle out, and push the door against the body to be sure the striker allows a flush fit. If the door latches properly, tighten the screws and recheck. Page 3162 Transmission Position Switch/Sensor: Service and Repair Transmission Range Switch Replacement 1. Raise the vehicle, and make sure it is securely supported. 2. Shift to the N position. 3. Remove the transmission range switch cover (A). 4. Disconnect the transmission range switch connector (B). 5. Remove the old transmission range switch, and install the new switch. 6. Make sure that the control shaft is in the N position. If necessary, move the shift lever to the N position. Page 2503 48. Middle Of Engine (except GX) 49. Middle Of Engine (GX) Page 4944 ^ The left end goes behind the notch on the interlock lever. ^ Once the spring is correctly installed, make sure the lever moves freely and returns properly. 10. Insert the plunger into the interlock solenoid, then install the solenoid using a new screw. Make sure the groove of the solenoid plunger is in the fork on the lever. 11. Install a new plastic cover on the interlock solenoid. 12. Check the operation of the ignition switch key interlock: ^ Set the parking brake, and turn the ignition switch to ON (I I). ^ While pressing the brake pedal, shift the transmission to Neutral. ^ Try turning the ignition switch to LOCK (0) - If you cannot turn the switch to LOCK (0), your repair was successful; go to step 15. - If you can turn the switch to LOCK (0), the interlock is not working; go to step 13. Page 6744 101. Under Front Passenger's Seat (passenger's similar) Page 2738 ^ Start the engine and let it warm up to its normal operating temperature (the cooling fans cycle twice). ^ Let the engine idle (throttle closed and all electrical items off) for 10 minutes. 17. CR-V only: Reset the power window control unit: ^ Turn the ignition switch to ON (II). ^ Make sure the driver's window is fully closed. ^ Push down and hold the window switch until the window goes all the way down. ^ Pull back and hold the window switch until the window goes all the way up, then hold the switch for at least 2 more seconds. 18. Enter the audio unit anti-theft code, and set the clock. Enter the audio presets. Disclaimer Diagram Information and Instructions Shift Indicator: Diagram Information and Instructions Terminal Numbering System Terminal Numbering System Connector terminals are numbered according to the cavities they're in. The cavities are numbered starting from the upper left, looking at the male terminals from the terminal side or looking at the female terminals from the wire side. Both views are in the same direction so the numbers are the same. All actual cavities are numbered, even if they have no wire terminals in them. NOTE: Data Link Connector (DLC) terminals are numbered according 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 below is #6. Locations 58. Under Left Side Of Dash (Honda Accessory) Page 8877 3. Move the spotlight assembly away from the side that sticks, then tighten the mounting screws. 4. Use a small screwdriver to push back any headliner material that comes through the lens slot. 5. Reinstall the lenses and test the light. ^ If the lens no longer sticks, the repair is complete. ^ If the lens still sticks, remove the spotlight assembly and use a razor blade to trim the headliner material. Disclaimer Page 1581 235. Under-dash Fuse/Relay Box Part 8 Page 5878 Under-hood Fuse/Relay Box (2-door) Page 9803 1. Remove the driver's side grip cover: ^ Using a trim tool, pry out the front edge of the cover to release the front clip. ^ Pry out along the bottom to release the lower hooks. ^ Pry out along the top to release the upper hooks. ^ Pull the cover forward to release the rear clip. 2. Disconnect the power window master switch connector. 3. Remove the two screws that attach the power window switch base to the armrest, then remove the switch base. 4. Remove the three screws, then replace the power window master switch assembly. Page 9203 1. Remove the terminal. 2. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE E: 1. Remove the terminal. 2. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE F: Page 7972 3. Use the clamp carriage lever to position the clamp unit so the tracer is directly over the flat surface of the code device, just ahead of the cam blades. 4. Pull the vertical carriage lever toward you until the tracer just touches the flat surface ahead of the cam blades. Watch the arrows on the keypad: ^ If the double-headed arrow in the middle of the keypad lights green, the tracer and cutter bit are properly aligned. ^ If the arrow on the left of the keypad lights red, the cutter bit is not touching the jaw. Turn the micrometric ring nut above the tracer to the left until the double-headed arrow lights green. ^ If the vertical arrow on the right of the keypad lights red, the tracer is not touching the jaw. Turn the micrometric ring nut above the tracer to the right until the double-headed arrow lights green. *5. Turn the micrometric ring nut to the right five clicks so the cutter bit is slightly higher than the tracer. The arrow on the left should light red. Raise the vertical carriage. NOTE: Setting the tracer five clicks lower than the cutter bit at this point has the effect of making the cutter bit cut the duplicated key a little shallower. This will protect the locking jaws from being damaged.* 6. Optional: Loosen the set screw, and adjust the hand rest to a comfortable position. Tighten the screw. 7. Pull the clamp carriage lever toward you until the clamp carriage clicks into its end-of-run position. 8. Clean any metal shavings or debris out of the center jaw. (A soft-bristle toothbrush is ideal for this purpose.) Then open the jaws with the jaws knob, and slide the key blank with its flat side down into the jaw up to the key stop. Close the jaw with the jaws knob to lock the key blank into place. Visually inspect the key for proper alignment in the jaw. 9. Set and lock the cam sets on the code device. ^ Starting with the left cam set, make sure the lock pin is pulled all the way out. (This releases the cams.) Page 7765 ^ If the trunk opens and closes smoothly, return the vehicle to the customer. ^ If the trunk lid is still difficult to close, go to REPAIR PROCEDURE E. REPAIR PROCEDURE E 1. Look at the back of the lock cylinder while you turn the key from lock to unlock. ^ Refer to page 20-158 of the 2001-04 Civic Service Manual. ^ In ISIS, use the keyword LID LOCK, and select Trunk Lid Lock Cylinder Replacement from the list. 2. Check the operation of the trunk lid lock cylinder: ^ If the lock cylinder is difficult to turn or binds, go to step 3. ^ If the lock cylinder operates properly, and the trunk lid is still difficult to close, refer to the appropriate body repair manual, and check for body inaccuracies. 3. Replace the lock cylinder, and re-key the cylinder to the customer's original key; on 2-door Civics, replace the lock cylinder and the lock cylinder rod: ^ Refer to page 20-158 of the 2001-04 Civic Service Manual. ^ In ISIS, use the keyword LID LOCK, and select Trunk Lid Lock Cylinder Replacement from the list. 4. Check the trunk operation, and return the vehicle to the customer. Disclaimer Connector Views Engine Control Module: Connector Views 228. ECM/PCM Part 1 228. ECM/PCM Part 2 Component Locations Keyless Entry Receiver: Component Locations Relay And Control Unit Locations - Dashboard Page 4826 6. Replace the 1st/2nd synchro hub/sleeve, and reassemble the countershaft; see page 13-34 (13-48 for Hybrid) of the service manual. 7. Check the countershaft clearance; see page 13-30 (13-44 for Hybrid) of the service manual. Page 3143 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. How to Replace Connector Terminals Terminal Replacement Procedure HOW TO REPLACE CONNECTOR TERMINALS The terminal repair kits provide necessary tools and materials (terminals, wire seals, and splice connectors) to repair many damaged or faulty connector terminals. However, not all terminals for all connectors are available. Refer to the labels on the lids of the repair kits for replacement terminal availability. IMPORTANT SAFETY INFORMATION: On some models, the SRS wires are in a separate harness. If the SRS harness is damaged, replace the harness; do not repair it. On other models, wire harnesses include yellow SRS wires. If any SRS wire is damaged, replace the entire harness; do not repair it. Before you begin, inspect the wire you are about to repair for damage and length. Make sure the wire will be long enough to make a terminal repair without stretching it when you reinstall the terminal in the connector. If the wire is too short, or if access to the connector is too restricted to make a terminal repair, you may need to install a pigtail terminal (a short length of wire with a factory-crimped terminal on it). Refer to HOW TO INSTALL PIGTAIL TERMINALS. Removing the Terminal Page 6957 1. On Accords and Pilots, remove the front passenger's seat-back panel by prying out the bottom. Replace the two lower clips. 2. On all models except Accords and Pilots, unzip the two seat cover zippers on the back of the front passenger's seat. 3. Pull back the seat-back cover from the left side bolster to access the OPDS unit cover. 4. Remove the OPDS unit cover from the seat frame. 5. Check the part number of the installed OPDS unit. Page 4455 Clutch Master Cylinder: Service and Repair Clutch Master Cylinder Removal NOTE: Do not spill brake fluid on the vehicle; it may damage the paint, if brake fluid does contact the paint, wash it off immediately with water. 1. Remove the brake fluid from the clutch master cylinder reservoir with a syringe. 2. If the master cylinder is equipped with the retaining clip holder (A) remove it. Remove the retaining clip 3. Disconnect the clutch line (C) and reservoir hose (D). Plug the end of the clutch line and reservoir hose with a shop towel to prevent brake fluid from coming out. 4. Pry out the lock pin (A), and pull the pedal pin (B) out of the yoke. Remove the nuts (C). 5. Remove the clutch master cylinder. Page 1706 Compression Check: Testing and Inspection Engine Compression Inspection 1. Warm up the engine to normal operating temperature (cooling fan comes on). 2. Turn the ignition switch OFF. 3. Remove the air cleaner housing. 4. Disconnect all four injector connectors. 5. Remove the four ignition coils. 6. Remove the four spark plugs. 7. Attach the compression gauge to the spark plug hole. 8. Connect a tachometer. 9. Open the throttle fully, then crank the engine with the starter motor and measure the compression. Compression Pressure: Above 930 kPa (9.5 kgf/cm2, 135 psi) 10. Measure the compression on the remaining cylinders. Maximum variation: Within 200 kPa (2.0 kgf/cm2, 28 psi) 11. If the compression is not within specifications, check the following items, then re-measure the compression. ^ Damaged or worn valves and seats ^ Damaged cylinder head gasket ^ Damaged or worn piston rings ^ Damaged or worn piston and cylinder bore Page 7594 glass run channel (G) away as needed from the center channel. 5. Move the center channel (A) away from the quarter glass (B), and the rear door glass (C), and remove the center channel out through the window slot. Take care not to damage the outer weatherstrip (D) 6. Remove the quarter glass (A). Take care not to damage the outer weatherstrip (B). 7. Carefully remove the glass (A) out through the window slot. Take care not to drop the glass inside the door. Page 5204 Skill Level: Repair Technician INSPECTION PROCEDURE 1. Remove the steering column covers. Refer to section 17 of the appropriate service manual. 2. On the lower side of the ignition switch, look at the interlock cylinder cover: ^ If the cover is square, the ignition switch was already replaced with an updated part, and a key interlock repair kit is not needed. Go to step 3. ^ If the cover is round, go to REPAIR PROCEDURE. 3. Reinstall the steering column covers. 4. Center-punch a completion mark above the seventh character of the engine compartment VIN. REPAIR PROCEDURE Page 2464 Knock Sensor: Description and Operation Knock Sensor The knock control system adjusts the ignition timing to minimize knock. Page 7621 NOTE: You need to make the corrections listed in CODE BOOK CORRECTIONS at the end of this service bulletin. TRACER AND CUTTER BIT INSTALLATION 1. Turn the power switch on the back of the machine to ON. (This turns on the built-in work light.) 2. Use the Allen wrench from the built-in tool drawer to loosen the setscrew on the left sleeve of the vertical carriage. Slide the tracer all the way into the sleeve, and tighten the screw. 3. Turn the plastic shield on the right sleeve of the vertical carriage so you can access the setscrew on the sleeve. Use the Allen wrench to loosen the screw. Slide the cutter bit all the way into the sleeve, and tighten the screw. Turn the plastic shield so the open side is in the back. MACHINE COMPONENTS Page 501 136. Brake Pedal Position Switch Page 6323 9. Mark the cam positions of the adjusting bolt (A) and adjusting cam (B), then remove the self-locking nut (C), adjusting cam, and adjusting bolt. Discard the self-locking nut. 10. Remove the flange bolt (D), and remove the knuckle. 11. Install the knuckle in the reverse order of removal, and note these items: ^ First install all the suspension components, and lightly tighten bolts and nuts, then place a floor jack under the trailing arm, and raise the suspension to load it with the vehicle's weight before fully tightening bolts and nuts to the specified torque values. ^ Align the cam positions of the adjusting bolt (A) and adjusting cam (B) with the marked positions when tightening. ^ Use a new self-locking nut on reassembly. ^ Tighten all the mounting hardware to the specified torque values. ^ Use a new spindle nut on reassembly. ^ Before installing the spindle nut, apply a small amount of engine oil to the seating surface of the nut. After tightening, use a drift to stake the spindle nut shoulder against the spindle. ^ Before installing the brake drum, clean the mating surface of the hub and the inside of the brake drum. ^ Use a new hub cap on reassembly. ^ Before installing the wheel, clean the mating surface of the brake drum and the inside of the wheel. ^ Check the wheel alignment, and adjust it if necessary. Page 4104 - 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. Troubleshooting Tests 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 test 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 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. 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 Drop Page 6506 Relay And Control Unit Locations - Engine Compartment Locations Air Bag Control Module: Locations Relay And Control Unit Locations - Dashboard Page 1074 - 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. Troubleshooting Tests 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 test 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 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. 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 Drop 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 8778 13. Plug in the heat gun, and turn it on. Start at the middle of the splice connector, and move the gun toward the ends as the tube shrinks. Apply heat evenly by rotating the curved heat spreader around the splice connector. Shrinking is complete when a small amount of sealant appears at each end of the tube. Pigtail Terminal Selection Chart PIGTAIL TERMINAL SELECTION CHART Select the proper size pigtail terminal by matching the replacement terminal part number and the wire size being repaired to the corresponding pigtail terminal part number. Then use the color (size) splice connector listed. In some instances you may also have to match the wire seal style to select the proper pigtail terminal. Pigtail terminals are available through your parts department, in quantities of 10, using normal parts ordering procedures. Checking For Poor Fir of Terminals CHECKING FOR POOR FIT OF TERMINALS Loose terminal fit can cause a number of intermittent problems in electrical circuits. By using the Terminal Inspection Feeler Tool Set you can inspect the terminal fit between the two matching connectors without removing the terminals from the connector body. 1. Find the terminal tool that best matches the male terminal in the mating connector. Page 5128 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 Short Circuit Locator (Short Finder) 1. Remove the blown fuse. Leave the battery connected. Page 308 166. PGM-FI Main Relays 1 And 2 Page 2787 Engine Control Module: Service and Repair Monitors, Trips, and/or Drive Cycle (Readiness Codes) Malfunction Indicator Lamp (MIL) Indication (In relation to Readiness Codes) The vehicle has certain "readiness codes" that are part of the on-board diagnostics for the emissions systems. If the vehicle's battery has been disconnected or gone dead, if the DTCs have been cleared, or if the ECM/PCM has been reset, these codes are reset. In some states, part of the emissions testing is to make sure these codes are set to complete. If all of them are not set to complete, the vehicle may fail the emissions test, or the test cannot be finished. To check if the readiness codes are complete, turn the ignition switch ON (II), but do not start the engine. The MIL will come on for 15 - 20 seconds. If it then goes off, the readiness codes are complete. If it blinks several times, one or more readiness codes are not complete. To set readiness codes from incomplete to complete, do the procedure for the appropriate code. Catalytic Converter Monitor and Readiness Code NOTE: - Do not turn the ignition switch off during the procedure. - All readiness codes are cleared when the battery is disconnected or when the ECM/PCM is cleared with the OBD II scan tool or Honda PGM Tester. - Low ambient temperatures or excessive stop-and-go traffic may increase the drive time needed to switch the readiness code from incomplete to complete. - The readiness code will not switch to complete until all the enable criteria are met. - If a fault in the secondary HO2S system caused the MIL to come on, the readiness code cannot be set to complete until you correct the fault. Enable Criteria - ECT at 158 °F (70 °C) or higher. - Intake air temperature (IAT) at 20 °F (-7 °C) or higher. - Vehicle speed is steady, and vehicle speed sensor (VSS) reads more then 25 mph (40 km/h). Procedure 1. Connect the scan tool to the vehicle's data link connector (DLC), and bring up the tool's generic OBD II mode. 2. Start the engine. 3. Test-drive the vehicle under stop-and-go conditions with short periods of steady cruise. After about 5 miles (8 km), the readiness code should switch from incomplete to complete. 4. If the readiness code is still set to incomplete, check for a temporary DTC. If there is no DTC, one or more of the enable criteria were probably not met; repeat the procedure. Evaporative Emissions (EVAP) Control System Monitor and Readiness code NOTE: - All readiness code are cleared when the battery is disconnected or when the ECM/PCM is cleared with the OBD II scan tool or Honda PGM Tester. - The enable criteria must be repeated if the intake air temperature (IAT) drops lower then 36 °F (2 °C) from its value at engine start up. Enable Criteria - At engine start up, ECT and IAT are higher than 32 °F (O °C), but lower than 95 °F (35 °C). - At engine start up, the ECT and IAT are within 12 °F (7 °C) of each other. Procedure 1. Connect the scan tool to the vehicle's data link connector (DLC), and bring up the tool's generic OBD II mode. 2. Start the engine. 3. Test-drive the vehicle under stop-and-go conditions with short periods of steady cruise. After about 2.5 miles (4 km), the readiness code should switch from incomplete to complete. 4. If the readiness code is still set to incomplete, check for a temporary DTC. If there is no DTC, one or more of the enable criteria were probably not met; repeat the procedure. Air Fuel Ratio (A/F) Sensor Monitor and Readiness Code NOTE: - Do not turn the ignition switch off during the procedure. - All readiness codes are cleared when the battery is disconnected or when the ECM/PCM is cleared with the OBD II scan tool or Honda PGM Tester. Enable Criteria Page 6856 12. On Accords and Pilots, install the new seat-back clips on the seat-back panel. Turn the clips so their retaining tabs are horizontal. 13. On Accords and Pilots, install the seat-back panel. 14. On all models except Accords and Pilots, zip the seat-back cover closed. 15. Initialize the OPDS unit. ^ To initialize with the HDS, go to Initializing the OPDS Unit: HDS Method. ^ To initialize with the SCS service connector, go to Initializing the OPDS Unit: Manual Mode. Initializing the OPDS Unit: HDS Method NOTE: Non-Honda seat covers will interfere with the performance of the OPDS and are not recommended. 1. Adjust the front passenger's seat-back to an upright position, then remove anything on or near the seat. 2. Turn the ignition switch to LOCK (0). 3. Connect the HDS to the vehicle's DLC (data link connector). 4. Turn the ignition switch to ON (II), then turn on the HDS. 5. At the screen prompts, enter the VIN and the odometer reading. Also verify the correct date and time. 6. From the System Selection menu, select SRS. Page 6305 ^ Be careful not to damage the ball joint boot when connecting the lower arm to the knuckle. ^ Tighten all mounting hardware to the specified torque values. ^ First install all the components and lightly tighten the bolts and nuts, then raise the suspension to load it with the vehicle's weight before fully tightening to the specified torques. ^ Torque the castle nut to the lower torque specification, then tighten it only far enough to align the slot with the ball joint pin hole. Do not align the castle nut by loosening it. ^ Install a new lock pin on the castle nut after torquing. ^ Before installing the wheel, clean the mating surface of the brake disc and the inside of the wheel. ^ Check the wheel alignment, and adjust it if necessary. Page 8357 6. Sanding After drying, wet sand the area of the intermediate coat. Use the #600 sandpaper. NOTE: Do not use #600 or less. 7. Air blowing/degreasing Use alcohol, a tack cloth, and wax and grease remover. Also clean and degrease the surfaces where the masking tape will be attached. Intermediate Coating Intermediate Coating NOTE: You must do this procedure on the PP parts of the bumper and side sill panel. 1. Masking Mask the area surrounding the damage to protect it from the intermediate coat overspray. Use masking tape and paper. 2. Spraying the top coat enamel - Spray the top coat enamel over the surface until the primer surfacer is fully covered. - Spray 2 - 3 coats to get 15 - 25 microns of thickness. - Use the 2-part polyester urethane top coat enamel and a spray gun - Mix the top coat enamel with the additive and solvent in the correct ratio. - Follow the top coat manufacturer's instructions. Drying NOTE: Take care not to let the heat lamp deform the bumper during the drying process. After spraying top coat enamel, allow for 5 - 10 minutes of normal drying, then force dry it with infrared lamps or other industrial dryer. 3. Polishing Page 9262 Headlamp Relay: Testing and Inspection Power Relay Test Use this chart to identify the type of relay, then do the test listed for it. NOTE: See the turn signal/hazard relay input test. Normally-open type A: Page 2074 93. VTEC Oil Pressure Switch (EX, HX) Page 9806 Power Windows Component Location Index Page 3423 4. Align the quick-connect fittings with the line (A), and align the retainer (B) locking pawls with the connector (C) grooves. Then press the quick-connect fittings onto the line until both retainer pawls lock with a clicking sound. NOTE: If it is hard to connect, put a small amount of new engine oil on the line end. 5. Make sure the connection is secure and that the pawls are firmly locked into place; check visually and by pulling the connector. 6. Reconnect the negative cable to the battery, and turn the ignition switch ON (II). The fuel pump will run for about 2 seconds, and fuel pressure will rise. Repeat 2 or 3 times, and check that there are no fuel leaks. Page 4217 - 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. Troubleshooting Tests 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 test 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 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. 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 Drop Page 1899 Valve Spring: Service and Repair Valves, Springs and Valve Seals Installation Installation 1. Coat the valve stems with engine oil. Install the valves in the valve guides. 2. Check that the valves move up and down smoothly. 3. Install the spring seats on the cylinder head. 4. Install the new valve seals (A) using the valve guide seal installer (B). NOTE: Exhaust valve seal (C) has a black spring (D), and intake valve seal (E) has a white spring (F). They are not interchangeable. 5. Install the valve spring and valve retainer. Place the end of the valve spring with closely wound coils toward the cylinder head. 6. Install the valve spring compressor. Compress the spring and install the valve keepers. Page 5117 Resistor Variable Sensor Solenoid Transistors Circuit Schematics Body - Trunk Lid Hard to Close Trunk / Liftgate Latch: All Technical Service Bulletins Body - Trunk Lid Hard to Close 02-061 November 5, 2004 Applies To: See VEHICLES AFFECTED Trunk Lid is Difficult to Close (Supersedes 02-061, dated July 23, 2004) Updated information is shown with asterisks. SYMPTOM The trunk lid may be difficult to close or won't latch closed. PROBABLE CAUSE The trunk lid may be misaligned, and the trunk lid opener cable, trunk lid latch, lock cylinder, lock rod, and/or the trunk lid latch striker may need adjustment or replacement. VEHICLES AFFECTED CORRECTIVE ACTION Adjust the trunk lid and/or the trunk lid latch, or replace components as needed. PARTS INFORMATION Page 3324 Canister Purge Volume Control Valve: Description and Operation EVAP Two Way Valve and EVAP Bypass Solenoid Valve The EVAP two way valve is installed between the fuel tank and the EVAP canister line. The EVAP two way valve sends fuel vapor to the EVAP canister corresponding to the pressure inside the fuel tank and prevents excessive vacuum in the fuel tank by drawing in fresh air through the EVAP canister. The EVAP bypass solenoid valve opens to bypass the two way valve when doing the EVAP leak check. Page 2567 14. Disconnect the 22P connector "A" from the gauge assembly. 15. Touch a probe to the BLU/WHT wire, and connect it to body ground through a voltmeter. 16. Slowly rotate one wheel with the other wheel blocked. Does voltage pulse from 0 to about 5 V or more? YES - Replace the speedometer assembly. NO - Repair open in the BLU/WHT wire between the VSS and the speedometer. Page 1663 Wire Color Abbreviations Page 5956 Air Conditioning Component Location Index How to Remove the PCM Control Module: Service and Repair How to Remove the PCM How to Remove the PCM for Testing 1. Remove the passenger's dashboard lower cover, the right kick panel, and the glove box. 2. Remove the bolt. Cut the plastic cross brace in the glove box opening with diagonal cutters in the area shown, and discard it. 3. Remove the relays (A), then remove the bolts and the glove box frame (B). 4. Remove the gray 20P PCM wire harness connector from the PCM mounting bracket. Remove the PCM mounting bolt (A) and the bracket. 5. Remove the nuts, then remove the PCM (B). 6. Install the PCM in the reverse order of removal. Mainshaft Speed Sensor Replacement Transmission Speed Sensor: Service and Repair Mainshaft Speed Sensor Replacement Mainshaft Speed Sensor Replacement 1. Disconnect the mainshaft speed sensor connector. 2. Remove the mainshaft speed sensor (A). 3. Install the new mainshaft speed sensor with the new O-ring (B) and mainshaft speed sensor washer (C). NOTE: The mainshaft speed sensor washer is equipped on the SLXA automatic transmission; the BMXA does not have it. 4. Check the mainshaft speed sensor connector for rust, dirt, or oil, then connect the connector securely. Page 6227 2. Remove the access panel from the steering wheel, then disconnect the driver's airbag 4P connector (A) from the cable reel. Front Passenger's Airbag 3. Lower the glove box, then disconnect the front passenger's airbag 4P connector (A) from the dashboard wire harness B. Side Airbag 4. Disconnect both side airbag 2P connectors (A) from the floor wire harness. Seat Belt Tensioner 5. Disconnect both seat belt tensioner 2P connectors (A) from the floor wire harness. Seat Belt Buckle Tensioner Page 9694 Rear Window Defogger Component Location Index Page 945 VEHICLES AFFECTED CUSTOMER NOTIFICATION All owners of affected vehicles were mailed a notification of this warranty extension. A example of the customer notification is shown in this service bulletin. CORRECTIVE ACTION Repair the vehicle as indicated by the INSPECTION PROCEDURE. If needed, replace the OPDS unit. In rare cases where an updated OPDS unit was already installed, replace the OPDS sensor. Page 7302 Cellular Phone: Electrical Diagrams Diagram 152 Diagrams: Other diagrams referred to by number (See Diagram ##-#, etc.)within these diagrams can be found at Diagrams by Number. See: Diagrams/Electrical Diagrams/Diagrams By Number Locations: Location photographs (references to PHOTOS) referred to within these diagrams can be found at Locations by Photo Number. See: Locations/Component Locations/Locations By Photo Number Connector Views: Connector terminal views (references to VIEWS) referred to within these diagrams can be found at Connector Views by View Number. See: Diagrams/Connector Views/Connector Views By View Number Page 7653 3. Use the clamp carriage lever to position the clamp unit so the tracer is directly over the flat surface of the code device, just ahead of the cam blades. 4. Pull the vertical carriage lever toward you until the tracer just touches the flat surface ahead of the cam blades. Watch the arrows on the keypad: ^ If the double-headed arrow in the middle of the keypad lights green, the tracer and cutter bit are properly aligned. ^ If the arrow on the left of the keypad lights red, the cutter bit is not touching the jaw. Turn the micrometric ring nut above the tracer to the left until the double-headed arrow lights green. ^ If the vertical arrow on the right of the keypad lights red, the tracer is not touching the jaw. Turn the micrometric ring nut above the tracer to the right until the double-headed arrow lights green. *5. Turn the micrometric ring nut to the right five clicks so the cutter bit is slightly higher than the tracer. The arrow on the left should light red. Raise the vertical carriage. NOTE: Setting the tracer five clicks lower than the cutter bit at this point has the effect of making the cutter bit cut the duplicated key a little shallower. This will protect the locking jaws from being damaged.* 6. Optional: Loosen the set screw, and adjust the hand rest to a comfortable position. Tighten the screw. 7. Pull the clamp carriage lever toward you until the clamp carriage clicks into its end-of-run position. 8. Clean any metal shavings or debris out of the center jaw. (A soft-bristle toothbrush is ideal for this purpose.) Then open the jaws with the jaws knob, and slide the key blank with its flat side down into the jaw up to the key stop. Close the jaw with the jaws knob to lock the key blank into place. Visually inspect the key for proper alignment in the jaw. 9. Set and lock the cam sets on the code device. ^ Starting with the left cam set, make sure the lock pin is pulled all the way out. (This releases the cams.) Page 3224 8. Put the splice connector in the proper size slot in the Crimper Tool, slide it to one end (where the flare begins), and close the crimper handles far enough to hold it in place. To release the ratchet mechanism at any point after the first click, squeeze the handles slightly and push the release lever, then let the handles open. 9. Insert one of the bare wires into the splice connector end that is in the crimper jaws. Push the wire all the way into the splice connector, and squeeze the crimper handles. Keep squeezing until the jaws touch, and hold it at that position until the ratchet clicks again. 10. Crimp the other wire in the same way into the other end of the splice connector. 11. After crimping, gently pull on the wires in the opposite directions to make sure they are secure in the connector. 12. Separate the other wires in the harness from the repaired wire(s), and shield them with nonflammable material. Page 2879 18. Check for continuity between body ground and PGM-FI main relay 1 4P connector terminals No.2 and No.4 individually. Is there continuity? YES - Repair short in the wire between the No.6 ECU (ECM/PCM) (15A) fuse and PGM-FI main relay 1. Also replace the No.6 ECU (ECM/PCM) (15A) fuse. NO - Go to step 19. 19. Disconnect each of the components or connectors connector below, one at a time, and check for continuity between PGM-FI main relay 1 4P connector terminal No.1 and body ground. PGM-FI main relay 2 - ECM/PCM connector A (31P) - Each injector 2P connector - Idle air control (IAC) valve 3P connector - Camshaft position (CMP) sensor (Top dead center (TDC) sensor) 3P connector - Crankshaft position (CKP) sensor 3P connector Is there continuity? YES - Go to step 20. NO - Replace the component that made continuity to body ground go away when disconnected. If the item is the ECM/PCM, update the ECM/PCM if it does not have the latest software, or substitute a known-good ECM/PCM, then recheck. If the symptom/indication goes away with a known-good ECM/PCM, replace the original ECM/PCM. Also replace the No.6 ECU (ECM/PCM) (15A) fuse. 20. Disconnect the connectors of all these components. - PGM-FI main relay 2 - ECM/PCM connector A (31P) - Injectors - Idle air control (IAC) valve - Camshaft position (CMP) sensor (Top dead center (TDC) sensor) - Crankshaft position (CKP) sensor Page 6497 Compressor Clutch: Testing and Inspection Compressor Clutch Circuit Compressor Clutch Circuit Troubleshooting Note: Do not use this troubleshooting procedure if the fans are also inoperative with the A/C on. refer to the Symptom Troubleshooting index. See: Testing and Inspection - Before performing symptom troubleshooting, check for power train DTCs. See: Powertrain Management/Computers and Control Systems/Testing and Inspection 1. Check the No.1 (20 A) fuse in the under-hood fuse/relay box, and the No.14 (10 A) fuse in the under-dash fuse/relay box. Are the fuses OK? YES - Go to step 2. NO - Replace the fuse(s), and recheck. 2. Check the engine coolant temperature, throttle position, and idle speed (use the Honda PGM Tester PGM-FI data list if possible). Is the coolant temperature, throttle position, and idle speed okay? YES - Go to step 3. NO - Troubleshoot and repair the cause of the high engine coolant temperature, low idle, or excessively high throttle position sensor reading. 3. Remove the compressor clutch relay from the under-hood fuse/relay box, and test it. Is the relay OK? YES - Go to step 4. NO - Replace the compressor clutch relay. 4. Measure the voltage between the No.2 terminal of the compressor clutch relay 4P socket and body ground. Is there battery voltage? YES - Go to step 5. NO - Replace the under-hood fuse/relay box. Page 5277 Transmission Speed Sensor: Diagrams 34. Output Shaft (Countershaft) Speed Sensor (A/T Except CVT) 57. Input Shaft (Mainshaft) Speed Sensor (A/T Except CVT) Page 9842 16. With a sponge, carefully apply a light coat of body primer to any exposed paint or metal around the flange where new adhesive will be applied. Let the primer dry for at least 10 minutes: Do NOT apply body primer to any remaining original adhesive on the flange. - Be careful not to mix up the body and glass primer sponges. - Never touch the primed surfaces with your hands. 17. Cut a "V" in the end of the nozzle (A) on the adhesive cartridge as shown. 18. Put the cartridge in a caulking gun, and run a bead of adhesive (A) around the edge of the rear window (B) and moldings (C) as shown. Apply the adhesive within 30 minutes after applying the glass primer. Make a slightly thicker bead at each corner. Page 6971 Air Bag(s) Arming and Disarming: Vehicle Damage Warnings 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. - To prevent damage to the airbag assembly, keep free from any oil, grease, detergent, or water. - Store the removed airbag on a secure, fiat surface away from any high heat source (exceeding 200 °F / 93 °C). Page 1678 - 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. Troubleshooting Tests 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 test 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 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. 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 Drop Page 7774 13. Push the top of the retainer clip with a flat-tip screwdriver, and hold it. Release the retainer clip with a hook-shaped tool, then remove the lock cylinder. Go to step 14. 14. With the door lock cylinder out of the door handle remove the E-clip and the arm. 15. Try to insert the key into the cylinder and turn it. ^ If you can insert and turn the key, go to step 18. ^ If you cannot insert the key or turn it, go to step 16. 16. Carefully remove the spring and plastic retainer. Page 2944 DTC P0158 thru P0400 Page 9591 Tail Lamp Relay: Testing and Inspection Power Relay Test Use this chart to identify the type of relay, then do the test listed for it. NOTE: See the turn signal/hazard relay input test. Normally-open type A: Page 5073 Shift Solenoid: Testing and Inspection Shift Solenoid Valves A and B Test 1. Disconnect the shift solenoid valves A and B connector. 2. Measure shift solenoid valve A resistance between the No. 1 terminal of the shift solenoid valves A and B connector and body ground, and measure shift solenoid valve B resistance between the No. 2 terminal and body ground. STANDARD: 12 - 25 Ohms 3. Replace the shift solenoid valves A and B if either resistance is out of standard. 4. If the resistance is within the standard, connect the No. 1 terminal of the shift solenoid valve A to the battery positive terminal. A clicking sound should be heard. Connect the No. 2 terminal to the battery positive terminal. A clicking sound should be heard. Replace the shift solenoid valves A and B if no clicking sound is heard when either terminal is connected to the battery terminal. Page 7099 ^ If the OPDS unit has an original part number, go to step 6. ^ If the OPDS unit has a new part number (refer to PARTS INFORMATION) or higher, go to REPAIR PROCEDURE B: OPDS SENSOR REPLACEMENT. 6. Recline the seat-back to access the OPDS unit mounting screws. 7. Remove the mounting screws from the OPDS unit, and gently pull out the unit. 8. Disconnect the OPDS connectors, then remove the OPDS unit. 9. Install a new OPDS unit, then snap on its cover. 10. Slip the seat-back cover over the OPDS unit. 11. On Accords, check the seat-back clip attachment bosses on the seat-back panel: ^ If the attachment bosses are OK, go to step 12. ^ If the seat-back has a pocket, and the attachment bosses are deformed or damaged, do the repair procedure in S/B 02-010, Seat-Back Panel Is Loose or Detached. Then go to step 12. ^ If the seat-back does not have a pocket, and the attachment bosses are deformed or damaged, replace the seat-back. Then go to step 12. Page 7812 ^ If no key code can be found on the iN or with the Matrix H High Security key Codes Book, remove one tumbler at a time from the old inner cylinder, and match the number stamped on the old tumbler to a new tumbler from the kit. Insert the new tumbler and spring in the appropriate new inner cylinder cavity. ^ Do not use the old inner cylinder, springs, or tumblers. ^ Using your thumb and forefinger, hold the tumblers in place, insert the key in the cylinder and verify that all tumblers are flush with the cylinder. If not, double-check the key number, the cutting key code, the tumbler numbers, and the cavity locations. NOTE: If the key cannot be inserted, check the tumbler in the "J" cavity. It may be out of position. Page 4118 2. Cut off the wire about an inch back from where it connects to the damaged or faulty terminal, then strip about half of the insulation off that piece. This will be used to size the wire end of the replacement pigtail terminal. NOTE: If you are not sure of the wire size, start with a large enough hole on the stripper that will not nick or cut off any strands of wires. 3. Select a pigtail terminal that matches the original wire at both ends (same kind of terminal and same diameter bare wire). 4. Select the smallest splice connector (yellow, pink, or blue) that will fit onto the stripped end of the original wire. 5. Insert the pigtail terminal into the connector cavity; push it in until it locks in place. 6. Lay the pigtail and the original wire side-by-side, and cut off both ends at once. If you are making more than one splice, do not cut each pigtail at the same location; the resulting "lump" of splice connectors would interfere with rewrapping the harness. Instead, cut the first pigtail close enough to the terminal so you will have room to make each remaining cut about 20 mm (3/4 inch) farther down on the next pigtail. 7. If you are using a yellow splice connector, strip about 6 mm (1/4 inch) of insulation off the ends of both wires. If you are using a pink or blue splice connector, strip off about 8 mm (5/16 inch) of insulation. Page 3134 Power Distribution schematics show how power is supplied from the positive battery terminal to various circuits in the vehicle. Refer to the Power Distribution diagram set to get a more detailed understanding of how picture is supplied to the circuit you're working on. Individual circuit schematics begin with a fuse. So 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 Ground Distribution Schematics This sample Ground Distribution schematic shows all of the components that share the same ground point. Page 8628 3. Use the clamp carriage lever to position the clamp unit so the tracer is directly over the flat surface of the code device, just ahead of the cam blades. 4. Pull the vertical carriage lever toward you until the tracer just touches the flat surface ahead of the cam blades. Watch the arrows on the keypad: ^ If the double-headed arrow in the middle of the keypad lights green, the tracer and cutter bit are properly aligned. ^ If the arrow on the left of the keypad lights red, the cutter bit is not touching the jaw. Turn the micrometric ring nut above the tracer to the left until the double-headed arrow lights green. ^ If the vertical arrow on the right of the keypad lights red, the tracer is not touching the jaw. Turn the micrometric ring nut above the tracer to the right until the double-headed arrow lights green. *5. Turn the micrometric ring nut to the right five clicks so the cutter bit is slightly higher than the tracer. The arrow on the left should light red. Raise the vertical carriage. NOTE: Setting the tracer five clicks lower than the cutter bit at this point has the effect of making the cutter bit cut the duplicated key a little shallower. This will protect the locking jaws from being damaged.* 6. Optional: Loosen the set screw, and adjust the hand rest to a comfortable position. Tighten the screw. 7. Pull the clamp carriage lever toward you until the clamp carriage clicks into its end-of-run position. 8. Clean any metal shavings or debris out of the center jaw. (A soft-bristle toothbrush is ideal for this purpose.) Then open the jaws with the jaws knob, and slide the key blank with its flat side down into the jaw up to the key stop. Close the jaw with the jaws knob to lock the key blank into place. Visually inspect the key for proper alignment in the jaw. 9. Set and lock the cam sets on the code device. ^ Starting with the left cam set, make sure the lock pin is pulled all the way out. (This releases the cams.) Page 1189 1. Remove the screw and passenger's power window switch (A) from the door panel. 2. Disconnect the 5P connector (B) from the switch. 3. Check for continuity between the terminals in each switch position according to the table. 4. If the continuity is not as specified remove the two screws and replace the switch. Page 2906 141. HO2S, Secondary (except HX) Or Third (HX) Body/Frame - Universal Subframe Removal Adapter Subframe: Technical Service Bulletins Body/Frame - Universal Subframe Removal Adapter 05-066 November 24, 2005 Applies To: See VEHICLES AFFECTED Universal Front Subframe Removal Adapter (Replaces 01-043, Civic Front Sub frame Removal Adapter, dated September 11, 2001) The universal front subframe removal adapter is a required tool. When properly fitted to a transmission jack and the vehicle's front subframe, the adapter provides a convenient way to remove the subframe. Front subframe removal is required for transmission or engine removal. NOTE: The adapter will only support the subframe it will not support the entire powertrain assembly. Refer to the WARNING label on the adapter. VEHICLES AFFECTED 2003-06 Accord - ALL 2005-06 Accord Hybrid - ALL 2001-06 Civic - ALL 2001-06 Civic GX - ALL 2003-06 Civic Hybrid - ALL 2002-06 Civic Si - ALL 2002-06 CRV - ALL 2003-06 Element - ALL ORDERING INFORMATION The universal front subframe removal adapter is TIN VSB02C000016. To order additional adapters, call the Honda Tool and Equipment Program. USING THE ADAPTER NOTE: The adapter is designed to be used with the transmission jack, (new model number NRI-72500D), available through the Honda Tool and Equipment Program. (The old model number LSL-W93714 can still be used.). The adapter also works with many commercially available transmission jacks. 1. Loosen the four bolts that hold the adapter's adjustable arms to its center plate. Locations Seat Belt Buckle Switch: Locations 100. Under Driver's Seat 101. Under Front Passenger's Seat (Passenger's Similar) Page 9299 Power Distribution schematics show how power is supplied from the positive battery terminal to various circuits in the vehicle. Refer to the Power Distribution diagram set to get a more detailed understanding of how picture is supplied to the circuit you're working on. Individual circuit schematics begin with a fuse. So 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 Ground Distribution Schematics This sample Ground Distribution schematic shows all of the components that share the same ground point. Page 6776 Air Bag Control Module: Service and Repair OPDS Unit Replacement OPDS Unit Replacement NOTE: Review the seat replacement procedure in the body section before performing repair or service. Removal 1. Disconnect the battery negative cable, and wait at least 3 minutes before beginning work. 2. Disconnect the side airbag harness 2P connector. 3. Remove the seat assembly and seat-back cover. 4. Remove the cover (A), then disconnect the OPDS unit harness 8P and sensor connectors (B) from the OPDS unit. Installation 1. Place the new OPDS unit on the seat-back frame. Tighten the two screws, and connect the OPDS unit harness 8P and sensor connector to the OPDS unit. Reinstall the cover. 2. Install the seat-back cover. 3. Install the seat assembly, then connect the side airbag harness 2P connector. 4. Reconnect the battery negative cable. 5. Set the seat-back in the normal position, and make sure there is nothing on the front passenger's seat. 6. Initialize the OPDS unit. 7. After installing the OPDS unit, confirm proper system operation: Turn the ignition switch ON (II); the SRS indicator should come on for about 6 seconds and then go off. Locations Throttle Position Sensor: Locations PGM-FI System - Component Location Index Page 1047 143. Park Pin/Shift Switch (A/T) Shift Solenoid Valves A and B Test Shift Solenoid: Testing and Inspection Shift Solenoid Valves A and B Test Shift Solenoid Valves A and B Test 1. Disconnect the shift solenoid valves A and B connector. 2. Measure shift solenoid valve A resistance between the No. 1 terminal of the shift solenoid valves A and B connector and body ground, and measure shift solenoid valve B resistance between the No. 2 terminal and body ground. STANDARD: 12 - 25 Ohms 3. Replace the shift solenoid valves A and B if either resistance is out of standard. 4. If the resistance is within the standard, connect the No. 1 terminal of the shift solenoid valve A to the battery positive terminal. A clicking sound should be heard. Connect the No. 2 terminal to the battery positive terminal. A clicking sound should be heard. Replace the shift solenoid valves A and B if no clicking sound is heard when either terminal is connected to the battery terminal. M/T - Clicking Noise Driving in 2nd Gear Reverse Idler Gear: Customer Interest M/T - Clicking Noise Driving in 2nd Gear 03-009 June 10, 2003 Applies To: 2001-03 Civic DX, LX, HX, EX with M/T - ALL 2003 Civic Hybrid - From VIN JHMES95..3S000001 thru JHMES95..3S018631 Clicking Noise While Driving in 2nd (Supersedes 03-009, dated April 1, 2003) Updated information is shown with asterisks. SYMPTOM * While driving in 2nd gear, a clicking noise occurs when turning right (DX, LX, HX, and EX) or when turning left (Civic Hybrid).* PROBABLE CAUSE The reverse idler gear is contacting the 1st/2nd hub sleeve set. CORRECTIVE ACTION Replace the reverse idler gear, the 1st/2nd synchro hub/sleeve set, and the reverse gear holder. REQUIRED MATERIALS Honda Manual Transmission Fluid (1.7 quarts required): P/N 08798-9016, H/C 4928271 Liquid Gasket: P/N 08718-0001, H/C 2963817 PARTS INFORMATION WARRANTY CLAIM INFORMATION In warranty: The normal warranty applies. Operation Number: 213110 Page 8600 3. Use the clamp carriage lever to position the clamp unit so the tracer is directly over the flat surface of the code device, just ahead of the cam blades. 4. Pull the vertical carriage lever toward you until the tracer just touches the flat surface ahead of the cam blades. Watch the arrows on the keypad: ^ If the double-headed arrow in the middle of the keypad lights green, the tracer and cutter bit are properly aligned. ^ If the arrow on the left of the keypad lights red, the cutter bit is not touching the jaw. Turn the micrometric ring nut above the tracer to the left until the double-headed arrow lights green. ^ If the vertical arrow on the right of the keypad lights red, the tracer is not touching the jaw. Turn the micrometric ring nut above the tracer to the right until the double-headed arrow lights green. *5. Turn the micrometric ring nut to the right five clicks so the cutter bit is slightly higher than the tracer. The arrow on the left should light red. Raise the vertical carriage. NOTE: Setting the tracer five clicks lower than the cutter bit at this point has the effect of making the cutter bit cut the duplicated key a little shallower. This will protect the locking jaws from being damaged.* 6. Optional: Loosen the set screw, and adjust the hand rest to a comfortable position. Tighten the screw. 7. Pull the clamp carriage lever toward you until the clamp carriage clicks into its end-of-run position. 8. Clean any metal shavings or debris out of the center jaw. (A soft-bristle toothbrush is ideal for this purpose.) Then open the jaws with the jaws knob, and slide the key blank with its flat side down into the jaw up to the key stop. Close the jaw with the jaws knob to lock the key blank into place. Visually inspect the key for proper alignment in the jaw. 9. Set and lock the cam sets on the code device. ^ Starting with the left cam set, make sure the lock pin is pulled all the way out. (This releases the cams.) Page 9345 Diodes Light Emitting Diode (LED) Motor Pressure Sensor Page 8677 61. Under Left Side Of Dash Page 7518 Front Door Latch: Service and Repair Sedan Front Door Latch Replacement 4-door NOTE: Put on gloves to protect your hands. 1. Raise the glass fully. 2. Remove these items: - Door panel - Plastic cover, as necessary 3. Disconnect the cylinder rod from the lock cylinder, and disconnect the outer handle rod from the outer handle. 4. Remove the clip, and remove the lock rod protector (A) in the numbered sequence. 5. Pull the glass run channel (A) away as necessary, and remove the bolt, then remove the center lower channel (B) by pulling it downward. Page 7014 10. Remove the shoulder anchor adjuster (A). 11. Install the belt in the reverse order of removal, and note these items: - Apply liquid thread lock to the anchor bolts before reinstallation. - Check that the retractor locking mechanism functions. - Assemble the washers, collar and bushing on the upper and lower anchor bolts as shown. - If the seat belt tensioner has been deployed, replace the front seat belt protector (F) with a new one. - Before installing the anchor bolts, make sure there are no twists or kinks in the front seat belt. - Make sure the seat belt tensioner connector is plugged in properly. - Reconnect the negative cable to the battery. - Enter the anti-theft code for the radio, then enter the customer's radio station presets. - Reset the clock. - Do the ECM idle learn procedure. Front Seat Belt Buckle Front Seat Belt Replacement SRS components are located in this area. Review the SRS component locations and the precautions and procedures, in the SRS section before performing repairs or service. Page 3180 14. Disconnect the 22P connector "A" from the gauge assembly. 15. Touch a probe to the BLU/WHT wire, and connect it to body ground through a voltmeter. 16. Slowly rotate one wheel with the other wheel blocked. Does voltage pulse from 0 to about 5 V or more? YES - Replace the speedometer assembly. NO - Repair open in the BLU/WHT wire between the VSS and the speedometer. Page 8007 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. Obtain the customer's key code from the iN (Key Code Inquiry). Refer to the Honda High Security key Codes book that comes with the Matrix H key cutting machine. Write down the applicable cutting code for the key code number. Make sure the corrections to the code book listed in Service Bulletin 01-077, Cutting Sidewinder-Type keys With the Matrix H key Cutting Machine, have been made. 2. Use the chart shown to write down the numbers found in the key code book. 3. Remove the door panel. Refer to the appropriate service manual or use ISIS keyword Door Panel. 4. Remove the plastic cover as necessary. 5. Raise the window glass fully. 6. Remove the lock cylinder. ^ For Civic, go to step 7. ^ For CR-V, go to step 8. ^ For Element, go to step 11. 7. Pull down on the retainer clip with a hook-shaped tool. Remove the lock cylinder and disconnect the cylinder rod. Then go to step 14. Page 8037 10. Pull down on the retainer clip with a hook-shaped tool. Remove the lock cylinder. Then go to step 14. 11. Pull the glass run channel away as necessary, and remove the bolt, then remove the center lower channel by pulling it downward. 12. Remove the access seal, and disconnect the outer handle rod and the cylinder rod. Page 2852 Are there any DTCs? YES - Go to step 9. NO - Go to the Mode 2 test. Capacity Specifications Fluid - M/T: Capacity Specifications M/T Fluid Change ................................................................................................................................................ .............................................................. 1.5L (1.6 Qt) Overhaul .......................................................... ................................................................................................................................................. 1.6L (1.7 Qt) Page 3144 Use the tools from Pin Tool Set. First, check the connector that you are about to repair. - If it has a secondary terminal lock, go to Connectors With a Secondary Lock. A secondary lock, found on most connectors on some models, is an additional locking device on the connector housing as a backup for the primary lock on the terminal. - If the connector does not have a secondary lock, go to Connectors Without a Secondary Lock. Connectors With a Secondary Lock All examples are shown with the connector lock facing up. The illustrations are examples of the secondary terminal locks; however, the connector you are repairing may vary in size. Identify the connector by the type of secondary lock, not by the number of terminal cavities. EXAMPLE A: 1. Release the secondary lock. 2. Remove the terminal. 3. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE B: Page 8051 Disclaimer Cutting Procedure - By Copying 1. Press the ON/OFF button in the middle of the setting unit keypad. (This powers up the keypad.) 2. Turn the clamp unit lock lever to the left to release the clamp unit, and slide it all the way to the left until it stops. Turn the lever to the right to lock the clamp unit in place. 3. Use the clamp carriage lever to position the clamp unit so the tracer and cutter bit are centered directly over the base of the center and right jaws. 4. Pull the vertical carriage lever toward you until the tracer and the cutter bit just touch the base of each fixed jaw. Watch the arrows on the keypad: ^ If the double-headed arrow in the middle of the keypad lights green, the tracer and cutter bit are properly aligned. ^ If the arrow on the left of the keypad lights red, the cutter bit is not touching the fixed jaw. Turn the micrometric ring nut above the tracer to the left until the double-headed arrow lights green. ^ If the arrow on the right of the keypad lights red, the tracer is not touching the fixed jaw. Turn the micrometric ring nut above the tracer to the right until the double-headed arrow lights green. *5. Turn the micrometric ring nut to the right three clicks so the cutter bit is slightly higher than the tracer. The arrow on the left should light red. Raise the vertical carriage. NOTE: Setting the tracer three clicks lower than the cutter bit has the effect of making the cutter bit cut the duplicated key a little shallower. This will protect the locking jaws from being damaged.* 6. Optional: Loosen the setscrew, and adjust the hand rest to a comfortable position. Tighten the screw. 7. Pull the clamp carriage lever toward you until the clamp carriage clicks into its end-of-run position. Tighten both the lateral and spring tension adjustment knobs. 8. Make sure the center and right jaws are free of any metal shavings or debris. (A soft-bristle toothbrush is ideal for this purpose.) Page 3387 Idle Speed: Description and Operation Idle Control System When the engine is cold, the A/C compressor is on, the transmission is in gear, the brake pedal is pressed, the power steering load is high, or the alternator is charging, the ECM/PCM controls current to the Idle Air Control (IAC) valve to maintain the correct idle speed. Refer to the System Diagram to see the functional layout of the system. Idle Control System Diagram The idle speed of the engine is controlled by the idle air control (IAC) valve: - After the engine starts, the IAC valve opens for a certain amount of time. The amount of air is increased to raise the idle speed. - When the engine coolant temperature is low, the IAC valve is opened to obtain the proper fast idle speed. The amount of bypassed air is thus controlled in relation to engine coolant temperature. Page 4291 ^ The left end goes behind the notch on the interlock lever. ^ Once the spring is correctly installed, make sure the lever moves freely and returns properly. 10. Insert the plunger into the interlock solenoid, then install the solenoid using a new screw. Make sure the groove of the solenoid plunger is in the fork on the lever. 11. Install a new plastic cover on the interlock solenoid. 12. Check the operation of the ignition switch key interlock: ^ Set the parking brake, and turn the ignition switch to ON (I I). ^ While pressing the brake pedal, shift the transmission to Neutral. ^ Try turning the ignition switch to LOCK (0) - If you cannot turn the switch to LOCK (0), your repair was successful; go to step 15. - If you can turn the switch to LOCK (0), the interlock is not working; go to step 13. Page 2471 Manifold Pressure/Vacuum Sensor: Description and Operation Manifold Absolute Pressure (MAP) Sensor The MAP sensor converts manifold absolute pressure into electrical signals to the ECM/PCM. Page 7234 Page 2159 Use the tools from Pin Tool Set. First, check the connector that you are about to repair. - If it has a secondary terminal lock, go to Connectors With a Secondary Lock. A secondary lock, found on most connectors on some models, is an additional locking device on the connector housing as a backup for the primary lock on the terminal. - If the connector does not have a secondary lock, go to Connectors Without a Secondary Lock. Connectors With a Secondary Lock All examples are shown with the connector lock facing up. The illustrations are examples of the secondary terminal locks; however, the connector you are repairing may vary in size. Identify the connector by the type of secondary lock, not by the number of terminal cavities. EXAMPLE A: 1. Release the secondary lock. 2. Remove the terminal. 3. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE B: Page 7458 1. Remove the secondary locks. 2. Remove the terminal from the female half. 3. Remove the terminal from the male half. 4. Go to HOW TO INSTALL NEW TERMINALS. Connectors Without a Secondary Lock All examples are shown with the connector lock facing up. The illustrations are examples of connector terminals without a secondary lock; however, the connector you are repairing may vary in size and shape. EXAMPLE A: Page 4649 Shift Interlock Switch: Service and Repair Park Pin Switch Replacement 1. Remove the center console panel and center console. 2. Remove the screws (A), then remove the shift lever knob (B). 3. Remove the A/T gear position indicator panel light (c) from the A/T gear position indicator panel. 4. Remove the A/T gear position indicator panel and panel bracket as an assembly (D). 5. Disconnect the park pin switch connector (4P) (E), and remove it from the shift lever bracket base (F). 6. Remove the shift lock release (G) and spring (H). 7. Open the lock tabs (A) on the shift lever bracket base, then remove the park pin switch (B). 8. Install the new park pin switch. 9. Install the removed parts in the reverse order of removal. Page 7808 10. Pull down on the retainer clip with a hook-shaped tool. Remove the lock cylinder. Then go to step 14. 11. Pull the glass run channel away as necessary, and remove the bolt, then remove the center lower channel by pulling it downward. 12. Remove the access seal, and disconnect the outer handle rod and the cylinder rod. Page 9374 License Plate Lamp: Electrical Diagrams Diagram 110-13 Page 6479 Air Conditioning Component Location Index Diagrams Page 2367 155. A/F Sensor Relay (HX; '04-'05: DX, EX, LX) Body - Power Windows Inoperative/Intermittent Operation Power Window Switch: Customer Interest Body - Power Windows Inoperative/Intermittent Operation 06-010 March 8, 2006 Applies To: 2001-05 Civic - All LX and EX 4-door 2003-05 Civic Hybrid - ALL 2001-05 Civic GX ALL Power Window Does Not Work or Works Intermittently SYMPTOM One or more of the power windows does not work or works intermittently from the power window master switch (in the driver's door). PROBABLE CAUSE The power window master switch is faulty. CORRECTIVE ACTION Replace the power window master switch. PARTS INFORMATION WARRANTY CLAIM INFORMATION In warranty: The normal warranty applies. Operation Number: 744100 Flat Rate Time: 0.2 hr Failed Part: P/N 35750-S5A-A01ZA H/C 6453419 Defect Code: 03217 Symptom Code: 01201 Template ID: 06-010A (Black Switch) 06-010B (Medium Taupe Switch) 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 8024 9. Open the jaws with the jaws knob, and slide the original key with its flat side down into the center jaw up to the key stop. Slide the key blank with its flat side down into the right jaw up to the key stop. Close the jaws with the jaws knob to lock the keys into place. Visually inspect both keys for proper alignment in the jaws. 10. Loosen the lateral and spring tension adjustment knobs on the clamp carriage. With the clamp carriage lever, adjust the clamp carriage to position the tracer and the cutter bit over the middle of the two locked key blades. Tighten only the spring tension knob when done. NOTE: The clamp carriage has a spring system that puts lateral pressure on the tracer and cutting bit to make it easier to cut sidewinder-type keys. Do not tighten the lateral tension adjustment knob. This knob should be left loose. 11. Turn on the cutter motor with the motor start switch. [NOTICE] ^ To avoid damaging the locking jaws while cutting, keep your hand off the vertical carriage lever. Pressure on the lever will change the cutting depth. * ^ To avoid breaking the cutter bit, never back up while cutting.* ^ Wear proper eye protection (safety glasses, goggles, etc.) Page 8716 61. Under Left Side Of Dash Page 9096 1. Remove the terminal. 2. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE B: 1. Remove the terminal. 2. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE C: 1. Remove the terminal. 2. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE D: Page 7387 REPAIR PROCEDURE 1. Make sure you have the anti-theft code for the audio unit. Write down the customer's audio presets. 2. Disconnect the negative battery cable from the battery. 3. Remove the under-hood fuse/relay box cover. 4. Release the three clips, and remove the under- hood fuse/relay box from the holder. CR-V only: Release the wire harness clip from the fuse/relay box holder Locations Relay And Control Unit Locations - Engine Compartment Page 6958 ^ If the OPDS unit has an original part number, go to step 6. ^ If the OPDS unit has a new part number (refer to PARTS INFORMATION) or higher, go to REPAIR PROCEDURE B: OPDS SENSOR REPLACEMENT. 6. Recline the seat-back to access the OPDS unit mounting screws. 7. Remove the mounting screws from the OPDS unit, and gently pull out the unit. 8. Disconnect the OPDS connectors, then remove the OPDS unit. 9. Install a new OPDS unit, then snap on its cover. 10. Slip the seat-back cover over the OPDS unit. 11. On Accords, check the seat-back clip attachment bosses on the seat-back panel: ^ If the attachment bosses are OK, go to step 12. ^ If the seat-back has a pocket, and the attachment bosses are deformed or damaged, do the repair procedure in S/B 02-010, Seat-Back Panel Is Loose or Detached. Then go to step 12. ^ If the seat-back does not have a pocket, and the attachment bosses are deformed or damaged, replace the seat-back. Then go to step 12. Page 4107 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. How to Replace Connector Terminals Terminal Replacement Procedure HOW TO REPLACE CONNECTOR TERMINALS The terminal repair kits provide necessary tools and materials (terminals, wire seals, and splice connectors) to repair many damaged or faulty connector terminals. However, not all terminals for all connectors are available. Refer to the labels on the lids of the repair kits for replacement terminal availability. IMPORTANT SAFETY INFORMATION: On some models, the SRS wires are in a separate harness. If the SRS harness is damaged, replace the harness; do not repair it. On other models, wire harnesses include yellow SRS wires. If any SRS wire is damaged, replace the entire harness; do not repair it. Before you begin, inspect the wire you are about to repair for damage and length. Make sure the wire will be long enough to make a terminal repair without stretching it when you reinstall the terminal in the connector. If the wire is too short, or if access to the connector is too restricted to make a terminal repair, you may need to install a pigtail terminal (a short length of wire with a factory-crimped terminal on it). Refer to HOW TO INSTALL PIGTAIL TERMINALS. Removing the Terminal Locations 58. Under Left Side Of Dash (Honda Accessory) Page 4057 Differential Carrier Replacement 1. Remove the snap ring (A) from the differential assembly (B). 2. Remove the speedometer drive gear (B). 3. Remove final driven gear bolts, then separate the final driven gear and the differential carrier. The final driven gear bolts have left-hand threads. 4. Install the final driven gear (A) on the new differential carrier (B) with the chamfered side on the inner bore facing the differential carrier. 5. Tighten the bolts to 103 Nm (10.5 kgf-cm, 75.9 ft. lbs.) in a crisscross pattern. Page 2465 Knock Sensor: Service and Repair Replacement 1. Remove the oil filter with the special oil filter wrench. 2. Disconnect the knock sensor connector, then remove the knock sensor. 3. Install the knock sensor and oil filter. Page 8508 Doors - Component Location Index - 4-door Front Door Page 999 Power Steering Pressure Switch: Testing and Inspection PSP Switch Signal Circuit Troubleshooting 1. Turn the ignition switch ON (II). 2. Measure voltage between ECM/PCM connector terminals A24 and E16. Is there less than 1.0 V? YES - Go to step 3. NO - Go to step 6. 3. Start the engine. 4. Turn the steering wheel to the full lock position. 5. Measure voltage between ECM/PCM connector terminals A24 and E16. Is there battery voltage? YES - The PSP switch signal is OK. NO - Go to step 13. 6. Turn the ignition switch OFF. 7. Disconnect the PSP switch 2P connector. 8. Turn the ignition switch ON (II). 9. At the harness side, connect the PSP switch 2P connector terminals No.1 and No.2 with a jumper wire. 10. Measure voltage between ECM/PCM connector terminals A24 and E16. Is there less than 1.0 V? YES - Replace the PSP switch. NO - Go to step 11. 11. Turn the ignition switch OFF. Page 4093 Terminals - "T" Shielding Switches Fuses Page 2516 Terminals - "T" Shielding Switches Fuses Locations 77. Under Middle Of Dash Page 5375 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. Circuits must be operating when checking voltage drop. 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. 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 off, 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 Self-Powered Test Light or DVOM 1. Remove the blown fuse and disconnect the battery and load. Diagram Information and Instructions Courtesy Lamp: Diagram Information and Instructions Terminal Numbering System Terminal Numbering System Connector terminals are numbered according to the cavities they're in. The cavities are numbered starting from the upper left, looking at the male terminals from the terminal side or looking at the female terminals from the wire side. Both views are in the same direction so the numbers are the same. All actual cavities are numbered, even if they have no wire terminals in them. NOTE: Data Link Connector (DLC) terminals are numbered according 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 below is #6. Page 6558 Heater Control Valve Cable: Adjustments Heater Valve Cable Adjustment 1. From under the hood, open the cable clamp (A), then disconnect the heater valve cable (B) from the heater valve arm (C). 2. From under the dash, disconnect the heater valve cable housing from the cable clamp (A), and disconnect the heater valve cable (B) from the air mix control linkage (C). 3. Set the temperature control dial on Max Cool with the ignition switch ON (II). 4. Attach the heater valve cable (B) to the air mix control linkage (C) as shown. Hold the end of the heater valve cable housing against the stop (D), then snap the heater valve cable housing into the cable clamp (A). 5. From under the hood, turn the heater valve arm (C) to the fully closed position as shown, and hold it. Attach the heater valve cable (B) to the heater valve arm, and gently pull on the heater valve cable housing to take up any slack, then install the heater valve cable housing into the cable clamp (A). Page 1261 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. Locations Neutral Safety Switch: Locations Starting System Component Location Index Page 6963 12. Watch the SRS indicator: ^ If the indicator blinks twice and then goes off, the OPDS unit is initialized. Turn the ignition switch to LOCK (0), and disconnect the HDS. ^ If the indicator blinks twice and then stays on, the OPDS unit is initialized, but SRS DTCs need to be cleared. Go to step 13. ^ If the indicator stays on without first blinking, the OPDS unit is not initialized. Repeat steps 3 thru 12. 13. Turn the ignition switch to LOCK (0), then disconnect the HDS. 14. Reconnect the SCS service connector to the MES connector. Do not use a jumper wire. 15. Turn the ignition switch to ON (II). 16. Watch the SRS indicator. (It comes on for about 6 seconds and then goes off.) Disconnect the SCS service connector from the MES connector within 4 seconds after the indicator goes off. 17. When the SRS indicator comes on again, connect the SCS service connector to the MES connector within 4 seconds after the indicator comes on. 18. When the SRS indicator goes off, disconnect the SCS service connector from the MES connector within 4 seconds. (The SRS indicator blinks twice to indicate that the memory has been cleared.) 19. Turn the ignition switch to LOCK (0), and wait for 10 seconds. 20. Turn the ignition switch to ON (II). (The SRS is OK if the SRS indicator comes on for 6 seconds and then goes off.) If the DTC clearing fails, repeat the process two more times. If the DTC clearing fails again, check for set SRS DTCs, and troubleshoot them with the appropriate service manual. REPAIR PROCEDURE B: OPDS SENSOR REPLACEMENT 1. Remove the seat-back cover from the front passenger's seat: ^ Using the appropriate service manual, go to section 20 (Body), and do the removal steps under Front Seat Cover Replacement, or ^ Online, enter keyword SEAT COVER, then select Front Seat Cover Replacement from the list, and do the removal steps in the procedure. 2. Slide the seat-back cushion (foam) off the seat-back frame. (The OPDS sensor is built into the seat-back cushion.) 3. Slide a new seat-back cushion over the seat-back frame. Make sure the cushion is centered. 4. Install the seat-back cover: ^ Using the appropriate service manual, go to section 20 (Body), and do the installation step under Front Seat Cover Replacement, or ^ Online, enter keyword SEAT COVER, then select Front Seat Cover Replacement from the list, and do the installation step in the procedure. 5. Initialize the OPDS unit: ^ To initialize with the HDS, go to Initializing the OPDS Unit: HDS Method in this service bulletin. ^ To initialize with the SCS service connector, go to Initializing the OPDS Unit: Manual Mode in this service bulletin. Disclaimer Page 4789 1. Remove the secondary lock from the male terminal half. 2. Remove the secondary lock from the female terminal half. 3. Remove the terminal (same procedure for male and female). 4. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE C: 1. Remove the secondary lock. Page 1538 Fuse Block: Connector Locations 71. Under Left Side Of Dash 70. Under Left Side Of Dash Page 2759 DTC U0100 thru U1288 Disclaimer Page 948 1. On Accords and Pilots, remove the front passenger's seat-back panel by prying out the bottom. Replace the two lower clips. 2. On all models except Accords and Pilots, unzip the two seat cover zippers on the back of the front passenger's seat. 3. Pull back the seat-back cover from the left side bolster to access the OPDS unit cover. 4. Remove the OPDS unit cover from the seat frame. 5. Check the part number of the installed OPDS unit. Page 7410 9. Check for continuity between the rear window defogger negative terminal (A) connector and body ground. There should be continuity. If there is no continuity, check for: An open in the BLK wire (B) - An open in the rear window defogger wire - Poor ground (G701) (C) ATF Level Check Fluid - A/T: Service and Repair ATF Level Check ATF Level Check NOTE: Keep all foreign particles out of the transmission. 1. Warm up the engine to normal operating temperature (the radiator fan comes on). 2. Park the vehicle on level ground, and turn the engine off. 3. Remove the dipstick (yellow loop) (A) from the transmission, and wipe it with a clean cloth. 4. Insert the dipstick into the transmission. 5. Remove the dipstick and check the fluid level. It should be between the upper mark (B) and lower mark (C). 6. If the level is below the lower mark, pour the recommended fluid into the dipstick hole to bring it to the upper mark. Always use Honda ATF-Z1 Automatic Transmission Fluid (ATF). Using a non Honda ATF can affect shift quality. 7. Insert the dipstick back into the transmission in the direction shown. Page 9769 Front Door Window Motor: Connector Locations 123. Driver's Door (Coupe exc. DX, HX; Sedan exc. DX) 123. Driver's Door (Coupe Exc. DX, HX; Sedan Exc. DX) Page 6922 Air Bag Control Module: Diagrams 231. OPDS Unit Locations 25. Transmission Housing (CVT) Page 6807 Impact Sensor: Service and Repair Side Impact Sensor Side Impact Sensor Replacement Removal NOTE: - Removal of the side impact sensor must be performed according to the precautions/procedures described before. - Before disconnecting the side impact sensor 2P connector(s), disconnect the side airbag 2P connector(s). - Do not turn the ignition switch ON (II), and do not connect the battery cable while replacing the side impact sensor. 1. Disconnect the battery negative cable, and wait at least 3 minutes before beginning work. 2. 2-door: Slide the front seat forward. 4-door: Remove the seat assembly. 3. 2-door: Remove the rear seat-backs and rear seat cushion. 4-door: Remove the B-pillar lower trim panel. 4. 2-door: Remove the front seat belt lower anchor slide bar. 5. 2-door: Remove the side trim panel. 6. 2-door: Remove the middle cross-member gusset. 7. Disconnect the floor wire harness 2P connector (A) from the side impact sensor (B). 8. Remove the Torx bolt (C) using a Torx T30 bit, then remove the side impact sensor (B). Installation NOTE: - Be sure to install the harness wires so that they are not pinched or interfering with other parts. - Do not turn the ignition switch ON (II), and do not connect the battery cable while replacing the side impact sensor. 1. Install the new side impact sensor with a new Torx bolt (A) then connect the floor wire harness 2P connector (B) to the side impact sensor (C). 2. Reconnect the battery negative cable. 3. After installing the side impact sensor, confirm proper system operation: Turn the ignition switch ON (II): the SRS indicator should come on for about 6 seconds and then go off. 4. Install all remove parts. Page 2749 DTC P0401 thru P0562 Page 4004 Shift Solenoid: Diagrams 185. CVT Control Valves And Inhibitor Solenoid Assembly 73. Shift Solenoid Valve A And B (A/T Except CVT) 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 7249 Programming the Transmitter NOTES: ^ The system accepts up to three transmitters. The transmitter codes are stored in a stacking-type memory. If a fourth transmitter code is programmed, the code for the first transmitter is erased. ^ Entering the programming mode cancels all learned transmitter codes, so none of the previously programmed transmitters will work. You must reprogram all of the transmitters once you are in the programming mode. ^ You must complete steps 1-6 within 4 seconds of the previous step to keep the system from exiting the programming mode. 1. Turn the ignition switch to ON (II). 2. Press the "Lock" or "Unlock" button on one of the transmitters. (An unprogrammed transmitter can be used for this step.) 3. Turn the ignition switch to LOCK (0). 4. Repeat steps 1 2, and 3 two more times using the same transmitter used in step 2. 5. Turn the ignition switch to ON (II). 6. Press the "Lock" or "Unlock" button on the same transmitter. Make sure the power door locks cycle to confirm that the system is in programming mode. 7. Within 10 seconds, press the "Lock" or "Unlock" button on each transmitter. Make sure the power door locks cycle after you press each transmitter button to confirm that the system accepted the transmitter's code. 8. Turn the ignition switch to LOCK (0) to exit the programming mode. Ordering a Transmitter Transmitters can be ordered only by authorized Honda dealers. Order them from American Honda using normal parts ordering procedures. Batteries for the Transmitter The battery number is CR1616. Each transmitter uses one battery. 97-04 CR-V & 00-04 S2000 *1997-04 CR-V LX with dealer-installed keyless entry system 1998-04 CR-V EX with factory-installed keyless entry system 2000-01 CR-V SE with factory-installed keyless entry system 2000-04 S2000 with factory-installed keyless entry system 2002-04 CR-V with dealer-installed security system* Page 1670 Circuit Schematics Each schematic represents one circuit. A circuit's wires and components are arranged to show current flow from power at the top of the diagram 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 Page 8133 Programming the Transmitter This transmitter is not programmable. Ordering a Transmitter This transmitter is no longer available. Batteries for the Transmitter The battery number is CR2025. Each transmitter uses two batteries. 97-99 EV Plus With Factory-Installed Security System 1997-99 EV Plus with factory-installed security system Programming the Transmitter NOTES: ^ The system accepts up to three transmitters. The transmitter codes are stored in a stacking-type memory. If a fourth transmitter code is programmed, the code for the first transmitter is erased. ^ Entering the programming mode cancels all learned transmitter codes, so none of the previously programmed transmitters will work. You must reprogram all of the transmitters once you are in the programming mode. ^ You must complete steps 1-6 within 4 seconds of the previous step to keep the system from exiting the programming mode. 1. Turn the ignition switch to ON (II). 2. Press the "Lock" or "Unlock" button on one of the transmitters. (An unprogrammed transmitter can be used for this step.) 3. Turn the ignition switch to LOCK (0). 4. Repeat steps 1, 2, and 3 two more times using the same transmitter used in step 2. 5. Turn the ignition switch to ON (II). 6. Press the "Lock" or "Unlock" button on the same transmitter. Make sure the power door locks cycle to confirm that the system is in programming mode. 7. Within 10 seconds, press the "Lock" or "Unlock" button on each transmitter. Make sure the power door locks cycle after you press each transmitter button to confirm that the system accepted the transmitter's code. 5. Turn the ignition switch to LOCK (0) to exit the programming mode. Ordering a Transmitter Transmitters can be ordered only through Tech Line. Batteries for the Transmitter The battery number is CR2025. Each transmitter uses one battery. 00-04 Insight With Factory-Installed Keyless Entry System 2000-04 Insight with factory-installed keyless entry system Page 8123 2003-04 Accord DX with dealer-installed security system 2003-04 Element with dealer-installed keyless entry system or security system 2004 Element EX with factory-installed keyless entry system or dealer-installed security system 2003-04 Pilot EX models with factory-installed security system* Programming the Transmitter NOTES: ^ The system accepts up to three transmitters. The transmitter codes are stored in a stacking-type memory. If a fourth transmitter code is programmed, the code for the first transmitter is erased. ^ Entering the programming mode cancels all learned transmitter codes, so none of the previously programmed transmitters will work. You must reprogram all of the transmitters once you are in the programming mode. ^ You must complete steps 1-6 within 4 seconds of the previous step to keep the system from exiting the programming mode. 1. Turn the ignition switch to ON (II). 2. Press the "Lock" or "Unlock" button on one of the transmitters. (An unprogrammed transmitter can be used for this step.) 3. Turn the ignition switch to LOCK (0). 4. Repeat steps 1, 2, and 3 two more times using the same transmitter used in step 2. 5. Turn the ignition switch to ON (II). 6. Press the "Lock" or "Unlock" button on the same transmitter. Make sure the power door locks cycle to confirm that the system is in programming mode. 7. Within 10 seconds, press the "Lock" or "Unlock" button on each transmitter. Make sure the power door locks cycle after you press each transmitter button to confirm that the system accepted the transmitter's code. 8. Turn the ignition switch to LOCK (0) to exit the programming mode. Ordering a Transmitter Transmitters can be ordered only by authorized Honda dealers. Order them from American Honda using normal parts ordering procedures. Batteries for the Transmitter The battery number is CR2025. Each transmitter uses one battery. 91-93 Accord 5-D00R EX Locations Turn Signal Relay: Locations Turn Signal/Hazard Flasher Component Location Index Page 4515 4. Torque the mounting bolts in a crisscross pattern. Tighten the bolts in several steps to prevent warping the diaphragm spring. 5. Remove the special tools. 6. Make sure the diaphragm spring fingers are all the same height. Page 8317 Power Mirror Motor: Service and Repair Power Mirror Actuator Replacement 1. Remove the power mirror. 2. Carefully remove the mirror holder from the mirror housing. Gently pull it out by hand. 3. Disconnect the connector. 4. Remove the cover, then remove the two Torx screws from the mirror connector. 5. Record the terminal locations and wire colors. 6. Cut the wire harness with the wire cutter. 7. Remove the three Trox screws and separate the actuator (A) from the mirror housing (B). Component Locations Fuse Block: Component Locations Fuse and Relay Box Starting System Component Location Index Page 6234 Keyless/Power Door Lock System Component Location Index Seats With Side Airbags Air Bag(s) Arming and Disarming: Description and Operation Seats With Side Airbags Seats with Side Airbags Seats with side airbags have a tag attached to the seat-back. Because the component parts (seat-back cover, cushion, etc.) of seats with and without airbags are different, make sure you install only the correct replacement parts. Because the seats are made by more than one manufacturer, make sure you replace any seat components (seat-back cover, frame, etc.) with the correct parts. The name of the seat manufacturer is indicated on the seat-back. Moreover, the manufacturer name is indicated on the seat-back frame and the seat-back pad. Confirm the indication when you exchange these parts. * When cleaning, do not saturate the seat with liquid, and do not spray steam on the seat. * Do not repair torn or frayed seat-back covers. Replace the seat-back cover. * After a collision in which the side airbag was deployed, replace the seat-back cover and the side airbag with new parts. If the seat-back cushion is split, it must be replaced. If the seat-back frame is definitely deformed, it must be replaced. Page 901 160. Left Side Of Engine Compartment (except GX) Component Locations Moonroof Component Location Index Page 9843 19. Use suction cups to hold the rear window over the opening, align it with the alignment marks you made in step 13, and set it down on the adhesive. Lightly push on the rear window until its edges are fully seated on the adhesive all the way around. Do not open or close the doors until the adhesive is dry. 20. Scrape or wipe any excess adhesive off with a putty knife or towel. To remove adhesive from a painted surface or the rear window, use a soft shop towel dampened with alcohol. 21. Let the adhesive dry for at least 1 hour, then spray water over the rear window and check for leaks. Mark the leaking areas, let the rear window dry, then seal with sealant. Let the vehicle stand for at least 4 hours after rear window installation. If the vehicle has to be used within the first 4 hours, it must be driven slowly. 22. Reinstall all remaining removed parts. NOTE: Advise the customer not to do the following things for 2 to 3 days: Slam the doors with all the windows rolled up. - Twist the body excessively (such as when going in and out of driveways at an angle or driving over rough, uneven roads). 4-door NOTE: - Put on gloves to protect your hands. - Wear eye protection while cutting the glass adhesive with piano wire. - Cover interior surfaces to avoid damaging them. - Do not damage the rear window defogger grid lines, window antenna grid lines, and terminals. 1. Remove these items: - Trunk lid - Rear shelf 2. Remove the window antenna terminal cover (A) from the window antenna terminal cover base (B), and disconnect the window antenna connector (C). 3. Disconnect the rear window defogger connectors (D). 4. If the old rear window will be reinstalled, make alignment marks across the glass and body with a grease pencil. Page 3147 2. Remove the terminal (same procedure for male and female). 3. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE E: 1. Remove the secondary locks. 2. Remove the terminal (same procedure for male and female). 3. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE F: 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 9185 Circuit Schematics Each schematic represents one circuit. A circuit's wires and components are arranged to show current flow from power at the top of the diagram 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 Page 822 1. Remove the terminal. 2. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE B: 1. Remove the terminal. 2. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE C: 1. Remove the terminal. 2. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE D: Page 5174 156. A/T Reverse Relay (A/T, CVT) Page 1275 DIAGNOSTIC WORKSHEET REPAIR PROCEDURE A Page 9351 - Before connecting connectors, make sure the terminals (A) are in place and not bent. - Check for loose retainer (A) and rubber seals (B). - The backs of some connectors are packed with dielectric grease. Add grease if necessary. If the grease is contaminated, replace it. - Insert the connector all the way and make sure it is securely locked. - Position wires so that the open end of the cover faces down. Handling Wires and Harnesses - Secure wires and wire harnesses to the frame with their respective wire ties at the designated locations. Page 5987 Ground To Components Index (2-door) Locations Intake Air Temperature Sensor: Locations PGM-FI System - Component Location Index Page 3051 7. Remove the four screws that hold the two fuses, and remove the fuses. 8. Release the tab that holds the ELD, and pull up on the ELD to remove it. 9. Remove the bus bar from the ELD, and insert the bar into the new ELD. 10. Install the new ELD and bus bar into the fuse/relay box. 11. Reinstall the two fuses. 12. Reinstall the 3P ELD connector and the lower fusel relay box cover. 13. Reinstall the fuse/relay box onto its holder. CR-V only: Reinstall the wire harness clip onto the holder. 14. Reinstall the fuse/relay box cover. 15. Reconnect the negative battery cable. 16. Do the idle learn procedure: ^ Make sure all electrical items (A/C, audio unit, defogger, lights, etc.) are off. Page 3924 Two updating modes can be used with the HIM: Pass-Thru mode and Storage mode. Pass-Thru mode is used when the HIM can be connected to an iN workstation and the vehicle at the same time. Storage mode is used when the HIM cannot be connected to the iN workstation and the vehicle at the same time. HIM Updating in Pass-Thru Mode NOTE: If the red No.3 LED on the HIM comes on or flashes during the update, go to Diagnosing HIM Error Codes. 1. If not already done, load the latest HDS PC software onto your iN workstation. For loading instructions, refer to the Tool Information publication Installation Instructions for HDS PC Software on ISIS. NOTE: If the latest software is not loaded and you do a control unit/module update, the software may indicate the vehicle has the latest update when it doesn't. Updates not done with the latest software are not covered under warranty. 2. From the iN workstation desktop, select CM Update (ECU Rewrite). 3. Connect the PC interface cable to the iN workstation and to the HIM. 4. Return to the Updating Honda Control Modules main screen, and click on Pass-thru-Mode. 5. Connect the HIM to the vehicle's DLC. 6. Turn the ignition switch to ON (II), and wait until the green No.1 LED on the HIM stays on. Click on the check mark to continue. Each updatable vehicle system is checked to make sure it is current. Any systems needing an update are listed on the screen. Highlight the system you want to update, then click on the check mark to continue. Page 8800 2. Remove the access panel from the steering wheel, then disconnect the driver's airbag 4P connector (A) from the cable reel. Front Passenger's Airbag 3. Lower the glove box, then disconnect the front passenger's airbag 4P connector (A) from the dashboard wire harness B. Side Airbag 4. Disconnect both side airbag 2P connectors (A) from the floor wire harness. Seat Belt Tensioner 5. Disconnect both seat belt tensioner 2P connectors (A) from the floor wire harness. Seat Belt Buckle Tensioner Page 9181 Splices Components Ground - "G" Page 9094 2. Remove the terminal (same procedure for male and female). 3. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE E: 1. Remove the secondary locks. 2. Remove the terminal (same procedure for male and female). 3. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE F: Page 5903 Splices Components Ground - "G" Page 3914 NOTE: If the Database Update is an earlier version than the one listed in a Honda service communication (service bulletin, product update, iN message, etc.), press ESC, then update your MVCI before continuing. 6. Wait for the MVCI to check the vehicle for reprogrammable systems. This may take up to 90 seconds. 7. If there are multiple reprogrammable systems that need to be updated, select the applicable system. Press ENTER to continue, or press ESC to exit. 8. The current program ID, the recommended update, and other details appear. Press ENTER to continue, or press ESC to exit. Locations Knock Sensor: Locations PGM-FI System - Component Location Index Page 6039 235. Under-dash Fuse/Relay Box Part 8 Page 2456 53. IAT Sensor Page 8066 Page 6745 Air Bag: Diagrams 74. Side Airbag Inflator, Driver's 75. Side Airbag Inflator, Front Passenger's (Sedan) 76. Side Airbag Inflator, Passenger's (Coupe) Page 8307 13. After completing the right edge, push all of the cam blades to the right until they touch the cams, then trace the cam blades from back to front. (The cutter bit cuts the same contours into the left edge of the key from tip to head.) Turn off the cutter motor. 14. Release the vertical carriage lever. Push all the cam blades to the left until they touch the cams. Pull the vertical carriage lever towards you until the tracer touches the flat surface on the right side, at the front of the cams. Gently twist the lever clockwise to lock the vertical carriage at this height. Do not overtighten the lever. 15. Turn on the cutter motor, then retrace the cam blades from front to back. Push all the cam blades to the right until they touch the cams, and then retrace the cam blades from back to front (retracing cleans up the cuts on the key). Turn off the cutter motor. 16. Release the vertical carriage lever. Open the jaw and remove the key. Make sure the jaw is free of any metal shavings or debris. Turn the key over so the blank side is up, then slide it into the jaw up to the key stop. Close the jaw to lock the key in place. 17. Push all the cam blades to the left until they touch the cams. Repeat steps 10 through 15 to cut both edges on the other side of the key. 18. When you are done making the required cuts, release the vertical carriage lever. Open the jaw and remove the key. 19. Make sure the key works in the ignition switch and the locks. If the key does not work, recut the key, and try it again. 20. Depending on the type of key, code the key transponder. Equipment Service and Warranty To service the MATRIX H Key Cutting Machine, refer to section 7 of the MATRIX H Operating Manual. It tells you how to replace parts that commonly wear out such as the drive belt, the work light bulb, and the tension spring on the vertical carriage. It also covers checking and replacing fuses and replacing the printed circuit board for the setting unit keypad. If you have technical questions on the equipment, contact the Ilco Technical Assistance Department. Mail: Kaba Ilco Technical Assistance Department 400 Jeffreys Road Rocky Mount, NC 27804 Phone: 800-452-6872 Ext: 200, 384, 323, 398, 356 Fax: 252-446-4702 The MATRIX H Key Cutting Machine comes with a 3-year limited warranty. This warranty does not cover the cutter bit or the work light bulb. CODE BOOK CORRECTIONS In the code book Honda High Security key Codes, correct these errors: Pages 4 thru 51, code headings: ^ Incorrect: J H G F Z X E D C B M/S X ^ Correct: J H G F A X E D C B M/S X Page 2, last paragraph: Page 5417 Brake Rotor/Disc: Testing and Inspection Front Brake Disc Inspection Runout 1. Raise the front of the vehicle, and support it with safety stands in the proper locations. Remove the front wheels. 2. Remove the brake pads. 3. Inspect the disc surface for damage and cracks. Clean the disc thoroughly, and remove all rust. 4. Install suitable flat washers (A) and wheel nuts, and tighten the nuts to the specified torque to hold the brake disc securely against the hub. 5. Set up the dial gauge against the brake disc as shown, and measure the runout at 5 mm (0.2 inch) from the outer edge of the disc. Brake Disc Runout: Service Limit: 0.10 mm (0.004 inch) 6. If the disc is beyond the service limit, refinish the brake disc. Max. Refinish Limit: 19.0 mm (0.75 inch) NOTE: ^ If the brake disc is beyond the service limit for refinishing, replace it. ^ A new disc should be refinished if its runout is greater than 0.10 mm (0.004 inch). Thickness and Parallelism 1. Raise the front of the vehicle, and support it with safety stands in the proper locations. Remove the front wheels. 2. Remove the brake pads. 3. Using a micrometer, measure disc thickness at eight points, approximately 45° apart and 10 mm (0.4 inch) in from the outer edge of the disc. Replace the brake disc if the smallest measurement is less than the max. refinishing limit. Brake Disc Thickness: Standard: 20.9 - 21.8 mm (0.82 - 0.86 inch) Max. Refinishing Limit: 19.0 mm (0.75 inch) Brake Disc Parallelism: 0.015 mm (0.0006 inch) max. NOTE: This is the maximum allowable difference between the thickness measurements. 4. If the disc is beyond the service limit for parallelism, refinish the brake disc with an on-car brake lathe. The Kwik-Lathe produced by Kwik-way Manufacturing Co. and the "Front Brake Disc Lathe" offered by Snap-on Tools Co. are approved for this operation. NOTE: If the brake disc is beyond the service limit for refinishing, replace it. Page 8755 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. Below most connector numbers and component names are PHOTO and VIEW numbers. The PHOTO number refers to a photo in the back of the book that shows the connector's location on the car. The VIEW number refers to an illustration in the back of the book that shows the connector terminals, wire colors, connector cavity numbers, and other details. The connector cavity numbering sequence begins at the top left corner of the connector as seen from either of the viewpoints shown on diagram [8] . Except for the DLC (data link 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 C554, for example, means those terminals join in cavity 2 of connector C554. Power Distribution Schematics Power Distribution Schematics Page 7213 2003-04 Accord DX with dealer-installed security system 2003-04 Element with dealer-installed keyless entry system or security system 2004 Element EX with factory-installed keyless entry system or dealer-installed security system 2003-04 Pilot EX models with factory-installed security system* Programming the Transmitter NOTES: ^ The system accepts up to three transmitters. The transmitter codes are stored in a stacking-type memory. If a fourth transmitter code is programmed, the code for the first transmitter is erased. ^ Entering the programming mode cancels all learned transmitter codes, so none of the previously programmed transmitters will work. You must reprogram all of the transmitters once you are in the programming mode. ^ You must complete steps 1-6 within 4 seconds of the previous step to keep the system from exiting the programming mode. 1. Turn the ignition switch to ON (II). 2. Press the "Lock" or "Unlock" button on one of the transmitters. (An unprogrammed transmitter can be used for this step.) 3. Turn the ignition switch to LOCK (0). 4. Repeat steps 1, 2, and 3 two more times using the same transmitter used in step 2. 5. Turn the ignition switch to ON (II). 6. Press the "Lock" or "Unlock" button on the same transmitter. Make sure the power door locks cycle to confirm that the system is in programming mode. 7. Within 10 seconds, press the "Lock" or "Unlock" button on each transmitter. Make sure the power door locks cycle after you press each transmitter button to confirm that the system accepted the transmitter's code. 8. Turn the ignition switch to LOCK (0) to exit the programming mode. Ordering a Transmitter Transmitters can be ordered only by authorized Honda dealers. Order them from American Honda using normal parts ordering procedures. Batteries for the Transmitter The battery number is CR2025. Each transmitter uses one battery. 91-93 Accord 5-D00R EX Locations 12. Middle of Engine Page 2255 Radiator Cooling Fan Temperature Sensor / Switch: Service and Repair Radiator Fan Switch Replacement 1. Disconnect the radiator fan switch connector, then remove the radiator fan switch (A). 2. Install the radiator fan switch using a new O-ring (B). Page 3483 94. Behind Glove Box (except GX) Page 5999 1. Remove the terminal. 2. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE C: 1. Remove the terminal. 2. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE D: Page 2965 ECM/PCM Inputs And Outputs At Connector B (24P) Air Bag Disarming and Arming Air Bag(s) Arming and Disarming: Service and Repair Air Bag Disarming and Arming 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 8516 Power Door Lock Switch: Testing and Inspection Door Lock Switch Test Door Lock Switch Test 1. Remove the driver's door panel. 2. Remove the two mounting screws and the door lock switch. 3. Check for continuity between the terminals. - There should be continuity between the No.1 and No.2 terminals when the door lock switch is in the LOCKED position. - There should be continuity between the No.2 and No.3 terminals when the door lock switch is in the UNLOCKED position. 4. If the continuity is not as specified, replace the switch. Page 117 PGM-F1 Main Relay 1, 2 Type 1, 2 Check for continuity between the terminals. - There should be continuity between the No.1 and No.2 terminals when power and ground are connected to the No.3 and No.4 terminals. - There should be no continuity between the No.1 and No.2 terminals when power is disconnected. Normally-open type B: Rear Window Defogger Relay Locations Knock Sensor: Locations PGM-FI System - Component Location Index Page 6630 Compressor Clutch Relay: Testing and Inspection Power Relay Test Use this chart to identify the type of relay, then do the test listed for it. NOTE: See the turn signal/hazard relay input test. Normally-open type A: Page 8787 Air Bag(s) Arming and Disarming: Vehicle Damage Warnings 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. - To prevent damage to the airbag assembly, keep free from any oil, grease, detergent, or water. - Store the removed airbag on a secure, fiat surface away from any high heat source (exceeding 200 °F / 93 °C). Page 1021 Page 5560 ^ Incorrect: "If a Master Key is to be cut, put a five (5) in the blank space. Use a two (2) if a valet key is needed." ^ Correct: "If a Master Key is to be cut, put an M in the blank space. Use an S if a valet key is needed." Page 2, legend at the bottom: ^ Incorrect: "C. If a Master key is desired, then the number five (5) should be placed in the M/S position. Place the number two (2) in the M/S column if a Sub (Valet) key is needed." ^ Correct: "C. If a Master Key is desired, then an M should be placed in the M/S position. Place an S in the MIS column if a Sub (Valet) key is needed." Page 1182 6. Separate the master switch plate (A) from the armrest (B). 7. Remove the three screws and replace the switch. 2-door Page 1596 Malfunction Indicator Lamp: Testing and Inspection MIL Circuit Troubleshooting 1. Connect an OBD II scan tool/Honda PGM Tester. 2. Turn the ignition switch ON (II) and read the OBD II scan tool/Honda PGM Tester. Does the OBD II scan tool/Honda PGM Tester communicate with the ECM/PCM? YES - Go to step 3. NO - Go to troubleshooting "DLC Circuit Troubleshooting". 3. Check the OBD II scan tool/Honda PGM Tester for DTCs. Are any DTCs indicated? YES - Go to the DTC Troubleshooting index. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Descriptions NO - Go to step 4. 4. Turn the ignition switch OFF. 5. Turn the ignition switch ON (II) and watch the Malfunction Indicator Lamp (MIL). Does the MIL come on and stay on for more than 20 seconds after turning the ignition switch ON (II)? YES - If the MIL always comes on and stays on, go to step 74. But if the MIL sometimes works normally, first check for these problems. An intermittent short in the wire between the ECM/PCM (E29) and the data link connector (DLC). - An intermittent short in the wire between the ECM/PCM (E31) and the gauge assembly. NO - If the MIL is always off, go to step 6. But if the MIL sometimes works normally, first check for these problems. A loose No.10 METER (7.5A) fuse in the under-dash fuse/relay box. - A loose No.20 IG (40A) fuse in the under-hood fuse/relay box. - A loose No.6 ECU (ECM/PCM) (15A) fuse in the under-hood fuse/relay box. - A loose No.17 FUEL PUMP (15A) fuse in the under-dash fuse/relay box. - A poor connection at ECM/PCM terminal E31. - An intermittent open in the GRN/ORN wire between the ECM/PCM (E31) and the gauge assembly. - An intermittent short in the wire between the ECM/PCM (A21) and the manifold absolute pressure (MAP) sensor, CVT driven pulley speed sensor (CVT), or CVT speed sensor 1 (CVT). - An intermittent short in the wire between the ECM/PCM (A20) and the throttle position (TP) sensor, knock sensor, exhaust gas recirculation (EGR) valve position sensor, CVT drive pulley speed sensor (CVT), or CVT speed sensor 2 (CVT). - An intermittent short in the wire between the ECM/PCM (A5) and the knock sensor. - An intermittent short in the wire between the ECM/PCM (E5) and the fuel tank pressure (FTP) sensor. 6. Turn the ignition switch OFF. 7. Turn the ignition switch ON (II). Is the low oil pressure light on? YES - Go to step 10. NO - Go to step 8. 8. Inspect the No.10 METER (7.5 A) fuse in the under-dash fuse/relay box. Is the fuse OK? YES - Go to step 9. NO - Repair short in the wire between No.10 METER (7.5A) fuse and the gauge assembly. Also replace the No.10 METER (7.5A) fuse. 9. Inspect the No.20 IGN (40A) fuse in the under-hood fuse/relay box. Is the fuse OK? Page 3987 Shift Solenoid: Testing and Inspection Shift Solenoid Valves A and B Test 1. Disconnect the shift solenoid valves A and B connector. 2. Measure shift solenoid valve A resistance between the No. 1 terminal of the shift solenoid valves A and B connector and body ground, and measure shift solenoid valve B resistance between the No. 2 terminal and body ground. STANDARD: 12 - 25 Ohms 3. Replace the shift solenoid valves A and B if either resistance is out of standard. 4. If the resistance is within the standard, connect the No. 1 terminal of the shift solenoid valve A to the battery positive terminal. A clicking sound should be heard. Connect the No. 2 terminal to the battery positive terminal. A clicking sound should be heard. Replace the shift solenoid valves A and B if no clicking sound is heard when either terminal is connected to the battery terminal. Specifications Brake Pad: Specifications Brake pads Thickness Standard or New ........................................................................................................................................................ 9.5 - 10.5 mm (0.37 - 0.41 inch) Service Limit ........................................................................................... ...................................................................................... 1.6 mm (0.06 inch) Page 4302 143. Park Pin/Shift Switch (A/T) Page 7995 Trim Panel: Service and Repair Trim Removal/Installation - Seat Side and Rear Shelf Area Trim Removal/Installation - Seat Side and Rear Shelf Area Special Tools Required KTC trim tool set SOJATP2014 2-door NOTE: - Put on gloves to protect your hands. - Use the appropriate tool from the KTC trim tool set to avoid damage when prying components. - Take care not to bend or scratch the trim and panels. 1. Remove the trim as shown. To remove the side trim panel, remove the rear seat-back and rear seat cushion. 2. Install the parts in the reverse order of removal, and note these items: - Before installing the rear shelf, remove the clips from the body, and install them to the rear shelf. - Replace any damaged clips. - When installing the rear shelf, slip the rear seat belts and center belt through the slits in the rear shelf. - Make sure the high mount brake light connector is plugged in properly. - Apply liquid thread lock to the anchor bolts before installation. Page 4629 the mounting stud while the shift cable is on the shift cable bracket base. 12. Install and tighten the nut. 13. Remove the 6.0 mm (0.24 inch) pin that was installed to hold the shift lever. 14. Move the shift lever to each position, and verify that the A/T gear position indicator follows the transmission range switch. 15. Push the shift lock release, and verify that the shift lever releases. 16. Reinstall the center console, console panel, and related parts. Locations 94. Behind Glove Box (except GX) Page 1496 Air Bag(s) Arming and Disarming: Description and Operation SRS Operation SRS Operation The main circuit in the SRS unit senses and judges the force of impact and, if necessary, ignites the inflator charges. 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: Seat Belt Tensioners and Seat Belt Buckle Tensioners 1. A front impact sensor must activate and send electric signals to the microprocessor. 2. The microprocessor must compute the signals and send them to the tensioners. 3. The charges must ignite and deploy the tensioners. Driver's and Front Passenger's Airbag(s) 1. A front impact sensor must activate, and send electric signals to the microprocessor. 2. The microprocessor must compute the signals, and depending on the severity of the collision and whether the seat belt buckle switch is ON or OFF, it sends the appropriate signals to the airbag inflator(s). 3. The inflators that received signals must ignite and deploy the airbags. Side Airbag(s) 1. Aside impact sensor must activate, and send electric signals to the microprocessor. 2. The microprocessor must compute the signals and send them to the side airbag inflator(s). However, the microprocessor cuts off the signals to the front passenger's side airbag if the OPDS unit determines that the front passenger's head is in the deployment path of the side airbag. 3. The inflator that received the signal must ignite and deploy the side airbag. Self-diagnosis System A self-diagnosis circuit is built into the SRS unit; when the ignition switch is turned ON (II), the SRS indicator comes on and goes off after about 6 seconds if the SRS is operating normally. If the indicator does not come on, or does not go off after 6 seconds, or if it comes on while driving, it indicates an abnormality in the SRS. The SRS must be inspected and repaired as soon as possible. For better serviceability, the SRS unit memory stores a DTC that relates to the cause of the malfunction, and the unit is connected to the data link circuit. This information can be read with the Honda PGM Tester when it is connected to the data link connector (DLC). Page 8588 21. Leave the key in the cylinder. Reinstall the plastic retainer and spring if you removed them in step 16. Hold the plastic retainer and spring on the housing, and insert the inner cylinder. Rotate it left and right to engage the spring to the inner cylinder. Make sure the spring is properly seated to the inner cylinder. 22. Install the arm with a new cylinder rod clip and a new E-clip. 23. Make sure the key can be inserted and removed easily, and that the cylinder turns with the key. Specifications Piston: Specifications Piston Skirt O.D. at 13 mm (0.5 inch) from bottom of skirt Standard or New .......................................................................................................................................... 74.98 74.99 mm (2.9520 - 2.9524 inch) Service limit .................................................................................... ....................................................................................... 74.97 mm (2.9516 inch) Clearance in cylinder Standard or New .......................................................................................................................................... 0.010 0.040 mm (0.0004 - 0.0016 inch) Service Limit ................................................................................... .......................................................................................... 0.05 mm (0.002 inch) Page 2522 Transmission Position Switch/Sensor: Diagnostic Aids General Troubleshooting Information General Troubleshooting Information Tips and Precautions Before Troubleshooting 1. Check applicable fuses in the appropriate fuse/relay box. 2. Check the battery for damage, state of charge, and clean and tight connections. NOTE: 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. Handling Connectors - Make sure the connectors are clean and have no loose wire terminals. - Make sure multiple cavity connectors are packed with dielectric grease (except watertight connectors). - All connectors have push-down release type locks (A). - Some connectors have a clip on their side used to attach them to a mount bracket on the body or on another component. This clip has a pull type lock. - Some mounted connectors cannot be disconnected unless you first release the lock and remove the connector from its mount bracket (A). - Never try to disconnect connectors by pulling on their wires; pull on the connector halves instead. - Always reinstall plastic covers. Page 3854 Page 1176 Power Window Switch: Diagrams (Sedan Except DX) (Sedan Except DX) Page 9494 - 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. Troubleshooting Tests 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 test 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 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. 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 Drop Page 5253 2. Remove the terminal (same procedure for male and female). 3. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE E: 1. Remove the secondary locks. 2. Remove the terminal (same procedure for male and female). 3. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE F: Page 330 166. PGM-FI Main Relays 1 And 2 Page 736 114. FTP Sensor (except GX) Page 2653 Ignition System Component Location Index Page 182 1. Remove the terminal. 2. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE E: 1. Remove the terminal. 2. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE F: Page 9190 - Remove clips carefully; don't damage their locks (A). - Slip pliers (A) under the clip base and through the hole at an angle, then squeeze the expansion tabs to release the clip. - After installing harness clips, make sure the harness doesn't interfere with any moving parts. - Keep wire harnesses away from exhaust pipes and other hot parts, from sharp edges of brackets and holes, and from exposed screws and bolts. - Seat grommets in their grooves properly (A). Do not leave grommets distorted (B). Testing and Repairs - Do not use wires or harnesses with broken insulation. Replace them or repair them by wrapping the break with electrical tape. - After installing parts, make sure that no wires are pinched under them. - When using electrical test equipment, follow the manufacturer's instructions and those described. - If possible, insert the probe of the tester from the wire side (except waterproof connector). - Use back probe adaptor 07TAZ-001020A. - Refer to the instructions in the Honda Terminal Kit for identification and replacement of connector terminals. Five-Step Troubleshooting Five-Step Troubleshooting 1. Verify The Complaint Page 6031 71. Under Left Side Of Dash Under-hood Fuse/Relay Box Diagram Information and Instructions Interior Lighting Module: Diagram Information and Instructions Terminal Numbering System Terminal Numbering System Connector terminals are numbered according to the cavities they're in. The cavities are numbered starting from the upper left, looking at the male terminals from the terminal side or looking at the female terminals from the wire side. Both views are in the same direction so the numbers are the same. All actual cavities are numbered, even if they have no wire terminals in them. NOTE: Data Link Connector (DLC) terminals are numbered according 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 below is #6. Page 5382 1. Remove the secondary locks. 2. Remove the terminal from the female half. 3. Remove the terminal from the male half. 4. Go to HOW TO INSTALL NEW TERMINALS. Connectors Without a Secondary Lock All examples are shown with the connector lock facing up. The illustrations are examples of connector terminals without a secondary lock; however, the connector you are repairing may vary in size and shape. EXAMPLE A: Page 5310 Transmission Speed Sensor: Locations 25. Transmission Housing (CVT) 26. Transmission Housing (CVT) Page 8252 8. Release the clip, detach the hook, and remove the lock rod protector. 9. Disconnect the outer handle rod and cylinder rod. Page 378 VEHICLES AFFECTED CUSTOMER NOTIFICATION All owners of affected vehicles were mailed a notification of this warranty extension. A example of the customer notification is shown in this service bulletin. CORRECTIVE ACTION Repair the vehicle as indicated by the INSPECTION PROCEDURE. If needed, replace the OPDS unit. In rare cases where an updated OPDS unit was already installed, replace the OPDS sensor. Engine Controls - DTC P0171 Set Absolute Pressure Sensor: Technical Service Bulletins Engine Controls - DTC P0171 Set SOURCE: Honda Service News TITLE: Got a DTC P0171? Check the Short-Term Fuel Trim APPLIES TO: 03-04 Accord 01-04 Civic 02-04 CR-V 03-04 Element 02-04 Odyssey 03-04 Pilot SERVICE TIP: Got a vehicle in your shop that purrs like a kitten but it sets a DTC P0171 (fuel system too lean)? Check the short-term fuel trim (ST FUEL TRIM B1). If the value reads higher than 1.05, then check the MAP SENSOR value with the engine turned off and the ignition switch turned to ON (II). - If the MAP SENSOR and BARO SENSOR values match, the MAP sensor is working OK. Do the normal troubleshooting for DTC P0171. - If the MAP SENSOR and BARO SENSOR values don't match, install a known-good MAP sensor, and retest. If the sensor values now match, clear the DTC, and make sure the ST FUEL TRIM B1 value is normal (it reads about 1.0). Recall - Ignition/Shift Interlock Defect Technical Service Bulletin # 10-059 Date: 101001 Recall - Ignition/Shift Interlock Defect 10-059 October 1, 2010 Applies To: See VEHICLES AFFECTED Safety Recall: Accord, Civic, and Element Ignition Switch Key Interlock BACKGROUND Under certain conditions, the interlock lever of the ignition switch may unexpectedly deform. The interlock ensures the transmission is in Park before the ignition key can be removed. Interlock failure may allow the ignition key to be removed when the shift lever is not in Park. If the driver fails to engage the parking brake, the vehicle could roll away, increasing the risk of a crash. VEHICLES AFFECTED Not all vehicles within the VIN ranges are affected by this recall. Before beginning work on a vehicle, verify its eligibility by checking at least one of these items: ^ The customer has a notification letter. Page 7933 NOTE: You need to make the corrections listed in CODE BOOK CORRECTIONS at the end of this service bulletin. TRACER AND CUTTER BIT INSTALLATION 1. Turn the power switch on the back of the machine to ON. (This turns on the built-in work light.) 2. Use the Allen wrench from the built-in tool drawer to loosen the setscrew on the left sleeve of the vertical carriage. Slide the tracer all the way into the sleeve, and tighten the screw. 3. Turn the plastic shield on the right sleeve of the vertical carriage so you can access the setscrew on the sleeve. Use the Allen wrench to loosen the screw. Slide the cutter bit all the way into the sleeve, and tighten the screw. Turn the plastic shield so the open side is in the back. MACHINE COMPONENTS Page 8796 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 902 119. Knock Sensor (except GX) 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 9780 Power Windows Component Location Index Page 2935 12. Check for continuity between PSP switch 2P connector terminal No.2 and body ground. Is there continuity? YES - Repair open in the wire between the PSP switch and ECM/PCM (E16). NO - Repair open in the wire between the PSP switch and G201. 13. Turn the ignition switch OFF. 14. Disconnect the PSP switch 2P connector. 15. Turn the ignition switch ON (II). 16. Measure voltage between ECM/PCM connector terminals A24 and E16. Is there battery voltage? YES - Replace the PSP switch. NO - Go to step 17. 17. Turn the ignition switch OFF. 18. Disconnect ECM/PCM connector E (31P). 19. Check for continuity between body ground and ECM/PCM connector terminal E16. Is there continuity? YES - Repair short in the wire between ECM/PCM (E16) and the PSP switch. NO - Update the ECM/PCM if it does not have the latest software, or substitute a known-good ECM/PCM, then recheck. If the Page 1408 Coolant: Testing and Inspection Check 1. Look at the coolant level in the coolant reservoir. Make sure it is between the MAX (A) and MIN mark (B). 2. If the coolant level in the coolant reservoir is at or below the MIN mark, add coolant to bring it up to the MAX mark, and inspect the cooling system for leaks. Page 4620 Transmission Speed Sensor: Locations 25. Transmission Housing (CVT) 26. Transmission Housing (CVT) Page 4790 2. Remove the terminal from the female half. 3. Remove the terminal from the male half. 4. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE D: 1. Remove the secondary locks. Page 9448 5. Make these input tests at the connector. - If any test indicates a problem, find and correct the cause, then recheck the system. - If all the input tests prove OK, the control unit must be faulty; replace it. Page 6572 - Refill the cooling system with engine coolant. - Be sure to connect the drain hose securely. - Adjust the heater valve cable. - Make sure that there is no coolant leakage. - Make sure that there is no air leakage. - With air conditioning, refer to evaporator core replacement. - Do the ECM/PCM idle learn procedure. - Enter the anti-theft code for the radio, then enter the customer's radio station presets. Page 3125 Wire Color Abbreviations Page 1325 3. Replace the plug at the specified interval, or if the center electrode is rounded (A). Use only the spark plugs listed. 4. Apply a small quantity of anti-seize compound to the plug threads, and screw the plugs into the cylinder head finger-tight. Then torque them to 18 N.m (1.8 kgf.m, 13 lbf.ft). Locations Heating Component Location Index Page 3219 1. Remove the terminal. 2. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE E: 1. Remove the terminal. 2. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE F: Page 2266 Thermostat: Testing and Inspection Test Replace the thermostat if it is open at room temperature. To test a closed thermostat: 1. Suspend the thermostat (A) in a container of water. Do not let the thermometer (B) touch the bottom of the hot container. 2. Heat the water and check the temperature with a thermometer. Check the temperature at which the thermostat first opens, and at which it is fully open. 3. Measure the lift height of the thermostat when it is fully open: Standard Thermostat Lift height: above 8.0 mm (0.31 inch) Starts opening: 169 - 176°F (76 - 80°C) Fully open: 194°F (90°C) Page 9453 Daytime Running Lamp Relay: Testing and Inspection Power Relay Test Use this chart to identify the type of relay, then do the test listed for it. NOTE: See the turn signal/hazard relay input test. Normally-open type A: Check for continuity between the terminals. - There should be continuity between the No.1 and No.2 terminals when power and ground are connected to the No.3 and No.4 terminals. - There should be no continuity between the No.1 and No.2 terminals when power is disconnected. Page 2040 Diodes Light Emitting Diode (LED) Motor Pressure Sensor Page 5933 27. Accessory Power Socket Page 7690 ^ If the trunk opens and closes smoothly, return the vehicle to the customer. ^ If the trunk lid is still difficult to close, go to REPAIR PROCEDURE E. REPAIR PROCEDURE E 1. Look at the back of the lock cylinder while you turn the key from lock to unlock. ^ Refer to page 20-158 of the 2001-04 Civic Service Manual. ^ In ISIS, use the keyword LID LOCK, and select Trunk Lid Lock Cylinder Replacement from the list. 2. Check the operation of the trunk lid lock cylinder: ^ If the lock cylinder is difficult to turn or binds, go to step 3. ^ If the lock cylinder operates properly, and the trunk lid is still difficult to close, refer to the appropriate body repair manual, and check for body inaccuracies. 3. Replace the lock cylinder, and re-key the cylinder to the customer's original key; on 2-door Civics, replace the lock cylinder and the lock cylinder rod: ^ Refer to page 20-158 of the 2001-04 Civic Service Manual. ^ In ISIS, use the keyword LID LOCK, and select Trunk Lid Lock Cylinder Replacement from the list. 4. Check the trunk operation, and return the vehicle to the customer. Disclaimer Page 4753 Flywheel: Service and Repair Flywheel Inspection Clutch Replacement Special Tools Required ^ Clutch alignment shaft 07LAF-PT00110 ^ Clutch alignment disc 07JAF-PM7011A ^ Remover handle 07936-3710100 ^ Ring gear holder 07LAB-PV00100 or 07924-PD20003 ^ Attachment, 57 x 40 mm 07746-0010200 ^ Driver 077 49-0010000 Flywheel Inspection 1. Inspect the ring gear teeth for wear and damage. 2. Inspect the clutch disc mating surface on the flywheel for wear, cracks and burning. 3. Measure the flywheel (A) runout using a dial indicator (B) through at least two full turns with the engine installed. Push against the flywheel each time you turn it to take up the crankshaft thrust washer clearance. If the runout is more than the service limit, replace the flywheel and recheck the runout. Standard (New): 0.06 mm (0.002 inch) max. Service Limit: 0.15 mm (0.006 inch) 4. Turn the inner race of the pilot bearing (A) with your finger. The bearing should turn smoothly and quietly. Check that the bearing outer race fits tightly in the flywheel. If the race does not turn smoothly, quietly, or fit tight in the flywheel, replace the bearing. Locations 12. Middle Of Engine Page 262 DTC P0750 thru P0977 Page 7733 WARRANTY CLAIM INFORMATION In warranty: The normal warranty applies. Failed Part: P/N 68500-S5P-A90ZZ H/C 6528640 *Defect Code: 07406* Symptom Code: 03220 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 A 1. Check the side-to-side alignment of the trunk lid latch to the striker: ^ Refer to page 20-132 of the 2001-04 Civic Service Manual. ^ In ISIS, use the keyword TRUNK ADJUST, and select Trunk Lid Adjustment from the list. 2. Make sure the gaps of the trunk lid are even on all sides. ^ If the trunk is misaligned, go to step 3. ^ If the trunk lid is properly aligned on all sides, go to REPAIR PROCEDURE B. 3. Adjust the trunk lid hinges: ^ Refer to page 20-132 of the 2001-04 Civic Service Manual. ^ In ISIS, use the keyword TRUNK ADJUST, and select Trunk Lid Adjustment from the list. 4. Check the trunk operation: ^ If the trunk opens and closes smoothly and is properly aligned, return the vehicle to the customer. ^ If the trunk lid is still difficult to close, go to REPAIR PROCEDURE B. REPAIR PROCEDURE B Page 9736 125. Passenger's Door (Coupe Except DX, HX) 126. Front Passenger's Door (Sedan Except DX) Page 100 Compressor Clutch Relay: Testing and Inspection Power Relay Test Use this chart to identify the type of relay, then do the test listed for it. NOTE: See the turn signal/hazard relay input test. Normally-open type A: Page 7060 157. Behind Left Side Of Front Bumper Page 4090 Wires Page 6753 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 9824 Power Window Switch: Testing and Inspection Passenger's Window Switch Test/Replacement Passenger's Window Switch Test/Replacement 4-door 1. Remove the door grip cover. 2. Disconnect the 5P connector (A) from the passenger's power window switch (B). 3. Check for continuity between the terminals in each switch position according to the table. 4. If the continuity is not as specified, remove the two screws and replace the switch. 2-door Page 2763 ERROR: undefined OFFENDING COMMAND: f‘~ STACK: Page 7778 21. Leave the key in the cylinder. Reinstall the plastic retainer and spring if you removed them in step 16. Hold the plastic retainer and spring on the housing, and insert the inner cylinder. Rotate it left and right to engage the spring to the inner cylinder. Make sure the spring is properly seated to the inner cylinder. 22. Install the arm with a new cylinder rod clip and a new E-clip. 23. Make sure the key can be inserted and removed easily, and that the cylinder turns with the key. Page 324 PGM-F1 Main Relay 1, 2 Type 1, 2 Check for continuity between the terminals. - There should be continuity between the No.1 and No.2 terminals when power and ground are connected to the No.3 and No.4 terminals. - There should be no continuity between the No.1 and No.2 terminals when power is disconnected. Normally-open type B: Rear Window Defogger Relay Page 9580 7. Using a jumper wire, connect the steering column. - If the horn sounds, replace the steering column. - If the horn does not sound, replace the horn and contact plate. Locations Relay And Control Unit Locations - Dashboard Page 6318 16. Remove the snap ring (A) and the splash guard (B) from the knuckle (C). 17. Press the wheel bearing (A) out of the knuckle (B) using the special tool and a press. 18. Wash the knuckle and hub thoroughly in high flash point solvent before reassembly. 19. Press a new wheel bearing (A) into the knuckle (B) using the old bearing (C), a steel plate (D), the special tool, and a press. Place the wheel bearing on the knuckle with the pack seal side facing (metal color) toward the inside. Be careful not to damage the sleeve of the pack seal. 20. Install the snap ring (A) securely in the knuckle (B). 21. Install the splash guard (C), and tighten the screws (D) to the specified torque. Page 5321 Braking Sensor/Switch: Testing and Inspection Brake Pedal Position Switch Signal Circuit Troubleshooting 1. Check the brake lights. Are the brake lights on without pressing the brake pedal? YES - Inspect the brake pedal position switch. NO - Go to step 2. 2. Press the brake pedal. Do the brake lights come on? YES - Go to step 3. NO - Go to step 4. 3. Measure voltage between ECM/PCM connector terminals A24 and E22 with the brake pedal pressed. Is there battery voltage? YES - The brake pedal position switch signal is OK. NO - Repair open in the wire between the ECM/PCM (E22) and the brake pedal position switch. 4. Inspect the No.7 HORN, STOP (15A) fuse in the under-hood fuse/relay box. Is the fuse OK? YES - Repair open in the wire between the brake pedal position switch and the No.7 HORN, STOP (15A) fuse. Inspect the brake pedal position switch. NO - Repair short in the wire between the ECM/PCM (E22) and the No.7 HORN, STOP (15A) fuse. Replace the No.7 HORN, STOP (15A) fuse. Page 1580 234. Under-dash Fuse/Relay Box Part 7 Page 1334 7. Insert the feeler gauge (A) between the adjusting screw (B) and the end of the valve stem and slide it back and forth; you should feel a slight amount of drag. 8. If you feel too much or too little drag, loosen the locknut (A), and turn the adjusting screw (B) until the drag on the feeler gauge is correct. 9. Tighten the locknut and recheck the clearance. Repeat the adjustment, if necessary. Page 2489 Oxygen Sensor: Service and Repair Secondary HO2S Replacement Secondary HO2S Replacement Special Tools Required O2 sensor wrench, Snap-on YA8875, SP Tools 93750, or equivalent, commercially available NOTE: The secondary HO2S and the third HO2S must be replaced together (D17A6 engine except '01 model) 1. Disconnect the secondary HO2S 4P connector (A), then remove the secondary HO2S (B). 2. Install the secondary HO2S in the reverse order of removal. Page 1889 Exhaust: 18.65 - 19.15 (0.734 - 0.754 inch) 9. Coat both reamer and valve guide with cutting oil. 10. Rotate the reamer clockwise the full length of the valve guide bore. 11. Continue to rotate the reamer clockwise while removing it from the bore. 12. Thoroughly wash the guide in detergent and water to remove any cutting residue. 13. Check the clearance with a valve. Verify that the valve slides in the intake and exhaust valve guides without exerting pressure. Page 7399 ^ Start the engine and let it warm up to its normal operating temperature (the cooling fans cycle twice). ^ Let the engine idle (throttle closed and all electrical items off) for 10 minutes. 17. CR-V only: Reset the power window control unit: ^ Turn the ignition switch to ON (II). ^ Make sure the driver's window is fully closed. ^ Push down and hold the window switch until the window goes all the way down. ^ Pull back and hold the window switch until the window goes all the way up, then hold the switch for at least 2 more seconds. 18. Enter the audio unit anti-theft code, and set the clock. Enter the audio presets. Disclaimer Locations Cruise Control Module: Locations Cruise Control Component Location Index Page 2042 Circuit Schematics Each schematic represents one circuit. A circuit's wires and components are arranged to show current flow from power at the top of the diagram 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 Page 2114 Ignition System Component Location Index Page 9308 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. How to Replace Connector Terminals Terminal Replacement Procedure HOW TO REPLACE CONNECTOR TERMINALS The terminal repair kits provide necessary tools and materials (terminals, wire seals, and splice connectors) to repair many damaged or faulty connector terminals. However, not all terminals for all connectors are available. Refer to the labels on the lids of the repair kits for replacement terminal availability. IMPORTANT SAFETY INFORMATION: On some models, the SRS wires are in a separate harness. If the SRS harness is damaged, replace the harness; do not repair it. On other models, wire harnesses include yellow SRS wires. If any SRS wire is damaged, replace the entire harness; do not repair it. Before you begin, inspect the wire you are about to repair for damage and length. Make sure the wire will be long enough to make a terminal repair without stretching it when you reinstall the terminal in the connector. If the wire is too short, or if access to the connector is too restricted to make a terminal repair, you may need to install a pigtail terminal (a short length of wire with a factory-crimped terminal on it). Refer to HOW TO INSTALL PIGTAIL TERMINALS. Removing the Terminal Testing and Inspection Voltage Signal: Testing and Inspection Alternator FR Signal Circuit Troubleshooting 1. Disconnect the alternator 4P connector from the alternator. 2. Turn the ignition switch ON (II). 3. Measure voltage between ECM/PCM connector terminals A24 and B13. Is there about 5 V? YES - Go to step 4. NO - Go to step 13 4. Turn the ignition switch OFF. 5. Reconnect the alternator 4P connector. 6. Start the engine. Hold the engine at 3,000 rpm with no load (in Park or neutral) until the radiator fan comes on, then let it idle. 7. Measure voltage between ECM/PCM connector terminals A24 and B13. Does the voltage decrease when the headlights and rear window defogger are turned on? YES - The alternator FR signal is OK. NO - Go to step 8. 8. Turn the ignition switch OFF. 9. Disconnect ECM/PCM connector B (24P). 10. Disconnect the alternator 4P connector. 11. Connect alternator 4P connector terminal No.4 to body ground with a jumper wire. Page 4247 Page 5858 Under-hood Fuse/Relay Box Page 415 Control Module: Service and Repair Updating the ECM/PCM PCM Updating and Substitution for Testing Special Tools Required Honda Interface Module (HIM) P/N EQS05A35570 Use this procedure when you have to substitute a known-good PCM in a troubleshooting procedure. Update the PCM only if the PCM does not already have the latest software loaded. NOTE: Do not turn the ignition switch OFF while updating; the PCM can be damaged. How to Update the PCM NOTE: To ensure the latest program is installed, do an PCM update whenever the PCM is substituted or replaced. - Before you update the PCM, make sure the vehicle's battery is fully charged. - To prevent PCM damage, do not operate anything electrical (audio system, brakes, A/C, power windows, moon roof, door locks, etc.) during the update. - If you need to diagnose the Honda Interface Module (HIM) because the HIM's red (#3) light came on or was flashing during the update, leave the ignition switch in the ON (II) position when you disconnect the HIM from the Data Link Connector (DLC). This will prevent PCM damage. 1. Turn the ignition switch ON (II). Do not start the engine. 2. Connect the HIM to the DLC (A) located under the driver's side of dashboard. 3. Do the PCM update procedure as described on the HIM label and in the PCM update system. If the software in the PCM is the latest version, replace the PCM. How to End a Troubleshooting Session This procedure must be done after any troubleshooting. 1. Clear the DTC(s) with the Scan Tool or HDS, or reset the PCM by removing the No. 6 (PCM) fuse in the under-hood fuse/relay box for more than 10 seconds. 2. Turn the ignition switch ON (II). 3. Start the engine in the P or N position, and warm it up to normal operating temperature (the radiator fans come on). 4. To verify that the problem is repaired, test-drive the vehicle for several minutes at speeds over 30 mph (50 km/h) or in freeze data range. Page 8975 9. Install a 2 Ohms resistor between fuel pump 5P connector terminals No.1 and No.2, then turn the ignition switch ON (II). 10. Check that the pointer of the fuel gauge indicates "F". - If the pointer of the fuel gauge does not indicates "F", replace the gauge. - If the gauge is OK, inspect the fuel gauge sending unit. NOTE: The pointer of the fuel gauge returns to the bottom on the gauge dial when the ignition switch is OFF, regardless of the fuel level. 11. Relieve the fuel pressure. 12. Remove the fuel fill cap. 13. Disconnect the quick-connect fittings from the fuel pump. 14. Using the special tool, loosen the fuel tank unit locknut (A). Page 6352 2. Remove the cotter pin (A) from the tie-rod end ball joint, and remove the nut (B). 3. Disconnect the tie-rod end from the steering arm on the damper using the special tool. 4. Remove the bolts (A), and remove the wheel sensor harness bracket (B) and brake hose bracket (C) from the damper. Do not disconnect the wheel sensor connector. 5. Remove the damper pinch bolts (A) while holding the nuts (B). Page 5747 13. Plug in the heat gun, and turn it on. Start at the middle of the splice connector, and move the gun toward the ends as the tube shrinks. Apply heat evenly by rotating the curved heat spreader around the splice connector. Shrinking is complete when a small amount of sealant appears at each end of the tube. Pigtail Terminal Selection Chart PIGTAIL TERMINAL SELECTION CHART Select the proper size pigtail terminal by matching the replacement terminal part number and the wire size being repaired to the corresponding pigtail terminal part number. Then use the color (size) splice connector listed. In some instances you may also have to match the wire seal style to select the proper pigtail terminal. Pigtail terminals are available through your parts department, in quantities of 10, using normal parts ordering procedures. Checking For Poor Fir of Terminals CHECKING FOR POOR FIT OF TERMINALS Loose terminal fit can cause a number of intermittent problems in electrical circuits. By using the Terminal Inspection Feeler Tool Set you can inspect the terminal fit between the two matching connectors without removing the terminals from the connector body. 1. Find the terminal tool that best matches the male terminal in the mating connector. Page 2887 58. Check for continuity between ECM/PCM connector terminal A21 and body ground. Is there continuity? YES - Repair short in the wire between the ECM/PCM (A21) and the MAP sensor, CVT driven pulley speed sensor (CVT), or CVT speed sensor 1 (CVT). NO - Update the ECM/PCM if it does not have the latest software, or substitute a known-good ECM/PCM, then recheck. If the symptom/indication goes away with a known-good ECM/PCM, replace the original ECM/PCM. 59. Measure voltage between body ground and ECM/PCM connector terminal A20. Is there about 5 V? YES - Go to step 66. NO - Go to step 60. 60. Turn the ignition switch OFF. 61. Disconnect the 3P connector from each of these sensors, one at a time, and measure voltage between body ground and ECM/PCM connector terminal A20 with the ignition switch ON (II). Exhaust gas recirculation (EGR) valve position sensor - Knock sensor - Throttle position (TP) sensor - CVT drive pulley speed sensor (CVT) - CVT speed sensor 2 (CVT) Is there about 5 V? Page 5264 195. Tranmission Range Switch Page 3133 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. Below most connector numbers and component names are PHOTO and VIEW numbers. The PHOTO number refers to a photo in the back of the book that shows the connector's location on the car. The VIEW number refers to an illustration in the back of the book that shows the connector terminals, wire colors, connector cavity numbers, and other details. The connector cavity numbering sequence begins at the top left corner of the connector as seen from either of the viewpoints shown on diagram [8] . Except for the DLC (data link 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 C554, for example, means those terminals join in cavity 2 of connector C554. Power Distribution Schematics Power Distribution Schematics A/C - Heater Blows Cool Air At Idle Heater Core: Technical Service Bulletins A/C - Heater Blows Cool Air At Idle Heater Blows Cool Air When Coming to a Stop or at Idle Got a 01-05 Civic with a heater that blows warm air while driving but starts blowing Cool air when coming to a stop or at idle? What's most likely causing this problem is air trapped in the heater core. To fix this problem, you've got to bleed the cooling system (replacing the thermostat won't do the trick). Here's how you do it: 1. Fill the reserve tank with Honda All Season Antifreeze/Coolant Type 2 50 the coolant level is between the MIN and MAX marks on the tank. 2. Remove the radiator cap. Make sure the coolant level is up to the base of the filler neck. Add coolant if needed. 3. Loosely install the radiator cap. 4. Set the temperature control knob to maximum. 5. Start the engine, and let it run until it reaches normal operating temperature (the cooling fans cycle twice). Shut off the engine. 6. Remove the radiator cap. Make sure the coolant level is up to the base of the filler neck. Add coolant if needed. 7. Securely install the radiator cap. 8. Start the engine, and check for leaks. Page 2085 Fuel Pressure: Testing and Inspection Fuel Pressure Test Special Tools Required - Fuel pressure gauge 07406-004000A - Fuel pressure gauge set 07ZAJ-S5A0100 1. Relieve the fuel pressure. 2. Disconnect the quick-connect fitting (A). Attach the fuel pressure gauge set and fuel pressure gauge. 3. Start the engine and let it idle. - If the engine starts, go to step 5. - If the engine does not start, go to step 4. 4. Check to see if the fuel pump is running: listen to the fuel fill port with the fuel fill cap removed. The fuel pump should run for 2 seconds when the ignition switch is first turned on. If the pump runs, step 5. - If the pump does not run, perform the fuel pump circuit troubleshooting. 5. Read the pressure gauge. The pressure should be 270 - 320 kPa (2.8 - 3.3 kgf/sq.cm, 40 - 47 psi) - If the pressure is OK, the test is complete. - If the pressure is out of specification, replace the fuel pressure regulator and the fuel filter, then recheck the fuel pressure. Page 8076 Keyless Entry Module: Diagrams (EX; '04: LX, GX) (Honda Accessory) Page 3727 Shift Indicator: Service and Repair Indicator Bulb Replacement SRS components are located in this area. Review the SRS component locations, precautions, and procedures in SRS before performing repairs or service. 1. Remove the gauge assembly. 2. Replace the bulb (A) in the gauge assembly (B). Page 9196 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. How to Replace Connector Terminals Terminal Replacement Procedure HOW TO REPLACE CONNECTOR TERMINALS The terminal repair kits provide necessary tools and materials (terminals, wire seals, and splice connectors) to repair many damaged or faulty connector terminals. However, not all terminals for all connectors are available. Refer to the labels on the lids of the repair kits for replacement terminal availability. IMPORTANT SAFETY INFORMATION: On some models, the SRS wires are in a separate harness. If the SRS harness is damaged, replace the harness; do not repair it. On other models, wire harnesses include yellow SRS wires. If any SRS wire is damaged, replace the entire harness; do not repair it. Before you begin, inspect the wire you are about to repair for damage and length. Make sure the wire will be long enough to make a terminal repair without stretching it when you reinstall the terminal in the connector. If the wire is too short, or if access to the connector is too restricted to make a terminal repair, you may need to install a pigtail terminal (a short length of wire with a factory-crimped terminal on it). Refer to HOW TO INSTALL PIGTAIL TERMINALS. Removing the Terminal Page 6973 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. SRS Unit, Front Sensors and Side Impact Sensors SRS Unit, Front Sensors and Side Impact Sensors Be careful not to bump or impact the SRS unit, front sensors, or the side impact sensors whenever the ignition switch is ON (II), or for at least 3 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, front sensors, and the side impact sensor. The airbags could accidentally deploy and cause damage or injury. After a collision in which any airbags or seat belt tensioners were deployed, replace the SRS unit, front sensors, and other related components. After a collision in which a side airbag was deployed, replace the side impact sensor on the deployed side 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, front sensors, 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 3 minutes before beginning installation or replacement of the SRS unit, or disconnecting 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 N.m (1.0 kgf.m, 7.2 lbf.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 °G) and dry (less than 80% relative humidity, no moisture) area. Wiring Precautions Wiring Precautions SRS wiring can be identified by special yellow outer covering (except the SRS indicator light circuit). Page 157 Wire Color Abbreviations Page 8127 1997 Accord SE With Factory-Installed Security System 1997 Accord SE with factory-installed security system Programming the Transmitter NOTES: ^ The system accepts up to three transmitters. The transmitter codes are stored in a stacking-type memory. If a fourth transmitter code is programmed, the code for the first transmitter is erased. ^ Entering the programming mode cancels all learned transmitter codes, so none of the previously programmed transmitters will work. You must reprogram all of the transmitters once you are in the programming mode. ^ You must complete steps 1-6 within 4 seconds of the previous step to keep the system from exiting the programming mode. 1. Turn the ignition switch to ON (II). 2. Press the "Lock" or "Unlock" button on one of the transmitters. (An unprogrammed transmitter can be used for this step.) 3. Turn the ignition switch to LOCK (0). 4. Repeat steps 1, 2, and 3 two more times using the same transmitter used in step 2. 5. Turn the ignition switch to ON (II). 6. Press the "Lock" or "Unlock" button on the same transmitter. Make sure the power door locks cycle to confirm that the system is in programming mode. 7. Within 10 seconds, press the "Lock" or "Unlock" button on each transmitter. Make sure the power door locks cycle after you press each transmitter button to confirm that the system accepted the transmitter's code. 5. Turn the ignition switch to LOCK (0) to exit the programming mode. Ordering a Transmitter Transmitters can be ordered only by authorized Honda dealers. Order them from American Honda using normal parts ordering procedures. Batteries for the Transmitter The battery number is CR2025. Each transmitter uses one battery. 98-02 Accord EX & 00-02 Accord SE 1998-02 Accord EX with factory-installed security system 2000 and 2002 Accord SE with factory-installed security system Page 2926 12. Check for continuity between PSP switch 2P connector terminal No. 2 and body ground. Is there continuity? YES - Repair open in the wire between the PSP switch and ECM/PCM (E16). NO - Repair open in the wire between the PSP switch andG201. 13. Turn the ignition switch OFF. 14. Disconnect the PSP switch 2P connector. 15. Turn the ignition switch ON (II). 16. Measure voltage between ECM/PCM connector terminals A24 and E16. Is there battery voltage? YES - Replace the PSP switch. NO - Go to step 17. 17. Turn the ignition switch OFF. 18. Disconnect ECM/PCM connector E (31P). 19. Check for continuity between body ground and ECM/PCM connector terminal E16. Is there continuity? YES - Repair short in the wire between ECM/PCM (E16) and the PSP switch. NO - Update the ECM/PCM if it does not have the latest software, or substitute a known-good ECM/PCM,then recheck. If the symptom/indication Page 958 OPDS Unit - Connectors A, B, C, D Page 4003 23. Transmission Housing (A/T) Locations Knock Sensor: Locations PGM-FI System - Component Location Index Locations Rear Door Window Motor: Locations 129. Left Rear Door (Right Similar) 129. Left Rear Door (Sedan Except DX) (Right Similar) Page 9393 - Before connecting connectors, make sure the terminals (A) are in place and not bent. - Check for loose retainer (A) and rubber seals (B). - The backs of some connectors are packed with dielectric grease. Add grease if necessary. If the grease is contaminated, replace it. - Insert the connector all the way and make sure it is securely locked. - Position wires so that the open end of the cover faces down. Handling Wires and Harnesses - Secure wires and wire harnesses to the frame with their respective wire ties at the designated locations. Page 4222 1. Remove the secondary lock from the male terminal half. 2. Remove the secondary lock from the female terminal half. 3. Remove the terminal (same procedure for male and female). 4. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE C: 1. Remove the secondary lock. Gauges - Eratic Gauges Or Odd Odometer Display Speedometer Head: Technical Service Bulletins Gauges - Eratic Gauges Or Odd Odometer Display SOURCE: Honda Service News February 2003 TITLE: Erratic Gauges or Odd Odometer Display? Reset the Gauge Control Module. APPLIES TO: 2003 Accords, 2001-03 Civics, or 2002-03 CR-Vs SERVICE TIP: If owners are complaining that the gauge needles are bouncing around or the odometer display is blank or displays nonsense, try resetting the gauge control module. Here's how: 1. Make sure you have the anti-theft code for the radio and the navigation system (if equipped), then write down your customer's radio station presets. 2. Disconnect the battery cables, starting with the negative cable. 3. Touch the battery cable ends together for about 1 minute. 4. Reconnect the battery cables, starting with the positive cable. 5. Start the engine, and watch the gauge assembly. - If the gauges or odometer still don't work right, shut off the engine, and do the self diagnostic procedure in the Body Electrical section of the appropriate S/M. Then go to step 6 - If the gauges and odometer work OK, shut off the engine, and go to step 6. 6. Do the idle learn procedure: - Make sure all electrical items (A/C, audio unit, defogger, lights, etc.) are turned off, then start the engine. - Let the engine reach its normal operating temperature (the cooling fans cycle twice). - Let the engine idle (throttle fully closed and with all electrical items off ) for 10 minutes. Shut off the engine. 7. Initialize the driver's window auto-up feature (if applicable): - Turn the ignition switch to ON (II). Make sure the driver's window is fully closed. - Push down and hold the window switch. Make sure the window goes all the way down. - Pull back and hold the window switch. Make sure the window goes all the way up, then hold the switch for at least 2 more seconds. 8. Enter the anti-theft code for the radio and the navigation system (if equipped). Enter your customer's radio station presets. Set the clock. Locations Page 2065 8. Put the splice connector in the proper size slot in the Crimper Tool, slide it to one end (where the flare begins), and close the crimper handles far enough to hold it in place. To release the ratchet mechanism at any point after the first click, squeeze the handles slightly and push the release lever, then let the handles open. 9. Insert one of the bare wires into the splice connector end that is in the crimper jaws. Push the wire all the way into the splice connector, and squeeze the crimper handles. Keep squeezing until the jaws touch, and hold it at that position until the ratchet clicks again. 10. Crimp the other wire in the same way into the other end of the splice connector. 11. After crimping, gently pull on the wires in the opposite directions to make sure they are secure in the connector. 12. Separate the other wires in the harness from the repaired wire(s), and shield them with nonflammable material. Page 240 Relay Box: Diagrams 234. Under-dash Fuse/Relay Box Part 1 Page 9341 Wires Page 2910 Oxygen Sensor: Description and Operation Secondary Heated Oxygen Sensor (Secondary HO2S) Secondary Heated Oxygen Sensor (Secondary HO2S) The secondary HO2S detects the oxygen content in the exhaust gas downstream of the TWC and sends signals to the ECM/PCM which checks the efficiency of the TWC. To stabilize its output, the sensor has an internal heater. The secondary HO2S is installed in the TWC. Locations Exterior Lights Component Location Index Page 9072 Wire Color Abbreviations Page 2955 DTC U0100 thru U1288 Disclaimer Page 5774 Rear Window Defogger Component Location Index Page 6255 7. Install the steering rack guard (A). 8. Install the engine wire harness (B) on the harness bracket (C). 9. Under the steering gearbox, install the return hose clamp (A) on the gearbox. 10. Above the steering gearbox, connect the feed line (A) securely, and tighten the 14 mm flare nut (B). 11. Connect the return line (C) securely, and tighten the 16 mm flare nut (D). Page 9282 53. Steering Wheel (Airbag Inflators Removed) Page 5443 8. Apply Dow Corning Molykote M77 or Daikalub 528D grease to both sides of the pad shim (A), the back of the pads (B), and the other areas indicated by the arrows. Wipe excess grease off the shim. Contaminated brake discs and pads reduce stopping ability. Keep grease off the discs and pads. 9. Install the brake pads and pad shim correctly. Install the pads with the wear indicators (C) on the inside. If you are reusing the pads, always reinstall the brake pads in their original positions to prevent a momentary loss of braking efficiency. 10. Push in the piston (A) so the caliper will fit over the pads. Make sure the piston boot is in position to prevent damaging it when pivoting the caliper down. 11. Pivot the caliper down into position. Being careful not to damage the pin boots, install the bolt (B), and tighten it to the specified torque. 12. Press the brake pedal several times to make sure the brake works, then test-drive. NOTE: Engagement of the brake may require a greater pedal stroke immediately after the brake pads have been replaced as a set. Several applications of the brake pedal will restore the normal pedal stroke. 13. After installation, check for leaks at hose and line joints or connections, and retighten if necessary. Page 5902 Connectors - "C" Page 2767 ECM/PCM Inputs And Outputs At Connector A (31P) Page 3314 Vacuum Hose Routing Page 8689 Cruise Control Servo: Testing and Inspection Cruise Control Actuator Test Cruise Control Actuator Test 1. Disconnect the 4P connector (A) from the cruise control actuator (B). 2. Remove the cover (A), and check the output linkage (B) for smooth movement. 3. Connect the battery power to the No.2 terminal and ground to the No.1 terminal. 4. Check for a clicking sound from the magnetic clutch, The output linkage should be locked. 5. If the output linkage is not locked, replace the cruise control actuator assembly. Page 837 10. Connect the connector securely, then install the transmission range switch cover. 11. Turn the ignition switch ON (II). Move the shift lever through all gear positions, and cheek the transmission range switch synchronization with the A/T gear position indicator. 12. Allow the wheels to rotate freely, then start the engine. 13. Move the shift lever through all gear positions, and verify the following: ^ The engine will not start in any position other than N or P. ^ The back-up lights come on when the shift lever is in the R position. Page 5599 Alternator: Service and Repair Overhaul Alternator Overhaul Alternator Overhaul - Exploded View Exploded View Special Tools Required - Handle driver 07749-0010000 - Driver attachment, 52 x 55 mm 07746-0010400 NOTE: Refer to the Exploded View as needed during this procedure. 1. Test the alternator and regulator before you remove them. 2. Remove the alternator. Page 229 Wiper/Washer Component Location Index Bearing Size Codes Crankshaft Main Bearing: Specifications Bearing Size Codes Main Bearing Selection Crankshaft Bore Code Location Letters have been stamped on the end of the block as a code for the size of each of the five main journal bores. Use them, and the numbers stamped on the crankshaft (codes for main journal size), to choose the correct bearings. If the codes are indecipherable because of an accumulation of dirt and dust, do not scrub them with a wire brush or scraper. Clean them only with solvent or detergent. Page 2384 Blower Motor Relay Type 1, Type 2 Check for continuity between the terminals. - There should be continuity between the No.1 and No.3 terminals when power and ground are connected to the No.2 and No.4 terminals. - There should be no continuity between the No.1 and No.3 terminals when power is disconnected. Five-terminal type Check for continuity between the terminals. - There should be continuity between the No.1 and No.2 terminals when power and ground are connected to the No.3 and No.5 terminals. - There should be continuity between the No.1 and No.4 terminals when power is disconnected. Page 3769 13. Remove the solenoid cover, and make sure the solenoid plunger groove is installed in the fork on the lever. ^ If needed, correct the position of the solenoid plunger, then go to step 14. ^ If the solenoid plunger is correctly installed, there is an electrical problem with the key interlock system; refer to the Automatic Transmission section of the appropriate service manual for troubleshooting information. Once the key interlock is working normally, go to step 14. 14. Install the solenoid cover. 15. Reinstall the steering column covers. 16. Center-punch a completion mark above the seventh character of the engine compartment VIN. Disclaimer Page 957 104. In Front Passenger's or Passenger's Seat Page 9514 Diagram 115-2 (Coupe EX) 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 1335 10. Rotate the crankshaft 180° counterclockwise (camshaft pulley turns 90°). The "UP" mark (A) on the camshaft pulley should be toward the exhaust side of the head. 11. Check and, if necessary, adjust the valve clearance on No. 3 cylinder. 12. Rotate the crankshaft 180° counterclockwise to bring No. 4 piston to TDC. TDC marks (A) are visible again. 13. Check and, if necessary, adjust the valve clearance on No. 4 cylinder. 14. Rotate the crankshaft 180° counterclockwise to bring No. 2 piston to TDC. The "UP" mark (A) should be on the intake side of the head. 15. Check and, if necessary, adjust the valve clearance on No. 2 cylinder. 16. Install the cylinder head cover. Page 7671 - Make sure the cable actuates the latch before you close the hood. - Adjust the hood latch alignment. - Make sure the hood opens properly and locks securely. Locations Throttle Position Sensor: Locations PGM-FI System - Component Location Index How to Remove the PCM Control Module: Service and Repair How to Remove the PCM How to Remove the PCM for Testing 1. Remove the passenger's dashboard lower cover, the right kick panel, and the glove box. 2. Remove the bolt. Cut the plastic cross brace in the glove box opening with diagonal cutters in the area shown, and discard it. 3. Remove the relays (A), then remove the bolts and the glove box frame (B). 4. Remove the gray 20P PCM wire harness connector from the PCM mounting bracket. Remove the PCM mounting bolt (A) and the bracket. 5. Remove the nuts, then remove the PCM (B). 6. Install the PCM in the reverse order of removal. Page 976 Technical Service Bulletin # 01-077 Date: 060419 Ignition/Locks - Cutting Sidewinder-Type Keys 01-077 April 19, 2006 Applies To: Models With Sidewinder-Type Keys - All Cutting Sidewinder-Type Keys With the MATRIX H Key Cutting Machine (Supersedes 01-077, dated January 12, 2005) Updated information is noted by asterisks. MATRIX H Key Cutting Machine, manufactured by Silca and supplied by Kaba Ilco Corporation, is a portable, power-operated tool that cuts sidewinder-type automotive keys exclusively. The machine lets you cut these keys either by copying or by code. The code function is designed and built to meet the Honda code requirements. No other similar machine has this capability. This service bulletin gives you information for ordering and servicing this special tool, and guides you through the entire key cutting process from setting up the machine to cutting the key blank. TOOL INFORMATION Order through the Honda Tool and Equipment Program: MATRIX H Key Cutting Machine: Model No. ILCMATRIXSH Cutter Bit: Model No. ILCF3O Fixed Jaw: Model No. ILCMTX-H Mobile Jaw (Right Side): Model No. ILCRTMTX-H Mobile Jaw (Left Side): Model No. ILCLTMTX-H *Remanufactured Clamp Unit: Model No. ILCMATRIXHCR* PARTS INFORMATION *For some models, there are two choices for sidewinder-type key blanks: ^ T-5 sidewinder key blanks ^ Honda sidewinder key blanks For other models, only Honda sidewinder key blanks can be used. See DETERMINING WHICH KEY TO USE to determine which key blank you should choose. Ordering T-5 key blanks through the Honda Tool and Equipment Program: T-5 Programmable Key Blank (Master): P/N ILC-35111-T-5H T-5 Programmable Key Blank (Valet): P/N ILC-35112-T-5H Practice Key Blanks (five per pack): ILC-35111DEMO* NOTE: Do not use practice key blanks for replacement purposes. Practice keys do not have an immobilizer chip. Page 6913 NOTE: For color information, refer to PIB A05-0005, Child Seat Anchor Buttons. Click PARTS, then click PARTS LIBRARY, then click Parts Bulletins. Select Child Seat Anchor Buttons from the list. (Each part contains fabric washers, button posts, and back portions.) WARRANTY CLAIM INFORMATION In warranty: The normal warranty applies. Failed Part: 82123-SDA-305ZA Defect Code: 07801 Symptom Code: 03220 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. Remove the rear seat-back cover just enough to allow access to the opening where the button will be attached: ^ Refer to Section 20, Rear Seat-back Cover Replacement, in the appropriate service manual, or ^ Online, enter keyword SEAT COVER, and select the appropriate Rear Seat-back Cover Replacement procedure from the list. 2. Select the appropriate button from the Child Seat Anchor Service Set. 3. Attach the button to the rear seat-back cover: ^ Place a fabric washer over the button post. ^ Insert the post through the opening in the cover. ^ Snap the back portion onto the post. Page 9847 15. Set the rear window in the opening, and center it. Make alignment marks (A) across the rear window and body with a grease pencil at the four points shown. Be careful not to touch the rear window where adhesive will be applied. 16. Remove the rear window. 17. With a sponge, apply a light coat of glass primer along the edge of the rear window (A) and molding (B) as shown, then lightly wipe it off with gauze or cheesecloth: Do not apply body primer to the rear window, and do not get body and glass primer sponges mixed up. - Never touch the primed surfaces with your hands. If you do, the adhesive may not bond to the rear window properly, causing a leak after the rear window is installed. - Keep water, dust, and abrasive materials away from the primed surfaces. 18. With a sponge, carefully apply a light coat of body primer to any exposed paint or metal around the flange where new adhesive will be applied. Let the primer dry for at least 10 minutes: Do NOT apply body primer to any remaining original adhesive on the flange. - Be careful not to mix up the body and glass primer sponges. Page 9107 Locations/Component Locations/Locations By Photo Number Connector Views: Connector terminal views (references to VIEWS) referred to within these diagrams can be found at Connector Views by View Number. See: Diagrams/Connector Views/Connector Views By View Number Circuit Diagram - Brake Lights Antitheft System - Alarm Will Not Arm/Arms By Itself Alarm Module: Customer Interest Antitheft System - Alarm Will Not Arm/Arms By Itself 05-025 July 1, 2005 Applies To: 2001-05 Civic - ALL 2002-05 CR-V - ALL 2003-04 Element - ALL Accessory Security System Changes Modes By Itself (Supersedes 05-025, dated June 10, 2005, to update the information indicated by black bars and asterisks.) SYMPTOM The security system will not arm or it arms by itself. PROBABLE CAUSE Key switch contact chatter causes the control unit to change modes. CORRECTIVE ACTION * Civic: Replace the security control unit, and reprogram the remote(s).* * CR-V and Element: Replace the security control unit and the microphone, then reprogram the remote(s).* * NOTE: You must replace the microphone on the CR-V and Element because the security control units are matched to their microphones when they are manufactured. Using the original microphone may result in security system problems.* PARTS INFORMATION WARRANTY CLAIM INFORMATION In warranty: The normal warranty applies. Out of warranty: Any repair performed after warranty expiration may be eligible for goodwill consideration by the District Parts and Service Manager or your Zone Office. You must request consideration, and get a decision, before starting work. REPAIR PROCEDURE NOTE: Before starting, make sure you have all of the remotes (three maximum) the customer wishes to use. Page 5949 Under-dash Fuse/Relay Box 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 9482 Splices Components Ground - "G" Page 424 Heated Glass Element Relay: Testing and Inspection Power Relay Test Use this chart to identify the type of relay, then do the test listed for it. NOTE: See the turn signal/hazard relay input test. Normally-open type B: Rear Window Defogger Relay Check for continuity between the terminals. - There should be continuity between the No.1 and No.3 terminals when power and ground are connected to the No.2 and No.4 terminals. - There should be no continuity between the No.1 and No.3 terminals when power is disconnected. Page 1689 1. Remove the terminal. 2. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE G: 1. Remove the terminal. 2. Go to HOW TO INSTALL NEW TERMINALS. How to Install New Terminals HOW TO INSTALL NEW TERMINALS 1. Carefully match the old terminal with a new one from the terminal repair kit. Choose the correct replacement terminal based on the wire size range the terminal will accommodate. NOTE: If the replacement terminal quantities are low, reorder them by using the terminal part number listed on the inside lid of the terminal repair kit. Replacement terminals are available through your parts department using normal parts ordering procedures. 2. Depending on the size of the wire you are repairing, use the proper size slot in the crimping tool. Driver's Air Bag - Replace Torx Bolts Properly Air Bag: All 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 3858 Transmission Speed Sensor: Service and Repair Countershaft Speed Sensor Replacement Countershaft Speed Sensor Replacement 1. Disconnect the countershaft speed sensor connector. 2. Remove the countershaft speed sensor (A). 3. Install the new countershaft speed sensor with the new O-ring (B). 4. Check the countershaft speed sensor connector for rust, dirt, or oil, then connect the connector securely. Page 3635 Pressure Regulating Solenoid: Diagrams 25. A/T Clutch Pressure Control Solenoid Valve A 26. A/T Clutch Pressure Control Solenoid Valve B Page 5542 64. Under Left Side Of Dash (M/T) Page 5981 234. Under-dash Fuse/Relay Box Part 7 Page 611 8. Remove the locknut (A) and the fuel tank unit. 9. Remove the stopper (O). Release the hook (P) and remove the fuel filter (B), the fuel gauge sending unit (C), the case (D), the wire harness (E), and the fuel pressure regulator (F). 10. When connecting the fuel tank unit, make sure the connection is secure and the suction filter (G) is firmly connected to the fuel pump (H). 11. Install in the reverse order of removal with a new base gasket (I) and new O-rings (J), then check these items: - When connecting the wire harness, make sure the connection is secure and the connector (K) is firmly locked into the place. - When installing the fuel gauge sending unit, make sure the connection is secure and the connector is firmly locked into place. Be careful not to bend or twist the connector excessively. - When installing the fuel tank unit, align the marks (L) on the fuel tank (M) and the fuel tank unit (N). Page 4391 3. Strip the insulation off the end of the wire so the wire fits in the new terminal as shown. (If the wire has a wire seal, replace it with a new one from the kit.) NOTE: After stripping the end of the wire, make sure you did not cut any wire strands. If you did, cut the wire off even with the insulation, and strip it again. 4. Position the terminal in the crimping tool slot with the solid portion of the terminal toward the anvil and the open section toward the former. 5. Insert the wire in the terminal to the position shown in step 3. 6. Squeeze the tool with both hands until the stops make contact. 7. Crimp the insulation crimp. - If you do not have a wire seal, then use the next larger size crimp slot. Position the crimping tool over the insulation crimp section of the terminal, then squeeze the tool with both hands until the stops make contact. - If you have a wire seal, position the insulation crimp in the 5.5 crimping slot, then carefully squeeze the crimp closed until its ends are touching and making a full-circle shape. Page 6274 78. Coat the new O-ring (A) with multipurpose grease, and carefully fit it on the valve housing. 79. Apply multipurpose grease to the needle bearing (B) in the gearbox housing, then install the valve body unit (C) by engaging the gears. Note the valve body unit installation position (direction of the line connections). Tighten the flange bolts (D) to the specified torque. 80. Apply multipurpose grease to the sliding surface of the rack guide (A), and install it onto the gearbox housing. Wipe the grease off the threaded section of the housing. 81. Apply sealant all around the threads on the rack guide screw (B), then install the spring (C), rack guide screw, and locknut (D). 82. Center the steering rack within its stroke, and align the slider guide (B) with the holes (C) in boot A. Fit the slider guide to boot A by pressing around the edges of the holes securely. 83. Before installing the bracket (D), clean the mating surface of the 12 mm flange bolts (E) and bracket. Coat the new O-rings (F) with multipurpose grease, and install them on the 12 mm flange bolts. 84. Loosely install the bracket on the steering rack by tightening the 12 mm flange bolts to 25 Nm (2.5 kgf-cm, 18 ft. lbs.). Page 9128 Resistor Variable Sensor Solenoid Transistors Circuit Schematics Page 5628 12. Pull the vertical carriage lever toward you while you position the tracer on the right edge of the original key at its head, using the clamp carriage lever. Let the cutter bit cut into the key blank, then stop. Gently twist the lever clockwise to lock the vertical carriage at this height. Do not overtighten the lever. 13. Use the clamp carriage lever and the tracer to follow the contours of the original key. (The cutter bit cuts the same contours into the key blank.) Working from right to left, follow the right edge of the original key from head to tip, then the left edge of the key from tip to head. Turn off the cutter motor. 14. Reposition the tracer on the right edge of the original key at its head, using the clamp carriage lever. Turn on the cutter motor. Retrace the key from head to tip, then from tip to head. (This retracing cleans up the cuts on the key.) Turn off the cutter motor. 15. Release the vertical carriage lever. Open the jaw and remove only the new key. Make sure the jaw is free of any metal shavings or debris, then turn the new key over and slide the key with its blank side up into the jaw up to the key stop. Close the jaw to lock the key into place. 16. Turn on the cutter motor, and repeat steps 12 thru 14 to cut both edges of the other side of the key. 17. When you are finished making the required cuts, turn off the cutter motor, and release the vertical carriage lever. Open the jaws, and remove the keys. 18. Use a wire brush to smooth the cut surfaces on the new key. 19. Make sure the key works in the ignition switch and all the locks. If the key does not work, recut the key, and try it again. 20. Depending on the type of key blank you have used, do this: ^ If you have used a Honda key blank, add the transponder code of the new key to the immobilizer system with the Honda Diagnostic System (HDS). ^ If you have used a T-5 programmable key blank ("T-5" stamped on the shank), code the key's transponder with the Ilco Immobilizer Key Code Duplicator (see S/B 99-053, Ilco Immobilizer key Code Duplicator). Cutting Procedure - By Code 1. Press the ON/OFF button in the middle of the setting unit keypad. (This powers up the keypad.) 2. Turn the clamp unit lock lever to the left to release the clamp unit, and slide it to the right until the bottom left side is flush with the base edge. Turn the lever to the right to lock the clamp unit in place. Loosen the lateral and spring tension adjustment knobs on the clamp carriage. Page 6002 Multiple Junction Connector: Service and Repair How to Install New Terminals HOW TO INSTALL NEW TERMINALS 1. Carefully match the old terminal with a new one from the terminal repair kit. Choose the correct replacement terminal based on the wire size range the terminal will accommodate. NOTE: If the replacement terminal quantities are low, reorder them by using the terminal part number listed on the inside lid of the terminal repair kit. Replacement terminals are available through your parts department using normal parts ordering procedures. 2. Depending on the size of the wire you are repainng, use the proper size slot in the crimping tool. 3. Strip the insulation off the end of the wire so the wire fits in the new terminal as shown. (If the wire has a wire seal, replace it with a new one from the kit.) NOTE: After stripping the end of the wire, make sure you did not cut any wire strands. If you did, cut the wire off even with the insulation, and strip it again. 4. Position the terminal in the crimping tool slot with the solid portion of the terminal toward the anvil and the open section toward the former. 5. Insert the wire in the terminal to the position shown in step 3. 6. Squeeze the tool with both hands until the stops make contact. Page 3127 Connectors - "C" Page 4989 2. Remove the terminal (same procedure for male and female). 3. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE E: 1. Remove the secondary locks. 2. Remove the terminal (same procedure for male and female). 3. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE F: Page 3084 Manifold Pressure/Vacuum Sensor: Description and Operation Manifold Absolute Pressure (MAP) Sensor The MAP sensor converts manifold absolute pressure into electrical signals to the ECM/PCM. Page 271 Engine Control Module: Technical Service Bulletins Engine Controls - Replace ECM/PCM For DTC P1607 SOURCE: Honda Service News May 2003 TITLE: Replace ECM/PCM for DTC P1607 APPLIES TO: 2002-03 Civic SERVICE TIP If you've got a DTC P1607 (ECM/PCM internal circuit malfunction) set, you need to replace the ECM/PCM. These units may have defective printed circuit boards. Page 7097 WARRANTY CLAIM INFORMATION Out of warranty: Any repairs to the SRS system for problems other than the 15-1, 15-2, and 15-3 DTCs that are done 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. INSPECTION PROCEDURE NOTE: ^ When you check for SRS DTCs with the HDS, codes other than 15-1, 15-2, and 15-3 are not covered by this warranty extension bulletin. ^ If the vehicle is covered by warranty, repair it using the normal warranty repair procedures. If the vehicle's warranty is expired, give your customer an estimate for the cost of the repair. Do the appropriate inspection, based on the DTC. SRS DTC 15-1 Clear the DTC with the HDS. ^ If DTC 15-1 does not set again, go to REPAIR PROCEDURE A: OPDS UNIT REPLACEMENT. ^ If DTC 15-1 sets again, continue with normal troubleshooting. ^ If the OPDS unit causes DTC 15-1 to set repeatedly, yet passes the other troubleshooting steps, go to REPAIR PROCEDURE A: OPDS UNIT REPLACEMENT. SRS DTC 15-2 1. Inspect the connections and the wiring in the side airbag cutoff indicator circuit. ^ If all the connections and the wiring are OK, go to step 2. ^ If any of the connections or the wiring are faulty, repair the circuit, then go to step 2. 2. Clear the DTC with the HDS. ^ If DTC 15-2 does not set again, go to REPAIR PROCEDURE A: OPDS UNIT REPLACEMENT. ^ If DTC 15-2 sets again, continue with normal troubleshooting. ^ If the OPDS unit causes DTC 15-2 to set repeatedly, yet passes the other troubleshooting steps, go to REPAIR PROCEDURE A: OPDS UNIT REPLACEMENT. SRS DTC 15-3 1. Clear the DTC with the HDS. ^ If DTC 15-3 does not set again, go to step 2. ^ If DTC 15-3 sets again, continue with normal troubleshooting. 2. Ask your customer if electrical devices such as a laptop computer or a fluorescent map light are ever used near the front passenger's seat-back. (Some electrical devices that plug into the vehicle's accessory power socket, especially those using a power inverter/converter, can interfere with the seat-back sensors and cause SRS DTC 15-3 to set.) ^ If your customer uses any of these devices operate the device near the front passenger's seat-back. If DTC 15-3 sets again, clear it, then return the vehicle to the customer. Advise the customer to avoid using the device near the front passenger's seat-back. ^ If your customer does not use any of these devices and DTC 15-3 does not set again, go to REPAIR PROCEDURE A: OPDS UNIT REPLACEMENT. REPAIR PROCEDURE A: OPDS UNIT REPLACEMENT Page 2564 Vehicle Speed Sensor: Description and Operation Vehicle Speed Sensor (VSS) The VSS is driven by the differential. It generates a pulsed signal from an input of 1 volts. The number of pulses per minute increases/decreases with the speed of the vehicle. Page 7308 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 9007 Resistor Variable Sensor Solenoid Transistors Circuit Schematics Page 2051 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. Circuits must be operating when checking voltage drop. 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. 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 off, 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 Self-Powered Test Light or DVOM 1. Remove the blown fuse and disconnect the battery and load. Page 8304 12. Pull the vertical carriage lever toward you while you position the tracer on the right edge of the original key at its head, using the clamp carriage lever. Let the cutter bit cut into the key blank, then stop. Gently twist the lever clockwise to lock the vertical carriage at this height. Do not overtighten the lever. 13. Use the clamp carriage lever and the tracer to follow the contours of the original key. (The cutter bit cuts the same contours into the key blank.) Working from right to left, follow the right edge of the original key from head to tip, then the left edge of the key from tip to head. Turn off the cutter motor. 14. Reposition the tracer on the right edge of the original key at its head, using the clamp carriage lever. Turn on the cutter motor. Retrace the key from head to tip, then from tip to head. (This retracing cleans up the cuts on the key.) Turn off the cutter motor. 15. Release the vertical carriage lever. Open the jaw and remove only the new key. Make sure the jaw is free of any metal shavings or debris, then turn the new key over and slide the key with its blank side up into the jaw up to the key stop. Close the jaw to lock the key into place. 16. Turn on the cutter motor, and repeat steps 12 thru 14 to cut both edges of the other side of the key. 17. When you are finished making the required cuts, turn off the cutter motor, and release the vertical carriage lever. Open the jaws, and remove the keys. 18. Use a wire brush to smooth the cut surfaces on the new key. 19. Make sure the key works in the ignition switch and all the locks. If the key does not work, recut the key, and try it again. 20. Depending on the type of key blank you have used, do this: ^ If you have used a Honda key blank, add the transponder code of the new key to the immobilizer system with the Honda Diagnostic System (HDS). ^ If you have used a T-5 programmable key blank ("T-5" stamped on the shank), code the key's transponder with the Ilco Immobilizer Key Code Duplicator (see S/B 99-053, Ilco Immobilizer key Code Duplicator). Cutting Procedure - By Code 1. Press the ON/OFF button in the middle of the setting unit keypad. (This powers up the keypad.) 2. Turn the clamp unit lock lever to the left to release the clamp unit, and slide it to the right until the bottom left side is flush with the base edge. Turn the lever to the right to lock the clamp unit in place. Loosen the lateral and spring tension adjustment knobs on the clamp carriage. Page 8101 1. Remove the driver's dashboard lower cover. (See the body section of the appropriate service manual.) 2. Replace the security control unit. ^ Civic: Remove the security control unit, and install the new security control unit. ^ * CR-V and Element: Remove the security control unit and microphone. Install the new security control unit and new microphone.* 3. Reprogram the keyless receiver unit. NOTE: The codes of up to three transmitters can be stored in the keyless receiver unit memory. If a fourth code is stored, the code that was input first will be erased. It is important to maintain the time limits between the steps. Make sure the doors and the trunk/tailgate/hatch are closed, and that you have all of the remotes the customer wishes to use. ^ Turn the ignition switch to ON (II). ^ Within 1 to 4 seconds, push the transmitter lock or unlock button. ^ Within 1 to 4 seconds, turn the ignition switch to LOCK (0). ^ Within 1 to 4 seconds, turn the ignition to ON (II). ^ Within 1 to 4 seconds, push the transmitter lock or unlock button. ^ Within 1 to 4 seconds, turn the ignition switch to LOCK (0). ^ Within 1 to 4 seconds, turn the ignition switch to ON (II). ^ Within 1 to 4 seconds, push the transmitter lock or unlock button. Page 277 228. ECM/PCM Part 3 228. ECM/PCM Part 4 Page 1688 1. Remove the terminal. 2. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE E: 1. Remove the terminal. 2. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE F: Page 9715 1. Remove the driver's side grip cover: ^ Using a trim tool, pry out the front edge of the cover to release the front clip. ^ Pry out along the bottom to release the lower hooks. ^ Pry out along the top to release the upper hooks. ^ Pull the cover forward to release the rear clip. 2. Disconnect the power window master switch connector. 3. Remove the two screws that attach the power window switch base to the armrest, then remove the switch base. 4. Remove the three screws, then replace the power window master switch assembly. Page 2216 8. Remove the mounting nut from the heater unit. Take care not to damage or bend the fuel lines and the brake lines, etc. 9. Remove the dashboard. 10. Remove the blower unit. 11. Disconnect the drain hose (A), then remove the mounting bolts and the heater unit (B). 12. Remove the self-tapping screws and the expansion valve cover (A). With air conditioning; carefully pull out the evaporator core (B) so you don't bend the inlet and outlet pipes. Remove the self-tapping screws and the flange cover (C), then remove the grommet (D), and carefully pull out the heater core (E) so you don't bend the inlet and outlet pipes. 13. Install the heater core and the evaporator core (with A/C) in the reverse order of removal. 14. Install the heater unit in the reverse order of removal, and note these items: - Do not interchange the inlet and outlet heater hoses, and install the hose clamps securely. Page 950 12. On Accords and Pilots, install the new seat-back clips on the seat-back panel. Turn the clips so their retaining tabs are horizontal. 13. On Accords and Pilots, install the seat-back panel. 14. On all models except Accords and Pilots, zip the seat-back cover closed. 15. Initialize the OPDS unit. ^ To initialize with the HDS, go to Initializing the OPDS Unit: HDS Method. ^ To initialize with the SCS service connector, go to Initializing the OPDS Unit: Manual Mode. Initializing the OPDS Unit: HDS Method NOTE: Non-Honda seat covers will interfere with the performance of the OPDS and are not recommended. 1. Adjust the front passenger's seat-back to an upright position, then remove anything on or near the seat. 2. Turn the ignition switch to LOCK (0). 3. Connect the HDS to the vehicle's DLC (data link connector). 4. Turn the ignition switch to ON (II), then turn on the HDS. 5. At the screen prompts, enter the VIN and the odometer reading. Also verify the correct date and time. 6. From the System Selection menu, select SRS. Page 6412 Tires: Specifications Design Specifications Tires Size of front and rear tire U.S.: DX, HX, LX ................................................................................................................................. ........................................... P185/70R14 87S Canada: DX, LX .......................................................... ..................................................................................................................... P185/70R14 87S U.S.: EX ........................................................................................................................................................ ................................... P185/65R15 86H Canada: SI .......................................................................... .............................................................................................................. P185/65R15 86H Size of spare tires U.S.: DX, HX, LX ................................................................................................................................. .......................................... T115/70D14 88M Canada: DX, LX ........................................................... ................................................................................................................... T115/70D14 88M U.S.: EX, LX with ABS .................................................................................................................................. ................................ T125/70D15 95M Canada: SI, DX, LX with ABS ....................................................................................................................................................... T125/70D15 95M Page 9157 Interior Lights - Circuit Diagram Without Moonroof Page 7442 Circuit Schematics Each schematic represents one circuit. A circuit's wires and components are arranged to show current flow from power at the top of the diagram 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 Air Bag Disarming and Arming Air Bag(s) Arming and Disarming: Service and Repair Air Bag Disarming and Arming 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 459 118. Driver's Door (Coupe Exc. DX, HX; Sedan Exc: DX) 121. Driver's Door (Coupe Except DX) Page 1129 Transmission Position Switch/Sensor: Testing and Inspection Transmission Range Switch Test Transmission Range Switch Test 1. Remove the transmission range switch harness connector (A) from the connector bracket (B), then disconnect the connector. 2. Check for continuity between terminals at the harness connector. There should be continuity between the terminals listed for each switch position. In the P position, between terminals: ^ No. 1 and No. 3 ^ No. 1 and No. 8 ^ No. 3 and No. 8 In the R position, between terminals: ^ No. 1 and No. 9 In the N position and between terminals: ^ No. 1 and No. 3 ^ No. 1 and No. 10 ^ No. 3 and No. 10 In the D position, between terminals: ^ No. 1 and No. 2 ^ No. 1 and No. 4 ^ No.2 and No.4 In the D3 position, between terminals: ^ No. 1 and No. 2 ^ No. 1 and No. 5 ^ No.2 and No.5 In the 2 position, between terminals: ^ No. 1 and No. 6 Page 6956 WARRANTY CLAIM INFORMATION Out of warranty: Any repairs to the SRS system for problems other than the 15-1, 15-2, and 15-3 DTCs that are done 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. INSPECTION PROCEDURE NOTE: ^ When you check for SRS DTCs with the HDS, codes other than 15-1, 15-2, and 15-3 are not covered by this warranty extension bulletin. ^ If the vehicle is covered by warranty, repair it using the normal warranty repair procedures. If the vehicle's warranty is expired, give your customer an estimate for the cost of the repair. Do the appropriate inspection, based on the DTC. SRS DTC 15-1 Clear the DTC with the HDS. ^ If DTC 15-1 does not set again, go to REPAIR PROCEDURE A: OPDS UNIT REPLACEMENT. ^ If DTC 15-1 sets again, continue with normal troubleshooting. ^ If the OPDS unit causes DTC 15-1 to set repeatedly, yet passes the other troubleshooting steps, go to REPAIR PROCEDURE A: OPDS UNIT REPLACEMENT. SRS DTC 15-2 1. Inspect the connections and the wiring in the side airbag cutoff indicator circuit. ^ If all the connections and the wiring are OK, go to step 2. ^ If any of the connections or the wiring are faulty, repair the circuit, then go to step 2. 2. Clear the DTC with the HDS. ^ If DTC 15-2 does not set again, go to REPAIR PROCEDURE A: OPDS UNIT REPLACEMENT. ^ If DTC 15-2 sets again, continue with normal troubleshooting. ^ If the OPDS unit causes DTC 15-2 to set repeatedly, yet passes the other troubleshooting steps, go to REPAIR PROCEDURE A: OPDS UNIT REPLACEMENT. SRS DTC 15-3 1. Clear the DTC with the HDS. ^ If DTC 15-3 does not set again, go to step 2. ^ If DTC 15-3 sets again, continue with normal troubleshooting. 2. Ask your customer if electrical devices such as a laptop computer or a fluorescent map light are ever used near the front passenger's seat-back. (Some electrical devices that plug into the vehicle's accessory power socket, especially those using a power inverter/converter, can interfere with the seat-back sensors and cause SRS DTC 15-3 to set.) ^ If your customer uses any of these devices operate the device near the front passenger's seat-back. If DTC 15-3 sets again, clear it, then return the vehicle to the customer. Advise the customer to avoid using the device near the front passenger's seat-back. ^ If your customer does not use any of these devices and DTC 15-3 does not set again, go to REPAIR PROCEDURE A: OPDS UNIT REPLACEMENT. REPAIR PROCEDURE A: OPDS UNIT REPLACEMENT Front Page 5919 Use the tools from Pin Tool Set. First, check the connector that you are about to repair. - If it has a secondary terminal lock, go to Connectors With a Secondary Lock. A secondary lock, found on most connectors on some models, is an additional locking device on the connector housing as a backup for the primary lock on the terminal. - If the connector does not have a secondary lock, go to Connectors Without a Secondary Lock. Connectors With a Secondary Lock All examples are shown with the connector lock facing up. The illustrations are examples of the secondary terminal locks; however, the connector you are repairing may vary in size. Identify the connector by the type of secondary lock, not by the number of terminal cavities. EXAMPLE A: 1. Release the secondary lock. 2. Remove the terminal. 3. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE B: Page 2486 Oxygen Sensor: Description and Operation Third Heated Oxygen Sensor (Third HO2S) Third Heated Oxygen Sensor (Third HO2S) (D17A6 engine) The third HO2S detects the oxygen content in the exhaust gas downstream of the NOX Adsorptive Three Way Catalytic Converter (NOX Adsorptive TWC) and sends signals to the ECM/PCM which varies the duration of fuel injection accordingly. To stabilize its output, the sensor has an internal heater. The third HO2S is installed behind the NOX Adsorptive TWC. Page 5505 Electronic Brake Control Module: Testing and Inspection ABS Control Unit Inputs and Outputs for 31P Connector Page 1216 Wiper Switch: Testing and Inspection Wiper/Washer Switch Test/Replacement 1. Remove the dashboard lower cover. 2. Remove the steering column covers. 3. Disconnect the 14P connector (A) from the wiper/washer switch (B) 4. Remove the two screws, then pull out the wiper/washer switch. 5. Inspect the connector terminals to be sure they are all making good contact. - If the terminals are bent, loose or corroded, repair them as necessary, and recheck the system. - If the terminals look OK, check for continuity between the terminals in each switch position according to the tables. If the continuity is not as specified, replace the switch. Page 5065 Shift Interlock Solenoid: Testing and Inspection Shift Lock Solenoid Test 1. Remove the center console panel and center console. 2. Disconnect the shift lock solenoid connector (2P). 3. Connect the No. 1 terminal of the shift lock solenoid connector (2P) to the battery positive terminal, and connect the No. 2 terminal to the battery negative terminal. 4. Check that the shift lever can be moved from the P position. Release the battery terminals from the shift lock solenoid connector. Move the shift lever back to the P position, and make sure it locks. NOTE: Do not connect power to the No. 2 terminal (reverse polarity) or you will damage the diode inside the solenoid. 5. Check that the shift lock releases when the shift lock release is pushed, and check that it locks when the shift lock release is released. 6. If the shift lock solenoid does not work properly, replace it. Page 5206 5. Attach the slide hammer to the interlock lever pin, and tighten the slide hammer clamping bolt. Then use the slide hammer to remove the pin. Discard the pin, the lever, and the spring. 6. Wipe off any debris from the lever's sliding surface on the ignition switch with a clean cloth or a cotton swab. NOTE: To keep debris out of the ignition switch, do not clean it with compressed air. Locations Hazard Flasher Relay: Locations Turn Signal/Hazard Flasher - Component Location Index Page 7449 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 Locater) 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. Troubleshooting Precautions Troubleshooting Precautions Before Troubleshooting 1. Check the main fuse and the fuse 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, or you will damage the alternator diodes. - Do not attempt to crank the engine with the ground cable disconnected 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. Page 3053 Electric Load Sensor: Locations PGM-FI System - Component Location Index Page 3913 details, refer to the MVCI User Guide on ISIS. The Database Update version appears when you select Reprogramming, then press ENTER. 1. Connect the DLC cable to the MVCI and to the vehicle's DLC. 2. Turn the ignition switch to ON (II). The MVCI automatically boots up. 3. Press the ENTER button on the MVCI to see the User Config menu. Select CM Update Mode. 4. Select Reprogramming, then press ENTER. NOTE: Use these MVCI default settings: Setting 1Destination: USA Language: American English Setting 2 - Auto Detect: Yes Continuous Mode: No For more information on these settings, refer to the MVCI User Guide. 5. The CM Update software information appears. Press ENTER to continue. Page 2252 10. Middle Of Engine Page 6128 ^ 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 470 Power Mirror Switch: Testing and Inspection Power Mirror Switch Test 1. Remove the driver's pocket. 2. Disconnect the 13P connector (A) from the switch. 3. Remove the power mirror switch (B). 4. Check for continuity between the terminals in each switch position according to the table. 5. If the continuity is not as specified, replace the power mirror switch. Page 2481 141. HO2S, Secondary (except HX) Or Third (HX) Page 9473 PGM-F1 Main Relay 1, 2 Type 1, 2 Check for continuity between the terminals. - There should be continuity between the No.1 and No.2 terminals when power and ground are connected to the No.3 and No.4 terminals. - There should be no continuity between the No.1 and No.2 terminals when power is disconnected. Normally-open type B: Rear Window Defogger Relay Locations Crankshaft Position Sensor: Locations PGM-FI System - Component Location Index Page 6449 Air Door Actuator / Motor: Description and Operation How the Circuit Works The heater control unit-panel controls the blower controls, air delivery, and A/C compressor controls automatically. With the ignition switch in ON (II), battery voltage is supplied through fuse 14. The control unit is grounded at G502. Air Delivery The heater control unit-panel controls the blower motor and supplies a 5 VDC reference voltage to the air mixture control motor. The air mix and mode control motors each receive inputs from the control unit. The air mix motor regulates the mixture of cold and hot air by varying the position of the heater-evaporator door. The mode control motor controls the direction and volume of outlet air. Use the mode control dial to select the vents the air flows from. Some air will flow from the dashboard corner vents in all modes. Both the air mix control motor and mode control motor are grounded by the control unit. The recirculation control motor receives battery voltage through fuse 14 when the ignition switch is ON (II). It regulates the position of the fresh/recirc door, and is controlled by the heater control unit-panel when the recirculation button is pressed at the recir-A/C-rear defogger switch assembly. Page 1776 Variable Valve Timing Actuator: Testing and Inspection VTEC Solenoid Valve Test 1. Remove the resonator. 2. Disconnect the VTEC solenoid valve 1P connector. 3. Measure resistance between the VTEC solenoid valve 1P connector terminal No.1 and body ground. 4. If the resistance is within specifications, remove the VTEC solenoid valve assembly (A) from the cylinder head, and check the filter (B) for clogging. If there is clogging, replace the solenoid valve filter, the engine oil filter, and the engine oil. Page 3953 NOTE: If the latest sofiware is not loaded and you do a control unit/module update, the software may indicate the vehicle has the latest update when it doesn't. Updates not done with the latest software are not covered under warranty. 2. From the iN workstation desktop, select CM Update (ECU Rewrite). 3. Click on the Tools button on the right side of the screen, and make sure the interface device is set to GNA600. 4. Return to the Updating Honda Control Modules main screen, then click on Storage Mode and follow the on-screen instructions. 5. Take the GNA600 to the vehicle. Connect the DLC cable to the GNA600 and to the vehicle's DLC. 6. Turn the ignition switch to ON (II), and wait until the green No.2 LED on the GNA6OO stays on. Turn the ignition switch to LOCK (0), and disconnect the DLC cable from the vehicle. 7. Connect the USB PC interface cable to the iN workstation and to the GNA6OO. Connect the power supply unit and power supply cord to the GNA600. The GNA600 does a self-check and, after about 30 seconds, its yellow No.1 and green No.2 LEDs flash. Each updatable vehicle system is checked to make sure it is current. Any systems needing an update are listed on the screen. Highlight the system you want to update, then click on the check mark to continue. NOTE: Update the systems one at a time. Page 6377 1. Compress the damper spring with a commercially available strut spring compressor (A) according to the manufacturer's instructions, then remove the self-locking nut (B) while holding the damper shaft (C) with a hex wrench (D). Do not compress the spring more than necessary to remove the nut. 2. Release the pressure from the strut spring compressor, then disassemble the damper as shown in the Exploded View. 3. Reassemble all the parts, except for the spring. 4. Compress the damper assembly by hand, and check for smooth operation through a full stroke, both compression and extension. The damper should extend smoothly and constantly when compression is released. If it does not, the gas is leaking and the damper should be replaced. 5. Check for oil leaks, abnormal noises, or binding during these tests. Reassembly 1. Install all the parts except the damper mounting washer and self-locking nut onto the damper unit by referring to the Exploded View. Align the bottom of the spring (A) and the stepped part of the lower spring seat (B), and align the damper mounting base as shown. 2. Install the damper assembly on a commercially available strut spring compressor (C). 3. Compress the damper spring with the strut spring compressor. Page 7388 5. Remove the lower cover from the fuse/relay box. 6. Disconnect the 3P ELD connector. Page 2688 Brake Signal: Testing and Inspection Brake Pedal Position Switch Signal Circuit Troubleshooting 1. Check the brake lights. Are the brake lights on without pressing the brake pedal? YES - Inspect the brake pedal position switch. NO - Go to step 2. 2. Press the brake pedal. Do the brake lights come on? YES - Go to step 3. NO - Go to step 4. 3. Measure voltage between ECM/PCM connector terminals A24 and E22 with the brake pedal pressed. Is there battery voltage? YES - The brake pedal position switch signal is OK NO - Repair open in the wire between the ECM/PCM (E22) and the brake pedal position switch. 4. Inspect the No.7 HORN, STOP (15 A) fuse in the under-hood fuse/relay box. Is the fuse OK? YES - Repair open in the wire between the brake pedal position switch and the No.7 HORN, STOP (15 A) fuse. Inspect the brake pedal position switch. NO - Repair short in the wire between the ECM/PCM (E22) and the No.7 HORN, STOP (15 A) fuse. Replace the No.7 HORN, STOP (15 A) fuse. Page 5411 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 5652 1. Cut off the female S terminal from the harness, making the cut as close to the terminal as possible. 2. Strip 6 mm of insulation from the wire using the 2.0 slot on the crimping tool. NOTE: Make sure no wire strands were removed when you stripped the insulation. If any were removed, cut the wire off even with the insulation, and strip it again. 3. Insert the wire into the new terminal so it fits as shown. 4. Using the 2.0 slot on the crimping tool, position the terminal in the tool slot with the solid portion of the terminal toward the anvil and the open section toward the former. Page 6315 3. Remove the brake hose bracket mounting bolt (A). 4. Remove the caliper bracket mounting bolts (B), and remove the caliper assembly (C) from the knuckle. To prevent damage to the caliper assembly or brake hose, use a short piece of wire to hang the caliper assembly from the undercarriage. Do not twist the brake hose with force. 5. Raise the stake (A), and remove the spindle nut (B), then remove and discard the nut. 6. Remove the brake disc retaining flat screws (A). 7. Screw two 8 x 1.25 mm bolts (B) into the disc to push it away from the hub. Turn each bolt 2 turns at a time to prevent cocking the disc excessively. Page 4825 3. Remove and discard the shift fork. 4. Apply vinyl tape to the mainshaft splines to protect the seal, then remove the mainshaft and shift forks as an assembly from the clutch housing. 5. Disassemble the countershaft assembly; see page 13-32 (13-45 for Hybrid) of the service manual. Page 5882 Relay Box: Diagrams 234. Under-dash Fuse/Relay Box Part 1 Page 2178 Relay And Control Unit Locations - Engine Compartment Page 5270 10. Connect the connector securely, then install the transmission range switch cover. 11. Turn the ignition switch ON (II). Move the shift lever through all gear positions, and cheek the transmission range switch synchronization with the A/T gear position indicator. 12. Allow the wheels to rotate freely, then start the engine. 13. Move the shift lever through all gear positions, and verify the following: ^ The engine will not start in any position other than N or P. ^ The back-up lights come on when the shift lever is in the R position. Page 5416 Brake Rotor/Disc: Specifications Brake disc Thickness Standard or New ...................................................................................................................................................... 20.9 - 21.8 mm (0.82 - 0.86 inch) Service Limit ........................................................................................... .................................................................................... 19.0 mm (0.75 inch) Runout Service Limit ........................................................................................................................................ ..................................... 0.10 mm (0.004 inch) Parallelism Service Limit ........................................................................................................................................ ................................. 0.015 mm (0.0006 inch) Diagram Information and Instructions Transmission Position Switch/Sensor: Diagram Information and Instructions Terminal Numbering System Terminal Numbering System Connector terminals are numbered according to the cavities they're in. The cavities are numbered starting from the upper left, looking at the male terminals from the terminal side or looking at the female terminals from the wire side. Both views are in the same direction so the numbers are the same. All actual cavities are numbered, even if they have no wire terminals in them. NOTE: Data Link Connector (DLC) terminals are numbered according 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 below is #6. Specifications Page 6248 Steering Gear: Adjustments Rack Guide Adjustment Special Tools Required Locknut wrench, 40 mm 07916-SA50001 1. Set the wheels in the straight ahead position. 2. Loosen the rack guide screw locknut (A) with the special tool, then remove the rack guide screw (B). 3. Remove the old sealant from rack guide screw, and apply new sealant all around the threads (C). Loosely install the rack guide screw on the steering gearbox. 4. Tighten the rack guide screw (A) to 25 Nm (2.5 kgf-cm, 18 ft. lbs.). then loosen it. 5. Retighten the rack guide screw to 3.9 Nm (0.4 kgf-cm, 2.9 ft. lbs.), then back it off to specified angle. Specified Return Angle: 20° Max. 6. Tighten the locknut (B) while holding the rack guide screw. 7. Check for unusual steering effort through the complete turning travel. 8. Check the steering wheel rotational play and the power assist. Page 3979 Shift Interlock Solenoid: Testing and Inspection Shift Lock Solenoid Test 1. Remove the center console panel and center console. 2. Disconnect the shift lock solenoid connector (2P). 3. Connect the No. 1 terminal of the shift lock solenoid connector (2P) to the battery positive terminal, and connect the No. 2 terminal to the battery negative terminal. 4. Check that the shift lever can be moved from the P position. Release the battery terminals from the shift lock solenoid connector. Move the shift lever back to the P position, and make sure it locks. NOTE: Do not connect power to the No. 2 terminal (reverse polarity) or you will damage the diode inside the solenoid. 5. Check that the shift lock releases when the shift lock release is pushed, and check that it locks when the shift lock release is released. 6. If the shift lock solenoid does not work properly, replace it. Page 4268 ^ The vehicle is shown as eligible on a VIN status inquiry. In addition, check for a punch mark above the seventh character of the engine compartment VIN. A punch mark in that location means the ignition switch key interlock has already been inspected/repaired. 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 a VIN status inquiry before selling it. CUSTOMER NOTIFICATION All owners of affected vehicles will be sent a notification of this campaign. An example of the customer notification is at the end of this service bulletin. CORRECTIVE ACTION Inspect the ignition switch and, if needed, install a Key Interlock Repair Kit. PARTS INFORMATION Key Interlock Repair Kit: P/N 06351-SDA-000 REQUIRED SPECIAL TOOLS Interlock Slide Hammer: T/N 07AAC-S84A100 NOTE: ^ An initial quantity of Permalube grease to lubricate the sliding surface of the interlock lever is included with the slide hammer. To order more Permalube, use P/N 08734-0030. ^ To order a replacement clamping bolt for the slide hammer, use T/N 07AAC-S84A400. WARRANTY CLAIM INFORMATION Failed Part: P/N 35100-SDA-A31 Defect Code: 5GC00 Symptom Code: R4400 Page 2973 ECM/PCM Inputs And Outputs At Connector A (31P) Page 4772 Splices Components Ground - "G" Page 5186 Skill Level: Repair Technician INSPECTION PROCEDURE 1. Remove the steering column covers. Refer to section 17 of the appropriate service manual. 2. On the lower side of the ignition switch, look at the interlock cylinder cover: ^ If the cover is square, the ignition switch was already replaced with an updated part, and a key interlock repair kit is not needed. Go to step 3. ^ If the cover is round, go to REPAIR PROCEDURE. 3. Reinstall the steering column covers. 4. Center-punch a completion mark above the seventh character of the engine compartment VIN. REPAIR PROCEDURE Page 6703 Owners of affected vehicles have or will receive a notification of this campaign. An example of the customer notification is at the end of this service bulletin. CORRECTIVE ACTION Install a driver's airbag inflator kit, then return the original, undeployed inflator to its supplier, ideally within 48 hours of the repair. NOTE: If the original, undeployed inflator is not returned, the warranty claim for that vehicle will be charged back to your dealership. PARTS INFORMATION Driver's Airbag Inflator Kit: P/N 04770-S5A-308(*) Includes inflator with wire harness, locknuts (4), felt tape, felt washers (4), Torx bolts (2), and shipping instructions. NOTE: ^ The felt tape and the felt washers are used only on Accords. ^ The inflator kit box must be used to return the old inflator to its supplier. Be careful not to damage the inflator kit box. (*)The kit contains Fed Ex Ground shipping documents and instructions for the airbag inflator. If you are a dealer in Alaska or Hawaii, call the WPI Page 2348 Engine Control Module: Service and Repair Monitors, Trips, and/or Drive Cycle (Readiness Codes) Malfunction Indicator Lamp (MIL) Indication (In relation to Readiness Codes) The vehicle has certain "readiness codes" that are part of the on-board diagnostics for the emissions systems. If the vehicle's battery has been disconnected or gone dead, if the DTCs have been cleared, or if the ECM/PCM has been reset, these codes are reset. In some states, part of the emissions testing is to make sure these codes are set to complete. If all of them are not set to complete, the vehicle may fail the emissions test, or the test cannot be finished. To check if the readiness codes are complete, turn the ignition switch ON (II), but do not start the engine. The MIL will come on for 15 - 20 seconds. If it then goes off, the readiness codes are complete. If it blinks several times, one or more readiness codes are not complete. To set readiness codes from incomplete to complete, do the procedure for the appropriate code. Catalytic Converter Monitor and Readiness Code NOTE: - Do not turn the ignition switch off during the procedure. - All readiness codes are cleared when the battery is disconnected or when the ECM/PCM is cleared with the OBD II scan tool or Honda PGM Tester. - Low ambient temperatures or excessive stop-and-go traffic may increase the drive time needed to switch the readiness code from incomplete to complete. - The readiness code will not switch to complete until all the enable criteria are met. - If a fault in the secondary HO2S system caused the MIL to come on, the readiness code cannot be set to complete until you correct the fault. Enable Criteria - ECT at 158 °F (70 °C) or higher. - Intake air temperature (IAT) at 20 °F (-7 °C) or higher. - Vehicle speed is steady, and vehicle speed sensor (VSS) reads more then 25 mph (40 km/h). Procedure 1. Connect the scan tool to the vehicle's data link connector (DLC), and bring up the tool's generic OBD II mode. 2. Start the engine. 3. Test-drive the vehicle under stop-and-go conditions with short periods of steady cruise. After about 5 miles (8 km), the readiness code should switch from incomplete to complete. 4. If the readiness code is still set to incomplete, check for a temporary DTC. If there is no DTC, one or more of the enable criteria were probably not met; repeat the procedure. Evaporative Emissions (EVAP) Control System Monitor and Readiness code NOTE: - All readiness code are cleared when the battery is disconnected or when the ECM/PCM is cleared with the OBD II scan tool or Honda PGM Tester. - The enable criteria must be repeated if the intake air temperature (IAT) drops lower then 36 °F (2 °C) from its value at engine start up. Enable Criteria - At engine start up, ECT and IAT are higher than 32 °F (O °C), but lower than 95 °F (35 °C). - At engine start up, the ECT and IAT are within 12 °F (7 °C) of each other. Procedure 1. Connect the scan tool to the vehicle's data link connector (DLC), and bring up the tool's generic OBD II mode. 2. Start the engine. 3. Test-drive the vehicle under stop-and-go conditions with short periods of steady cruise. After about 2.5 miles (4 km), the readiness code should switch from incomplete to complete. 4. If the readiness code is still set to incomplete, check for a temporary DTC. If there is no DTC, one or more of the enable criteria were probably not met; repeat the procedure. Air Fuel Ratio (A/F) Sensor Monitor and Readiness Code NOTE: - Do not turn the ignition switch off during the procedure. - All readiness codes are cleared when the battery is disconnected or when the ECM/PCM is cleared with the OBD II scan tool or Honda PGM Tester. Enable Criteria Page 2373 Fuel Pump Relay: Testing and Inspection Power Relay Test Use this chart to identify the type of relay, then do the test listed for it. NOTE: See the turn signal/hazard relay input test. Normally-open type A: Page 1980 10. Install the back cover (A), then install the camshaft pulley (B). Page 9192 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 Locater) 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. Troubleshooting Precautions Troubleshooting Precautions Before Troubleshooting 1. Check the main fuse and the fuse 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, or you will damage the alternator diodes. - Do not attempt to crank the engine with the ground cable disconnected 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. Page 6192 17. Attach a hose (A) to the end of the pressure control valve (B) as shown. Then submerge the pressure control valve in a container of power steering fluid or solvent (C), and blow in the hose. ^ If air bubbles leak through the valve at less than 98 kPa (1.0 kgf/cm2, 14.2 psi), replace the pump as an assembly. The pressure control valve is not available separately. ^ If the pressure control valve is OK, set it aside for reassembly later. 18. Inspect the ball bearing by rotating the outer race slowly. If you feel any play (axial or radial) or roughness, remove the faulty ball bearing (A), and install a new one (B). 19. Inspect each part shown with an asterisk in the Exploded View; if any of them are worn or damaged, replace the pump as an assembly. Reassembly 20. Install the new pump seal (A) (with its grooved side facing in) into the pump housing (B) by hand first, then drive it in using the special tools until the seal is fully seated in the pump housing. Shift Lever Removal Shifter CVT: Service and Repair Shift Lever Removal Shift Lever Removal 1. Shift the transmission into the N position. 2. Remove the center console panel and center console. 3. Remove the nut securing the shift cable end (A), then separate the cable end from the shift lever assembly. 4. Rotate the socket holder (A) on the shift cable (B) toward the shift lever a quarter turn, then slide the holder out to remove the shift cable from the shift cable bracket base (C). NOTE: Do not remove the shift cable by twisting the shift cable Guide (D). Page 288 ECM/PCM Inputs And Outputs At Connector A (31P) Page 9353 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. Test Equipment 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. Page 6147 1. Turn the steering wheel fully to the right and left while applying the brake, and check the turning angles of both front wheels. If the turning angle is not within the specification or the inward turning angles differ between the right and left side, go to step 2. 2. Check the toe. If it is correct, but the turning angle is not within the specification, check for bent or damaged suspension components. Page 1556 Charging System Component Location Index 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. Service and Repair Wheel Cylinder: Service and Repair Rear Wheel Cylinder Replacement NOTE: ^ Do not spill brake fluid on the vehicle; it may damage the paint; if brake fluid does contact the paint, wash it off immediately with water. To prevent spills, cover the hose joints with rags or shop towels. ^ Use only a genuine Honda wheel cylinder special bolt. 1. Remove the brake shoes. 2. Disconnect the brake line (A) from the wheel cylinder (B). 3. Remove the bolt (C) and the wheel cylinder from the backing plate. 4. Apply Three Bond 1109G sealant or equivalent (E) between the wheel cylinder (B) and backing plate (D), and install the wheel cylinder. 5. Install the removed parts in the reverse order of removal. 6. Bleed the brake system. 7. Check for leaks at the line joint and bleed screw, and retighten if necessary. Page 8232 WARRANTY CLAIM INFORMATION In warranty: The normal warranty applies. Failed Part: P/N 68500-S5P-A90ZZ H/C 6528640 *Defect Code: 07406* Symptom Code: 03220 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 A 1. Check the side-to-side alignment of the trunk lid latch to the striker: ^ Refer to page 20-132 of the 2001-04 Civic Service Manual. ^ In ISIS, use the keyword TRUNK ADJUST, and select Trunk Lid Adjustment from the list. 2. Make sure the gaps of the trunk lid are even on all sides. ^ If the trunk is misaligned, go to step 3. ^ If the trunk lid is properly aligned on all sides, go to REPAIR PROCEDURE B. 3. Adjust the trunk lid hinges: ^ Refer to page 20-132 of the 2001-04 Civic Service Manual. ^ In ISIS, use the keyword TRUNK ADJUST, and select Trunk Lid Adjustment from the list. 4. Check the trunk operation: ^ If the trunk opens and closes smoothly and is properly aligned, return the vehicle to the customer. ^ If the trunk lid is still difficult to close, go to REPAIR PROCEDURE B. REPAIR PROCEDURE B Page 184 3. Strip the insulation off the end of the wire so the wire fits in the new terminal as shown. (If the wire has a wire seal, replace it with a new one from the kit.) NOTE: After stripping the end of the wire, make sure you did not cut any wire strands. If you did, cut the wire off even with the insulation, and strip it again. 4. Position the terminal in the crimping tool slot with the solid portion of the terminal toward the anvil and the open section toward the former. 5. Insert the wire in the terminal to the position shown in step 3. 6. Squeeze the tool with both hands until the stops make contact. 7. Crimp the insulation crimp. - If you do not have a wire seal, then use the next larger size crimp slot. Position the crimping tool over the insulation crimp section of the terminal, then squeeze the tool with both hands until the stops make contact. - If you have a wire seal, position the insulation crimp in the 5.5 crimping slot, then carefully squeeze the crimp closed until its ends are touching and making a full-circle shape. Page 5942 Under-dash Fuse/Relay Box (4-door) Under-Dash Fuse/Relay Box Under-dash Fuse/Relay Box Page 42 6. Disconnect the M, P, K, and J connectors from the under-dash fuse/relay box, and make these input tests at the connectors. - If any test indicates a problem, find and correct the cause, then recheck the system. - If all the input tests prove OK, the multiplex control unit must be faulty. Replace the under-dash fuse/relay box assembly. Page 4612 3. If there is no continuity between any terminal, remove the transmission range switch cover, and disconnect the connector (A) at the switch (B). 4. Check for continuity between terminals at the switch connector (c). There should be continuity between the terminals listed for each position. In the P position, between terminals: ^ No. 4 and No. 5 ^ No. 4 and No. 6 ^ No. 5 and No. 6 In the R position, between terminals: ^ No. 1 and No. 4 In the N position, between terminals: ^ No. 4 and No. 5 ^ No. 4 and No. 7 ^ No.5 and No.7 In the D position, between terminals: ^ No.2 and No.4 ^ No. 2 and No. 10 ^ No. 4 and No. 10 In the D3 position, between terminals: ^ No. 4 and No. 8 ^ No. 4 and No. 10 ^ No. 8 and No. 10 In the 2 position, between terminals: ^ No.3 and No.4 5. If there is no continuity between any terminals, adjust the transmission range switch installation. If the transmission range switch installation is OK, replace the switch. 6. If the transmission range switch continuity check was OK, replace the faulty transmission range switch harness. Page 7974 13. After completing the right edge, push all of the cam blades to the right until they touch the cams, then trace the cam blades from back to front. (The cutter bit cuts the same contours into the left edge of the key from tip to head.) Turn off the cutter motor. 14. Release the vertical carriage lever. Push all the cam blades to the left until they touch the cams. Pull the vertical carriage lever towards you until the tracer touches the flat surface on the right side, at the front of the cams. Gently twist the lever clockwise to lock the vertical carriage at this height. Do not overtighten the lever. 15. Turn on the cutter motor, then retrace the cam blades from front to back. Push all the cam blades to the right until they touch the cams, and then retrace the cam blades from back to front (retracing cleans up the cuts on the key). Turn off the cutter motor. 16. Release the vertical carriage lever. Open the jaw and remove the key. Make sure the jaw is free of any metal shavings or debris. Turn the key over so the blank side is up, then slide it into the jaw up to the key stop. Close the jaw to lock the key in place. 17. Push all the cam blades to the left until they touch the cams. Repeat steps 10 through 15 to cut both edges on the other side of the key. 18. When you are done making the required cuts, release the vertical carriage lever. Open the jaw and remove the key. 19. Make sure the key works in the ignition switch and the locks. If the key does not work, recut the key, and try it again. 20. Depending on the type of key, code the key transponder. Equipment Service and Warranty To service the MATRIX H Key Cutting Machine, refer to section 7 of the MATRIX H Operating Manual. It tells you how to replace parts that commonly wear out such as the drive belt, the work light bulb, and the tension spring on the vertical carriage. It also covers checking and replacing fuses and replacing the printed circuit board for the setting unit keypad. If you have technical questions on the equipment, contact the Ilco Technical Assistance Department. Mail: Kaba Ilco Technical Assistance Department 400 Jeffreys Road Rocky Mount, NC 27804 Phone: 800-452-6872 Ext: 200, 384, 323, 398, 356 Fax: 252-446-4702 The MATRIX H Key Cutting Machine comes with a 3-year limited warranty. This warranty does not cover the cutter bit or the work light bulb. CODE BOOK CORRECTIONS In the code book Honda High Security key Codes, correct these errors: Pages 4 thru 51, code headings: ^ Incorrect: J H G F Z X E D C B M/S X ^ Correct: J H G F A X E D C B M/S X Page 2, last paragraph: Diagrams Page 9759 1. Remove the screws and the power window master switch (A) from the door panel. 2. Disconnect the 14P connector (B) from the switch. 3. Check for continuity between the terminals in each switch position according to the table. Driver's Switch: The driver's switch is combined with the control unit so you cannot isolate the switch to test it. Instead, run the master switch input test procedures. If the tests are normal, the driver's switch must be faulty. 4. If the switch is faulty, remove the three screws and replace the switch. Page 212 Relay And Control Unit Locations - Dashboard Page 484 174. Moonroof Switch (EX) Locations Sunroof / Moonroof Motor: Locations Moonroof Component Location Index 138. Rear Of Roof (EX) Page 9323 Interior Lighting Module: Electrical Diagrams Diagram 115-0 (except EX) Page 8754 Circuit Schematics Each schematic represents one circuit. A circuit's wires and components are arranged to show current flow from power at the top of the diagram 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 Page 6353 6. Remove the flange nuts (A) from the top of the damper. 7. Lower the lower arm, and remove the damper assembly (B). Disassembly/Inspection 1. Compress the damper spring with a commercially available strut spring compressor (A) according to the manufacturer's instructions, then remove the self-locking nut (B) while holding the damper shaft (C) with a hex wrench (D). Do not compress the spring more than necessary to remove the nut. 2. Release the pressure from the strut spring compressor, then disassemble the damper as shown in the Exploded View. 3. Reassemble all the parts, except for the spring. 4. Compress the damper assembly by hand, and check for smooth operation through a full stroke, both compression and extension. The damper should extend smoothly and constantly when compression is released. If it does not, the gas is leaking and the damper should be replaced. 5. Check for oil leaks, abnormal noises, and binding during these tests. Reassembly Page 9202 1. Remove the terminal. 2. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE B: 1. Remove the terminal. 2. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE C: 1. Remove the terminal. 2. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE D: Page 4621 Page 478 Sunroof / Moonroof Limit Switch: Adjustments Limit Switch Adjustment 1. Remove the headliner. 2. With the moonroof wrench, close the glass (A) fully: - Make sure both link lifters (B) are parallel, and in the position shown. - Check the glass fit to the roof panel and the glass height. 3. With an open-end wrench, loosen the limit switch mounting bolts (C). 4. Adjust the limit switch (D): - Move the switch plate (E) a little at a time, then secure it at the position where you hear a faint click when the switch cam (P) pushes the limit switch (open/close). - Check that the switch plate contacts the switch bracket (G). 5. Check the operation of the glass (from the tilt-up position to fully closed position, from the fully open position to the fully closed position) by operating the moonroof switch. Page 2568 Vehicle Speed Sensor: Service and Repair VSS Replacement 1. Remove the intake resonator. 2. Disconnect the 3P connector (A) from the vehicle speed sensor (VSS) (B). 3. Remove the mounting bolt, then remove the VSS. 4. Install the VSS in the reverse order of removal. Body - Door Lock Cylinders Bind Fuel Door Lock Cylinder: Customer Interest Body - Door Lock Cylinders Bind 03-068 October 29, 2004 Applies To: See VEHICLES AFFECTED Door Lock Cylinder Binds (Supersedes 03-068, dated April 20, 2004) Updated information is shown with asterisks and black bars. SYMPTOM The key will not go into the door lock cylinder, or if it goes in, it will not turn. PROBABLE CAUSE The door lock tumblers are damaged or worn. VEHICLES AFFECTED CORRECTIVE ACTION Remove the door lock cylinder, and replace the inner cylinder, springs, and tumblers. Locations Main Relay (Computer/Fuel System): Locations Relay And Control Unit Locations - Dashboard Page 7770 PARTS INFORMATION REQUIRED MATERIALS WARRANTY CLAIM INFORMATION In warranty: The normal warranty applies. Failed Part: P/N 72185-S9A-003 H/C 6896716 Defect Code: 00503 Symptom Code: 07902 Skill Level: Repair Technician Service and Repair Power Steering Line/Hose: Service and Repair Power Steering Hoses, Lines, and Pressure Switch Replacement Note these items during installation: ^ Connect each hose to the corresponding line securely until it contacts the stop on the line. Install the clamp or adjustable clamp at the specified distance from the hose end as shown. ^ Check all clamps for deterioration or deformation; replace the clamps with new ones, if necessary. ^ Add the recommended power steering fluid to the specified level on the reservoir and check for leaks. Page 3551 124. CMP (TDC) Sensor Page 632 Backup Lamp Switch: Testing and Inspection Back-Up Light Switch Test 1. Disconnect the back-up light switch (A) connector. 2. Check for continuity between the back-up light switch 3P connector No. 1 and No. 2 terminals. There should be continuity when the shift lever is in reverse. 3. If necessary, replace the switch. Page 6048 Charging System Component Location Index Page 8245 ^ If the trunk opens and closes smoothly, return the vehicle to the customer. ^ If the trunk lid is still difficult to close, go to REPAIR PROCEDURE E. REPAIR PROCEDURE E 1. Look at the back of the lock cylinder while you turn the key from lock to unlock. ^ Refer to page 20-158 of the 2001-04 Civic Service Manual. ^ In ISIS, use the keyword LID LOCK, and select Trunk Lid Lock Cylinder Replacement from the list. 2. Check the operation of the trunk lid lock cylinder: ^ If the lock cylinder is difficult to turn or binds, go to step 3. ^ If the lock cylinder operates properly, and the trunk lid is still difficult to close, refer to the appropriate body repair manual, and check for body inaccuracies. 3. Replace the lock cylinder, and re-key the cylinder to the customer's original key; on 2-door Civics, replace the lock cylinder and the lock cylinder rod: ^ Refer to page 20-158 of the 2001-04 Civic Service Manual. ^ In ISIS, use the keyword LID LOCK, and select Trunk Lid Lock Cylinder Replacement from the list. 4. Check the trunk operation, and return the vehicle to the customer. Disclaimer Page 1686 1. Remove the secondary locks. 2. Remove the terminal from the female half. 3. Remove the terminal from the male half. 4. Go to HOW TO INSTALL NEW TERMINALS. Connectors Without a Secondary Lock All examples are shown with the connector lock facing up. The illustrations are examples of connector terminals without a secondary lock; however, the connector you are repairing may vary in size and shape. EXAMPLE A: Page 8965 Door Switch: Locations Entry Light Control System Component Location Index Locations Transmission Position Switch/Sensor: Locations Electronic Controls Location, CVT 25. Transmission Housing (CVT) Locations 94. Behind Glove Box (except GX) Page 4554 6. Measure the clearance between the 80 mm set ring and carrier bearing outer race with a feeler gauge. 7. If the clearance is out of standard, remove the 80 mm set ring, and measure its thickness. 8. Select and install a new set ring, then recheck the clearance and make sure it is within the standard. SET RING, 80 mm Page 8512 Power Door Lock Switch: Diagrams 109. Door Lock Knob Switch, Driver's (except DX) 110. Door Lock Switch, Driver's Page 9009 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. Below most connector numbers and component names are PHOTO and VIEW numbers. The PHOTO number refers to a photo in the back of the book that shows the connector's location on the car. The VIEW number refers to an illustration in the back of the book that shows the connector terminals, wire colors, connector cavity numbers, and other details. The connector cavity numbering sequence begins at the top left corner of the connector as seen from either of the viewpoints shown on diagram [8] . Except for the DLC (data link 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 C554, for example, means those terminals join in cavity 2 of connector C554. Power Distribution Schematics Power Distribution Schematics Page 1905 Valve: Testing and Inspection Valve Stem-to-Guide Clearance Inspection Inspection 1. Slide the valve out of its guide about 10 mm, then measure the guide-to-stem clearance with a dial indicator while rocking the stem in the direction of normal thrust (wobble method). ^ If the measurement exceeds the service limit, recheck it using a new valve. ^ If the measurement is now within the service limit, reassemble using a new valve. ^ If the measurement with a new valve still exceeds the service limit, go to step 2. Intake Valve Stem-to-Guide Clearance Standard (New): 0.04 - 0.10 mm (0.002 - 0.004 inch) Service Limit: 0.16 mm (0.006 inch) Exhaust Valve Stem-to-Guide Clearance Standard (New): 0.10 - 0.16 mm (0.004 0.006 inch) Service Limit: 0.22 mm (0.009 inch) 2. Subtract the O.D. of the valve stem, measured with a micrometer, from the I.D. of the valve guide, measured with an inside micrometer or ball gauge. Take the measurements in three places along the valve stem and three places inside the valve guide. The difference between the largest guide measurement and the smallest stem measurement should not exceed the service limit. Intake Valve Stem-to-Guide Clearance Standard (New): 0.02 - 0.05 mm (0.0008 - 0.0020 inch) Service Limit: 0.08 mm (0.003 inch) Exhaust Valve Stem-to-Guide Clearance Standard (New): 0.05 - 0.08 mm (0.0020 - 0.0031 inch) Service Limit: 0.11 mm (0.004 inch) Page 756 120. MAP Sensor Page 7969 Disclaimer Cutting Procedure - By Copying 1. Press the ON/OFF button in the middle of the setting unit keypad. (This powers up the keypad.) 2. Turn the clamp unit lock lever to the left to release the clamp unit, and slide it all the way to the left until it stops. Turn the lever to the right to lock the clamp unit in place. 3. Use the clamp carriage lever to position the clamp unit so the tracer and cutter bit are centered directly over the base of the center and right jaws. 4. Pull the vertical carriage lever toward you until the tracer and the cutter bit just touch the base of each fixed jaw. Watch the arrows on the keypad: ^ If the double-headed arrow in the middle of the keypad lights green, the tracer and cutter bit are properly aligned. ^ If the arrow on the left of the keypad lights red, the cutter bit is not touching the fixed jaw. Turn the micrometric ring nut above the tracer to the left until the double-headed arrow lights green. ^ If the arrow on the right of the keypad lights red, the tracer is not touching the fixed jaw. Turn the micrometric ring nut above the tracer to the right until the double-headed arrow lights green. *5. Turn the micrometric ring nut to the right three clicks so the cutter bit is slightly higher than the tracer. The arrow on the left should light red. Raise the vertical carriage. NOTE: Setting the tracer three clicks lower than the cutter bit has the effect of making the cutter bit cut the duplicated key a little shallower. This will protect the locking jaws from being damaged.* 6. Optional: Loosen the setscrew, and adjust the hand rest to a comfortable position. Tighten the screw. 7. Pull the clamp carriage lever toward you until the clamp carriage clicks into its end-of-run position. Tighten both the lateral and spring tension adjustment knobs. 8. Make sure the center and right jaws are free of any metal shavings or debris. (A soft-bristle toothbrush is ideal for this purpose.) Page 4365 Wires Page 2139 Coolant: Testing and Inspection Check 1. Look at the coolant level in the coolant reservoir. Make sure it is between the MAX (A) and MIN mark (B). 2. If the coolant level in the coolant reservoir is at or below the MIN mark, add coolant to bring it up to the MAX mark, and inspect the cooling system for leaks. Specifications Fuel Pressure: Specifications Fuel Pressure at idle .................................................................................................................................... 270 - 320 kPa (2.8 - 3.3 kgf/sq.cm, 40 - 47 psi) Page 6344 Subframe: Service and Repair Subframe Replacement Subframe Torque After loosening the subframe mounting bolts, be sure to replace them with new ones Page 4357 156. A/T Reverse Relay (A/T, CVT) Page 3273 5. If the filter is not clogged, push the VTEC solenoid valve with your finger and check its movement. If the VTEC solenoid valve moves, check the engine oil pressure. Page 9044 Speedometer Head: Description and Operation How the Circuit Works The indicators are controlled by relative conditions in their associated systems. For the following indicators the information supplied to the gauge assembly is received via the multiplex control unit: - Charging System - Door Indicator Light - Maintenance Required Indicator - Seat Belt Reminder - Trunk Indicator Light Refer to each associated system to see its entire schematic. Speedometer and Odometer The odometer circuit drive and the speedometer are controlled by the CPU built-in the gauge assembly. The CPU receives pulses from the vehicle speed sensor (except CVT) or PCM (CVT). The pulse rate increases as the car accelerates. The frequency and duration of these input pulses are measured by the CPU. Restraints - Child Seat Anchor Locating Button Missing Child Seat: Customer Interest Restraints - Child Seat Anchor Locating Button Missing 05-016 May 17, 2005 Applies To: See VEHICLES AFFECTED Child Seat Anchor Locating Button Is Missing PROBLEM The small button on the rear seat-back cover that marks the location of each child seat LATCH lower anchor is missing. VEHICLES AFFECTED 2001-05 Accord - ALL 2001-05 Civic - ALL 2003-05 Civic Hybrid - ALL 2002-05 Civic Si - ALL 2001-05 CR-V - ALL 2003-05 Element - ALL 2001-05 Odyssey - ALL 2003-05 Pilot - ALL CORRECTIVE ACTION Replace the button. NOTE: Older vehicles have buttons without a child seat icon. The buttons in newer vehicles and the replacement buttons all have an icon. If your customer requests matching buttons, replace all the buttons at the same time as a set. PARTS INFORMATION Child Seat ISOFIX Button Kit: (Kit contains buttons in nine different colors; 10 buttons of each color.) P/N 070AZ-SHJA190, H/C 7979016 Child Seat ISOFIX Button Kit Replacement Parts: Page 380 WARRANTY CLAIM INFORMATION Out of warranty: Any repairs to the SRS system for problems other than the 15-1, 15-2, and 15-3 DTCs that are done 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. INSPECTION PROCEDURE NOTE: ^ When you check for SRS DTCs with the HDS, codes other than 15-1, 15-2, and 15-3 are not covered by this warranty extension bulletin. ^ If the vehicle is covered by warranty, repair it using the normal warranty repair procedures. If the vehicle's warranty is expired, give your customer an estimate for the cost of the repair. Do the appropriate inspection, based on the DTC. SRS DTC 15-1 Clear the DTC with the HDS. ^ If DTC 15-1 does not set again, go to REPAIR PROCEDURE A: OPDS UNIT REPLACEMENT. ^ If DTC 15-1 sets again, continue with normal troubleshooting. ^ If the OPDS unit causes DTC 15-1 to set repeatedly, yet passes the other troubleshooting steps, go to REPAIR PROCEDURE A: OPDS UNIT REPLACEMENT. SRS DTC 15-2 1. Inspect the connections and the wiring in the side airbag cutoff indicator circuit. ^ If all the connections and the wiring are OK, go to step 2. ^ If any of the connections or the wiring are faulty, repair the circuit, then go to step 2. 2. Clear the DTC with the HDS. ^ If DTC 15-2 does not set again, go to REPAIR PROCEDURE A: OPDS UNIT REPLACEMENT. ^ If DTC 15-2 sets again, continue with normal troubleshooting. ^ If the OPDS unit causes DTC 15-2 to set repeatedly, yet passes the other troubleshooting steps, go to REPAIR PROCEDURE A: OPDS UNIT REPLACEMENT. SRS DTC 15-3 1. Clear the DTC with the HDS. ^ If DTC 15-3 does not set again, go to step 2. ^ If DTC 15-3 sets again, continue with normal troubleshooting. 2. Ask your customer if electrical devices such as a laptop computer or a fluorescent map light are ever used near the front passenger's seat-back. (Some electrical devices that plug into the vehicle's accessory power socket, especially those using a power inverter/converter, can interfere with the seat-back sensors and cause SRS DTC 15-3 to set.) ^ If your customer uses any of these devices operate the device near the front passenger's seat-back. If DTC 15-3 sets again, clear it, then return the vehicle to the customer. Advise the customer to avoid using the device near the front passenger's seat-back. ^ If your customer does not use any of these devices and DTC 15-3 does not set again, go to REPAIR PROCEDURE A: OPDS UNIT REPLACEMENT. REPAIR PROCEDURE A: OPDS UNIT REPLACEMENT Locations Power Window Relay: Locations Relay And Control Unit Locations - Dashboard Page 1879 Rocker Arm Assembly: Service and Repair Rocker Arm Assembly Removal Removal 1. Loosen the adjusting screws (A). 2. Remove the bolts and the rocker arm assembly. -1 Unscrew the camshaft holder bolts two turns at a time, in a crisscross pattern, to prevent damaging the valves or rocker arm assembly. -2 When removing the rocker arm assembly, do not remove the camshaft holder bolts. The bolts will keep the camshaft holders, the springs and the rocker arms on the shafts. Camshaft Holder Bolt Loosening Sequence Page 5532 Wheel Speed Sensor: Diagrams 95. Wheel Speed Sensor, Left Front (EX, GX) 96. Wheel Speed Sensor, Left Rear (EX, GX) 97. Wheel Speed Sensor, Right Front (EX, GX) Page 9760 Power Window Switch: Service and Repair Passenger's Window Switch Test/Replacement Passenger's Window Switch Test/Replacement 4-door 1. Remove the door grip cover. 2. Disconnect the 5P connector (A) from the passenger's power window switch (B). 3. Check for continuity between the terminals in each switch position according to the table. 4. If the continuity is not as specified, remove the two screws and replace the switch. 2-door Page 5360 Wires Page 2450 114. FTP Sensor (except GX) Page 5889 235. Under-dash Fuse/Relay Box Part 8 Page 9348 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. Below most connector numbers and component names are PHOTO and VIEW numbers. The PHOTO number refers to a photo in the back of the book that shows the connector's location on the car. The VIEW number refers to an illustration in the back of the book that shows the connector terminals, wire colors, connector cavity numbers, and other details. The connector cavity numbering sequence begins at the top left corner of the connector as seen from either of the viewpoints shown on diagram [8] . Except for the DLC (data link 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 C554, for example, means those terminals join in cavity 2 of connector C554. Power Distribution Schematics Power Distribution Schematics Page 9740 169. Power Window Switch, Passenger's (Coupe Except DX, HX) 232. Power Window Master Switch Page 3155 8. Put the splice connector in the proper size slot in the Crimper Tool, slide it to one end (where the flare begins), and close the crimper handles far enough to hold it in place. To release the ratchet mechanism at any point after the first click, squeeze the handles slightly and push the release lever, then let the handles open. 9. Insert one of the bare wires into the splice connector end that is in the crimper jaws. Push the wire all the way into the splice connector, and squeeze the crimper handles. Keep squeezing until the jaws touch, and hold it at that position until the ratchet clicks again. 10. Crimp the other wire in the same way into the other end of the splice connector. 11. After crimping, gently pull on the wires in the opposite directions to make sure they are secure in the connector. 12. Separate the other wires in the harness from the repaired wire(s), and shield them with nonflammable material. Locations Transmission Position Switch/Sensor: Locations Component Location Index, A/T Page 3992 87. TCC Solenoid Valve (A/T Except CVT) Page 7083 ^ If the OPDS unit has an original part number, go to step 6. ^ If the OPDS unit has a new part number (refer to PARTS INFORMATION) or higher, go to REPAIR PROCEDURE B: OPDS SENSOR REPLACEMENT. 6. Recline the seat-back to access the OPDS unit mounting screws. 7. Remove the mounting screws from the OPDS unit, and gently pull out the unit. 8. Disconnect the OPDS connectors, then remove the OPDS unit. 9. Install a new OPDS unit, then snap on its cover. 10. Slip the seat-back cover over the OPDS unit. 11. On Accords, check the seat-back clip attachment bosses on the seat-back panel: ^ If the attachment bosses are OK, go to step 12. ^ If the seat-back has a pocket, and the attachment bosses are deformed or damaged, do the repair procedure in S/B 02-010, Seat-Back Panel Is Loose or Detached. Then go to step 12. ^ If the seat-back does not have a pocket, and the attachment bosses are deformed or damaged, replace the seat-back. Then go to step 12. Page 5787 69. Under Left Side Of Dash Page 7451 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. Circuits must be operating when checking voltage drop. 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. 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 off, 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 Self-Powered Test Light or DVOM 1. Remove the blown fuse and disconnect the battery and load. Page 7085 7. From the Mode menu, select Miscellaneous Test. 8. From the Miscellaneous Test menu, select OPDS Initialization. 9. Follow the remaining screen prompts to complete the OPDS initialization. If the initialization fails repeat the process two more times. If the initialization fails again, check for SRS DTCs, then troubleshoot them using the appropriate service manual. Initializing the OPDS Unit: Manual Mode NOTE: Non-Honda seat covers will interfere with the performance of the OPDS and are not recommended. 1. Adjust the front passenger's seat-back to an upright position, then remove anything on or near the seat. 2. Turn the ignition switch to LOCK (0). 3. Connect the HDS to the vehicle's DLC (data link connector). 4. Keep the ignition switch at LOCK (0), and turn on the HDS. 5. At the screen prompts, enter the VIN and the odometer reading. 6. From the Select Mode screen, select SCS, and follow the screen prompts. Page 1531 67. Under Left Side Of Dash Page 4552 3. Install the oil seal in the transmission housing with the special tools. 4. Install the oil seal (A) in the torque converter housing with the special tools. Carrier Bearing Side Clearance Inspection Special Tools Required Driver 40 mm I.D. 07746-0030100 1. Install the 80 mm set ring (A) in the transmission housing (B). Page 5372 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. Test Equipment 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. Page 8184 Power Door Lock Actuator: Diagrams 35. Door Lock Actuator, Driver's (except DX) 36. Door Lock Actuator, Front Passenger's (Sedan Except DX) 37. Door Lock Actuator, Left Rear Or Right Rear (Sedan Except DX) Page 4511 Pressure Plate: Service and Repair Flywheel Inspection Clutch Replacement Special Tools Required ^ Clutch alignment shaft 07LAF-PT00110 ^ Clutch alignment disc 07JAF-PM7011A ^ Remover handle 07936-3710100 ^ Ring gear holder 07LAB-PV00100 or 07924-PD20003 ^ Attachment, 57 x 40 mm 07746-0010200 ^ Driver 077 49-0010000 Flywheel Inspection 1. Inspect the ring gear teeth for wear and damage. 2. Inspect the clutch disc mating surface on the flywheel for wear, cracks and burning. 3. Measure the flywheel (A) runout using a dial indicator (B) through at least two full turns with the engine installed. Push against the flywheel each time you turn it to take up the crankshaft thrust washer clearance. If the runout is more than the service limit, replace the flywheel and recheck the runout. Standard (New): 0.06 mm (0.002 inch) max. Service Limit: 0.15 mm (0.006 inch) 4. Turn the inner race of the pilot bearing (A) with your finger. The bearing should turn smoothly and quietly. Check that the bearing outer race fits tightly in the flywheel. If the race does not turn smoothly, quietly, or fit tight in the flywheel, replace the bearing. Page 407 156. A/T Reverse Relay (A/T, CVT) Page 5983 Fuse Block: Service and Repair Removal and Installation SRS components are located in this area. Review the SRS component locations and precautions and procedures in the SRS section before performing repairs or service. Removal 1. Make sure you have the anti-theft code for the radio, then write down the frequencies for the radio's preset buttons. 2. Disconnect the battery negative cable, then disconnect the positive cable, and wait at least 3 minutes. 3. Remove the dashboard lower cover. 4. Disconnect the connectors from the fuse side of the under-dash fuse/relay box. 5. Remove the mounting bolt and slide the under-dash fuse/relay box (A) down from the bracket (B). 6. Disconnect the connectors from the back side of the under-dash fuse/relay box, and remove the fuse/relay box. NOTE: The SRS connector is a spring-loaded lock type. Installation 1. Install the under-dash fuse/relay box in the reverse order of removal and connect all connectors to the under-dash fuse/relay box. 2. Install the dashboard lower cover. 3. Connect both the negative cable and positive cable to the battery. 4. Enter the anti-theft code for the radio, then enter the customer's radio station presets. 5. Confirm that all systems work properly. 6. Do the ECM/PCM idle learn procedure. Page 5205 1. Remove and discard the plastic cover from the ignition switch key interlock solenoid. 2. Note the position of the interlock solenoid plunger; you'll need to install it the same way. 3. Remove the screw from the solenoid, but keep the solenoid attached to its electrical connector. Discard the screw. NOTE: ^ Be careful not to lose the solenoid plunger; it slides out easily. ^ Keep the plunger free of dirt and grease while it's removed from the solenoid. 4. Note the position of the interlock lever spring; you'll need to install the new spring the same way. Page 8182 121. Driver's Door (Coupe Except DX) 122. Driver's Door (Sedan Except DX) Page 5130 Use the tools from Pin Tool Set. First, check the connector that you are about to repair. - If it has a secondary terminal lock, go to Connectors With a Secondary Lock. A secondary lock, found on most connectors on some models, is an additional locking device on the connector housing as a backup for the primary lock on the terminal. - If the connector does not have a secondary lock, go to Connectors Without a Secondary Lock. Connectors With a Secondary Lock All examples are shown with the connector lock facing up. The illustrations are examples of the secondary terminal locks; however, the connector you are repairing may vary in size. Identify the connector by the type of secondary lock, not by the number of terminal cavities. EXAMPLE A: 1. Release the secondary lock. 2. Remove the terminal. 3. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE B: Locations Under-dash Fuse/Relay Box Page 5191 13. Remove the solenoid cover, and make sure the solenoid plunger groove is installed in the fork on the lever. ^ If needed, correct the position of the solenoid plunger, then go to step 14. ^ If the solenoid plunger is correctly installed, there is an electrical problem with the key interlock system; refer to the Automatic Transmission section of the appropriate service manual for troubleshooting information. Once the key interlock is working normally, go to step 14. 14. Install the solenoid cover. 15. Reinstall the steering column covers. 16. Center-punch a completion mark above the seventh character of the engine compartment VIN. Disclaimer Page 4219 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 Short Circuit Locator (Short Finder) 1. Remove the blown fuse. Leave the battery connected. Locations Pressure Regulating Solenoid: Locations 23. Transmission Housing (A/T) Page 7165 80. Under Middle of Dash Page 5428 Reassembly 1. Connect the parking brake cable to the parking brake lever. 2. Apply MolyKote grease 44MA on the sliding surfaces as illustrated. Wipe off any excess. Do not get grease on the brake linings. 3. Install the parking brake lever (A) on the rear brake shoe (B), and secure it with the pivot pin (C), wave washer (D), and a new U-clip (E). Pinch the U-clip securely to prevent it from coming off. 4. Install the self-adjuster (C) and self-adjuster spring (D) on the front brake shoe (E). 5. Assemble the brake shoes with clevis A, adjuster bolt (F), clevis B. and the upper return spring (G). NOTE: Thread the adjuster bolt fully into clevis A. Page 1512 Fuse: Locations Under-Hood Fuse/Relay Box Under-hood Fuse/Relay Box Page 8358 Check the top coat enamel has dried thoroughly, then sand the top coat enamel. Use a flexible block and #600 - #800 - #1000 sandpapers. NOTE: Be careful not to sand down to the primer surfacer. When the painting repair is almost complete, polish the top coat. Use #1500 sandpaper and compound. 4. Air blowing/degreasing Use alcohol, a tack cloth, and wax and grease remover. Clean and degrease the surfaces where the masking tape will be attached. Top Coating Top Coating 1. Masking Mask the area surrounding the damage to protect it from the top coat overspray. Use masking tape and paper. 2. Spraying top coat enamel/clear coat Spray 2 - 3 coats until the intermediate coat is fully covered. NOTE: Do not cover the surface with one heavy coat. - Apply several thin coats. Use the 2-part polyester urethane top coat enamel and a spray gun. - Mix the top coat enamel with the additive and solvent in the correct ratio. - Follow the top coat manufacturer's instructions. After spraying the top coat enamel, allow for 5 - 10 minutes drying time before you spray the clear coat. Drying NOTE: Take care not to let the heat lamp deform the bumper during the drying process. After spraying the clear coat, allow for 5 - 10 minutes drying time before you force dry it with infrared lamps or other industrial dryer. 3. Polishing/buffing - Check that the clear coat has dried thoroughly. - Wet sand to remove any imperfections. Use a flexible block, Soap,and #2000 sandpaper Page 6784 227. Cable Reel Locations Transmission Position Switch/Sensor: Locations Component Location Index, A/T Page 8643 Front Door Weatherstrip: Service and Repair Front Door Weatherstrip Replacement Front Door Weatherstrip Replacement NOTE: - Take care not to scratch the door. - Use a clip remover to remove the clips. Page 808 Transmission Position Switch/Sensor: Diagnostic Aids General Troubleshooting Information General Troubleshooting Information Tips and Precautions Before Troubleshooting 1. Check applicable fuses in the appropriate fuse/relay box. 2. Check the battery for damage, state of charge, and clean and tight connections. NOTE: 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. Handling Connectors - Make sure the connectors are clean and have no loose wire terminals. - Make sure multiple cavity connectors are packed with dielectric grease (except watertight connectors). - All connectors have push-down release type locks (A). - Some connectors have a clip on their side used to attach them to a mount bracket on the body or on another component. This clip has a pull type lock. - Some mounted connectors cannot be disconnected unless you first release the lock and remove the connector from its mount bracket (A). - Never try to disconnect connectors by pulling on their wires; pull on the connector halves instead. - Always reinstall plastic covers. Page 8697 Cruise Control Servo Cable: Service and Repair Cruise Control Actuator/Cable Replacement Except 2-door D17A1, D17A2 engine: 1. Loosen the lockout (A), then disconnect the actuator cable (B) from the throttle linkage. 2. Disconnect the 4P connector from the cruise control actuator. 3. Remove the two mounting bolts, and remove the cruise control actuator assembly. 4. Remove the cruise control actuator cover from the cruise control actuator. Page 815 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 Short Circuit Locator (Short Finder) 1. Remove the blown fuse. Leave the battery connected. Crankshaft and Piston Removal Piston: Service and Repair Crankshaft and Piston Removal Removal 1. Remove the engine assembly. 2. Remove the transmission: ^ Manual transmission. ^ Automatic transmission. 3. Remove the cylinder head. 4. Remove the oil pan. 5. Remove the engine block end cover. 6. Remove the oil screen (A), then remove the oil pump (B). Seats With Side Airbags Air Bag(s) Arming and Disarming: Description and Operation Seats With Side Airbags Seats with Side Airbags Seats with side airbags have a tag attached to the seat-back. Because the component parts (seat-back cover, cushion, etc.) of seats with and without airbags are different, make sure you install only the correct replacement parts. Because the seats are made by more than one manufacturer, make sure you replace any seat components (seat-back cover, frame, etc.) with the correct parts. The name of the seat manufacturer is indicated on the seat-back. Moreover, the manufacturer name is indicated on the seat-back frame and the seat-back pad. Confirm the indication when you exchange these parts. * When cleaning, do not saturate the seat with liquid, and do not spray steam on the seat. * Do not repair torn or frayed seat-back covers. Replace the seat-back cover. * After a collision in which the side airbag was deployed, replace the seat-back cover and the side airbag with new parts. If the seat-back cushion is split, it must be replaced. If the seat-back frame is definitely deformed, it must be replaced. Page 5718 Connectors - "C" Front Bumper Front Bumper: Service and Repair Front Bumper Front Bumper Removal/Installation NOTE: - Have an assistant help you when removing and installing the front bumper. - Take care not to scratch the front bumper and body. - Put on gloves to protect your hands. Remove the front bumper as shown. Install the bumper in the reverse order of removal, and note these items: - Make sure the front bumper engages the hooks of the side spacers and upper beams on both sides securely. - Replace any damaged clips. Page 8909 26. Remove PGM-FI main relay 2 (A). 27. Check for continuity between ECM/PCM connector terminal E9 and body ground. Is there continuity? YES - Repair short in the wire between the No.17 FUEL PUMP (15A) fuse and the ECM/PCM (E9), or the No.17 FUEL PUMP (15A) fuse and the PGM-FI main relay 2. Also replace the No.17 FUEL PUMP (15A) fuse. NO - Go to step 28. 28. Remove the rear seat cushion. 29. Remove the access panel from the floor. 30. Disconnect the fuel pump 5P connector. 31. Check for continuity between fuel pump 5P connector terminal No.5 and body ground. Is there continuity? YES - Repair short in the wire between the fuel pump and the PGM-FI main relay 2. Also replace the No.17 FUEL PUMP (15A) fuse. NO - Go to step 32. Page 5841 1. Right Side Of Engine Compartment Page 9400 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. How to Replace Connector Terminals Terminal Replacement Procedure HOW TO REPLACE CONNECTOR TERMINALS The terminal repair kits provide necessary tools and materials (terminals, wire seals, and splice connectors) to repair many damaged or faulty connector terminals. However, not all terminals for all connectors are available. Refer to the labels on the lids of the repair kits for replacement terminal availability. IMPORTANT SAFETY INFORMATION: On some models, the SRS wires are in a separate harness. If the SRS harness is damaged, replace the harness; do not repair it. On other models, wire harnesses include yellow SRS wires. If any SRS wire is damaged, replace the entire harness; do not repair it. Before you begin, inspect the wire you are about to repair for damage and length. Make sure the wire will be long enough to make a terminal repair without stretching it when you reinstall the terminal in the connector. If the wire is too short, or if access to the connector is too restricted to make a terminal repair, you may need to install a pigtail terminal (a short length of wire with a factory-crimped terminal on it). Refer to HOW TO INSTALL PIGTAIL TERMINALS. Removing the Terminal Page 5038 3. If there is no continuity between any terminal, remove the transmission range switch cover, and disconnect the connector (A) at the switch (B). 4. Check for continuity between terminals at the switch connector (c). There should be continuity between the terminals listed for each position. In the P position, between terminals: ^ No. 4 and No. 5 ^ No. 4 and No. 6 ^ No. 5 and No. 6 In the R position, between terminals: ^ No. 1 and No. 4 In the N position, between terminals: ^ No. 4 and No. 5 ^ No. 4 and No. 7 ^ No.5 and No.7 In the D position, between terminals: ^ No.2 and No.4 ^ No. 2 and No. 10 ^ No. 4 and No. 10 In the D3 position, between terminals: ^ No. 4 and No. 8 ^ No. 4 and No. 10 ^ No. 8 and No. 10 In the 2 position, between terminals: ^ No.3 and No.4 5. If there is no continuity between any terminals, adjust the transmission range switch installation. If the transmission range switch installation is OK, replace the switch. 6. If the transmission range switch continuity check was OK, replace the faulty transmission range switch harness. Page 3701 - Remove clips carefully; don't damage their locks (A). - Slip pliers (A) under the clip base and through the hole at an angle, then squeeze the expansion tabs to release the clip. - After installing harness clips, make sure the harness doesn't interfere with any moving parts. - Keep wire harnesses away from exhaust pipes and other hot parts, from sharp edges of brackets and holes, and from exposed screws and bolts. - Seat grommets in their grooves properly (A). Do not leave grommets distorted (B). Testing and Repairs - Do not use wires or harnesses with broken insulation. Replace them or repair them by wrapping the break with electrical tape. - After installing parts, make sure that no wires are pinched under them. - When using electrical test equipment, follow the manufacturer's instructions and those described. - If possible, insert the probe of the tester from the wire side (except waterproof connector). - Use back probe adaptor 07TAZ-001020A. - Refer to the instructions in the Honda Terminal Kit for identification and replacement of connector terminals. Five-Step Troubleshooting Five-Step Troubleshooting 1. Verify The Complaint Page 4123 Circuit Diagram Page 1752 Variable Valve Timing Actuator: Diagnostic Aids General Troubleshooting Information General Troubleshooting Information Tips and Precautions Before Troubleshooting 1. Check applicable fuses in the appropriate fuse/relay box. 2. Check the battery for damage, state of charge, and clean and tight connections. NOTE: 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. Handling Connectors - Make sure the connectors are clean and have no loose wire terminals. - Make sure multiple cavity connectors are packed with dielectric grease (except watertight connectors). - All connectors have push-down release type locks (A). - Some connectors have a clip on their side used to attach them to a mount bracket on the body or on another component. This clip has a pull type lock. - Some mounted connectors cannot be disconnected unless you first release the lock and remove the connector from its mount bracket (A). - Never try to disconnect connectors by pulling on their wires; pull on the connector halves instead. - Always reinstall plastic covers. Locations Intake Air Temperature Sensor: Locations PGM-FI System - Component Location Index Locations Impact Sensor: Locations SRS Component Location Index Page 6187 Power Steering Pump: Testing and Inspection Pump Pressure Test With T/N 07406-0010001 Test Special Tools Required ^ P/S joint adapter (pump) 07RAK-S040111 or 07RAK-S040110 ^ P/S joint adapter those) 07RAK-S040122 ^ P/S pressure gauge 07406-0010001 Check the fluid pressure as follows to determine whether the trouble is in the pump or gearbox. 1. Check the power steering fluid level and pump belt tension. 2. Disconnect the pump outlet hose (A) from the pump outlet with care so as not to spill the power steering fluid on the frame and other parts. Install the P/S Joint adapter (pump) on the pump outlet (B). 3. Connect the P/S joint adapter (hose) to the P/S pressure gauge, then connect the pump outlet hose (A) to the P/S joint adapter (hose). 4. Install the P/S pressure gauge to the P/S joint adapter (pump). 5. Fully open the shut-off valve (A). 6. Fully open the pressure control valve (B). 7. Start the engine and let it idle. 8. Turn the steering wheel from lock-to-lock several times to warm the fluid to operating temperature at 158°F (70°). 9. Measure steady-state fluid pressure while the engine is idling. If the pump is in good condition, the gauge should be no more than 690 - 1,500 kPa (7 - 15 kgf/cm2, 100 - 214 psi). If it reads higher, check for: ^ Clogged or deformed feed or return line between the pump and gearbox. ^ Clogged valve body unit. Raise the engine speed to 3,000 rpm, and measure the fluid pressure. If the pump is in good condition, the gauge should read at least 290 - 1,100 kPa (3 - 11 kgf/cm2, 43 - 156 psi). If it reads less, repair or replace the pump. 10. Lower the engine speed and let it idle. Close the shut-off valve, then close the pressure control valve gradually until the pressure gauge needle is stable. Read the pressure. NOTICE: Do not keep the shut-off valve closed more than 5 seconds or the pump could be damaged by overheating. 11. Immediately open the pressure control valve fully. If the pump is in good condition, the gauge should read at least 7,600 - 8,300 kPa (78 - 85 kgf/cm2, 1,110 - 1,210 psi) ('01-03 models), or 7,800-8,500 kPa (80-87 kgf/cm2, 1,140-1,240 psi) ('04 model). A low reading means pump output is too low for full assist. Repair or replace the pump. Page 5998 2. Remove the terminal from the female half. 3. Remove the terminal from the male half. 4. Go to HOW TO INSTALL NEW TERMINALS. Connectors Without a Secondary Lock All examples are shown with the connector lock facing up. The illustrations are examples of connector terminals without a secondary lock; however, the connector you are repairing may vary in size and shape. EXAMPLE A: 1. Remove the terminal. 2. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE B: Page 4430 Clutch Disc: Service and Repair Release Bearing Replacement Clutch Replacement Special Tools Required ^ Clutch alignment shaft 07LAF-PT00110 ^ Clutch alignment disc 07JAF-PM7011A ^ Remover handle 07936-3710100 ^ Ring gear holder 07LAB-PV00100 or 07924-PD20003 ^ Attachment, 57 x 40 mm 07746-0010200 ^ Driver 07749-0010000 Release Bearing Replacement 1. Remove the release fork boot (A) from the clutch housing (B). 2. Remove the release fork (C) from the clutch housing (B) by squeezing the release fork set spring (D) with pliers. Remove the release bearing (E). 3. Check the release bearing for play by spinning it by hand. If there is excessive play, replace the release bearing with a new one. NOTE: The release bearing is packed with grease. Do not wash it in solvent. Page 2813 Connectors - "C" Page 3267 2. Cut off the wire about an inch back from where it connects to the damaged or faulty terminal, then strip about half of the insulation off that piece. This will be used to size the wire end of the replacement pigtail terminal. NOTE: If you are not sure of the wire size, start with a large enough hole on the stripper that will not nick or cut off any strands of wires. 3. Select a pigtail terminal that matches the original wire at both ends (same kind of terminal and same diameter bare wire). 4. Select the smallest splice connector (yellow, pink, or blue) that will fit onto the stripped end of the original wire. 5. Insert the pigtail terminal into the connector cavity; push it in until it locks in place. 6. Lay the pigtail and the original wire side-by-side, and cut off both ends at once. If you are making more than one splice, do not cut each pigtail at the same location; the resulting "lump" of splice connectors would interfere with rewrapping the harness. Instead, cut the first pigtail close enough to the terminal so you will have room to make each remaining cut about 20 mm (3/4 inch) farther down on the next pigtail. 7. If you are using a yellow splice connector, strip about 6 mm (1/4 inch) of insulation off the ends of both wires. If you are using a pink or blue splice connector, strip off about 8 mm (5/16 inch) of insulation. Page 9101 2. Cut off the wire about an inch back from where it connects to the damaged or faulty terminal, then strip about half of the insulation off that piece. This will be used to size the wire end of the replacement pigtail terminal. NOTE: If you are not sure of the wire size, start with a large enough hole on the stripper that will not nick or cut off any strands of wires. 3. Select a pigtail terminal that matches the original wire at both ends (same kind of terminal and same diameter bare wire). 4. Select the smallest splice connector (yellow, pink, or blue) that will fit onto the stripped end of the original wire. 5. Insert the pigtail terminal into the connector cavity; push it in until it locks in place. 6. Lay the pigtail and the original wire side-by-side, and cut off both ends at once. If you are making more than one splice, do not cut each pigtail at the same location; the resulting "lump" of splice connectors would interfere with rewrapping the harness. Instead, cut the first pigtail close enough to the terminal so you will have room to make each remaining cut about 20 mm (3/4 inch) farther down on the next pigtail. 7. If you are using a yellow splice connector, strip about 6 mm (1/4 inch) of insulation off the ends of both wires. If you are using a pink or blue splice connector, strip off about 8 mm (5/16 inch) of insulation. Page 6896 8. Disconnect the 4P connector between the seat belt buckle tensioner (A) and floor wire harness. 9. Pull the seat belt out all the way and cut it. 10. Cutoff each connector, strip the ends of the wires, and connect the deployment tool alligator clips (A) to the wires. Place the deployment tool at least 30 feet (10 meters) away from the vehicle. NOTE: The driver's airbag and the front passenger's airbag has four wires, two yellow and two red. Twist each pair of unlike colored wires together, and connect an alligator clip to each pair. 11. Connect a 12 volt battery to the tool. - If the green light on the tool comes on, the igniter circuit is defective and cannot deploy the component. Go to Disposal of Damaged Components. - If the red light on the tool comes on, the component is ready to be deployed. 12. Push the tool's deployment switch. The airbags and tensioners should deploy (deployment is both highly audible and visible: a loud noise and rapid inflation of the bag, followed by slow deflation). If the components deploy and the green light on the tool comes on, continue with this procedure. - If an component doesn't deploy, yet the green light comes ON, its igniter is defective. Go to Disposal of Damaged Components. - During deployment the airbag can become hot enough to burn you. Wait 30 minutes after deployment before touching the airbag. 13. Dispose of the complete airbag. No part of it can be reused. Place it in a sturdy plastic bag (A), and seal it securely. Locations 75. Behind Recir-A/C-Rear Defogger Switch Assembly Service and Repair Fluid Filter - CVT: Service and Repair CVT ATF Filter Installation 1. Install the ATF filter brackets (A) on the ATF filter (B). 2. Install the ATF filter and bracket on the body. Page 490 89. Trunk Latch Switch Page 7272 Terminals - "T" Shielding Switches Fuses Page 6269 52. Position the new O-ring (A) and new piston seal ring (B) on the special tool, then slide them down toward the big end of the tool. Note these items during reassembly: ^ Do not over expand the resin seal rings. Install the resin seal rings with care so as not to damage them. After installation, be sure to contract the seal ring using the special tool (sizing tool). ^ Replace piston's O-ring and seal ring as a set. 53. Pull the O-ring off into the piston groove, then pull the piston seal ring off into the piston groove on top of the O-ring. 54. Coat the piston seal ring (A) and the inside of the special tool with power steering fluid, then carefully slide the tool onto the rack and over the piston seal ring. 55. Move the special tool back and forth several times to make the piston seal ring fit snugly in the piston. 56. Set the new bushing (A) on the special tool, and insert the special tools into the cylinder housing (B). 57. Set the cylinder in a press, and install the bushing (A) into the bottom of the cylinder by pressing on the tool with press. Do not push on the tool with excessive force as it may damage the new bushing. 58. Coat the sliding surface of the special tool (A) and new cylinder end seal (B) with power steering fluid. Place the seal on the special tool with its grooved side (C) facing opposite the special tool. Electrical - DTC P1298 Stored in ECM/PCM Electric Load Sensor: Customer Interest Electrical - DTC P1298 Stored in ECM/PCM 05-006 May 6, 2005 Updated information is noted by asterisks. Applies To: 2001-05 Civic - ALL *2002-04 CR-V - ALL* DTC P1298 Is Stored in the ECM/PCM (Supersedes 05-006, dated February 25, 2005, to change the CR-V model-year range) SYMPTOM DTC P1298 (electrical load detector (ELD) circuit high voltage) is stored in the ECM/PCM. PROBABLE CAUSE The electronic load detector (ELD) has a faulty solder joint. CORRECTIVE ACTION Replace the ELD. NOTE: Previously, if an ELD required replacement, you had to replace the under-hood fuse/relay box. To reduce repair costs, replacement ELDs are now available. PARTS INFORMATION Electronic Load Detector: P/N 38255-S5A-003, H/C 7987571 WARRANTY CLAIM INFORMATION In warranty: The normal warranty applies. Operation Number: 121195 Flat Rate Time: 0.4 hour Failed Part: Civic P/N 38250-S5A-A03 H/C 7472277 CR-V P/N 38250-S9A-A01 H/C 6890594 Defect Code: 06402 Symptom Code: 01201 Template ID: 05-006A 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 5602 11. Use a hand press to install the new rear bearing. Apply pressure only on the inner race to avoid damaging the bearing. 12. Remove the front bearing retainer plate. 13. Support the drive-end housing in a vise, and drive out the front bearing with a brass drift (A) and hammer. Locations Throttle Position Sensor: Locations PGM-FI System - Component Location Index Page 177 1. Remove the secondary lock from the male terminal half. 2. Remove the secondary lock from the female terminal half. 3. Remove the terminal (same procedure for male and female). 4. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE C: 1. Remove the secondary lock. Page 2293 Exhaust Pipe: Service and Repair Exhaust Pipe and Muffler Replacement NOTE: Use new gaskets and self-locking nuts when reassembling. Page 9516 Diagram 115-4 (Sedan EX) Locations Air Bag Control Module: Locations Relay And Control Unit Locations - Dashboard Page 4098 Power Distribution schematics show how power is supplied from the positive battery terminal to various circuits in the vehicle. Refer to the Power Distribution diagram set to get a more detailed understanding of how picture is supplied to the circuit you're working on. Individual circuit schematics begin with a fuse. So 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 Ground Distribution Schematics This sample Ground Distribution schematic shows all of the components that share the same ground point. Page 7479 5. Reconnect the connectors to the under-dash fuse/relay box, and make sure these input tests at the appropriate connectors on the under-dash fuse/relay box. If any test indicates a problem, find and correct the cause, then recheck the system. - If all the input tests prove OK, the multiplex control unit must be faulty, replace the under-dash fuse/relay box assembly. Locations Keyless/Power Door Lock System Component Location Index Page 3700 - Before connecting connectors, make sure the terminals (A) are in place and not bent. - Check for loose retainer (A) and rubber seals (B). - The backs of some connectors are packed with dielectric grease. Add grease if necessary. If the grease is contaminated, replace it. - Insert the connector all the way and make sure it is securely locked. - Position wires so that the open end of the cover faces down. Handling Wires and Harnesses - Secure wires and wire harnesses to the frame with their respective wire ties at the designated locations. Page 8013 ^ If no key code can be found on the iN or with the Matrix H High Security key Codes Book, remove one tumbler at a time from the old inner cylinder, and match the number stamped on the old tumbler to a new tumbler from the kit. Insert the new tumbler and spring in the appropriate new inner cylinder cavity. ^ Do not use the old inner cylinder, springs, or tumblers. ^ Using your thumb and forefinger, hold the tumblers in place, insert the key in the cylinder and verify that all tumblers are flush with the cylinder. If not, double-check the key number, the cutting key code, the tumbler numbers, and the cavity locations. NOTE: If the key cannot be inserted, check the tumbler in the "J" cavity. It may be out of position. Page 9182 Terminals - "T" Shielding Switches Fuses Page 7464 2. Cut off the wire about an inch back from where it connects to the damaged or faulty terminal, then strip about half of the insulation off that piece. This will be used to size the wire end of the replacement pigtail terminal. NOTE: If you are not sure of the wire size, start with a large enough hole on the stripper that will not nick or cut off any strands of wires. 3. Select a pigtail terminal that matches the original wire at both ends (same kind of terminal and same diameter bare wire). 4. Select the smallest splice connector (yellow, pink, or blue) that will fit onto the stripped end of the original wire. 5. Insert the pigtail terminal into the connector cavity; push it in until it locks in place. 6. Lay the pigtail and the original wire side-by-side, and cut off both ends at once. If you are making more than one splice, do not cut each pigtail at the same location; the resulting "lump" of splice connectors would interfere with rewrapping the harness. Instead, cut the first pigtail close enough to the terminal so you will have room to make each remaining cut about 20 mm (3/4 inch) farther down on the next pigtail. 7. If you are using a yellow splice connector, strip about 6 mm (1/4 inch) of insulation off the ends of both wires. If you are using a pink or blue splice connector, strip off about 8 mm (5/16 inch) of insulation. Page 1768 1. Remove the terminal. 2. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE G: 1. Remove the terminal. 2. Go to HOW TO INSTALL NEW TERMINALS. How to Install New Terminals HOW TO INSTALL NEW TERMINALS 1. Carefully match the old terminal with a new one from the terminal repair kit. Choose the correct replacement terminal based on the wire size range the terminal will accommodate. NOTE: If the replacement terminal quantities are low, reorder them by using the terminal part number listed on the inside lid of the terminal repair kit. Replacement terminals are available through your parts department using normal parts ordering procedures. 2. Depending on the size of the wire you are repairing, use the proper size slot in the crimping tool. Page 6125 DIAGNOSTIC WORKSHEET REPAIR PROCEDURE A Antitheft System - Alarm Will Not Arm/Arms By Itself Alarm Module: Customer Interest Antitheft System - Alarm Will Not Arm/Arms By Itself 05-025 July 1, 2005 Applies To: 2001-05 Civic - ALL 2002-05 CR-V - ALL 2003-04 Element - ALL Accessory Security System Changes Modes By Itself (Supersedes 05-025, dated June 10, 2005, to update the information indicated by black bars and asterisks.) SYMPTOM The security system will not arm or it arms by itself. PROBABLE CAUSE Key switch contact chatter causes the control unit to change modes. CORRECTIVE ACTION * Civic: Replace the security control unit, and reprogram the remote(s).* * CR-V and Element: Replace the security control unit and the microphone, then reprogram the remote(s).* * NOTE: You must replace the microphone on the CR-V and Element because the security control units are matched to their microphones when they are manufactured. Using the original microphone may result in security system problems.* PARTS INFORMATION WARRANTY CLAIM INFORMATION In warranty: The normal warranty applies. Out of warranty: Any repair performed after warranty expiration may be eligible for goodwill consideration by the District Parts and Service Manager or your Zone Office. You must request consideration, and get a decision, before starting work. REPAIR PROCEDURE NOTE: Before starting, make sure you have all of the remotes (three maximum) the customer wishes to use. Page 6233 Key Reminder Switch: Locations Entry Light Control System Component Location Index Page 5751 Auxiliary Power Outlet: Testing and Inspection Test/Replacement 1. Carefully pry the accessory power socket (A) out from the center lower cover. 2. Disconnect the 2P connector (B) from the socket. 3. Inspect the connector terminals to be sure they are all making good contact. - If the terminals are bent, loose or corroded, repair them as necessary, and recheck the system. - If the terminals look OK, go to step 4. 4. Turn the ignition switch ACC (I), and check for voltage between the No.1 and No.2 terminals. - There should be battery voltage. - If there is no battery voltage, check for: poor ground (G502). - an open in the wire. - blown No.18 (15 A) fuse in the under-dash fuse/relay box. Page 505 4. With the engine off, inspect the play (A) on the pedal pad (B) by pushing the pedal by hand. Free Play: 0.4 - 3.0 mm (0.016 - 0.118 inch) 5. If the pedal free play is out of specification, adjust the brake pedal position switch (C). If the pedal free play is insufficient, it may result in brake drag. 6. Push in the brake pedal position switch until its plunger is fully pressed (threaded end (A) touching the pad (B) on the pedal arm). Then, turn the brake pedal position switch clockwise to lock it. Make sure the brake lights go off when the pedal is released. 7. Check the brake pedal free play. Page 4538 Shift Interlock Solenoid: Testing and Inspection Shift Lock Solenoid Test 1. Remove the center console panel and center console. 2. Disconnect the shift lock solenoid connector (2P). 3. Connect the No. 1 terminal of the shift lock solenoid connector (2P) to the battery positive terminal, and connect the No. 2 terminal to the battery negative terminal. 4. Check that the shift lever can be moved from the P position. Release the battery terminals from the shift lock solenoid connector. Move the shift lever back to the P position, and make sure it locks. NOTE: Do not connect power to the No. 2 terminal (reverse polarity) or you will damage the diode inside the solenoid. 5. Check that the shift lock releases when the shift lock release is pushed, and check that it locks when the shift lock release is released. 6. If the shift lock solenoid does not work properly, replace it. Page 8214 1. Check the depth adjustment of the trunk lid: ^ Refer to page 20-132 of the 2001-04 Civic Service Manual. ^ In ISIS, use the keyword TRUNK ADJUST, and select Trunk Lid Adjustment from the list. 2. Make sure the trunk lid is flush on all sides and corners. ^ If the trunk is misaligned, go to step 3. ^ If the trunk lid is properly aligned on all sides and corners, go to REPAIR PROCEDURE C. 3. Adjust the striker depth position and the trunk lid edge cushions: ^ Refer to page 20-132 of the 2001-04 Civic Service Manual. ^ In ISIS, use the keyword TRUNK ADJUST, and select Trunk Lid Adjustment from the list. 4. Check the trunk operation: ^ If the trunk opens and closes smoothly, return the vehicle to the customer. ^ If the trunk lid is still difficult to close, go to REPAIR PROCEDURE C. REPAIR PROCEDURE C 1. Use a small screwdriver to manually set and release the trunk lid latch. Check the operation of the latch: ^ If the latch is difficult to set or release, go to step 2. ^ If the latch operates properly, go to REPAIR PROCEDURE D. 2. Replace the trunk lid latch: ^ Refer to page 20-157 of the 2001-04 Civic Service Manual. ^ In ISIS, use the keyword LID LATCH, and select Trunk Lid Latch Replacement from the list. 3. Check the trunk operation: ^ If the trunk opens and closes smoothly, return the vehicle to the customer. ^ If the trunk lid is still difficult to close, go to REPAIR PROCEDURE D. REPAIR PROCEDURE D 1. Disconnect the trunk lid opener cable from the trunk lid latch. Check the cable operation: ^ Refer to page 20-157 of the 2001-04 Civic Service Manual. ^ In ISIS, use the keyword LID LATCH, and select Trunk Lid Latch Replacement from the list. 2. Check that there is no friction or binding of the cable by holding the outside casing and pulling back and forth on the inner cable: ^ If the cable is difficult to move or binds, go to step 3. ^ If the cable operates smoothly, go to REPAIR PROCEDURE E. 3. Replace the trunk lid opener cable: ^ Refer to page 20-151 of the 2001-04 Civic Service Manual. ^ In ISIS, use the keyword LID OPEN, and select Trunk Lid Opener/Fuel Fill Door Opener Cable Replacement from the list. 4. Check the trunk operation: Page 3137 - Remove clips carefully; don't damage their locks (A). - Slip pliers (A) under the clip base and through the hole at an angle, then squeeze the expansion tabs to release the clip. - After installing harness clips, make sure the harness doesn't interfere with any moving parts. - Keep wire harnesses away from exhaust pipes and other hot parts, from sharp edges of brackets and holes, and from exposed screws and bolts. - Seat grommets in their grooves properly (A). Do not leave grommets distorted (B). Testing and Repairs - Do not use wires or harnesses with broken insulation. Replace them or repair them by wrapping the break with electrical tape. - After installing parts, make sure that no wires are pinched under them. - When using electrical test equipment, follow the manufacturer's instructions and those described. - If possible, insert the probe of the tester from the wire side (except waterproof connector). - Use back probe adaptor 07TAZ-001020A. - Refer to the instructions in the Honda Terminal Kit for identification and replacement of connector terminals. Five-Step Troubleshooting Five-Step Troubleshooting 1. Verify The Complaint Ceiling Light/Spotlight Test/Replacement Dome Lamp: Testing and Inspection Ceiling Light/Spotlight Test/Replacement Ceiling Light/Spotlights Test/Replacement - With Moonroof 1. Turn the ceiling light/spotlights switches OFF. 2. Carefully pry off the lens (A) with a small screwdriver. 3. Remove the two screws and the housing (B). 4. Disconnect the 4P connector (C) from the housing. 5. Check the bulbs. If the bulbs are OK, check for continuity between the terminals in each switch position according to the table. 6. If the continuity is not as specified, replace the ceiling light. Page 7063 Impact Sensor: Service Precautions SRS Unit, Front Impact Sensors, and Side Impact Sensors - Be careful not to bump or impact the SRS unit, front impact sensors, or side impact sensors whenever the ignition switch is ON (II), or for at least 3 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, front impact sensors, and side impact sensors. The airbags could accidentally deploy and cause damage or injury. - After a collision in which any airbags or seat belt tensioners were deployed, replace the SRS unit, front impact sensors, and other related components. After a collision in which a side airbag was deployed, replace the side impact sensor on the deployed side 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, front impact sensors, and side impact sensors. If there is any damage, replace the SRS unit, front impact sensors and/or side impact sensors. - Do not disassemble the SRS unit, front impact sensors, or the side impact sensors. - Turn the ignition switch OFF, disconnect the battery negative cable, and wait at least 3 minutes before beginning installation or replacement of the SRS unit, or disconnecting the connectors from the SRS unit. - Be sure the SRS unit, front impact sensors, and side impact sensors are installed securely with the mounting bolts torqued to 9.8 N.m (1.0 kgf.m, 7.2 lbf.ft) - Do not spill water or oil on the SRS unit, front impact sensors, or side impact sensors, and keep them away from dust. - Store the SRS unit, front impact sensors, and side impact sensors in a cool (less than 104 °F/40 °C) and dry (less than 80 % relative humidity, no moisture) area. Page 2977 ECM/PCM Inputs And Outputs At Connector E (31P) Page 200 Low Beam Relay: Testing and Inspection Power Relay Test Use this chart to identify the type of relay, then do the test listed for it. NOTE: See the turn signal/hazard relay input test. Normally-open type A: Page 1847 3. Measure the piston pin-to-piston clearance. Piston Pin-to-Piston Clearance Standard (New): 0.010 - 0.020 mm (0.0004 - 0.0008 inch) 4. Check the difference between the piston pin diameter and connecting rod small end diameter. Piston Pin-to-Connecting Rod Interference Standard (New): 0.016 - 0.036 mm (0.0006 - 0.0014 inch) Reassembly 1. Assemble the piston and connecting rod with the connecting rod oil hole (A) facing the "IN" mark (B). Locations 12. Middle Of Engine Page 6146 3. Loosen the locknut (A) while holding the tie-rod arm (B). 4. Turn the tie-rod end (C) until the toe is correct. NOTE: Adjust both the right and left wheels at the same time by the same amount in opposite directions to obtain the correct toe. 5. After adjusting, tighten the locknut while holding the tie-rod arm. Make sure the toe setting does not change. Rear Toe Inspection/Adjustment Use commercially-available computerized four wheel alignment equipment to measure wheel alignment (caster, camber, toe, and turning angle). Follow the equipment manufacturer's instructions. 1. Release the parking brake. 2. Check the toe. If it is not within the specification, go to step 3. Rear toe-in: 2 [+2/-1] mm (0.08 [+0.08/-0.04] inch) 3. Loosen the self-locking nut (A) while holding the adjusting bolt (B). NOTICE: Do not loosen the special bolts (C) on the lower arm to adjust the alignment. 4. Replace the self-locking nut with a new one, and lightly tighten it. NOTE: Always use a new self-locking nut whenever you loosened it. 5. Turn the adjusting bolt until the toe is correct. 6. Tighten the self-locknut to the specified torque while holding the adjusting bolt. Turning Angle Inspection Use commercially-available computerized four wheel alignment equipment to measure wheel alignment (caster, camber, toe, and turning angle). Follow the equipment manufacturer's instructions. Page 8006 PARTS INFORMATION REQUIRED MATERIALS WARRANTY CLAIM INFORMATION In warranty: The normal warranty applies. Failed Part: P/N 72185-S9A-003 H/C 6896716 Defect Code: 00503 Symptom Code: 07902 Skill Level: Repair Technician Page 6628 Relay And Control Unit Locations - Engine Compartment Page 5527 Parking Brake Warning Switch: Testing and Inspection Parking Brake Switch Test 1. Remove the console, and disconnect the connector (A) from the switch (B). 2. Check for continuity between the positive terminal and body ground: ^ With the brake lever up, there should be continuity. ^ With the brake lever down, there should be no continuity. Page 704 172. EGR Valve And EGR Valve Position Sensor (EX, HX; '04-'05: DX, LX) Page 7940 ^ Incorrect: "If a Master Key is to be cut, put a five (5) in the blank space. Use a two (2) if a valet key is needed." ^ Correct: "If a Master Key is to be cut, put an M in the blank space. Use an S if a valet key is needed." Page 2, legend at the bottom: ^ Incorrect: "C. If a Master key is desired, then the number five (5) should be placed in the M/S position. Place the number two (2) in the M/S column if a Sub (Valet) key is needed." ^ Correct: "C. If a Master Key is desired, then an M should be placed in the M/S position. Place an S in the MIS column if a Sub (Valet) key is needed." Page 9509 8. Put the splice connector in the proper size slot in the Crimper Tool, slide it to one end (where the flare begins), and close the crimper handles far enough to hold it in place. To release the ratchet mechanism at any point after the first click, squeeze the handles slightly and push the release lever, then let the handles open. 9. Insert one of the bare wires into the splice connector end that is in the crimper jaws. Push the wire all the way into the splice connector, and squeeze the crimper handles. Keep squeezing until the jaws touch, and hold it at that position until the ratchet clicks again. 10. Crimp the other wire in the same way into the other end of the splice connector. 11. After crimping, gently pull on the wires in the opposite directions to make sure they are secure in the connector. 12. Separate the other wires in the harness from the repaired wire(s), and shield them with nonflammable material. Page 4206 Terminals - "T" Shielding Switches Fuses Locations Seat Belt Buckle Switch: Locations 100. Under Driver's Seat 101. Under Front Passenger's Seat (Passenger's Similar) Page 7228 system will not enter the programming mode.) 3. Within 10 seconds, close and open the door two times. 4. Turn the ignition switch to the ACC position and then to the LOCK position three times. Close and open the door. (Complete this process within 10 seconds.) Verify that the power door locks cycle once to confirm that the system is in programming mode. 5. Within 20 seconds, press the "LOCK" button on the transmitter you are programming. Verify that the door locks cycle once. 6. Within 20 seconds, press the "UNLOCK" button on the transmitter. Verify that the door locks cycle once to confirm that the system has accepted the transmitter's code. Turning the Audible Chirp On/Off (1998-99 only) NOTE: On '00-02 Passports, the audible chirp sounds only when you push the LOCK button on the transmitter a second time. 1. Open the driver's door, then insert the key in the driver's door lock. 2. Turn the key to the "LOCK" position, then to the "UNLOCK" position. Repeat this two more times. (Complete this procedure within 10 seconds.) 3. Within 10 seconds, close and open the door two times. 4. Within 10 seconds, turn the key to the "LOCK" position, and then to the "UNLOCK" position, three times. Close and open the door once. Verify that the power door locks cycle once to confirm that the chirp has been turned on/off. Ordering a Transmitter Transmitters can be ordered only by authorized Honda dealers. Order them from American Honda using normal parts ordering procedures. Batteries for the Transmitter The battery number is CR2016. Each transmitter uses two batteries. Locations 9. Middle Of Engine Compartment Page 8269 12. Pull the vertical carriage lever toward you while you position the tracer on the right edge of the original key at its head, using the clamp carriage lever. Let the cutter bit cut into the key blank, then stop. Gently twist the lever clockwise to lock the vertical carriage at this height. Do not overtighten the lever. 13. Use the clamp carriage lever and the tracer to follow the contours of the original key. (The cutter bit cuts the same contours into the key blank.) Working from right to left, follow the right edge of the original key from head to tip, then the left edge of the key from tip to head. Turn off the cutter motor. 14. Reposition the tracer on the right edge of the original key at its head, using the clamp carriage lever. Turn on the cutter motor. Retrace the key from head to tip, then from tip to head. (This retracing cleans up the cuts on the key.) Turn off the cutter motor. 15. Release the vertical carriage lever. Open the jaw and remove only the new key. Make sure the jaw is free of any metal shavings or debris, then turn the new key over and slide the key with its blank side up into the jaw up to the key stop. Close the jaw to lock the key into place. 16. Turn on the cutter motor, and repeat steps 12 thru 14 to cut both edges of the other side of the key. 17. When you are finished making the required cuts, turn off the cutter motor, and release the vertical carriage lever. Open the jaws, and remove the keys. 18. Use a wire brush to smooth the cut surfaces on the new key. 19. Make sure the key works in the ignition switch and all the locks. If the key does not work, recut the key, and try it again. 20. Depending on the type of key blank you have used, do this: ^ If you have used a Honda key blank, add the transponder code of the new key to the immobilizer system with the Honda Diagnostic System (HDS). ^ If you have used a T-5 programmable key blank ("T-5" stamped on the shank), code the key's transponder with the Ilco Immobilizer Key Code Duplicator (see S/B 99-053, Ilco Immobilizer key Code Duplicator). Cutting Procedure - By Code 1. Press the ON/OFF button in the middle of the setting unit keypad. (This powers up the keypad.) 2. Turn the clamp unit lock lever to the left to release the clamp unit, and slide it to the right until the bottom left side is flush with the base edge. Turn the lever to the right to lock the clamp unit in place. Loosen the lateral and spring tension adjustment knobs on the clamp carriage. Page 4845 Flat Rate Time: 4.0 hours Failed Part: P/N 24230-PLW-000 H/C 6568653 Defect Code: 042 Contention Code: B07 Template ID: 03-009A (DX, LX, EX) 03-009B (HX) 03-009C (Hybrid) 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. * Remove the transmission. See page 13-4 of the 2001-2003 Civic Service Manual; for the Hybrid, see page 13-18. Then remove the housing. See page 13-16 of the 2001-2003 Civic Service Manual; for the Hybrid, see page 13-32.* 2. * Remove the reverse idler shaft and the reverse idler gear; discard the gear. See page 13-17 (13-32 for Hybrid) of the service manual.* Page 3164 10. Connect the connector securely, then install the transmission range switch cover. 11. Turn the ignition switch ON (II). Move the shift lever through all gear positions, and cheek the transmission range switch synchronization with the A/T gear position indicator. 12. Allow the wheels to rotate freely, then start the engine. 13. Move the shift lever through all gear positions, and verify the following: ^ The engine will not start in any position other than N or P. ^ The back-up lights come on when the shift lever is in the R position. Pump Pressure Test With T/N 07406-001000A Power Steering Pump: Testing and Inspection Pump Pressure Test With T/N 07406-001000A Test Special Tools Required ^ P/S joint adapter (pump) 07RAK-S040111 or 07RAK-S040110 ^ P/S joint adapter (hose) 07RAK-S040122 ^ P/S pressure gauge 07406-001000A Check the fluid pressure as follows to determine whether the trouble is in the pump or gearbox. 1. Check the power steering fluid level and pump belt tension. 2. Disconnect the pump outlet hose (A) from the pump outlet with care so as not to spill the power steering fluid on the frame and other parts. Install the P/S joint adapter (pump) on the pump outlet (B). 3. Connect the P/S joint adapter (hose) to the P/S pressure gauge, then connect the pump outlet hose (A) to the P/S joint adapter (hose). 4. Install the P/S pressure gauge to the P/S joint adapter (pump). 5. Open the pressure control valve (A) fully. 6. Start the engine and let it idle. 7. Turn the steering wheel from lock-to-lock several times to warm the fluid to operating temperature at 158°F (70°C). 8. Measure steady-state fluid pressure while the engine is idling. If the pump is in good condition, the gauge should be no more than 690 - 1,500 kPa (7 - 15 kgf/cm2, 100 - 214 psi). If it reads higher, check for: ^ Clogged or deformed feed or return line between the pump and gearbox. ^ Clogged valve body unit. Raise the engine speed to 3,000 rpm, and measure the fluid pressure. If the pump is in good condition, the gauge should read at least 290 - 1,100 kPa (3 - 11 kgf/cm2, 43 - 156 psi). If it reads less, repair or replace the pump. 9. Lower the engine speed and let it idle. Close the pressure control valve gradually until the pressure gauge needle is stable. Read the pressure. NOTICE: Do not keep the pressure control valve closed more than 5 seconds or the pump could be damaged by over-heating. 10. Immediately open the pressure control valve fully. If the pump is in good condition, the gauge should read at least 7,600 - 8,300 kPa (78 - 85 kgf/cm2, 1,110 - 1,210 psi). A low reading means pump output is too low for full assist. Repair or replace the pump. Page 7338 5. Click Warranty Audio Order to view the Warranty Audio Order form. 6. Enter the VIN and the mileage, then click the Submit button to view the Warranty Audio Order form. Use the completed Audio/Navigation/RES Worksheet to help you answer the questions on the Warranty Audio Order form. Questions with a red asterisk (*) are required fields that you must answer to submit the form. Make sure the information is complete (17-digit VIN, etc.). This information is critical to the remanufacturing process. Screen # 2 of the form contains the problem description, condition information, and shared functions. Fill this section out with as much information as possible. Select one part number from the list provided, then click Submit. It is your responsibility to ensure the correct part number is selected based on color and application information. Page 1118 Shift Interlock Switch: Testing and Inspection Park Pin Switch Test Park Pin Switch Test 1. Remove the center console panel and center console. 2. Disconnect the park pin switch connector (4P). 3. Shift to the P position, then check for continuity between the No. 3 and No. 4 terminals. There should be no continuity. 4. Shift out of the P position, and check for continuity between terminals No. 3 and No. 4. There should be continuity. 5. If the park pin switch is faulty, replace it. Page 4608 195. Tranmission Range Switch Page 5301 Transmission Position Switch/Sensor: Testing and Inspection Transmission Range Switch Test Transmission Range Switch Test 1. Remove the transmission range switch harness connector (A) from the connector bracket (B), then disconnect the connector. 2. Check for continuity between terminals at the harness connector. There should be continuity between the terminals listed for each switch position. In the P position, between terminals: ^ No. 1 and No. 3 ^ No. 1 and No. 8 ^ No. 3 and No. 8 In the R position, between terminals: ^ No. 1 and No. 9 In the N position and between terminals: ^ No. 1 and No. 3 ^ No. 1 and No. 10 ^ No. 3 and No. 10 In the D position, between terminals: ^ No. 1 and No. 2 ^ No. 1 and No. 4 ^ No.2 and No.4 In the D3 position, between terminals: ^ No. 1 and No. 2 ^ No. 1 and No. 5 ^ No.2 and No.5 In the 2 position, between terminals: ^ No. 1 and No. 6 Page 4134 Pressure Regulating Solenoid: Service and Repair A/T Clutch Pressure Control Solenoid Valves A and B Replacement 1. Remove the mounting bolts and the A/T clutch pressure control solenoid valves A and B. 2. Clean the mounting surface and fluid passage of the A/T clutch pressure control solenoid valves A and B and the transmission housing. 3. Install the new filter/gasket (c) in the solenoid valve assembly body groove. 4. Install the new A/T clutch pressure control solenoid valves A and B. Do not pinch the filter/gasket. 5. Check the A/T clutch pressure control solenoid valve connectors for rust, dirt, or oil, then connect them securely. Page 5328 Electronic Brake Control Module: Testing and Inspection ABS Control Unit Inputs and Outputs for 31P Connector Page 3771 Page 4290 7. Apply a small amount of Permalube grease to the base of the new lever. Then attach the slide hammer to the new lever pin, insert the lever into the ignition switch, and seat the pin with the slide hammer. 8. Check the installed height of the pin with vernier calipers. If the height is more than 5.0 mm, the pin is not seated. If needed, reattach the slide hammer, and seat the pin. NOTE: It's normal for the interlock lever to be loose, even when the pin is fully seated. 9. Install a new spring on the lever. Make sure you attach the ends of the spring correctly: ^ The right end goes into the slot on the ignition switch. Locations Main Relay (Computer/Fuel System): Locations Relay And Control Unit Locations - Dashboard System Description Information Bus: Description and Operation System Description System Descriptions The Multiplex Control System has four internal functions: - Multiplexing (send multiple signals over shared wires) - Wake up/sleep (runs at full power only on demand to reduce battery draw) - Fail-safe (fixes or ignores faulty signals) - Self-diagnosis (Mode 1 for the system. Mode 2 for input lines) The system controls the function of these circuits: - Entry light control (ignition key light and ceiling light) - Wiper/washer (including intermittent wipe and park functions) - Interlock system - Keyless/power Door Lock - Key-in reminder - Meter assembly, temperature gauge, and indicator lights - HVAC (compressor and fan control) Multiplex Communication To reduce the number of wire harnesses, digital signals are sent via shared multiplex communication lines rather than sending normal electrical signals through individual wires. - The input signals from each switch are converted to digital signals at the central processing unit (CPU). - The digital signals are sent from the transmitting unit to the receiving unit as serial signals. - The transmitted signal is converted to a switch signal at the receiving unit, and it operates the related component or monitors a switch. - There are exclusive communication lines between the ECM/PCM, the gauge assembly, and the under-dash fuse/relay box, Wake-up and Sleep The multiplex control system has "wake-up" and "sleep" functions to decrease parasitic draw on the battery when the ignition switch is OFF. - In the sleep mode, the multiplex control unit stops functioning (communication and CPU control) when it is not necessary for the system to operate. - As soon as any operation is requested (for example, a door is unlocked), the related control unit in the sleep mode immediately wakes up and begins to function. - When the ignition switch is turned OFF, and the driver's or front passenger's door is opened, then closed, there is about a 10 second delay before the control unit goes from the wake-up mode to the sleep mode. - If any door is open, the sleep mode will not function. - If a key is in the ignition switch, the sleep mode will not function. - When in sleep mode, the draw is reduced from 70 - 80 mA to less than 10 mA. Fail-safe To prevent improper operation, the multiplex control system has a fail-safe function. In the fail-safe mode, the output signal is fixed when any part of the system malfunctions (for example a faulty control unit or communication line). Each control unit has a hardware fail-safe function that fixes the output signal when there is any CPU malfunction, and a software fail-safe function that ignores the signal from the malfunctioning control unit and allows the system to operate normally. Page 4701 Transmission Speed Sensor: Locations 25. Transmission Housing (CVT) 26. Transmission Housing (CVT) Page 4348 Transmission Cooler: Service and Repair ATF Cooler Cleaning Special Tools Required ^ ATF Cooler Cleaner GHITTCF6H ^ Magnetic Nonbypass Spin-on Filter GTHGNBP2 (Available through the Honda Tool and Equipment Program 1-888-424-6857) Before installing an overhauled or remanufactured automatic transmission, you must thoroughly clean the ATF cooler to prevent system contamination. Failure to do so could cause a repeat automatic transmission failure. The cleaning procedure involves heated ATF-Z1 delivered under high pressure (100 psi). Check the security of all hoses and connections. Always wear safety glasses or a face shield, along with gloves and protective clothing. If you get ATF in your eyes or on your skin, rinse with water immediately. WARNING: ^ Improper use of the ATF cooler cleaner can result in burns and other serious injuries. ^ Always wear eye protection and protective clothing, and follow this procedure. 1. Check the fluid in the cooler cleaner tank. (The fluid level should be 4.5 inches from the top of the filler neck.) Adjust the level if needed; do not overfill. Use only Honda ATF-Z1; do not use any additives. 2. Plug the 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; you would damage the unit. 3. Flip the HEAT toggle switch to ON; the green indicator above the toggle switch comes 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.) NOTE: If the red indicator above the HEAT toggle switch comes on, the fluid level in the tank is too low for the tank heater to work. Service and Repair Marker Lamp Bulb: Service and Repair Front Turn Signal / Side Marker Lights: Parking Light: 1. Remove the inner fender. 2. Disconnect the connectors (A) from the lights. 3. Turn the bulb sockets (B) 45 ° counterclockwise to remove them from the headlight housing. 4. Install the new bulb(s) in the reverse order of removal. Locations 144. Right Side of Rear Shelf Page 3516 Throttle Position Sensor: Description and Operation Throttle Position (TP) Sensor The TP sensor is a potentiometer connected to the throttle valve shaft. As the throttle position changes, the sensor varies the signal voltage to the ECM/PCM. The TP sensor is not replaceable apart from the throttle body. Page 8040 19. Using your thumb and forefinger to hold the tumblers, remove the key from the inner cylinder, being careful not to drop any tumblers and springs. 20. *Using the key code from the iN that you have written down at step 2, build a new inner cylinder with new springs, new cylinder, and tumblers from the door lock cylinder kit. Make sure you put the appropriate numbered tumbler in the proper inner cylinder cavity. Apply a thin layer of Permalube to each tumbler to help lubricate and retain it.* NOTE: ^ There are two types of tumblers. The "SUBLOCK" tumbler goes only in cavity A." The "DISC" tumbler goes in cavities "B" through "J." ^ Cavity "E" is empty on all cylinders. Page 8265 *T-5 Sidewinder Key Applications ^ 2003-05 Civic ^ 2004-05 Civic Hybrid ^ 2003-05 Civic GX (CNG) ^ 2004-05 S2000 ^ 2002-06 CR-V ^ 2003-06 Element ^ 2003-04 Odyssey ^ 2003-04 Pilot Ordering Honda key blanks through normal parts ordering channels: Refer to the parts catalog for correct key(s) for your application. PROGRAMMING KEYS Depending on the type of key blank you use, do this: ^ If you have used a T-5 programmable key blank ("T-5" stamped on the shank), you must code the key's transponder with the Ilco Immobilizer Key Code Duplicator (see S/B 99-053, Ilco Immobilizer key Code Duplicator). ^ If you have used a Honda key blank, add the* transponder code of the new key to the immobilizer system with the Honda Diagnostic System (HDS). ORDERING INFORMATION *To order the MATRIX H Key Cutting Machine, replacement cutter bits, fixed jaws and mobile jaws, T-5 programmable key blanks, and practice key blanks, contact the Honda Tool and Equipment Program by calling 888-424-6857 or using the fax order form provided in your Honda Tool and Equipment Program Catalog.* Order Honda key blanks through normal parts ordering channels. WARRANTY CLAIM INFORMATION None. This service bulletin is for information only. *DETERMINING WHICH KEY TO USE T-5 keys require less time to program and should be the first choice. They can be used as long as the following requirements are met: ^ Do you have the customer's operating key? ^ Does the vehicle fall within the T-5 Sidewinder Key Applications? ^ Does your dealership have an Ilco Immobilizer Key Code Duplicator? If the answer to all three questions on the above is yes, the 1-5 key option is the easier procedure. If you answered no to any of the questions, you should order the key(s) from the parts catalogue, and program it using the HDS.* BEFORE YOU START CUTTING 1. Get the original key or the key number from your customer or from the iN. 2. Get the applicable key blank. 3. If cutting by code, look up the applicable 9-digit cutting code for the key number. Refer to the code book Honda High Security key Codes that comes with the machine. Page 7328 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 8608 PARTS INFORMATION REQUIRED MATERIALS WARRANTY CLAIM INFORMATION In warranty: The normal warranty applies. Failed Part: P/N 72185-S9A-003 H/C 6896716 Defect Code: 00503 Symptom Code: 07902 Skill Level: Repair Technician Page 5798 235. Under-dash Fuse/Relay Box Part 8 Page 7146 59. Under Left Side Of Dash Page 31 9. Check for continuity between the rear window defogger negative terminal (A) connector and body ground. There should be continuity. If there is no continuity, check for: An open in the BLK wire (B) - An open in the rear window defogger wire - Poor ground (G701) (C) Service and Repair Shift Linkage: Service and Repair Gearshift Mechanism Replacement Page 1479 Add the recommended refrigerant oil in the amount listed if you replace any of the following parts. - To avoid contamination, do not return the oil to the container once dispensed, and never mix it with other refrigerant oils. - Immediately after using the oil, replace the cap on the container, and seal it to avoid moisture absorption. - Do not spill the refrigerant oil on the vehicle; it may damage the paint; if it gets on the paint, wash it off immediately. Page 4369 Diodes Light Emitting Diode (LED) Motor Pressure Sensor Page 9290 Wire Color Abbreviations M/T - Clicking Noise Driving in 2nd Gear Synchronizer Ring: All Technical Service Bulletins M/T - Clicking Noise Driving in 2nd Gear 03-009 June 10, 2003 Applies To: 2001-03 Civic DX, LX, HX, EX with M/T - ALL 2003 Civic Hybrid - From VIN JHMES95..3S000001 thru JHMES95..3S018631 Clicking Noise While Driving in 2nd (Supersedes 03-009, dated April 1, 2003) Updated information is shown with asterisks. SYMPTOM * While driving in 2nd gear, a clicking noise occurs when turning right (DX, LX, HX, and EX) or when turning left (Civic Hybrid).* PROBABLE CAUSE The reverse idler gear is contacting the 1st/2nd hub sleeve set. CORRECTIVE ACTION Replace the reverse idler gear, the 1st/2nd synchro hub/sleeve set, and the reverse gear holder. REQUIRED MATERIALS Honda Manual Transmission Fluid (1.7 quarts required): P/N 08798-9016, H/C 4928271 Liquid Gasket: P/N 08718-0001, H/C 2963817 PARTS INFORMATION WARRANTY CLAIM INFORMATION In warranty: The normal warranty applies. Operation Number: 213110 Page 7539 Front Door Weatherstrip: Service and Repair Door Upper Seal Replacement Door Upper Seal Replacement 2-door NOTE: - Take care not to scratch the door. - Use a clip remover to remove the clips. 1. Remove these items: - Power mirror/manual mirror, as necessary - Door glass outer weatherstrip - Door sash trim 2. Detach the door weatherstrip clips (A, B), then remove the door upper seal (C). 3. Install the seal in the reverse order of removal, and note these items: - Replace the clip (A) if it's damaged. - Make sure the upper seal is installed in the holder (D) securely. - Check for water leaks. - Test-drive and check for wind noise. Component Locations Fuse Block: Component Locations Fuse and Relay Box Starting System Component Location Index Keyless Entry - Remote Transmitter Information Technical Service Bulletin # 98-011 Date: 040220 Keyless Entry - Remote Transmitter Information 98-011 February 20, 2004 Applies To: ALL Keyless Remote Transmitter Information (Supersedes 98-011, dated February 6, 2003) Updated information is shown by asterisks and a black bar. This service bulletin gives you information about keyless remote transmitters for most Honda vehicles. Each procedure describes transmitter programming (if applicable), transmitter ordering, and transmitter batteries. A remote transmitter quick reference guide is shown below. Page 3708 Use the tools from Pin Tool Set. First, check the connector that you are about to repair. - If it has a secondary terminal lock, go to Connectors With a Secondary Lock. A secondary lock, found on most connectors on some models, is an additional locking device on the connector housing as a backup for the primary lock on the terminal. - If the connector does not have a secondary lock, go to Connectors Without a Secondary Lock. Connectors With a Secondary Lock All examples are shown with the connector lock facing up. The illustrations are examples of the secondary terminal locks; however, the connector you are repairing may vary in size. Identify the connector by the type of secondary lock, not by the number of terminal cavities. EXAMPLE A: 1. Release the secondary lock. 2. Remove the terminal. 3. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE B: Page 4942 5. Attach the slide hammer to the interlock lever pin, and tighten the slide hammer clamping bolt. Then use the slide hammer to remove the pin. Discard the pin, the lever, and the spring. 6. Wipe off any debris from the lever's sliding surface on the ignition switch with a clean cloth or a cotton swab. NOTE: To keep debris out of the ignition switch, do not clean it with compressed air. Page 7743 ^ If the trunk opens and closes smoothly, return the vehicle to the customer. ^ If the trunk lid is still difficult to close, go to REPAIR PROCEDURE E. REPAIR PROCEDURE E 1. Look at the back of the lock cylinder while you turn the key from lock to unlock. ^ Refer to page 20-158 of the 2001-04 Civic Service Manual. ^ In ISIS, use the keyword LID LOCK, and select Trunk Lid Lock Cylinder Replacement from the list. 2. Check the operation of the trunk lid lock cylinder: ^ If the lock cylinder is difficult to turn or binds, go to step 3. ^ If the lock cylinder operates properly, and the trunk lid is still difficult to close, refer to the appropriate body repair manual, and check for body inaccuracies. 3. Replace the lock cylinder, and re-key the cylinder to the customer's original key; on 2-door Civics, replace the lock cylinder and the lock cylinder rod: ^ Refer to page 20-158 of the 2001-04 Civic Service Manual. ^ In ISIS, use the keyword LID LOCK, and select Trunk Lid Lock Cylinder Replacement from the list. 4. Check the trunk operation, and return the vehicle to the customer. Disclaimer Page 2710 213. DLC Page 4456 6. Remove the O-ring (A) and the clutch master cylinder seal (B) from the master cylinder (C). Clutch Master Cylinder Installation NOTE: Do not spill brake fluid on the vehicle, it may damage the paint, if brake fluid does contact the paint, wash it off immediately with water. 1. Fit to the clutch master cylinder (A) a new O-ring (B) and a clutch master cylinder seal (C). 2. Remove the clutch line (A) from the clutch hose clip (B) (2 places). 3. Fit to the master cylinder (A) the reservoir hose (B), the clutch line (C) and a new retaining clip (D). If the master cylinder was equipped with a retaining clip holder (E), reinstall it on the master cylinder. Page 2039 Terminals - "T" Shielding Switches Fuses Under-Dash Fuse/Relay Box Fuse: Locations Under-Dash Fuse/Relay Box Under-dash Fuse/Relay Box Locations EVAP System - Component Location Index Locations 12. Middle Of Engine Page 9178 Wire Color Abbreviations Page 968 32. Clutch Interlock Switch (M/T) Page 185 8. Inspect the quality of the wire crimp. If it has any of the following NO GOOD crimps, cut it off and start over. 9. Insert the terminal into the connector. Make sure the wire seals are pushed all the way into the connector. Lightly pull on the wires to make sure the terminal is locked into place. 10. Close or insert the secondary terminal lock, if applicable, and reconnect the connector. How to Install Pigtail Terminals HOW TO INSTALL PIGTAIL TERMINALS Pigtail terminals (short pieces of wire with a factory crimped terminal) are used when the wire is too short or when access to the connector is too restricted to make a terminal repair. NOTE: To replace just a connector terminal, go to How to Replace Connector Terminals. IMPORTANT SAFETY INFORMATION: On some models, the SRS wires are in a separate harness. If the SRS harness is damaged, replace the harness; do not repair it. On other models, wire harnesses include yellow SRS wires. If any SRS wire is damaged, replace the entire harness; do not repair it. 1. Remove the damaged or faulty terminal from the connector. Use the proper removal tool from Pin Tool Set. Component Locations Shift Interlock Switch: Component Locations Component Location Index Page 5794 234. Under-dash Fuse/Relay Box Part 4 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 2660 Compression Check: Testing and Inspection Engine Compression Inspection 1. Warm up the engine to normal operating temperature (cooling fan comes on). 2. Turn the ignition switch OFF. 3. Remove the air cleaner housing. 4. Disconnect all four injector connectors. 5. Remove the four ignition coils. 6. Remove the four spark plugs. 7. Attach the compression gauge to the spark plug hole. 8. Connect a tachometer. 9. Open the throttle fully, then crank the engine with the starter motor and measure the compression. Compression Pressure: Above 930 kPa (9.5 kgf/cm2, 135 psi) 10. Measure the compression on the remaining cylinders. Maximum variation: Within 200 kPa (2.0 kgf/cm2, 28 psi) 11. If the compression is not within specifications, check the following items, then re-measure the compression. ^ Damaged or worn valves and seats ^ Damaged cylinder head gasket ^ Damaged or worn piston rings ^ Damaged or worn piston and cylinder bore Page 7435 Wire Color Abbreviations Page 1457 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 887 Technical Service Bulletin # 01-077 Date: 060419 Ignition/Locks - Cutting Sidewinder-Type Keys 01-077 April 19, 2006 Applies To: Models With Sidewinder-Type Keys - All Cutting Sidewinder-Type Keys With the MATRIX H Key Cutting Machine (Supersedes 01-077, dated January 12, 2005) Updated information is noted by asterisks. MATRIX H Key Cutting Machine, manufactured by Silca and supplied by Kaba Ilco Corporation, is a portable, power-operated tool that cuts sidewinder-type automotive keys exclusively. The machine lets you cut these keys either by copying or by code. The code function is designed and built to meet the Honda code requirements. No other similar machine has this capability. This service bulletin gives you information for ordering and servicing this special tool, and guides you through the entire key cutting process from setting up the machine to cutting the key blank. TOOL INFORMATION Order through the Honda Tool and Equipment Program: MATRIX H Key Cutting Machine: Model No. ILCMATRIXSH Cutter Bit: Model No. ILCF3O Fixed Jaw: Model No. ILCMTX-H Mobile Jaw (Right Side): Model No. ILCRTMTX-H Mobile Jaw (Left Side): Model No. ILCLTMTX-H *Remanufactured Clamp Unit: Model No. ILCMATRIXHCR* PARTS INFORMATION *For some models, there are two choices for sidewinder-type key blanks: ^ T-5 sidewinder key blanks ^ Honda sidewinder key blanks For other models, only Honda sidewinder key blanks can be used. See DETERMINING WHICH KEY TO USE to determine which key blank you should choose. Ordering T-5 key blanks through the Honda Tool and Equipment Program: T-5 Programmable Key Blank (Master): P/N ILC-35111-T-5H T-5 Programmable Key Blank (Valet): P/N ILC-35112-T-5H Practice Key Blanks (five per pack): ILC-35111DEMO* NOTE: Do not use practice key blanks for replacement purposes. Practice keys do not have an immobilizer chip. Page 7420 Part 1 5. Reconnect all connections to the under-dash fuse/relay box, and make these input tests at the appropriate connectors on the under-dash fuse/relay box. If any test indicates a problem, find and correct the cause, then recheck the system. - If all the input tests prove OK, go to step 6. Part 2 Locations Main Relay (Computer/Fuel System): Locations Relay And Control Unit Locations - Dashboard Recall 10V364000: Ignition Interlock Defect Shift Interlock Switch: All Technical Service Bulletins Recall 10V364000: Ignition Interlock Defect VEHICLE MAKE/MODEL: MODEL YEAR(S): Honda/Accord 2003 Honda/Civic 2003 Honda/Element 2003-2004 MANUFACTURER: Honda (American Honda Motor Co.) MFR'S REPORT DATE: August 04, 2010 NHTSA CAMPAIGN ID NUMBER: 10V364000 NHTSA ACTION NUMBER: EA09001 COMPONENT: Electrical System: Ignition POTENTIAL NUMBER OF UNITS AFFECTED: 384220 SUMMARY: Honda is recalling certain model year 2003 Honda Accord, Civic two and four door, and model year 2003-2004 Honda Element vehicles. The interlock lever of the ignition switch may unexpectedly deform, which can allow the interlock function of a vehicle with an automatic transmission to be defeated. CONSEQUENCE: Removal of the ignition key when the gear selector of a vehicle with an automatic transmission has not been shifted to the park position can allow the vehicle to roll away, increasing the risk of a crash. REMEDY: Dealers will remove the original interlock pin and lever within the ignition switch, and replace them with newly, designed components. This service will be performed free of charge. The safety recall is expected to begin on or about September 29, 2010. Owners may contact Honda at 1-800-999-1009. NOTES: Honda safety recall No. R44. 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 2057 2. Remove the terminal (same procedure for male and female). 3. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE E: 1. Remove the secondary locks. 2. Remove the terminal (same procedure for male and female). 3. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE F: SRS Unit Replacement Air Bag Control Module: Service and Repair SRS Unit Replacement SRS Unit Replacement Removal 1. Disconnect the battery negative cable, and wait at least 3 minutes before beginning work. 2. Disconnect the driver's and front passenger's airbag connectors. 3. Disconnect the side airbag connectors. 4. Disconnect both seat belt tensioner connectors and both seat belt buckle tensioner connectors. 5. Remove the dashboard center lower cover. 6. Pull down the carpet, then remove the Torx bolt (A) from the SRS unit. 7. Disconnect the connectors and remove the two Torx bolts (A), then pull out the SRS unit. Installation 1. Install the new SRS unit (A) with Torx bolts (B), then connect the connectors (C) to the SRS unit; push it into position until it clicks. NOTE: When tightening the Torx bolts to the specified torque after replacement, be careful to turn them in so that their heads rest squarely on the Page 4239 Transmission Position Switch/Sensor: Service and Repair Transmission Range Switch Replacement 1. Raise the vehicle, and make sure it is securely supported. 2. Shift to the N position. 3. Remove the transmission range switch cover (A). 4. Disconnect the transmission range switch connector (B). 5. Remove the old transmission range switch, and install the new switch. 6. Make sure that the control shaft is in the N position. If necessary, move the shift lever to the N position. Page 6089 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 3605 3. Use the clamp carriage lever to position the clamp unit so the tracer is directly over the flat surface of the code device, just ahead of the cam blades. 4. Pull the vertical carriage lever toward you until the tracer just touches the flat surface ahead of the cam blades. Watch the arrows on the keypad: ^ If the double-headed arrow in the middle of the keypad lights green, the tracer and cutter bit are properly aligned. ^ If the arrow on the left of the keypad lights red, the cutter bit is not touching the jaw. Turn the micrometric ring nut above the tracer to the left until the double-headed arrow lights green. ^ If the vertical arrow on the right of the keypad lights red, the tracer is not touching the jaw. Turn the micrometric ring nut above the tracer to the right until the double-headed arrow lights green. *5. Turn the micrometric ring nut to the right five clicks so the cutter bit is slightly higher than the tracer. The arrow on the left should light red. Raise the vertical carriage. NOTE: Setting the tracer five clicks lower than the cutter bit at this point has the effect of making the cutter bit cut the duplicated key a little shallower. This will protect the locking jaws from being damaged.* 6. Optional: Loosen the set screw, and adjust the hand rest to a comfortable position. Tighten the screw. 7. Pull the clamp carriage lever toward you until the clamp carriage clicks into its end-of-run position. 8. Clean any metal shavings or debris out of the center jaw. (A soft-bristle toothbrush is ideal for this purpose.) Then open the jaws with the jaws knob, and slide the key blank with its flat side down into the jaw up to the key stop. Close the jaw with the jaws knob to lock the key blank into place. Visually inspect the key for proper alignment in the jaw. 9. Set and lock the cam sets on the code device. ^ Starting with the left cam set, make sure the lock pin is pulled all the way out. (This releases the cams.) Page 4623 Transmission Speed Sensor: Service and Repair Speed Sensors Replacement 1. Disconnect connectors from the drive pulley speed sensor (A), driven pulley speed sensor (B), CVT speed sensor (C), and CVT speed sensor 2 (D). 2. Remove the 6 mm bolts, then remove the speed sensors. Remove the sensor washer (E) from the vehicle speed sensor (C). 3. Replace the O-rings (F) with new ones before installing the speed sensors. 4. Install the sensor washer on the CVT speed sensor 2, and install them. 5. Install the drive pulley speed sensor, driven pulley speed sensor, and CVT speed sensor. 6. Check the speed sensor connectors for rust, dirt, or oil, then connect the connectors securely. Page 6226 Air Bag(s) Arming and Disarming: Service and Repair Connector Disconnection / Connection Disconnecting System Connectors Before removing a front airbag, side airbag, or other SRS related devices (the SRS unit, the cable reel, front sensor, the side impact sensors, the seat belt buckle tensioners, and the seat belt tensioner connector), disconnecting connectors from related devices, or removing the dashboard or the steering column, disconnect the airbag connectors or the side airbag connectors to prevent accidental deployment. Turn the ignition switch OFF, disconnect the negative cable from the battery, and wait at least 3 minutes before beginning the following procedures. - Before disconnecting SRS unit connector A (A) from the SRS unit, disconnect the driver's airbag 4P connector (C), the front passenger's airbag 4P connector (D), the driver's seat belt tensioner 2P connector (F), and the front passenger's seat belt tensioner 2P connector (G). - Before disconnecting SRS unit connector B (1) from the SRS unit, disconnect both side airbag 2P connectors (L, M) and both seat belt buckle tensioner 4P connectors (J, K). - Before disconnecting the cable reel 4P connector (B), disconnect the driver's airbag 4P connector (C). - Before disconnecting the floor wire harness 4P connector (E), disconnect both seat belt tensioner 2P connectors (F, G). 1. Disconnect the battery negative cable, and wait at least 3 minutes. Driver's Airbag Page 3464 Fuel Supply System - Component Location Index Page 2436 REPAIR PROCEDURE 1. Make sure you have the anti-theft code for the audio unit. Write down the customer's audio presets. 2. Disconnect the negative battery cable from the battery. 3. Remove the under-hood fuse/relay box cover. 4. Release the three clips, and remove the under- hood fuse/relay box from the holder. CR-V only: Release the wire harness clip from the fuse/relay box holder Page 7973 ^ Going from front to back, use the middle lock pin to set the first cam to the appropriate key code number in the code book. (The cam is properly set when the number on the cam lines up with the red scribe mark on the clamp unit.) ^ Slide the lock pin through the notch in the cam. (This locks the cam in place.) ^ Keep doing this for each of the remaining cams in the set until all the cams are set and locked, then push the lock pin all the way in. Repeat this process to set and lock the cams for the right cam set. NOTE: Make sure you set the MIS cam in the right cam set for the type of key you are cutting. For a master key, set the cam to M; for a valet key, set it to S. When you are done, push all the cam blades to the left until they touch the cams in the left cam set. 10. Pull the vertical carriage lever toward you until the tracer touches the flat surface on the right side at the front of the cams. Gently twist the lever clockwise to lock the vertical carriage at this height. Do not overtighten the lever. 11. Turn on the cutter motor with the motor start switch. [NOTICE] ^ To avoid damaging the locking jaws while cutting, keep your hand off the vertical carriage lever. Pressure on the lever will change the cutting depth. * ^ To avoid breaking the cutter bit, never back up while cutting.* ^ Wear proper eye protection (safety glasses, goggles, etc.) 12. Use the clamp carriage lever and the tracer to follow the contours of the cam blades from front to back. (The cutter bit cuts the same contours into the right edge of the key blank, from head to tip.) Page 8233 1. Check the depth adjustment of the trunk lid: ^ Refer to page 20-132 of the 2001-04 Civic Service Manual. ^ In ISIS, use the keyword TRUNK ADJUST, and select Trunk Lid Adjustment from the list. 2. Make sure the trunk lid is flush on all sides and corners. ^ If the trunk is misaligned, go to step 3. ^ If the trunk lid is properly aligned on all sides and corners, go to REPAIR PROCEDURE C. 3. Adjust the striker depth position and the trunk lid edge cushions: ^ Refer to page 20-132 of the 2001-04 Civic Service Manual. ^ In ISIS, use the keyword TRUNK ADJUST, and select Trunk Lid Adjustment from the list. 4. Check the trunk operation: ^ If the trunk opens and closes smoothly, return the vehicle to the customer. ^ If the trunk lid is still difficult to close, go to REPAIR PROCEDURE C. REPAIR PROCEDURE C 1. Use a small screwdriver to manually set and release the trunk lid latch. Check the operation of the latch: ^ If the latch is difficult to set or release, go to step 2. ^ If the latch operates properly, go to REPAIR PROCEDURE D. 2. Replace the trunk lid latch: ^ Refer to page 20-157 of the 2001-04 Civic Service Manual. ^ In ISIS, use the keyword LID LATCH, and select Trunk Lid Latch Replacement from the list. 3. Check the trunk operation: ^ If the trunk opens and closes smoothly, return the vehicle to the customer. ^ If the trunk lid is still difficult to close, go to REPAIR PROCEDURE D. REPAIR PROCEDURE D 1. Disconnect the trunk lid opener cable from the trunk lid latch. Check the cable operation: ^ Refer to page 20-157 of the 2001-04 Civic Service Manual. ^ In ISIS, use the keyword LID LATCH, and select Trunk Lid Latch Replacement from the list. 2. Check that there is no friction or binding of the cable by holding the outside casing and pulling back and forth on the inner cable: ^ If the cable is difficult to move or binds, go to step 3. ^ If the cable operates smoothly, go to REPAIR PROCEDURE E. 3. Replace the trunk lid opener cable: ^ Refer to page 20-151 of the 2001-04 Civic Service Manual. ^ In ISIS, use the keyword LID OPEN, and select Trunk Lid Opener/Fuel Fill Door Opener Cable Replacement from the list. 4. Check the trunk operation: Component Locations Page 5120 Power Distribution schematics show how power is supplied from the positive battery terminal to various circuits in the vehicle. Refer to the Power Distribution diagram set to get a more detailed understanding of how picture is supplied to the circuit you're working on. Individual circuit schematics begin with a fuse. So 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 Ground Distribution Schematics This sample Ground Distribution schematic shows all of the components that share the same ground point. Page 2800 Fuel Tank Pressure Sensor: Description and Operation The FTP sensor converts fuel tank absolute pressure into an electrical input to the ECM/PCM. Ceiling Light/Spotlights Test/Replacement - With Moonroof Map Light: Service and Repair Ceiling Light/Spotlights Test/Replacement - With Moonroof Ceiling Light/Spotlights Test/Replacement - With Moonroof 1. Turn the ceiling light/spotlights switches OFF. 2. Carefully pry off the lens (A) with a small screwdriver. 3. Remove the two screws and the housing (B). 4. Disconnect the 4P connector (C) from the housing. 5. Check the bulbs. If the bulbs are OK, check for continuity between the terminals in each switch position according to the table. 6. If the continuity is not as specified, replace the ceiling light. Page 8703 53. Steering Wheel (Airbag Inflators Removed) 57. Under Left Side Of Dash Diagrams Description and Operation Barometric Pressure Sensor: Description and Operation Barometric Pressure (BARO) Sensor The BARO sensor is inside the ECM/PCM. It converts atmospheric pressure into a voltage signal that the ECM/PCM uses to modify the basic duration of the fuel injection discharge. Page 8227 ^ If the trunk opens and closes smoothly, return the vehicle to the customer. ^ If the trunk lid is still difficult to close, go to REPAIR PROCEDURE E. REPAIR PROCEDURE E 1. Look at the back of the lock cylinder while you turn the key from lock to unlock. ^ Refer to page 20-158 of the 2001-04 Civic Service Manual. ^ In ISIS, use the keyword LID LOCK, and select Trunk Lid Lock Cylinder Replacement from the list. 2. Check the operation of the trunk lid lock cylinder: ^ If the lock cylinder is difficult to turn or binds, go to step 3. ^ If the lock cylinder operates properly, and the trunk lid is still difficult to close, refer to the appropriate body repair manual, and check for body inaccuracies. 3. Replace the lock cylinder, and re-key the cylinder to the customer's original key; on 2-door Civics, replace the lock cylinder and the lock cylinder rod: ^ Refer to page 20-158 of the 2001-04 Civic Service Manual. ^ In ISIS, use the keyword LID LOCK, and select Trunk Lid Lock Cylinder Replacement from the list. 4. Check the trunk operation, and return the vehicle to the customer. Disclaimer Technical Service Bulletin # 02-061 Date: 041105 Body - Trunk Lid Hard to Close 02-061 November 5, 2004 Applies To: See VEHICLES AFFECTED Trunk Lid is Difficult to Close (Supersedes 02-061, dated July 23, 2004) Updated information is shown with asterisks. SYMPTOM The trunk lid may be difficult to close or won't latch closed. PROBABLE CAUSE The trunk lid may be misaligned, and the trunk lid opener cable, trunk lid latch, lock cylinder, lock rod, and/or the trunk lid latch striker may need adjustment or replacement. Page 84 207. Cruise Control Unit (USA: HX; Sedan: LX, EX, GX) Page 3676 107. Behind A/T Shift Lever (except M/T) Service and Repair License Plate Frame: Service and Repair Rear License Trim Replacement 1. On the inside of the trunk lid, remove the nut(s) (A), and release the clips (B), then remove the rear license trim (C). Take care not to scratch the trunk lid. 2. Install the trim in the reverse order of removal, and note these items: - Replace any damaged clips. - Push the clip portions into place securely. Page 608 9. Install a 2 Ohms resistor between fuel pump 5P connector terminals No.1 and No.2, then turn the ignition switch ON (II). 10. Check that the pointer of the fuel gauge indicates "F". - If the pointer of the fuel gauge does not indicates "F", replace the gauge. - If the gauge is OK, inspect the fuel gauge sending unit. NOTE: The pointer of the fuel gauge returns to the bottom on the gauge dial when the ignition switch is OFF, regardless of the fuel level. 11. Relieve the fuel pressure. 12. Remove the fuel fill cap. 13. Disconnect the quick-connect fittings from the fuel pump. 14. Using the special tool, loosen the fuel tank unit locknut (A). Locations Control Module: Locations Electronic Controls Location Page 1183 1. Remove the screws and the power window master switch (A) from the door panel. 2. Disconnect the 14P connector (B) from the switch. 3. Check for continuity between the terminals in each switch position according to the table. Driver's Switch: The driver's switch is combined with the control unit so you cannot isolate the switch to test it. Instead, run the master switch input test procedures. If the tests are normal, the driver's switch must be faulty. 4. If the switch is faulty, remove the three screws and replace the switch. Fuel Gauge Sending Unit - New Wrench Available Fuel Gauge Sender: Technical Service Bulletins Fuel Gauge Sending Unit - New Wrench Available SOURCE: Honda Service News February 2003 TITLE: New Fuel Gauge Sending Unit Wrench Available APPLIES TO: All Models SERVICE TIP: There's a new fuel gauge sending unit wrench available in Honda parts stock. The new wrench T/N 07AAA-S0XA100) is a beefier version of the old one (T/N 07XAA-001010A) and supersedes it. The new wrench is much less prone to bending when you're removing a stubborn fuel pump/sender assembly locknut. Order it through normal parts ordering channels. Page 5319 136. Brake Pedal Position Switch Page 7824 12. Pull the vertical carriage lever toward you while you position the tracer on the right edge of the original key at its head, using the clamp carriage lever. Let the cutter bit cut into the key blank, then stop. Gently twist the lever clockwise to lock the vertical carriage at this height. Do not overtighten the lever. 13. Use the clamp carriage lever and the tracer to follow the contours of the original key. (The cutter bit cuts the same contours into the key blank.) Working from right to left, follow the right edge of the original key from head to tip, then the left edge of the key from tip to head. Turn off the cutter motor. 14. Reposition the tracer on the right edge of the original key at its head, using the clamp carriage lever. Turn on the cutter motor. Retrace the key from head to tip, then from tip to head. (This retracing cleans up the cuts on the key.) Turn off the cutter motor. 15. Release the vertical carriage lever. Open the jaw and remove only the new key. Make sure the jaw is free of any metal shavings or debris, then turn the new key over and slide the key with its blank side up into the jaw up to the key stop. Close the jaw to lock the key into place. 16. Turn on the cutter motor, and repeat steps 12 thru 14 to cut both edges of the other side of the key. 17. When you are finished making the required cuts, turn off the cutter motor, and release the vertical carriage lever. Open the jaws, and remove the keys. 18. Use a wire brush to smooth the cut surfaces on the new key. 19. Make sure the key works in the ignition switch and all the locks. If the key does not work, recut the key, and try it again. 20. Depending on the type of key blank you have used, do this: ^ If you have used a Honda key blank, add the transponder code of the new key to the immobilizer system with the Honda Diagnostic System (HDS). ^ If you have used a T-5 programmable key blank ("T-5" stamped on the shank), code the key's transponder with the Ilco Immobilizer Key Code Duplicator (see S/B 99-053, Ilco Immobilizer key Code Duplicator). Cutting Procedure - By Code 1. Press the ON/OFF button in the middle of the setting unit keypad. (This powers up the keypad.) 2. Turn the clamp unit lock lever to the left to release the clamp unit, and slide it to the right until the bottom left side is flush with the base edge. Turn the lever to the right to lock the clamp unit in place. Loosen the lateral and spring tension adjustment knobs on the clamp carriage. Page 1495 Air Bag(s) Arming and Disarming: Description and Operation SRS Components SRS Components Airbags The SRS is a safety device which, when used 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 (A), the cable reel (B), the driver's airbag (C), the front passenger's airbag (D), seat belt tensioners (I), seat belt buckle tensioners (J), and front impact sensors (K). Since the driver's and front passenger's airbags use the same sensors, both normally inflate at the same time. However, it is possible for only one airbag to inflate. This can occur when the severity of a collision is at the margin, or threshold, that determines whether or not the airbags will deploy. In such cases, the seat belt will provide sufficient protection, and the supplemental protection offered by the airbag would be minimal. Side Airbags The side airbags (E) are in each front seat-back. They help protect the upper torso of the driver or front seat passenger during a moderate to severe side impact. Side impact sensors (F) in each door sill and in the SRS unit detect such an impact and instantly inflate the driver's or the passenger's side airbag. Only one side airbag will deploy during a side impact. If the impact is on the passenger's side, the passenger's side airbag will deploy even if there is no passenger. 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. OPDS The side airbag system also includes an occupant position detection system (OPDS). This system consists of sensors (G) and a OPDS unit (H) in the front passenger's seat-back. The OPDS unit sends occupant height and position data to the SRS unit. If the OPDS unit determines that the front passenger is of small stature (for example, a child) and the front passenger is leaning into the side airbag deployment path, the SRS unit will automatically disable the passenger's side airbag. The SRS unit will also disable the airbag when the OPDS detects certain objects on the seat. When the side airbag is disabled, the side airbag cutoff indicator on the instrument panel alerts the driver that the passenger's side airbag will not deploy in a side impact. When the object is removed, or the passenger sits upright, the Side Airbag Cutoff indicator will go off after a few seconds, alerting the driver that the passenger's side airbag will deploy in a side impact. Page 4024 Pressure Regulating Solenoid: Service and Repair A/T Clutch Pressure Control Solenoid Valves A and B Replacement 1. Remove the mounting bolts and the A/T clutch pressure control solenoid valves A and B. 2. Clean the mounting surface and fluid passage of the A/T clutch pressure control solenoid valves A and B and the transmission housing. 3. Install the new filter/gasket (c) in the solenoid valve assembly body groove. 4. Install the new A/T clutch pressure control solenoid valves A and B. Do not pinch the filter/gasket. 5. Check the A/T clutch pressure control solenoid valve connectors for rust, dirt, or oil, then connect them securely. Locations Pressure Regulating Solenoid: Locations 23. Transmission Housing (A/T) Page 4978 - Before connecting connectors, make sure the terminals (A) are in place and not bent. - Check for loose retainer (A) and rubber seals (B). - The backs of some connectors are packed with dielectric grease. Add grease if necessary. If the grease is contaminated, replace it. - Insert the connector all the way and make sure it is securely locked. - Position wires so that the open end of the cover faces down. Handling Wires and Harnesses - Secure wires and wire harnesses to the frame with their respective wire ties at the designated locations. Page 8043 24. Remove the key. Reinstall the retainer clip in the door handle, and push the lock cylinder into place. 25. Civic: Reconnect the cylinder rod. 26. CR-V: Reconnect the cylinder rod, the outer handle rod, and the rod protector. 27. Element: Reconnect the cylinder rod, the outer handle rod, and the access seal. Reinstall the lower run channel. 28. Reinstall the plastic covering, and lower the window glass. Install the door panel. 29. Check that the door lock and handle operate smoothly. Disclaimer Page 959 Seat Occupant Sensor: Description and Operation OPDS (Occupant Position Detection System) The side airbag system also includes an Occupant Position Detection System (OPDS). This system consists of Sensors (G) and a OPDS Unit (H) in the front passenger's seat-back. The OPDS unit sends occupant height and position data to the SRS unit. If the SRS unit determines that the front passenger is of small stature (for example, a child) and the front passenger is leaning into the side airbag deployment path, it will automatically disable the airbag. The SRS unit will also disable the airbag when the OPDS detects certain objects on the seat. Side Airbag Cutoff Indicator When the side airbag is disabled, the Side Airbag Cutoff Indicator on the instrument panel alerts the driver that the passenger's side airbag will not deploy in a side impact. When the object is removed, or the passenger sits upright, the Side Airbag Cutoff indicator will go off, alerting the driver that the side airbag will deploy in a side impact. Page 2125 Valve Clearance: Adjustments Adjustment NOTE: Adjust the valves only when the cylinder head temperature is less than 100°F (38°C). 1. Remove the ignition coil cover, then remove the four ignition coils. 2. Remove the throttle cable clamps and harness holder from the cylinder head cover. 3. Remove the cylinder head cover. 4. Remove the grommet from the upper cover, and disconnect the camshaft position (CMP) (top dead center (TDC)) sensor connector. Remove the upper cover. 5. Set the No. 1 piston at TDC. The "UP" mark (A) on the camshaft pulley should be at the top, and the TDC marks (B) on the pulley should line up with the top edge of the head. 6. Select the correct thickness feeler gauge for the valves you're going to check. Intake: 0.18 - 0.22 mm (0.007 - 0.009 inch) Exhaust: 0.23 - 0.27 mm (0.009 - 0.011 inch) Adjusting screw location: Page 4346 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. Recall 10V364000: Ignition Interlock Defect Shift Interlock Switch: Recalls Recall 10V364000: Ignition Interlock Defect VEHICLE MAKE/MODEL: MODEL YEAR(S): Honda/Accord 2003 Honda/Civic 2003 Honda/Element 2003-2004 MANUFACTURER: Honda (American Honda Motor Co.) MFR'S REPORT DATE: August 04, 2010 NHTSA CAMPAIGN ID NUMBER: 10V364000 NHTSA ACTION NUMBER: EA09001 COMPONENT: Electrical System: Ignition POTENTIAL NUMBER OF UNITS AFFECTED: 384220 SUMMARY: Honda is recalling certain model year 2003 Honda Accord, Civic two and four door, and model year 2003-2004 Honda Element vehicles. The interlock lever of the ignition switch may unexpectedly deform, which can allow the interlock function of a vehicle with an automatic transmission to be defeated. CONSEQUENCE: Removal of the ignition key when the gear selector of a vehicle with an automatic transmission has not been shifted to the park position can allow the vehicle to roll away, increasing the risk of a crash. REMEDY: Dealers will remove the original interlock pin and lever within the ignition switch, and replace them with newly, designed components. This service will be performed free of charge. The safety recall is expected to begin on or about September 29, 2010. Owners may contact Honda at 1-800-999-1009. NOTES: Honda safety recall No. R44. 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 5611 32. Clutch Interlock Switch (M/T) Page 7735 ^ If the trunk opens and closes smoothly, return the vehicle to the customer. ^ If the trunk lid is still difficult to close, go to REPAIR PROCEDURE E. REPAIR PROCEDURE E 1. Look at the back of the lock cylinder while you turn the key from lock to unlock. ^ Refer to page 20-158 of the 2001-04 Civic Service Manual. ^ In ISIS, use the keyword LID LOCK, and select Trunk Lid Lock Cylinder Replacement from the list. 2. Check the operation of the trunk lid lock cylinder: ^ If the lock cylinder is difficult to turn or binds, go to step 3. ^ If the lock cylinder operates properly, and the trunk lid is still difficult to close, refer to the appropriate body repair manual, and check for body inaccuracies. 3. Replace the lock cylinder, and re-key the cylinder to the customer's original key; on 2-door Civics, replace the lock cylinder and the lock cylinder rod: ^ Refer to page 20-158 of the 2001-04 Civic Service Manual. ^ In ISIS, use the keyword LID LOCK, and select Trunk Lid Lock Cylinder Replacement from the list. 4. Check the trunk operation, and return the vehicle to the customer. Disclaimer Locations Oil Pressure Sender: Locations Gauges Component Location Index (Part 1 Of 4) Page 4259 Shift Interlock Solenoid: Service and Repair Shift Lock Solenoid Replacement 1. Remove the center console panel and center console. 2. Disconnect the shift lock solenoid connector (2P), and remove it from the shift lever bracket base. 3. Push the lock tab (A), pry the shift lock solenoid (B) to clear the projected tips (C) with a screwdriver, and remove the shift lock solenoid. 4. Install the shift lock solenoid plunger (D) and plunger spring (E) in the new shift lock solenoid. 5. Install the shift lock solenoid by aligning the joint (F) of the shift lock solenoid plunger with the tip (G) of the shift lock stop. 6. Connect the shift lock solenoid connector, and install it on the shift lever bracket base. 7. Install the center console and console panel. Specifications Valve Clearance: Specifications Valve Clearance Intake ................................................................................................................................................... ...................... 0.18 - 0.22 mm (0.007 - 0.009 inch) Exhaust ............................................................... ....................................................................................................... 0.23 - 0.27 mm (0.009 - 0.011 inch) Page 7623 9. Open the jaws with the jaws knob, and slide the original key with its flat side down into the center jaw up to the key stop. Slide the key blank with its flat side down into the right jaw up to the key stop. Close the jaws with the jaws knob to lock the keys into place. Visually inspect both keys for proper alignment in the jaws. 10. Loosen the lateral and spring tension adjustment knobs on the clamp carriage. With the clamp carriage lever, adjust the clamp carriage to position the tracer and the cutter bit over the middle of the two locked key blades. Tighten only the spring tension knob when done. NOTE: The clamp carriage has a spring system that puts lateral pressure on the tracer and cutting bit to make it easier to cut sidewinder-type keys. Do not tighten the lateral tension adjustment knob. This knob should be left loose. 11. Turn on the cutter motor with the motor start switch. [NOTICE] ^ To avoid damaging the locking jaws while cutting, keep your hand off the vertical carriage lever. Pressure on the lever will change the cutting depth. * ^ To avoid breaking the cutter bit, never back up while cutting.* ^ Wear proper eye protection (safety glasses, goggles, etc.) Page 4480 ^ If the noise is still present, look for other causes. 7. Test-drive the vehicle to check for proper clutch operation. Disclaimer Page 8075 80. Under Middle of Dash Page 1262 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. Body - Door Lock Cylinders Bind Trunk / Liftgate Lock Cylinder: All Technical Service Bulletins Body - Door Lock Cylinders Bind 03-068 October 29, 2004 Applies To: See VEHICLES AFFECTED Door Lock Cylinder Binds (Supersedes 03-068, dated April 20, 2004) Updated information is shown with asterisks and black bars. SYMPTOM The key will not go into the door lock cylinder, or if it goes in, it will not turn. PROBABLE CAUSE The door lock tumblers are damaged or worn. VEHICLES AFFECTED CORRECTIVE ACTION Remove the door lock cylinder, and replace the inner cylinder, springs, and tumblers. Page 7320 ^ 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 7008 Seat Belt: Testing and Inspection SRS components are located in this area. Review the SRS component locations, precautions, and procedures before preforming repairs or service WARNING: To avoid accidental deployment and possible injury, always disconnect the seat belt tensioner connector before removing the retractor. In-vehicle Seat Belt Inspection 1. Check that the seat belt is not twisted or caught on anything. 2. After installing the anchors, check for free movement on the anchor bolts. If necessary, remove the anchor bolts, and check that the washers and other parts are not damaged or improperly installed. 3. Check the seat belts for damage or discoloration. Clean with a shop towel if necessary. CAUTION: Use only soap and water to clean. NOTE: Dirt build-up in the metal loops of the upper anchors can cause the seat belts to retract slowly. Wipe the inside of the loops with a clean cloth dampened in isopropyl alcohol. 4. Check that the seat belt does not lock when pulled out slowly. The seat belt is designed to lock only during a sudden stop or impact. 5. Make sure that the seat belt will retract automatically when released. 6. For each passenger's seat belt, make sure that the locking mechanism in the seat belt retractor will engage when the seat belt is pulled all the way out. 7. Replace the seat belt with a new assembly if there is any abnormality. Do not disassemble any part of the seat belt for any reason. Page 1092 195. Tranmission Range Switch Page 955 Page 8187 2. Disconnect the 2P connector from the actuator. 3. Check actuator operation by connecting power and ground according to the table. To prevent damage to the actuator, apply battery voltage only momentarily. 4. If the actuator does not operate as specified, replace it. Page 363 PARTS INFORMATION TOOL INFORMATION Page 3212 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. How to Replace Connector Terminals Terminal Replacement Procedure HOW TO REPLACE CONNECTOR TERMINALS The terminal repair kits provide necessary tools and materials (terminals, wire seals, and splice connectors) to repair many damaged or faulty connector terminals. However, not all terminals for all connectors are available. Refer to the labels on the lids of the repair kits for replacement terminal availability. IMPORTANT SAFETY INFORMATION: On some models, the SRS wires are in a separate harness. If the SRS harness is damaged, replace the harness; do not repair it. On other models, wire harnesses include yellow SRS wires. If any SRS wire is damaged, replace the entire harness; do not repair it. Before you begin, inspect the wire you are about to repair for damage and length. Make sure the wire will be long enough to make a terminal repair without stretching it when you reinstall the terminal in the connector. If the wire is too short, or if access to the connector is too restricted to make a terminal repair, you may need to install a pigtail terminal (a short length of wire with a factory-crimped terminal on it). Refer to HOW TO INSTALL PIGTAIL TERMINALS. Removing the Terminal Shift Solenoid Valves A and B Test Shift Solenoid: Testing and Inspection Shift Solenoid Valves A and B Test Shift Solenoid Valves A and B Test 1. Disconnect the shift solenoid valves A and B connector. 2. Measure shift solenoid valve A resistance between the No. 1 terminal of the shift solenoid valves A and B connector and body ground, and measure shift solenoid valve B resistance between the No. 2 terminal and body ground. STANDARD: 12 - 25 Ohms 3. Replace the shift solenoid valves A and B if either resistance is out of standard. 4. If the resistance is within the standard, connect the No. 1 terminal of the shift solenoid valve A to the battery positive terminal. A clicking sound should be heard. Connect the No. 2 terminal to the battery positive terminal. A clicking sound should be heard. Replace the shift solenoid valves A and B if no clicking sound is heard when either terminal is connected to the battery terminal. Locations 94. Behind Glove Box (except GX) Page 5254 1. Remove the secondary locks. 2. Remove the terminal from the female half. 3. Remove the terminal from the male half. 4. Go to HOW TO INSTALL NEW TERMINALS. Connectors Without a Secondary Lock All examples are shown with the connector lock facing up. The illustrations are examples of connector terminals without a secondary lock; however, the connector you are repairing may vary in size and shape. EXAMPLE A: Service and Repair Rear Door Window Regulator: Service and Repair Rear Door Glass, Quarter Glass, and Regulator Replacement 4-door NOTE: Put on gloves to protect your hands. 1. Raise the glass fully. 2. Remove these items: - Door panel - Plastic cover, as necessary - Rod protector 3. Carefully move the glass (A) until you can see the bolts, then remove them. Remove the glass from the regulator (B), and carefully lower the glass. Take care not to drop the glass inside the door. 4. Remove the bolts (A, B) and collar (C) from the center channel (D). Pull the upper seal (E) away as needed, and remove the screw (F). Pull the Procedures Cabin Ventilation Duct: Procedures Rear Air Outlet Replacement 1. Remove the rear bumper. 2. Detach the hooks (A), then remove the rear air outlet (B). Take care not to scratch the body. 3. Install the air outlet by pushing on the hook portions until the hooks snap into place. Page 9085 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. Test Equipment 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. Page 7517 6. Release the lock knob (A) from the knob bracket (B), and detach the inner handle rod (C) from the rod holder (D). Detach the harness clip (E), and disconnect the actuator connectors (F). 7. Remove the screws, then remove the latch (A) through the hole in the door. Take care not to bend the outer handle rod (B), cylinder rod (C), inner handle rod (D), and lock knob cable (E). 8. If necessary, disconnect the lock knob cable (A) from the latch (B). 9. Install the latch in the reverse order of removal, and note these items: - Make sure the actuator connectors are plugged in properly, and each rod and cable is connected securely. - Make sure the door locks and opens properly. - When reinstalling the door panel, make sure the plastic cover is installed properly and sealed around its outside perimeter to seal out water Page 3315 Canister Purge Control Valve: Description and Operation EVAP Canister Purge Valve When the engine coolant temperature is below 158 °F (70 °C), the ECM/PCM turns off the EVAP canister purge valve which cuts vacuum to the EVAP canister. Page 764 Oxygen Sensor: Connector Locations 10. Middle Of Engine 11. Middle Of Engine (except EX) Page 8511 122. Driver's Door (Sedan Except DX) Page 4112 1. Remove the secondary locks. 2. Remove the terminal from the female half. 3. Remove the terminal from the male half. 4. Go to HOW TO INSTALL NEW TERMINALS. Connectors Without a Secondary Lock All examples are shown with the connector lock facing up. The illustrations are examples of connector terminals without a secondary lock; however, the connector you are repairing may vary in size and shape. EXAMPLE A: Page 3592 Crankshaft Position Sensor: Description and Operation Crankshaft Position (CKP) Sensor The CKP sensor detects engine speed, and is used by the ECM/PCM to determine ignition timing and timing for fuel injection of each cylinder. Page 7636 10. Pull down on the retainer clip with a hook-shaped tool. Remove the lock cylinder. Then go to step 14. 11. Pull the glass run channel away as necessary, and remove the bolt, then remove the center lower channel by pulling it downward. 12. Remove the access seal, and disconnect the outer handle rod and the cylinder rod. Page 250 Under-hood Fuse/Relay Box Service and Repair Strut / Shock Tower: Service and Repair Removal Page 2936 symptom/indication goes away with a known-good ECM/PCM, replace the original ECM/PCM. Page 8865 Air Bag(s) Arming and Disarming: Service and Repair Connector Disconnection / Connection Disconnecting System Connectors Before removing a front airbag, side airbag, or other SRS related devices (the SRS unit, the cable reel, front sensor, the side impact sensors, the seat belt buckle tensioners, and the seat belt tensioner connector), disconnecting connectors from related devices, or removing the dashboard or the steering column, disconnect the airbag connectors or the side airbag connectors to prevent accidental deployment. Turn the ignition switch OFF, disconnect the negative cable from the battery, and wait at least 3 minutes before beginning the following procedures. - Before disconnecting SRS unit connector A (A) from the SRS unit, disconnect the driver's airbag 4P connector (C), the front passenger's airbag 4P connector (D), the driver's seat belt tensioner 2P connector (F), and the front passenger's seat belt tensioner 2P connector (G). - Before disconnecting SRS unit connector B (1) from the SRS unit, disconnect both side airbag 2P connectors (L, M) and both seat belt buckle tensioner 4P connectors (J, K). - Before disconnecting the cable reel 4P connector (B), disconnect the driver's airbag 4P connector (C). - Before disconnecting the floor wire harness 4P connector (E), disconnect both seat belt tensioner 2P connectors (F, G). 1. Disconnect the battery negative cable, and wait at least 3 minutes. Driver's Airbag Page 8692 5. Remove the actuator cable from the cruise control actuator. 6. Install the reverse order of removal, and adjust the free play at the throttle linkage after connecting the actuator cable. 2-door D17A1, D17A2 engines: 1. Loosen the locknut (A), then disconnect the actuator cable (B) from the throttle linkage. 2. Disconnect the actuator cable from the cruise control actuator. Page 3927 the HIM from the vehicle. 7. Connect the PC interface cable to the iN workstation and to the HIM. Connect the power supply unit and power supply cord to the HIM. After several seconds, the green and yellow LEDs flash. Each updatable vehicle system is checked to make sure it is current. Any systems needing an update are listed on the screen. Highlight the system you want to update, then click on the check mark to continue. NOTE: Update the systems one at a time. 8. Verify that the Program ID and the Program Part No. are correct, then click on the check mark. 9. Confirm the control module update by Program ID and Program Part No. Make sure this corresponds with any information provided in the service bulletin for the update you are doing. Click on Yes to continue. Within a few seconds, the CM Update software loads the program file onto the HIM. 10. Disconnect the HIM from the PC interface cable. 11. Reconnect the HIM to the vehicle's DLC. 12. Turn the ignition switch to ON (II), and wait until the green No.1 LED on the HIM stays on. Press and release the ENTER button on the HIM. Page 4628 8. Insert a 6.0 mm (0.24 inch) pin (A) through the positioning hole (B) on the shift lever bracket base and into the positioning hole (C) on the shift lever assembly. The shift lever is secured in the N position. 9. Align the socket holder (A) on the shift cable (B) with the slot in the cable bracket base (C), then slide the holder into the base. Install the shift cable end (D) over the mounting stud (E) by aligning its square hole (F) with the square fitting (G) at the bottom of the stud. Rotate the holder clockwise a quarter turn to secure the shift cable. NOTE: Do not install the shift cable by twisting the shift cable guide (H). 10. Verify that the shift cable end (A) is properly installed on the mounting stud (B). 11. If improperly installed, remove the shift cable from the shift cable bracket base, and reinstall the shift cable. Do not install the shift cable end on Page 7846 1. Check the depth adjustment of the trunk lid: ^ Refer to page 20-132 of the 2001-04 Civic Service Manual. ^ In ISIS, use the keyword TRUNK ADJUST, and select Trunk Lid Adjustment from the list. 2. Make sure the trunk lid is flush on all sides and corners. ^ If the trunk is misaligned, go to step 3. ^ If the trunk lid is properly aligned on all sides and corners, go to REPAIR PROCEDURE C. 3. Adjust the striker depth position and the trunk lid edge cushions: ^ Refer to page 20-132 of the 2001-04 Civic Service Manual. ^ In ISIS, use the keyword TRUNK ADJUST, and select Trunk Lid Adjustment from the list. 4. Check the trunk operation: ^ If the trunk opens and closes smoothly, return the vehicle to the customer. ^ If the trunk lid is still difficult to close, go to REPAIR PROCEDURE C. REPAIR PROCEDURE C 1. Use a small screwdriver to manually set and release the trunk lid latch. Check the operation of the latch: ^ If the latch is difficult to set or release, go to step 2. ^ If the latch operates properly, go to REPAIR PROCEDURE D. 2. Replace the trunk lid latch: ^ Refer to page 20-157 of the 2001-04 Civic Service Manual. ^ In ISIS, use the keyword LID LATCH, and select Trunk Lid Latch Replacement from the list. 3. Check the trunk operation: ^ If the trunk opens and closes smoothly, return the vehicle to the customer. ^ If the trunk lid is still difficult to close, go to REPAIR PROCEDURE D. REPAIR PROCEDURE D 1. Disconnect the trunk lid opener cable from the trunk lid latch. Check the cable operation: ^ Refer to page 20-157 of the 2001-04 Civic Service Manual. ^ In ISIS, use the keyword LID LATCH, and select Trunk Lid Latch Replacement from the list. 2. Check that there is no friction or binding of the cable by holding the outside casing and pulling back and forth on the inner cable: ^ If the cable is difficult to move or binds, go to step 3. ^ If the cable operates smoothly, go to REPAIR PROCEDURE E. 3. Replace the trunk lid opener cable: ^ Refer to page 20-151 of the 2001-04 Civic Service Manual. ^ In ISIS, use the keyword LID OPEN, and select Trunk Lid Opener/Fuel Fill Door Opener Cable Replacement from the list. 4. Check the trunk operation: Body - Door Lock Cylinders Bind Door Lock Cylinder: Customer Interest Body - Door Lock Cylinders Bind 03-068 October 29, 2004 Applies To: See VEHICLES AFFECTED Door Lock Cylinder Binds (Supersedes 03-068, dated April 20, 2004) Updated information is shown with asterisks and black bars. SYMPTOM The key will not go into the door lock cylinder, or if it goes in, it will not turn. PROBABLE CAUSE The door lock tumblers are damaged or worn. VEHICLES AFFECTED CORRECTIVE ACTION Remove the door lock cylinder, and replace the inner cylinder, springs, and tumblers. Diagram Information and Instructions Auxiliary Power Outlet: Diagram Information and Instructions Terminal Numbering System Terminal Numbering System Connector terminals are numbered according to the cavities they're in. The cavities are numbered starting from the upper left, looking at the male terminals from the terminal side or looking at the female terminals from the wire side. Both views are in the same direction so the numbers are the same. All actual cavities are numbered, even if they have no wire terminals in them. NOTE: Data Link Connector (DLC) terminals are numbered according 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 below is #6. Page 829 13. Plug in the heat gun, and turn it on. Start at the middle of the splice connector, and move the gun toward the ends as the tube shrinks. Apply heat evenly by rotating the curved heat spreader around the splice connector. Shrinking is complete when a small amount of sealant appears at each end of the tube. Pigtail Terminal Selection Chart PIGTAIL TERMINAL SELECTION CHART Select the proper size pigtail terminal by matching the replacement terminal part number and the wire size being repaired to the corresponding pigtail terminal part number. Then use the color (size) splice connector listed. In some instances you may also have to match the wire seal style to select the proper pigtail terminal. Pigtail terminals are available through your parts department, in quantities of 10, using normal parts ordering procedures. Checking For Poor Fir of Terminals CHECKING FOR POOR FIT OF TERMINALS Loose terminal fit can cause a number of intermittent problems in electrical circuits. By using the Terminal Inspection Feeler Tool Set you can inspect the terminal fit between the two matching connectors without removing the terminals from the connector body. 1. Find the terminal tool that best matches the male terminal in the mating connector. Shift Solenoid Valves A and B Test Shift Solenoid: Testing and Inspection Shift Solenoid Valves A and B Test Shift Solenoid Valves A and B Test 1. Disconnect the shift solenoid valves A and B connector. 2. Measure shift solenoid valve A resistance between the No. 1 terminal of the shift solenoid valves A and B connector and body ground, and measure shift solenoid valve B resistance between the No. 2 terminal and body ground. STANDARD: 12 - 25 Ohms 3. Replace the shift solenoid valves A and B if either resistance is out of standard. 4. If the resistance is within the standard, connect the No. 1 terminal of the shift solenoid valve A to the battery positive terminal. A clicking sound should be heard. Connect the No. 2 terminal to the battery positive terminal. A clicking sound should be heard. Replace the shift solenoid valves A and B if no clicking sound is heard when either terminal is connected to the battery terminal. Page 1571 Relay Box: Connector Locations Under-dash Fuse/Relay Box Removal and Installation Engine Control Module: Service and Repair Removal and Installation How to Remove the ECM/PCM for Testing 1. Remove the passenger's dashboard lower cover, the right kick panel, and the glove box. 2. Remove the bolt. Cut the plastic cross brace in the glove box opening with diagonal cutters in the area shown, and discard it. 3. Remove the relays (A), then remove the bolts and the glove box frame (B). 4. Remove the gray 20P ECM/PCM wire harness connector from the ECM/PCM mounting bracket. Remove the ECM/PCM mounting bolt (A) and the bracket. 5. Remove the nuts, then remove the ECM/PCM (B). 6. Install the ECM/PCM in the reverse order of removal. Diagrams Page 649 Door Switch: Locations Entry Light Control System Component Location Index Page 2132 Water Pump: Service and Repair Replacement 1. Remove the timing belt. 2. Remove the water pump (A) by removing four bolts. 3. Inspect and clean the O-ring groove and mating surface with the cylinder block. 4. Install the water pump with a new O-ring (B) in the reverse order of removal. 5. Clean up any spilled engine coolant. Page 6015 Air Conditioning Component Location Index Page 6888 Side Air Bag: 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/Service and Repair Page 1491 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. SRS Unit, Front Sensors and Side Impact Sensors SRS Unit, Front Sensors and Side Impact Sensors Be careful not to bump or impact the SRS unit, front sensors, or the side impact sensors whenever the ignition switch is ON (II), or for at least 3 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, front sensors, and the side impact sensor. The airbags could accidentally deploy and cause damage or injury. After a collision in which any airbags or seat belt tensioners were deployed, replace the SRS unit, front sensors, and other related components. After a collision in which a side airbag was deployed, replace the side impact sensor on the deployed side 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, front sensors, 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 3 minutes before beginning installation or replacement of the SRS unit, or disconnecting 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 N.m (1.0 kgf.m, 7.2 lbf.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 °G) and dry (less than 80% relative humidity, no moisture) area. Wiring Precautions Wiring Precautions SRS wiring can be identified by special yellow outer covering (except the SRS indicator light circuit). Page 2045 Variable Valve Timing Actuator: Diagnostic Aids General Troubleshooting Information General Troubleshooting Information Tips and Precautions Before Troubleshooting 1. Check applicable fuses in the appropriate fuse/relay box. 2. Check the battery for damage, state of charge, and clean and tight connections. NOTE: 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. Handling Connectors - Make sure the connectors are clean and have no loose wire terminals. - Make sure multiple cavity connectors are packed with dielectric grease (except watertight connectors). - All connectors have push-down release type locks (A). - Some connectors have a clip on their side used to attach them to a mount bracket on the body or on another component. This clip has a pull type lock. - Some mounted connectors cannot be disconnected unless you first release the lock and remove the connector from its mount bracket (A). - Never try to disconnect connectors by pulling on their wires; pull on the connector halves instead. - Always reinstall plastic covers. Page 8109 ^ Within 1 to 4 seconds, turn the ignition switch to LOCK (0). ^ Within 1 to 4 seconds, turn the ignition to ON (II). ^ Within 1 to 4 seconds, push the transmitter lock or unlock button. ^ Confirm you can hear the sound of the door lock actuators. Within 1 to 4 seconds, push the transmitter lock or unlock button again. ^ Within 10 seconds, aim the transmitters (up to two additional ones) whose codes you want to store at the receiver, and press the transmitter lock or unlock button. Confirm that you can hear the sound of the door lock actuators after each transmitter code is stored. ^ Turn the ignition switch to LOCK (0), and pull out the key. 4. Confirm proper operation of the transmitters. Disclaimer Page 2016 5. Install the crankshaft position (CKP) sensor. 6. Install the ail bolts loosely, then tighten the mounting bolts as the numbered sequence shown. 7. Install the lower cover. 8. Clean the pulley bolt and washer. Page 3907 ^ Updating with the HIM - HIM Updating in Pass-Thru Mode - HIM Updating in Storage Mode - Diagnosing HIM Error Codes - HIM Self-Test NOTE: Whenever you install a new, reprogrammable control unit/module, check that it has the latest software, and update it if needed. WARRANTY CLAIM INFORMATION Skill Level: Repair Technician Refer to the specific service bulletin for the symptom you are repairing. QUESTIONS ABOUT THE UPDATING EQUIPMENT OR THE INTERACTIVE NETWORK For questions about the Honda-supplied updating equipment, call American Honda's Special Tools hotline. For questions about the iN, call the iN Support Center. REQUIRED TOOLS AND EQUIPMENT NOTE: Updating for most control units/modules can be done with any of the following tools. Page 6851 VEHICLES AFFECTED CUSTOMER NOTIFICATION All owners of affected vehicles were mailed a notification of this warranty extension. A example of the customer notification is shown in this service bulletin. CORRECTIVE ACTION Repair the vehicle as indicated by the INSPECTION PROCEDURE. If needed, replace the OPDS unit. In rare cases where an updated OPDS unit was already installed, replace the OPDS sensor. Page 7650 Disclaimer Cutting Procedure - By Copying 1. Press the ON/OFF button in the middle of the setting unit keypad. (This powers up the keypad.) 2. Turn the clamp unit lock lever to the left to release the clamp unit, and slide it all the way to the left until it stops. Turn the lever to the right to lock the clamp unit in place. 3. Use the clamp carriage lever to position the clamp unit so the tracer and cutter bit are centered directly over the base of the center and right jaws. 4. Pull the vertical carriage lever toward you until the tracer and the cutter bit just touch the base of each fixed jaw. Watch the arrows on the keypad: ^ If the double-headed arrow in the middle of the keypad lights green, the tracer and cutter bit are properly aligned. ^ If the arrow on the left of the keypad lights red, the cutter bit is not touching the fixed jaw. Turn the micrometric ring nut above the tracer to the left until the double-headed arrow lights green. ^ If the arrow on the right of the keypad lights red, the tracer is not touching the fixed jaw. Turn the micrometric ring nut above the tracer to the right until the double-headed arrow lights green. *5. Turn the micrometric ring nut to the right three clicks so the cutter bit is slightly higher than the tracer. The arrow on the left should light red. Raise the vertical carriage. NOTE: Setting the tracer three clicks lower than the cutter bit has the effect of making the cutter bit cut the duplicated key a little shallower. This will protect the locking jaws from being damaged.* 6. Optional: Loosen the setscrew, and adjust the hand rest to a comfortable position. Tighten the screw. 7. Pull the clamp carriage lever toward you until the clamp carriage clicks into its end-of-run position. Tighten both the lateral and spring tension adjustment knobs. 8. Make sure the center and right jaws are free of any metal shavings or debris. (A soft-bristle toothbrush is ideal for this purpose.) Component Locations Shift Interlock Switch: Component Locations Component Location Index Page 9619 Turn Signal/Hazard Flasher - Component Location Index Page 5846 69. Under Left Side Of Dash 70. Under Left Side Of Dash Page 2061 1. Remove the terminal. 2. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE G: 1. Remove the terminal. 2. Go to HOW TO INSTALL NEW TERMINALS. How to Install New Terminals HOW TO INSTALL NEW TERMINALS 1. Carefully match the old terminal with a new one from the terminal repair kit. Choose the correct replacement terminal based on the wire size range the terminal will accommodate. NOTE: If the replacement terminal quantities are low, reorder them by using the terminal part number listed on the inside lid of the terminal repair kit. Replacement terminals are available through your parts department using normal parts ordering procedures. 2. Depending on the size of the wire you are repairing, use the proper size slot in the crimping tool. Page 3764 Skill Level: Repair Technician INSPECTION PROCEDURE 1. Remove the steering column covers. Refer to section 17 of the appropriate service manual. 2. On the lower side of the ignition switch, look at the interlock cylinder cover: ^ If the cover is square, the ignition switch was already replaced with an updated part, and a key interlock repair kit is not needed. Go to step 3. ^ If the cover is round, go to REPAIR PROCEDURE. 3. Reinstall the steering column covers. 4. Center-punch a completion mark above the seventh character of the engine compartment VIN. REPAIR PROCEDURE Page 9206 8. Inspect the quality of the wire crimp. If it has any of the following NO GOOD crimps, cut it off and start over. 9. Insert the terminal into the connector. Make sure the wire seals are pushed all the way into the connector. Lightly pull on the wires to make sure the terminal is locked into place. 10. Close or insert the secondary terminal lock, if applicable, and reconnect the connector. How to Install Pigtail Terminals HOW TO INSTALL PIGTAIL TERMINALS Pigtail terminals (short pieces of wire with a factory crimped terminal) are used when the wire is too short or when access to the connector is too restricted to make a terminal repair. NOTE: To replace just a connector terminal, go to How to Replace Connector Terminals. IMPORTANT SAFETY INFORMATION: On some models, the SRS wires are in a separate harness. If the SRS harness is damaged, replace the harness; do not repair it. On other models, wire harnesses include yellow SRS wires. If any SRS wire is damaged, replace the entire harness; do not repair it. 1. Remove the damaged or faulty terminal from the connector. Use the proper removal tool from Pin Tool Set. Description and Operation Fuel Cut Control Unit: Description and Operation Fuel Cut-off Control During deceleration with the throttle valve closed, current to the injectors is cut off to improve fuel economy at speeds over 850 rpm. Fuel cut-off action also occurs when engine speed exceeds 6,900 rpm, regardless of the position of the throttle valve, to protect the engine from over-revving. With A/T model, when the vehicle is stopped, the PCM cuts the fuel at engine speeds over 5,000 rpm. Locations Parking Brake Warning Switch: Locations Gauges Component Location Index (Part 1 Of 4) Page 5819 7. Crimp the insulation crimp. - If you do not have a wire seal, then use the next larger size crimp slot. Position the crimping tool over the insulation crimp section of the terminal, then squeeze the tool with both hands until the stops make contact. - If you have a wire seal, position the insulation crimp in the 5.5 crimping slot, then carefully squeeze the crimp closed until its ends are touching and making a full-circle shape. 8. Inspect the quality of the wire crimp. If it has any of the following NO GOOD crimps, cut it off and start over. 9. Insert the terminal into the connector. Make sure the wire seals are pushed all the way into the connector. Lightly pull on the wires to make sure the terminal is locked into place. 10. Close or insert the secondary terminal lock, if applicable, and reconnect the connector. Page 6017 Rear Window Defogger Component Location Index Page 9166 5. Make these input tests at the connector. - If any test indicates a problem, find and correct the cause, then recheck the system. - If all the input tests prove OK, the control unit must be faulty; replace it. Removal and Installation Seat Occupant Sensor: Service and Repair Removal and Installation OPDS Unit Replacement NOTE: Review the seat replacement procedure in the body section before performing repair or service. Removal 1. Disconnect the battery negative cable, and wait at least 3 minutes before beginning work. 2. Disconnect the side airbag harness 2P connector. 3. Remove the seat assembly and seat-back cover. 4. Remove the cover (A), then disconnect the OPDS unit harness 8P and sensor connectors (B) from the OPDS unit. 5. Remove the two screws (C) and OPDS unit (D). Installation 1. Place the new OPDS unit on the seat-back frame. Tighten the two screws, and connect the OPDS unit harness 8P and sensor connector to the OPDS unit. Reinstall the cover. 2. Install the seat-back cover. 3. Install the seat assembly, then connect the side airbag harness 2P connector. 4. Reconnect the battery negative cable. 5. Set the seat-back in the normal position, and make sure there is nothing on the front passenger's seat. 6. Initialize the OPDS unit. 7. After installing the OPDS unit, confirm proper system operation. Turn the ignition switch ON (II); the SRS indicator light should come on for about 6 seconds and then go off. Page 1918 Drive Belt: Testing and Inspection Alternator Belt Alternator Belt Inspection and Adjustment Special Tools Required Belt tension gauge 07JGG-001010A Belt Tension Gauge Method Inspection 1. Attach the belt tension gauge to the belt and measure the tension. Follow the gauge manufacturer's instructions. If the belt is worn or damaged, replace it. If the belt needs adjustment, go to step 2. Adjustment 2. Loosen the mounting bolt (A), lock bolt (B) and lower bracket mounting bolt (C). 3. Torque the mounting bolt to 20 N.m (2.0 kgf.m, 14 lbf.ft). 4. Turn the adjusting bolt (D) to obtain the proper belt tension, then retighten the lock bolt, mounting bolt and lower bracket mounting bolt. 5. Recheck the belt tension. 6. If you installed a new belt, run the engine for 5 minutes, then readjust the belt to the used belt specification. 7. Check the power steering pump belt adjustment. Deflection Method Inspection Page 2967 ECM/PCM Inputs And Outputs At Connector C (22P) Page 6005 the same location; the resulting "lump" of splice connectors would interfere with rewrapping the harness. Instead, cut the first pigtail close enough to the terminal so you will have room to make each remaining cut about 20 mm (3/4 inch) farther down on the next pigtail. 7. If you are using a yellow splice connector, strip about 6 mm (1/4 inch) of insulation off the ends of both wires. If you are using a pink or blue splice connector, strip off about 8 mm (5/16 inch) of insulation. 8. Put the splice connector in the proper size slot in the Crimper Tool, slide it to one end (where the flare begins), and close the crimper handles far enough to hold it in place. To release the ratchet mechanism at any point after the first click, squeeze the handles slightly and push the release lever, then let the handles open. 9. Insert one of the bare wires into the splice connector end that is in the crimper jaws. Push the wire all the way into the splice connector, and squeeze the crimper handles. Keep squeezing until the jaws touch, and hold it at that position until the ratchet clicks again. 10. Crimp the other wire in the same way into the other end of the splice connector. 11. After crimping, gently pull on the wires in the opposite directions to make sure they are secure in the connector. 12. Separate the other wires in the harness from the repaired wire(s), and shield them with nonflammable material. Page 8623 *T-5 Sidewinder Key Applications ^ 2003-05 Civic ^ 2004-05 Civic Hybrid ^ 2003-05 Civic GX (CNG) ^ 2004-05 S2000 ^ 2002-06 CR-V ^ 2003-06 Element ^ 2003-04 Odyssey ^ 2003-04 Pilot Ordering Honda key blanks through normal parts ordering channels: Refer to the parts catalog for correct key(s) for your application. PROGRAMMING KEYS Depending on the type of key blank you use, do this: ^ If you have used a T-5 programmable key blank ("T-5" stamped on the shank), you must code the key's transponder with the Ilco Immobilizer Key Code Duplicator (see S/B 99-053, Ilco Immobilizer key Code Duplicator). ^ If you have used a Honda key blank, add the* transponder code of the new key to the immobilizer system with the Honda Diagnostic System (HDS). ORDERING INFORMATION *To order the MATRIX H Key Cutting Machine, replacement cutter bits, fixed jaws and mobile jaws, T-5 programmable key blanks, and practice key blanks, contact the Honda Tool and Equipment Program by calling 888-424-6857 or using the fax order form provided in your Honda Tool and Equipment Program Catalog.* Order Honda key blanks through normal parts ordering channels. WARRANTY CLAIM INFORMATION None. This service bulletin is for information only. *DETERMINING WHICH KEY TO USE T-5 keys require less time to program and should be the first choice. They can be used as long as the following requirements are met: ^ Do you have the customer's operating key? ^ Does the vehicle fall within the T-5 Sidewinder Key Applications? ^ Does your dealership have an Ilco Immobilizer Key Code Duplicator? If the answer to all three questions on the above is yes, the 1-5 key option is the easier procedure. If you answered no to any of the questions, you should order the key(s) from the parts catalogue, and program it using the HDS.* BEFORE YOU START CUTTING 1. Get the original key or the key number from your customer or from the iN. 2. Get the applicable key blank. 3. If cutting by code, look up the applicable 9-digit cutting code for the key number. Refer to the code book Honda High Security key Codes that comes with the machine. Locations 13. Middle Of Engine (EX, HX) Locations Oxygen Sensor Relay: Locations PGM-FI System - Component Location Index Page 2740 PGM-FI System - Component Location Index Page 4229 3. Strip the insulation off the end of the wire so the wire fits in the new terminal as shown. (If the wire has a wire seal, replace it with a new one from the kit.) NOTE: After stripping the end of the wire, make sure you did not cut any wire strands. If you did, cut the wire off even with the insulation, and strip it again. 4. Position the terminal in the crimping tool slot with the solid portion of the terminal toward the anvil and the open section toward the former. 5. Insert the wire in the terminal to the position shown in step 3. 6. Squeeze the tool with both hands until the stops make contact. 7. Crimp the insulation crimp. - If you do not have a wire seal, then use the next larger size crimp slot. Position the crimping tool over the insulation crimp section of the terminal, then squeeze the tool with both hands until the stops make contact. - If you have a wire seal, position the insulation crimp in the 5.5 crimping slot, then carefully squeeze the crimp closed until its ends are touching and making a full-circle shape. Page 3524 Throttle Body Disassembly/Reassembly Page 2545 195. Tranmission Range Switch Page 8204 Power Door Lock Switch: Testing and Inspection Door Lock Switch Test Door Lock Switch Test 1. Remove the driver's door panel. 2. Remove the two mounting screws and the door lock switch. 3. Check for continuity between the terminals. - There should be continuity between the No.1 and No.2 terminals when the door lock switch is in the LOCKED position. - There should be continuity between the No.2 and No.3 terminals when the door lock switch is in the UNLOCKED position. 4. If the continuity is not as specified, replace the switch. Page 6129 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 9214 Diagram 114-4 (Sedan EX) Diagrams: Other diagrams referred to by number (See Diagram ##-#, etc.)within these diagrams can be found at Diagrams by Number. See: Diagrams/Electrical Diagrams/Diagrams By Number Locations: Location photographs (references to PHOTOS) referred to within these diagrams can be found at Locations by Photo Number. See: Locations/Component Locations/Locations By Photo Number Connector Views: Connector terminal views (references to VIEWS) referred to within these diagrams can be found at Connector Views by View Number. See: Diagrams/Connector Views/Connector Views By View Number Page 6868 PARTS INFORMATION TOOL INFORMATION Page 4696 10. Connect the connector securely, then install the transmission range switch shaft cap (A). 11. Turn the ignition switch ON (II). Move the shift lever through all gear positions, and check the transmission range switch is synchronization with the A/T gear position indicator. 12. Raise the vehicle, and make sure it is securely supported. 13. Allow the wheels to rotate freely, then start the engine. 14. Move the shift lever through all gear positions, and verify the following: ^ The engine will not start in any position other than N or P. ^ The back-up lights come on when the shift lever is in the R position. Page 5111 Wire Color Abbreviations Page 5582 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 4495 4. Inspect the pressure plate (A) surface for wear, cracks, and burning. 5. Inspect the fingers of the diaphragm spring (B) for wear at the release bearing contact area. 6. Inspect for warpage using a straight edge (A) and feeler gauge (B). Measure across the pressure plate (C). If the warpage is more than the service limit, replace the pressure plate. Standard (New): 0.03 mm (0.001 inch) max. Service Limit: 0.15 mm (0.006 inch) 7. Remove the clutch disc and special tools. 8. Inspect the lining of the clutch disc for signs of slipping or oil. If the clutch disc is burned black or oil soaked, replace it. Locations Cruise Control Component Location Index Page 1567 1. Right Side Of Engine Compartment Page 8534 138. Rear of Roof (EX) How to Remove the PCM Control Module: Service and Repair How to Remove the PCM How to Remove the PCM for Testing 1. Remove the passenger's dashboard lower cover, the right kick panel, and the glove box. 2. Remove the bolt. Cut the plastic cross brace in the glove box opening with diagonal cutters in the area shown, and discard it. 3. Remove the relays (A), then remove the bolts and the glove box frame (B). 4. Remove the gray 20P PCM wire harness connector from the PCM mounting bracket. Remove the PCM mounting bolt (A) and the bracket. 5. Remove the nuts, then remove the PCM (B). 6. Install the PCM in the reverse order of removal. Page 9103 13. Plug in the heat gun, and turn it on. Start at the middle of the splice connector, and move the gun toward the ends as the tube shrinks. Apply heat evenly by rotating the curved heat spreader around the splice connector. Shrinking is complete when a small amount of sealant appears at each end of the tube. Pigtail Terminal Selection Chart PIGTAIL TERMINAL SELECTION CHART Select the proper size pigtail terminal by matching the replacement terminal part number and the wire size being repaired to the corresponding pigtail terminal part number. Then use the color (size) splice connector listed. In some instances you may also have to match the wire seal style to select the proper pigtail terminal. Pigtail terminals are available through your parts department, in quantities of 10, using normal parts ordering procedures. Checking For Poor Fir of Terminals CHECKING FOR POOR FIT OF TERMINALS Loose terminal fit can cause a number of intermittent problems in electrical circuits. By using the Terminal Inspection Feeler Tool Set you can inspect the terminal fit between the two matching connectors without removing the terminals from the connector body. 1. Find the terminal tool that best matches the male terminal in the mating connector. Page 8856 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 1811 Service Limit: 0.005 mm (0.0002 inch) Page 6941 1. On Accords and Pilots, remove the front passenger's seat-back panel by prying out the bottom. Replace the two lower clips. 2. On all models except Accords and Pilots, unzip the two seat cover zippers on the back of the front passenger's seat. 3. Pull back the seat-back cover from the left side bolster to access the OPDS unit cover. 4. Remove the OPDS unit cover from the seat frame. 5. Check the part number of the installed OPDS unit. Page 688 124. CMP (TDC) Sensor Page 230 67. Under Left Side Of Dash Locations 40. Left Side Of Engine Compartment (EX, GX) Page 3796 107. Behind A/T Shift Lever (except M/T) Page 723 5. Remove the lower cover from the fuse/relay box. 6. Disconnect the 3P ELD connector. Page 2838 3. Strip the insulation off the end of the wire so the wire fits in the new terminal as shown. (If the wire has a wire seal, replace it with a new one from the kit.) NOTE: After stripping the end of the wire, make sure you did not cut any wire strands. If you did, cut the wire off even with the insulation, and strip it again. 4. Position the terminal in the crimping tool slot with the solid portion of the terminal toward the anvil and the open section toward the former. 5. Insert the wire in the terminal to the position shown in step 3. 6. Squeeze the tool with both hands until the stops make contact. 7. Crimp the insulation crimp. - If you do not have a wire seal, then use the next larger size crimp slot. Position the crimping tool over the insulation crimp section of the terminal, then squeeze the tool with both hands until the stops make contact. - If you have a wire seal, position the insulation crimp in the 5.5 crimping slot, then carefully squeeze the crimp closed until its ends are touching and making a full-circle shape. Page 9821 4. Disconnect the 20P connector and make these input tests. 5. Reconnect the connector to the power window master switch and make these input tests. 2-door NOTE: The power window control unit is built into the power window master switch, and it only controls the driver's window operations. 1. Remove the door grip cover. Diagram Information and Instructions Transmission Position Switch/Sensor: Diagram Information and Instructions Terminal Numbering System Terminal Numbering System Connector terminals are numbered according to the cavities they're in. The cavities are numbered starting from the upper left, looking at the male terminals from the terminal side or looking at the female terminals from the wire side. Both views are in the same direction so the numbers are the same. All actual cavities are numbered, even if they have no wire terminals in them. NOTE: Data Link Connector (DLC) terminals are numbered according 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 below is #6. Page 1924 1. Apply a force of 98 N (10 kgf, 22 lbf), and measure the deflection at the mid point (A) between the alternator and crankshaft pulley. If the belt is worn or damaged, replace it. If the belt needs adjustment, go to step 2. Adjustment 2. Loosen the mounting bolt (B), lock bolt (C) and lower bracket mounting bolt (D). 3. Torque the mounting bolt to 20 N.m (2.0 kgf.m, 14 lbf.ft). 4. Turn the adjusting bolt (E) to obtain the proper belt tension, then retighten the lock bolt, mounting bolt and lower bracket mounting bolt. 5. Recheck the belt tension. 6. If you installed a new belt, run the engine for 5 minutes, then readjust the belt to the used belt specification. 7. Check the power steering pump belt adjustment. Page 8251 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. Obtain the customer's key code from the iN (Key Code Inquiry). Refer to the Honda High Security key Codes book that comes with the Matrix H key cutting machine. Write down the applicable cutting code for the key code number. Make sure the corrections to the code book listed in Service Bulletin 01-077, Cutting Sidewinder-Type keys With the Matrix H key Cutting Machine, have been made. 2. Use the chart shown to write down the numbers found in the key code book. 3. Remove the door panel. Refer to the appropriate service manual or use ISIS keyword Door Panel. 4. Remove the plastic cover as necessary. 5. Raise the window glass fully. 6. Remove the lock cylinder. ^ For Civic, go to step 7. ^ For CR-V, go to step 8. ^ For Element, go to step 11. 7. Pull down on the retainer clip with a hook-shaped tool. Remove the lock cylinder and disconnect the cylinder rod. Then go to step 14. Page 6631 PGM-F1 Main Relay 1, 2 Type 1, 2 Check for continuity between the terminals. - There should be continuity between the No.1 and No.2 terminals when power and ground are connected to the No.3 and No.4 terminals. - There should be no continuity between the No.1 and No.2 terminals when power is disconnected. Normally-open type B: Rear Window Defogger Relay Page 830 2. Insert the terminal tool into the female terminal, and then remove the terminal tool. NOTE: Make sure you do not select a terminal tool that is larger than the mating male terminal because it would spread the female terminal and cause a loose fit. 3. Compare the drag to the other terminals in the connector. If the drag is less, replace the terminal with a replacement terminal from the appropriate terminal repair kit. Page 4122 Shift Indicator: Electrical Diagrams Automatic Transmission Circuit Diagram Continuously Variable Transmission Page 3719 8. Put the splice connector in the proper size slot in the Crimper Tool, slide it to one end (where the flare begins), and close the crimper handles far enough to hold it in place. To release the ratchet mechanism at any point after the first click, squeeze the handles slightly and push the release lever, then let the handles open. 9. Insert one of the bare wires into the splice connector end that is in the crimper jaws. Push the wire all the way into the splice connector, and squeeze the crimper handles. Keep squeezing until the jaws touch, and hold it at that position until the ratchet clicks again. 10. Crimp the other wire in the same way into the other end of the splice connector. 11. After crimping, gently pull on the wires in the opposite directions to make sure they are secure in the connector. 12. Separate the other wires in the harness from the repaired wire(s), and shield them with nonflammable material. Page 4256 107. Behind A/T Shift Lever (except M/T) Page 9061 PGM-F1 Main Relay 1, 2 Type 1, 2 Check for continuity between the terminals. - There should be continuity between the No.1 and No.2 terminals when power and ground are connected to the No.3 and No.4 terminals. - There should be no continuity between the No.1 and No.2 terminals when power is disconnected. Normally-open type B: Rear Window Defogger Relay Page 8750 Splices Components Ground - "G" Page 9391 Power Distribution schematics show how power is supplied from the positive battery terminal to various circuits in the vehicle. Refer to the Power Distribution diagram set to get a more detailed understanding of how picture is supplied to the circuit you're working on. Individual circuit schematics begin with a fuse. So 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 Ground Distribution Schematics This sample Ground Distribution schematic shows all of the components that share the same ground point. Service and Repair Towing Information: Service and Repair Towing If the vehicle needs to be towed, call a professional towing service. Never tow the vehicle behind another vehicle with just a rope or chain. It is very dangerous. Emergency Towing There are three popular methods of towing a vehicle. Flat-bed Equipment - The operator loads the vehicle on the back of a truck. This is the best way of transporting the vehicle. To accommodate the flat-bed equipment, the vehicle is equipped with towing hooks (A) and tie down slots (B). The towing hook can be used with a winch to pull the vehicle onto the truck, and the tie down slots can be used to secure the vehicle to truck. Wheel Lift Equipment - The tow truck uses two pivoting arms that go under the tires (front or rear) and lift them off the ground. The other two wheels remain on the ground. Sling-type Equipment - The tow truck uses metal cables with hooks on the ends. These hooks go around parts of the frame or suspension and the cables lift that end of the vehicle off the ground. The vehicle's suspension and body can be seriously damaged if this method of towing is attempted. If the vehicle cannot be transported by flat-bed, it should be towed with the front wheels off the ground. If due to damage, the vehicle must be towed with the front wheels on the ground, do the following: Manual Transmission - Release the parking brake. - Shift the transmission in Neutral. Automatic Transmission and CVT - Release the parking brake. - Start the engine. - Shift to D position, then N position. Page 889 NOTE: You need to make the corrections listed in CODE BOOK CORRECTIONS at the end of this service bulletin. TRACER AND CUTTER BIT INSTALLATION 1. Turn the power switch on the back of the machine to ON. (This turns on the built-in work light.) 2. Use the Allen wrench from the built-in tool drawer to loosen the setscrew on the left sleeve of the vertical carriage. Slide the tracer all the way into the sleeve, and tighten the screw. 3. Turn the plastic shield on the right sleeve of the vertical carriage so you can access the setscrew on the sleeve. Use the Allen wrench to loosen the screw. Slide the cutter bit all the way into the sleeve, and tighten the screw. Turn the plastic shield so the open side is in the back. MACHINE COMPONENTS Locations Keyless/Power Door Lock System Component Location Index Page 9556 Combination Switch: Service and Repair Combination Light Switch Test/Replacement 1. Remove the dashboard lower cover. 2. Remove the steering column covers. 3. Disconnect the 16P connector (A) from the combination light switch (B). 4. Remove the two screws, then slide out the combination light switch. 5. Inspect the connector terminals to be sure they are all making good contact. - If the terminals are bent, loose or corroded, repair them as necessary, and recheck the system. - If the terminals look OK, check for continuity between the terminals in each switch position according to the tables. If the continuity is not as specified, replace the switch. Main Switch Cruise Control Switch: Service and Repair Main Switch Main Switch Test/Replacement 1. Carefully pry the switch panel assembly out of the instrument panel. 2. Disconnect the 5P connector (A) from the main switch (B), then remove the switch. 3. Check for continuity between the terminals in each switch position according to the table. If the continuity is not as specified, replace the illumination bulbs (C) or the switch. Page 9386 Terminals - "T" Shielding Switches Fuses Service and Repair Fluid Filter - CVT: Service and Repair CVT ATF Filter Installation 1. Install the ATF filter brackets (A) on the ATF filter (B). 2. Install the ATF filter and bracket on the body. Page 7723 Trunk / Liftgate Latch Release Cable: Service and Repair 4 Door Trunk Lid Opener Cable/Fuel Fill Door Opener Cable Replacement 4-door SRS components are located in this area. Review the SRS component locations and the precautions and procedures before performing repairs or service. NOTE: - Put on gloves to protect your hands. - Take care not to scratch the body and related parts. 1. Remove these items from the left side of the vehicle: - Front door sill trim - Seat side trim - Trunk side trim panel 2. Pull the carpet back as necessary. 3. Disconnect the trunk lid opener/fuel fill door opener cable (A) from the opener (B). 4. Release the opener cable from the clip (C). Remove the cushion tape (D), and detach the clip (E) by using a clip remover. 5. Remove the fuel fill door latch (F) by turning it 90 °, and detach the opener cable junction box (G) from the body. Page 1233 ^ 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 1619 Tires: Specifications Design Specifications Tires Size of front and rear tire U.S.: DX, HX, LX ................................................................................................................................. ........................................... P185/70R14 87S Canada: DX, LX .......................................................... ..................................................................................................................... P185/70R14 87S U.S.: EX ........................................................................................................................................................ ................................... P185/65R15 86H Canada: SI .......................................................................... .............................................................................................................. P185/65R15 86H Size of spare tires U.S.: DX, HX, LX ................................................................................................................................. .......................................... T115/70D14 88M Canada: DX, LX ........................................................... ................................................................................................................... T115/70D14 88M U.S.: EX, LX with ABS .................................................................................................................................. ................................ T125/70D15 95M Canada: SI, DX, LX with ABS ....................................................................................................................................................... T125/70D15 95M Maintenance Required Indicator Doesn't Reset Maintenance Required Lamp/Indicator: Technical Service Bulletins Maintenance Required Indicator Doesn't Reset SOURCE: Honda Service News February 2003 TITLE: Maintenance Required Indicator Doesn't Reset APPLIES TO: 2001-03 Civics, 2002-03 Civic Sis, 2003 Civic Hybrids, 2002-03 CR-Vs, and 2003 Elements. SERVICE TIP: Are customers complaining that they can't reset the maintenance required indicator (MAINT REQ'D) on the instrument panel? Find out if the headlights, parking lights, or both were turned on when they tried to reset it. The maintenance required indicator can't be reset if any of these lights are on. In fact, some aftermarket daytime running light devices designed to turn on the headlights, parking lights, or both as soon as you turn the ignition switch to ON (II), must be disabled before the indicator can be reset. Page 9754 5. Disconnect the 5P connector, and make these input tests. Page 6823 Page 557 Cruise Control Switch: Testing and Inspection Set/Resume/Cancel Switch Set/Resume/Cancel Switch Test/Replacement 1. Remove the two screws, then remove the switch. 2. Check for continuity between the terminals in switch position according to the table. - If there is continuity, and it matches the table, but switch failure is occurred on the cruise control unit input test, check and repair the wire harness on the switch circuit. - If there is no continuity in one or both positions, replace the switch. Seats With Side Airbags Air Bag(s) Arming and Disarming: Description and Operation Seats With Side Airbags Seats with Side Airbags Seats with side airbags have a tag attached to the seat-back. Because the component parts (seat-back cover, cushion, etc.) of seats with and without airbags are different, make sure you install only the correct replacement parts. Because the seats are made by more than one manufacturer, make sure you replace any seat components (seat-back cover, frame, etc.) with the correct parts. The name of the seat manufacturer is indicated on the seat-back. Moreover, the manufacturer name is indicated on the seat-back frame and the seat-back pad. Confirm the indication when you exchange these parts. * When cleaning, do not saturate the seat with liquid, and do not spray steam on the seat. * Do not repair torn or frayed seat-back covers. Replace the seat-back cover. * After a collision in which the side airbag was deployed, replace the seat-back cover and the side airbag with new parts. If the seat-back cushion is split, it must be replaced. If the seat-back frame is definitely deformed, it must be replaced. Page 1435 Fluid - M/T: Fluid Type Specifications M/T Fluid Type ........................................................................................................................................ Honda Manual Transmission Fluid (MTF): P/N 08798-9016 If not available you may use 10W-30 or 10W-40 motor oil as a temporary replacement. An API Certification seal that says "For Gasoline Engines" should be used as a temporary replacement. Replace with Honda MTF as soon as it is convenient. Using motor oil can cause stiffer shifting because it does not contain the proper additives. Page 5845 Relay Box: Connector Locations Under-dash Fuse/Relay Box Page 1038 Page 6979 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 9500 2. Remove the terminal from the female half. 3. Remove the terminal from the male half. 4. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE D: 1. Remove the secondary locks. Page 161 Terminals - "T" Shielding Switches Fuses Page 159 Connectors - "C" Page 986 Ignition Switch Lock Cylinder: Technical Service Bulletins Ignition Keys Gets Warm While Driving SOURCE: Honda Service News July 2003 TITLE: Ignition Key Gets Warm While Driving APPLIES TO: 2003 Accords, 2001-03 Civics, 2002-03 CR-Vs SERVICE TIP: Are owners of complaining of the ignition key getting warm while driving? The key interlock solenoid in the ignition switch is the likely culprit. This solenoid is energized anytime the shift lever isn't in Park, so the heat from the solenoid gets transferred to the ignition key. This is a normal characteristic of the vehicle, and can't be fixed by replacing the key interlock solenoid, the ignition lockset, or any other component. Page 5141 8. Put the splice connector in the proper size slot in the Crimper Tool, slide it to one end (where the flare begins), and close the crimper handles far enough to hold it in place. To release the ratchet mechanism at any point after the first click, squeeze the handles slightly and push the release lever, then let the handles open. 9. Insert one of the bare wires into the splice connector end that is in the crimper jaws. Push the wire all the way into the splice connector, and squeeze the crimper handles. Keep squeezing until the jaws touch, and hold it at that position until the ratchet clicks again. 10. Crimp the other wire in the same way into the other end of the splice connector. 11. After crimping, gently pull on the wires in the opposite directions to make sure they are secure in the connector. 12. Separate the other wires in the harness from the repaired wire(s), and shield them with nonflammable material. Page 2984 ECT at 140 °F (60 °C) or higher. Procedure 1. Connect the scan tool to the vehicle's data link connector (DLC), and bring up the tool's generic OBD II mode. 2. Start the engine. 3. Test-drive the vehicle under stop-and-go conditions with short periods of steady cruise. During the drive, decelerate (with the throttle fully closed) for 5 seconds. After about 3.5 miles (5.6 km), the readiness code should switch from incomplete to complete. 4. If the readiness code is still set to incomplete, check for a temporary DTC. If there is no DTC, the enable criteria was probably not met; repeat the procedure. Air/Fuel Ratio (A/F) Sensor Heater Monitor Readiness Code NOTE: All readiness codes are cleared when the battery is disconnected or when the ECM/PCM is cleared with the OBD II scan tool or Honda PGM Tester. Procedure 1. Connect the scan tool to the vehicle's data link connector (DLC), and bring up the tool's generic OBD II mode. 2. Start the engine, and let it idle for 1 minute. The readiness code should switch from incomplete to complete. 3. If the readiness code is still set to incomplete, check for a temporary DTC. If there is no DTC, repeat the procedure. Misfire Monitor and Readiness Code - This readiness code is always set to available because misfiring is continuously monitored. - Monitoring pauses, and the misfire counter resets, if the vehicle is driven over a rough road. - Monitoring also pauses, and the misfire counter holds at its current value, if the throttle position changes more than a predetermined value, or if driving conditions fall outside the range of any related enable criteria. Fuel System Monitor and Readiness Code - This readiness code is always set to available because the fuel system is continuously monitored during closed loop operation. - Monitoring pauses when the catalytic converter, EVAP control system, and A/F sensor monitors are active. - Monitoring also pauses when any related enable criteria are not being met. Monitoring resumes when the enable criteria is again being met. Comprehensive Component Monitor and Readiness Code This readiness code is always set to available because the comprehensive component monitor is continuously running whenever the engine is cranking or running. EGR Monitor and Readiness Code NOTE: - Do not turn the ignition switch off during the procedure. - All readiness Codes are cleared when the battery is disconnected or when the ECM/PCM is cleared with the OBD II scan tool or Honda PGM Tester. Enable Criteria - ECT at 176 °F (80 °C) or higher Procedure 1. Connect the scan tool to the vehicle's data link connector (DLC), and bring up the tool's generic OBD II mode. 2. Start the engine. 3. Drive at a steady speed with the CVT and A/T in D position or M/T in 4th gear, 50 - 62mph (80 - 100 km/h) or above for more than 10 seconds. 4. With the CVT and A/Tin D position or M/T in 4th gear, decelerate from 62 mph (100km/h) or above by completely releasing the throttle for at least 5 seconds. If the engine is stopped during this procedure, go to step 3 and do the procedure again. 5. If the readiness code is still set to incomplete, check for a temporary DTC. If there is no DTC, the enable criteria was probably not met; repeat the procedure. Page 4709 6. Remove the ATF strainer (B) (two bolts). 7. Remove the lower valve body assembly (C) (eight bolts). 8. Remove the bolt securing the solenoid harness connector (D) with holding the lower valve body assembly, and remove the connector and valve body assembly. Lower Valve Body Assemble Installation 1. Install the solenoid harness connector (A) with holding the lower valve body assembly (B). 2. Install the lower valve body assembly (eight bolts). 3. Install the ATF strainer (C) (two bolts). 4. Install the ATF pan (D) with the two dowel pins (E) and new gasket (F). 5. Check the solenoid harness connector for rust, dirt, or oil, then connect the connector securely. 6. Refill the transmission with ATF. 7. Perform the start clutch calibration procedure. Page 5113 Connectors - "C" Page 2340 ECM/PCM Inputs And Outputs At Connector C (22P) Page 1995 161. Middle Of Engine Compartment Page 9397 - 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. Troubleshooting Tests 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 test 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 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. 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 Drop Page 5558 ^ Going from front to back, use the middle lock pin to set the first cam to the appropriate key code number in the code book. (The cam is properly set when the number on the cam lines up with the red scribe mark on the clamp unit.) ^ Slide the lock pin through the notch in the cam. (This locks the cam in place.) ^ Keep doing this for each of the remaining cams in the set until all the cams are set and locked, then push the lock pin all the way in. Repeat this process to set and lock the cams for the right cam set. NOTE: Make sure you set the MIS cam in the right cam set for the type of key you are cutting. For a master key, set the cam to M; for a valet key, set it to S. When you are done, push all the cam blades to the left until they touch the cams in the left cam set. 10. Pull the vertical carriage lever toward you until the tracer touches the flat surface on the right side at the front of the cams. Gently twist the lever clockwise to lock the vertical carriage at this height. Do not overtighten the lever. 11. Turn on the cutter motor with the motor start switch. [NOTICE] ^ To avoid damaging the locking jaws while cutting, keep your hand off the vertical carriage lever. Pressure on the lever will change the cutting depth. * ^ To avoid breaking the cutter bit, never back up while cutting.* ^ Wear proper eye protection (safety glasses, goggles, etc.) 12. Use the clamp carriage lever and the tracer to follow the contours of the cam blades from front to back. (The cutter bit cuts the same contours into the right edge of the key blank, from head to tip.) Page 2905 Oxygen Sensor: Diagrams 130. A/F Sensor 140. HO2S, Primary (GX; '01-'03: EX, DX, LX) Or Secondary (HX) Page 7967 *T-5 Sidewinder Key Applications ^ 2003-05 Civic ^ 2004-05 Civic Hybrid ^ 2003-05 Civic GX (CNG) ^ 2004-05 S2000 ^ 2002-06 CR-V ^ 2003-06 Element ^ 2003-04 Odyssey ^ 2003-04 Pilot Ordering Honda key blanks through normal parts ordering channels: Refer to the parts catalog for correct key(s) for your application. PROGRAMMING KEYS Depending on the type of key blank you use, do this: ^ If you have used a T-5 programmable key blank ("T-5" stamped on the shank), you must code the key's transponder with the Ilco Immobilizer Key Code Duplicator (see S/B 99-053, Ilco Immobilizer key Code Duplicator). ^ If you have used a Honda key blank, add the* transponder code of the new key to the immobilizer system with the Honda Diagnostic System (HDS). ORDERING INFORMATION *To order the MATRIX H Key Cutting Machine, replacement cutter bits, fixed jaws and mobile jaws, T-5 programmable key blanks, and practice key blanks, contact the Honda Tool and Equipment Program by calling 888-424-6857 or using the fax order form provided in your Honda Tool and Equipment Program Catalog.* Order Honda key blanks through normal parts ordering channels. WARRANTY CLAIM INFORMATION None. This service bulletin is for information only. *DETERMINING WHICH KEY TO USE T-5 keys require less time to program and should be the first choice. They can be used as long as the following requirements are met: ^ Do you have the customer's operating key? ^ Does the vehicle fall within the T-5 Sidewinder Key Applications? ^ Does your dealership have an Ilco Immobilizer Key Code Duplicator? If the answer to all three questions on the above is yes, the 1-5 key option is the easier procedure. If you answered no to any of the questions, you should order the key(s) from the parts catalogue, and program it using the HDS.* BEFORE YOU START CUTTING 1. Get the original key or the key number from your customer or from the iN. 2. Get the applicable key blank. 3. If cutting by code, look up the applicable 9-digit cutting code for the key number. Refer to the code book Honda High Security key Codes that comes with the machine. Automatic Transmission Flex Plate: Specifications Automatic Transmission Drive Plate Tighten the six bolts in a crisscross pattern. Locations Data Link Connector: Locations PGM-FI System - Component Location Index Page 1831 4. Measure wear and taper in direction X and Y at three levels in each cylinder as shown. If measurements in any cylinder are beyond the Oversize Bore Service Limit, replace the block. If the block is to be rebored, refer to step 6 after reboring. Cylinder Bore Size Standard (New): 75.00 - 75.02 mm (2.9528 - 2.9535 inch) Service Limit: 75.07 mm (2.9555 inch) Oversize: 0.25: 75.25 - 75.27 mm (2.9626 - 2.9634 inch) 0.50: 75.50 - 75.52 mm (2.9724 - 2.9732 inch) Reboring limit: 0.5 mm (0.02 inch) max. Bore Taper: Limit: (Difference between first and third measurement) 0.05 mm (0.002 inch) 5. Scored or scratched cylinder bores must be honed. Page 9297 Circuit Schematics Each schematic represents one circuit. A circuit's wires and components are arranged to show current flow from power at the top of the diagram 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 Page 3853 Transmission Speed Sensor: Locations 22. Transmission Housing (A/T Except CVT) 19. Transmission Housing (A/T Except CVT) Page 7717 WARRANTY CLAIM INFORMATION In warranty: The normal warranty applies. Failed Part: P/N 68500-S5P-A90ZZ H/C 6528640 *Defect Code: 07406* Symptom Code: 03220 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 A 1. Check the side-to-side alignment of the trunk lid latch to the striker: ^ Refer to page 20-132 of the 2001-04 Civic Service Manual. ^ In ISIS, use the keyword TRUNK ADJUST, and select Trunk Lid Adjustment from the list. 2. Make sure the gaps of the trunk lid are even on all sides. ^ If the trunk is misaligned, go to step 3. ^ If the trunk lid is properly aligned on all sides, go to REPAIR PROCEDURE B. 3. Adjust the trunk lid hinges: ^ Refer to page 20-132 of the 2001-04 Civic Service Manual. ^ In ISIS, use the keyword TRUNK ADJUST, and select Trunk Lid Adjustment from the list. 4. Check the trunk operation: ^ If the trunk opens and closes smoothly and is properly aligned, return the vehicle to the customer. ^ If the trunk lid is still difficult to close, go to REPAIR PROCEDURE B. REPAIR PROCEDURE B Page 4342 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 2323 Main Switch Cruise Control Switch: Service and Repair Main Switch Main Switch Test/Replacement 1. Carefully pry the switch panel assembly out of the instrument panel. 2. Disconnect the 5P connector (A) from the main switch (B), then remove the switch. 3. Check for continuity between the terminals in each switch position according to the table. If the continuity is not as specified, replace the illumination bulbs (C) or the switch. Page 9782 PGM-F1 Main Relay 1, 2 Type 1, 2 Check for continuity between the terminals. - There should be continuity between the No.1 and No.2 terminals when power and ground are connected to the No.3 and No.4 terminals. - There should be no continuity between the No.1 and No.2 terminals when power is disconnected. Normally-open type B: Rear Window Defogger Relay Page 6639 PGM-F1 Main Relay 1, 2 Type 1, 2 Check for continuity between the terminals. - There should be continuity between the No.1 and No.2 terminals when power and ground are connected to the No.3 and No.4 terminals. - There should be no continuity between the No.1 and No.2 terminals when power is disconnected. Normally-open type B: Rear Window Defogger Relay Page 1683 1. Remove the secondary lock from the male terminal half. 2. Remove the secondary lock from the female terminal half. 3. Remove the terminal (same procedure for male and female). 4. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE C: 1. Remove the secondary lock. Page 8185 38. Door Lock Actuator, Passenger's (Coupe Except DX) Page 224 Exterior Lights Component Location Index Locations Relay And Control Unit Locations - Engine Compartment Locations Camshaft Position Sensor: Locations PGM-FI System - Component Location Index Page 7462 3. Strip the insulation off the end of the wire so the wire fits in the new terminal as shown. (If the wire has a wire seal, replace it with a new one from the kit.) NOTE: After stripping the end of the wire, make sure you did not cut any wire strands. If you did, cut the wire off even with the insulation, and strip it again. 4. Position the terminal in the crimping tool slot with the solid portion of the terminal toward the anvil and the open section toward the former. 5. Insert the wire in the terminal to the position shown in step 3. 6. Squeeze the tool with both hands until the stops make contact. 7. Crimp the insulation crimp. - If you do not have a wire seal, then use the next larger size crimp slot. Position the crimping tool over the insulation crimp section of the terminal, then squeeze the tool with both hands until the stops make contact. - If you have a wire seal, position the insulation crimp in the 5.5 crimping slot, then carefully squeeze the crimp closed until its ends are touching and making a full-circle shape. Page 6796 58. MES Connector Locations 4. Right Side Of Engine Compartment Page 298 Engine Control Module: Service and Repair Monitors, Trips, and/or Drive Cycle (Readiness Codes) Malfunction Indicator Lamp (MIL) Indication (In relation to Readiness Codes) The vehicle has certain "readiness codes" that are part of the on-board diagnostics for the emissions systems. If the vehicle's battery has been disconnected or gone dead, if the DTCs have been cleared, or if the ECM/PCM has been reset, these codes are reset. In some states, part of the emissions testing is to make sure these codes are set to complete. If all of them are not set to complete, the vehicle may fail the emissions test, or the test cannot be finished. To check if the readiness codes are complete, turn the ignition switch ON (II), but do not start the engine. The MIL will come on for 15 - 20 seconds. If it then goes off, the readiness codes are complete. If it blinks several times, one or more readiness codes are not complete. To set readiness codes from incomplete to complete, do the procedure for the appropriate code. Catalytic Converter Monitor and Readiness Code NOTE: - Do not turn the ignition switch off during the procedure. - All readiness codes are cleared when the battery is disconnected or when the ECM/PCM is cleared with the OBD II scan tool or Honda PGM Tester. - Low ambient temperatures or excessive stop-and-go traffic may increase the drive time needed to switch the readiness code from incomplete to complete. - The readiness code will not switch to complete until all the enable criteria are met. - If a fault in the secondary HO2S system caused the MIL to come on, the readiness code cannot be set to complete until you correct the fault. Enable Criteria - ECT at 158 °F (70 °C) or higher. - Intake air temperature (IAT) at 20 °F (-7 °C) or higher. - Vehicle speed is steady, and vehicle speed sensor (VSS) reads more then 25 mph (40 km/h). Procedure 1. Connect the scan tool to the vehicle's data link connector (DLC), and bring up the tool's generic OBD II mode. 2. Start the engine. 3. Test-drive the vehicle under stop-and-go conditions with short periods of steady cruise. After about 5 miles (8 km), the readiness code should switch from incomplete to complete. 4. If the readiness code is still set to incomplete, check for a temporary DTC. If there is no DTC, one or more of the enable criteria were probably not met; repeat the procedure. Evaporative Emissions (EVAP) Control System Monitor and Readiness code NOTE: - All readiness code are cleared when the battery is disconnected or when the ECM/PCM is cleared with the OBD II scan tool or Honda PGM Tester. - The enable criteria must be repeated if the intake air temperature (IAT) drops lower then 36 °F (2 °C) from its value at engine start up. Enable Criteria - At engine start up, ECT and IAT are higher than 32 °F (O °C), but lower than 95 °F (35 °C). - At engine start up, the ECT and IAT are within 12 °F (7 °C) of each other. Procedure 1. Connect the scan tool to the vehicle's data link connector (DLC), and bring up the tool's generic OBD II mode. 2. Start the engine. 3. Test-drive the vehicle under stop-and-go conditions with short periods of steady cruise. After about 2.5 miles (4 km), the readiness code should switch from incomplete to complete. 4. If the readiness code is still set to incomplete, check for a temporary DTC. If there is no DTC, one or more of the enable criteria were probably not met; repeat the procedure. Air Fuel Ratio (A/F) Sensor Monitor and Readiness Code NOTE: - Do not turn the ignition switch off during the procedure. - All readiness codes are cleared when the battery is disconnected or when the ECM/PCM is cleared with the OBD II scan tool or Honda PGM Tester. Enable Criteria Page 5750 Auxiliary Power Outlet: Electrical Diagrams Diagram 155 Diagrams: Other diagrams referred to by number (See Diagram ##-#, etc.)within these diagrams can be found at Diagrams by Number. See: Diagrams/Electrical Diagrams/Diagrams By Number Locations: Location photographs (references to PHOTOS) referred to within these diagrams can be found at Locations by Photo Number. See: Locations/Component Locations/Locations By Photo Number Connector Views: Connector terminal views (references to VIEWS) referred to within these diagrams can be found at Connector Views by View Number. See: Diagrams/Connector Views/Connector Views By View Number Page 194 Diagram 115-4 (Sedan EX) Page 5836 Power Windows Component Location Index Page 780 65. PSP Switch Page 1560 Rear Window Defogger Component Location Index Page 8010 13. Push the top of the retainer clip with a flat-tip screwdriver, and hold it. Release the retainer clip with a hook-shaped tool, then remove the lock cylinder. Go to step 14. 14. With the door lock cylinder out of the door handle remove the E-clip and the arm. 15. Try to insert the key into the cylinder and turn it. ^ If you can insert and turn the key, go to step 18. ^ If you cannot insert the key or turn it, go to step 16. 16. Carefully remove the spring and plastic retainer. Page 617 Keyless/Power Door Lock System Component Location Index Page 5684 ^ Start the engine, and let it warm up to its normal operating temperature (the cooling fans cycle twice). ^ Let the engine idle (throttle closed and all electrical items off) for 10 minutes. Disclaimer Locations 162. Right Side Of Engine Compartment Component Locations Oxygen Sensor: Component Locations PGM-FI System - Component Location Index Diagrams (Except GX) Page 7300 2. Insert the terminal tool into the female terminal, and then remove the terminal tool. NOTE: Make sure you do not select a terminal tool that is larger than the mating male terminal because it would spread the female terminal and cause a loose fit. 3. Compare the drag to the other terminals in the connector. If the drag is less, replace the terminal with a replacement terminal from the appropriate terminal repair kit. Page 2629 Idle Speed: Testing and Inspection Idle Speed Inspection NOTE: - Leave the Idle Air Control (IAC) valve connected. - Before checking the idle speed, check these items: The Malfunction Indicator Lamp (MIL) has not been reported on. - Ignition timing - Spark plugs - Air cleaner - PCV system - On Canadian models, pull the parking brake lever up, start the engine, then check that the headlights are off. 1. Disconnect the Evaporative Emission (EVAP) canister purge valve 2P connector. 2. Connect a tachometer. 3. Start the engine. Hold the engine at 3,000 rpm with no load (in neutral) unit the radiator fan comes on, then let it idle. 4. Check the idle speed with no-load conditions: headlights, blower fan, radiator fan, and air conditioner are not operating. 5. Idle the engine for 1 minute with the heater fan switch on HI and air conditioner on, then check the idle speed. NOTE: If the idle speed is not within specification, see the Symptom Chart. 6. Reconnect the EVAP canister purge valve 2P connector. Locations 21. Transmission Housing (A/T) Page 173 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. Circuits must be operating when checking voltage drop. 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. 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 off, 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 Self-Powered Test Light or DVOM 1. Remove the blown fuse and disconnect the battery and load. Page 2329 ECM/PCM Inputs And Outputs At Connector A (31P) Service and Repair Wheel Cylinder: Service and Repair Rear Wheel Cylinder Replacement NOTE: ^ Do not spill brake fluid on the vehicle; it may damage the paint; if brake fluid does contact the paint, wash it off immediately with water. To prevent spills, cover the hose joints with rags or shop towels. ^ Use only a genuine Honda wheel cylinder special bolt. 1. Remove the brake shoes. 2. Disconnect the brake line (A) from the wheel cylinder (B). 3. Remove the bolt (C) and the wheel cylinder from the backing plate. 4. Apply Three Bond 1109G sealant or equivalent (E) between the wheel cylinder (B) and backing plate (D), and install the wheel cylinder. 5. Install the removed parts in the reverse order of removal. 6. Bleed the brake system. 7. Check for leaks at the line joint and bleed screw, and retighten if necessary. Specifications Page 4833 Flat Rate Time: 4.0 hours Failed Part: P/N 24230-PLW-000 H/C 6568653 Defect Code: 042 Contention Code: B07 Template ID: 03-009A (DX, LX, EX) 03-009B (HX) 03-009C (Hybrid) 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. * Remove the transmission. See page 13-4 of the 2001-2003 Civic Service Manual; for the Hybrid, see page 13-18. Then remove the housing. See page 13-16 of the 2001-2003 Civic Service Manual; for the Hybrid, see page 13-32.* 2. * Remove the reverse idler shaft and the reverse idler gear; discard the gear. See page 13-17 (13-32 for Hybrid) of the service manual.* Page 8167 6. Press and hold the green programming button on the side of the control unit until the LED on the instrument panel begins to flash, then release the button. (Steps 6 and 7 must be done within 5 seconds of each other.) 7. Press and release the bottom button on the transmitter. Verify that the LED goes out, the siren chirps twice, and the front sidemarker lights flash twice to confirm that the transmitter's code was accepted by the control unit. 8. Turn the ignition switch to LOCK. Test the transmitter you just programmed. If it doesn't work repeat steps 2 thru 7. 9. If you have another transmitter to program, repeat steps 2 thru 7. Ordering a Transmitter Transmitters can be ordered only by authorized Honda dealers. Order them from American Honda using normal parts ordering procedures. Batteries for the Transmitter The battery number is CR2025. Each transmitter uses one battery. 98-02 Passport With Factory-Installed Security System 1998-02 Passport with factory-installed security system Programming the Transmitter To program the transmitters, use one of these two procedures: ^ Procedure One cancels all learned transmitter codes and adds one new transmitter. None of the previously programmed transmitters will work. Use this programming procedure only if all transmitters were lost or stolen, or if a new control unit has been installed. ^ Procedure Two adds additional transmitters without cancelling any of the previously learned codes. The system will accept up to four transmitters. Procedure One (cancels all codes, adds one new transmitter) 1. Open the driver's door. 2. Turn the ignition switch to the ACC position and then to the LOCK position three times. (This step must be completed within 10 seconds, or the system will not enter the programming mode.) 3. Within 10 seconds, close and open the door two times. 4. Turn the ignition switch to the ACC position and then to the LOCK position five times. Close and open the door. (Complete this process within 10 seconds.) Verify that the power door locks cycle once to confirm that the system is in programming mode. 5. Within 20 seconds, press the "LOCK" button on the transmitter you are programming. Verify that the door locks cycle once. 6. Within 20 seconds, press the "UNLOCK" button on the transmitter. Verify that the door locks cycle once to confirm that the system has accepted the transmitter's code. Procedure Two (adds transmitters) 1. Open the driver's door. 2. Turn the ignition switch to the ACC position and then to the LOCK position three times. (This step must be completed within 10 seconds, or the Page 741 36. Left Side Of Engine Compartment (except GX) Page 3248 Variable Valve Timing Actuator: Diagnostic Aids General Troubleshooting Information General Troubleshooting Information Tips and Precautions Before Troubleshooting 1. Check applicable fuses in the appropriate fuse/relay box. 2. Check the battery for damage, state of charge, and clean and tight connections. NOTE: 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. Handling Connectors - Make sure the connectors are clean and have no loose wire terminals. - Make sure multiple cavity connectors are packed with dielectric grease (except watertight connectors). - All connectors have push-down release type locks (A). - Some connectors have a clip on their side used to attach them to a mount bracket on the body or on another component. This clip has a pull type lock. - Some mounted connectors cannot be disconnected unless you first release the lock and remove the connector from its mount bracket (A). - Never try to disconnect connectors by pulling on their wires; pull on the connector halves instead. - Always reinstall plastic covers. Page 5049 Transmission Speed Sensor: Service and Repair Speed Sensors Replacement 1. Disconnect connectors from the drive pulley speed sensor (A), driven pulley speed sensor (B), CVT speed sensor (C), and CVT speed sensor 2 (D). 2. Remove the 6 mm bolts, then remove the speed sensors. Remove the sensor washer (E) from the vehicle speed sensor (C). 3. Replace the O-rings (F) with new ones before installing the speed sensors. 4. Install the sensor washer on the CVT speed sensor 2, and install them. 5. Install the drive pulley speed sensor, driven pulley speed sensor, and CVT speed sensor. 6. Check the speed sensor connectors for rust, dirt, or oil, then connect the connectors securely. Page 5830 Charging System Component Location Index Specifications Page 9722 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. DIAGNOSIS Pull up the outer edge of the windshield molding. Check if the inner lip is folded over anywhere. ^ If the inner lip is folded over, go to REPAIR PROCEDURE. ^ If the inner lip is not folded, disregard this bulletin, and look for other possible causes. REPAIR PROCEDURE 1. Protect the roof by applying a strip of 2-inch-wide masking tape along the outer edge of the windshield molding. 2. Pull up the outer edge of the molding, and use scissors or an X-Acto knife to remove its entire inner lip. Antitheft System - Alarm Will Not Arm/Arms By Itself Keyless Entry Transmitter: Customer Interest Antitheft System - Alarm Will Not Arm/Arms By Itself 05-025 July 1, 2005 Applies To: 2001-05 Civic - ALL 2002-05 CR-V - ALL 2003-04 Element - ALL Accessory Security System Changes Modes By Itself (Supersedes 05-025, dated June 10, 2005, to update the information indicated by black bars and asterisks.) SYMPTOM The security system will not arm or it arms by itself. PROBABLE CAUSE Key switch contact chatter causes the control unit to change modes. CORRECTIVE ACTION * Civic: Replace the security control unit, and reprogram the remote(s).* * CR-V and Element: Replace the security control unit and the microphone, then reprogram the remote(s).* * NOTE: You must replace the microphone on the CR-V and Element because the security control units are matched to their microphones when they are manufactured. Using the original microphone may result in security system problems.* PARTS INFORMATION WARRANTY CLAIM INFORMATION In warranty: The normal warranty applies. Out of warranty: Any repair performed after warranty expiration may be eligible for goodwill consideration by the District Parts and Service Manager or your Zone Office. You must request consideration, and get a decision, before starting work. REPAIR PROCEDURE NOTE: Before starting, make sure you have all of the remotes (three maximum) the customer wishes to use. Page 2319 DTC P2240 thru U0073 Page 7525 7. Install the door panel in the reverse order of removal, and note these items: - Replace any damaged clips. - Make sure the connectors are plugged in properly, and the rod is connected properly. - Make sure the window and power door locks operate properly. - If applicable, install the regulator handle so it points forward and up at a 45 ° angle with the glass fully closed. Page 3487 PGM-F1 Main Relay 1, 2 Type 1, 2 Check for continuity between the terminals. - There should be continuity between the No.1 and No.2 terminals when power and ground are connected to the No.3 and No.4 terminals. - There should be no continuity between the No.1 and No.2 terminals when power is disconnected. Normally-open type B: Rear Window Defogger Relay Page 3514 48. Middle Of Engine (except GX) 49. Middle Of Engine (GX) Page 3458 (Except GX) Page 4163 Page 7192 ^ Within 1 to 4 seconds, turn the ignition switch to LOCK (0). ^ Within 1 to 4 seconds, turn the ignition to ON (II). ^ Within 1 to 4 seconds, push the transmitter lock or unlock button. ^ Confirm you can hear the sound of the door lock actuators. Within 1 to 4 seconds, push the transmitter lock or unlock button again. ^ Within 10 seconds, aim the transmitters (up to two additional ones) whose codes you want to store at the receiver, and press the transmitter lock or unlock button. Confirm that you can hear the sound of the door lock actuators after each transmitter code is stored. ^ Turn the ignition switch to LOCK (0), and pull out the key. 4. Confirm proper operation of the transmitters. Disclaimer Description and Operation Barometric Pressure Sensor: Description and Operation Barometric Pressure (BARO) Sensor The BARO sensor is inside the ECM/PCM. It converts atmospheric pressure into a voltage signal that the ECM/PCM uses to modify the basic duration of the fuel injection discharge. Body - Windshield Moulding Warped/Deformed Windshield Moulding / Trim: All Technical Service Bulletins Body - Windshield Moulding Warped/Deformed 00-064 March 17, 2009 Applied Vehicles Deformed Windshield Molding (Supersedes 00-064, dated November 13, 2007, to update the information marked by the black bars) REVISION SUMMARY SYMPTOM The windshield molding is warped or deformed. PROBABLE CAUSE The inner lip is folded, causing a poor fit against the body. CORRECTIVE ACTION Remove the entire inner lip, and fill the channel between the molding and the body with silicone sealant. REQUIRED MATERIALS WARRANTY CLAIM INFORMATION In warranty: The normal warranty applies. Operation Number: 831004 Flat Rate Time: 0.7 hour Failed Part: P/N 73150-S84-A01 H/C 5443387 Defect Code: 00401 Symptom Code: 00101 Template ID: 00-064A Skill Level: Repair Technician Locations Manifold Pressure/Vacuum Sensor: Locations PGM-FI System - Component Location Index Pressure Test Pressure Test Capacity Specifications Coolant: Capacity Specifications Engine Coolant Refill Capacity (including the reservoir capacity of 0.4 L (0.4 US qt): M/T ...................................................................................................................................................... ................................................. 4.0 L (4.2 US qt.) A/T, CVT ............................................................... ................................................................................................................................ 3.9 L (4.1 US qt.) Page 9414 2. Insert the terminal tool into the female terminal, and then remove the terminal tool. NOTE: Make sure you do not select a terminal tool that is larger than the mating male terminal because it would spread the female terminal and cause a loose fit. 3. Compare the drag to the other terminals in the connector. If the drag is less, replace the terminal with a replacement terminal from the appropriate terminal repair kit. Page 3955 NOTE: To avoid control unit/module damage, do not interrupt the update. 14. When the No.1 LED stays on and the No.2 LED goes off, turn the ignition switch to LOCK (0). 15. Turn the ignition switch to ON (II). When the No.1 and No.2 LEDs stay on, the control unit/module is updated. 16. Turn the ignition switch to LOCK (0), and disconnect the DLC cable from the vehicle. To do the same update on an identical vehicle, repeat steps 11 thru 16. UPDATING WITH THE HDS TABLET AND THE HDS POCKET TESTER NOTE: This procedure explains how to update with the HDS tablet. Updating with the HDS pocket tester is similar, but the user interface is modified to fit its smaller screen. 1. If not already done, load the latest HDS PC sofiware onto your HDS tablet or HDS pocket tester. Refer to the instructions included with the HDS Installation Disc. NOTE: If the latest sofiware is not loaded and you do a control unit/module update, the software may indicate the vehicle has the latest update when it doesn't. Updates not done with the latest software are not covered under warranty. 2. On the HDS Switchboard screen, click on the CM update icon. Page 8354 Preprocessing of Painting Preprocessing of Painting 1. Sanding Sand the damage area flat and smooth. Page 8150 This system uses ROM chips that match the transmitter to the security system control unit. When replacing a lost or stolen transmitter, you need to use the three ROM chips (provided with the new transmitter) to match the old transmitter with the new transmitter and the control unit. 1. Remove the rear cover from the old transmitter and the new one. 2. Remove the ROM chip from the old transmitter by sliding its socket holder toward the ROM chip. 3. Insert a new ROM chip into the socket holder, then slide the socket holder toward the socket to lock the chip in place. 4. Repeat step 3 to install a ROM chip into the new transmitter. 5. Reinstall the rear covers on the transmitters. 6. Remove the security system control unit from under the driver's seat. 7. Open the access cover on the control unit, and replace the ROM chip. (Use the same procedure as in steps 2 and 3.) 8. Press the reset button next to the ROM chip. 9. Close the access cover, and reinstall the control unit. If you are replacing a damaged transmitter, don't replace the ROM chips in the transmitters and the control unit; just remove the chip from the old transmitter and install it in the new one. Ordering a Transmitter Transmitters can be ordered only by authorized Honda dealers. Order them from American Honda using normal parts ordering procedures. If your customer wants to add a third transmitter to the system, you need to order a four ROM chip set directly from Alpine Electronics of America. The Alpine part number for the four ROM chip set is 5319. This ROM chip set does not come with a transmitter. Order the additional transmitter from American Honda. If you have questions about how to order a four ROM chip set, call Alpine's parts department at (800) 421-2284, extension 8885. Batteries for the Transmitter Diagrams Exhaust Pipe: Diagrams Page 1595 Malfunction Indicator Lamp: Description and Operation Malfunction Indicator Lamp (MIL) Indication (In relation to Readiness Codes) The vehicle has certain "readiness codes" that are part of the on-board diagnostics for the emissions systems. If the vehicle's battery has been disconnected or gone dead, if the DTCs have been cleared, or if the ECM/PCM has been reset, these codes are reset. In some states, part of the emissions testing is to make sure these codes are set to complete. If all of them are not set to complete, the vehicle may fail the test or the test cannot be finished. To check if the readiness codes are set to complete, turn the ignition switch ON (II), but do not start the engine. The MIL will come on for 15 - 20 seconds. If it then goes off, the readiness codes are set. If it blinks several times, one or more readiness codes are not set to complete. To set each code, drive the vehicle or run the engine as described in the procedures to set them in this section. How to Remove the PCM Control Module: Service and Repair How to Remove the PCM How to Remove the PCM for Testing 1. Remove the passenger's dashboard lower cover, the right kick panel, and the glove box. 2. Remove the bolt. Cut the plastic cross brace in the glove box opening with diagonal cutters in the area shown, and discard it. 3. Remove the relays (A), then remove the bolts and the glove box frame (B). 4. Remove the gray 20P PCM wire harness connector from the PCM mounting bracket. Remove the PCM mounting bolt (A) and the bracket. 5. Remove the nuts, then remove the PCM (B). 6. Install the PCM in the reverse order of removal. Page 7475 Are there any DTCs? YES - Go to step 9. NO - Go to the Mode 2 test. Page 9023 2. Remove the terminal (same procedure for male and female). 3. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE E: 1. Remove the secondary locks. 2. Remove the terminal (same procedure for male and female). 3. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE F: Page 7275 Circuit Schematics Each schematic represents one circuit. A circuit's wires and components are arranged to show current flow from power at the top of the diagram 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 Locations Pressure Regulating Solenoid: Locations Electronic Controls Location Page 1355 1. Apply a force of 98 N (10 kgf, 22 lbf), and measure the deflection at the mid point (A) between the alternator and crankshaft pulley. If the belt is worn or damaged, replace it. If the belt needs adjustment, go to step 2. Adjustment 2. Loosen the mounting bolt (B), lock bolt (C) and lower bracket mounting bolt (D). 3. Torque the mounting bolt to 20 N.m (2.0 kgf.m, 14 lbf.ft). 4. Turn the adjusting bolt (E) to obtain the proper belt tension, then retighten the lock bolt, mounting bolt and lower bracket mounting bolt. 5. Recheck the belt tension. 6. If you installed a new belt, run the engine for 5 minutes, then readjust the belt to the used belt specification. 7. Check the power steering pump belt adjustment. Page 2889 70. Measure voltage between body ground and ECM/PCM connector terminal E5. Is there about 5 V? YES - Replace the FTP sensor. NO - Go to step 71. 71. Turn the ignition switch OFF. 72. Disconnect ECM/PCM connector E (31P). 73. Check for continuity between ECM/PCM connector terminal E5 and body ground. Is there continuity? YES - Repair short in the wire between the ECM/PCM (E5) and the FTP sensor. NO - Update the ECM/PCM if it does not have the latest software, or substitute a known-good ECM/PCM, then recheck. If the symptom/indication goes away with a known-good ECM/PCM, replace the original ECM/PCM. 74. Turn the ignition switch OFF. 75. Turn the ignition switch ON (II). 76. Measure voltage between ECM/PCM connector terminal E29 and body ground. Is there about 5 V (or battery voltage)? YES - Go to step 80. Page 6755 Air Bag: Service and Repair Driver Airbag Spring-Loaded Lock Connector Spring-loaded Lock Connector Some SRS system connectors have a spring-loaded lock. Front Airbag Connectors: Disconnecting To release the lock, pull the spring-loaded sleeve (A) toward the stop (B) while holding the opposite half of the connector. Then pull the connector halves apart. Be sure to pull on the sleeve and not on the connector. Connecting 1. To reconnect, hold the pawl-side connector, and press on the back of the sleeve-side connector in the direction shown. As the two connector halves are pressed together, the sleeve (A) is pushed back by the pawl (C). Do not touch the sleeve. 2. When the connector halves are completely connected, the pawl is released, and the spring-loaded sleeve locks the connector. Removal and Installation Driver's Airbag Replacement Removal 1. Disconnect the battery negative cable, and wait at least 3 minutes before beginning work. Page 2217 - Refill the cooling system with engine coolant. - Be sure to connect the drain hose securely. - Adjust the heater valve cable. - Make sure that there is no coolant leakage. - Make sure that there is no air leakage. - With air conditioning, refer to evaporator core replacement. - Do the ECM/PCM idle learn procedure. - Enter the anti-theft code for the radio, then enter the customer's radio station presets. Page 8537 Sunroof / Moonroof Switch: Service and Repair Switch Test/Replacement 1. Remove the driver's pocket. 2. Disconnect the 6P connector (A) from the moonroof switch (B), and remove the moonroof switch. 3. Check for continuity between the terminals in each switch position according to the table. 4. If the continuity is not as specified, replace the illumination bulb (C) or the moonroof switch. Page 2536 1. Remove the terminal. 2. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE B: 1. Remove the terminal. 2. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE C: 1. Remove the terminal. 2. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE D: Page 9770 Front Door Window Motor: Diagrams (Sedan Except DX) (Coupe Except DX, HX) (Except DX, HX) Page 8501 2. Disconnect the 2P connector from the actuator. 3. Check actuator operation by connecting power and ground according to the table. To prevent damage to the actuator, apply battery voltage only momentarily. 4. If the actuator does not operate as specified, replace it. Page 5883 234. Under-dash Fuse/Relay Box Part 2 Page 5632 ^ Incorrect: "If a Master Key is to be cut, put a five (5) in the blank space. Use a two (2) if a valet key is needed." ^ Correct: "If a Master Key is to be cut, put an M in the blank space. Use an S if a valet key is needed." Page 2, legend at the bottom: ^ Incorrect: "C. If a Master key is desired, then the number five (5) should be placed in the M/S position. Place the number two (2) in the M/S column if a Sub (Valet) key is needed." ^ Correct: "C. If a Master Key is desired, then an M should be placed in the M/S position. Place an S in the MIS column if a Sub (Valet) key is needed." Page 9814 169. Power Window Switch, Passenger's (Coupe Except DX, HX) 232. Power Window Master Switch Page 8482 10. Pull out the headrest guides (A) while pinching the end of the guides, and remove them. 11. Pull back the seat-back cover all the way around, then remove it. 12. Install the cover in the reverse order of removal, and note these items: - To prevent wrinkles when installing a seat-back cover, make sure the material is stretched evenly over the pad before securing the hooks and hook springs. - Make sure the side airbag harness and OPDS harness (passenger's seat) are routed properly. Seat Cushion Cover 1. Remove the front seat. 2. Remove the recline cover and center cover, drivers seat, 2-door passenger's seat, 4-door passenger's seat. 3. With side airbag: From under the seat cushion, detach the side airbag connector clip, and on the passenger's seat, detach the OPDS unit connector clip. Release the hook springs. 4. Release the hooks (A) from both sides of the seat cushion. 5. Release the seat cushion cover (A) from the cushion frame spring (B), and release the hooks (C) from under the seat cushion. Page 5339 162. Right Side Of Engine Compartment 165. Under Left Side Of Floor (EX) Page 56 6. Disconnect the M, P, K, and J connectors from the under-dash fuse/relay box, and make these input tests at the connectors. - If any test indicates a problem, find and correct the cause, then recheck the system. - If all the input tests prove OK, the multiplex control unit must be faulty. Replace the under-dash fuse/relay box assembly. Page 6984 2. Remove the access panel from the steering wheel, then disconnect the driver's airbag 4P connector (A) from the cable reel. Front Passenger's Airbag 3. Lower the glove box, then disconnect the front passenger's airbag 4P connector (A) from the dashboard wire harness B. Side Airbag 4. Disconnect both side airbag 2P connectors (A) from the floor wire harness. Seat Belt Tensioner 5. Disconnect both seat belt tensioner 2P connectors (A) from the floor wire harness. Seat Belt Buckle Tensioner Page 1171 Power Windows Component Location Index 119. Driver's Door (Coupe except DX, HX) Page 7460 1. Remove the terminal. 2. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE E: 1. Remove the terminal. 2. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE F: Page 1104 Page 7807 8. Release the clip, detach the hook, and remove the lock rod protector. 9. Disconnect the outer handle rod and cylinder rod. Description and Operation Barometric Pressure Sensor: Description and Operation Barometric Pressure (BARO) Sensor The BARO sensor is inside the ECM/PCM. It converts atmospheric pressure into a voltage signal that the ECM/PCM uses to modify the basic duration of the fuel injection discharge. Page 5865 Air Conditioning Component Location Index Page 897 Ignition Switch Lock Cylinder: Technical Service Bulletins Ignition Keys Gets Warm While Driving SOURCE: Honda Service News July 2003 TITLE: Ignition Key Gets Warm While Driving APPLIES TO: 2003 Accords, 2001-03 Civics, 2002-03 CR-Vs SERVICE TIP: Are owners of complaining of the ignition key getting warm while driving? The key interlock solenoid in the ignition switch is the likely culprit. This solenoid is energized anytime the shift lever isn't in Park, so the heat from the solenoid gets transferred to the ignition key. This is a normal characteristic of the vehicle, and can't be fixed by replacing the key interlock solenoid, the ignition lockset, or any other component. Page 5123 - Remove clips carefully; don't damage their locks (A). - Slip pliers (A) under the clip base and through the hole at an angle, then squeeze the expansion tabs to release the clip. - After installing harness clips, make sure the harness doesn't interfere with any moving parts. - Keep wire harnesses away from exhaust pipes and other hot parts, from sharp edges of brackets and holes, and from exposed screws and bolts. - Seat grommets in their grooves properly (A). Do not leave grommets distorted (B). Testing and Repairs - Do not use wires or harnesses with broken insulation. Replace them or repair them by wrapping the break with electrical tape. - After installing parts, make sure that no wires are pinched under them. - When using electrical test equipment, follow the manufacturer's instructions and those described. - If possible, insert the probe of the tester from the wire side (except waterproof connector). - Use back probe adaptor 07TAZ-001020A. - Refer to the instructions in the Honda Terminal Kit for identification and replacement of connector terminals. Five-Step Troubleshooting Five-Step Troubleshooting 1. Verify The Complaint Page 6421 Wheel Bearing: Testing and Inspection End Play Inspection 1. Raise the vehicle, and support it with safety stands in the proper locations. Remove the wheels. 2. Install suitable flat washers (A) and wheel nuts, and tighten the nuts to the specified torque to hold the brake disc or drum securely against the hub. 3. Set up the dial gauge against the hub flange as shown, and measure the bearing end play moving the brake disc or drum inward and outward. Bearing end play: Standard: Front/Rear: 0 - 0.05 mm (0 - 0.002 inch) 4. If the bearing end play is more than the standard, replace the wheel bearing. Front Wheelhouse/Damper Housing Front Fender Liner: Service and Repair Front Wheelhouse/Damper Housing Removal Service and Repair Splash Guard: Service and Repair Fuel Pipe Protector Replacement 1. Remove the clips, then remove the fuel pipe protector (A). Take care not to scratch the body. 2. Install the protector in the reverse order of removal, and note these items: - Replace any damaged clips. - Push the clips into place securely. Page 4089 Wire Color Abbreviations Page 5012 Page 9170 158. DRL Relay (Canada); Low Beam Cut Relay ('01-'03 Canada) Locations 12. Middle of Engine Page 9163 208. DRL Control Unit (Canada) Page 2403 Camshaft Position Sensor: Description and Operation Camshaft Position (CMP) Sensor (Top Dead Center (TDC) Sensor) The CMP (TDC) sensor detects the position of the No.1 cylinder as a reference for sequential fuel injection to each cylinder. Body - Trunk Lid Hard to Close Trunk / Liftgate Lock Cylinder: Customer Interest Body - Trunk Lid Hard to Close 02-061 November 5, 2004 Applies To: See VEHICLES AFFECTED Trunk Lid is Difficult to Close (Supersedes 02-061, dated July 23, 2004) Updated information is shown with asterisks. SYMPTOM The trunk lid may be difficult to close or won't latch closed. PROBABLE CAUSE The trunk lid may be misaligned, and the trunk lid opener cable, trunk lid latch, lock cylinder, lock rod, and/or the trunk lid latch striker may need adjustment or replacement. VEHICLES AFFECTED CORRECTIVE ACTION Adjust the trunk lid and/or the trunk lid latch, or replace components as needed. PARTS INFORMATION Page 5013 Transmission Speed Sensor: Diagrams 34. Output Shaft (Countershaft) Speed Sensor (A/T Except CVT) 57. Input Shaft (Mainshaft) Speed Sensor (A/T Except CVT) Page 270 DTC U0100 thru U1288 Disclaimer Locations Under-dash Fuse/Relay Box Page 8987 Key Reminder Switch: Testing and Inspection Ignition Key Switch Test NOTE: For more key-in beeper information, refer to the circuit diagram and input test. When the ignition key is in the ignition switch the multiplex control unit senses ground through the closed ignition key switch. When you open the driver's door, the beeper circuit senses ground through the closed door switch and sounds the beeper. 1. Remove the steering column upper and lower covers. 2. Disconnect the 6P connector. 3. Check for continuity between the No.1 and No.2 terminals. - There should be continuity with the key in the ignition switch. - There should be no continuity with the key removed. 4. If the continuity is not as specified, replace the ignition switch. Page 5006 10. Connect the connector securely, then install the transmission range switch cover. 11. Turn the ignition switch ON (II). Move the shift lever through all gear positions, and cheek the transmission range switch synchronization with the A/T gear position indicator. 12. Allow the wheels to rotate freely, then start the engine. 13. Move the shift lever through all gear positions, and verify the following: ^ The engine will not start in any position other than N or P. ^ The back-up lights come on when the shift lever is in the R position. 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 7054 13. Dispose of the complete airbag. No part of it can be reused. Place it in a sturdy plastic bag (A), and seal it securely. Deploying Airbags/Tensioner (Outside Vehicle) Airbag Disposal Special Tool Required Deployment tool 07HAZ-SG00500 Before scrapping any airbags, side airbags, seat belt tensioners or seat belt buckle tensioners (including those in a whole vehicle to be scrapped), the airbags, side airbags, seat belt tensioners or seat belt buckle tensioners must be deployed. If the vehicle is still within the warranty period, the Honda District Service Manager must give approval and/or special instruction before deploying the airbags, side airbags, seat belt tensioners or seat belt buckle tensioners. Only after the airbags, side airbags, seat belt tensioners or seat belt buckle tensioners have been deployed (as the result of vehicle collision, for example), can they be scrapped. If the airbags, side airbags, seat belt tensioners and seat belt buckle tensioners appear intact (not deployed), treat them with extreme caution. Follow this procedure. Deploying the Components Out of the Vehicle If an intact airbag or tensioner has been removed from a scrapped vehicle, or has been found defective or damaged during transit, storage, or service, it should be deployed as follows: 1. Confirm that the special tool is functioning properly by following the check procedure or on the tool label. 2. Position the airbag face up, outdoors on flat ground at least 30 feet (10 meters) from any obstacles or people. 3. Follow steps 10, 11, and 12 of the in-vehicle deployment procedure. Page 7527 3. Remove the grip cover (A). To remove the passenger's grip cover, refer to rear door panel removal/installation. 1. Using a trim tool, pry out the front edge of the cover to release the clips (B). 2. Pry out along the bottom to release the lower hooks (C). 3. Pry out along the top to release the upper hooks (D), and release the clip (E) by pulling the cover forward. 4. Driver's door: Disconnect the power window switch connector (A) (for some models). Remove the screws from the grip base (B). 5. Remove the mirror mount cover. 6. Release the clips that hold the door panel (A) with a commercially available trim pad remover (B), then remove the door panel by pulling it upward. Passenger's door: Disconnect the power window switch connector (for some models). Remove the door panel with as little bending as possible to avoid creasing or breaking it. 7. Install the door panel in the reverse order of removal, and note these items: - Replace any damaged clips. - Make sure the connectors are plugged in properly, and the rod is connected properly. - Make sure the window and power door locks operate properly. Locations Intake Air System - Component Location Index Page 3265 3. Strip the insulation off the end of the wire so the wire fits in the new terminal as shown. (If the wire has a wire seal, replace it with a new one from the kit.) NOTE: After stripping the end of the wire, make sure you did not cut any wire strands. If you did, cut the wire off even with the insulation, and strip it again. 4. Position the terminal in the crimping tool slot with the solid portion of the terminal toward the anvil and the open section toward the former. 5. Insert the wire in the terminal to the position shown in step 3. 6. Squeeze the tool with both hands until the stops make contact. 7. Crimp the insulation crimp. - If you do not have a wire seal, then use the next larger size crimp slot. Position the crimping tool over the insulation crimp section of the terminal, then squeeze the tool with both hands until the stops make contact. - If you have a wire seal, position the insulation crimp in the 5.5 crimping slot, then carefully squeeze the crimp closed until its ends are touching and making a full-circle shape. 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 8718 Cruise Control Module: Testing and Inspection Cruise Control Unit Input Test Except 2-door D17A1, D17A2 engines: SRS components are located in this area. Review the SRS component locations, precautions, and procedures, in the SRS before performing repairs or service. 1. Remove the driver's dashboard lower cover. 2. Disconnect the 14P connector from the control unit. 3. Inspect the connector and socket terminals to be sure they are all making good contact. - If the terminals are bent, loose, or corroded, repair them as necessary, and recheck the system. - If the terminals look OK, go to step 4. Page 3055 111. ELD Unit (USA) Page 2538 1. Remove the terminal. 2. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE G: 1. Remove the terminal. 2. Go to HOW TO INSTALL NEW TERMINALS. How to Install New Terminals HOW TO INSTALL NEW TERMINALS 1. Carefully match the old terminal with a new one from the terminal repair kit. Choose the correct replacement terminal based on the wire size range the terminal will accommodate. NOTE: If the replacement terminal quantities are low, reorder them by using the terminal part number listed on the inside lid of the terminal repair kit. Replacement terminals are available through your parts department using normal parts ordering procedures. 2. Depending on the size of the wire you are repairing, use the proper size slot in the crimping tool. Service and Repair Hood Latch: Service and Repair Hood Latch Replacement NOTE: - Put on gloves to protect your hands. - Take care not to scratch the body. 1. Remove the bolts, then remove the hood latch (A) from the body. 2. Disconnect the hood opener cable (B) from the hood latch. Take care not to kink the cable. 3. Install the latch in the reverse order of removal, and note these items: - Apply multipurpose grease to the hood latch as indicated by the arrows. - Make sure the hood opener cable is connected properly. Page 2950 DTC P1486 thru P1585 Locations 94. Behind Glove Box (except GX) Page 6760 Air Bag: Service and Repair Side Airbag Spring-Loaded Lock Connector Spring-loaded Lock Connector Some SRS system connectors have a spring-loaded lock. Side Airbag Connector: Disconnecting To release the lock, pull the spring-loaded sleeve (A) and the slider (B) while holding the opposite half of the connector. Then pull the connector halves apart. Be sure to pull on the sleeve and not on the connector half. Connecting Hold both connector halves, and press them firmly together until the projection (C) of the sleeve-side connector clicks. Removal and Installation Side Airbag Replacement NOTE: Review the seat replacement procedure in the body section before performing repair or service. Removal 1. Disconnect the battery negative cable, and wait at least 3 minutes before beginning work. See: Air Bag(s) Arming and Disarming Ignition/Locks - Cutting Sidewinder-Type Keys Technical Service Bulletin # 01-077 Date: 060419 Ignition/Locks - Cutting Sidewinder-Type Keys 01-077 April 19, 2006 Applies To: Models With Sidewinder-Type Keys - All Cutting Sidewinder-Type Keys With the MATRIX H Key Cutting Machine (Supersedes 01-077, dated January 12, 2005) Updated information is noted by asterisks. MATRIX H Key Cutting Machine, manufactured by Silca and supplied by Kaba Ilco Corporation, is a portable, power-operated tool that cuts sidewinder-type automotive keys exclusively. The machine lets you cut these keys either by copying or by code. The code function is designed and built to meet the Honda code requirements. No other similar machine has this capability. This service bulletin gives you information for ordering and servicing this special tool, and guides you through the entire key cutting process from setting up the machine to cutting the key blank. TOOL INFORMATION Order through the Honda Tool and Equipment Program: MATRIX H Key Cutting Machine: Model No. ILCMATRIXSH Cutter Bit: Model No. ILCF3O Fixed Jaw: Model No. ILCMTX-H Mobile Jaw (Right Side): Model No. ILCRTMTX-H Mobile Jaw (Left Side): Model No. ILCLTMTX-H *Remanufactured Clamp Unit: Model No. ILCMATRIXHCR* PARTS INFORMATION *For some models, there are two choices for sidewinder-type key blanks: ^ T-5 sidewinder key blanks ^ Honda sidewinder key blanks For other models, only Honda sidewinder key blanks can be used. See DETERMINING WHICH KEY TO USE to determine which key blank you should choose. Ordering T-5 key blanks through the Honda Tool and Equipment Program: T-5 Programmable Key Blank (Master): P/N ILC-35111-T-5H T-5 Programmable Key Blank (Valet): P/N ILC-35112-T-5H Practice Key Blanks (five per pack): ILC-35111DEMO* NOTE: Do not use practice key blanks for replacement purposes. Practice keys do not have an immobilizer chip. Page 2209 Heater Control Valve Cable: Adjustments Heater Valve Cable Adjustment 1. From under the hood, open the cable clamp (A), then disconnect the heater valve cable (B) from the heater valve arm (C). 2. From under the dash, disconnect the heater valve cable housing from the cable clamp (A), and disconnect the heater valve cable (B) from the air mix control linkage (C). 3. Set the temperature control dial on Max Cool with the ignition switch ON (II). 4. Attach the heater valve cable (B) to the air mix control linkage (C) as shown. Hold the end of the heater valve cable housing against the stop (D), then snap the heater valve cable housing into the cable clamp (A). 5. From under the hood, turn the heater valve arm (C) to the fully closed position as shown, and hold it. Attach the heater valve cable (B) to the heater valve arm, and gently pull on the heater valve cable housing to take up any slack, then install the heater valve cable housing into the cable clamp (A). Electrical - DTC P1298 Stored in ECM/PCM Electric Load Sensor: All Technical Service Bulletins Electrical - DTC P1298 Stored in ECM/PCM 05-006 May 6, 2005 Updated information is noted by asterisks. Applies To: 2001-05 Civic - ALL *2002-04 CR-V - ALL* DTC P1298 Is Stored in the ECM/PCM (Supersedes 05-006, dated February 25, 2005, to change the CR-V model-year range) SYMPTOM DTC P1298 (electrical load detector (ELD) circuit high voltage) is stored in the ECM/PCM. PROBABLE CAUSE The electronic load detector (ELD) has a faulty solder joint. CORRECTIVE ACTION Replace the ELD. NOTE: Previously, if an ELD required replacement, you had to replace the under-hood fuse/relay box. To reduce repair costs, replacement ELDs are now available. PARTS INFORMATION Electronic Load Detector: P/N 38255-S5A-003, H/C 7987571 WARRANTY CLAIM INFORMATION In warranty: The normal warranty applies. Operation Number: 121195 Flat Rate Time: 0.4 hour Failed Part: Civic P/N 38250-S5A-A03 H/C 7472277 CR-V P/N 38250-S9A-A01 H/C 6890594 Defect Code: 06402 Symptom Code: 01201 Template ID: 05-006A 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 199 158. DRL Relay (Canada); Low Beam Cut Relay ('01-'03 Canada) Locations 94. Behind Glove Box (except GX) Page 4344 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 4985 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. How to Replace Connector Terminals Terminal Replacement Procedure HOW TO REPLACE CONNECTOR TERMINALS The terminal repair kits provide necessary tools and materials (terminals, wire seals, and splice connectors) to repair many damaged or faulty connector terminals. However, not all terminals for all connectors are available. Refer to the labels on the lids of the repair kits for replacement terminal availability. IMPORTANT SAFETY INFORMATION: On some models, the SRS wires are in a separate harness. If the SRS harness is damaged, replace the harness; do not repair it. On other models, wire harnesses include yellow SRS wires. If any SRS wire is damaged, replace the entire harness; do not repair it. Before you begin, inspect the wire you are about to repair for damage and length. Make sure the wire will be long enough to make a terminal repair without stretching it when you reinstall the terminal in the connector. If the wire is too short, or if access to the connector is too restricted to make a terminal repair, you may need to install a pigtail terminal (a short length of wire with a factory-crimped terminal on it). Refer to HOW TO INSTALL PIGTAIL TERMINALS. Removing the Terminal Page 8056 13. After completing the right edge, push all of the cam blades to the right until they touch the cams, then trace the cam blades from back to front. (The cutter bit cuts the same contours into the left edge of the key from tip to head.) Turn off the cutter motor. 14. Release the vertical carriage lever. Push all the cam blades to the left until they touch the cams. Pull the vertical carriage lever towards you until the tracer touches the flat surface on the right side, at the front of the cams. Gently twist the lever clockwise to lock the vertical carriage at this height. Do not overtighten the lever. 15. Turn on the cutter motor, then retrace the cam blades from front to back. Push all the cam blades to the right until they touch the cams, and then retrace the cam blades from back to front (retracing cleans up the cuts on the key). Turn off the cutter motor. 16. Release the vertical carriage lever. Open the jaw and remove the key. Make sure the jaw is free of any metal shavings or debris. Turn the key over so the blank side is up, then slide it into the jaw up to the key stop. Close the jaw to lock the key in place. 17. Push all the cam blades to the left until they touch the cams. Repeat steps 10 through 15 to cut both edges on the other side of the key. 18. When you are done making the required cuts, release the vertical carriage lever. Open the jaw and remove the key. 19. Make sure the key works in the ignition switch and the locks. If the key does not work, recut the key, and try it again. 20. Depending on the type of key, code the key transponder. Equipment Service and Warranty To service the MATRIX H Key Cutting Machine, refer to section 7 of the MATRIX H Operating Manual. It tells you how to replace parts that commonly wear out such as the drive belt, the work light bulb, and the tension spring on the vertical carriage. It also covers checking and replacing fuses and replacing the printed circuit board for the setting unit keypad. If you have technical questions on the equipment, contact the Ilco Technical Assistance Department. Mail: Kaba Ilco Technical Assistance Department 400 Jeffreys Road Rocky Mount, NC 27804 Phone: 800-452-6872 Ext: 200, 384, 323, 398, 356 Fax: 252-446-4702 The MATRIX H Key Cutting Machine comes with a 3-year limited warranty. This warranty does not cover the cutter bit or the work light bulb. CODE BOOK CORRECTIONS In the code book Honda High Security key Codes, correct these errors: Pages 4 thru 51, code headings: ^ Incorrect: J H G F Z X E D C B M/S X ^ Correct: J H G F A X E D C B M/S X Page 2, last paragraph: Page 3765 1. Remove and discard the plastic cover from the ignition switch key interlock solenoid. 2. Note the position of the interlock solenoid plunger; you'll need to install it the same way. 3. Remove the screw from the solenoid, but keep the solenoid attached to its electrical connector. Discard the screw. NOTE: ^ Be careful not to lose the solenoid plunger; it slides out easily. ^ Keep the plunger free of dirt and grease while it's removed from the solenoid. 4. Note the position of the interlock lever spring; you'll need to install the new spring the same way. Page 9812 Power Window Switch: Diagrams (Sedan Except DX) (Sedan Except DX) Page 3657 Torque Converter Clutch Solenoid: Testing and Inspection Torque Converter Clutch Solenoid Valve Test 1. Disconnect the torque converter clutch solenoid valve connector. 2. Measure the resistance between the No. 1 and No. 2 terminals of the torque converter solenoid valve connector. STANDARD: 12 - 25 Ohms 3. Replace the torque converter clutch solenoid valve if the resistance is out of standard. 4. If the resistance is within the standard, connect the No. 2 terminal to the battery positive terminal, and connect the No. 1 terminal to the battery negative terminal. A clicking sound should be heard. Replace the torque converter clutch solenoid valve if no sound is heard when connecting the battery positive terminal. Page 5517 136. Brake Pedal Position Switch Page 7610 17. Using a small screwdriver, push down on the tip of the last tumbler to release it, then remove the cylinder from the housing, being careful not to drop any tumblers and springs. Use your thumb and forefinger to hold the tumblers in place. Then go to step 20. 18. While turning the key left and right and pushing on the rear of the inner cylinder to release the spring, slowly remove the cylinder from the housing. Locations Shift Interlock Solenoid: Locations 107. Behind A/T Shift Lever (except M/T) Page 8374 Part 1 5. Reconnect all connections to the under-dash fuse/relay box, and make these input tests at the appropriate connectors on the under-dash fuse/relay box. If any test indicates a problem, find and correct the cause, then recheck the system. - If all the input tests prove OK, go to step 6. Part 2 Page 1832 6. Check the top of the block for warpage. Measure along the edges and across the center as shown. Engine Block Warpage Standard (New): 0.07 mm (0.003 inch) max. Service Limit: 0.10 mm (0.004 inch) 7. Calculate the difference between the cylinder bore diameter and the piston diameter. If the clearance is near or exceeds the service limit, inspect the piston and cylinder block for excessive wear. Piston-to-Cylinder Clearance Standard (New): 0.010 - 0.040 mm (0.0004 - 0.0016 inch) Service Limit: 0.05 mm (0.002 inch) Page 1668 Diodes Light Emitting Diode (LED) Motor Pressure Sensor Page 226 Rear Window Defogger Component Location Index Page 3818 Power Distribution schematics show how power is supplied from the positive battery terminal to various circuits in the vehicle. Refer to the Power Distribution diagram set to get a more detailed understanding of how picture is supplied to the circuit you're working on. Individual circuit schematics begin with a fuse. So 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 Ground Distribution Schematics This sample Ground Distribution schematic shows all of the components that share the same ground point. Page 7859 89. Trunk Latch Switch Antitheft System - Alarm Will Not Arm/Arms By Itself Keyless Entry Transmitter: All Technical Service Bulletins Antitheft System - Alarm Will Not Arm/Arms By Itself 05-025 July 1, 2005 Applies To: 2001-05 Civic - ALL 2002-05 CR-V - ALL 2003-04 Element - ALL Accessory Security System Changes Modes By Itself (Supersedes 05-025, dated June 10, 2005, to update the information indicated by black bars and asterisks.) SYMPTOM The security system will not arm or it arms by itself. PROBABLE CAUSE Key switch contact chatter causes the control unit to change modes. CORRECTIVE ACTION * Civic: Replace the security control unit, and reprogram the remote(s).* * CR-V and Element: Replace the security control unit and the microphone, then reprogram the remote(s).* * NOTE: You must replace the microphone on the CR-V and Element because the security control units are matched to their microphones when they are manufactured. Using the original microphone may result in security system problems.* PARTS INFORMATION WARRANTY CLAIM INFORMATION In warranty: The normal warranty applies. Out of warranty: Any repair performed after warranty expiration may be eligible for goodwill consideration by the District Parts and Service Manager or your Zone Office. You must request consideration, and get a decision, before starting work. REPAIR PROCEDURE NOTE: Before starting, make sure you have all of the remotes (three maximum) the customer wishes to use. Page 8900 Maintenance Required Lamp/Indicator: Service and Repair 1. Turn off the engine. 2. Press and hold the Select/Reset button in the instrument panel, then turn the ignition switch ON (Position II). 3. Hold the button for at least 10 seconds, until the indicator resets. Page 2876 Malfunction Indicator Lamp: Description and Operation Malfunction Indicator Lamp (MIL) Indication (In relation to Readiness Codes) The vehicle has certain "readiness codes" that are part of the on-board diagnostics for the emissions systems. If the vehicle's battery has been disconnected or gone dead, if the DTCs have been cleared, or if the ECM/PCM has been reset, these codes are reset. In some states, part of the emissions testing is to make sure these codes are set to complete. If all of them are not set to complete, the vehicle may fail the test or the test cannot be finished. To check if the readiness codes are set to complete, turn the ignition switch ON (II), but do not start the engine. The MIL will come on for 15 - 20 seconds. If it then goes off, the readiness codes are set. If it blinks several times, one or more readiness codes are not set to complete. To set each code, drive the vehicle or run the engine as described in the procedures to set them in this section. Page 6610 Refrigerant Oil: Fluid Type Specifications Type ................................................................................................................................... SANDEN: SP-10 (P/N 38897-P13-A01AH or 38899-P13-A01) Page 3819 Transmission Position Switch/Sensor: Diagnostic Aids General Troubleshooting Information General Troubleshooting Information Tips and Precautions Before Troubleshooting 1. Check applicable fuses in the appropriate fuse/relay box. 2. Check the battery for damage, state of charge, and clean and tight connections. NOTE: 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. Handling Connectors - Make sure the connectors are clean and have no loose wire terminals. - Make sure multiple cavity connectors are packed with dielectric grease (except watertight connectors). - All connectors have push-down release type locks (A). - Some connectors have a clip on their side used to attach them to a mount bracket on the body or on another component. This clip has a pull type lock. - Some mounted connectors cannot be disconnected unless you first release the lock and remove the connector from its mount bracket (A). - Never try to disconnect connectors by pulling on their wires; pull on the connector halves instead. - Always reinstall plastic covers. Page 3649 23. Transmission Housing (A/T) Capacity Specifications Fluid - M/T: Capacity Specifications M/T Fluid Change ................................................................................................................................................ .............................................................. 1.5L (1.6 Qt) Overhaul .......................................................... ................................................................................................................................................. 1.6L (1.7 Qt) Page 6759 1. Place the new front passenger's airbag (A) into the dashboard. Tighten the front passenger's airbag mounting nuts (B). 2. Connect the front passenger's airbag 4P connector (A) to the dashboard wire harness B, then reinstall the glove box. 3. Reconnect the battery negative cable. 4. After installing the airbag, confirm proper system operation: Turn the ignition switch ON (II); the SRS indicator should come on for about 6 seconds and then go off. Locations Transmission Position Switch/Sensor: Locations Component Location Index, A/T Front Door Glass Outer Weatherstrip Replacement Front Door Window Glass Weatherstrip: Service and Repair Front Door Glass Outer Weatherstrip Replacement Front Door Glass Outer Weatherstrip Replacement 4-door NOTE: - Put on gloves to protect your hands. - Take care not to scratch the door. 1. Remove the mirror. 2. Starting at the rear, pry the door glass outer weatherstrip (A) up to detach the clips (B, C), then remove the weatherstrip. 3. Install the weatherstrip in the reverse order of removal, and replace any damaged clips. Testing and Inspection Wiper Control Module: Testing and Inspection Control Unit Input Test 1. Before testing, troubleshoot the multiplex control system. 2. Remove the dashboard lower cover. 3. Disconnect the under-dash fuse/relay box connectors B, G, J, X and Y. NOTE: All connectors are wire side of female terminals. 4. Inspect the connector and socket terminals to be sure they are all making good contact. - If the terminals are bent, loose or corroded, repair them as necessary, and recheck the system. - If the terminals are OK, go to step 5. 5. Reconnect the connectors, and make these input tests at the connector. - If any test indicates a problem, find and correct the cause, then recheck the system. Page 8222 1. Check the depth adjustment of the trunk lid: ^ Refer to page 20-132 of the 2001-04 Civic Service Manual. ^ In ISIS, use the keyword TRUNK ADJUST, and select Trunk Lid Adjustment from the list. 2. Make sure the trunk lid is flush on all sides and corners. ^ If the trunk is misaligned, go to step 3. ^ If the trunk lid is properly aligned on all sides and corners, go to REPAIR PROCEDURE C. 3. Adjust the striker depth position and the trunk lid edge cushions: ^ Refer to page 20-132 of the 2001-04 Civic Service Manual. ^ In ISIS, use the keyword TRUNK ADJUST, and select Trunk Lid Adjustment from the list. 4. Check the trunk operation: ^ If the trunk opens and closes smoothly, return the vehicle to the customer. ^ If the trunk lid is still difficult to close, go to REPAIR PROCEDURE C. REPAIR PROCEDURE C 1. Use a small screwdriver to manually set and release the trunk lid latch. Check the operation of the latch: ^ If the latch is difficult to set or release, go to step 2. ^ If the latch operates properly, go to REPAIR PROCEDURE D. 2. Replace the trunk lid latch: ^ Refer to page 20-157 of the 2001-04 Civic Service Manual. ^ In ISIS, use the keyword LID LATCH, and select Trunk Lid Latch Replacement from the list. 3. Check the trunk operation: ^ If the trunk opens and closes smoothly, return the vehicle to the customer. ^ If the trunk lid is still difficult to close, go to REPAIR PROCEDURE D. REPAIR PROCEDURE D 1. Disconnect the trunk lid opener cable from the trunk lid latch. Check the cable operation: ^ Refer to page 20-157 of the 2001-04 Civic Service Manual. ^ In ISIS, use the keyword LID LATCH, and select Trunk Lid Latch Replacement from the list. 2. Check that there is no friction or binding of the cable by holding the outside casing and pulling back and forth on the inner cable: ^ If the cable is difficult to move or binds, go to step 3. ^ If the cable operates smoothly, go to REPAIR PROCEDURE E. 3. Replace the trunk lid opener cable: ^ Refer to page 20-151 of the 2001-04 Civic Service Manual. ^ In ISIS, use the keyword LID OPEN, and select Trunk Lid Opener/Fuel Fill Door Opener Cable Replacement from the list. 4. Check the trunk operation: Page 8169 Keyless Entry Transmitter: Testing and Inspection Transmitter Test NOTE: - If the doors unlock or lock with the transmitter, but the LED on the transmitter does not come on, the LED is faulty; replace the transmitter. - If any door is open, you cannot lock the door with the transmitter. - If you unlocked the doors with the transmitter, but do not open any of the doors within 30 seconds, the doors relock automatically. - The doors do not lock or unlock with the transmitter if the ignition key is inserted in the ignition switch. 1. Press the lock or unlock button 5 or 6 times to reset the transmitter. - If the locks work, the transmitter is OK. - If the locks don't work, go to step 2. 2. Open the transmitter and check for water damage. - If you find any water damage, replace the transmitter. - If there is no water damage, go to step 3. 3. Replace the transmitter battery (A) with a new one, and try to lock and unlock the doors with the transmitter by pressing the lock or unlock button 5 or 6 times. If the doors lock and unlock, the transmitter is OK. - If the doors don't lock and unlock, go to step 4. 4. Reprogram the transmitter, then try to lock and unlock the doors. - If the doors lock and unlock, the transmitter is OK. - If the doors don't lock and unlock, replace the transmitter. Page 7688 WARRANTY CLAIM INFORMATION In warranty: The normal warranty applies. Failed Part: P/N 68500-S5P-A90ZZ H/C 6528640 *Defect Code: 07406* Symptom Code: 03220 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 A 1. Check the side-to-side alignment of the trunk lid latch to the striker: ^ Refer to page 20-132 of the 2001-04 Civic Service Manual. ^ In ISIS, use the keyword TRUNK ADJUST, and select Trunk Lid Adjustment from the list. 2. Make sure the gaps of the trunk lid are even on all sides. ^ If the trunk is misaligned, go to step 3. ^ If the trunk lid is properly aligned on all sides, go to REPAIR PROCEDURE B. 3. Adjust the trunk lid hinges: ^ Refer to page 20-132 of the 2001-04 Civic Service Manual. ^ In ISIS, use the keyword TRUNK ADJUST, and select Trunk Lid Adjustment from the list. 4. Check the trunk operation: ^ If the trunk opens and closes smoothly and is properly aligned, return the vehicle to the customer. ^ If the trunk lid is still difficult to close, go to REPAIR PROCEDURE B. REPAIR PROCEDURE B Page 8380 165. Moonroof Close And Open Relay (EX) Page 8866 2. Remove the access panel from the steering wheel, then disconnect the driver's airbag 4P connector (A) from the cable reel. Front Passenger's Airbag 3. Lower the glove box, then disconnect the front passenger's airbag 4P connector (A) from the dashboard wire harness B. Side Airbag 4. Disconnect both side airbag 2P connectors (A) from the floor wire harness. Seat Belt Tensioner 5. Disconnect both seat belt tensioner 2P connectors (A) from the floor wire harness. Seat Belt Buckle Tensioner Page 3485 Main Relay (Computer/Fuel System): Description and Operation PGM-FI Main Relay 1 and 2 The PGM-FI relay consists of two separate relays. PGM-FI main relay 1 is energized whenever the ignition switch is ON (II) which supplies battery voltage to ECM/PCM, power to the injectors, and power for PGM-FI main relay 2. PGM-FI main relay 2 is energized to supply power to the fuel pump for 2 seconds when the ignition switch is turned ON (II), and when the engine is running. Page 2805 Idle Speed/Throttle Actuator - Electronic: Description and Operation Idle Air Control (IAC) Valve To maintain the proper idle speed, the IAC valve changes the amount of air bypassing the throttle body in response to an electrical signal from the ECM/PCM. Page 5965 Under-dash Fuse/Relay Box (2-door) Page 2946 DTC P0563 thru P0748 Front Seat Cover Replacement Seat Cover: Service and Repair Front Seat Cover Replacement Front Seat Cover Replacement For some models: SRS components are located in this area. Review the SRS component locations and the precautions and procedures before performing repairs or service. NOTE: - Take care not to tear the seams or damage the seat covers. - On the passenger's seat with side airbag, do not touch the OPDS sensor in the seat-back pad, and keep it away from oil. Oil can corrode the sensor causing it to fail. - Put on gloves to protect your hands. Seat-back Cover 1. Remove the front seat. 2. Remove the headrest. 3. Driver's seat: If equipped, remove the armrest. 4. With side airbag: From under the seat cushion, detach the side airbag connector clip (A), and on the passenger's seat, detach the OPDS unit connector clip (B). Release the hook springs (C), then pull the harness guide (D) back. The passenger's seat is shown, the driver's seat is symmetrical except it has no OPDS unit connector. 5. Fold the seat-back forward. 6. Without side airbag: Release the hook (A), and fold back the seat-back cover (B). Master Switch Test/Replacement Power Window Switch: Testing and Inspection Master Switch Test/Replacement Master Switch Test/Replacement 4-door 1. Remove the door grip cover. 2. Disconnect the 20P connector from the power window master switch. Page 3950 14. After finishing the updating procedure, the MVCI gives you the option of updating the same system on another vehicle. For more information on updating several vehicles, see the MVCI User Guide. 15. If an error occurs during the updating procedure, an error message appears. Keep the ignition switch in ON (II). Press ENTER to display the error code. Refer to the CM Update Error Code Table in the MVCI User Guide for more information about the code and its solutions.* UPDATING WITH THE GNA600 NOTE: For more information on the GNA6OO, refer to the GNA600 User's Guide. This guide is on ISIS, under the Tool Information heading. Two modes of updating can be used with the GNA600: Pass-Thru mode and Storage mode. Use Pass-Thru mode when the GNA6OO can be connected to an iN workstation and the vehicle at the same time. Use Storage mode when the GNA6OO cannot be connected to the iN workstation and the vehicle at the same time. GNA600 Updating in Pass-Thru Mode 1. If not already done, load the latest HDS PC software onto your iN workstation. For loading instructions, refer to the Tool Information publication Installation Instructions for HDS PC Software on ISIS. Page 2316 DTC P1586 thru P1678 Page 3609 Ignition Switch Lock Cylinder: Technical Service Bulletins Ignition Keys Gets Warm While Driving SOURCE: Honda Service News July 2003 TITLE: Ignition Key Gets Warm While Driving APPLIES TO: 2003 Accords, 2001-03 Civics, 2002-03 CR-Vs SERVICE TIP: Are owners of complaining of the ignition key getting warm while driving? The key interlock solenoid in the ignition switch is the likely culprit. This solenoid is energized anytime the shift lever isn't in Park, so the heat from the solenoid gets transferred to the ignition key. This is a normal characteristic of the vehicle, and can't be fixed by replacing the key interlock solenoid, the ignition lockset, or any other component. Page 6687 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". Locations Turn Signal/Hazard Flasher Component Location Index Locations Crankshaft Position Sensor: Locations PGM-FI System - Component Location Index Page 1078 Use the tools from Pin Tool Set. First, check the connector that you are about to repair. - If it has a secondary terminal lock, go to Connectors With a Secondary Lock. A secondary lock, found on most connectors on some models, is an additional locking device on the connector housing as a backup for the primary lock on the terminal. - If the connector does not have a secondary lock, go to Connectors Without a Secondary Lock. Connectors With a Secondary Lock All examples are shown with the connector lock facing up. The illustrations are examples of the secondary terminal locks; however, the connector you are repairing may vary in size. Identify the connector by the type of secondary lock, not by the number of terminal cavities. EXAMPLE A: 1. Release the secondary lock. 2. Remove the terminal. 3. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE B: Page 7827 13. After completing the right edge, push all of the cam blades to the right until they touch the cams, then trace the cam blades from back to front. (The cutter bit cuts the same contours into the left edge of the key from tip to head.) Turn off the cutter motor. 14. Release the vertical carriage lever. Push all the cam blades to the left until they touch the cams. Pull the vertical carriage lever towards you until the tracer touches the flat surface on the right side, at the front of the cams. Gently twist the lever clockwise to lock the vertical carriage at this height. Do not overtighten the lever. 15. Turn on the cutter motor, then retrace the cam blades from front to back. Push all the cam blades to the right until they touch the cams, and then retrace the cam blades from back to front (retracing cleans up the cuts on the key). Turn off the cutter motor. 16. Release the vertical carriage lever. Open the jaw and remove the key. Make sure the jaw is free of any metal shavings or debris. Turn the key over so the blank side is up, then slide it into the jaw up to the key stop. Close the jaw to lock the key in place. 17. Push all the cam blades to the left until they touch the cams. Repeat steps 10 through 15 to cut both edges on the other side of the key. 18. When you are done making the required cuts, release the vertical carriage lever. Open the jaw and remove the key. 19. Make sure the key works in the ignition switch and the locks. If the key does not work, recut the key, and try it again. 20. Depending on the type of key, code the key transponder. Equipment Service and Warranty To service the MATRIX H Key Cutting Machine, refer to section 7 of the MATRIX H Operating Manual. It tells you how to replace parts that commonly wear out such as the drive belt, the work light bulb, and the tension spring on the vertical carriage. It also covers checking and replacing fuses and replacing the printed circuit board for the setting unit keypad. If you have technical questions on the equipment, contact the Ilco Technical Assistance Department. Mail: Kaba Ilco Technical Assistance Department 400 Jeffreys Road Rocky Mount, NC 27804 Phone: 800-452-6872 Ext: 200, 384, 323, 398, 356 Fax: 252-446-4702 The MATRIX H Key Cutting Machine comes with a 3-year limited warranty. This warranty does not cover the cutter bit or the work light bulb. CODE BOOK CORRECTIONS In the code book Honda High Security key Codes, correct these errors: Pages 4 thru 51, code headings: ^ Incorrect: J H G F Z X E D C B M/S X ^ Correct: J H G F A X E D C B M/S X Page 2, last paragraph: Page 7081 WARRANTY CLAIM INFORMATION Out of warranty: Any repairs to the SRS system for problems other than the 15-1, 15-2, and 15-3 DTCs that are done 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. INSPECTION PROCEDURE NOTE: ^ When you check for SRS DTCs with the HDS, codes other than 15-1, 15-2, and 15-3 are not covered by this warranty extension bulletin. ^ If the vehicle is covered by warranty, repair it using the normal warranty repair procedures. If the vehicle's warranty is expired, give your customer an estimate for the cost of the repair. Do the appropriate inspection, based on the DTC. SRS DTC 15-1 Clear the DTC with the HDS. ^ If DTC 15-1 does not set again, go to REPAIR PROCEDURE A: OPDS UNIT REPLACEMENT. ^ If DTC 15-1 sets again, continue with normal troubleshooting. ^ If the OPDS unit causes DTC 15-1 to set repeatedly, yet passes the other troubleshooting steps, go to REPAIR PROCEDURE A: OPDS UNIT REPLACEMENT. SRS DTC 15-2 1. Inspect the connections and the wiring in the side airbag cutoff indicator circuit. ^ If all the connections and the wiring are OK, go to step 2. ^ If any of the connections or the wiring are faulty, repair the circuit, then go to step 2. 2. Clear the DTC with the HDS. ^ If DTC 15-2 does not set again, go to REPAIR PROCEDURE A: OPDS UNIT REPLACEMENT. ^ If DTC 15-2 sets again, continue with normal troubleshooting. ^ If the OPDS unit causes DTC 15-2 to set repeatedly, yet passes the other troubleshooting steps, go to REPAIR PROCEDURE A: OPDS UNIT REPLACEMENT. SRS DTC 15-3 1. Clear the DTC with the HDS. ^ If DTC 15-3 does not set again, go to step 2. ^ If DTC 15-3 sets again, continue with normal troubleshooting. 2. Ask your customer if electrical devices such as a laptop computer or a fluorescent map light are ever used near the front passenger's seat-back. (Some electrical devices that plug into the vehicle's accessory power socket, especially those using a power inverter/converter, can interfere with the seat-back sensors and cause SRS DTC 15-3 to set.) ^ If your customer uses any of these devices operate the device near the front passenger's seat-back. If DTC 15-3 sets again, clear it, then return the vehicle to the customer. Advise the customer to avoid using the device near the front passenger's seat-back. ^ If your customer does not use any of these devices and DTC 15-3 does not set again, go to REPAIR PROCEDURE A: OPDS UNIT REPLACEMENT. REPAIR PROCEDURE A: OPDS UNIT REPLACEMENT Page 7855 ^ If the trunk opens and closes smoothly, return the vehicle to the customer. ^ If the trunk lid is still difficult to close, go to REPAIR PROCEDURE E. REPAIR PROCEDURE E 1. Look at the back of the lock cylinder while you turn the key from lock to unlock. ^ Refer to page 20-158 of the 2001-04 Civic Service Manual. ^ In ISIS, use the keyword LID LOCK, and select Trunk Lid Lock Cylinder Replacement from the list. 2. Check the operation of the trunk lid lock cylinder: ^ If the lock cylinder is difficult to turn or binds, go to step 3. ^ If the lock cylinder operates properly, and the trunk lid is still difficult to close, refer to the appropriate body repair manual, and check for body inaccuracies. 3. Replace the lock cylinder, and re-key the cylinder to the customer's original key; on 2-door Civics, replace the lock cylinder and the lock cylinder rod: ^ Refer to page 20-158 of the 2001-04 Civic Service Manual. ^ In ISIS, use the keyword LID LOCK, and select Trunk Lid Lock Cylinder Replacement from the list. 4. Check the trunk operation, and return the vehicle to the customer. Disclaimer Page 4343 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 9658 8. Put the splice connector in the proper size slot in the Crimper Tool, slide it to one end (where the flare begins), and close the crimper handles far enough to hold it in place. To release the ratchet mechanism at any point after the first click, squeeze the handles slightly and push the release lever, then let the handles open. 9. Insert one of the bare wires into the splice connector end that is in the crimper jaws. Push the wire all the way into the splice connector, and squeeze the crimper handles. Keep squeezing until the jaws touch, and hold it at that position until the ratchet clicks again. 10. Crimp the other wire in the same way into the other end of the splice connector. 11. After crimping, gently pull on the wires in the opposite directions to make sure they are secure in the connector. 12. Separate the other wires in the harness from the repaired wire(s), and shield them with nonflammable material. Page 5879 Relay Box: Connector Locations Under-dash Fuse/Relay Box Page 2166 1. Remove the terminal. 2. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE G: 1. Remove the terminal. 2. Go to HOW TO INSTALL NEW TERMINALS. How to Install New Terminals HOW TO INSTALL NEW TERMINALS 1. Carefully match the old terminal with a new one from the terminal repair kit. Choose the correct replacement terminal based on the wire size range the terminal will accommodate. NOTE: If the replacement terminal quantities are low, reorder them by using the terminal part number listed on the inside lid of the terminal repair kit. Replacement terminals are available through your parts department using normal parts ordering procedures. 2. Depending on the size of the wire you are repairing, use the proper size slot in the crimping tool. Locations Wheel Speed Sensor: Locations 145. Right Side Of Floor (EX) 159. Left Side Of Engine Compartment Locations Control Module: Locations Electronic Controls Location Page 6550 Evaporator Temperature Sensor / Switch: Testing and Inspection Evaporator Temperature Sensor Test 1. Dip the sensor in ice water, and measure the resistance between its terminals. 2. Then pour hot water on the sensor, and check for a change in resistance, 3. Compare the resistance readings with the specifications shown in the graph; the resistance should be within the specifications. Page 1014 Skill Level: Repair Technician INSPECTION PROCEDURE 1. Remove the steering column covers. Refer to section 17 of the appropriate service manual. 2. On the lower side of the ignition switch, look at the interlock cylinder cover: ^ If the cover is square, the ignition switch was already replaced with an updated part, and a key interlock repair kit is not needed. Go to step 3. ^ If the cover is round, go to REPAIR PROCEDURE. 3. Reinstall the steering column covers. 4. Center-punch a completion mark above the seventh character of the engine compartment VIN. REPAIR PROCEDURE Page 1684 2. Remove the terminal from the female half. 3. Remove the terminal from the male half. 4. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE D: 1. Remove the secondary locks. Page 2338 ECM/PCM Inputs And Outputs At Connector A (31P) Page 8360 Mixing Ratio: Drying Time: 2. Sanding filler Spray the bumper primer on the area where the PP material was used. 3. Primer surfacer The primer surfacer is used to protect the PP resin surface and fill cavities or flaws before the intermediate coat and top coat. Use the 2-component type primer surfacer (gray). Mixing Ratio: 4. Intermediate coat and top coat Use the 2-part polyester urethane top coat. Top coat is also used for an intermediate coat. Mixing Ratio: NOTE: Be sure to mix the correct amount of the hardener and softener. Page 7222 Programming the Transmitter NOTES: ^ The system accepts up to three transmitters. The transmitter codes are stored in a stacking-type memory. If a fourth transmitter code is programmed, the code for the first transmitter is erased. ^ Entering the programming mode cancels all learned transmitter codes, so none of the previously programmed transmitters will work. You must reprogram all of the transmitters once you are in the programming mode. ^ You must complete steps 1-6 within 4 seconds of the previous step to keep the system from exiting the programming mode. 1. Turn the ignition switch to ON (II). 2. Press the "Lock" or "Unlock" button on one of the transmitters. (An unprogrammed transmitter can be used for this step.) 3. Turn the ignition switch to LOCK (0). 4. Repeat steps 1, 2, and 3 two more times using the same transmitter used in step 2. 5. Turn the ignition switch to ON (II). 6. Press the "Lock" or "Unlock" button on the same transmitter. Make sure the power door locks cycle to confirm that the system is in programming mode. 7. Within 10 seconds, press the "Lock" or "Unlock" button on each transmitter. Make sure the power door locks cycle after you press each transmitter button to confirm that the system accepted the transmitter's code. 8. Turn the ignition switch to LOCK (0) to exit the programming mode. Ordering a Transmitter Transmitters can be ordered only by authorized Honda dealers. Order them from American Honda using normal parts ordering procedures. Batteries for the Transmitter The battery number is CR2025. Each transmitter uses one battery. 88-91 Prelude With Dealer-Installed Security System 1988-91 Prelude with dealer-installed security system Page 8915 58. Check for continuity between ECM/PCM connector terminal A21 and body ground. Is there continuity? YES - Repair short in the wire between the ECM/PCM (A21) and the MAP sensor, CVT driven pulley speed sensor (CVT), or CVT speed sensor 1 (CVT). NO - Update the ECM/PCM if it does not have the latest software, or substitute a known-good ECM/PCM, then recheck. If the symptom/indication goes away with a known-good ECM/PCM, replace the original ECM/PCM. 59. Measure voltage between body ground and ECM/PCM connector terminal A20. Is there about 5 V? YES - Go to step 66. NO - Go to step 60. 60. Turn the ignition switch OFF. 61. Disconnect the 3P connector from each of these sensors, one at a time, and measure voltage between body ground and ECM/PCM connector terminal A20 with the ignition switch ON (II). Exhaust gas recirculation (EGR) valve position sensor - Knock sensor - Throttle position (TP) sensor - CVT drive pulley speed sensor (CVT) - CVT speed sensor 2 (CVT) Is there about 5 V? Page 9618 Relay And Control Unit Locations - Dashboard Page 4389 1. Remove the terminal. 2. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE E: 1. Remove the terminal. 2. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE F: Technician Safety Information Air Bag(s) Arming and Disarming: Technician Safety Information Technician Safety Information Page 2828 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 Short Circuit Locator (Short Finder) 1. Remove the blown fuse. Leave the battery connected. Locations 21. Transmission Housing (A/T) Locations Camshaft Position Sensor: Locations PGM-FI System - Component Location Index Component Locations 105. Left B-pillar (right similar) Page 6107 ^ 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 6207 Power Steering Pressure Switch: Service and Repair Power Steering Hoses, Lines, and Pressure Switch Replacement Note these items during installation: ^ Connect each hose to the corresponding line securely until it contacts the stop on the line. Install the clamp or adjustable clamp at the specified distance from the hose end as shown. ^ Check all clamps for deterioration or deformation; replace the clamps with new ones, if necessary. ^ Add the recommended power steering fluid to the specified level on the reservoir and check for leaks. Page 5365 Resistor Variable Sensor Solenoid Transistors Circuit Schematics Page 5875 1. Right Side Of Engine Compartment Page 7771 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. Obtain the customer's key code from the iN (Key Code Inquiry). Refer to the Honda High Security key Codes book that comes with the Matrix H key cutting machine. Write down the applicable cutting code for the key code number. Make sure the corrections to the code book listed in Service Bulletin 01-077, Cutting Sidewinder-Type keys With the Matrix H key Cutting Machine, have been made. 2. Use the chart shown to write down the numbers found in the key code book. 3. Remove the door panel. Refer to the appropriate service manual or use ISIS keyword Door Panel. 4. Remove the plastic cover as necessary. 5. Raise the window glass fully. 6. Remove the lock cylinder. ^ For Civic, go to step 7. ^ For CR-V, go to step 8. ^ For Element, go to step 11. 7. Pull down on the retainer clip with a hook-shaped tool. Remove the lock cylinder and disconnect the cylinder rod. Then go to step 14. Page 8338 Vehicle Identification Number - U.S Model 2-door Page 5796 234. Under-dash Fuse/Relay Box Part 6 Page 6093 ^ 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 8985 55. In Steering Column Cover Page 9655 3. Strip the insulation off the end of the wire so the wire fits in the new terminal as shown. (If the wire has a wire seal, replace it with a new one from the kit.) NOTE: After stripping the end of the wire, make sure you did not cut any wire strands. If you did, cut the wire off even with the insulation, and strip it again. 4. Position the terminal in the crimping tool slot with the solid portion of the terminal toward the anvil and the open section toward the former. 5. Insert the wire in the terminal to the position shown in step 3. 6. Squeeze the tool with both hands until the stops make contact. 7. Crimp the insulation crimp. - If you do not have a wire seal, then use the next larger size crimp slot. Position the crimping tool over the insulation crimp section of the terminal, then squeeze the tool with both hands until the stops make contact. - If you have a wire seal, position the insulation crimp in the 5.5 crimping slot, then carefully squeeze the crimp closed until its ends are touching and making a full-circle shape. Page 5885 234. Under-dash Fuse/Relay Box Part 4 Page 1540 Under-dash Fuse/Relay Box Page 5996 3. Remove the terminal from the male half. 4. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE D: 1. Remove the secondary locks. 2. Remove the terminal (same procedure for male and female). 3. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE E: Locations Fuel Supply System - Component Location Index SRS Unit Replacement Air Bag Control Module: Service and Repair SRS Unit Replacement SRS Unit Replacement Removal 1. Disconnect the battery negative cable, and wait at least 3 minutes before beginning work. 2. Disconnect the driver's and front passenger's airbag connectors. 3. Disconnect the side airbag connectors. 4. Disconnect both seat belt tensioner connectors and both seat belt buckle tensioner connectors. 5. Remove the dashboard center lower cover. 6. Pull down the carpet, then remove the Torx bolt (A) from the SRS unit. 7. Disconnect the connectors and remove the two Torx bolts (A), then pull out the SRS unit. Installation 1. Install the new SRS unit (A) with Torx bolts (B), then connect the connectors (C) to the SRS unit; push it into position until it clicks. NOTE: When tightening the Torx bolts to the specified torque after replacement, be careful to turn them in so that their heads rest squarely on the Page 2179 Radiator Cooling Fan Motor Relay: Testing and Inspection Power Relay Test Use this chart to identify the type of relay, then do the test listed for it. NOTE: See the turn signal/hazard relay input test. Normally-open type A: Page 7066 Impact Sensor: Service and Repair Side Impact Sensor Side Impact Sensor Replacement Removal NOTE: - Removal of the side impact sensor must be performed according to the precautions/procedures described before. - Before disconnecting the side impact sensor 2P connector(s), disconnect the side airbag 2P connector(s). - Do not turn the ignition switch ON (II), and do not connect the battery cable while replacing the side impact sensor. 1. Disconnect the battery negative cable, and wait at least 3 minutes before beginning work. 2. 2-door: Slide the front seat forward. 4-door: Remove the seat assembly. 3. 2-door: Remove the rear seat-backs and rear seat cushion. 4-door: Remove the B-pillar lower trim panel. 4. 2-door: Remove the front seat belt lower anchor slide bar. 5. 2-door: Remove the side trim panel. 6. 2-door: Remove the middle cross-member gusset. 7. Disconnect the floor wire harness 2P connector (A) from the side impact sensor (B). 8. Remove the Torx bolt (C) using a Torx T30 bit, then remove the side impact sensor (B). Installation NOTE: - Be sure to install the harness wires so that they are not pinched or interfering with other parts. - Do not turn the ignition switch ON (II), and do not connect the battery cable while replacing the side impact sensor. 1. Install the new side impact sensor with a new Torx bolt (A) then connect the floor wire harness 2P connector (B) to the side impact sensor (C). 2. Reconnect the battery negative cable. 3. After installing the side impact sensor, confirm proper system operation: Turn the ignition switch ON (II): the SRS indicator should come on for about 6 seconds and then go off. 4. Install all remove parts. Page 1093 Transmission Position Switch/Sensor: Electrical Diagrams Circuit Diagram Page 176 Use the tools from Pin Tool Set. First, check the connector that you are about to repair. - If it has a secondary terminal lock, go to Connectors With a Secondary Lock. A secondary lock, found on most connectors on some models, is an additional locking device on the connector housing as a backup for the primary lock on the terminal. - If the connector does not have a secondary lock, go to Connectors Without a Secondary Lock. Connectors With a Secondary Lock All examples are shown with the connector lock facing up. The illustrations are examples of the secondary terminal locks; however, the connector you are repairing may vary in size. Identify the connector by the type of secondary lock, not by the number of terminal cavities. EXAMPLE A: 1. Release the secondary lock. 2. Remove the terminal. 3. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE B: Page 428 Power Windows Component Location Index Page 8760 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. Test Equipment 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. Diagram Information and Instructions Brake Lamp: Diagram Information and Instructions Terminal Numbering System Terminal Numbering System Connector terminals are numbered according to the cavities they're in. The cavities are numbered starting from the upper left, looking at the male terminals from the terminal side or looking at the female terminals from the wire side. Both views are in the same direction so the numbers are the same. All actual cavities are numbered, even if they have no wire terminals in them. NOTE: Data Link Connector (DLC) terminals are numbered according 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 below is #6. Page 7821 NOTE: You need to make the corrections listed in CODE BOOK CORRECTIONS at the end of this service bulletin. TRACER AND CUTTER BIT INSTALLATION 1. Turn the power switch on the back of the machine to ON. (This turns on the built-in work light.) 2. Use the Allen wrench from the built-in tool drawer to loosen the setscrew on the left sleeve of the vertical carriage. Slide the tracer all the way into the sleeve, and tighten the screw. 3. Turn the plastic shield on the right sleeve of the vertical carriage so you can access the setscrew on the sleeve. Use the Allen wrench to loosen the screw. Slide the cutter bit all the way into the sleeve, and tighten the screw. Turn the plastic shield so the open side is in the back. MACHINE COMPONENTS Page 2429 7. Remove the four screws that hold the two fuses, and remove the fuses. 8. Release the tab that holds the ELD, and pull up on the ELD to remove it. 9. Remove the bus bar from the ELD, and insert the bar into the new ELD. 10. Install the new ELD and bus bar into the fuse/relay box. 11. Reinstall the two fuses. 12. Reinstall the 3P ELD connector and the lower fusel relay box cover. 13. Reinstall the fuse/relay box onto its holder. CR-V only: Reinstall the wire harness clip onto the holder. 14. Reinstall the fuse/relay box cover. 15. Reconnect the negative battery cable. 16. Do the idle learn procedure: ^ Make sure all electrical items (A/C, audio unit, defogger, lights, etc.) are off. Page 4847 6. Replace the 1st/2nd synchro hub/sleeve, and reassemble the countershaft; see page 13-34 (13-48 for Hybrid) of the service manual. 7. Check the countershaft clearance; see page 13-30 (13-44 for Hybrid) of the service manual. Page 1830 Piston: Testing and Inspection Inspection 1. Remove the crankshaft and pistons 2. Check the piston for distortion or cracks. 3. Measure the piston diameter at a point 13 mm (0.5 inch) from the bottom of the skirt. Piston Diameter Standard (New): 74.98 - 74.99 mm (2.9520 - 2.9524 inch) Service Limit: 74.97 mm (2.9516 inch) Oversize Piston Diameter 0.25: 75.23 - 75.24 mm (2.9618 - 2.9622 inch) 0.50: 75.48 - 75.49 mm (2.9716 - 2.9720 inch) Front Page 82 Relay And Control Unit Locations - Dashboard Coupe Front Door Latch: Service and Repair Coupe Door Latch Replacement 2-door NOTE: Put on gloves to protect your hands. 1. Raise the glass fully. 2. Remove these items: - Door panel - Plastic cover, as necessary 3. Pull the glass run channel (A) away as necessary, and remove the bolt, then remove the center lower channel (B) by pulling it downward. 4. Disconnect the cylinder rod from the lock cylinder, and disconnect the outer handle rod from the outer handle. 5. Remove the screw, and release the clip (A) and hook (B) while pulling the cable protector (C) forward, then remove it from the latch (D) and door. Automatic Transmission Shift Indicator: Locations Automatic Transmission Component Location Index Page 6859 7. Connect the SCS service connector to the 2P MES (memory erase signal) connector, as shown. Do not use a jumper wire. 8. Turn the ignition switch to ON (II). 9. Watch the SRS indicator. (It comes on for about 6 seconds and then goes off.) Disconnect the SCS service connector from the MES connector within 4 seconds after the indicator goes off. 10. When the SRS indicator comes on again, connect the SCS service connector to the MES connector within 4 seconds after the indicator comes on. 11. When the SRS indicator goes off, disconnect the SCS service connector from the MES connector within 4 seconds. Page 1549 234. Under-dash Fuse/Relay Box Part 7 Page 281 ECM/PCM Inputs And Outputs At Connector C (22P) Page 3809 Wire Color Abbreviations Page 5286 107. Behind A/T Shift Lever (except M/T) Locations 44. Behind A/C Condenser Fan Motor Page 1605 52. Measure voltage between body ground and ECM/PCM connector terminal A21. Is there about 5 V? YES - Go to step 59. NO - Go to step 53. 53. Turn the ignition switch OFF. 54. Disconnect the 3P connector from each of these sensors, one at a time, and measure voltage between body ground and ECM/PCM connector terminal A21 with the ignition switch ON (II). Manifold absolute pressure (MAP) sensor - CVT driven pulley speed sensor (CVT) - CVT speed sensor 1 (CVT) Is there about 5 V? YES - Replace the sensor that restored 5 V when disconnected. NO - Go to step 55. 55. Turn the ignition switch OFF. 56. Disconnect the 3P connector from the following sensors. - Manifold absolute pressure (MAP) sensor - CVT driven pulley speed sensor (CVT) - CVT speed sensor 1 57. Disconnect ECM/PCM connector A (31P). Page 4286 ^ The vehicle is shown as eligible on a VIN status inquiry. In addition, check for a punch mark above the seventh character of the engine compartment VIN. A punch mark in that location means the ignition switch key interlock has already been inspected/repaired. 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 a VIN status inquiry before selling it. CUSTOMER NOTIFICATION All owners of affected vehicles will be sent a notification of this campaign. An example of the customer notification is at the end of this service bulletin. CORRECTIVE ACTION Inspect the ignition switch and, if needed, install a Key Interlock Repair Kit. PARTS INFORMATION Key Interlock Repair Kit: P/N 06351-SDA-000 REQUIRED SPECIAL TOOLS Interlock Slide Hammer: T/N 07AAC-S84A100 NOTE: ^ An initial quantity of Permalube grease to lubricate the sliding surface of the interlock lever is included with the slide hammer. To order more Permalube, use P/N 08734-0030. ^ To order a replacement clamping bolt for the slide hammer, use T/N 07AAC-S84A400. WARRANTY CLAIM INFORMATION Failed Part: P/N 35100-SDA-A31 Defect Code: 5GC00 Symptom Code: R4400 Page 3419 Fuel Line Coupler: Service and Repair Fuel Line/Quick-Connect Fitting Precaution The fuel line/quick-connect fittings connect the fuel rail (A) to fuel feed line (B), the fuel feed line (B) to the fuel pipe (C), and the fuel line (D) to the fuel tank unit (E). When removing or installing the fuel feed hose, fuel tank unit or fuel tank, it is necessary to disconnect or connect the quick-connect fittings. Pay attention to the following: - The fuel feed hose (B), fuel line (D), and quick-connect fittings (E) are not heat-resistant; be careful not to damage them during welding or other heat-generating procedures. - The fuel feed hose (B), fuel line (D), and quick-connect fittings (E) are not acid-proof; do not touch them with a shop towel used for wiping battery electrolyte. Replace them if they came into contact with electrolyte or something similar. - When connecting or disconnecting the fuel feed hose (B), fuel line (D), and quick-connect fittings (E), be careful not to bend or twist them excessively. Replace them if they are damaged. A disconnected quick-connect fitting can be reconnected, but the retainer on the mating line cannot be reused once it has been removed from the line. Page 2054 Use the tools from Pin Tool Set. First, check the connector that you are about to repair. - If it has a secondary terminal lock, go to Connectors With a Secondary Lock. A secondary lock, found on most connectors on some models, is an additional locking device on the connector housing as a backup for the primary lock on the terminal. - If the connector does not have a secondary lock, go to Connectors Without a Secondary Lock. Connectors With a Secondary Lock All examples are shown with the connector lock facing up. The illustrations are examples of the secondary terminal locks; however, the connector you are repairing may vary in size. Identify the connector by the type of secondary lock, not by the number of terminal cavities. EXAMPLE A: 1. Release the secondary lock. 2. Remove the terminal. 3. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE B: Locations Cruise Control Switch: Locations Cruise Control Component Location Index Page 5922 2. Remove the terminal (same procedure for male and female). 3. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE E: 1. Remove the secondary locks. 2. Remove the terminal (same procedure for male and female). 3. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE F: Page 6680 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. SRS Unit, Front Sensors and Side Impact Sensors SRS Unit, Front Sensors and Side Impact Sensors Be careful not to bump or impact the SRS unit, front sensors, or the side impact sensors whenever the ignition switch is ON (II), or for at least 3 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, front sensors, and the side impact sensor. The airbags could accidentally deploy and cause damage or injury. After a collision in which any airbags or seat belt tensioners were deployed, replace the SRS unit, front sensors, and other related components. After a collision in which a side airbag was deployed, replace the side impact sensor on the deployed side 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, front sensors, 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 3 minutes before beginning installation or replacement of the SRS unit, or disconnecting 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 N.m (1.0 kgf.m, 7.2 lbf.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 °G) and dry (less than 80% relative humidity, no moisture) area. Wiring Precautions Wiring Precautions SRS wiring can be identified by special yellow outer covering (except the SRS indicator light circuit). Page 4401 Transmission Position Switch/Sensor: Service and Repair Transmission Range Switch Replacement 1. Raise the vehicle, and make sure it is securely supported. 2. Shift to the N position. 3. Remove the transmission range switch cover (A). 4. Disconnect the transmission range switch connector (B). 5. Remove the old transmission range switch, and install the new switch. 6. Make sure that the control shaft is in the N position. If necessary, move the shift lever to the N position. Page 5703 Relay And Control Unit Locations - Dashboard Mechanical Specifications Thermostat: Mechanical Specifications THERMOSTAT REPLACEMENT Page 7564 5. Remove the screws securing the latch (A), then move the latch down. Take care not to bend any of the rods. 6. Remove the nuts securing the outer handle (A) and outer handle protector (B). 7. Remove the outer handle protector (A) from the outer handle (B). Page 7007 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 6120 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 2214 Heating Component Location Index Page 7253 Programming the Transmitter This transmitter is not programmable. Ordering a Transmitter This transmitter is no longer available. Batteries for the Transmitter The battery number is CR2025. Each transmitter uses two batteries. 97-99 EV Plus With Factory-Installed Security System 1997-99 EV Plus with factory-installed security system Programming the Transmitter NOTES: ^ The system accepts up to three transmitters. The transmitter codes are stored in a stacking-type memory. If a fourth transmitter code is programmed, the code for the first transmitter is erased. ^ Entering the programming mode cancels all learned transmitter codes, so none of the previously programmed transmitters will work. You must reprogram all of the transmitters once you are in the programming mode. ^ You must complete steps 1-6 within 4 seconds of the previous step to keep the system from exiting the programming mode. 1. Turn the ignition switch to ON (II). 2. Press the "Lock" or "Unlock" button on one of the transmitters. (An unprogrammed transmitter can be used for this step.) 3. Turn the ignition switch to LOCK (0). 4. Repeat steps 1, 2, and 3 two more times using the same transmitter used in step 2. 5. Turn the ignition switch to ON (II). 6. Press the "Lock" or "Unlock" button on the same transmitter. Make sure the power door locks cycle to confirm that the system is in programming mode. 7. Within 10 seconds, press the "Lock" or "Unlock" button on each transmitter. Make sure the power door locks cycle after you press each transmitter button to confirm that the system accepted the transmitter's code. 5. Turn the ignition switch to LOCK (0) to exit the programming mode. Ordering a Transmitter Transmitters can be ordered only through Tech Line. Batteries for the Transmitter The battery number is CR2025. Each transmitter uses one battery. 00-04 Insight With Factory-Installed Keyless Entry System 2000-04 Insight with factory-installed keyless entry system Page 9111 Brake Light Switch: Description and Operation Brake Pedal Position Switch The brake pedal position switch signals the ECM/PCM when the brake pedal is pressed. Page 269 DTC P2240 thru U0073 Page 1138 Transmission Speed Sensor: Locations 25. Transmission Housing (CVT) 26. Transmission Housing (CVT) Page 9834 Power Window Switch: Service and Repair Passenger's Window Switch Test/Replacement Passenger's Window Switch Test/Replacement 4-door 1. Remove the door grip cover. 2. Disconnect the 5P connector (A) from the passenger's power window switch (B). 3. Check for continuity between the terminals in each switch position according to the table. 4. If the continuity is not as specified, remove the two screws and replace the switch. 2-door Connector Views 161. Fuel Tank Unit (except GX) Locations Transmission Position Switch/Sensor: Locations Component Location Index, A/T Page 4498 Clutch Release Bearing: Service and Repair Flywheel Replacement Clutch Replacement Special Tools Required ^ Clutch alignment shaft 07LAF-PT00110 ^ Clutch alignment disc 07JAF-PM7011A ^ Remover handle 07936-3710100 ^ Ring gear holder 07LAB-PV00100 or 07924-PD20003 ^ Attachment, 57 x 40 mm 07746-0010200 ^ Driver 077 49-0010000 Flywheel Replacement NOTE: Do not disassemble the flexible plate from the flywheel. 1. Install the special tool. 2. Remove the flywheel mounting bolts in a crisscross pattern in several steps, then remove the flywheel. 3. Remove the pilot bearing (A) from the flywheel (B). 4. Drive the new bearing into the flywheel using the special tools as shown. Apply a light coat of oil to the outside of the bearing surface. Page 4403 10. Connect the connector securely, then install the transmission range switch cover. 11. Turn the ignition switch ON (II). Move the shift lever through all gear positions, and cheek the transmission range switch synchronization with the A/T gear position indicator. 12. Allow the wheels to rotate freely, then start the engine. 13. Move the shift lever through all gear positions, and verify the following: ^ The engine will not start in any position other than N or P. ^ The back-up lights come on when the shift lever is in the R position. Page 7809 13. Push the top of the retainer clip with a flat-tip screwdriver, and hold it. Release the retainer clip with a hook-shaped tool, then remove the lock cylinder. Go to step 14. 14. With the door lock cylinder out of the door handle remove the E-clip and the arm. 15. Try to insert the key into the cylinder and turn it. ^ If you can insert and turn the key, go to step 18. ^ If you cannot insert the key or turn it, go to step 16. 16. Carefully remove the spring and plastic retainer. Page 939 Page 9490 - Before connecting connectors, make sure the terminals (A) are in place and not bent. - Check for loose retainer (A) and rubber seals (B). - The backs of some connectors are packed with dielectric grease. Add grease if necessary. If the grease is contaminated, replace it. - Insert the connector all the way and make sure it is securely locked. - Position wires so that the open end of the cover faces down. Handling Wires and Harnesses - Secure wires and wire harnesses to the frame with their respective wire ties at the designated locations. Page 4051 Control Module: Service and Repair How to Substitute the PCM How to Substitute the PCM 1. Remove the PCM from the vehicle. 2. Install a known-good PCM in the vehicle. 3. Rewrite the immobilizer code with the PCM replacement procedure in the Honda PGM Tester; It allows you to start the engine. 4. After completing your tests, reinstall the original PCM and rewrite the immobilizer code with the PCM replacement procedure in the HDS Tester again. Page 1744 Connectors - "C" Page 5363 Terminals - "T" Shielding Switches Fuses Service and Repair Fuel Pressure Release: Service and Repair Fuel Pressure Relieving Before disconnecting fuel lines or hoses, relieve pressure from the system by disconnecting the fuel tube/quick connect fitting in the engine compartment. 1. Make sure you have the antitheft code for the radio, then write down the frequencies for the radio's preset buttons. 2. Turn the ignition switch OFF. 3. Remove the glove box, then remove the PGM-FI main relay 2 (A). 4. Start the engine, and let it idle until it is stalls. NOTE: The DTCs or Temporary DTCs P0301, P0302, P0303, P0304 may come on during this procedure. If any DTCs are stored, ignore them. 5. Turn the ignition switch OFF. 6. Remove the fuel fill cap to relieve fuel pressure in the fuel tank. 7. Disconnect the negative cable from the battery. 8. Remove the bolt (A) and the fuel feed pipe mounting bracket (B), then remove the quick-connect fining covers (C). 9. Check the fuel quick-connect fitting for dirt, and clean if necessary. 10. Place a rag or shop towel over the quick-connect fitting (D). Page 2957 Engine Control Module: Locations Multiplex Control System Component Location Index Page 9493 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 Locater) 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. Troubleshooting Precautions Troubleshooting Precautions Before Troubleshooting 1. Check the main fuse and the fuse 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, or you will damage the alternator diodes. - Do not attempt to crank the engine with the ground cable disconnected 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. Page 9521 158. DRL Relay (Canada); Low Beam Cut Relay ('01-'03 Canada) Page 504 Braking Sensor/Switch: Adjustments Brake Pedal and Brake Pedal Position Switch Adjustment Pedal Height 1. Disconnect the brake pedal position switch connector, turn the brake pedal position switch (A) counterclockwise and pull it back until it is no longer touching the brake pedal. 2. Lift up the carpet (B). At the insulator cutout, measure the pedal height (C) from the middle of the right side of the pedal pad (D). Standard Pedal Height (with carpet removed): M/T: 184 mm (7 4/16 inch) A/T: 188 mm (7 6/16 inch) 3. Loosen the pushrod locknut (A), and screw the pushrod in or out with pliers until the standard pedal height from the floor is reached. After adjustment, tighten the locknut firmly. Do not adjust the pedal height with the pushrod pressed. Pedal Free Play Page 3599 Technical Service Bulletin # 01-077 Date: 060419 Ignition/Locks - Cutting Sidewinder-Type Keys 01-077 April 19, 2006 Applies To: Models With Sidewinder-Type Keys - All Cutting Sidewinder-Type Keys With the MATRIX H Key Cutting Machine (Supersedes 01-077, dated January 12, 2005) Updated information is noted by asterisks. MATRIX H Key Cutting Machine, manufactured by Silca and supplied by Kaba Ilco Corporation, is a portable, power-operated tool that cuts sidewinder-type automotive keys exclusively. The machine lets you cut these keys either by copying or by code. The code function is designed and built to meet the Honda code requirements. No other similar machine has this capability. This service bulletin gives you information for ordering and servicing this special tool, and guides you through the entire key cutting process from setting up the machine to cutting the key blank. TOOL INFORMATION Order through the Honda Tool and Equipment Program: MATRIX H Key Cutting Machine: Model No. ILCMATRIXSH Cutter Bit: Model No. ILCF3O Fixed Jaw: Model No. ILCMTX-H Mobile Jaw (Right Side): Model No. ILCRTMTX-H Mobile Jaw (Left Side): Model No. ILCLTMTX-H *Remanufactured Clamp Unit: Model No. ILCMATRIXHCR* PARTS INFORMATION *For some models, there are two choices for sidewinder-type key blanks: ^ T-5 sidewinder key blanks ^ Honda sidewinder key blanks For other models, only Honda sidewinder key blanks can be used. See DETERMINING WHICH KEY TO USE to determine which key blank you should choose. Ordering T-5 key blanks through the Honda Tool and Equipment Program: T-5 Programmable Key Blank (Master): P/N ILC-35111-T-5H T-5 Programmable Key Blank (Valet): P/N ILC-35112-T-5H Practice Key Blanks (five per pack): ILC-35111DEMO* NOTE: Do not use practice key blanks for replacement purposes. Practice keys do not have an immobilizer chip. Page 4990 1. Remove the secondary locks. 2. Remove the terminal from the female half. 3. Remove the terminal from the male half. 4. Go to HOW TO INSTALL NEW TERMINALS. Connectors Without a Secondary Lock All examples are shown with the connector lock facing up. The illustrations are examples of connector terminals without a secondary lock; however, the connector you are repairing may vary in size and shape. EXAMPLE A: Front Wheel Bearing: Service and Repair Front Knuckle/Hub/Wheel Bearing Replacement Special Tools Required Hub dis/assembly tool 07GAF-SE00100 - Ball joint remover, 28 mm 07MAC-SL00200 - Attachment 62 x 68 mm 07746-0010500 - Driver 07749-0010000 - Support base 07965-SD90100 1. Raise the front of the vehicle, and support it with safety stands in the proper locations. 2. Remove the wheel cap, wheel nuts, and front wheel. Service and Repair Differential: Service and Repair Component Location Index Backlash Inspection 1. Install both axles in the differential, and place the differential assembly on V-blocks (A). 2. Check the backlash of the pinion gears (B) with a dial indicator (C). STANDARD: 0.08 - 0.15 mm (0.003 - 0.006 inch) 3. If the backlash is out of standard, replace the differential carrier. Differential Carrier/Final Driven Gear Replacement Page 8693 3. Disconnect the 12P connector from the cruise control actuator. 4. Remove the three mounting bolts, and remove the cruise control actuator. 5. Install the reverse order of removal, and adjust the free play at the throttle linkage after connecting the actuator cable. Page 7890 3. Using an O-ring pick or similar tool, pull up the outer edge of the molding, and apply 3M Black Super Silicone Sealant under it, along the A-pillars and the upper edge of the windshield. 4. Push down on the molding, and smooth it out until it sits flush with the roof. 5. Wait 5 minutes, then remove the masking tape. 6. Clean up any excess sealant with 3M General Purpose Adhesive Cleaner. Disclaimer Immobilizer Control Unit-Receiver Alarm System Transmitter: Service and Repair Immobilizer Control Unit-Receiver Immobilizer Control Unit-Receiver Replacement 1. Remove the dashboard lower cover. 2. Remove the steering column covers. 3. Disconnect the 7P connector (A) from the immobilizer control unit-receiver (B). 4. Remove the two screws and the immobilizer control unit-receiver from the ignition key cylinder (c). 5. Install the immobilizer control unit-receiver in the reverse order of removal. 6. After replacement, rewrite the unit with a Honda PGM Tester, then check the immobilizer system. Page 8079 6. Disconnect the M, P, K, and J connectors from the under-dash fuse/relay box, and make these input tests at the connectors. - If any test indicates a problem, find and correct the cause, then recheck the system. - If all the input tests prove OK, the multiplex control unit must be faulty. Replace the under-dash fuse/relay box assembly. Page 8704 Cruise Control Switch: Diagrams 139. Cruise Control Set/Resume/Cancel Switch (except DX) 157. Cruise Control Main Switch (except DX) Diagrams 71. Security LED Connector (Honda Accessory) Page 3956 3. Turn the ignition switch to ON (II), and connect the DLC cable to the vehicle's DLC. In the Updating Honda Control Modules screen, click on the check mark. Each updatable vehicle system is checked to make sure it is current. Any systems needing an update are listed on the screen. Highlight the system you want to update, then click on the check mark to continue. NOTE: Update the Systems one at a time. 4. Verify that the Program ID and the Program Part No. are correct, then click on the check mark. Page 6123 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 6701 Page 8166 96-97 Passport With Dealer-Installed Security System 1996-97 Passport with dealer-installed security system NOTES: ^ The system uses a stacking-type memory that accepts up to two transmitters. If you program a third transmitter, the memory for the first transmitter is pushed out, and it will no longer work. ^ To clear a lost or stolen transmitter from the system's memory, program a transmitter two times. This will remove the missing transmitter from memory, since only two transmitter codes can be accepted. ^ Another way to clear a lost or stolen transmitter is to erase all transmitter codes and then reprogram them. To do this, refer to the security system owner's manual. Programming the Transmitter 1. Move the driver's seat forward. Locate the security system control unit mounted on the floor underneath the seat. 2. Turn the ignition switch to ON. 3. Use a pen or pencil to press and hold the green programming button on the side of the control unit. When the security system LED on the instrument panel comes on, release the programming button. (Steps 3 and 4 must be done within 5 seconds of each other.) 4. Press and release the top button on the transmitter. Verify that the LED goes out, the siren chirps once, and the front sidemarker lights flash to confirm that the transmitter's code was accepted by the control unit. 5. Turn the ignition switch to LOCK, then to ON. Page 2783 Engine Control Module: Testing and Inspection How to Troubleshoot Circuits At the ECM/PCM How to Troubleshoot Circuits at the ECM/PCM Special Tools Required - Digital Multimeter KS-AHM-32-003 (1) or a commercially available digital multimeter - Backprobe Set 07SAZ-001000A (2) 1. Connect the backprobe adapters (A) to the stacking patch cords (B), and connect the cords to a digital multimeter (C). 2. Using the wire insulation as a guide for the contoured tip of the backprobe adapter, gently slide the tip into the connector from the wire side until it touches the end of the wire terminal. 3. If you cannot get to the wire side of the connector or the wire side is sealed (A), disconnect the connector and probe the terminals (B) from the terminal side. Do not force the probe into the connector. NOTE: Do not puncture the insulation on a wire. Punctures can cause poor or intermittent electrical connections. Page 8379 138. Rear Of Roof (EX) Page 7609 13. Push the top of the retainer clip with a flat-tip screwdriver, and hold it. Release the retainer clip with a hook-shaped tool, then remove the lock cylinder. Go to step 14. 14. With the door lock cylinder out of the door handle remove the E-clip and the arm. 15. Try to insert the key into the cylinder and turn it. ^ If you can insert and turn the key, go to step 18. ^ If you cannot insert the key or turn it, go to step 16. 16. Carefully remove the spring and plastic retainer. Page 3601 NOTE: You need to make the corrections listed in CODE BOOK CORRECTIONS at the end of this service bulletin. TRACER AND CUTTER BIT INSTALLATION 1. Turn the power switch on the back of the machine to ON. (This turns on the built-in work light.) 2. Use the Allen wrench from the built-in tool drawer to loosen the setscrew on the left sleeve of the vertical carriage. Slide the tracer all the way into the sleeve, and tighten the screw. 3. Turn the plastic shield on the right sleeve of the vertical carriage so you can access the setscrew on the sleeve. Use the Allen wrench to loosen the screw. Slide the cutter bit all the way into the sleeve, and tighten the screw. Turn the plastic shield so the open side is in the back. MACHINE COMPONENTS Page 1524 Air Conditioning Component Location Index Page 727 PGM-FI System - Component Location Index Page 5368 Power Distribution schematics show how power is supplied from the positive battery terminal to various circuits in the vehicle. Refer to the Power Distribution diagram set to get a more detailed understanding of how picture is supplied to the circuit you're working on. Individual circuit schematics begin with a fuse. So 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 Ground Distribution Schematics This sample Ground Distribution schematic shows all of the components that share the same ground point. Page 6785 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 3448 Fuel Line Inspection Part 2 Fuel Line Inspection Check the fuel system lines, hoses, and fuel filter for damage, leaks, and deterioration. Replace any damaged parts. Page 7107 104. In Front Passenger's or Passenger's Seat Fuel System - FTP Sensor Diagnostics/DTC P0497 Fuel Tank Pressure Sensor: Technical Service Bulletins Fuel System - FTP Sensor Diagnostics/DTC P0497 How to Tell a Bad FTP Sensor From an EVAP Leak Troubleshooting a '01-05 Civic with DTC P0497 (EVAP system low purge flow)? When the fuel tank pressure (FTP) sensor doesn't respond to vacuum testing, it's really easy to think you've got a leak in the FVAP system. Here's an simple way to tell if the problem is just a bad FTP sensor or an actual system leak: 1. Connect the HDS to the 16P DLC. Turn the ignition switch to ON (II). Turn on the HDS. 2. At the screen prompts, enter the VIN (if you're asked) and the odometer reading. 3. From the Select Mode screen, select Honda Systems. From the System Selection Menu, select PGM-FI. From the Mode Menu, select All Data List. 4. Disconnect the two FTP sensor vacuum lines. Look at the FTP Sensor value on the display screen. ^ If the value reads between 2.45 and 2.55 volts, go to step 6. ^ If the value doesn't read between 2.45 and 2.55 volts, check the electrical connections. If you find any problems, fix them, then go to step 5. If the circuits are OK, replace the FTP sensor, then go to step 5. 5. Look at the FTP Sensor value on the display screen. ^ If the value now reads between 2.45 and 2.55 volts, reconnect the vacuum lines and disconnect the HDS. Return the vehicle to your customer. ^ If the value still doesn't read between 2.45 and 2.55 volts, go to step 6. 6. Connect a vacuum pump to the larger FTP sensor hose (the smaller hose is the FTP vent) Slowly squeeze the pump handle to pull a vacuum on the FTP sensor. Look at the sensor value on the display screen. ^ If the value changes, continue troubleshooting for DTC P0497. ^ If the value stays the same, the FTP sensor has a leak. Replace the sensor. Page 5893 Relay Box: Service and Repair Removal and Installation SRS components are located in this area. Review the SRS component locations and precautions and procedures in the SRS section before performing repairs or service. Removal 1. Make sure you have the anti-theft code for the radio, then write down the frequencies for the radio's preset buttons. 2. Disconnect the battery negative cable, then disconnect the positive cable, and wait at least 3 minutes. 3. Remove the dashboard lower cover. 4. Disconnect the connectors from the fuse side of the under-dash fuse/relay box. 5. Remove the mounting bolt and slide the under-dash fuse/relay box (A) down from the bracket (B). 6. Disconnect the connectors from the back side of the under-dash fuse/relay box, and remove the fuse/relay box. NOTE: The SRS connector is a spring-loaded lock type. Installation 1. Install the under-dash fuse/relay box in the reverse order of removal and connect all connectors to the under-dash fuse/relay box. 2. Install the dashboard lower cover. 3. Connect both the negative cable and positive cable to the battery. 4. Enter the anti-theft code for the radio, then enter the customer's radio station presets. 5. Confirm that all systems work properly. 6. Do the ECM/PCM idle learn procedure. Page 6143 Alignment: Specifications Trim Height Honda Motor Company does not list ride height/trim height specifications. Page 3816 Circuit Schematics Each schematic represents one circuit. A circuit's wires and components are arranged to show current flow from power at the top of the diagram 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 Page 874 Camshaft Position Sensor: Service and Repair CMP (TDC) Sensor Replacement 1. Remove the grommet (A) from the upper cover, and disconnect the camshaft position (CMP) (top dead center (TDC)) sensor connector (B). 2. Remove the upper cover (C). 3. Remove the CMP (TDC) sensor from the cylinder head. 4. Install the CMP (TDC) sensor in reverse order of removal. Page 5247 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. Circuits must be operating when checking voltage drop. 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. 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 off, 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 Self-Powered Test Light or DVOM 1. Remove the blown fuse and disconnect the battery and load. Page 9805 Power Window Switch: Locations Relay And Control Unit Locations - Door, Roof And Seat Page 8231 Disclaimer Technical Service Bulletin # 02-061 Date: 041105 Body - Trunk Lid Hard to Close 02-061 November 5, 2004 Applies To: See VEHICLES AFFECTED Trunk Lid is Difficult to Close (Supersedes 02-061, dated July 23, 2004) Updated information is shown with asterisks. SYMPTOM The trunk lid may be difficult to close or won't latch closed. PROBABLE CAUSE The trunk lid may be misaligned, and the trunk lid opener cable, trunk lid latch, lock cylinder, lock rod, and/or the trunk lid latch striker may need adjustment or replacement. VEHICLES AFFECTED CORRECTIVE ACTION Adjust the trunk lid and/or the trunk lid latch, or replace components as needed. PARTS INFORMATION Page 7236 Service and Repair Cowl Moulding / Trim: Service and Repair Cowl Cover Replacement 1. Remove the windshield wiper arms. 2. Using a clip remover, detach the clips (A), then remove the hood rear seal (B), and detach the clips (C) from the cowl covers. Take care not to scratch the cowl covers. 3. Detach the clip (D) or clip (E), and clips (F, G), and release the hook (H) by carefully pulling the passenger's cowl cover (I) upward, and pull the cover forward to release the hooks (J), then remove the cover. Take care not to scratch the body. 4. Detach the clips (D) or clips (E), and clips (F, G) by carefully pulling the driver's cowl cover (K) upward, and pull the cover forward to release the hooks (L), then remove the cover. Take care not to scratch the body. 5. Install the cover in the reverse order of removal, and note these items: - Replace any damaged clips. - Push the clip portions into place securely. Page 4879 Flat Rate Time: 4.0 hours Failed Part: P/N 24230-PLW-000 H/C 6568653 Defect Code: 042 Contention Code: B07 Template ID: 03-009A (DX, LX, EX) 03-009B (HX) 03-009C (Hybrid) 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. * Remove the transmission. See page 13-4 of the 2001-2003 Civic Service Manual; for the Hybrid, see page 13-18. Then remove the housing. See page 13-16 of the 2001-2003 Civic Service Manual; for the Hybrid, see page 13-32.* 2. * Remove the reverse idler shaft and the reverse idler gear; discard the gear. See page 13-17 (13-32 for Hybrid) of the service manual.* Page 1637 3. Remove the hub cap (A), raise the stake (B), and remove the spindle nut (C). 4. Screw two 8 x 1.25 mm bolts (A) into the drum to push it away from the hub. Turn each bolt 2 turns at a time to prevent cocking the drum excessively. 5. Remove the brake drum (A), and remove the hub bearing unit (B) from the spindle. If the brake drum has stuck to the hub bearing unit, pull them out together. Do not tap on the aluminum brake drum. 6. Install the hub bearing unit in the reverse order of removal, and note these items: - Tighten all mounting hardware to the specified torque values. - Before installing the brake drum, clean the mating surface of the hub and the inside of the brake drum. - Use a new spindle nut on reassembly. - Before installing the spindle nut, apply a small amount of engine oil to the seating surface of the nut. After tightening, use a drift to stake the spindle nut shoulder against the spindle. - Use a new hub cap on reassembly. - Before installing the wheel, clean the mating surface of the brake drum and the inside of the wheel. Page 3697 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. Below most connector numbers and component names are PHOTO and VIEW numbers. The PHOTO number refers to a photo in the back of the book that shows the connector's location on the car. The VIEW number refers to an illustration in the back of the book that shows the connector terminals, wire colors, connector cavity numbers, and other details. The connector cavity numbering sequence begins at the top left corner of the connector as seen from either of the viewpoints shown on diagram [8] . Except for the DLC (data link 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 C554, for example, means those terminals join in cavity 2 of connector C554. Power Distribution Schematics Power Distribution Schematics Page 5555 9. Open the jaws with the jaws knob, and slide the original key with its flat side down into the center jaw up to the key stop. Slide the key blank with its flat side down into the right jaw up to the key stop. Close the jaws with the jaws knob to lock the keys into place. Visually inspect both keys for proper alignment in the jaws. 10. Loosen the lateral and spring tension adjustment knobs on the clamp carriage. With the clamp carriage lever, adjust the clamp carriage to position the tracer and the cutter bit over the middle of the two locked key blades. Tighten only the spring tension knob when done. NOTE: The clamp carriage has a spring system that puts lateral pressure on the tracer and cutting bit to make it easier to cut sidewinder-type keys. Do not tighten the lateral tension adjustment knob. This knob should be left loose. 11. Turn on the cutter motor with the motor start switch. [NOTICE] ^ To avoid damaging the locking jaws while cutting, keep your hand off the vertical carriage lever. Pressure on the lever will change the cutting depth. * ^ To avoid breaking the cutter bit, never back up while cutting.* ^ Wear proper eye protection (safety glasses, goggles, etc.) Page 9021 1. Remove the secondary lock from the male terminal half. 2. Remove the secondary lock from the female terminal half. 3. Remove the terminal (same procedure for male and female). 4. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE C: 1. Remove the secondary lock. Page 9457 159. Fog Light Relays 1 And 2 (Honda Accessory) Page 6500 Compressor Clutch: Service and Repair Compressor Clutch Overhaul Special Tool Required A/C clutch holder, Robinair 10204, Kent-Moore J37872, or Honda Tool and Equipment KMT-J33939, commercially available 1. Remove the center nut (A) while holding the armature plate with a commercially available A/C clutch holder (B). 2. Remove the armature plate (A) and shim(s) (B), taking care not to lose the shim(s). If the clutch needs adjustment, increase or decrease the number and thickness of shims as necessary, then reinstall the armature plate, and recheck its clearance. NOTE: The shims are available in four thickness: 0.1 mm, 0.2 mm, 0.4 mm, and 0.5 mm. 3. If you are replacing the field coil, remove the snap ring (A) with snap ring pliers, then remove the rotor pulley (B). Be careful not to damage the rotor pulley or the compressor. Locations 94. Behind Glove Box (except GX) Page 3586 Camshaft Position Sensor: Service and Repair CMP (TDC) Sensor Replacement 1. Remove the grommet (A) from the upper cover, and disconnect the camshaft position (CMP) (top dead center (TDC)) sensor connector (B). 2. Remove the upper cover (C). 3. Remove the CMP (TDC) sensor from the cylinder head. 4. Install the CMP (TDC) sensor in reverse order of removal. Page 5496 9. Remove the brake booster (A) from the engine compartment. 10. Install the brake booster in the reverse order of removal, and note these items: ^ Adjust the pushrod clearance before installing the brake booster. ^ Use a new clip whenever installing. ^ After installing the brake booster and master cylinder, fill the reservoir with new brake fluid, bleed the brake system, and adjust the brake pedal height and free play. Page 7799 1. Check the depth adjustment of the trunk lid: ^ Refer to page 20-132 of the 2001-04 Civic Service Manual. ^ In ISIS, use the keyword TRUNK ADJUST, and select Trunk Lid Adjustment from the list. 2. Make sure the trunk lid is flush on all sides and corners. ^ If the trunk is misaligned, go to step 3. ^ If the trunk lid is properly aligned on all sides and corners, go to REPAIR PROCEDURE C. 3. Adjust the striker depth position and the trunk lid edge cushions: ^ Refer to page 20-132 of the 2001-04 Civic Service Manual. ^ In ISIS, use the keyword TRUNK ADJUST, and select Trunk Lid Adjustment from the list. 4. Check the trunk operation: ^ If the trunk opens and closes smoothly, return the vehicle to the customer. ^ If the trunk lid is still difficult to close, go to REPAIR PROCEDURE C. REPAIR PROCEDURE C 1. Use a small screwdriver to manually set and release the trunk lid latch. Check the operation of the latch: ^ If the latch is difficult to set or release, go to step 2. ^ If the latch operates properly, go to REPAIR PROCEDURE D. 2. Replace the trunk lid latch: ^ Refer to page 20-157 of the 2001-04 Civic Service Manual. ^ In ISIS, use the keyword LID LATCH, and select Trunk Lid Latch Replacement from the list. 3. Check the trunk operation: ^ If the trunk opens and closes smoothly, return the vehicle to the customer. ^ If the trunk lid is still difficult to close, go to REPAIR PROCEDURE D. REPAIR PROCEDURE D 1. Disconnect the trunk lid opener cable from the trunk lid latch. Check the cable operation: ^ Refer to page 20-157 of the 2001-04 Civic Service Manual. ^ In ISIS, use the keyword LID LATCH, and select Trunk Lid Latch Replacement from the list. 2. Check that there is no friction or binding of the cable by holding the outside casing and pulling back and forth on the inner cable: ^ If the cable is difficult to move or binds, go to step 3. ^ If the cable operates smoothly, go to REPAIR PROCEDURE E. 3. Replace the trunk lid opener cable: ^ Refer to page 20-151 of the 2001-04 Civic Service Manual. ^ In ISIS, use the keyword LID OPEN, and select Trunk Lid Opener/Fuel Fill Door Opener Cable Replacement from the list. 4. Check the trunk operation: Page 1359 Drive Belt: Adjustments Alternator - A/C Compressor Belt Inspection and Adjustment Alternator - A/C Compressor Belt Inspection and Adjustment Special Tools Required Belt tension gauge 07JGG-001010A Belt Tension Gauge Method Inspection 1. Attach the belt tension gauge to the belt and measure the tension. Follow the gauge manufacturer's instructions. If the belt is worn or damaged, replace it. If the belt needs adjustment, go to step 2. Adjustment 2. Loosen the mounting bolt (A), lock bolt (B) and lower bracket mounting bolt (C). 3. Torque the mounting bolt to 20 N.m (2.0 kgf.m, 14 lbf.ft). 4. Turn the adjusting bolt (D) to obtain the proper belt tension, then retighten the lock bolt, mounting bolt and lower bracket mounting bolt. 5. Recheck the belt tension. 6. If you installed a new belt, run the engine for 5 minutes, then readjust the belt to the used belt specification. 7. Check the power steering pump belt adjustment. Deflection Method Inspection Page 8933 consideration by the District Parts and Service Manager or your Zone Office. You must request consideration, and get a decision, before starting work. WARRANTY MILEAGE CONVERSION NOTE: Follow normal warranty claim coding when submitting a claim. SERVICE BULLETINS AFFECTED BY EXTENDED MILEAGE COVERAGE Disclaimer Page 8986 Technician Safety Information Air Bag(s) Arming and Disarming: Technician Safety Information Technician Safety Information Page 7289 2. Remove the terminal from the female half. 3. Remove the terminal from the male half. 4. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE D: 1. Remove the secondary locks. Page 9617 Under-dash Fuse/Relay Box Page 2449 163. Under Left Side Of Floor (except GX) Page 384 7. From the Mode menu, select Miscellaneous Test. 8. From the Miscellaneous Test menu, select OPDS Initialization. 9. Follow the remaining screen prompts to complete the OPDS initialization. If the initialization fails repeat the process two more times. If the initialization fails again, check for SRS DTCs, then troubleshoot them using the appropriate service manual. Initializing the OPDS Unit: Manual Mode NOTE: Non-Honda seat covers will interfere with the performance of the OPDS and are not recommended. 1. Adjust the front passenger's seat-back to an upright position, then remove anything on or near the seat. 2. Turn the ignition switch to LOCK (0). 3. Connect the HDS to the vehicle's DLC (data link connector). 4. Keep the ignition switch at LOCK (0), and turn on the HDS. 5. At the screen prompts, enter the VIN and the odometer reading. 6. From the Select Mode screen, select SCS, and follow the screen prompts. Page 4454 ^ If the noise is still present, look for other causes. 7. Test-drive the vehicle to check for proper clutch operation. Disclaimer Page 3294 Vehicle Speed Sensor: Service and Repair VSS Replacement 1. Remove the intake resonator. 2. Disconnect the 3P connector (A) from the vehicle speed sensor (VSS) (B). 3. Remove the mounting bolt, then remove the VSS. 4. Install the VSS in the reverse order of removal. Page 5039 Transmission Position Switch/Sensor: Service and Repair Transmission Range Switch Replacement 1. Remove the intake air duct and resonator. 2. Shift to the N position. 3. Remove the transmission range switch shaft cap (A). 4. Disconnect the transmission range switch connector (A). 5. Remove the transmission range switch (B). 6. Make sure that the control lever is in the N position. Page 178 2. Remove the terminal from the female half. 3. Remove the terminal from the male half. 4. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE D: 1. Remove the secondary locks. Locations 75. Behind Recir-A/C-Rear Defogger Switch Assembly Locations Main Relay (Computer/Fuel System): Locations Relay And Control Unit Locations - Dashboard Page 3232 7. Align the cutouts (A) on the rotary-frame with the neutral positioning cutouts (B) on the transmission range switch, then put a 2.0 mm (0.08 inch) feeler gauge blade (C) in the cutouts to hold it in the N position. NOTE: Be sure to use a 2.0 mm (0.08 inch) blade or equivalent to hold the switch in the N position. 8. Install the transmission range switch (A) gently on the control shaft (B) with holding the N position with the 2.0 mm (0.08 inch) blade (C). 9. Tighten the bolts on the transmission range switch while you continue to hold it in the N position. Do not move the transmission range switch when tightening the bolts. Remove the feeler gauge. Page 383 12. On Accords and Pilots, install the new seat-back clips on the seat-back panel. Turn the clips so their retaining tabs are horizontal. 13. On Accords and Pilots, install the seat-back panel. 14. On all models except Accords and Pilots, zip the seat-back cover closed. 15. Initialize the OPDS unit. ^ To initialize with the HDS, go to Initializing the OPDS Unit: HDS Method. ^ To initialize with the SCS service connector, go to Initializing the OPDS Unit: Manual Mode. Initializing the OPDS Unit: HDS Method NOTE: Non-Honda seat covers will interfere with the performance of the OPDS and are not recommended. 1. Adjust the front passenger's seat-back to an upright position, then remove anything on or near the seat. 2. Turn the ignition switch to LOCK (0). 3. Connect the HDS to the vehicle's DLC (data link connector). 4. Turn the ignition switch to ON (II), then turn on the HDS. 5. At the screen prompts, enter the VIN and the odometer reading. Also verify the correct date and time. 6. From the System Selection menu, select SRS. Page 8678 207. Cruise Control Unit (USA: HX; Sedan: LX, EX, GX) Page 6393 8. Remove the flange bolt (A) and wheel sensor (B) from the knuckle. Do not disconnect the wheel sensor connector. 9. Remove the flange nut (A) while holding the joint pin (B) with a hex wrench (C), and disconnect the stabilizer link (D) from the lower arm (E). 10. Remove the lock pin (A) from the lower arm ball joint, and remove the castle nut (B). NOTE: During installation, insert the lock pin into the ball joint pin in the range of 180 degrees or below from the inside of the vehicle. Insert the lock pin from the inside to the outside of the vehicle. 11. Disconnect the lower arm from the knuckle using the special too. Page 1835 7. Remove the bearing cap bolts. To prevent warpage, unscrew the bolts in sequence 1/3 turn at a time; repeat the sequence until all bolts are loosened. 8. Remove the bearing cap bridge/bearings. Keep all bearings in order. 9. Turn the crankshaft so No. 2 and No. 3 crankpins are at the top. 10. Remove the rod caps/bearings. Keep all caps/bearings in order. 11. Lift the crankshaft out of the engine, being careful not to damage the journals. 12. Remove the upper bearing halves from the connecting rods, and set them aside with their respective caps. 13. Reinstall the bearing cap bridge and bearings on the engine in the proper order. 14. If you can feel a ridge of metal or hard carbon around the top of each cylinder, remove it with a ridge reamer (A). Follow the reamer manufacturer's instructions. If the ridge is not removed, it may damage the pistons as they are pushed out. Page 2172 2. Insert the terminal tool into the female terminal, and then remove the terminal tool. NOTE: Make sure you do not select a terminal tool that is larger than the mating male terminal because it would spread the female terminal and cause a loose fit. 3. Compare the drag to the other terminals in the connector. If the drag is less, replace the terminal with a replacement terminal from the appropriate terminal repair kit. Page 8561 2. Clean the grooves in the front bumper and the air spoiler with isopropyl alcohol. 3. Apply a small bead (3 to 5 mm) of 3M Weatherstrip Adhesive in the groove in the front bumper air spoiler. 4. Install the front bumper air spoiler to the bumper. 5. Install the four spoiler plates and the two push clips. 6. Install the four bolts, and torque them to 9.8 N.m (7.2 lb-ft). 7. Clean any excessive adhesive from the front bumper air spoiler. Page 3706 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 Short Circuit Locator (Short Finder) 1. Remove the blown fuse. Leave the battery connected. Alternator - A/C Compressor Belt Inspection and Adjustment Drive Belt: Testing and Inspection Alternator - A/C Compressor Belt Inspection and Adjustment Alternator - A/C Compressor Belt Inspection and Adjustment Special Tools Required Belt tension gauge 07JGG-001010A Belt Tension Gauge Method Inspection 1. Attach the belt tension gauge to the belt and measure the tension. Follow the gauge manufacturer's instructions. If the belt is worn or damaged, replace it. If the belt needs adjustment, go to step 2. Adjustment 2. Loosen the mounting bolt (A), lock bolt (B) and lower bracket mounting bolt (C). 3. Torque the mounting bolt to 20 N.m (2.0 kgf.m, 14 lbf.ft). 4. Turn the adjusting bolt (D) to obtain the proper belt tension, then retighten the lock bolt, mounting bolt and lower bracket mounting bolt. 5. Recheck the belt tension. 6. If you installed a new belt, run the engine for 5 minutes, then readjust the belt to the used belt specification. 7. Check the power steering pump belt adjustment. Deflection Method Inspection Page 2798 163. Under Left Side Of Floor (except GX) Page 4981 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 Locater) 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. Troubleshooting Precautions Troubleshooting Precautions Before Troubleshooting 1. Check the main fuse and the fuse 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, or you will damage the alternator diodes. - Do not attempt to crank the engine with the ground cable disconnected 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. Page 9268 158. DRL Relay (Canada); Low Beam Cut Relay ('01-'03 Canada) Continuously Variable Transmission Shift Interlock Switch: Testing and Inspection Continuously Variable Transmission Park Pin Switch Test 1. Remove the center console panel and center console. 2. Disconnect the park pin switch connector (4P). 3. Shift to the P position, then check for continuity between the No. 3 and No. 4 terminals. There should be no continuity. 4. Shift out of the P position, and check for continuity between terminals No. 3 and No. 4. There should be no continuity. 5. If the park pin switch is faulty, replace it. Page 9845 12. Attach the upper fasteners (A) and side fasteners (B) with adhesive tape to the inside face of the rear window-(C) as shown. Apply primer to the inside face of the rear window as shown. If necessary, apply primer to the areas where the window antenna terminal base (D) will be attached, then attach the base with adhesive tape: Be sure the fasteners (and window antenna terminal cover base) line up with the alignment marks (E). - Be careful not to touch the rear window where adhesive will be applied. Diagrams Page 7989 - To remove the seat side trim, remove the rear seat side bolster. - To remove the front side cap and opener lock cylinder, refer to trunk lid opener/fuel fill door opener replacement. 2. Install the parts in the reverse order of removal, and note these items: - Replace any damaged clips. - Apply liquid thread lock to the anchor bolts before installation. - Before installing the anchor bolts, make sure there are no twists or kinks in the seat belts. Page 7912 2. Line up the slots in the arms with the bolt holes on the corners of the jack base, then attach the adapter to the jack base with the bolts that came with the jack. Tighten all of the bolts securely. 3. Raise the jack to vehicle height. 4. With the rear bar of the adapter spanning the sides of the subframe, route the adapter's strap around the front of the subframe. Pull the strap as tightly as possible, insert the pin through the appropriate loop, then tighten the wing nut. 5. With all of the vehicle parts properly supported or removed (see Engine or Transmission Removal in the appropriate service manual), carefully lower the subframe using the controls on the jack. Disclaimer Page 4500 Clutch Release Bearing: Service and Repair Clutch Disc and Pressure Plate Installation Clutch Replacement Special Tools Required ^ Clutch alignment shaft 07LAF-PT00110 ^ Clutch alignment disc 07JAF-PM7011A ^ Remover handle 07936-3710100 ^ Ring gear holder 07LAB-PV00100 or 07924-PD20003 ^ Attachment, 57 x 40 mm 07746-0010200 ^ Driver 077 49-0010000 Clutch Disc and Pressure Plate Installation 1. Install the ring gear holder. 2. Apply super high temp urea grease (P/N 08798-9002) to the splines (A) of the clutch disc (B), then install the clutch disc using the special tools. 3. Install the pressure plate (A) and the mounting bolts (B) finger-tight. Page 1523 Charging System Component Location Index Page 7477 3. Operate the switches listed. If the circuit is ok, the spotlight and ceiling lights will blink once. If the circuit is faulty, the lights will not blink. Tip: Operate the switches most closely related to the problem you are diagnosing is a quick way of testing the circuits integrity. 4. If all inputs were confirmed, or multiple circuits failed at the same time in mode 2, go to the multiplex sleep mode test. If a single switch fails in mode 2, troubleshoot its circuit. Multiplex Sleep Mode Test 1. Connect the positive lead of a voltmeter to terminal 10 of the under-dash fuse/relay box connector E (YEL) or K (WHT/GRN) and the negative lead to body ground. 2. Connect ammeter between the negative battery cable and the negative battery post. 3. Remove the special tool from the multiplex inspection connector. 4. Close the doors, the hatch, turn the headlights off, turn off the ignition switch and remove the key. 5. Within 1 minute the voltage on the communication wire (E10 or K10) should change from approx 4 - 10 V to battery voltage and the amperage at the negative battery terminal should drop from approx. 70 - 80 mA to less than 10 mA. 6. Record your findings and go to the Multiplex Wake-up Test. Multiplex Wake-up Test 1. From the sleep mode. Wake-up the multiplex system by performing one of the following operations: 2. As the system shifts to its active (wake-up) mode, communication wire voltage will return to 4 - 10 V and the battery terminal current will return to 70 - 80 mA. 3. If the system does not go into sleep mode or wake-up properly, perform the Multiplex Control Unit Input Test. NOTE: If multiple circuits fail to respond in the mode 2 tests and/or the multiplex circuit fails to go into sleep mode or wake-up, it may mean that a control unit failed without triggering a DTC in mode 1. Perform the Multiplex Control Unit Input Test. If the input test confirms that all the inputs are working properly, substitute a known-good multiplex control unit, gauge assembly or ECM one at a time. If after swapping one of the above components the system works properly, replace the original component, it is faulty. Page 1627 Page 8397 142. Moonroof Limit Switch (EX) Page 5423 6. If the brake lining thickness is less than the service limit, replace the brake shoes as a set. 7. Check the hub bearing for smooth operation. If it requires servicing, replace it. 8. Measure the inside diameter of the brake drum with inside vernier calipers. Drum Inside Diameter: Standard: 199.9 - 200 mm (7.870 - 7.874 inch) Service Limit: 201 mm (7.91 inch) 9. If the inside diameter of the brake drum is more than the service limit, replace the brake drum. 10. Check the brake drum for scoring, grooves, corrosion, and cracks. Page 7786 NOTE: You need to make the corrections listed in CODE BOOK CORRECTIONS at the end of this service bulletin. TRACER AND CUTTER BIT INSTALLATION 1. Turn the power switch on the back of the machine to ON. (This turns on the built-in work light.) 2. Use the Allen wrench from the built-in tool drawer to loosen the setscrew on the left sleeve of the vertical carriage. Slide the tracer all the way into the sleeve, and tighten the screw. 3. Turn the plastic shield on the right sleeve of the vertical carriage so you can access the setscrew on the sleeve. Use the Allen wrench to loosen the screw. Slide the cutter bit all the way into the sleeve, and tighten the screw. Turn the plastic shield so the open side is in the back. MACHINE COMPONENTS Page 8153 2003-04 Accord DX with dealer-installed security system 2003-04 Element with dealer-installed keyless entry system or security system 2004 Element EX with factory-installed keyless entry system or dealer-installed security system 2003-04 Pilot EX models with factory-installed security system* Programming the Transmitter NOTES: ^ The system accepts up to three transmitters. The transmitter codes are stored in a stacking-type memory. If a fourth transmitter code is programmed, the code for the first transmitter is erased. ^ Entering the programming mode cancels all learned transmitter codes, so none of the previously programmed transmitters will work. You must reprogram all of the transmitters once you are in the programming mode. ^ You must complete steps 1-6 within 4 seconds of the previous step to keep the system from exiting the programming mode. 1. Turn the ignition switch to ON (II). 2. Press the "Lock" or "Unlock" button on one of the transmitters. (An unprogrammed transmitter can be used for this step.) 3. Turn the ignition switch to LOCK (0). 4. Repeat steps 1, 2, and 3 two more times using the same transmitter used in step 2. 5. Turn the ignition switch to ON (II). 6. Press the "Lock" or "Unlock" button on the same transmitter. Make sure the power door locks cycle to confirm that the system is in programming mode. 7. Within 10 seconds, press the "Lock" or "Unlock" button on each transmitter. Make sure the power door locks cycle after you press each transmitter button to confirm that the system accepted the transmitter's code. 8. Turn the ignition switch to LOCK (0) to exit the programming mode. Ordering a Transmitter Transmitters can be ordered only by authorized Honda dealers. Order them from American Honda using normal parts ordering procedures. Batteries for the Transmitter The battery number is CR2025. Each transmitter uses one battery. 91-93 Accord 5-D00R EX Page 9472 Horn Relay: Testing and Inspection Power Relay Test Use this chart to identify the type of relay, then do the test listed for it. NOTE: See the turn signal/hazard relay input test. Normally-open type A: Page 9340 Wire Color Abbreviations Page 3515 125. TP Sensor Page 8118 Page 3607 13. After completing the right edge, push all of the cam blades to the right until they touch the cams, then trace the cam blades from back to front. (The cutter bit cuts the same contours into the left edge of the key from tip to head.) Turn off the cutter motor. 14. Release the vertical carriage lever. Push all the cam blades to the left until they touch the cams. Pull the vertical carriage lever towards you until the tracer touches the flat surface on the right side, at the front of the cams. Gently twist the lever clockwise to lock the vertical carriage at this height. Do not overtighten the lever. 15. Turn on the cutter motor, then retrace the cam blades from front to back. Push all the cam blades to the right until they touch the cams, and then retrace the cam blades from back to front (retracing cleans up the cuts on the key). Turn off the cutter motor. 16. Release the vertical carriage lever. Open the jaw and remove the key. Make sure the jaw is free of any metal shavings or debris. Turn the key over so the blank side is up, then slide it into the jaw up to the key stop. Close the jaw to lock the key in place. 17. Push all the cam blades to the left until they touch the cams. Repeat steps 10 through 15 to cut both edges on the other side of the key. 18. When you are done making the required cuts, release the vertical carriage lever. Open the jaw and remove the key. 19. Make sure the key works in the ignition switch and the locks. If the key does not work, recut the key, and try it again. 20. Depending on the type of key, code the key transponder. Equipment Service and Warranty To service the MATRIX H Key Cutting Machine, refer to section 7 of the MATRIX H Operating Manual. It tells you how to replace parts that commonly wear out such as the drive belt, the work light bulb, and the tension spring on the vertical carriage. It also covers checking and replacing fuses and replacing the printed circuit board for the setting unit keypad. If you have technical questions on the equipment, contact the Ilco Technical Assistance Department. Mail: Kaba Ilco Technical Assistance Department 400 Jeffreys Road Rocky Mount, NC 27804 Phone: 800-452-6872 Ext: 200, 384, 323, 398, 356 Fax: 252-446-4702 The MATRIX H Key Cutting Machine comes with a 3-year limited warranty. This warranty does not cover the cutter bit or the work light bulb. CODE BOOK CORRECTIONS In the code book Honda High Security key Codes, correct these errors: Pages 4 thru 51, code headings: ^ Incorrect: J H G F Z X E D C B M/S X ^ Correct: J H G F A X E D C B M/S X Page 2, last paragraph: Page 3221 3. Strip the insulation off the end of the wire so the wire fits in the new terminal as shown. (If the wire has a wire seal, replace it with a new one from the kit.) NOTE: After stripping the end of the wire, make sure you did not cut any wire strands. If you did, cut the wire off even with the insulation, and strip it again. 4. Position the terminal in the crimping tool slot with the solid portion of the terminal toward the anvil and the open section toward the former. 5. Insert the wire in the terminal to the position shown in step 3. 6. Squeeze the tool with both hands until the stops make contact. 7. Crimp the insulation crimp. - If you do not have a wire seal, then use the next larger size crimp slot. Position the crimping tool over the insulation crimp section of the terminal, then squeeze the tool with both hands until the stops make contact. - If you have a wire seal, position the insulation crimp in the 5.5 crimping slot, then carefully squeeze the crimp closed until its ends are touching and making a full-circle shape. Page 6266 32. Press the valve oil seal (A) and bushing (B) out of the valve housing using a hydraulic press and special tool. Reassembly 33. Apply vinyl tape (A) to the stepped portion of the pinion shaft, and coat the surface of the vinyl tape with the power steering fluid. 34. Install the wave washer (B). Coat the inside surface of the new valve oil seal (C) with power steering fluid, and install the seal with its grooved side facing opposite the bearing, then slide it over the pinion shaft, being careful not to damage its sealing lip (D). Remove the vinyl tape. 35. Install the special tool over the pinion, and coat the surface of the tool with the power steering fluid. Slip the new O-ring (A) and new valve seal ring (B) over the special tool, and expand them. 36. Fit the O-ring and in the groove of the pinion shaft. Then slide the valve seal ring over the shaft and in the groove on the pinion shaft. 37. Remove the special tool, and apply power steering fluid to the surface of the valve seal ring (A). 38. Apply power steering fluid to the inside of the special tool. Set the larger diameter end of the special tool over the valve seal ring, and move the Page 8465 19. Install the seat. 20. Confirm that the problem is resolved. If the driver's seat still rocks, look for other causes. 21. Reconnect the battery. 22. Turn the ignition switch to ON (II), and check the SRS indicator. If the indicator comes on for 6 seconds and then turns off, the SRS is OK. If the indicator stays on, check for codes, and do normal troubleshooting. 23. Enter the anti-theft code for the radio, and then enter the customer's radio station presets. 24. Set the clock. 25. Do the ECM/PCM idle learn procedure: ^ Make sure all electrical items (A/C, audio unit, defogger, lights, etc.) are off. ^ Start the engine and let it warm up to its normal operating temperature (the cooling fans cycle twice). ^ Let the engine idle (throttle fully closed and all electrical items off) for 10 minutes. 26. For 2001 2-doors up to VIN 1L016502, do the cruise control learn procedure. Drive the vehicle for 10 minutes at over 40 mph with the cruise control on. Disclaimer Campaign - OPDS Unit Warranty Extension Technical Service Bulletin # 06-009 Date: 080205 Campaign - OPDS Unit Warranty Extension 06-009 February 5, 2008 Applies To: See VEHICLES AFFECTED Warranty Extension: OPDS Unit or OPDS Sensor Triggers SRS DTC(s) 15-1, 15-2, 15-3 (Supersedes 06-009, dated September 21, 2007) Updated information is shown with asterisks. BACKGROUND *NOTE: Because of a class action settlement, the warranty extension coverage for the OPDS unit and the OPDS sensor on 2002 Accords, 2002-04 Civics, 2003-04 Civic Hybrids, 2002-04 CR-Vs, 2003 Elements, 2002 Odysseys, and 2003-04 Pilots purchased or leased between April 13, 2002, and November 7, 2006, is now 10 years or 157,500 miles, whichever occurs first. For more information, refer to Service Bulletin 06-085, Warranty Extension: Vehicle Warranty Mileage.* Several vehicle models may have a problem with the OPDS (occupant position detection system) that causes the SRS indicator to stay on. Typically, one or more of these DTCs will be set: ^ SRS DTC 15-1 (faulty OPDS unit or OPDS not initialized) ^ SRS DTC 15-2 (faulty side airbag indicator circuit) ^ SRS DTC 15-3 (faulty OPDS sensor) To ensure continued reliability with the OPDS, American Honda is extending the warranty on the OPDS unit and the OPDS sensor to 10 years or 150,000 miles, whichever occurs first. This warranty extension does not apply to any vehicle that has ever been declared a total loss, or any that has been issued a salvage, branded, or similar title under any state's law. To check for vehicle eligibility, you must do a VIN status inquiry Page 9501 2. Remove the terminal (same procedure for male and female). 3. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE E: 1. Remove the secondary locks. 2. Remove the terminal (same procedure for male and female). 3. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE F: Page 1733 8. Tighten each bolt two turns at a time, in the sequence shown below, to ensure that the rockers do not bind on the valves. Specified torque 8 mm bolts: 20 Nm (2.0 kgf-cm, 14 ft. lbs.) Apply engine oil to the bolt threads. 6 mm bolts: 12 Nm (1.2 kgf-cm, 8.7 ft. lbs.) Apply engine oil to the bolt threads. 6 mm bolts: (11), (12), (13), (14) 9. Align the marks (A) on the new cylinder head plug (B) with the top edge of the head, then install the cylinder head plug in the cylinder head. Page 8042 21. Leave the key in the cylinder. Reinstall the plastic retainer and spring if you removed them in step 16. Hold the plastic retainer and spring on the housing, and insert the inner cylinder. Rotate it left and right to engage the spring to the inner cylinder. Make sure the spring is properly seated to the inner cylinder. 22. Install the arm with a new cylinder rod clip and a new E-clip. 23. Make sure the key can be inserted and removed easily, and that the cylinder turns with the key. Page 1532 Under-dash Fuse/Relay Box (4-door) Page 6895 5. Lower the glove box, then disconnect the front passenger's airbag 4P connector (A) from dashboard wire harness B. Side Airbag: 6. Disconnect the 2P connector between the side airbag (A) and the floor wire harness. Seat belt tensioner: 7. Disconnect the 2P connector between the seat belt tensioner (A) and floor wire harness. Seat belt buckle tensioner: Locations Manifold Pressure/Vacuum Sensor: Locations PGM-FI System - Component Location Index How to Remove the PCM Control Module: Service and Repair How to Remove the PCM How to Remove the PCM for Testing 1. Remove the passenger's dashboard lower cover, the right kick panel, and the glove box. 2. Remove the bolt. Cut the plastic cross brace in the glove box opening with diagonal cutters in the area shown, and discard it. 3. Remove the relays (A), then remove the bolts and the glove box frame (B). 4. Remove the gray 20P PCM wire harness connector from the PCM mounting bracket. Remove the PCM mounting bolt (A) and the bracket. 5. Remove the nuts, then remove the PCM (B). 6. Install the PCM in the reverse order of removal. Page 1760 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. How to Replace Connector Terminals Terminal Replacement Procedure HOW TO REPLACE CONNECTOR TERMINALS The terminal repair kits provide necessary tools and materials (terminals, wire seals, and splice connectors) to repair many damaged or faulty connector terminals. However, not all terminals for all connectors are available. Refer to the labels on the lids of the repair kits for replacement terminal availability. IMPORTANT SAFETY INFORMATION: On some models, the SRS wires are in a separate harness. If the SRS harness is damaged, replace the harness; do not repair it. On other models, wire harnesses include yellow SRS wires. If any SRS wire is damaged, replace the entire harness; do not repair it. Before you begin, inspect the wire you are about to repair for damage and length. Make sure the wire will be long enough to make a terminal repair without stretching it when you reinstall the terminal in the connector. If the wire is too short, or if access to the connector is too restricted to make a terminal repair, you may need to install a pigtail terminal (a short length of wire with a factory-crimped terminal on it). Refer to HOW TO INSTALL PIGTAIL TERMINALS. Removing the Terminal Page 6836 ^ If the OPDS unit has an original part number, go to step 6. ^ If the OPDS unit has a new part number (refer to PARTS INFORMATION) or higher, go to REPAIR PROCEDURE B: OPDS SENSOR REPLACEMENT. 6. Recline the seat-back to access the OPDS unit mounting screws. 7. Remove the mounting screws from the OPDS unit, and gently pull out the unit. 8. Disconnect the OPDS connectors, then remove the OPDS unit. 9. Install a new OPDS unit, then snap on its cover. 10. Slip the seat-back cover over the OPDS unit. 11. On Accords, check the seat-back clip attachment bosses on the seat-back panel: ^ If the attachment bosses are OK, go to step 12. ^ If the seat-back has a pocket, and the attachment bosses are deformed or damaged, do the repair procedure in S/B 02-010, Seat-Back Panel Is Loose or Detached. Then go to step 12. ^ If the seat-back does not have a pocket, and the attachment bosses are deformed or damaged, replace the seat-back. Then go to step 12. Page 4425 Clutch Disc: Service and Repair Flywheel Inspection Clutch Replacement Special Tools Required ^ Clutch alignment shaft 07LAF-PT00110 ^ Clutch alignment disc 07JAF-PM7011A ^ Remover handle 07936-3710100 ^ Ring gear holder 07LAB-PV00100 or 07924-PD20003 ^ Attachment, 57 x 40 mm 07746-0010200 ^ Driver 077 49-0010000 Flywheel Inspection 1. Inspect the ring gear teeth for wear and damage. 2. Inspect the clutch disc mating surface on the flywheel for wear, cracks and burning. 3. Measure the flywheel (A) runout using a dial indicator (B) through at least two full turns with the engine installed. Push against the flywheel each time you turn it to take up the crankshaft thrust washer clearance. If the runout is more than the service limit, replace the flywheel and recheck the runout. Standard (New): 0.06 mm (0.002 inch) max. Service Limit: 0.15 mm (0.006 inch) 4. Turn the inner race of the pilot bearing (A) with your finger. The bearing should turn smoothly and quietly. Check that the bearing outer race fits tightly in the flywheel. If the race does not turn smoothly, quietly, or fit tight in the flywheel, replace the bearing. Locations Control Module: Locations Electronic Controls Location Page 2562 20. Transmission Housing Page 566 12. Oil Pressure Switch Page 4666 Shifter CVT: Service and Repair Shift Lever Disassembly/Reassembly Shift Lever Disassembly/Reassembly Page 4111 2. Remove the terminal (same procedure for male and female). 3. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE E: 1. Remove the secondary locks. 2. Remove the terminal (same procedure for male and female). 3. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE F: Page 758 Manifold Pressure/Vacuum Sensor: Service and Repair MAP Sensor Replacement 1. Disconnect the MAP sensor 3P connector. 2. Remove the MAP sensor (A). 3. Install the sensor in the reverse order of removal with a new O-ring (B). Page 1793 2. Insert the pilot collar (A) into the piston and connecting rod. 3. With the embossed mark facing up, place the piston assembly (B) on the special tool (C). Be sure you position the recessed flat on the piston against the lugs on the base attachment. 4. Press the pin (D) in with the pin driver (E) and a hydraulic press. Page 3420 Replace the retainer when - replacing the fuel rail. - replacing the fuel line. - replacing the fuel pump. - replacing the fuel filter. - replacing the fuel pressure regulator. - replacing the fuel gauge sending unit. - it has been removed from the line. - it is damaged. Fuel Line/Quick-Connect Fittings Removal 1. Relieve the fuel pressure. 2. Check the fuel quick-connect fittings for dirt, and clean them if necessary. 3. Hold the connector (A) with one hand, and squeeze the retainer tabs (B) with the other hand to release the tabs from the locking pawls (C). Pull the connector off. NOTE: Be careful not to damage the line (D) or other parts. Do not use tools. - If the connector does not move, keep the retainer tabs pressed down, and alternately pull and push the connector until it comes off easily. - Do not remove the retainer from the pipe; once removed, the retainer must be replaced with a new one. 4. Check the contact area (A) of the line (B) for dirt and damage. - If the surface is dirty, clean it. - If the surface is rusty or damaged, replace the fuel pump, fuel filter, or fuel feed line. Locations 61. Under Left Side Of Dash Page 4271 5. Attach the slide hammer to the interlock lever pin, and tighten the slide hammer clamping bolt. Then use the slide hammer to remove the pin. Discard the pin, the lever, and the spring. 6. Wipe off any debris from the lever's sliding surface on the ignition switch with a clean cloth or a cotton swab. NOTE: To keep debris out of the ignition switch, do not clean it with compressed air. Page 370 7. Connect the SCS service connector to the 2P MES (memory erase signal) connector, as shown. Do not use a jumper wire. 8. Turn the ignition switch to ON (II). 9. Watch the SRS indicator. (It comes on for about 6 seconds and then goes off.) Disconnect the SCS service connector from the MES connector within 4 seconds after the indicator goes off. 10. When the SRS indicator comes on again, connect the SCS service connector to the MES connector within 4 seconds after the indicator comes on. 11. When the SRS indicator goes off, disconnect the SCS service connector from the MES connector within 4 seconds. Page 49 Keyless Entry Module: Testing and Inspection Control Unit Input Test 1. Before testing, troubleshoot the multiplex control system. 2. Remove the dashboard lower cover. 3. Disconnect the under-dash fuse/relay box connectors. NOTE: All connectors are wire side of female terminals. 4. Inspect the connector and socket terminals to be sure they are all making good contact. - If the terminals are bent, loose or corroded, repair them as necessary, and recheck the system. - If the terminals look OK, go to step 5. Page 6004 Multiple Junction Connector: Service and Repair How to Install Pigtail Terminals HOW TO INSTALL PIGTAIL TERMINALS Pigtail terminals (short pieces of wire with a factory crimped terminal) are used when the wire is too short or when access to the connector is too restricted to make a terminal repair. NOTE: To replace just a connector terminal, go to How to Replace Connector Terminals. IMPORTANT SAFETY INFORMATION: On some models, the SRS wires are in a separate harness. If the SRS harness is damaged, replace the harness; do not repair it. On other models, wire harnesses include yellow SRS wires. If any SRS wire is damaged, replace the entire harness; do not repair it. 1. Remove the damaged or faulty terminal from the connector. Use the proper removal tool from Pin Tool Set. 2. Cut off the wire about an inch back from where it connects to the damaged or faulty terminal, then strip about half of the insulation off that piece. This will be used to size the wire end of the replacement pigtail terminal. NOTE: If you are not sure of the wire size, start with a large enough hole on the stripper that will not nick or cut off any strands of wires. 3. Select a pigtail terminal that matches the original wire at both ends (same kind of terminal and same diameter bare wire). 4. Select the smallest splice connector (yellow, pink, or blue) that will fit onto the stripped end of the original wire. 5. Insert the pigtail terminal into the connector cavity; push it in until it locks in place. 6. Lay the pigtail and the original wire side-by-side, and cut off both ends at once. If you are making more than one splice, do not cut each pigtail at Page 5880 69. Under Left Side Of Dash 70. Under Left Side Of Dash Page 1846 4. With the embossed mark facing up, place the piston assembly (A) on the special tool (B). Be sure you position the recessed flat on the piston against the lugs on the base attachment. 5. Press the pin (C) out with the pin driver (D), pilot collar (E) and a hydraulic press. Inspection 1. Measure the diameter of the piston pin. Piston Pin Diameter Standard (New): 18.996 - 19.000 mm (0.7479 - 0.7480 inch) 2. Zero the dial indicator to the piston pin diameter. Page 2116 Spark Plug: Testing and Inspection Spark Plug Inspection 1. Inspect the electrodes and ceramic insulator. Burned or worn electrodes may be caused by: Advanced ignition timing - Loose spark plug - Plug heat range too hot - Insufficient cooling Fouled plug may be caused by: Retarded ignition timing - Oil in combustion chamber - Incorrect spark plug gap - Plug heat range too cold - Excessive idling/low speed running - Clogged air cleaner element - Deteriorated ignition coils 2. Do not adjust the gap of platinum tip plugs (A); replace the spark plug if the gap is out of specification. Page 7215 On the order form, you must include the serial number of the keyless control unit or the number from one of the original transmitters. If you need a transmitter shipped overnight, fill out the order form, then call Kenwood at (500) 552-4690, or fax them at (310) 595-1029 (weekdays from 5:30A.M. thru 4:00 P.M. Pacific time). You will need to give the information on the order form to the Kenwood representative. The transmitter will be sent to your dealership COD. Additional shipping and handling charges will be applied to the order. Batteries for the Transmitter The battery number is CR1220. Each transmitter uses two batteries. 94-97 Accord 5-Door EX, 95-98 Odyssey EX 1994-97 Accord 5-door EX with factory-installed keyless entry system 1995-98 Odyssey EX with factory-installed keyless entry system Programming the Transmitter NOTE: ^ The system accepts up to two transmitters. ^ Entering the programming mode cancels all learned transmitter codes, so none of the previously programmed transmitters will work. You must reprogram all of the transmitters once you are in the programming mode. 1. Open the driver's door. 2. Push the driver's power door lock switch to the unlock position and hold it. (Continue to hold the switch during this procedure.) 3. Insert the key into the ignition switch, then remove it. Repeat this four more times (five times total) within 10 seconds. (You must complete steps 3 and 4 within 10 seconds or the system will exit the programming mode.) 4. Insert the key into the ignition switch. After you insert the key, make sure the power door locks cycle to confirm that the system is in the programming mode. 5. Press the "LOCK" or "UNLOCK" button on the transmitter. All the power door locks (except the driver's door) should cycle to confirm that the system accepted the transmitter's code. 6. To program a second transmitter, press its "LOCK" or "UNLOCK" button within 10 seconds of programming the first transmitter. 7. Release the master power door lock switch to exit the programming mode. Ordering a Transmitter Transmitters can be ordered only by authorized Honda dealers. Order them from American Honda using normal parts ordering procedures. Batteries for the Transmitter The battery number is CR2016. Each transmitter uses two batteries. 96-04 Accord, CRV, DelSOL, Ody., Prelude, S2000, Insight, Pilot 1996-02 Accord with dealer-installed security system 1998-02 Accord DX & LX with dealer-installed keyless entry system Page 5136 1. Remove the terminal. 2. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE E: 1. Remove the terminal. 2. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE F: Page 9779 Power Windows Component Location Index Page 3040 REPAIR PROCEDURE 1. Make sure you have the anti-theft code for the audio unit. Write down the customer's audio presets. 2. Disconnect the negative battery cable from the battery. 3. Remove the under-hood fuse/relay box cover. 4. Release the three clips, and remove the under- hood fuse/relay box from the holder. CR-V only: Release the wire harness clip from the fuse/relay box holder Page 9783 Blower Motor Relay Type 1, Type 2 Check for continuity between the terminals. - There should be continuity between the No.1 and No.3 terminals when power and ground are connected to the No.2 and No.4 terminals. - There should be no continuity between the No.1 and No.3 terminals when power is disconnected. Five-terminal type Check for continuity between the terminals. - There should be continuity between the No.1 and No.2 terminals when power and ground are connected to the No.3 and No.5 terminals. - There should be continuity between the No.1 and No.4 terminals when power is disconnected. Page 2060 1. Remove the terminal. 2. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE E: 1. Remove the terminal. 2. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE F: Page 1694 13. Plug in the heat gun, and turn it on. Start at the middle of the splice connector, and move the gun toward the ends as the tube shrinks. Apply heat evenly by rotating the curved heat spreader around the splice connector. Shrinking is complete when a small amount of sealant appears at each end of the tube. Pigtail Terminal Selection Chart PIGTAIL TERMINAL SELECTION CHART Select the proper size pigtail terminal by matching the replacement terminal part number and the wire size being repaired to the corresponding pigtail terminal part number. Then use the color (size) splice connector listed. In some instances you may also have to match the wire seal style to select the proper pigtail terminal. Pigtail terminals are available through your parts department, in quantities of 10, using normal parts ordering procedures. Checking For Poor Fir of Terminals CHECKING FOR POOR FIT OF TERMINALS Loose terminal fit can cause a number of intermittent problems in electrical circuits. By using the Terminal Inspection Feeler Tool Set you can inspect the terminal fit between the two matching connectors without removing the terminals from the connector body. 1. Find the terminal tool that best matches the male terminal in the mating connector. Page 7323 ^ 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. Locations Blower Motor Relay: Locations Under-hood Fuse/Relay Box Page 3493 Fuel Pump Relay: Description and Operation PGM-FI Main Relay 1 and 2 The PGM-FI relay consists of two separate relays. PGM-FI main relay 1 is energized whenever the ignition switch is ON (II) which supplies battery voltage to ECM/PCM, power to the injectors, and power for PGM-FI main relay 2. PGM-FI main relay 2 is energized to supply power to the fuel pump for 2 seconds when the ignition switch is turned ON (II), and when the engine is running. Page 9854 Front Door Window Glass Weatherstrip: Service and Repair Door Glass Outer Weatherstrip Replacement Door Glass Outer Weatherstrip Replacement 2-door NOTE: - Put on gloves to protect your hands. - Take care not to scratch the door. 1. Remove the mirror. 2. Starting at the front, pry the door glass outer weatherstrip (A) up to detach the clips (B), and release the weatherstrip from the door sash trim (C), then remove the weatherstrip. 3. Install the weatherstrip in the reverse order of removal, and replace any damaged clips. Page 372 Page 2634 Air Filter Element: Service and Repair Air Cleaner Element Replacement 1. Open the air cleaner housing cover (A). 2. Remove the air cleaner (B) from the air cleaner housing (C). 3. Install in the reverse order of removal. Page 5598 9. Set the clock. 10. Perform the engine control module (ECM)/powertrain control module (PCM) idle learn procedure. Page 8801 6. Disconnect both seat belt buckle tensioner 4P connectors (A). Page 9317 3. Strip the insulation off the end of the wire so the wire fits in the new terminal as shown. (If the wire has a wire seal, replace it with a new one from the kit.) NOTE: After stripping the end of the wire, make sure you did not cut any wire strands. If you did, cut the wire off even with the insulation, and strip it again. 4. Position the terminal in the crimping tool slot with the solid portion of the terminal toward the anvil and the open section toward the former. 5. Insert the wire in the terminal to the position shown in step 3. 6. Squeeze the tool with both hands until the stops make contact. 7. Crimp the insulation crimp. - If you do not have a wire seal, then use the next larger size crimp slot. Position the crimping tool over the insulation crimp section of the terminal, then squeeze the tool with both hands until the stops make contact. - If you have a wire seal, position the insulation crimp in the 5.5 crimping slot, then carefully squeeze the crimp closed until its ends are touching and making a full-circle shape. Page 61 165. Moonroof Close And Open Relay (EX) Page 9090 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. How to Replace Connector Terminals Terminal Replacement Procedure HOW TO REPLACE CONNECTOR TERMINALS The terminal repair kits provide necessary tools and materials (terminals, wire seals, and splice connectors) to repair many damaged or faulty connector terminals. However, not all terminals for all connectors are available. Refer to the labels on the lids of the repair kits for replacement terminal availability. IMPORTANT SAFETY INFORMATION: On some models, the SRS wires are in a separate harness. If the SRS harness is damaged, replace the harness; do not repair it. On other models, wire harnesses include yellow SRS wires. If any SRS wire is damaged, replace the entire harness; do not repair it. Before you begin, inspect the wire you are about to repair for damage and length. Make sure the wire will be long enough to make a terminal repair without stretching it when you reinstall the terminal in the connector. If the wire is too short, or if access to the connector is too restricted to make a terminal repair, you may need to install a pigtail terminal (a short length of wire with a factory-crimped terminal on it). Refer to HOW TO INSTALL PIGTAIL TERMINALS. Removing the Terminal Page 175 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. How to Replace Connector Terminals Terminal Replacement Procedure HOW TO REPLACE CONNECTOR TERMINALS The terminal repair kits provide necessary tools and materials (terminals, wire seals, and splice connectors) to repair many damaged or faulty connector terminals. However, not all terminals for all connectors are available. Refer to the labels on the lids of the repair kits for replacement terminal availability. IMPORTANT SAFETY INFORMATION: On some models, the SRS wires are in a separate harness. If the SRS harness is damaged, replace the harness; do not repair it. On other models, wire harnesses include yellow SRS wires. If any SRS wire is damaged, replace the entire harness; do not repair it. Before you begin, inspect the wire you are about to repair for damage and length. Make sure the wire will be long enough to make a terminal repair without stretching it when you reinstall the terminal in the connector. If the wire is too short, or if access to the connector is too restricted to make a terminal repair, you may need to install a pigtail terminal (a short length of wire with a factory-crimped terminal on it). Refer to HOW TO INSTALL PIGTAIL TERMINALS. Removing the Terminal Page 991 143. Park Pin/Shift Switch (A/T) Page 3041 5. Remove the lower cover from the fuse/relay box. 6. Disconnect the 3P ELD connector. Page 2402 124. CMP (TDC) Sensor Page 2070 5. If the filter is not clogged, push the VTEC solenoid valve with your finger and check its movement. If the VTEC solenoid valve moves, check the engine oil pressure. Page 8597 Disclaimer Cutting Procedure - By Copying 1. Press the ON/OFF button in the middle of the setting unit keypad. (This powers up the keypad.) 2. Turn the clamp unit lock lever to the left to release the clamp unit, and slide it all the way to the left until it stops. Turn the lever to the right to lock the clamp unit in place. 3. Use the clamp carriage lever to position the clamp unit so the tracer and cutter bit are centered directly over the base of the center and right jaws. 4. Pull the vertical carriage lever toward you until the tracer and the cutter bit just touch the base of each fixed jaw. Watch the arrows on the keypad: ^ If the double-headed arrow in the middle of the keypad lights green, the tracer and cutter bit are properly aligned. ^ If the arrow on the left of the keypad lights red, the cutter bit is not touching the fixed jaw. Turn the micrometric ring nut above the tracer to the left until the double-headed arrow lights green. ^ If the arrow on the right of the keypad lights red, the tracer is not touching the fixed jaw. Turn the micrometric ring nut above the tracer to the right until the double-headed arrow lights green. *5. Turn the micrometric ring nut to the right three clicks so the cutter bit is slightly higher than the tracer. The arrow on the left should light red. Raise the vertical carriage. NOTE: Setting the tracer three clicks lower than the cutter bit has the effect of making the cutter bit cut the duplicated key a little shallower. This will protect the locking jaws from being damaged.* 6. Optional: Loosen the setscrew, and adjust the hand rest to a comfortable position. Tighten the screw. 7. Pull the clamp carriage lever toward you until the clamp carriage clicks into its end-of-run position. Tighten both the lateral and spring tension adjustment knobs. 8. Make sure the center and right jaws are free of any metal shavings or debris. (A soft-bristle toothbrush is ideal for this purpose.) Page 6310 5. Install the gusset in the reverse order of removal, and note these items: - When installing the mounting bolts for the middle cross-member gusset (A), torque the mounting hardware in the sequence shown. If the mounting bolts are not torqued in this sequence, damage to the quarter panel will occur. - Replace the damaged cushion tape (P/N 91902-SB2-003). Page 2470 120. MAP Sensor Page 9648 1. Remove the secondary lock from the male terminal half. 2. Remove the secondary lock from the female terminal half. 3. Remove the terminal (same procedure for male and female). 4. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE C: 1. Remove the secondary lock. Locations Air Door Actuator / Motor: Locations Heating Component Location Index Page 429 Power Windows Component Location Index Locations 6. Transmission Housing (M/T) Page 364 WARRANTY CLAIM INFORMATION Out of warranty: Any repairs to the SRS system for problems other than the 15-1, 15-2, and 15-3 DTCs that are done 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. INSPECTION PROCEDURE NOTE: ^ When you check for SRS DTCs with the HDS, codes other than 15-1, 15-2, and 15-3 are not covered by this warranty extension bulletin. ^ If the vehicle is covered by warranty, repair it using the normal warranty repair procedures. If the vehicle's warranty is expired, give your customer an estimate for the cost of the repair. Do the appropriate inspection, based on the DTC. SRS DTC 15-1 Clear the DTC with the HDS. ^ If DTC 15-1 does not set again, go to REPAIR PROCEDURE A: OPDS UNIT REPLACEMENT. ^ If DTC 15-1 sets again, continue with normal troubleshooting. ^ If the OPDS unit causes DTC 15-1 to set repeatedly, yet passes the other troubleshooting steps, go to REPAIR PROCEDURE A: OPDS UNIT REPLACEMENT. SRS DTC 15-2 1. Inspect the connections and the wiring in the side airbag cutoff indicator circuit. ^ If all the connections and the wiring are OK, go to step 2. ^ If any of the connections or the wiring are faulty, repair the circuit, then go to step 2. 2. Clear the DTC with the HDS. ^ If DTC 15-2 does not set again, go to REPAIR PROCEDURE A: OPDS UNIT REPLACEMENT. ^ If DTC 15-2 sets again, continue with normal troubleshooting. ^ If the OPDS unit causes DTC 15-2 to set repeatedly, yet passes the other troubleshooting steps, go to REPAIR PROCEDURE A: OPDS UNIT REPLACEMENT. SRS DTC 15-3 1. Clear the DTC with the HDS. ^ If DTC 15-3 does not set again, go to step 2. ^ If DTC 15-3 sets again, continue with normal troubleshooting. 2. Ask your customer if electrical devices such as a laptop computer or a fluorescent map light are ever used near the front passenger's seat-back. (Some electrical devices that plug into the vehicle's accessory power socket, especially those using a power inverter/converter, can interfere with the seat-back sensors and cause SRS DTC 15-3 to set.) ^ If your customer uses any of these devices operate the device near the front passenger's seat-back. If DTC 15-3 sets again, clear it, then return the vehicle to the customer. Advise the customer to avoid using the device near the front passenger's seat-back. ^ If your customer does not use any of these devices and DTC 15-3 does not set again, go to REPAIR PROCEDURE A: OPDS UNIT REPLACEMENT. REPAIR PROCEDURE A: OPDS UNIT REPLACEMENT Page 1746 Terminals - "T" Shielding Switches Fuses Page 8369 Part 1 5. Reconnect all connections to the under-dash fuse/relay box, and make these input tests at the appropriate connectors on the under-dash fuse/relay box. If any test indicates a problem, find and correct the cause, then recheck the system. - If all the input tests prove OK, go to step 6. Part 2 Page 687 39. Left Side Of Engine Compartment Page 4224 2. Remove the terminal (same procedure for male and female). 3. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE E: 1. Remove the secondary locks. 2. Remove the terminal (same procedure for male and female). 3. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE F: Page 6964 Component Locations Shift Interlock Switch: Component Locations Component Location Index Page 7142 1. Remove the driver's dashboard lower cover. (See the body section of the appropriate service manual.) 2. Replace the security control unit. ^ Civic: Remove the security control unit, and install the new security control unit. ^ * CR-V and Element: Remove the security control unit and microphone. Install the new security control unit and new microphone.* 3. Reprogram the keyless receiver unit. NOTE: The codes of up to three transmitters can be stored in the keyless receiver unit memory. If a fourth code is stored, the code that was input first will be erased. It is important to maintain the time limits between the steps. Make sure the doors and the trunk/tailgate/hatch are closed, and that you have all of the remotes the customer wishes to use. ^ Turn the ignition switch to ON (II). ^ Within 1 to 4 seconds, push the transmitter lock or unlock button. ^ Within 1 to 4 seconds, turn the ignition switch to LOCK (0). ^ Within 1 to 4 seconds, turn the ignition to ON (II). ^ Within 1 to 4 seconds, push the transmitter lock or unlock button. ^ Within 1 to 4 seconds, turn the ignition switch to LOCK (0). ^ Within 1 to 4 seconds, turn the ignition switch to ON (II). ^ Within 1 to 4 seconds, push the transmitter lock or unlock button. Page 3117 125. TP Sensor Computers/Controls - Updating Control Units And Modules PROM - Programmable Read Only Memory: All Technical Service Bulletins Computers/Controls Updating Control Units And Modules 01-023 April 10, 2010 Applies To: Honda Vehicles With Programmable Control Units/Modules Updating Control Units/Modules (Supersedes 01-023, dated May 15, 2009, to revise the information marked by the black bars and asterisks) REVISION SUMMARY *^Under REQUIRED TOOLS AND EQUIPMENT, the MVCI was added. ^ Under UPDATING TIPS AND PRECAUTIONS MVCI information was added. ^ UPDATING WITH THE MVCI was added.* The procedures in this service bulletin are used and referenced in other service bulletins. Most 2002 and later Hondas have reprogrammable control units/modules. To update (reprogram) any of these control units/modules, you need the vehicle you're working on and one of these systems: *^MVCI unit with latest control module (CM) update software installed* ^ GNA600 gateway device and an iN workstation with the latest HDS software installed ^ HDS Tablet with the latest HDS software installed ^ HDS Pocket Tester with the latest HDS software installed ^ HIM and an iN workstation with the latest HDS software installed ^ A compatible J2534 device and a PC with Honda's J2534 software installed This service bulletin describes these subjects: ^ Who to contact for questions or problems when using Honda-supplied updating equipment or the iN. ^ Required Tools and Equipment - MVCI - GNA600 - HDS Tablet - HDS Pocket Tester - HIM ^ Updating Tips and Precautions ^ Updating with the MVCI ^ Updating with the GNA600 - GNA6OO Updating in Pass-Thru Mode - GNA6OO Updating in Storage Mode ^ Updating with the HDS Tablet and the HDS Pocket Tester Diagram Information and Instructions Variable Valve Timing Actuator: Diagram Information and Instructions Terminal Numbering System Terminal Numbering System Connector terminals are numbered according to the cavities they're in. The cavities are numbered starting from the upper left, looking at the male terminals from the terminal side or looking at the female terminals from the wire side. Both views are in the same direction so the numbers are the same. All actual cavities are numbered, even if they have no wire terminals in them. NOTE: Data Link Connector (DLC) terminals are numbered according 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 below is #6. Page 7936 12. Pull the vertical carriage lever toward you while you position the tracer on the right edge of the original key at its head, using the clamp carriage lever. Let the cutter bit cut into the key blank, then stop. Gently twist the lever clockwise to lock the vertical carriage at this height. Do not overtighten the lever. 13. Use the clamp carriage lever and the tracer to follow the contours of the original key. (The cutter bit cuts the same contours into the key blank.) Working from right to left, follow the right edge of the original key from head to tip, then the left edge of the key from tip to head. Turn off the cutter motor. 14. Reposition the tracer on the right edge of the original key at its head, using the clamp carriage lever. Turn on the cutter motor. Retrace the key from head to tip, then from tip to head. (This retracing cleans up the cuts on the key.) Turn off the cutter motor. 15. Release the vertical carriage lever. Open the jaw and remove only the new key. Make sure the jaw is free of any metal shavings or debris, then turn the new key over and slide the key with its blank side up into the jaw up to the key stop. Close the jaw to lock the key into place. 16. Turn on the cutter motor, and repeat steps 12 thru 14 to cut both edges of the other side of the key. 17. When you are finished making the required cuts, turn off the cutter motor, and release the vertical carriage lever. Open the jaws, and remove the keys. 18. Use a wire brush to smooth the cut surfaces on the new key. 19. Make sure the key works in the ignition switch and all the locks. If the key does not work, recut the key, and try it again. 20. Depending on the type of key blank you have used, do this: ^ If you have used a Honda key blank, add the transponder code of the new key to the immobilizer system with the Honda Diagnostic System (HDS). ^ If you have used a T-5 programmable key blank ("T-5" stamped on the shank), code the key's transponder with the Ilco Immobilizer Key Code Duplicator (see S/B 99-053, Ilco Immobilizer key Code Duplicator). Cutting Procedure - By Code 1. Press the ON/OFF button in the middle of the setting unit keypad. (This powers up the keypad.) 2. Turn the clamp unit lock lever to the left to release the clamp unit, and slide it to the right until the bottom left side is flush with the base edge. Turn the lever to the right to lock the clamp unit in place. Loosen the lateral and spring tension adjustment knobs on the clamp carriage. Page 2003 8. Tighten each bolt two turns at a time, in the sequence shown below, to ensure that the rockers do not bind on the valves. Specified torque 8 mm bolts: 20 Nm (2.0 kgf-cm, 14 ft. lbs.) Apply engine oil to the bolt threads. 6 mm bolts: 12 Nm (1.2 kgf-cm, 8.7 ft. lbs.) Apply engine oil to the bolt threads. 6 mm bolts: (11), (12), (13), (14) 9. Align the marks (A) on the new cylinder head plug (B) with the top edge of the head, then install the cylinder head plug in the cylinder head. Locations Pressure Regulating Solenoid: Locations Electronic Controls Location Locations Starter Relay: Locations Starting System Component Location Index Page 4755 5. Align the hole in the flywheel with the crankshaft dowel pin, and install the flywheel. Install the mounting bolts finger-tight. 6. Install the special tool, then torque the flywheel mounting bolts in a crisscross pattern in several steps. Locations Pressure Regulating Solenoid: Locations 23. Transmission Housing (A/T) Page 4800 13. Plug in the heat gun, and turn it on. Start at the middle of the splice connector, and move the gun toward the ends as the tube shrinks. Apply heat evenly by rotating the curved heat spreader around the splice connector. Shrinking is complete when a small amount of sealant appears at each end of the tube. Pigtail Terminal Selection Chart PIGTAIL TERMINAL SELECTION CHART Select the proper size pigtail terminal by matching the replacement terminal part number and the wire size being repaired to the corresponding pigtail terminal part number. Then use the color (size) splice connector listed. In some instances you may also have to match the wire seal style to select the proper pigtail terminal. Pigtail terminals are available through your parts department, in quantities of 10, using normal parts ordering procedures. Checking For Poor Fir of Terminals CHECKING FOR POOR FIT OF TERMINALS Loose terminal fit can cause a number of intermittent problems in electrical circuits. By using the Terminal Inspection Feeler Tool Set you can inspect the terminal fit between the two matching connectors without removing the terminals from the connector body. 1. Find the terminal tool that best matches the male terminal in the mating connector. Page 6852 PARTS INFORMATION TOOL INFORMATION Page 4126 Shift Indicator: Testing and Inspection Continuously Variable Transmission Indicator Input Test SRS components are located in this area. Review the SRS component locations, precautions, and procedures in the SRS section before performing repairs or service. 1. If the MIL has been reported, check for a DTC, and repair the system as indicated by DTC. 2. If the MIL does not come on, and the A/T gear position indicator P, N, or R does not come on. Turn the ignition switch off, remove the gauge assembly from the dashboard, then disconnect gauge assembly connector A (22P) and B (22P). 3. Inspect the connectors and connector terminals to be sure they are making good contact. 4. If the terminals are bent, loose, or corroded, repair them as necessary, and recheck the system. 5. Shift to the P position, and check for continuity between AS terminal (BLU/BLK) and ground. There should be continuity in the P position and no continuity in any other shift lever position. If your test results are different, check for a faulty transmission range switch or an open in the wire. 6. Shift to the N position, and check for continuity between AS terminal (BLK/RED) and ground. There should be continuity in the N position and no continuity in any-other shift lever position. If your test results are different, check for a faulty transmission range switch or an open in the wire. 7. Turn the ignition switch ON (II), shift to the R position, and check for voltage between A11 terminal (WHT) and ground. There should be 0 V in the R position. There should be about 5 V in any other shift lever position. If your test results are different, check for a faulty transmission range switch or an open in the wire. 8. Check for voltage between B17 terminal (YEL) and ground with the ignition switch ON (II). There should be battery voltage. If your test results are different, check for a blown No. 10 (7.5A) fuse in the under-dash fuse/relay box or an open in the wire. 9. Turn the ignition switch OFF, and check for continuity between B16terminal (BLK) and ground under all conditions. There should be continuity. If your test results are different, check for a poor ground (G501) or an open in the wire. 10. If all input tests prove OK, but the indicator is faulty, replace the printed circuit board. Page 7820 *T-5 Sidewinder Key Applications ^ 2003-05 Civic ^ 2004-05 Civic Hybrid ^ 2003-05 Civic GX (CNG) ^ 2004-05 S2000 ^ 2002-06 CR-V ^ 2003-06 Element ^ 2003-04 Odyssey ^ 2003-04 Pilot Ordering Honda key blanks through normal parts ordering channels: Refer to the parts catalog for correct key(s) for your application. PROGRAMMING KEYS Depending on the type of key blank you use, do this: ^ If you have used a T-5 programmable key blank ("T-5" stamped on the shank), you must code the key's transponder with the Ilco Immobilizer Key Code Duplicator (see S/B 99-053, Ilco Immobilizer key Code Duplicator). ^ If you have used a Honda key blank, add the* transponder code of the new key to the immobilizer system with the Honda Diagnostic System (HDS). ORDERING INFORMATION *To order the MATRIX H Key Cutting Machine, replacement cutter bits, fixed jaws and mobile jaws, T-5 programmable key blanks, and practice key blanks, contact the Honda Tool and Equipment Program by calling 888-424-6857 or using the fax order form provided in your Honda Tool and Equipment Program Catalog.* Order Honda key blanks through normal parts ordering channels. WARRANTY CLAIM INFORMATION None. This service bulletin is for information only. *DETERMINING WHICH KEY TO USE T-5 keys require less time to program and should be the first choice. They can be used as long as the following requirements are met: ^ Do you have the customer's operating key? ^ Does the vehicle fall within the T-5 Sidewinder Key Applications? ^ Does your dealership have an Ilco Immobilizer Key Code Duplicator? If the answer to all three questions on the above is yes, the 1-5 key option is the easier procedure. If you answered no to any of the questions, you should order the key(s) from the parts catalogue, and program it using the HDS.* BEFORE YOU START CUTTING 1. Get the original key or the key number from your customer or from the iN. 2. Get the applicable key blank. 3. If cutting by code, look up the applicable 9-digit cutting code for the key number. Refer to the code book Honda High Security key Codes that comes with the machine. Page 3781 ^ The vehicle is shown as eligible on a VIN status inquiry. In addition, check for a punch mark above the seventh character of the engine compartment VIN. A punch mark in that location means the ignition switch key interlock has already been inspected/repaired. 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 a VIN status inquiry before selling it. CUSTOMER NOTIFICATION All owners of affected vehicles will be sent a notification of this campaign. An example of the customer notification is at the end of this service bulletin. CORRECTIVE ACTION Inspect the ignition switch and, if needed, install a Key Interlock Repair Kit. PARTS INFORMATION Key Interlock Repair Kit: P/N 06351-SDA-000 REQUIRED SPECIAL TOOLS Interlock Slide Hammer: T/N 07AAC-S84A100 NOTE: ^ An initial quantity of Permalube grease to lubricate the sliding surface of the interlock lever is included with the slide hammer. To order more Permalube, use P/N 08734-0030. ^ To order a replacement clamping bolt for the slide hammer, use T/N 07AAC-S84A400. WARRANTY CLAIM INFORMATION Failed Part: P/N 35100-SDA-A31 Defect Code: 5GC00 Symptom Code: R4400 Front Wheel Bearing: Service and Repair Front Knuckle/Hub/Wheel Bearing Replacement Special Tools Required Hub dis/assembly tool 07GAF-SE00100 - Ball joint remover, 28 mm 07MAC-SL00200 - Attachment 62 x 68 mm 07746-0010500 - Driver 07749-0010000 - Support base 07965-SD90100 1. Raise the front of the vehicle, and support it with safety stands in the proper locations. 2. Remove the wheel cap, wheel nuts, and front wheel. Page 3149 1. Remove the terminal. 2. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE B: 1. Remove the terminal. 2. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE C: 1. Remove the terminal. 2. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE D: Page 3054 PGM-FI System - Component Location Index Page 1917 1. Apply a force of 98 N (10 kgf, 22 lbf), and measure the deflection at the mid point (A) between the alternator and crankshaft pulley. If the belt is worn or damaged, replace it. If the belt needs adjustment, go to step 2. Adjustment 2. Loosen the mounting bolt (B), lock bolt (C) and lower bracket mounting bolt (D). 3. Torque the mounting bolt to 20 N.m (2.0 kgf.m, 14 lbf.ft). 4. Turn the adjusting bolt (E) to obtain the proper belt tension, then retighten the lock bolt, mounting bolt and lower bracket mounting bolt. 5. Recheck the belt tension. 6. If you installed a new belt, run the engine for 5 minutes, then readjust the belt to the used belt specification. 7. Check the power steering pump belt adjustment. Page 807 Power Distribution schematics show how power is supplied from the positive battery terminal to various circuits in the vehicle. Refer to the Power Distribution diagram set to get a more detailed understanding of how picture is supplied to the circuit you're working on. Individual circuit schematics begin with a fuse. So 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 Ground Distribution Schematics This sample Ground Distribution schematic shows all of the components that share the same ground point. Page 6296 Ball Joint: Specifications TORQUE SPECIFICATIONS Castle Nut Lower ................................................................................................................................. .................................. 59 - 69 Nm (43 - 51 ft. lbs.) Page 9059 (A/T, CVT) Page 2757 DTC P1861 thru P2238 Page 4716 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 5735 Use the tools from Pin Tool Set. First, check the connector that you are about to repair. - If it has a secondary terminal lock, go to Connectors With a Secondary Lock. A secondary lock, found on most connectors on some models, is an additional locking device on the connector housing as a backup for the primary lock on the terminal. - If the connector does not have a secondary lock, go to Connectors Without a Secondary Lock. Connectors With a Secondary Lock All examples are shown with the connector lock facing up. The illustrations are examples of the secondary terminal locks; however, the connector you are repairing may vary in size. Identify the connector by the type of secondary lock, not by the number of terminal cavities. EXAMPLE A: 1. Release the secondary lock. 2. Remove the terminal. 3. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE B: Page 2713 YES - Update the ECM/PCM if it does not have the latest software, or substitute a known-good ECM/PCM, then recheck. If the symptom/indication goes away with a known-good ECM/PCM, replace the original ECM/PCM. NO - Repair open in the wire between DLC terminal No.7 and the ECM/PCM (E23). After repairing the wire, check the DTC with the OBD II scan tool/Honda PGM Tester and go to the DTC Troubleshooting index. See: Testing and Inspection/Diagnostic Trouble Code Descriptions 10. Turn the ignition switch OFF. 11. Disconnect ECM/PCM connector E (31P). Make sure the OBD II scan tool or Honda PGM Tester is disconnected from the DLC. 12. Turn the ignition switch ON (II). 13. Measure voltage between DLC terminals No.5 and No.7. Is there 0 V? YES - Update the ECM/PCM if it does not have the latest software, or substitute a known-good ECM/PCM, then recheck. If the symptom/indication goes away with a known-good ECM/PCM, replace the original ECM/PCM. NO - Repair short to power in the wire between the DLC terminal No.7 and the ECM/PCM (E23). After repairing the wire, check the DTC with the OBD II scan tool/Honda PGM Tester, and go to the DTC Troubleshooting index. See: Testing and Inspection/Diagnostic Trouble Code Descriptions Page 6165 8. Remove the flange bolt (A) and wheel sensor (B) from the knuckle. Do not disconnect the wheel sensor connector. 9. Remove the flange nut (A) while holding the joint pin (B) with a hex wrench (C), and disconnect the stabilizer link (D) from the lower arm (E). 10. Remove the lock pin (A) from the lower arm ball joint, and remove the castle nut (B). NOTE: During installation, insert the lock pin into the ball joint pin in the range of 180 degrees or below from the inside of the vehicle. Insert the lock pin from the inside to the outside of the vehicle. 11. Disconnect the lower arm from the knuckle using the special too. Page 7662 Fuel Door Release Cable: Service and Repair 4 Door Trunk Lid Opener Cable/Fuel Fill Door Opener Cable Replacement 4-door SRS components are located in this area. Review the SRS component locations and the precautions and procedures before performing repairs or service. NOTE: - Put on gloves to protect your hands. - Take care not to scratch the body and related parts. 1. Remove these items from the left side of the vehicle: - Front door sill trim - Seat side trim - Trunk side trim panel 2. Pull the carpet back as necessary. 3. Disconnect the trunk lid opener/fuel fill door opener cable (A) from the opener (B). 4. Release the opener cable from the clip (C). Remove the cushion tape (D), and detach the clip (E) by using a clip remover. 5. Remove the fuel fill door latch (F) by turning it 90 °, and detach the opener cable junction box (G) from the body. Page 4327 7. Remove the shift cable covers (A), then remove the bolts securing the shift cable holder (B). 8. Remove the lock bolt securing the control lever (c), then remove the shift cable (D) with the control lever from the control shaft (E). 9. Insert the new shift cable through the grommet hole, then install the shift cable guide bracket. 10. Verify that the transmission is in the N position on the control shaft. 11. Install the control lever with the shift cable on the control shaft. Do not bend the shift cable excessively. 12. Secure the shift cable holder with the bolts on the transmission. 13. Install the lock bolt with a new lock washer (G), then bend the lock washer tab against the bolt head. 14. Install the shift cable covers. 15. Turn the ignition switch ON (II), and verify that the N position indicator comes on. 16. Install the shift cable to the shift lever. If necessary, adjust the shift cable. Page 8769 2. Remove the terminal (same procedure for male and female). 3. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE E: 1. Remove the secondary locks. 2. Remove the terminal (same procedure for male and female). 3. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE F: Page 4289 5. Attach the slide hammer to the interlock lever pin, and tighten the slide hammer clamping bolt. Then use the slide hammer to remove the pin. Discard the pin, the lever, and the spring. 6. Wipe off any debris from the lever's sliding surface on the ignition switch with a clean cloth or a cotton swab. NOTE: To keep debris out of the ignition switch, do not clean it with compressed air. Page 9639 - Before connecting connectors, make sure the terminals (A) are in place and not bent. - Check for loose retainer (A) and rubber seals (B). - The backs of some connectors are packed with dielectric grease. Add grease if necessary. If the grease is contaminated, replace it. - Insert the connector all the way and make sure it is securely locked. - Position wires so that the open end of the cover faces down. Handling Wires and Harnesses - Secure wires and wire harnesses to the frame with their respective wire ties at the designated locations. Page 86 4. With the 14P connector disconnected, make these input tests. 5. If any test indicates a problem, find and correct the cause, then recheck the system. If all the input tests prove OK, the control unit may be faulty. Substitute a known-good control unit and retest. If the system works properly, replace the control unit. Page 6043 Relay Box: Service and Repair Removal and Installation SRS components are located in this area. Review the SRS component locations and precautions and procedures in the SRS section before performing repairs or service. Removal 1. Make sure you have the anti-theft code for the radio, then write down the frequencies for the radio's preset buttons. 2. Disconnect the battery negative cable, then disconnect the positive cable, and wait at least 3 minutes. 3. Remove the dashboard lower cover. 4. Disconnect the connectors from the fuse side of the under-dash fuse/relay box. 5. Remove the mounting bolt and slide the under-dash fuse/relay box (A) down from the bracket (B). 6. Disconnect the connectors from the back side of the under-dash fuse/relay box, and remove the fuse/relay box. NOTE: The SRS connector is a spring-loaded lock type. Installation 1. Install the under-dash fuse/relay box in the reverse order of removal and connect all connectors to the under-dash fuse/relay box. 2. Install the dashboard lower cover. 3. Connect both the negative cable and positive cable to the battery. 4. Enter the anti-theft code for the radio, then enter the customer's radio station presets. 5. Confirm that all systems work properly. 6. Do the ECM/PCM idle learn procedure. Page 6803 78. Side Impact Sensor, Front Passenger's (Sedan) 79. Side Impact Sensor, Passenger's (Coupe) Page 1161 5. Reinstall the parts in the reverse order of removal. 6. Test the operation of all windows with the power window master switch.If any of the windows do not work correctly, continue with normal troubleshooting, and do the master switch input test: ^ Refer to page 22-168 of the 2001-05 Civic Service Manual, or ^ Online, enter keyword MASTER TEST, and select Power Window Master Switch Input Test (4-door) from the list. Disclaimer Front Adjustments Shift Cable: Adjustments Shift Cable Adjustment 1. Shift the transmission into the N position. 2. Remove the center console panel and center console. 3. Remove the nut securing the shift cable end (A), then separate the cable end from the shift lever assembly. 4. Rotate the socket holder (A) on the shift cable (B) toward the shift lever a quarter turn, then slide the holder out to remove the shift cable from the shift cable bracket base (C). NOTE: Do not remove the shift cable by twisting the shift cable guide (D). 5. Push the shift cable until it stops, then release it. Pull the shift cable back two steps so that the shift position is in N. 6. Turn the ignition switch ON (II), and verify that the N position indicator comes on. 7. Turn the ignition switch OFF. Page 3178 Vehicle Speed Sensor: Testing and Inspection Vehicle Speed Signal Circuit Troubleshooting Special Tools Required: Test Harness 07LAJ-PT3020A Before testing, inspect the No.4 (10 A) and No.10 (7.5 A) fuses in the under-dash fuse/relay box. 1. Disconnect the 3P connector from the vehicle speed sensor (VSS) (A). 2. Connect the test harness only to the engine wire harness. 3. Connect the RED test harness clip (B) to the positive probe of an ohmmeter. Cover the white (C) and green (D) test harness leads with protective tape (E). 4. Check for continuity between the RED test harness clip and body ground. Is there continuity? YES - Go to step 5. NO - Repair open in the BLK wire between the VSS and G101. 5. Connect the WHT test harness clip (B) to the positive probe of a voltmeter, and connect the RED test harness clip (C) to the negative probe. 6. Turn the ignition switch ON (II). Is there battery voltage? YES - Go to step 7. NO - Repair open in the BLK/YEL wire between the VSS and the under-dash fuse/relay box. 7. Disconnect the WHT test harness clip (B). Page 8087 Keyless/Power Door Lock System Component Location Index Page 2131 Water Pump: Testing and Inspection Inspection 1. Remove the timing belt. 2. Turn the water pump pulley counterclockwise. Check that it turns freely. 3. Check for signs of seal leakage. A small amount of "weeping" from the bleed hole (A) is normal. Page 8038 13. Push the top of the retainer clip with a flat-tip screwdriver, and hold it. Release the retainer clip with a hook-shaped tool, then remove the lock cylinder. Go to step 14. 14. With the door lock cylinder out of the door handle remove the E-clip and the arm. 15. Try to insert the key into the cylinder and turn it. ^ If you can insert and turn the key, go to step 18. ^ If you cannot insert the key or turn it, go to step 16. 16. Carefully remove the spring and plastic retainer. Locations Compressor Clutch Relay: Locations Air Conditioning Component Location Index Locations 12. Middle Of Engine Page 1841 Piston: Service and Repair Piston Installation Installation If the crankshaft is already installed 1. Set the crankshaft to BDC for each cylinder. 2. Remove the connecting rod caps, and slip short sections of rubber hose (A) over the connecting rod bolts. Then install the ring compressor, and check that the bearing is securely in place. 3. Position the arrow (B) facing the timing belt side of the engine. 4. Position the piston in the cylinder, and tap it in using the wooden handle of a hammer (A). Maintain downward force on the ring compressor (B) to prevent the rings from expanding before entering the cylinder bore. 5. Stop after the ring compressor pops free, and check the connecting rod-to-crank journal alignment before pushing the piston into place. 6. Check the connecting rod bearing clearance with plastigage. 7. Apply engine oil to the bolt threads, then install the rod caps with bearings. Torque the nuts to 32 Nm (3.3 kgf-cm, 24 ft. lbs.). If the crankshaft is not installed 1. Remove the connecting rod caps, then install the ring compressor, and check that the bearing is securely in place. 2. Position the arrow (A) facing the timing belt side of the engine. Page 2443 Electric Load Sensor: Description and Operation Electrical Load Detector (ELD) Since the early 1990's, 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's 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 Cruise Control Component Location Index Page 1197 1. Remove the screws and the power window master switch (A) from the door panel. 2. Disconnect the 14P connector (B) from the switch. 3. Check for continuity between the terminals in each switch position according to the table. Driver's Switch: The driver's switch is combined with the control unit so you cannot isolate the switch to test it. Instead, run the master switch input test procedures. If the tests are normal, the driver's switch must be faulty. 4. If the switch is faulty, remove the three screws and replace the switch. Page 7538 1. At the A-pillar, remove the door checker mounting bolt (A). 2. Detach the clips (B, C, D), then remove the door weatherstrip (E). 3. Install the weatherstrip in the reverse order of removal, and note these items: - Replace any damaged clips. - Make sure the weatherstrip is installed in the holder (F) securely. - Apply liquid thread lock to the door checker mounting bolt before installation. - Check for water leaks. - Test-drive and check for wind noise. Page 984 13. After completing the right edge, push all of the cam blades to the right until they touch the cams, then trace the cam blades from back to front. (The cutter bit cuts the same contours into the left edge of the key from tip to head.) Turn off the cutter motor. 14. Release the vertical carriage lever. Push all the cam blades to the left until they touch the cams. Pull the vertical carriage lever towards you until the tracer touches the flat surface on the right side, at the front of the cams. Gently twist the lever clockwise to lock the vertical carriage at this height. Do not overtighten the lever. 15. Turn on the cutter motor, then retrace the cam blades from front to back. Push all the cam blades to the right until they touch the cams, and then retrace the cam blades from back to front (retracing cleans up the cuts on the key). Turn off the cutter motor. 16. Release the vertical carriage lever. Open the jaw and remove the key. Make sure the jaw is free of any metal shavings or debris. Turn the key over so the blank side is up, then slide it into the jaw up to the key stop. Close the jaw to lock the key in place. 17. Push all the cam blades to the left until they touch the cams. Repeat steps 10 through 15 to cut both edges on the other side of the key. 18. When you are done making the required cuts, release the vertical carriage lever. Open the jaw and remove the key. 19. Make sure the key works in the ignition switch and the locks. If the key does not work, recut the key, and try it again. 20. Depending on the type of key, code the key transponder. Equipment Service and Warranty To service the MATRIX H Key Cutting Machine, refer to section 7 of the MATRIX H Operating Manual. It tells you how to replace parts that commonly wear out such as the drive belt, the work light bulb, and the tension spring on the vertical carriage. It also covers checking and replacing fuses and replacing the printed circuit board for the setting unit keypad. If you have technical questions on the equipment, contact the Ilco Technical Assistance Department. Mail: Kaba Ilco Technical Assistance Department 400 Jeffreys Road Rocky Mount, NC 27804 Phone: 800-452-6872 Ext: 200, 384, 323, 398, 356 Fax: 252-446-4702 The MATRIX H Key Cutting Machine comes with a 3-year limited warranty. This warranty does not cover the cutter bit or the work light bulb. CODE BOOK CORRECTIONS In the code book Honda High Security key Codes, correct these errors: Pages 4 thru 51, code headings: ^ Incorrect: J H G F Z X E D C B M/S X ^ Correct: J H G F A X E D C B M/S X Page 2, last paragraph: Page 4993 1. Remove the terminal. 2. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE G: 1. Remove the terminal. 2. Go to HOW TO INSTALL NEW TERMINALS. How to Install New Terminals HOW TO INSTALL NEW TERMINALS 1. Carefully match the old terminal with a new one from the terminal repair kit. Choose the correct replacement terminal based on the wire size range the terminal will accommodate. NOTE: If the replacement terminal quantities are low, reorder them by using the terminal part number listed on the inside lid of the terminal repair kit. Replacement terminals are available through your parts department using normal parts ordering procedures. 2. Depending on the size of the wire you are repairing, use the proper size slot in the crimping tool. Page 9510 13. Plug in the heat gun, and turn it on. Start at the middle of the splice connector, and move the gun toward the ends as the tube shrinks. Apply heat evenly by rotating the curved heat spreader around the splice connector. Shrinking is complete when a small amount of sealant appears at each end of the tube. Pigtail Terminal Selection Chart PIGTAIL TERMINAL SELECTION CHART Select the proper size pigtail terminal by matching the replacement terminal part number and the wire size being repaired to the corresponding pigtail terminal part number. Then use the color (size) splice connector listed. In some instances you may also have to match the wire seal style to select the proper pigtail terminal. Pigtail terminals are available through your parts department, in quantities of 10, using normal parts ordering procedures. Checking For Poor Fir of Terminals CHECKING FOR POOR FIT OF TERMINALS Loose terminal fit can cause a number of intermittent problems in electrical circuits. By using the Terminal Inspection Feeler Tool Set you can inspect the terminal fit between the two matching connectors without removing the terminals from the connector body. 1. Find the terminal tool that best matches the male terminal in the mating connector. Page 5373 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 Locater) 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. Troubleshooting Precautions Troubleshooting Precautions Before Troubleshooting 1. Check the main fuse and the fuse 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, or you will damage the alternator diodes. - Do not attempt to crank the engine with the ground cable disconnected 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. Page 624 108. Middle Of Floor Page 7899 - From the wheelhouse side, plug weld the holes in the dashboard upper and damper housing extension. - Weld the front wheelhouse, damper housing, and front side - Weld the wheelhouse upper member. When replacing the front wheelhouse only, but weld the wheelhouse upper member. Page 2525 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. Test Equipment 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. Page 2829 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. How to Replace Connector Terminals Terminal Replacement Procedure HOW TO REPLACE CONNECTOR TERMINALS The terminal repair kits provide necessary tools and materials (terminals, wire seals, and splice connectors) to repair many damaged or faulty connector terminals. However, not all terminals for all connectors are available. Refer to the labels on the lids of the repair kits for replacement terminal availability. IMPORTANT SAFETY INFORMATION: On some models, the SRS wires are in a separate harness. If the SRS harness is damaged, replace the harness; do not repair it. On other models, wire harnesses include yellow SRS wires. If any SRS wire is damaged, replace the entire harness; do not repair it. Before you begin, inspect the wire you are about to repair for damage and length. Make sure the wire will be long enough to make a terminal repair without stretching it when you reinstall the terminal in the connector. If the wire is too short, or if access to the connector is too restricted to make a terminal repair, you may need to install a pigtail terminal (a short length of wire with a factory-crimped terminal on it). Refer to HOW TO INSTALL PIGTAIL TERMINALS. Removing the Terminal Page 8753 Resistor Variable Sensor Solenoid Transistors Circuit Schematics 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 7465 8. Put the splice connector in the proper size slot in the Crimper Tool, slide it to one end (where the flare begins), and close the crimper handles far enough to hold it in place. To release the ratchet mechanism at any point after the first click, squeeze the handles slightly and push the release lever, then let the handles open. 9. Insert one of the bare wires into the splice connector end that is in the crimper jaws. Push the wire all the way into the splice connector, and squeeze the crimper handles. Keep squeezing until the jaws touch, and hold it at that position until the ratchet clicks again. 10. Crimp the other wire in the same way into the other end of the splice connector. 11. After crimping, gently pull on the wires in the opposite directions to make sure they are secure in the connector. 12. Separate the other wires in the harness from the repaired wire(s), and shield them with nonflammable material. Page 9656 8. Inspect the quality of the wire crimp. If it has any of the following NO GOOD crimps, cut it off and start over. 9. Insert the terminal into the connector. Make sure the wire seals are pushed all the way into the connector. Lightly pull on the wires to make sure the terminal is locked into place. 10. Close or insert the secondary terminal lock, if applicable, and reconnect the connector. How to Install Pigtail Terminals HOW TO INSTALL PIGTAIL TERMINALS Pigtail terminals (short pieces of wire with a factory crimped terminal) are used when the wire is too short or when access to the connector is too restricted to make a terminal repair. NOTE: To replace just a connector terminal, go to How to Replace Connector Terminals. IMPORTANT SAFETY INFORMATION: On some models, the SRS wires are in a separate harness. If the SRS harness is damaged, replace the harness; do not repair it. On other models, wire harnesses include yellow SRS wires. If any SRS wire is damaged, replace the entire harness; do not repair it. 1. Remove the damaged or faulty terminal from the connector. Use the proper removal tool from Pin Tool Set. Service and Repair Camshaft Oil Seal: Service and Repair Camshaft, Rocker Arm, Camshaft Seal and Pulley Installation NOTE: To prevent the rocker arm assembly from coming apart, leave the camshaft holder bolts in the holes. 1. After wiping down the camshaft and the journals in the cylinder head, lubricate both surfaces and install the camshaft. 2. Clean and install the oil control orifice (A) with a new O-ring (B) (D17A2, D17A6 engines). 3. Clean and install the oil control orifice (C) (D17A1 engine). 4. Turn the camshaft until its keyway (D) is facing up (No.1 piston TDC). 5. Loosen all the valve adjusting screws. 6. Apply liquid gasket to the head mating surface (shaded areas) of the No. 1 and No. 5 camshaft holders. 7. Set the rocker arm assembly in place and loosely install the bolts. Make sure that the rocker arms are properly positioned on the valve stems. Page 5844 Under-hood Fuse/Relay Box (2-door) Page 8156 1997-01 CR-V with dealer-installed security system 1996-97 del Sol with dealer-installed security system 1996-98 Odyssey with dealer-installed security system *1999-04 Odyssey LX with dealer-installed keyless entry system or security system* 1996-01 Prelude with dealer-installed security system *2000-04 S2000 with dealer-installed security system 2000-04 Insight with dealer-installed security system 2003-04 Pilot LX with dealer-installed keyless entry system or security system* Programming the Transmitter NOTES: ^ The system accepts up to three transmitters. The transmitter codes are stored in a stacking-type memory. If a fourth transmitter code is programmed, the code for the first transmitter is erased. ^ Entering the programming mode cancels all learned transmitter codes, so none of the previously programmed transmitters will work. You must reprogram all of the transmitters once you are in the programming mode. ^ You must complete steps 1-6 within 4 seconds of the previous step to keep the system from exiting the programming mode. 1. Turn the ignition switch to ON (II). 2. Press the "Lock" or "Unlock" button on one of the transmitters. (An unprogrammed transmitter can be used for this step.) 3. Turn the ignition switch to LOCK (0). 4. Repeat steps 1, 2, and 3 two more times using the same transmitter used in step 2. 5. Turn the ignition switch to ON (II). 6. Press the "Lock" or "Unlock" button on the same transmitter. Make sure the power door locks cycle to confirm that the system is in programming mode. 7. Within 10 seconds, press the "Lock" or "Unlock" button on each transmitter. Make sure the power door locks cycle after you press each transmitter button to confirm that the system accepted the transmitter's code. 8. Turn the ignition switch to LOCK (0) to exit the programming mode. Ordering a Transmitter Transmitters can be ordered only by authorized Honda dealers. Order them from American Honda using normal parts ordering procedures. Batteries for the Transmitter The battery number is CR2025. Each transmitter uses one battery. Page 7654 ^ Going from front to back, use the middle lock pin to set the first cam to the appropriate key code number in the code book. (The cam is properly set when the number on the cam lines up with the red scribe mark on the clamp unit.) ^ Slide the lock pin through the notch in the cam. (This locks the cam in place.) ^ Keep doing this for each of the remaining cams in the set until all the cams are set and locked, then push the lock pin all the way in. Repeat this process to set and lock the cams for the right cam set. NOTE: Make sure you set the MIS cam in the right cam set for the type of key you are cutting. For a master key, set the cam to M; for a valet key, set it to S. When you are done, push all the cam blades to the left until they touch the cams in the left cam set. 10. Pull the vertical carriage lever toward you until the tracer touches the flat surface on the right side at the front of the cams. Gently twist the lever clockwise to lock the vertical carriage at this height. Do not overtighten the lever. 11. Turn on the cutter motor with the motor start switch. [NOTICE] ^ To avoid damaging the locking jaws while cutting, keep your hand off the vertical carriage lever. Pressure on the lever will change the cutting depth. * ^ To avoid breaking the cutter bit, never back up while cutting.* ^ Wear proper eye protection (safety glasses, goggles, etc.) 12. Use the clamp carriage lever and the tracer to follow the contours of the cam blades from front to back. (The cutter bit cuts the same contours into the right edge of the key blank, from head to tip.) Page 1927 Drive Belt: Tools and Equipment Honda Serpintine Belt Wrench AST tool# HON1419 -Lightweight and slim design -Equipped with 14mm and 19mm, 12 point securing attachments Page 5566 143. Park Pin/Shift Switch (A/T) Specifications Valve Clearance: Specifications Valve Clearance Intake ................................................................................................................................................... ...................... 0.18 - 0.22 mm (0.007 - 0.009 inch) Exhaust ............................................................... ....................................................................................................... 0.23 - 0.27 mm (0.009 - 0.011 inch) Page 3636 Pressure Regulating Solenoid: Testing and Inspection A/T Clutch Pressure Control Solenoid Valves A and B Test 1. Disconnect the connectors from the A/T clutch pressure control solenoid valves A and B. 2. Measure the resistance of the A/T clutch pressure control solenoid valves A and B between the No. 1 and No. 2 terminals of each connector. STANDARD: About 5.0 Ohms 3. If the resistance of either A/T clutch pressure control solenoid is out of standard, replace the A/T clutch pressure control solenoid valves A and B. 4. Connect the No. 1 terminal of the A/T clutch pressure control solenoid valve A (and B) to the battery positive terminal, and connect the No. 2 terminal to the battery negative terminal. A clicking sound should be heard. 5. If no sound is heard, remove the A/T clutch pressure control solenoid valves A and B. 6. Check the fluid passage of the A/T clutch pressure control solenoid valve for dust and dirt. 7. Connect the No. 1 terminal of the A/T clutch pressure control solenoid valves A and B to the battery positive terminal, and connect the No. 2 terminal to the battery negative terminal. Make sure the A/T clutch pressure control solenoid valves A and B move. 8. Disconnect one of the battery terminal and check valve movement. NOTE: You can see valve movement through the fluid passage in the mounting surface of the A/T clutch pressure control solenoid valves A and B body (c). 9. If either valve binds or moves sluggishly, or if the A/T clutch pressure control solenoid does not operate, replace the A/T clutch pressure control solenoid valves A and B. Component Locations Page 8157 1997 Accord SE With Factory-Installed Security System 1997 Accord SE with factory-installed security system Programming the Transmitter NOTES: ^ The system accepts up to three transmitters. The transmitter codes are stored in a stacking-type memory. If a fourth transmitter code is programmed, the code for the first transmitter is erased. ^ Entering the programming mode cancels all learned transmitter codes, so none of the previously programmed transmitters will work. You must reprogram all of the transmitters once you are in the programming mode. ^ You must complete steps 1-6 within 4 seconds of the previous step to keep the system from exiting the programming mode. 1. Turn the ignition switch to ON (II). 2. Press the "Lock" or "Unlock" button on one of the transmitters. (An unprogrammed transmitter can be used for this step.) 3. Turn the ignition switch to LOCK (0). 4. Repeat steps 1, 2, and 3 two more times using the same transmitter used in step 2. 5. Turn the ignition switch to ON (II). 6. Press the "Lock" or "Unlock" button on the same transmitter. Make sure the power door locks cycle to confirm that the system is in programming mode. 7. Within 10 seconds, press the "Lock" or "Unlock" button on each transmitter. Make sure the power door locks cycle after you press each transmitter button to confirm that the system accepted the transmitter's code. 5. Turn the ignition switch to LOCK (0) to exit the programming mode. Ordering a Transmitter Transmitters can be ordered only by authorized Honda dealers. Order them from American Honda using normal parts ordering procedures. Batteries for the Transmitter The battery number is CR2025. Each transmitter uses one battery. 98-02 Accord EX & 00-02 Accord SE 1998-02 Accord EX with factory-installed security system 2000 and 2002 Accord SE with factory-installed security system Component Locations Shift Solenoid: Component Locations Electronic Controls Location Page 7745 WARRANTY CLAIM INFORMATION In warranty: The normal warranty applies. Failed Part: P/N 68500-S5P-A90ZZ H/C 6528640 *Defect Code: 07406* Symptom Code: 03220 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 A 1. Check the side-to-side alignment of the trunk lid latch to the striker: ^ Refer to page 20-132 of the 2001-04 Civic Service Manual. ^ In ISIS, use the keyword TRUNK ADJUST, and select Trunk Lid Adjustment from the list. 2. Make sure the gaps of the trunk lid are even on all sides. ^ If the trunk is misaligned, go to step 3. ^ If the trunk lid is properly aligned on all sides, go to REPAIR PROCEDURE B. 3. Adjust the trunk lid hinges: ^ Refer to page 20-132 of the 2001-04 Civic Service Manual. ^ In ISIS, use the keyword TRUNK ADJUST, and select Trunk Lid Adjustment from the list. 4. Check the trunk operation: ^ If the trunk opens and closes smoothly and is properly aligned, return the vehicle to the customer. ^ If the trunk lid is still difficult to close, go to REPAIR PROCEDURE B. REPAIR PROCEDURE B Page 246 234. Under-dash Fuse/Relay Box Part 7 Page 2286 Exhaust Manifold: Service and Repair EXHAUST MANIFOLD REPLACEMENT W/ RELATED COMPONENTS NOTE: Use new gaskets and self-locking nuts when reassembling. D17A2 Engine Page 8861 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 5473 Brake Master Cylinder: Service and Repair Replacement NOTE: Do not spill brake fluid on the vehicle; it may damage the paint; if brake fluid does contact the paint, wash it off immediately with water. 1. Remove the reservoir cap and brake fluid from the master cylinder reservoir. 2. Remove the brake fluid level sensor connector (A). 3. Disconnect the brake lines (B) from the master cylinder (C). To prevent spills, cover the hose joints with rags or shop towels. 4. Remove the master cylinder mounting nuts (D) and washers. 5. Remove the master cylinder from the brake booster (E). Be careful not to bend or damage the brake lines when removing the master cylinder. 6. Remove the rod seal (F) from the brake booster or master cylinder. 7. Install the master cylinder in the reverse order of removal, and note these items: Replace all the rubber parts with new ones whenever the master cylinder is removed. ^ Check the pushrod clearance before installing the master cylinder, and adjust it if necessary. ^ Use a new rod seal on reassembly. ^ Coat the inner bore lip and outer circumference of the new rod seal with the recommended seal grease in the master cylinder set. Install the rod seal onto the brake booster with its grooved side toward the master cylinder. ^ Check the brake pedal height and free play after installing the master cylinder, and adjust it if necessary. Page 2812 Wires Locations Horn Switch: Locations Horn Component Location Index Page 3196 Connectors - "C" Page 5366 Circuit Schematics Each schematic represents one circuit. A circuit's wires and components are arranged to show current flow from power at the top of the diagram 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 Page 3083 120. MAP Sensor Recall - Ignition/Shift Interlock Defect Technical Service Bulletin # 10-059 Date: 101001 Recall - Ignition/Shift Interlock Defect 10-059 October 1, 2010 Applies To: See VEHICLES AFFECTED Safety Recall: Accord, Civic, and Element Ignition Switch Key Interlock BACKGROUND Under certain conditions, the interlock lever of the ignition switch may unexpectedly deform. The interlock ensures the transmission is in Park before the ignition key can be removed. Interlock failure may allow the ignition key to be removed when the shift lever is not in Park. If the driver fails to engage the parking brake, the vehicle could roll away, increasing the risk of a crash. VEHICLES AFFECTED Not all vehicles within the VIN ranges are affected by this recall. Before beginning work on a vehicle, verify its eligibility by checking at least one of these items: ^ The customer has a notification letter. Page 1131 Transmission Position Switch/Sensor: Service and Repair Transmission Range Switch Replacement 1. Remove the intake air duct and resonator. 2. Shift to the N position. 3. Remove the transmission range switch shaft cap (A). 4. Disconnect the transmission range switch connector (A). 5. Remove the transmission range switch (B). 6. Make sure that the control lever is in the N position. Page 3268 8. Put the splice connector in the proper size slot in the Crimper Tool, slide it to one end (where the flare begins), and close the crimper handles far enough to hold it in place. To release the ratchet mechanism at any point after the first click, squeeze the handles slightly and push the release lever, then let the handles open. 9. Insert one of the bare wires into the splice connector end that is in the crimper jaws. Push the wire all the way into the splice connector, and squeeze the crimper handles. Keep squeezing until the jaws touch, and hold it at that position until the ratchet clicks again. 10. Crimp the other wire in the same way into the other end of the splice connector. 11. After crimping, gently pull on the wires in the opposite directions to make sure they are secure in the connector. 12. Separate the other wires in the harness from the repaired wire(s), and shield them with nonflammable material. Page 1417 Fluid - A/T: Fluid Type Specifications A/T Fluid Type ..................................................................................................................................................... .......................................................... Honda ATF-Z1 Honda Service News Notice: If you're replacing transmission fluid in a CVT-equipped vehicle, or just topping it off, make sure you're using the new CVT fluid (P/N 08200-9006). From here on, DON'T put ATF-Z1 in a CVT. If you're topping off a CVT that's already got ATF-Z1, there's no need for concern; this fluid is compatible with ATF-Z1. All CVT-equipped Hondas starting with the 2006 models and onward will be factory-filled with the new CVT fluid. Page 3240 Connectors - "C" Component Locations Relay Box: Component Locations Relay Box Locations Starting System Component Location Index Service and Repair Valve Guide Seal: Service and Repair Installation 1. Coat the valve stems with engine oil. Install the valves in the valve guides. 2. Check that the valves move up and down smoothly. 3. Install the spring seats on the cylinder head. 4. Install the new valve seals (A) using the valve guide seal installer (B). NOTE: Exhaust valve seal (C) has a black spring (D), and intake valve seal (E) has a white spring (F). They are not interchangeable. 5. Install the valve spring and valve retainer. Place the end of the valve spring with closely wound coils toward the cylinder head. 6. Install the valve spring compressor. Compress the spring and install the valve keepers. Specifications Map Light: Specifications Locations Under-dash Fuse/Relay Box Page 4319 Shifter A/T: Service and Repair Shift Lever Disassembly/Reassembly Shift Lever Disassembly/Reassembly Page 7975 ^ Incorrect: "If a Master Key is to be cut, put a five (5) in the blank space. Use a two (2) if a valet key is needed." ^ Correct: "If a Master Key is to be cut, put an M in the blank space. Use an S if a valet key is needed." Page 2, legend at the bottom: ^ Incorrect: "C. If a Master key is desired, then the number five (5) should be placed in the M/S position. Place the number two (2) in the M/S column if a Sub (Valet) key is needed." ^ Correct: "C. If a Master Key is desired, then an M should be placed in the M/S position. Place an S in the MIS column if a Sub (Valet) key is needed." Page 1187 5. Disconnected the 14Pconnecter and, make these in put tests at the connector. Page 4586 Control Module: Service and Repair Updating the ECM/PCM PCM Updating and Substitution for Testing Special Tools Required Honda Interface Module (HIM) P/N EQS05A35570 Use this procedure when you have to substitute a known-good PCM in a troubleshooting procedure. Update the PCM only if the PCM does not already have the latest software loaded. NOTE: Do not turn the ignition switch OFF while updating; the PCM can be damaged. How to Update the PCM NOTE: To ensure the latest program is installed, do an PCM update whenever the PCM is substituted or replaced. - Before you update the PCM, make sure the vehicle's battery is fully charged. - To prevent PCM damage, do not operate anything electrical (audio system, brakes, A/C, power windows, moon roof, door locks, etc.) during the update. - If you need to diagnose the Honda Interface Module (HIM) because the HIM's red (#3) light came on or was flashing during the update, leave the ignition switch in the ON (II) position when you disconnect the HIM from the Data Link Connector (DLC). This will prevent PCM damage. 1. Turn the ignition switch ON (II). Do not start the engine. 2. Connect the HIM to the DLC (A) located under the driver's side of dashboard. 3. Do the PCM update procedure as described on the HIM label and in the PCM update system. If the software in the PCM is the latest version, replace the PCM. How to End a Troubleshooting Session This procedure must be done after any troubleshooting. 1. Clear the DTC(s) with the Scan Tool or HDS, or reset the PCM by removing the No. 6 (PCM) fuse in the under-hood fuse/relay box for more than 10 seconds. 2. Turn the ignition switch ON (II). 3. Start the engine in the P or N position, and warm it up to normal operating temperature (the radiator fans come on). 4. To verify that the problem is repaired, test-drive the vehicle for several minutes at speeds over 30 mph (50 km/h) or in freeze data range. Recall 10V364000: Ignition Interlock Defect Shift Interlock Switch: Recalls Recall 10V364000: Ignition Interlock Defect VEHICLE MAKE/MODEL: MODEL YEAR(S): Honda/Accord 2003 Honda/Civic 2003 Honda/Element 2003-2004 MANUFACTURER: Honda (American Honda Motor Co.) MFR'S REPORT DATE: August 04, 2010 NHTSA CAMPAIGN ID NUMBER: 10V364000 NHTSA ACTION NUMBER: EA09001 COMPONENT: Electrical System: Ignition POTENTIAL NUMBER OF UNITS AFFECTED: 384220 SUMMARY: Honda is recalling certain model year 2003 Honda Accord, Civic two and four door, and model year 2003-2004 Honda Element vehicles. The interlock lever of the ignition switch may unexpectedly deform, which can allow the interlock function of a vehicle with an automatic transmission to be defeated. CONSEQUENCE: Removal of the ignition key when the gear selector of a vehicle with an automatic transmission has not been shifted to the park position can allow the vehicle to roll away, increasing the risk of a crash. REMEDY: Dealers will remove the original interlock pin and lever within the ignition switch, and replace them with newly, designed components. This service will be performed free of charge. The safety recall is expected to begin on or about September 29, 2010. Owners may contact Honda at 1-800-999-1009. NOTES: Honda safety recall No. R44. 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 7250 Programming the Transmitter NOTES: ^ The system accepts up to three transmitters. The transmitter codes are stored in a stacking-type memory. If a fourth transmitter code is programmed, the code for the first transmitter is erased. ^ Entering the programming mode cancels all learned transmitter codes, so none of the previously programmed transmitters will work. You must reprogram all of the transmitters once you are in the programming mode. ^ You must complete each step within 4 seconds of the previous step to keep the system from exiting the programming mode. Program the transmitters within 10 seconds. 1. Turn the ignition switch to ON (II). 2. Press the "Lock" or "Unlock" button on one of the transmitters. (An unprogrammed transmitter can be used for this step.) 3. Turn the ignition switch to LOCK (0). 4. Repeat steps 1 2, and 3 two more times using the same transmitter used in step 2. 5. Turn the ignition switch to ON (II). 6. Press the "Lock" or "Unlock" button on the same transmitter. Make sure the power door locks cycle to confirm that the system is in programming mode. 7. Within 10 seconds, press the "Lock" or "Unlock" button on each transmitter. Make sure the power door locks cycle after you press each transmitter button to confirm that the system accepted the transmitter's code. 8. Turn the ignition switch to LOCK (0) to exit the programming mode. Ordering a Transmitter Transmitters can be ordered only by authorized Honda dealers. Order them from American Honda using normal parts ordering procedures. Batteries for the Transmitter The battery number is CR2025. Each transmitter uses one battery. 99-04 Odyssey EX 1999-00 Odyssey EX with factory-installed keyless entry system or dealer-installed security system *2001-04 Odyssey EX models with factory- installed security system* *Transmitter Identification Page 4159 5. Attach the slide hammer to the interlock lever pin, and tighten the slide hammer clamping bolt. Then use the slide hammer to remove the pin. Discard the pin, the lever, and the spring. 6. Wipe off any debris from the lever's sliding surface on the ignition switch with a clean cloth or a cotton swab. NOTE: To keep debris out of the ignition switch, do not clean it with compressed air. Page 5209 13. Remove the solenoid cover, and make sure the solenoid plunger groove is installed in the fork on the lever. ^ If needed, correct the position of the solenoid plunger, then go to step 14. ^ If the solenoid plunger is correctly installed, there is an electrical problem with the key interlock system; refer to the Automatic Transmission section of the appropriate service manual for troubleshooting information. Once the key interlock is working normally, go to step 14. 14. Install the solenoid cover. 15. Reinstall the steering column covers. 16. Center-punch a completion mark above the seventh character of the engine compartment VIN. Disclaimer Page 6329 6. Tighten the self-locking nut (A) and flange nut (B) to the specified torque values while holding the respective joint pins (C) with a hex wrench (D). 7. After 5 minutes, re-tighten the self-locking nut again with the specified torque. Locations Oxygen Sensor Relay: Locations PGM-FI System - Component Location Index Page 268 DTC P1861 thru P2238 Page 3864 107. Behind A/T Shift Lever (except M/T) Page 5193 Page 2833 2. Remove the terminal (same procedure for male and female). 3. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE E: 1. Remove the secondary locks. 2. Remove the terminal (same procedure for male and female). 3. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE F: Automatic Transmission Shift Indicator: Testing and Inspection Automatic Transmission Indicator Input Test SRS components are located in this area. Review the SRS component locations, precautions, and procedures in the SRS section before performing repairs or service. 1. If the MIL has been reported, check for a DTC, and repair the system as indicated by DTC. 2. If the MIL does not come on, and the A/T gear position indicator P, N, or R does not come on. Turn the ignition switch off, remove the gauge assembly from the dashboard, then disconnect gauge assembly connector A (22P) and B (22P). 3. Inspect the connectors and connector terminals to be sure they are making good contact. 4. If the terminals are bent, loose, or corroded, repair them as necessary, and recheck the system. 5. Shift to the P position, and check for continuity between AS terminal (BLU/BLK) and ground. There should be continuity in the P position and no continuity in any other shift lever position. If your test results are different, check for a faulty transmission range switch or an open in the wire. 6. Shift to the N position, and check for continuity between AS terminal (BLK/RED) and ground. There should be continuity in the N position and no continuity in any other shift lever position. If your test results are different, check for a faulty transmission range switch or an open in the wire. 7. Turn the ignition switch ON (II), shift to the R position, and check for voltage between All terminal (WHT) and ground. There should be 0 V in the [A position. There should be about 5 V in any other shift lever position. If your test results are different, check for a faulty transmission range switch or an open in the wire. 8. Check for voltage between B17 terminal (YEL) and ground with the ignition switch ON (II). There should be battery voltage. If your test results are different, check for a blown No. 10 (7.5A) fuse in the under-dash fuse/relay box or an open in the wire. 9. Turn the ignition switch OFF, and check for continuity between B16 terminal (BLK) and ground under all conditions. There should be continuity. If your test results are different, check for a poor ground (G501) or an open in the wire. 10. If all input tests prove OK, but the indicator is faulty, replace the printed circuit board. Page 6857 7. From the Mode menu, select Miscellaneous Test. 8. From the Miscellaneous Test menu, select OPDS Initialization. 9. Follow the remaining screen prompts to complete the OPDS initialization. If the initialization fails repeat the process two more times. If the initialization fails again, check for SRS DTCs, then troubleshoot them using the appropriate service manual. Initializing the OPDS Unit: Manual Mode NOTE: Non-Honda seat covers will interfere with the performance of the OPDS and are not recommended. 1. Adjust the front passenger's seat-back to an upright position, then remove anything on or near the seat. 2. Turn the ignition switch to LOCK (0). 3. Connect the HDS to the vehicle's DLC (data link connector). 4. Keep the ignition switch at LOCK (0), and turn on the HDS. 5. At the screen prompts, enter the VIN and the odometer reading. 6. From the Select Mode screen, select SCS, and follow the screen prompts. Page 3109 Power Steering Pressure Switch: Testing and Inspection PSP Switch Signal Circuit Troubleshooting 1. Turn the ignition switch ON (II). 2. Measure voltage between ECM/PCM connector terminals A24 and E16. Is there less than 1.0 V? YES - Go to step 3. NO - Go to step 6. 3. Start the engine. 4. Turn the steering wheel to the full lock position. 5. Measure voltage between ECM/PCM connector terminals A24 and E16. Is there battery voltage? YES - The PSP switch signal is OK. NO - Go to step 13. 6. Turn the ignition switch OFF. 7. Disconnect the PSP switch 2P connector. 8. Turn the ignition switch ON (II). 9. At the harness side, connect the PSP switch 2P connector terminals No.1 and No.2 with a jumper wire. 10. Measure voltage between ECM/PCM connector terminals A24 and E16. Is there less than 1.0 V? YES - Replace the PSP switch. NO - Go to step 11. 11. Turn the ignition switch OFF. Page 7917 - Push the clips into place securely. 4-door 1. Remove the front bumper. 2. Remove the screws (A) and clips (B), and remove the front grille (C) from the front bumper (D) by pulling it out. Take care not to scratch the front bumper. 3. Remove the screws, then remove the front grille the front grille molding (B)('04-05 models) from the front grille (C). 4. Install the grille in the reverse order of removal, and note these items. Page 7258 system will not enter the programming mode.) 3. Within 10 seconds, close and open the door two times. 4. Turn the ignition switch to the ACC position and then to the LOCK position three times. Close and open the door. (Complete this process within 10 seconds.) Verify that the power door locks cycle once to confirm that the system is in programming mode. 5. Within 20 seconds, press the "LOCK" button on the transmitter you are programming. Verify that the door locks cycle once. 6. Within 20 seconds, press the "UNLOCK" button on the transmitter. Verify that the door locks cycle once to confirm that the system has accepted the transmitter's code. Turning the Audible Chirp On/Off (1998-99 only) NOTE: On '00-02 Passports, the audible chirp sounds only when you push the LOCK button on the transmitter a second time. 1. Open the driver's door, then insert the key in the driver's door lock. 2. Turn the key to the "LOCK" position, then to the "UNLOCK" position. Repeat this two more times. (Complete this procedure within 10 seconds.) 3. Within 10 seconds, close and open the door two times. 4. Within 10 seconds, turn the key to the "LOCK" position, and then to the "UNLOCK" position, three times. Close and open the door once. Verify that the power door locks cycle once to confirm that the chirp has been turned on/off. Ordering a Transmitter Transmitters can be ordered only by authorized Honda dealers. Order them from American Honda using normal parts ordering procedures. Batteries for the Transmitter The battery number is CR2016. Each transmitter uses two batteries. Page 7471 Diagram 52-2 (LX-C) Diagrams: Other diagrams referred to by number (See Diagram ##-#, etc.)within these diagrams can be found at Diagrams by Number. See: Diagrams/Electrical Diagrams/Diagrams By Number Locations: Location photographs (references to PHOTOS) referred to within these diagrams can be found at Locations by Photo Number. See: Locations/Component Locations/Locations By Photo Number Connector Views: Connector terminal views (references to VIEWS) referred to within these diagrams can be found at Connector Views by View Number. See: Diagrams/Connector Views/Connector Views By View Number Page 933 ^ If the OPDS unit has an original part number, go to step 6. ^ If the OPDS unit has a new part number (refer to PARTS INFORMATION) or higher, go to REPAIR PROCEDURE B: OPDS SENSOR REPLACEMENT. 6. Recline the seat-back to access the OPDS unit mounting screws. 7. Remove the mounting screws from the OPDS unit, and gently pull out the unit. 8. Disconnect the OPDS connectors, then remove the OPDS unit. 9. Install a new OPDS unit, then snap on its cover. 10. Slip the seat-back cover over the OPDS unit. 11. On Accords, check the seat-back clip attachment bosses on the seat-back panel: ^ If the attachment bosses are OK, go to step 12. ^ If the seat-back has a pocket, and the attachment bosses are deformed or damaged, do the repair procedure in S/B 02-010, Seat-Back Panel Is Loose or Detached. Then go to step 12. ^ If the seat-back does not have a pocket, and the attachment bosses are deformed or damaged, replace the seat-back. Then go to step 12. Application and ID Turn Signal Flasher: Application and ID PLEASE NOTE: The flasher function for this vehicle is provided by the Turn Signal/Hazard Relay. Page 9285 7. Using a jumper wire, connect the steering column. - If the horn sounds, replace the steering column. - If the horn does not sound, replace the horn and contact plate. Page 2169 2. Cut off the wire about an inch back from where it connects to the damaged or faulty terminal, then strip about half of the insulation off that piece. This will be used to size the wire end of the replacement pigtail terminal. NOTE: If you are not sure of the wire size, start with a large enough hole on the stripper that will not nick or cut off any strands of wires. 3. Select a pigtail terminal that matches the original wire at both ends (same kind of terminal and same diameter bare wire). 4. Select the smallest splice connector (yellow, pink, or blue) that will fit onto the stripped end of the original wire. 5. Insert the pigtail terminal into the connector cavity; push it in until it locks in place. 6. Lay the pigtail and the original wire side-by-side, and cut off both ends at once. If you are making more than one splice, do not cut each pigtail at the same location; the resulting "lump" of splice connectors would interfere with rewrapping the harness. Instead, cut the first pigtail close enough to the terminal so you will have room to make each remaining cut about 20 mm (3/4 inch) farther down on the next pigtail. 7. If you are using a yellow splice connector, strip about 6 mm (1/4 inch) of insulation off the ends of both wires. If you are using a pink or blue splice connector, strip off about 8 mm (5/16 inch) of insulation. Body - Door Lock Cylinders Bind Fuel Door Lock Cylinder: All Technical Service Bulletins Body - Door Lock Cylinders Bind 03-068 October 29, 2004 Applies To: See VEHICLES AFFECTED Door Lock Cylinder Binds (Supersedes 03-068, dated April 20, 2004) Updated information is shown with asterisks and black bars. SYMPTOM The key will not go into the door lock cylinder, or if it goes in, it will not turn. PROBABLE CAUSE The door lock tumblers are damaged or worn. VEHICLES AFFECTED CORRECTIVE ACTION Remove the door lock cylinder, and replace the inner cylinder, springs, and tumblers. Page 4792 1. Remove the secondary locks. 2. Remove the terminal from the female half. 3. Remove the terminal from the male half. 4. Go to HOW TO INSTALL NEW TERMINALS. Connectors Without a Secondary Lock All examples are shown with the connector lock facing up. The illustrations are examples of connector terminals without a secondary lock; however, the connector you are repairing may vary in size and shape. EXAMPLE A: Page 5267 3. If there is no continuity between any terminal, remove the transmission range switch cover, and disconnect the connector (A) at the switch (B). 4. Check for continuity between terminals at the switch connector (c). There should be continuity between the terminals listed for each position. In the P position, between terminals: ^ No. 4 and No. 5 ^ No. 4 and No. 6 ^ No. 5 and No. 6 In the R position, between terminals: ^ No. 1 and No. 4 In the N position, between terminals: ^ No. 4 and No. 5 ^ No. 4 and No. 7 ^ No.5 and No.7 In the D position, between terminals: ^ No.2 and No.4 ^ No. 2 and No. 10 ^ No. 4 and No. 10 In the D3 position, between terminals: ^ No. 4 and No. 8 ^ No. 4 and No. 10 ^ No. 8 and No. 10 In the 2 position, between terminals: ^ No.3 and No.4 5. If there is no continuity between any terminals, adjust the transmission range switch installation. If the transmission range switch installation is OK, replace the switch. 6. If the transmission range switch continuity check was OK, replace the faulty transmission range switch harness. Locations Fuel Supply System Component Location Index Component Locations 55. In Steering Column Cover Page 6358 1. Compress the damper spring with a commercially available strut spring compressor (A) according to the manufacturer's instructions, then remove the self-locking nut (B) while holding the damper shaft (C) with a hex wrench (D). Do not compress the spring more than necessary to remove the nut. 2. Release the pressure from the strut spring compressor, then disassemble the damper as shown in the Exploded View. 3. Reassemble all the parts, except for the spring. 4. Compress the damper assembly by hand, and check for smooth operation through a full stroke, both compression and extension. The damper should extend smoothly and constantly when compression is released. If it does not, the gas is leaking and the damper should be replaced. 5. Check for oil leaks, abnormal noises, or binding during these tests. Reassembly 1. Install all the parts except the damper mounting washer and self-locking nut onto the damper unit by referring to the Exploded View. Align the bottom of the spring (A) and the stepped part of the lower spring seat (B), and align the damper mounting base as shown. 2. Install the damper assembly on a commercially available strut spring compressor (C). 3. Compress the damper spring with the strut spring compressor. Page 8163 Programming the Transmitter This transmitter is not programmable. Ordering a Transmitter This transmitter is no longer available. Batteries for the Transmitter The battery number is CR2025. Each transmitter uses two batteries. 97-99 EV Plus With Factory-Installed Security System 1997-99 EV Plus with factory-installed security system Programming the Transmitter NOTES: ^ The system accepts up to three transmitters. The transmitter codes are stored in a stacking-type memory. If a fourth transmitter code is programmed, the code for the first transmitter is erased. ^ Entering the programming mode cancels all learned transmitter codes, so none of the previously programmed transmitters will work. You must reprogram all of the transmitters once you are in the programming mode. ^ You must complete steps 1-6 within 4 seconds of the previous step to keep the system from exiting the programming mode. 1. Turn the ignition switch to ON (II). 2. Press the "Lock" or "Unlock" button on one of the transmitters. (An unprogrammed transmitter can be used for this step.) 3. Turn the ignition switch to LOCK (0). 4. Repeat steps 1, 2, and 3 two more times using the same transmitter used in step 2. 5. Turn the ignition switch to ON (II). 6. Press the "Lock" or "Unlock" button on the same transmitter. Make sure the power door locks cycle to confirm that the system is in programming mode. 7. Within 10 seconds, press the "Lock" or "Unlock" button on each transmitter. Make sure the power door locks cycle after you press each transmitter button to confirm that the system accepted the transmitter's code. 5. Turn the ignition switch to LOCK (0) to exit the programming mode. Ordering a Transmitter Transmitters can be ordered only through Tech Line. Batteries for the Transmitter The battery number is CR2025. Each transmitter uses one battery. 00-04 Insight With Factory-Installed Keyless Entry System 2000-04 Insight with factory-installed keyless entry system Page 517 98. Wheel Speed Sensor, Right Rear (EX, GX) Page 8015 24. Remove the key. Reinstall the retainer clip in the door handle, and push the lock cylinder into place. 25. Civic: Reconnect the cylinder rod. 26. CR-V: Reconnect the cylinder rod, the outer handle rod, and the rod protector. 27. Element: Reconnect the cylinder rod, the outer handle rod, and the access seal. Reinstall the lower run channel. 28. Reinstall the plastic covering, and lower the window glass. Install the door panel. 29. Check that the door lock and handle operate smoothly. Disclaimer Keyless Entry - Remote Transmitter Information Technical Service Bulletin # 98-011 Date: 040220 Keyless Entry - Remote Transmitter Information 98-011 February 20, 2004 Applies To: ALL Keyless Remote Transmitter Information (Supersedes 98-011, dated February 6, 2003) Updated information is shown by asterisks and a black bar. This service bulletin gives you information about keyless remote transmitters for most Honda vehicles. Each procedure describes transmitter programming (if applicable), transmitter ordering, and transmitter batteries. A remote transmitter quick reference guide is shown below. Page 3616 Knock Sensor: Service and Repair Replacement 1. Remove the oil filter with the special oil filter wrench. 2. Disconnect the knock sensor connector, then remove the knock sensor. 3. Install the knock sensor and oil filter. Page 904 Knock Sensor: Service and Repair Replacement 1. Remove the oil filter with the special oil filter wrench. 2. Disconnect the knock sensor connector, then remove the knock sensor. 3. Install the knock sensor and oil filter. Alternator FR Signal Circuit Troubleshooting Alternator: Testing and Inspection Alternator FR Signal Circuit Troubleshooting Alternator FR Signal Circuit Troubleshooting 1. Disconnect the alternator 4P connector from the alternator. 2. Turn the ignition switch ON (II). 3. Measure voltage between ECM/PCM connector terminals A24 and B13. Is there about 5 V? YES - Go to step 4. NO - Go to step 13 4. Turn the ignition switch OFF. 5. Reconnect the alternator 4P connector. 6. Start the engine. Hold the engine at 3,000 rpm with no load (in Park or neutral) until the radiator fan comes on, then let it idle. 7. Measure voltage between ECM/PCM connector terminals A24 and B13. Does the voltage decrease when the headlights and rear window defogger are turned on? YES - The alternator FR signal is OK. NO - Go to step 8. 8. Turn the ignition switch OFF. 9. Disconnect ECM/PCM connector B (24P). 10. Disconnect the alternator 4P connector. 11. Connect alternator 4P connector terminal No.4 to body ground with a jumper wire. Page 4311 Shift Solenoid: Testing and Inspection Shift Solenoid Valves A and B Test 1. Disconnect the shift solenoid valves A and B connector. 2. Measure shift solenoid valve A resistance between the No. 1 terminal of the shift solenoid valves A and B connector and body ground, and measure shift solenoid valve B resistance between the No. 2 terminal and body ground. STANDARD: 12 - 25 Ohms 3. Replace the shift solenoid valves A and B if either resistance is out of standard. 4. If the resistance is within the standard, connect the No. 1 terminal of the shift solenoid valve A to the battery positive terminal. A clicking sound should be heard. Connect the No. 2 terminal to the battery positive terminal. A clicking sound should be heard. Replace the shift solenoid valves A and B if no clicking sound is heard when either terminal is connected to the battery terminal. Page 6725 2. Remove the driver's airbag: ^ Refer to page 23-137 of the 2001-2005 Civic Service Manual, or * ^ Refer to page 23-131 of the 2002-2004 CR-V Service Manual, or ^ Refer to page 23-368 of the 199~2004 Odyssey Service Manual, or ^ Refer to page 23-105 of the 2003-2004 Pilot Service Manual, or* ^ Online, enter keywords DRIVER AIR, and select Driver's Airbag Replacement from the list. 3. Place the airbag, face down, on a clean shop towel. 4. Using needle-nose Vise Grips, remove the four locknuts from the inflator and discard them reused. NOTE: Do not remove the inflator from the airbag until you complete step 5. 5. Use shop air to clean any debris that may be on the inflator, then remove the inflator from the airbag. NOTE: ^ Do not allow any foreign objects to enter the inflator opening in the airbag. ^ Do not deploy the inflator. The inflator must be returned to its supplier in the box the new inflator came in (see INFLATOR PACKING AND GROUND SHIPPING INSTRUCTIONS: DEALERS IN THE 48 CONTIGUOUS STATES or INFLATOR PACKING AND AIR SHIPPING INSTRUCTIONS: DEALERS IN ALASKA AND HAWAII). 6. Turn over the airbag (inflator side down), and shake it to remove any debris from the inflator opening. 7. Install the new inflator in the airbag with new locknuts. Torque the locknuts to 3.9 N.m (2.8 lb-ft, 34 lb-in). NOTE: The 55A inflator is slightly taller than the S84 inflator, but they are still interchangeable. Page 5737 2. Remove the terminal from the female half. 3. Remove the terminal from the male half. 4. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE D: 1. Remove the secondary locks. Page 245 234. Under-dash Fuse/Relay Box Part 6 Page 8845 Fuel Gauge Sender: Service and Repair Fuel Pump/Fuel Gauge Sending Unit Replacement Special Tools Required Fuel sender wrench 07XAA-001010A 1. Relieve the fuel pressure. 2. Remove the fuel fill cap. 3. Remove the seat cushion. 4. Remove the access panel (A) from the floor. 5. Disconnect the fuel pump 5P connector (B). 6. Disconnect the quick-connect fitting (C) from the fuel tank unit. 7. Using the special tool, loosen the fuel tank unit locknut (A). Body - Trunk Lid Hard to Close Trunk / Liftgate Striker: All Technical Service Bulletins Body - Trunk Lid Hard to Close 02-061 November 5, 2004 Applies To: See VEHICLES AFFECTED Trunk Lid is Difficult to Close (Supersedes 02-061, dated July 23, 2004) Updated information is shown with asterisks. SYMPTOM The trunk lid may be difficult to close or won't latch closed. PROBABLE CAUSE The trunk lid may be misaligned, and the trunk lid opener cable, trunk lid latch, lock cylinder, lock rod, and/or the trunk lid latch striker may need adjustment or replacement. VEHICLES AFFECTED CORRECTIVE ACTION Adjust the trunk lid and/or the trunk lid latch, or replace components as needed. PARTS INFORMATION Page 9316 1. Remove the terminal. 2. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE G: 1. Remove the terminal. 2. Go to HOW TO INSTALL NEW TERMINALS. How to Install New Terminals HOW TO INSTALL NEW TERMINALS 1. Carefully match the old terminal with a new one from the terminal repair kit. Choose the correct replacement terminal based on the wire size range the terminal will accommodate. NOTE: If the replacement terminal quantities are low, reorder them by using the terminal part number listed on the inside lid of the terminal repair kit. Replacement terminals are available through your parts department using normal parts ordering procedures. 2. Depending on the size of the wire you are repairing, use the proper size slot in the crimping tool. Page 8367 Keyless Entry Module: Diagrams (EX; '04: LX, GX) (Honda Accessory) Locations 120. Driver's Door (Sedan except DX) Service and Repair 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. Page 3238 Wire Color Abbreviations Page 5681 ^ Refer to page 11-199 of the 2001-2005 Civic Service Manual, or ^ Online, enter keyword RESONATOR, and select Resonator Removal/Replacement from the list. 4. Disconnect the female terminal (BLK/WHT wire) from the S terminal of the starter solenoid. NOTE: A/T is shown. M/T is similar 5. Pull the boot back from the female S terminal, and check the terminal for signs of arcing. 6. Check the male S terminal at the starter for signs of arcing. 7. If either terminal has signs of arcing, go to REPAIR PROCEDURE. If neither terminal has signs of arcing, continue your diagnosis using the appropriate service manual. REPAIR PROCEDURE Page 8322 201. Power Mirror Switch (except DX) Page 7719 ^ If the trunk opens and closes smoothly, return the vehicle to the customer. ^ If the trunk lid is still difficult to close, go to REPAIR PROCEDURE E. REPAIR PROCEDURE E 1. Look at the back of the lock cylinder while you turn the key from lock to unlock. ^ Refer to page 20-158 of the 2001-04 Civic Service Manual. ^ In ISIS, use the keyword LID LOCK, and select Trunk Lid Lock Cylinder Replacement from the list. 2. Check the operation of the trunk lid lock cylinder: ^ If the lock cylinder is difficult to turn or binds, go to step 3. ^ If the lock cylinder operates properly, and the trunk lid is still difficult to close, refer to the appropriate body repair manual, and check for body inaccuracies. 3. Replace the lock cylinder, and re-key the cylinder to the customer's original key; on 2-door Civics, replace the lock cylinder and the lock cylinder rod: ^ Refer to page 20-158 of the 2001-04 Civic Service Manual. ^ In ISIS, use the keyword LID LOCK, and select Trunk Lid Lock Cylinder Replacement from the list. 4. Check the trunk operation, and return the vehicle to the customer. Disclaimer Page 2537 1. Remove the terminal. 2. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE E: 1. Remove the terminal. 2. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE F: Locations Parking Brake Warning Switch: Locations Gauges Component Location Index (Part 1 Of 4) Page 2237 Blower Motor Relay Type 1, Type 2 Check for continuity between the terminals. - There should be continuity between the No.1 and No.3 terminals when power and ground are connected to the No.2 and No.4 terminals. - There should be no continuity between the No.1 and No.3 terminals when power is disconnected. Five-terminal type Check for continuity between the terminals. - There should be continuity between the No.1 and No.2 terminals when power and ground are connected to the No.3 and No.5 terminals. - There should be continuity between the No.1 and No.4 terminals when power is disconnected. Page 9292 Connectors - "C" Page 5588 Alternator: Specifications Alternator Output at 13.5 V and normal engine temperature ......................................................................................................................................... 70 A Page 5129 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. How to Replace Connector Terminals Terminal Replacement Procedure HOW TO REPLACE CONNECTOR TERMINALS The terminal repair kits provide necessary tools and materials (terminals, wire seals, and splice connectors) to repair many damaged or faulty connector terminals. However, not all terminals for all connectors are available. Refer to the labels on the lids of the repair kits for replacement terminal availability. IMPORTANT SAFETY INFORMATION: On some models, the SRS wires are in a separate harness. If the SRS harness is damaged, replace the harness; do not repair it. On other models, wire harnesses include yellow SRS wires. If any SRS wire is damaged, replace the entire harness; do not repair it. Before you begin, inspect the wire you are about to repair for damage and length. Make sure the wire will be long enough to make a terminal repair without stretching it when you reinstall the terminal in the connector. If the wire is too short, or if access to the connector is too restricted to make a terminal repair, you may need to install a pigtail terminal (a short length of wire with a factory-crimped terminal on it). Refer to HOW TO INSTALL PIGTAIL TERMINALS. Removing the Terminal Page 5078 87. TCC Solenoid Valve (A/T Except CVT) Page 2328 ECM/PCM Inputs And Outputs At Connector A (31P) Service and Repair Fuel Pressure Release: Service and Repair Fuel Pressure Relieving Before disconnecting fuel lines or hoses, relieve pressure from the system by disconnecting the fuel tube/quick connect fitting in the engine compartment. 1. Make sure you have the antitheft code for the radio, then write down the frequencies for the radio's preset buttons. 2. Turn the ignition switch OFF. 3. Remove the glove box, then remove the PGM-FI main relay 2 (A). 4. Start the engine, and let it idle until it is stalls. NOTE: The DTCs or Temporary DTCs P0301, P0302, P0303, P0304 may come on during this procedure. If any DTCs are stored, ignore them. 5. Turn the ignition switch OFF. 6. Remove the fuel fill cap to relieve fuel pressure in the fuel tank. 7. Disconnect the negative cable from the battery. 8. Remove the bolt (A) and the fuel feed pipe mounting bracket (B), then remove the quick-connect fining covers (C). 9. Check the fuel quick-connect fitting for dirt, and clean if necessary. 10. Place a rag or shop towel over the quick-connect fitting (D). Page 2543 13. Plug in the heat gun, and turn it on. Start at the middle of the splice connector, and move the gun toward the ends as the tube shrinks. Apply heat evenly by rotating the curved heat spreader around the splice connector. Shrinking is complete when a small amount of sealant appears at each end of the tube. Pigtail Terminal Selection Chart PIGTAIL TERMINAL SELECTION CHART Select the proper size pigtail terminal by matching the replacement terminal part number and the wire size being repaired to the corresponding pigtail terminal part number. Then use the color (size) splice connector listed. In some instances you may also have to match the wire seal style to select the proper pigtail terminal. Pigtail terminals are available through your parts department, in quantities of 10, using normal parts ordering procedures. Checking For Poor Fir of Terminals CHECKING FOR POOR FIT OF TERMINALS Loose terminal fit can cause a number of intermittent problems in electrical circuits. By using the Terminal Inspection Feeler Tool Set you can inspect the terminal fit between the two matching connectors without removing the terminals from the connector body. 1. Find the terminal tool that best matches the male terminal in the mating connector. Page 4880 3. Remove and discard the shift fork. 4. Apply vinyl tape to the mainshaft splines to protect the seal, then remove the mainshaft and shift forks as an assembly from the clutch housing. 5. Disassemble the countershaft assembly; see page 13-32 (13-45 for Hybrid) of the service manual. Page 9358 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. How to Replace Connector Terminals Terminal Replacement Procedure HOW TO REPLACE CONNECTOR TERMINALS The terminal repair kits provide necessary tools and materials (terminals, wire seals, and splice connectors) to repair many damaged or faulty connector terminals. However, not all terminals for all connectors are available. Refer to the labels on the lids of the repair kits for replacement terminal availability. IMPORTANT SAFETY INFORMATION: On some models, the SRS wires are in a separate harness. If the SRS harness is damaged, replace the harness; do not repair it. On other models, wire harnesses include yellow SRS wires. If any SRS wire is damaged, replace the entire harness; do not repair it. Before you begin, inspect the wire you are about to repair for damage and length. Make sure the wire will be long enough to make a terminal repair without stretching it when you reinstall the terminal in the connector. If the wire is too short, or if access to the connector is too restricted to make a terminal repair, you may need to install a pigtail terminal (a short length of wire with a factory-crimped terminal on it). Refer to HOW TO INSTALL PIGTAIL TERMINALS. Removing the Terminal Page 9445 208. DRL Control Unit (Canada) Key Beeper, Light Chime & Ceiling Light Don't Work Key Reminder Switch: Technical Service Bulletins Key Beeper, Light Chime & Ceiling Light Don't Work SOURCE: Honda Service News April 2003 TITLE: Key Beeper, Light Chime, Ceiling Light Don't Work APPLIES TO: 2001-03 Civic, 2002-03 CR-V SERVICE TIP: If the ignition key-in beeper, the headlights-on chime, the ceiling light, and the driver's-dooropen indicator are all on the fritz check the driver's door switch in the doorjamb. A faulty door switch can cause all of these symptoms. Page 6867 VEHICLES AFFECTED CUSTOMER NOTIFICATION All owners of affected vehicles were mailed a notification of this warranty extension. A example of the customer notification is shown in this service bulletin. CORRECTIVE ACTION Repair the vehicle as indicated by the INSPECTION PROCEDURE. If needed, replace the OPDS unit. In rare cases where an updated OPDS unit was already installed, replace the OPDS sensor. Page 930 PARTS INFORMATION TOOL INFORMATION Page 6480 Relay And Control Unit Locations - Engine Compartment Page 650 110. Left B Pillar (Right Similar) 111. Left C Pillar (Sedan) (Right Similar) Page 5414 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 587 Evaporator Temperature Sensor / Switch: Testing and Inspection Evaporator Temperature Sensor Test 1. Dip the sensor in ice water, and measure the resistance between its terminals. 2. Then pour hot water on the sensor, and check for a change in resistance, 3. Compare the resistance readings with the specifications shown in the graph; the resistance should be within the specifications. Page 8855 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. SRS Unit, Front Sensors and Side Impact Sensors SRS Unit, Front Sensors and Side Impact Sensors Be careful not to bump or impact the SRS unit, front sensors, or the side impact sensors whenever the ignition switch is ON (II), or for at least 3 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, front sensors, and the side impact sensor. The airbags could accidentally deploy and cause damage or injury. After a collision in which any airbags or seat belt tensioners were deployed, replace the SRS unit, front sensors, and other related components. After a collision in which a side airbag was deployed, replace the side impact sensor on the deployed side 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, front sensors, 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 3 minutes before beginning installation or replacement of the SRS unit, or disconnecting 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 N.m (1.0 kgf.m, 7.2 lbf.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 °G) and dry (less than 80% relative humidity, no moisture) area. Wiring Precautions Wiring Precautions SRS wiring can be identified by special yellow outer covering (except the SRS indicator light circuit). Page 9284 Horn Switch: Testing and Inspection Horn Switch Test 1. Remove the steering column covers. 2. Disconnect the dashboard wire harness B 5P connector (A) from the cable reel (B). 3. Using a jumper wire, connect the dashboard wire harness B 5P connector (A) No.2 terminal to body ground. - If the horn sounds, go to step 4. - If the horn does not sound, check these items: horn relay - No.7 (15 A) fuse in the under-hood fuse/relay box - Horn. - An open in the wire. 4. Reconnect the dashboard wire harness B 5P connector (A), and disconnect the horn switch positive 1P connector (B). 5. Using a jumper wire, connect the horn switch positive 1P connector (B) to ground. - If the horn sounds, go to step 6. - If the horn does not sound, replace the cable reel. 6. Reconnect the horn switch positive connector (B). Page 4532 Shift Solenoid: Service and Repair Shift Solenoid Valves A and B Replacement NOTE: Shift solenoid valves A and B must be removed/ replaced as an assembly. 1. Remove the harness clamp (c) form the clamp bracket (D). 2. Remove the mounting bolts and the shift solenoid valves A and B. 3. Clean the mounting surface and fluid passage. 4. Install a new shift solenoid valves A and B with a new filter/gasket (E), and install the harness clamp on the clamp bracket. 5. Check the connector for rust, dirt, or oil, then reconnect the connector securely. Page 9301 - Before connecting connectors, make sure the terminals (A) are in place and not bent. - Check for loose retainer (A) and rubber seals (B). - The backs of some connectors are packed with dielectric grease. Add grease if necessary. If the grease is contaminated, replace it. - Insert the connector all the way and make sure it is securely locked. - Position wires so that the open end of the cover faces down. Handling Wires and Harnesses - Secure wires and wire harnesses to the frame with their respective wire ties at the designated locations. Page 3222 8. Inspect the quality of the wire crimp. If it has any of the following NO GOOD crimps, cut it off and start over. 9. Insert the terminal into the connector. Make sure the wire seals are pushed all the way into the connector. Lightly pull on the wires to make sure the terminal is locked into place. 10. Close or insert the secondary terminal lock, if applicable, and reconnect the connector. How to Install Pigtail Terminals HOW TO INSTALL PIGTAIL TERMINALS Pigtail terminals (short pieces of wire with a factory crimped terminal) are used when the wire is too short or when access to the connector is too restricted to make a terminal repair. NOTE: To replace just a connector terminal, go to How to Replace Connector Terminals. IMPORTANT SAFETY INFORMATION: On some models, the SRS wires are in a separate harness. If the SRS harness is damaged, replace the harness; do not repair it. On other models, wire harnesses include yellow SRS wires. If any SRS wire is damaged, replace the entire harness; do not repair it. 1. Remove the damaged or faulty terminal from the connector. Use the proper removal tool from Pin Tool Set. Page 6331 6. Tighten the self-locking nut (A) and flange nut (B) to the specified torque values while holding the respective joint pins (C) with a hex wrench (D). 7. After 5 minutes, re-tighten the self-locking nut again to the specified torque. Page 4213 - Before connecting connectors, make sure the terminals (A) are in place and not bent. - Check for loose retainer (A) and rubber seals (B). - The backs of some connectors are packed with dielectric grease. Add grease if necessary. If the grease is contaminated, replace it. - Insert the connector all the way and make sure it is securely locked. - Position wires so that the open end of the cover faces down. Handling Wires and Harnesses - Secure wires and wire harnesses to the frame with their respective wire ties at the designated locations. Page 9811 127. Left Rear Door (Sedan Except DX) (Right Similar) Page 2036 Wires Page 3287 Vehicle Speed Sensor: Locations Gauges Component Location Index (Part 1 Of 4) Page 4527 23. Transmission Housing (A/T) Page 8950 Oil Pressure Sender: Service and Repair Oil Pressure Switch Replacement 1. Remove the oil filter with the special oil filter wrench. 2. Disconnect the oil pressure switch connector, then remove the oil pressure switch. 3. Apply liquid gasket to the oil pressure switch threads, then install the oil pressure switch. 4. Install the oil filter. Page 131 Daytime Running Lamp Relay: Testing and Inspection Power Relay Test Use this chart to identify the type of relay, then do the test listed for it. NOTE: See the turn signal/hazard relay input test. Normally-open type A: Check for continuity between the terminals. - There should be continuity between the No.1 and No.2 terminals when power and ground are connected to the No.3 and No.4 terminals. - There should be no continuity between the No.1 and No.2 terminals when power is disconnected. Page 7292 1. Remove the terminal. 2. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE B: 1. Remove the terminal. 2. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE C: 1. Remove the terminal. 2. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE D: Page 6259 NOTE: Refer to the Exploded View as needed during this procedure. Removal 1. Remove the steering gearbox. Disassembly 2. Unbend the lock washer (A). 3. Hold the bracket (A) with one wrench, and unscrew both rack ends (B) with another wrench. Remove the lock washers. 4. Remove cylinder lines (A) from the gearbox. 5. Drain the fluid from the cylinder fittings by slowly moving the steering rack back and forth. Page 4043 87. TCC Solenoid Valve (A/T Except CVT) Page 2831 1. Remove the secondary lock from the male terminal half. 2. Remove the secondary lock from the female terminal half. 3. Remove the terminal (same procedure for male and female). 4. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE C: 1. Remove the secondary lock. Page 6525 Condenser Fan Motor Relay: Testing and Inspection Power Relay Test Use this chart to identify the type of relay, then do the test listed for it. NOTE: See the turn signal/hazard relay input test. Normally-open type A: Page 4444 VEHICLES AFFECTED CORRECTIVE ACTION Replace the master cylinder, and apply a thin film of silicone grease to the clutch line fitting. REQUIRED MATERIALS Silicone Grease: P/N 08C30-B0234M, H/C 6110928 Brake Fluid: P/N 08798-9008, H/C 4423802 PARTS INFORMATION Civic/Civic Hybrid Master Cylinder: P/N 46920-S5A-G04, H/C 7569452 Accord/Civic Si/CR-V/Element Master Cylinder: P/N 46920-57A-A02, H/C 7604507 WARRANTY CLAIM INFORMATION In warranty: The normal warranty applies. Operation Number: 211101 Flat Rate Time: 0.6 hour (All Civics) 0.8 hour (Accord/CR-V/Element) Failed Part: Civic/Civic Hybrid: P/N 46920-55A-G01 H/C 6571103 Accord/Civic Si/CR-V/Element: P/N 46920-S7A-A01 H/C 6729031 Defect Code: 03214 Symptom Code: 04201 Page 3945 HIM: UPDATING TIPS AND PRECAUTIONS ^ If you're updating a control module/unit on a new vehicle, make sure all its fuses were installed at PDI. ^ To prevent control unit/module damage, do not operate anything electrical (audio system, brakes, A/C, power windows, moonroof, etc.) during the update. ^ Make sure the HDS Tablet, the HDS Pocket Tester, or the iN workstation has the latest version of HDS software. The HDS version number is on the HDS start-up screen. To find the latest HDS software information on ISIS, select Search by Vehicle, select Technical Library, expand the ServiceNews branch, select Keyword (All Models), enter keywords HDS VERSION, then select the latest article. NOTE: The screen is from an iN workstation. The HDS tablet and pocket tester screens are similar. *^Make sure the Database Update listed in a Honda service communication (service bulletin, product update, iN message, etc.) is the same or earlier than the ones listed on the Reprogramming screen of the MVCI (on the MVCI, select CM Update Mode, then select Reprogramming), or on the Page 4429 4. Torque the mounting bolts in a crisscross pattern. Tighten the bolts in several steps to prevent warping the diaphragm spring. 5. Remove the special tools. 6. Make sure the diaphragm spring fingers are all the same height. Page 4490 Clutch Switch: Adjustments Clutch Pedal, Clutch Pedal Position Switch, and Clutch Interlock Switch Adjustment NOTE: ^ To check the clutch pedal position switch. ^ To check the clutch interlock switch. ^ Remove the driver's side floor mat before adjusting the clutch pedal. ^ The clutch is self-adjusting to compensate for wear. ^ If there is no clearance between the master cylinder piston and push rod, the release bearing is held against the diaphragm spring, which can result in clutch slippage or other clutch problems. 1. Loosen locknut (A), and back off the clutch pedal position switch (B) (or adjusting bolt) until it no longer touches the clutch pedal (C). 2. Loosen locknut (D), and turn the push rod (E) in or out to get the specified height (F) and stroke (G) at the clutch pedal. Clutch Pedal Stroke: 130 - 140 mm (5.1 - 5.5 inch) Clutch Pedal Height: 198 mm (7.8 inch) 3. Tighten locknut (D). 4. With the clutch pedal released, turn the clutch pedal position switch (B) in until it contacts the clutch pedal (C).. 5. Turn the clutch pedal position switch (B) in an additional 3/4 to 1 turn. 6. Tighten locknut (A). 7. Loosen locknut (H) and the clutch interlock switch (1) 8. Press the clutch pedal to the floor. 9. Release the clutch pedal 15 - 20 mm (0.59 - 0.79 inch) from the fully depressed position, and hold it there. Adjust the position of the clutch interlock switch (1) so that the engine will start with the clutch pedal in this position. 10. Tighten locknut (H). Page 3806 162. Right Side Of Engine Compartment Page 7470 Diagram 52-1 (LX-C) Page 7167 Keyless Entry Module: Testing and Inspection Control Unit Input Test 1. Before testing, troubleshoot the multiplex control system. 2. Remove the dashboard lower cover. 3. Disconnect the under-dash fuse/relay box connectors. NOTE: All connectors are wire side of female terminals. 4. Inspect the connector and socket terminals to be sure they are all making good contact. - If the terminals are bent, loose or corroded, repair them as necessary, and recheck the system. - If the terminals look OK, go to step 5. Page 5850 234. Under-dash Fuse/Relay Box Part 3 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 8554 2. Clean the grooves in the front bumper and the air spoiler with isopropyl alcohol. 3. Apply a small bead (3 to 5 mm) of 3M Weatherstrip Adhesive in the groove in the front bumper air spoiler. 4. Install the front bumper air spoiler to the bumper. 5. Install the four spoiler plates and the two push clips. 6. Install the four bolts, and torque them to 9.8 N.m (7.2 lb-ft). 7. Clean any excessive adhesive from the front bumper air spoiler. Page 5189 7. Apply a small amount of Permalube grease to the base of the new lever. Then attach the slide hammer to the new lever pin, insert the lever into the ignition switch, and seat the pin with the slide hammer. 8. Check the installed height of the pin with vernier calipers. If the height is more than 5.0 mm, the pin is not seated. If needed, reattach the slide hammer, and seat the pin. NOTE: It's normal for the interlock lever to be loose, even when the pin is fully seated. 9. Install a new spring on the lever. Make sure you attach the ends of the spring correctly: ^ The right end goes into the slot on the ignition switch. 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 4367 Splices Components Ground - "G" Page 5601 6. Separate the rear housing (A) and drive-end housing (B) with the stator (C) attached to the rear housing. 7. If you are not replacing the front bearing and/or rear bearing, go to step 15. Clamp the rotor in a soft-jawed vise, then remove the pulley locknut. 8. Remove the rotor using a puller as shown. 9. Inspect the rotor shaft for galling, and inspect the bearing journal surface in the drive-end housing for seizure marks. - If either the rotor or drive-end housing is damaged, replace the alternator. - If both the rotor and the drive-end housing are OK, go to step 10. 10. Remove the rear bearing using the puller as shown. Page 6138 ^ 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 3722 Shift Indicator: Electrical Diagrams Automatic Transmission Circuit Diagram Continuously Variable Transmission Page 2044 Power Distribution schematics show how power is supplied from the positive battery terminal to various circuits in the vehicle. Refer to the Power Distribution diagram set to get a more detailed understanding of how picture is supplied to the circuit you're working on. Individual circuit schematics begin with a fuse. So 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 Ground Distribution Schematics This sample Ground Distribution schematic shows all of the components that share the same ground point. Page 7954 Air Bag(s) Arming and Disarming: Description and Operation SRS Operation SRS Operation The main circuit in the SRS unit senses and judges the force of impact and, if necessary, ignites the inflator charges. 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: Seat Belt Tensioners and Seat Belt Buckle Tensioners 1. A front impact sensor must activate and send electric signals to the microprocessor. 2. The microprocessor must compute the signals and send them to the tensioners. 3. The charges must ignite and deploy the tensioners. Driver's and Front Passenger's Airbag(s) 1. A front impact sensor must activate, and send electric signals to the microprocessor. 2. The microprocessor must compute the signals, and depending on the severity of the collision and whether the seat belt buckle switch is ON or OFF, it sends the appropriate signals to the airbag inflator(s). 3. The inflators that received signals must ignite and deploy the airbags. Side Airbag(s) 1. Aside impact sensor must activate, and send electric signals to the microprocessor. 2. The microprocessor must compute the signals and send them to the side airbag inflator(s). However, the microprocessor cuts off the signals to the front passenger's side airbag if the OPDS unit determines that the front passenger's head is in the deployment path of the side airbag. 3. The inflator that received the signal must ignite and deploy the side airbag. Self-diagnosis System A self-diagnosis circuit is built into the SRS unit; when the ignition switch is turned ON (II), the SRS indicator comes on and goes off after about 6 seconds if the SRS is operating normally. If the indicator does not come on, or does not go off after 6 seconds, or if it comes on while driving, it indicates an abnormality in the SRS. The SRS must be inspected and repaired as soon as possible. For better serviceability, the SRS unit memory stores a DTC that relates to the cause of the malfunction, and the unit is connected to the data link circuit. This information can be read with the Honda PGM Tester when it is connected to the data link connector (DLC). Page 5252 2. Remove the terminal from the female half. 3. Remove the terminal from the male half. 4. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE D: 1. Remove the secondary locks. Service and Repair Crankshaft Gear/Sprocket: Service and Repair Timing Belt Drive Pulley Replacement 1.Remove the timing belt. 2.Remove the crankshaft position, (CKP) sensor. 3.Remove the timing belt drive pulley. 4. Install the new timing belt drive pulley. 5. Install the CKP sensor. 6. Install the timing belt. Page 9300 Interior Lighting Module: Diagnostic Aids General Troubleshooting Information General Troubleshooting Information Tips and Precautions Before Troubleshooting 1. Check applicable fuses in the appropriate fuse/relay box. 2. Check the battery for damage, state of charge, and clean and tight connections. NOTE: 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. Handling Connectors - Make sure the connectors are clean and have no loose wire terminals. - Make sure multiple cavity connectors are packed with dielectric grease (except watertight connectors). - All connectors have push-down release type locks (A). - Some connectors have a clip on their side used to attach them to a mount bracket on the body or on another component. This clip has a pull type lock. - Some mounted connectors cannot be disconnected unless you first release the lock and remove the connector from its mount bracket (A). - Never try to disconnect connectors by pulling on their wires; pull on the connector halves instead. - Always reinstall plastic covers. Air Mix Control Motor Air Door Actuator / Motor: Service and Repair Air Mix Control Motor Air Mix Control Motor Replacement 1. Remove the under-dash fuse/relay box. 2. Disconnect the 7P connector (A) from the air mix control motor (B). Remove the self-tapping screws and the air mix control motor from the heater unit. 3. Install the motor in the reverse order of removal. Make sure the pin on the motor is properly engaged with the linkage. After installation, make sure the motor runs smoothly. ATF Level Check Fluid - CVT: Service and Repair ATF Level Check ATF Level Check NOTE: Keep all foreign particles out of the transmission. 1. Warm up the engine to normal operating temperature (the radiator fan comes on). 2. Park the vehicle on level ground, and turn the engine off. 3. Remove the dipstick (yellow loop) (A) from the transmission, and wipe it with a clean cloth. 4. Insert the dipstick into the transmission. 5. Remove the dipstick and check the fluid level within 60 - 90 seconds after the engine is turned off. The dipstick should read between the upper mark (A) and the lower mark (B) on the HOT side of the gauge (C). Do not check the level on the COLD side of the gauge (D) when the ATF warmed up. NOTE: Some dipsticks have only the HOT gauge, in which case they might or might not have HOT stamped into the dipstick. 6. If the level is below the lower mark (B), check for fluid leaks at the transmission, hose and line joints, and cooler lines. 7. If the level exceeds the upper mark (A), drain the fluid for proper level. 8. Pour the recommended fluid into the dipstick hole to bring it to upper mark. Always use Honda ATF-Z1 Automatic Transmission Fluid (ATF). Using non-Honda ATF can affect shift quality. 9. Insert the dipstick back into the transmission. Locations SRS Component Location Index Page 1919 1. Apply a force of 98 N (10 kgf, 22 lbf), and measure the deflection at the mid point (A) between the alternator and crankshaft pulley. If the belt is worn or damaged, replace it. If the belt needs adjustment, go to step 2. Adjustment 2. Loosen the mounting bolt (B), lock bolt (C) and lower bracket mounting bolt (D). 3. Torque the mounting bolt to 20 N.m (2.0 kgf.m, 14 lbf.ft). 4. Turn the adjusting bolt (E) to obtain the proper belt tension, then retighten the lock bolt, mounting bolt and lower bracket mounting bolt. 5. Recheck the belt tension. 6. If you installed a new belt, run the engine for 5 minutes, then readjust the belt to the used belt specification. 7. Check the power steering pump belt adjustment. Page 98 Relay And Control Unit Locations - Engine Compartment Page 5855 235. Under-dash Fuse/Relay Box Part 8 Page 5261 8. Put the splice connector in the proper size slot in the Crimper Tool, slide it to one end (where the flare begins), and close the crimper handles far enough to hold it in place. To release the ratchet mechanism at any point after the first click, squeeze the handles slightly and push the release lever, then let the handles open. 9. Insert one of the bare wires into the splice connector end that is in the crimper jaws. Push the wire all the way into the splice connector, and squeeze the crimper handles. Keep squeezing until the jaws touch, and hold it at that position until the ratchet clicks again. 10. Crimp the other wire in the same way into the other end of the splice connector. 11. After crimping, gently pull on the wires in the opposite directions to make sure they are secure in the connector. 12. Separate the other wires in the harness from the repaired wire(s), and shield them with nonflammable material. Page 842 Variable Valve Timing Pressure Switch: Service and Repair VTEC Oil Pressure Switch Replacement 1. Remove the resonator (see step 5). 2. Remove the bolt (A) and loosen the bolt (B) securing the VTEC solenoid valve, then remove the harness bracket (C) from the VTEC solenoid valve. 3. Remove the harness clamp (D) from the connecting pipe. 4. Disconnect the VTEC oil pressure switch connector, then remove the VTEC oil Pressure switch (A). 5. Install the VTEC oil pressure switch using a new O-ring (B). Electrical - DTC P1298 Stored in ECM/PCM Electric Load Sensor: Customer Interest Electrical - DTC P1298 Stored in ECM/PCM 05-006 May 6, 2005 Updated information is noted by asterisks. Applies To: 2001-05 Civic - ALL *2002-04 CR-V - ALL* DTC P1298 Is Stored in the ECM/PCM (Supersedes 05-006, dated February 25, 2005, to change the CR-V model-year range) SYMPTOM DTC P1298 (electrical load detector (ELD) circuit high voltage) is stored in the ECM/PCM. PROBABLE CAUSE The electronic load detector (ELD) has a faulty solder joint. CORRECTIVE ACTION Replace the ELD. NOTE: Previously, if an ELD required replacement, you had to replace the under-hood fuse/relay box. To reduce repair costs, replacement ELDs are now available. PARTS INFORMATION Electronic Load Detector: P/N 38255-S5A-003, H/C 7987571 WARRANTY CLAIM INFORMATION In warranty: The normal warranty applies. Operation Number: 121195 Flat Rate Time: 0.4 hour Failed Part: Civic P/N 38250-S5A-A03 H/C 7472277 CR-V P/N 38250-S9A-A01 H/C 6890594 Defect Code: 06402 Symptom Code: 01201 Template ID: 05-006A 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 7889 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. DIAGNOSIS Pull up the outer edge of the windshield molding. Check if the inner lip is folded over anywhere. ^ If the inner lip is folded over, go to REPAIR PROCEDURE. ^ If the inner lip is not folded, disregard this bulletin, and look for other possible causes. REPAIR PROCEDURE 1. Protect the roof by applying a strip of 2-inch-wide masking tape along the outer edge of the windshield molding. 2. Pull up the outer edge of the molding, and use scissors or an X-Acto knife to remove its entire inner lip. Diagram Information and Instructions Transmission Position Switch/Sensor: Diagram Information and Instructions Terminal Numbering System Terminal Numbering System Connector terminals are numbered according to the cavities they're in. The cavities are numbered starting from the upper left, looking at the male terminals from the terminal side or looking at the female terminals from the wire side. Both views are in the same direction so the numbers are the same. All actual cavities are numbered, even if they have no wire terminals in them. NOTE: Data Link Connector (DLC) terminals are numbered according 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 below is #6. Page 5785 Under-hood Fuse/Relay Box (2-door) Page 6092 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 Locations Parking Brake Warning Switch: Locations Gauges Component Location Index (Part 1 Of 4) Page 9418 Diagram 114-4 (Sedan EX) Diagrams: Other diagrams referred to by number (See Diagram ##-#, etc.)within these diagrams can be found at Diagrams by Number. See: Diagrams/Electrical Diagrams/Diagrams By Number Locations: Location photographs (references to PHOTOS) referred to within these diagrams can be found at Locations by Photo Number. See: Locations/Component Locations/Locations By Photo Number Connector Views: Connector terminal views (references to VIEWS) referred to within these diagrams can be found at Connector Views by View Number. See: Diagrams/Connector Views/Connector Views By View Number Page 1186 2. Disconnect the 14P connector (A) from the master switch (B). 3. Inspect the connector and socket terminals to be sure they are all making good contact. - If the terminals are bent, loose or corroded, repair them as necessary, and recheck the system. - If the terminals look OK, Go to step 4. 4. Reconnect the 14P connector to the power window master switch, and perform the given input tests. Page 9384 Connectors - "C" Page 4846 3. Remove and discard the shift fork. 4. Apply vinyl tape to the mainshaft splines to protect the seal, then remove the mainshaft and shift forks as an assembly from the clutch housing. 5. Disassemble the countershaft assembly; see page 13-32 (13-45 for Hybrid) of the service manual. Page 166 Power Distribution schematics show how power is supplied from the positive battery terminal to various circuits in the vehicle. Refer to the Power Distribution diagram set to get a more detailed understanding of how picture is supplied to the circuit you're working on. Individual circuit schematics begin with a fuse. So 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 Ground Distribution Schematics This sample Ground Distribution schematic shows all of the components that share the same ground point. Removal and Installation Engine Control Module: Service and Repair Removal and Installation How to Remove the ECM/PCM for Testing 1. Remove the passenger's dashboard lower cover, the right kick panel, and the glove box. 2. Remove the bolt. Cut the plastic cross brace in the glove box opening with diagonal cutters in the area shown, and discard it. 3. Remove the relays (A), then remove the bolts and the glove box frame (B). 4. Remove the gray 20P ECM/PCM wire harness connector from the ECM/PCM mounting bracket. Remove the ECM/PCM mounting bolt (A) and the bracket. 5. Remove the nuts, then remove the ECM/PCM (B). 6. Install the ECM/PCM in the reverse order of removal. Service and Repair Valve Cover: Service and Repair Cylinder Head Cover Installation 1. Thoroughly clean the head cover gasket and the groove. 2. Install the head cover gasket (A) in the groove of the cylinder head cover (B). Seat the head cover gasket in the recesses for the camshaft first, then work it into the groove around the outside edges. Make sure the head cover gasket is seated securely in the corners of the recesses (C) with no gap. 3. Check that the mating surfaces are clean and dry. 4. Apply liquid gasket, P/N 08718-0001 or 08718-0003, to the head cover gasket at the four corners of the recesses (A). NOTE: Do not install the parts if 5 minutes or more have elapsed since applying liquid gasket. Instead, reapply liquid gasket after removing old residue. 5. Hold the head cover gasket in the groove by placing your fingers on the camshaft holder contacting surfaces (top of the semicircles). Set the spark plug seal (A) on the spark plug tubes. Once the cylinder head cover (B) is on the cylinder head, slide the cover slightly back and forth to seat the head cover casket. 6. Inspect the cover washers (C). Replace any washer that is damaged or deteriorated. Page 1061 Connectors - "C" Page 4110 2. Remove the terminal from the female half. 3. Remove the terminal from the male half. 4. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE D: 1. Remove the secondary locks. Page 279 ECM/PCM Inputs And Outputs At Connector A (31P) 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 2920 155. A/F Sensor Relay (HX; '04-'05: DX, EX, LX) Page 8213 WARRANTY CLAIM INFORMATION In warranty: The normal warranty applies. Failed Part: P/N 68500-S5P-A90ZZ H/C 6528640 *Defect Code: 07406* Symptom Code: 03220 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 A 1. Check the side-to-side alignment of the trunk lid latch to the striker: ^ Refer to page 20-132 of the 2001-04 Civic Service Manual. ^ In ISIS, use the keyword TRUNK ADJUST, and select Trunk Lid Adjustment from the list. 2. Make sure the gaps of the trunk lid are even on all sides. ^ If the trunk is misaligned, go to step 3. ^ If the trunk lid is properly aligned on all sides, go to REPAIR PROCEDURE B. 3. Adjust the trunk lid hinges: ^ Refer to page 20-132 of the 2001-04 Civic Service Manual. ^ In ISIS, use the keyword TRUNK ADJUST, and select Trunk Lid Adjustment from the list. 4. Check the trunk operation: ^ If the trunk opens and closes smoothly and is properly aligned, return the vehicle to the customer. ^ If the trunk lid is still difficult to close, go to REPAIR PROCEDURE B. REPAIR PROCEDURE B Page 847 Vehicle Speed Sensor: Locations Gauges Component Location Index (Part 1 Of 4) Page 3340 (Except GX) Page 325 Blower Motor Relay Type 1, Type 2 Check for continuity between the terminals. - There should be continuity between the No.1 and No.3 terminals when power and ground are connected to the No.2 and No.4 terminals. - There should be no continuity between the No.1 and No.3 terminals when power is disconnected. Five-terminal type Check for continuity between the terminals. - There should be continuity between the No.1 and No.2 terminals when power and ground are connected to the No.3 and No.5 terminals. - There should be continuity between the No.1 and No.4 terminals when power is disconnected. Testing and Inspection Trunk Lamp Switch: Testing and Inspection Trunk Lid Latch Switch Test 1. Open the trunk lid. 2. Disconnect the 2P connector (A) from the trunk lid latch (B). 3. Check for continuity between the No.1 and No.2 terminals. - There should be continuity with the trunk lid open. - There should be no continuity with the trunk lid closed. 4. If the continuity is not as specified, replace the trunk lid latch switch. Page 4013 72. Shift Lock Solenoid (A/T) Page 130 158. DRL Relay (Canada); Low Beam Cut Relay ('01-'03 Canada) Page 537 Radiator Cooling Fan Temperature Sensor / Switch: Testing and Inspection Radiator Fan Switch Test NOTE: Bleed air from the cooling system after installing the radiator fen switch. 1. Remove the radiator fan switch from the thermostat cover. 2. Suspend the radiator fan switch (A) in a container of water as shown. 3. Heat the water and check the temperature with a thermometer. Do not let the thermometer (B) touch the bottom of the hot container. 4. Measure the continuity between the A terminal (C) and B terminal (D) according to the table. Page 2141 9. Remove, drain and reinstall the reservoir. Fill the tank to the MAX mark (A) with Honda All Season Antifreeze/Coolant Type 2. 10. Pour Honda All Season Antifreeze/Coolant Type 2 into the radiator up to the base of the filler neck. NOTE: Always use Honda All Season Antifreeze/Coolant Type 2. Using a non-Honda coolant can result in corrosion, causing the cooling system to malfunction or fail. - Honda All Season Antifreeze/Coolant Type 2 is a mixture of 50% antifreeze and 50% water. Premixing is not required. Engine Coolant Refill Capacity (including the reservoir capacity of 0.4 L (0.4 US qt): M/T: 4.0 L (4.2 US qt.) A/T, CVT: 3.9 L (4.1 US qt.) 11. Install the radiator cap loosely. 12. Install the battery. 13. Start the engine and let it run until it warms up (the radiator fan comes on at least twice). 14. Turn off the engine. Check the level in the radiator, and add Honda All Season Antifreeze/Coolant Type 2 if needed. 15. Put the radiator cap on tightly, then run the engine again and check for leaks. 16. Enter the anti-theft code for the radio, then enter the customer's radio station presets. Page 7417 80. Under Middle of Dash Page 1606 58. Check for continuity between ECM/PCM connector terminal A21 and body ground. Is there continuity? YES - Repair short in the wire between the ECM/PCM (A21) and the MAP sensor, CVT driven pulley speed sensor (CVT), or CVT speed sensor 1 (CVT). NO - Update the ECM/PCM if it does not have the latest software, or substitute a known-good ECM/PCM, then recheck. If the symptom/indication goes away with a known-good ECM/PCM, replace the original ECM/PCM. 59. Measure voltage between body ground and ECM/PCM connector terminal A20. Is there about 5 V? YES - Go to step 66. NO - Go to step 60. 60. Turn the ignition switch OFF. 61. Disconnect the 3P connector from each of these sensors, one at a time, and measure voltage between body ground and ECM/PCM connector terminal A20 with the ignition switch ON (II). Exhaust gas recirculation (EGR) valve position sensor - Knock sensor - Throttle position (TP) sensor - CVT drive pulley speed sensor (CVT) - CVT speed sensor 2 (CVT) Is there about 5 V? Page 6872 12. On Accords and Pilots, install the new seat-back clips on the seat-back panel. Turn the clips so their retaining tabs are horizontal. 13. On Accords and Pilots, install the seat-back panel. 14. On all models except Accords and Pilots, zip the seat-back cover closed. 15. Initialize the OPDS unit. ^ To initialize with the HDS, go to Initializing the OPDS Unit: HDS Method. ^ To initialize with the SCS service connector, go to Initializing the OPDS Unit: Manual Mode. Initializing the OPDS Unit: HDS Method NOTE: Non-Honda seat covers will interfere with the performance of the OPDS and are not recommended. 1. Adjust the front passenger's seat-back to an upright position, then remove anything on or near the seat. 2. Turn the ignition switch to LOCK (0). 3. Connect the HDS to the vehicle's DLC (data link connector). 4. Turn the ignition switch to ON (II), then turn on the HDS. 5. At the screen prompts, enter the VIN and the odometer reading. Also verify the correct date and time. 6. From the System Selection menu, select SRS. Page 2115 Spark Plug: Application and ID NGK ..................................................................................................................................................... ............................................................... PZFR6F-11 DENSO ................................................................................................................................................ ......................................................... PKJ20CR-M11 Gap ...................................................................................................................................................... ................................. 1.0 -1.1 mm (0.039 - 0.043 in) Torque ................................................................................................................................................. ...................................................... 18 N.m (13 lb.ft) SRS Unit Replacement Air Bag Control Module: Service and Repair SRS Unit Replacement SRS Unit Replacement Removal 1. Disconnect the battery negative cable, and wait at least 3 minutes before beginning work. 2. Disconnect the driver's and front passenger's airbag connectors. 3. Disconnect the side airbag connectors. 4. Disconnect both seat belt tensioner connectors and both seat belt buckle tensioner connectors. 5. Remove the dashboard center lower cover. 6. Pull down the carpet, then remove the Torx bolt (A) from the SRS unit. 7. Disconnect the connectors and remove the two Torx bolts (A), then pull out the SRS unit. Installation 1. Install the new SRS unit (A) with Torx bolts (B), then connect the connectors (C) to the SRS unit; push it into position until it clicks. NOTE: When tightening the Torx bolts to the specified torque after replacement, be careful to turn them in so that their heads rest squarely on the Page 2283 D17A2 Engine Page 2170 8. Put the splice connector in the proper size slot in the Crimper Tool, slide it to one end (where the flare begins), and close the crimper handles far enough to hold it in place. To release the ratchet mechanism at any point after the first click, squeeze the handles slightly and push the release lever, then let the handles open. 9. Insert one of the bare wires into the splice connector end that is in the crimper jaws. Push the wire all the way into the splice connector, and squeeze the crimper handles. Keep squeezing until the jaws touch, and hold it at that position until the ratchet clicks again. 10. Crimp the other wire in the same way into the other end of the splice connector. 11. After crimping, gently pull on the wires in the opposite directions to make sure they are secure in the connector. 12. Separate the other wires in the harness from the repaired wire(s), and shield them with nonflammable material. Locations Relay And Control Unit Locations - Engine Compartment Page 5276 Page 9659 13. Plug in the heat gun, and turn it on. Start at the middle of the splice connector, and move the gun toward the ends as the tube shrinks. Apply heat evenly by rotating the curved heat spreader around the splice connector. Shrinking is complete when a small amount of sealant appears at each end of the tube. Pigtail Terminal Selection Chart PIGTAIL TERMINAL SELECTION CHART Select the proper size pigtail terminal by matching the replacement terminal part number and the wire size being repaired to the corresponding pigtail terminal part number. Then use the color (size) splice connector listed. In some instances you may also have to match the wire seal style to select the proper pigtail terminal. Pigtail terminals are available through your parts department, in quantities of 10, using normal parts ordering procedures. Checking For Poor Fir of Terminals CHECKING FOR POOR FIT OF TERMINALS Loose terminal fit can cause a number of intermittent problems in electrical circuits. By using the Terminal Inspection Feeler Tool Set you can inspect the terminal fit between the two matching connectors without removing the terminals from the connector body. 1. Find the terminal tool that best matches the male terminal in the mating connector. 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 1815 7. Remove the bearing cap bolts. To prevent warpage, unscrew the bolts in sequence 1/3 turn at a time; repeat the sequence until all bolts are loosened. 8. Remove the bearing cap bridge/bearings. Keep all bearings in order. 9. Turn the crankshaft so No. 2 and No. 3 crankpins are at the top. 10. Remove the rod caps/bearings. Keep all caps/bearings in order. 11. Lift the crankshaft out of the engine, being careful not to damage the journals. 12. Remove the upper bearing halves from the connecting rods, and set them aside with their respective caps. 13. Reinstall the bearing cap bridge and bearings on the engine in the proper order. 14. If you can feel a ridge of metal or hard carbon around the top of each cylinder, remove it with a ridge reamer (A). Follow the reamer manufacturer's instructions. If the ridge is not removed, it may damage the pistons as they are pushed out. Page 2226 Radiator: Service and Repair Radiator and Fans Replacement 1. Drain the engine coolant. 2. Remove the front bumper. 3. Remove the hood latch. 4. Remove the upper and lower radiator hoses, and automatic transmission fluid (ATF) cooler hoses. 5. Disconnect the fan motor connectors and compressor clutch connector. 6. Remove the radiator upper brackets, then pull up the radiator. 7. Remove the fan shroud assemblies and other parts from the radiator. 8. Install the radiator in the reverse order of removal. Make sure the upper and lower cushions are set securely. 9. Fill the radiator with engine coolant and bleed the air. Page 273 Page 1609 NO - Go to step 77. 77. Turn the ignition switch OFF. 78. Disconnect ECM/PCM connector E (31P). 79. Check for continuity between ECM/PCM connector terminal E29 and body ground. Is there continuity? YES - Repair short in the wire between the DLC and the ECM/PCM (E29). NO - Update the ECM/PCM if it does not have the latest software, or substitute a known-good ECM/PCM, then recheck. If the symptom/indication goes away with a known-good ECM/PCM, replace the original ECM/PCM. 80. Turn the ignition switch OFF. 81. Disconnect ECM/PCM connector E (31P). 82. Turn the ignition switch ON (II). Is the MIL on? YES - Repair short in the wire between the gauge assembly and the ECM/PCM (E31). If the wires are OK, replace the gauge assembly. NO - Update the ECM/PCM if it does not have the latest software, or substitute a known-good ECM/PCM, then recheck. If the symptom/indication goes away with a known-good ECM/PCM, replace the original ECM/PCM. Page 5683 5. With the wire inserted in the new terminal as shown in step 3, crimp the wire by squeezing the tool with both hands until the stops make contact. 6. Crimp the insulation by positioning the 5.5 slot on the tool over the insulation crimp section of the terminal and squeezing the tool with both hands until the stops make contact. 7. Inspect the quality of the wire crimp. If it has any of the following NO GOOD crimps, cut it off and start over. 8. Clean the starter side of the S terminal as needed using electric contact cleaner and an electrical connector cleaning brush (Snap-on P/N YA385A or equivalent). Blow out any debris remaining on or around the terminal with compressed air. 9. Apply silicone dielectric grease (3M silicone paste P/N 08946, Permatex Dielectric Tune-up grease P/N 67VR, or equivalent) to the female side of the S terminal, then carefully insert the terminal into the S terminal on the starter side. 10. Slide the boot completely over the S terminal. 11. Reconnect the positive battery cable, then reconnect the negative battery cable. 12. Enter the anti-theft code for the audio unit (if applicable), then enter the customer's audio presets. Set the clock. 13. Confirm that the starter engages properly by starting the engine several times. 14. Do the idle learn procedure: ^ Make sure all electrical items (A/C, audio unit, defogger, lights, etc.) are off. Page 9375 Diagram 110-14a (Sedan) Diagram 110-14b (Coupe) Diagrams: Other diagrams referred to by number (See Diagram ##-#, etc.)within these diagrams can be found at Diagrams by Number. See: Diagrams/Electrical Diagrams/Diagrams By Number Locations: Location photographs (references to PHOTOS) referred to within these diagrams can be found at Locations by Photo Number. See: Locations/Component Locations/Locations By Photo Number Connector Views: Connector terminal views (references to VIEWS) referred to within these diagrams can be found at Connector Views by View Number. See: Diagrams/Connector Views/Connector Views By View Number Page 9447 4. Make these input tests at the connector. - If any test indicates a problem, find and correct the cause, then recheck the system. - If all the input tests prove OK, the control unit must be faulty; replace it. '04 model Page 1342 18. Remove the crankshaft position (CKP) sensor from the oil pump without disconnecting the connector. 19. Apply a force of 98 Nm (10 kgf-cm, 22 ft. lbs.) to the timing belt at the mid point between the camshaft pulley and the water pump pulley and check that the auto-tensioner move smoothly. If the auto-tensioner does not move smoothly, replace the auto-tensioner. - Inspect the auto-tensioner when replacing the timing belt. 20. Move the auto-tensioner to remove tension from the timing belt, then remove the timing belt. Installation Special Tools Required Holder handle 07JAB-001020A - Holder attachment, 50 mm, offset 07MAB-PY3010A - Socket, 19 mm 07JAA-001020A or a commercially-available 19 mm socket NOTE: If you are removing the auto-tensioner, refer to the auto-tensioner installation procedure. 1. Clean the timing belt pulleys, and the upper and lower covers. Page 6475 Blower Motor: Service and Repair Components Replacement Blower Unit Components Replacement Note these items when overhauling the blower unit: - The recirculation control motor (A), the power transistor (B), the blower motor (C), and the dust and pollen filters (with A/C) (D) can be replaced without removing the blower unit. - Before reassembly, make sure that the recirculation control linkage and doors move smoothly. - After reassembly, make sure the recirculation control motor runs smoothly. Page 2789 Engine Control Module: Service and Repair Updating the ECM/PCM ECM/PCM Updating and Substitution for Testing Special Tools Required Honda Interface Module (HIM) - P/N EQS05A35570 Use this procedure when you have to substitute a known-good ECM/PCM in a troubleshooting procedure. Update the ECM/PCM only if the ECM/PCM does not already have the latest software loaded. NOTE: Do not turn the ignition switch OFF while updating; the ECM/PCM can be damaged. How to Update the ECM/PCM NOTE: - To ensure the latest program is installed, do an ECM/PCM update whenever the ECM/PCM is substituted or replaced. - Before you update the ECM/PCM, make sure the vehicle's battery is fully charged. - To prevent ECM/PCM damage, do not operate anything electrical (audio system, brakes, A/C, power windows, moon roof, door locks, etc.) during the update. - If you need to diagnose the Honda Interface Module (HIM) because the HIM's red (#3) light came on or was flashing during the update, leave the ignition switch in the ON (II) position when you disconnect the HIM from the Data Link Connector (DLC). This will prevent ECM/PCM damage. 1. Turn the ignition switch ON (II). Do not start the engine. 2. Connect the HIM to the DLC (A) located under the driver's side of dashboard. 3. Do the ECM/PCM update procedure as described on the HIM label and in the ECM/PCM update system. If the software in the ECM/PCM is the latest version, replace the ECM/PCM. How to Substitute the ECM/PCM 1. Remove the ECM/PCM from the vehicle. 2. Install a known-good ECM/PCM in the vehicle. 3. Rewrite the immobilizer code with the ECM/PCM replacement procedure in the Honda PGM Tester; It allows you to start the engine. 4. After completing your tests, reinstall the original ECM/PCM and rewrite the immobilizer code with the ECM/PCM replacement procedure in the Honda PGM Tester again. Service and Repair Evaporator Core: Service and Repair Evaporator Core Replacement 1. Recover the refrigerant with a recovery/recycling/charging station. 2. Remove the bolt, then disconnect the suction line (A) and the receiver line (B) from the evaporator core. 3. Remove the blower unit. 4. Remove the bolt and the ECM/PCM bracket (A). Remove the self-tapping screws and the expansion valve cover (B). 5. Carefully pull out the evaporator core without bending the pipes. 6. Install the core in the reverse order of removal, and note these items. - If you're installing a new evaporator core, add refrigerant oil (SANDEN SP-10). - Replace the O-rings with new ones at each fitting, and apply a thin coat of refrigerant oil before installing them. Be sure to use the correct O-rings for HFC-134a (R-134a) to avoid leakage. - Immediately after using the oil, reinstall the cap on the container, and seal it to avoid moisture absorption. - Do not spill the refrigerant oil on the vehicle; it may damage the paint. If the refrigerant oil contacts the paint, wash it off immediately. - Charge the system. Page 833 Transmission Position Switch/Sensor: Testing and Inspection Transmission Range Switch Test 1. Remove the transmission range switch harness connector (A) from the connector bracket (B), then disconnect the connector. 2. Check for continuity between terminals at the harness connector. There should be continuity between the terminals listed for each switch position. In the P position, between terminals: ^ No. 1 and No. 3 ^ No. 1 and No. 8 ^ No. 3 and No. 8 In the R position, between terminals: ^ No. 1 and No. 9 In the N position and between terminals: ^ No. 1 and No. 3 ^ No. 1 and No. 10 ^ No. 3 and No. 10 In the D position, between terminals: ^ No. 1 and No. 2 ^ No. 1 and No. 4 ^ No.2 and No.4 In the D3 position, between terminals: ^ No. 1 and No. 2 ^ No. 1 and No. 5 ^ No.2 and No.5 In the 2 position, between terminals: ^ No. 1 and No. 6 Page 9642 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 Locater) 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. Troubleshooting Precautions Troubleshooting Precautions Before Troubleshooting 1. Check the main fuse and the fuse 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, or you will damage the alternator diodes. - Do not attempt to crank the engine with the ground cable disconnected 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. Page 3261 1. Remove the secondary locks. 2. Remove the terminal from the female half. 3. Remove the terminal from the male half. 4. Go to HOW TO INSTALL NEW TERMINALS. Connectors Without a Secondary Lock All examples are shown with the connector lock facing up. The illustrations are examples of connector terminals without a secondary lock; however, the connector you are repairing may vary in size and shape. EXAMPLE A: Page 5101 Shift Interlock Solenoid: Service and Repair Shift Lock Solenoid Replacement 1. Remove the center console panel and center console. 2. Disconnect the shift lock solenoid connector (2P), and remove it from the shift lever bracket base. 3. Push the lock tab (A), pry the shift lock solenoid (B) to clear the projected tips (C) with a screwdriver, and remove the shift lock solenoid. 4. Install the shift lock solenoid plunger (D) and plunger spring (E) in the new shift lock solenoid. 5. Install the shift lock solenoid by aligning the joint (F) of the shift lock solenoid plunger with the tip (G) of the shift lock stop. 6. Connect the shift lock solenoid connector, and install it on the shift lever bracket base. 7. Install the center console and console panel. Locations Power Mirrors Component Location Index Page 8562 8. Tell the customer not to disturb the front bumper air spoiler for 24 hours to allow the adhesive to cure completely. Disclaimer Page 3272 Variable Valve Timing Actuator: Testing and Inspection VTEC Solenoid Valve Test 1. Remove the resonator. 2. Disconnect the VTEC solenoid valve 1P connector. 3. Measure resistance between the VTEC solenoid valve 1P connector terminal No.1 and body ground. 4. If the resistance is within specifications, remove the VTEC solenoid valve assembly (A) from the cylinder head, and check the filter (B) for clogging. If there is clogging, replace the solenoid valve filter, the engine oil filter, and the engine oil. Page 6276 90. Install the rack end plug (A). 91. Clean off any grease or contamination from the boot installation grooves (C) around on the housing. 92. Install boot B. and set the boot end in the installation grooves in the cylinder housing and rack end plug properly. 93. Install the clip (D) and boot guard (E). Install the new boot band (F) in the band grooves of boot B by aligning the tabs (G) with the holes (H) in the band. 94. Close the ear portion (A) of the band (B) with a commercially available pincers, Oetiker 1098 or equivalent (C). 95. Slide the rack right and left to be certain that the boots are not deformed or twisted. 96. Install the new lock washer (A) on the tie-rod (B) with the radiused side of the washer toward the tie-rod, and screw the tie-rod on the bracket (C). Repeat this step for the other tie-rod. Hold the bracket with one wrench, and tighten both tie-rods) to the specified torque with another wrench. Page 8751 Terminals - "T" Shielding Switches Fuses Electrical - DTC P1298 Stored in ECM/PCM Electric Load Sensor: Customer Interest Electrical - DTC P1298 Stored in ECM/PCM 05-006 May 6, 2005 Updated information is noted by asterisks. Applies To: 2001-05 Civic - ALL *2002-04 CR-V - ALL* DTC P1298 Is Stored in the ECM/PCM (Supersedes 05-006, dated February 25, 2005, to change the CR-V model-year range) SYMPTOM DTC P1298 (electrical load detector (ELD) circuit high voltage) is stored in the ECM/PCM. PROBABLE CAUSE The electronic load detector (ELD) has a faulty solder joint. CORRECTIVE ACTION Replace the ELD. NOTE: Previously, if an ELD required replacement, you had to replace the under-hood fuse/relay box. To reduce repair costs, replacement ELDs are now available. PARTS INFORMATION Electronic Load Detector: P/N 38255-S5A-003, H/C 7987571 WARRANTY CLAIM INFORMATION In warranty: The normal warranty applies. Operation Number: 121195 Flat Rate Time: 0.4 hour Failed Part: Civic P/N 38250-S5A-A03 H/C 7472277 CR-V P/N 38250-S9A-A01 H/C 6890594 Defect Code: 06402 Symptom Code: 01201 Template ID: 05-006A 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 6659 Evaporator Temperature Sensor / Switch: Testing and Inspection Evaporator Temperature Sensor Test 1. Dip the sensor in ice water, and measure the resistance between its terminals. 2. Then pour hot water on the sensor, and check for a change in resistance, 3. Compare the resistance readings with the specifications shown in the graph; the resistance should be within the specifications. Page 2624 Fuel Pressure: Testing and Inspection Fuel Pressure Test Special Tools Required - Fuel pressure gauge 07406-004000A - Fuel pressure gauge set 07ZAJ-S5A0100 1. Relieve the fuel pressure. 2. Disconnect the quick-connect fitting (A). Attach the fuel pressure gauge set and fuel pressure gauge. 3. Start the engine and let it idle. - If the engine starts, go to step 5. - If the engine does not start, go to step 4. 4. Check to see if the fuel pump is running: listen to the fuel fill port with the fuel fill cap removed. The fuel pump should run for 2 seconds when the ignition switch is first turned on. If the pump runs, step 5. - If the pump does not run, perform the fuel pump circuit troubleshooting. 5. Read the pressure gauge. The pressure should be 270 - 320 kPa (2.8 - 3.3 kgf/sq.cm, 40 - 47 psi) - If the pressure is OK, the test is complete. - If the pressure is out of specification, replace the fuel pressure regulator and the fuel filter, then recheck the fuel pressure. Service and Repair Grille: Service and Repair Front Grille Replacement 2-door 1. Remove the front bumper. 2. Remove the screws (A) and clips (B), and remove the front grille (C) from the front bumper (D) by pulling it out. Take care not to scratch the front bumper. 3. Remove the screws, then remove the front grille cover (A) ('01-03 models) or the front grille molding (B) ('04-05 models) from the front grille (C). 4. Install the grille in the reverse order of removal, and note these items: - Replace any damaged clips. Seats With Side Airbags Air Bag(s) Arming and Disarming: Description and Operation Seats With Side Airbags Seats with Side Airbags Seats with side airbags have a tag attached to the seat-back. Because the component parts (seat-back cover, cushion, etc.) of seats with and without airbags are different, make sure you install only the correct replacement parts. Because the seats are made by more than one manufacturer, make sure you replace any seat components (seat-back cover, frame, etc.) with the correct parts. The name of the seat manufacturer is indicated on the seat-back. Moreover, the manufacturer name is indicated on the seat-back frame and the seat-back pad. Confirm the indication when you exchange these parts. * When cleaning, do not saturate the seat with liquid, and do not spray steam on the seat. * Do not repair torn or frayed seat-back covers. Replace the seat-back cover. * After a collision in which the side airbag was deployed, replace the seat-back cover and the side airbag with new parts. If the seat-back cushion is split, it must be replaced. If the seat-back frame is definitely deformed, it must be replaced. Page 5126 - 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. Troubleshooting Tests 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 test 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 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. 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 Drop Page 7166 Keyless Entry Module: Diagrams (EX; '04: LX, GX) (Honda Accessory) Page 8586 19. Using your thumb and forefinger to hold the tumblers, remove the key from the inner cylinder, being careful not to drop any tumblers and springs. 20. *Using the key code from the iN that you have written down at step 2, build a new inner cylinder with new springs, new cylinder, and tumblers from the door lock cylinder kit. Make sure you put the appropriate numbered tumbler in the proper inner cylinder cavity. Apply a thin layer of Permalube to each tumbler to help lubricate and retain it.* NOTE: ^ There are two types of tumblers. The "SUBLOCK" tumbler goes only in cavity A." The "DISC" tumbler goes in cavities "B" through "J." ^ Cavity "E" is empty on all cylinders. Page 1018 ^ The left end goes behind the notch on the interlock lever. ^ Once the spring is correctly installed, make sure the lever moves freely and returns properly. 10. Insert the plunger into the interlock solenoid, then install the solenoid using a new screw. Make sure the groove of the solenoid plunger is in the fork on the lever. 11. Install a new plastic cover on the interlock solenoid. 12. Check the operation of the ignition switch key interlock: ^ Set the parking brake, and turn the ignition switch to ON (I I). ^ While pressing the brake pedal, shift the transmission to Neutral. ^ Try turning the ignition switch to LOCK (0) - If you cannot turn the switch to LOCK (0), your repair was successful; go to step 15. - If you can turn the switch to LOCK (0), the interlock is not working; go to step 13. Page 4638 Shift Interlock Solenoid: Testing and Inspection Shift Lock Solenoid Test 1. Remove the center console panel and center console. 2. Disconnect the shift lock solenoid connector (2P). 3. Connect the No. 1 terminal of the shift lock solenoid connector (2P) to the battery positive terminal, and connect the No. 2 terminal to the battery negative terminal. 4. Check that the shift lever can be moved from the P position. Release the battery terminals from the shift lock solenoid connector. Move the shift lever back to the P position, and make sure it locks. NOTE: Do not connect power to the No. 2 terminal (reverse polarity) or you will damage the diode inside the solenoid. 5. Check that the shift lock releases when the shift lock release is pushed, and check that it locks when the shift lock release is released. 6. If the shift lock solenoid does not work properly, replace it. Page 9183 Diodes Light Emitting Diode (LED) Motor Pressure Sensor Page 2756 DTC P1679 thru P1860 Locations Under-dash Fuse/Relay Box Page 962 Seat Occupant Sensor: Service and Repair Initializing the OPDS Unit Initializing the OPDS (Occupant Position Detection System) Special Tools Required SCS service connector 07PAZ-0010100 When the seat-back cover, seat-back cushion, and/or OPDS unit are replaced, initialize the OPDS by following the procedure below. NOTE: Make sure the passenger's seat is dry. Set the seat-back in the normal position, and make sure there is nothing on the front passenger's seat. 1. Make sure the ignition switch is OFF. 2. Connect the Honda PGM Tester (A) to the DLC (16P) (B), and follow the Tester's prompts in the "SCS" menu (see the Honda PGM Tester Operator's Manual). 3. Connect the SCS service connector (A) to the MES connector (2P) (B). Do not use a jumper wire. 4. Turn the ignition switch ON (II). 5. The SRS indicator comes on for about 6 seconds and goes off. Remove the SCS service connector from the MES connector within 4 seconds after the SRS indicator went off. 6. The SRS indicator comes on again. Reconnect the SCS service connector to the MES connector within 4 seconds after the SRS indicator comes on. 7. The SRS indicator goes off. Remove the SCS service connector from the MES connector within 4 seconds. 8. Watch the SRS indicator. - If the indicator blinks two times and then stays on, the OPDS is initialized, but the DTCs need to be erased. Go to step 9, then erase the DTCs. - If the indicator blinks two times and then goes off, the OPDS unit is initialized. Go to step 9. - If the indicator stays on without first blinking, the OPDS is not initialized. Read the DTC, and go to the appropriate page in the DTC Troubleshooting Index. 9. Turn the ignition switch off, and disconnect the PGM Tester. Specifications Idle Speed: Specifications Idle Speed With no-load conditions: USA model: M/T .................................................................................................................................. .................................................................................. 700 ± 50 rpm A/T, CVT .................................... ....................................................................................................................................... 700 ± 50 rpm (in Park or neutral) Canada model: M/T .............................................................................................. ...................................................................................................................... 720 ± 50 rpm A/T .......... .............................................................................................................................................................. ............. 720 ± 50 rpm (in Park or neutral) With load conditions: M/T ...................................................................................................................................................... .............................................................. 720 ± 50 rpm A/T, CVT ........................................................ ................................................................................................................... 720 ± 50 rpm (in Park or neutral) Diagrams 152. C555 (Side Airbag) Page 4645 143. Park Pin/Shift Switch (A/T) Page 9162 Exterior Lights Component Location Index Page 2550 7. Align the cutouts (A) on the rotary-frame with the neutral positioning cutouts (B) on the transmission range switch, then put a 2.0 mm (0.08 inch) feeler gauge blade (C) in the cutouts to hold it in the N position. NOTE: Be sure to use a 2.0 mm (0.08 inch) blade or equivalent to hold the switch in the N position. 8. Install the transmission range switch (A) gently on the control shaft (B) with holding the N position with the 2.0 mm (0.08 inch) blade (C). 9. Tighten the bolts on the transmission range switch while you continue to hold it in the N position. Do not move the transmission range switch when tightening the bolts. Remove the feeler gauge. Page 9139 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 Short Circuit Locator (Short Finder) 1. Remove the blown fuse. Leave the battery connected. Restraints - Child Seat Anchor Locating Button Missing Child Seat: Customer Interest Restraints - Child Seat Anchor Locating Button Missing 05-016 May 17, 2005 Applies To: See VEHICLES AFFECTED Child Seat Anchor Locating Button Is Missing PROBLEM The small button on the rear seat-back cover that marks the location of each child seat LATCH lower anchor is missing. VEHICLES AFFECTED 2001-05 Accord - ALL 2001-05 Civic - ALL 2003-05 Civic Hybrid - ALL 2002-05 Civic Si - ALL 2001-05 CR-V - ALL 2003-05 Element - ALL 2001-05 Odyssey - ALL 2003-05 Pilot - ALL CORRECTIVE ACTION Replace the button. NOTE: Older vehicles have buttons without a child seat icon. The buttons in newer vehicles and the replacement buttons all have an icon. If your customer requests matching buttons, replace all the buttons at the same time as a set. PARTS INFORMATION Child Seat ISOFIX Button Kit: (Kit contains buttons in nine different colors; 10 buttons of each color.) P/N 070AZ-SHJA190, H/C 7979016 Child Seat ISOFIX Button Kit Replacement Parts: Capacity Specifications Coolant: Capacity Specifications Engine Coolant Refill Capacity (including the reservoir capacity of 0.4 L (0.4 US qt): M/T ...................................................................................................................................................... ................................................. 4.0 L (4.2 US qt.) A/T, CVT ............................................................... ................................................................................................................................ 3.9 L (4.1 US qt.) Page 8846 8. Remove the locknut (A) and the fuel tank unit. 9. Remove the stopper (O). Release the hook (P) and remove the fuel filter (B), the fuel gauge sending unit (C), the case (D), the wire harness (E), and the fuel pressure regulator (F). 10. When connecting the fuel tank unit, make sure the connection is secure and the suction filter (G) is firmly connected to the fuel pump (H). 11. Install in the reverse order of removal with a new base gasket (I) and new O-rings (J), then check these items: - When connecting the wire harness, make sure the connection is secure and the connector (K) is firmly locked into the place. - When installing the fuel gauge sending unit, make sure the connection is secure and the connector is firmly locked into place. Be careful not to bend or twist the connector excessively. - When installing the fuel tank unit, align the marks (L) on the fuel tank (M) and the fuel tank unit (N). Page 6058 Under-dash Fuse/Relay Box (2-door) Page 8609 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. Obtain the customer's key code from the iN (Key Code Inquiry). Refer to the Honda High Security key Codes book that comes with the Matrix H key cutting machine. Write down the applicable cutting code for the key code number. Make sure the corrections to the code book listed in Service Bulletin 01-077, Cutting Sidewinder-Type keys With the Matrix H key Cutting Machine, have been made. 2. Use the chart shown to write down the numbers found in the key code book. 3. Remove the door panel. Refer to the appropriate service manual or use ISIS keyword Door Panel. 4. Remove the plastic cover as necessary. 5. Raise the window glass fully. 6. Remove the lock cylinder. ^ For Civic, go to step 7. ^ For CR-V, go to step 8. ^ For Element, go to step 11. 7. Pull down on the retainer clip with a hook-shaped tool. Remove the lock cylinder and disconnect the cylinder rod. Then go to step 14. Page 4898 156. A/T Reverse Relay (A/T, CVT) Page 4227 1. Remove the terminal. 2. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE E: 1. Remove the terminal. 2. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE F: Page 5694 3. Inspect the armature for wear or damage from contact with the permanent magnet. If there is wear or damage, replace the armature. 4. Check the commutator (A) surface. If the surface is dirty or burnt, resurface with emery cloth or a lathe within the given specifications, or recondition with # 500 or # 600 sandpaper (B). 5. Check the commutator diameter. If the diameter is below the service limit, replace the armature. Page 3160 Transmission Position Switch/Sensor: Testing and Inspection Transmission Range Switch Test 1. Remove the transmission range switch harness connector (A) from the connector bracket (B), then disconnect the connector. 2. Check for continuity between terminals at the harness connector. There should be continuity between the terminals listed for each switch position. In the P position, between terminals: ^ No. 1 and No. 3 ^ No. 1 and No. 8 ^ No. 3 and No. 8 In the R position, between terminals: ^ No. 1 and No. 9 In the N position and between terminals: ^ No. 1 and No. 3 ^ No. 1 and No. 10 ^ No. 3 and No. 10 In the D position, between terminals: ^ No. 1 and No. 2 ^ No. 1 and No. 4 ^ No.2 and No.4 In the D3 position, between terminals: ^ No. 1 and No. 2 ^ No. 1 and No. 5 ^ No.2 and No.5 In the 2 position, between terminals: ^ No. 1 and No. 6 Page 725 ^ Start the engine and let it warm up to its normal operating temperature (the cooling fans cycle twice). ^ Let the engine idle (throttle closed and all electrical items off) for 10 minutes. 17. CR-V only: Reset the power window control unit: ^ Turn the ignition switch to ON (II). ^ Make sure the driver's window is fully closed. ^ Push down and hold the window switch until the window goes all the way down. ^ Pull back and hold the window switch until the window goes all the way up, then hold the switch for at least 2 more seconds. 18. Enter the audio unit anti-theft code, and set the clock. Enter the audio presets. Disclaimer Page 8145 Page 9534 Relay And Control Unit Locations - Dashboard Page 3720 13. Plug in the heat gun, and turn it on. Start at the middle of the splice connector, and move the gun toward the ends as the tube shrinks. Apply heat evenly by rotating the curved heat spreader around the splice connector. Shrinking is complete when a small amount of sealant appears at each end of the tube. Pigtail Terminal Selection Chart PIGTAIL TERMINAL SELECTION CHART Select the proper size pigtail terminal by matching the replacement terminal part number and the wire size being repaired to the corresponding pigtail terminal part number. Then use the color (size) splice connector listed. In some instances you may also have to match the wire seal style to select the proper pigtail terminal. Pigtail terminals are available through your parts department, in quantities of 10, using normal parts ordering procedures. Checking For Poor Fir of Terminals CHECKING FOR POOR FIT OF TERMINALS Loose terminal fit can cause a number of intermittent problems in electrical circuits. By using the Terminal Inspection Feeler Tool Set you can inspect the terminal fit between the two matching connectors without removing the terminals from the connector body. 1. Find the terminal tool that best matches the male terminal in the mating connector. Page 1019 13. Remove the solenoid cover, and make sure the solenoid plunger groove is installed in the fork on the lever. ^ If needed, correct the position of the solenoid plunger, then go to step 14. ^ If the solenoid plunger is correctly installed, there is an electrical problem with the key interlock system; refer to the Automatic Transmission section of the appropriate service manual for troubleshooting information. Once the key interlock is working normally, go to step 14. 14. Install the solenoid cover. 15. Reinstall the steering column covers. 16. Center-punch a completion mark above the seventh character of the engine compartment VIN. Disclaimer Component Locations Front Door Window Motor: Component Locations Power Windows Component Location Index Page 2514 Connectors - "C" Component Locations Relay Box: Component Locations Relay Box Locations Starting System Component Location Index Page 3187 Throttle Position Sensor: Description and Operation Throttle Position (TP) Sensor The TP sensor is a potentiometer connected to the throttle valve shaft. As the throttle position changes, the sensor varies the signal voltage to the ECM/PCM. The TP sensor is not replaceable apart from the throttle body. Page 9035 Circuit Diagram Page 9017 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. Circuits must be operating when checking voltage drop. 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. 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 off, 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 Self-Powered Test Light or DVOM 1. Remove the blown fuse and disconnect the battery and load. Page 8305 3. Use the clamp carriage lever to position the clamp unit so the tracer is directly over the flat surface of the code device, just ahead of the cam blades. 4. Pull the vertical carriage lever toward you until the tracer just touches the flat surface ahead of the cam blades. Watch the arrows on the keypad: ^ If the double-headed arrow in the middle of the keypad lights green, the tracer and cutter bit are properly aligned. ^ If the arrow on the left of the keypad lights red, the cutter bit is not touching the jaw. Turn the micrometric ring nut above the tracer to the left until the double-headed arrow lights green. ^ If the vertical arrow on the right of the keypad lights red, the tracer is not touching the jaw. Turn the micrometric ring nut above the tracer to the right until the double-headed arrow lights green. *5. Turn the micrometric ring nut to the right five clicks so the cutter bit is slightly higher than the tracer. The arrow on the left should light red. Raise the vertical carriage. NOTE: Setting the tracer five clicks lower than the cutter bit at this point has the effect of making the cutter bit cut the duplicated key a little shallower. This will protect the locking jaws from being damaged.* 6. Optional: Loosen the set screw, and adjust the hand rest to a comfortable position. Tighten the screw. 7. Pull the clamp carriage lever toward you until the clamp carriage clicks into its end-of-run position. 8. Clean any metal shavings or debris out of the center jaw. (A soft-bristle toothbrush is ideal for this purpose.) Then open the jaws with the jaws knob, and slide the key blank with its flat side down into the jaw up to the key stop. Close the jaw with the jaws knob to lock the key blank into place. Visually inspect the key for proper alignment in the jaw. 9. Set and lock the cam sets on the code device. ^ Starting with the left cam set, make sure the lock pin is pulled all the way out. (This releases the cams.) Recall - Ignition/Shift Interlock Defect Technical Service Bulletin # 10-059 Date: 101001 Recall - Ignition/Shift Interlock Defect 10-059 October 1, 2010 Applies To: See VEHICLES AFFECTED Safety Recall: Accord, Civic, and Element Ignition Switch Key Interlock BACKGROUND Under certain conditions, the interlock lever of the ignition switch may unexpectedly deform. The interlock ensures the transmission is in Park before the ignition key can be removed. Interlock failure may allow the ignition key to be removed when the shift lever is not in Park. If the driver fails to engage the parking brake, the vehicle could roll away, increasing the risk of a crash. VEHICLES AFFECTED Not all vehicles within the VIN ranges are affected by this recall. Before beginning work on a vehicle, verify its eligibility by checking at least one of these items: ^ The customer has a notification letter. Page 465 Power Door Lock Switch: Testing and Inspection Door Lock Switch Test Door Lock Switch Test 1. Remove the driver's door panel. 2. Remove the two mounting screws and the door lock switch. 3. Check for continuity between the terminals. - There should be continuity between the No.1 and No.2 terminals when the door lock switch is in the LOCKED position. - There should be continuity between the No.2 and No.3 terminals when the door lock switch is in the UNLOCKED position. 4. If the continuity is not as specified, replace the switch. Page 519 Wheel Speed Sensor: Testing and Inspection Inspection 1. Inspect the front and rear pursers for chipped or damaged teeth. 2. Measure the air gap between the wheel sensor and the purser all the way around while rotating the purser. Remove the rear brake disc to measure the gap on the rear wheel sensor. If the gap exceeds 1.0 mm (0.04 inch), check for a bent suspension arm. Standard: Front: 0.4 - 1.0 mm (0.02 - 0.04 inch) Rear: 0.2 - 1.0 mm (0.01 - 0.04 inch) Page 7011 7. Remove the upper anchor cap (A), and remove the upper anchor bolt (B). 8. Disconnect the seat belt tensioner connector (A). Remove the retractor mounting self-tapping ET screw (B), and the retractor bolt (C), then remove the front seat belt (D) and retractor (E). 9. If necessary, remove the front seat belt protector (F). Page 7248 (Not interchangeable with CR-V and S2000 remote transmitter) Transmitter Identification The transmitter for the 1995-99 Accord and the 2000-02 Accord look identical, but they are not interchangeable. The 1995-99 transmitter works the doors of a 2000-02 Accord, but it does not open the trunk. If you are not sure which transmitter you have, press and hold the trunk release button while looking at the LED. The LED on the 1995-99 transmitter comes on in about 1.1 seconds. The LED on the 2000-02 transmitter comes on in about 0.5 second. Programming the Transmitter NOTES: ^ The system accepts up to three transmitters. The transmitter codes are stored in a stacking-type memory. If a fourth transmitter code is programmed, the code for the first transmitter is erased. ^ Entering the programming mode cancels all learned transmitter codes, so none of the previously programmed transmitters will work. You must reprogram all of the transmitters once you are in the programming mode. ^ You must complete steps 1-6 within 4 seconds of the previous step to keep the system from exiting the programming mode. 1. Turn the ignition switch to ON (II). 2. Press the "Lock" or "Unlock" button on one of the transmitters. (An unprogrammed transmitter can be used for this step.) 3. Turn the ignition switch to LOCK (0). 4. Repeat steps 1 2, and 3 two more times using the same transmitter used in step 2. 5. Turn the ignition switch to ON (II). 6. Press the "Lock" or "Unlock" button on the same transmitter. Make sure the power door locks cycle to confirm that the system is in programming mode. 7. Within 10 seconds, press the "Lock" or "Unlock" button on each transmitter. Make sure the power door locks cycle after you press each transmitter button to confirm that the system accepted the transmitter's code. 8. Turn the ignition switch to LOCK (0) to exit the programming mode. Ordering a Transmitter Transmitters can be ordered only by authorized Honda dealers. Order them from American Honda using normal parts ordering procedures. Batteries for the Transmitter The battery number is CR2025. Each transmitter uses one battery. 03-04 Accord LX and EX 2003-04 Accord LX and EX with factory-installed keyless entry system Page 191 Diagram 115-1 (except EX) Page 7445 Body Control Systems: Diagnostic Aids General Troubleshooting Information General Troubleshooting Information Tips and Precautions Before Troubleshooting 1. Check applicable fuses in the appropriate fuse/relay box. 2. Check the battery for damage, state of charge, and clean and tight connections. NOTE: 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. Handling Connectors - Make sure the connectors are clean and have no loose wire terminals. - Make sure multiple cavity connectors are packed with dielectric grease (except watertight connectors). - All connectors have push-down release type locks (A). - Some connectors have a clip on their side used to attach them to a mount bracket on the body or on another component. This clip has a pull type lock. - Some mounted connectors cannot be disconnected unless you first release the lock and remove the connector from its mount bracket (A). - Never try to disconnect connectors by pulling on their wires; pull on the connector halves instead. - Always reinstall plastic covers. Page 6825 12. Watch the SRS indicator: ^ If the indicator blinks twice and then goes off, the OPDS unit is initialized. Turn the ignition switch to LOCK (0), and disconnect the HDS. ^ If the indicator blinks twice and then stays on, the OPDS unit is initialized, but SRS DTCs need to be cleared. Go to step 13. ^ If the indicator stays on without first blinking, the OPDS unit is not initialized. Repeat steps 3 thru 12. 13. Turn the ignition switch to LOCK (0), then disconnect the HDS. 14. Reconnect the SCS service connector to the MES connector. Do not use a jumper wire. 15. Turn the ignition switch to ON (II). 16. Watch the SRS indicator. (It comes on for about 6 seconds and then goes off.) Disconnect the SCS service connector from the MES connector within 4 seconds after the indicator goes off. 17. When the SRS indicator comes on again, connect the SCS service connector to the MES connector within 4 seconds after the indicator comes on. 18. When the SRS indicator goes off, disconnect the SCS service connector from the MES connector within 4 seconds. (The SRS indicator blinks twice to indicate that the memory has been cleared.) 19. Turn the ignition switch to LOCK (0), and wait for 10 seconds. 20. Turn the ignition switch to ON (II). (The SRS is OK if the SRS indicator comes on for 6 seconds and then goes off.) If the DTC clearing fails, repeat the process two more times. If the DTC clearing fails again, check for set SRS DTCs, and troubleshoot them with the appropriate service manual. REPAIR PROCEDURE B: OPDS SENSOR REPLACEMENT 1. Remove the seat-back cover from the front passenger's seat: ^ Using the appropriate service manual, go to section 20 (Body), and do the removal steps under Front Seat Cover Replacement, or ^ Online, enter keyword SEAT COVER, then select Front Seat Cover Replacement from the list, and do the removal steps in the procedure. 2. Slide the seat-back cushion (foam) off the seat-back frame. (The OPDS sensor is built into the seat-back cushion.) 3. Slide a new seat-back cushion over the seat-back frame. Make sure the cushion is centered. 4. Install the seat-back cover: ^ Using the appropriate service manual, go to section 20 (Body), and do the installation step under Front Seat Cover Replacement, or ^ Online, enter keyword SEAT COVER, then select Front Seat Cover Replacement from the list, and do the installation step in the procedure. 5. Initialize the OPDS unit: ^ To initialize with the HDS, go to Initializing the OPDS Unit: HDS Method in this service bulletin. ^ To initialize with the SCS service connector, go to Initializing the OPDS Unit: Manual Mode in this service bulletin. Disclaimer Page 8840 Fuel Gauge Sender: Locations Gauges Component Location Index (Part 1 Of 4) Page 7634 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. Obtain the customer's key code from the iN (Key Code Inquiry). Refer to the Honda High Security key Codes book that comes with the Matrix H key cutting machine. Write down the applicable cutting code for the key code number. Make sure the corrections to the code book listed in Service Bulletin 01-077, Cutting Sidewinder-Type keys With the Matrix H key Cutting Machine, have been made. 2. Use the chart shown to write down the numbers found in the key code book. 3. Remove the door panel. Refer to the appropriate service manual or use ISIS keyword Door Panel. 4. Remove the plastic cover as necessary. 5. Raise the window glass fully. 6. Remove the lock cylinder. ^ For Civic, go to step 7. ^ For CR-V, go to step 8. ^ For Element, go to step 11. 7. Pull down on the retainer clip with a hook-shaped tool. Remove the lock cylinder and disconnect the cylinder rod. Then go to step 14. Specifications Page 9363 1. Remove the secondary locks. 2. Remove the terminal from the female half. 3. Remove the terminal from the male half. 4. Go to HOW TO INSTALL NEW TERMINALS. Connectors Without a Secondary Lock All examples are shown with the connector lock facing up. The illustrations are examples of connector terminals without a secondary lock; however, the connector you are repairing may vary in size and shape. EXAMPLE A: Page 9217 Dome Lamp: Testing and Inspection Ceiling Light Test/Replacement Ceiling Light Test/Replacement 1. Turn the light switch OFF. 2. Carefully pry off the lens (A) with a small screwdriver. 3. Remove the two mounting screws. 4. Disconnect the 3P connector (B) from the housing (C). 5. Check the bulbs. If the bulbs are OK, check for continuity between the terminals in each switch position according to the table. 6. If the continuity is not as specified, replace the ceiling light. Page 9189 - Before connecting connectors, make sure the terminals (A) are in place and not bent. - Check for loose retainer (A) and rubber seals (B). - The backs of some connectors are packed with dielectric grease. Add grease if necessary. If the grease is contaminated, replace it. - Insert the connector all the way and make sure it is securely locked. - Position wires so that the open end of the cover faces down. Handling Wires and Harnesses - Secure wires and wire harnesses to the frame with their respective wire ties at the designated locations. Locations 120. Driver's Door (Sedan except DX) Locations Intake Air System - Component Location Index Page 4854 Flat Rate Time: 4.0 hours Failed Part: P/N 24230-PLW-000 H/C 6568653 Defect Code: 042 Contention Code: B07 Template ID: 03-009A (DX, LX, EX) 03-009B (HX) 03-009C (Hybrid) 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. * Remove the transmission. See page 13-4 of the 2001-2003 Civic Service Manual; for the Hybrid, see page 13-18. Then remove the housing. See page 13-16 of the 2001-2003 Civic Service Manual; for the Hybrid, see page 13-32.* 2. * Remove the reverse idler shaft and the reverse idler gear; discard the gear. See page 13-17 (13-32 for Hybrid) of the service manual.* Page 4678 Follow these instructions to keep the ATF cooler cleaner working properly: ^ Replace the two magnetic nonbypass spin-on filters once a year or when you notice a restriction in the ATF flow. Check the level and condition of the fluid in the tank before each use. ^ Replace the ATF in the tank when it looks dark or dirty. Page 4893 Control Module: Service and Repair How to Substitute the PCM How to Substitute the PCM 1. Remove the PCM from the vehicle. 2. Install a known-good PCM in the vehicle. 3. Rewrite the immobilizer code with the PCM replacement procedure in the Honda PGM Tester; It allows you to start the engine. 4. After completing your tests, reinstall the original PCM and rewrite the immobilizer code with the PCM replacement procedure in the HDS Tester again. Disconnecting Airbag and Seat Belt Tensioner Connectors Seat Belt Tensioner: Service and Repair Disconnecting Airbag and Seat Belt Tensioner Connectors Before removing a front airbag, side airbag, or other SRS related devices (the SRS unit, the cable reel, the side impact sensors, the seat belt buckle tensioners, and the seat belt tensioner connector), disconnecting connectors from related devices, or removing the dashboard or the steering column, disconnect the airbag connectors or the side airbag connectors to prevent accidental deployment. Turn the ignition switch OFF, and disconnect the negative cable from the battery, and wait at least 3 minutes before beginning the following procedures. IMPORTANT: You have to wait at least 3 MINUTES after disconnecting the battery cable for the airbags to DISARM. Failure to do so might result in deployment of the airbags or tensioners. Seat Belt Tensioner Remove the left and (or) right center pillar lower trim panels. Disconnect both seat belt tensioner 2P connectors (A) from the floor wire harness 2P connectors (B). Page 5624 *T-5 Sidewinder Key Applications ^ 2003-05 Civic ^ 2004-05 Civic Hybrid ^ 2003-05 Civic GX (CNG) ^ 2004-05 S2000 ^ 2002-06 CR-V ^ 2003-06 Element ^ 2003-04 Odyssey ^ 2003-04 Pilot Ordering Honda key blanks through normal parts ordering channels: Refer to the parts catalog for correct key(s) for your application. PROGRAMMING KEYS Depending on the type of key blank you use, do this: ^ If you have used a T-5 programmable key blank ("T-5" stamped on the shank), you must code the key's transponder with the Ilco Immobilizer Key Code Duplicator (see S/B 99-053, Ilco Immobilizer key Code Duplicator). ^ If you have used a Honda key blank, add the* transponder code of the new key to the immobilizer system with the Honda Diagnostic System (HDS). ORDERING INFORMATION *To order the MATRIX H Key Cutting Machine, replacement cutter bits, fixed jaws and mobile jaws, T-5 programmable key blanks, and practice key blanks, contact the Honda Tool and Equipment Program by calling 888-424-6857 or using the fax order form provided in your Honda Tool and Equipment Program Catalog.* Order Honda key blanks through normal parts ordering channels. WARRANTY CLAIM INFORMATION None. This service bulletin is for information only. *DETERMINING WHICH KEY TO USE T-5 keys require less time to program and should be the first choice. They can be used as long as the following requirements are met: ^ Do you have the customer's operating key? ^ Does the vehicle fall within the T-5 Sidewinder Key Applications? ^ Does your dealership have an Ilco Immobilizer Key Code Duplicator? If the answer to all three questions on the above is yes, the 1-5 key option is the easier procedure. If you answered no to any of the questions, you should order the key(s) from the parts catalogue, and program it using the HDS.* BEFORE YOU START CUTTING 1. Get the original key or the key number from your customer or from the iN. 2. Get the applicable key blank. 3. If cutting by code, look up the applicable 9-digit cutting code for the key number. Refer to the code book Honda High Security key Codes that comes with the machine. Antitheft System - Alarm Will Not Arm/Arms By Itself Keyless Entry Transmitter: All Technical Service Bulletins Antitheft System - Alarm Will Not Arm/Arms By Itself 05-025 July 1, 2005 Applies To: 2001-05 Civic - ALL 2002-05 CR-V - ALL 2003-04 Element - ALL Accessory Security System Changes Modes By Itself (Supersedes 05-025, dated June 10, 2005, to update the information indicated by black bars and asterisks.) SYMPTOM The security system will not arm or it arms by itself. PROBABLE CAUSE Key switch contact chatter causes the control unit to change modes. CORRECTIVE ACTION * Civic: Replace the security control unit, and reprogram the remote(s).* * CR-V and Element: Replace the security control unit and the microphone, then reprogram the remote(s).* * NOTE: You must replace the microphone on the CR-V and Element because the security control units are matched to their microphones when they are manufactured. Using the original microphone may result in security system problems.* PARTS INFORMATION WARRANTY CLAIM INFORMATION In warranty: The normal warranty applies. Out of warranty: Any repair performed after warranty expiration may be eligible for goodwill consideration by the District Parts and Service Manager or your Zone Office. You must request consideration, and get a decision, before starting work. REPAIR PROCEDURE NOTE: Before starting, make sure you have all of the remotes (three maximum) the customer wishes to use. Page 3488 Blower Motor Relay Type 1, Type 2 Check for continuity between the terminals. - There should be continuity between the No.1 and No.3 terminals when power and ground are connected to the No.2 and No.4 terminals. - There should be no continuity between the No.1 and No.3 terminals when power is disconnected. Five-terminal type Check for continuity between the terminals. - There should be continuity between the No.1 and No.2 terminals when power and ground are connected to the No.3 and No.5 terminals. - There should be continuity between the No.1 and No.4 terminals when power is disconnected. Page 2062 3. Strip the insulation off the end of the wire so the wire fits in the new terminal as shown. (If the wire has a wire seal, replace it with a new one from the kit.) NOTE: After stripping the end of the wire, make sure you did not cut any wire strands. If you did, cut the wire off even with the insulation, and strip it again. 4. Position the terminal in the crimping tool slot with the solid portion of the terminal toward the anvil and the open section toward the former. 5. Insert the wire in the terminal to the position shown in step 3. 6. Squeeze the tool with both hands until the stops make contact. 7. Crimp the insulation crimp. - If you do not have a wire seal, then use the next larger size crimp slot. Position the crimping tool over the insulation crimp section of the terminal, then squeeze the tool with both hands until the stops make contact. - If you have a wire seal, position the insulation crimp in the 5.5 crimping slot, then carefully squeeze the crimp closed until its ends are touching and making a full-circle shape. Page 6869 WARRANTY CLAIM INFORMATION Out of warranty: Any repairs to the SRS system for problems other than the 15-1, 15-2, and 15-3 DTCs that are done 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. INSPECTION PROCEDURE NOTE: ^ When you check for SRS DTCs with the HDS, codes other than 15-1, 15-2, and 15-3 are not covered by this warranty extension bulletin. ^ If the vehicle is covered by warranty, repair it using the normal warranty repair procedures. If the vehicle's warranty is expired, give your customer an estimate for the cost of the repair. Do the appropriate inspection, based on the DTC. SRS DTC 15-1 Clear the DTC with the HDS. ^ If DTC 15-1 does not set again, go to REPAIR PROCEDURE A: OPDS UNIT REPLACEMENT. ^ If DTC 15-1 sets again, continue with normal troubleshooting. ^ If the OPDS unit causes DTC 15-1 to set repeatedly, yet passes the other troubleshooting steps, go to REPAIR PROCEDURE A: OPDS UNIT REPLACEMENT. SRS DTC 15-2 1. Inspect the connections and the wiring in the side airbag cutoff indicator circuit. ^ If all the connections and the wiring are OK, go to step 2. ^ If any of the connections or the wiring are faulty, repair the circuit, then go to step 2. 2. Clear the DTC with the HDS. ^ If DTC 15-2 does not set again, go to REPAIR PROCEDURE A: OPDS UNIT REPLACEMENT. ^ If DTC 15-2 sets again, continue with normal troubleshooting. ^ If the OPDS unit causes DTC 15-2 to set repeatedly, yet passes the other troubleshooting steps, go to REPAIR PROCEDURE A: OPDS UNIT REPLACEMENT. SRS DTC 15-3 1. Clear the DTC with the HDS. ^ If DTC 15-3 does not set again, go to step 2. ^ If DTC 15-3 sets again, continue with normal troubleshooting. 2. Ask your customer if electrical devices such as a laptop computer or a fluorescent map light are ever used near the front passenger's seat-back. (Some electrical devices that plug into the vehicle's accessory power socket, especially those using a power inverter/converter, can interfere with the seat-back sensors and cause SRS DTC 15-3 to set.) ^ If your customer uses any of these devices operate the device near the front passenger's seat-back. If DTC 15-3 sets again, clear it, then return the vehicle to the customer. Advise the customer to avoid using the device near the front passenger's seat-back. ^ If your customer does not use any of these devices and DTC 15-3 does not set again, go to REPAIR PROCEDURE A: OPDS UNIT REPLACEMENT. REPAIR PROCEDURE A: OPDS UNIT REPLACEMENT Page 3736 Control Module: Service and Repair Updating the ECM/PCM PCM Updating and Substitution for Testing Special Tools Required Honda Interface Module (HIM) P/N EQS05A35570 Use this procedure when you have to substitute a known-good PCM in a troubleshooting procedure. Update the PCM only if the PCM does not already have the latest software loaded. NOTE: Do not turn the ignition switch OFF while updating; the PCM can be damaged. How to Update the PCM NOTE: To ensure the latest program is installed, do an PCM update whenever the PCM is substituted or replaced. - Before you update the PCM, make sure the vehicle's battery is fully charged. - To prevent PCM damage, do not operate anything electrical (audio system, brakes, A/C, power windows, moon roof, door locks, etc.) during the update. - If you need to diagnose the Honda Interface Module (HIM) because the HIM's red (#3) light came on or was flashing during the update, leave the ignition switch in the ON (II) position when you disconnect the HIM from the Data Link Connector (DLC). This will prevent PCM damage. 1. Turn the ignition switch ON (II). Do not start the engine. 2. Connect the HIM to the DLC (A) located under the driver's side of dashboard. 3. Do the PCM update procedure as described on the HIM label and in the PCM update system. If the software in the PCM is the latest version, replace the PCM. How to End a Troubleshooting Session This procedure must be done after any troubleshooting. 1. Clear the DTC(s) with the Scan Tool or HDS, or reset the PCM by removing the No. 6 (PCM) fuse in the under-hood fuse/relay box for more than 10 seconds. 2. Turn the ignition switch ON (II). 3. Start the engine in the P or N position, and warm it up to normal operating temperature (the radiator fans come on). 4. To verify that the problem is repaired, test-drive the vehicle for several minutes at speeds over 30 mph (50 km/h) or in freeze data range. Primary HO2S and A/F Sensor Replacement Oxygen Sensor: Service and Repair Primary HO2S and A/F Sensor Replacement Primary HO2S and A/F Sensor Replacement Special Tools Required O2 sensor wrench, Snap-on YA8875, SP Tools 93750, or equivalent, commercially available 1. Disconnect the primary HO2S or A/F sensor 4P connector (A), then remove the primary HO2S or A/F sensor (B). 2. Install the primary HO2S or A/F sensor in the reverse order of removal. Locations Power Steering Pressure Switch: Locations Idle Control System - Component Location Index 34. Left Side Of Engine Compartment Page 344 SRS Component Location Index Page 9186 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. Below most connector numbers and component names are PHOTO and VIEW numbers. The PHOTO number refers to a photo in the back of the book that shows the connector's location on the car. The VIEW number refers to an illustration in the back of the book that shows the connector terminals, wire colors, connector cavity numbers, and other details. The connector cavity numbering sequence begins at the top left corner of the connector as seen from either of the viewpoints shown on diagram [8] . Except for the DLC (data link 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 C554, for example, means those terminals join in cavity 2 of connector C554. Power Distribution Schematics Power Distribution Schematics Locations Hazard Warning Switch: Locations Turn Signal/Hazard Flasher - Component Location Index Page 3840 13. Plug in the heat gun, and turn it on. Start at the middle of the splice connector, and move the gun toward the ends as the tube shrinks. Apply heat evenly by rotating the curved heat spreader around the splice connector. Shrinking is complete when a small amount of sealant appears at each end of the tube. Pigtail Terminal Selection Chart PIGTAIL TERMINAL SELECTION CHART Select the proper size pigtail terminal by matching the replacement terminal part number and the wire size being repaired to the corresponding pigtail terminal part number. Then use the color (size) splice connector listed. In some instances you may also have to match the wire seal style to select the proper pigtail terminal. Pigtail terminals are available through your parts department, in quantities of 10, using normal parts ordering procedures. Checking For Poor Fir of Terminals CHECKING FOR POOR FIT OF TERMINALS Loose terminal fit can cause a number of intermittent problems in electrical circuits. By using the Terminal Inspection Feeler Tool Set you can inspect the terminal fit between the two matching connectors without removing the terminals from the connector body. 1. Find the terminal tool that best matches the male terminal in the mating connector. Page 9321 13. Plug in the heat gun, and turn it on. Start at the middle of the splice connector, and move the gun toward the ends as the tube shrinks. Apply heat evenly by rotating the curved heat spreader around the splice connector. Shrinking is complete when a small amount of sealant appears at each end of the tube. Pigtail Terminal Selection Chart PIGTAIL TERMINAL SELECTION CHART Select the proper size pigtail terminal by matching the replacement terminal part number and the wire size being repaired to the corresponding pigtail terminal part number. Then use the color (size) splice connector listed. In some instances you may also have to match the wire seal style to select the proper pigtail terminal. Pigtail terminals are available through your parts department, in quantities of 10, using normal parts ordering procedures. Checking For Poor Fir of Terminals CHECKING FOR POOR FIT OF TERMINALS Loose terminal fit can cause a number of intermittent problems in electrical circuits. By using the Terminal Inspection Feeler Tool Set you can inspect the terminal fit between the two matching connectors without removing the terminals from the connector body. 1. Find the terminal tool that best matches the male terminal in the mating connector. Page 1730 12. Remove the sealing bolt (A) from the inspection hole (B), and connect an air pressure regulator with a 0 - 100 psi gauge (C). 13. Loosen the valve on the regulator, and apply the specified air pressure. Specified Air Pressure: 250 kPa (2.5 kgf/cm2, 36 psi) NOTE: If the synchronizing piston does not move after applying air pressure, move the primary or secondary rocker arm up and down manually by rotating the crankshaft counterclockwise. 14. Move the intake secondary rocker arm (A) for the No. 1 cylinder. The primary rocker arm (B) and secondary rocker arm should move together. ^ If the intake primary rocker arm does not move, remove the primary and secondary rocker arms as an assembly and check that the pistons in the secondary and primary rocker arms move smoothly. If any rocker arm needs replacing, replace the primary and secondary rocker arms as an assembly, and retest. 15. Remove the special tools. Specifications Brake Fluid: Specifications Geniune Honda Brake Fluid ................................................................................................................ ...................................................................... Dot 3 Page 6519 23. A/C Condenser Fan Motor Locations Clockspring Assembly / Spiral Cable: Locations 54. In Steering Column Cover 56. In Steering Column Cover Page 3465 Fuel Gauge Sender: Testing and Inspection Fuel Gauge Sending Unit Test Special Tools Required Fuel sender wrench 07XAA-001010A NOTE: For the fuel gauge system circuit diagram, refer to the Gauges Circuit Diagram. 1. Check the No.10 METER (7.5A) fuse in the under-dash fuse/relay box before testing. 2. Do the gauge drive circuit check. - If the fuel gauge needle sweeps from minimum to maximum position and then returns to the minimum position, the gauge is OK. Go to step 3. - If the fuel gauge needle does not sweep from minimum to maximum position and then return to the minimum position, replace the gauge assembly and retest. 3. Turn the ignition switch OFF. 4. Remove the rear seat cushion. 5. Remove the access panel from the floor. 6. Disconnect the fuel pump 5P connector. 7. Measure voltage between fuel pump 5P connector terminals No.1 and No.2 with the ignition switch ON (II). There should be battery voltage. - If the voltage is OK, go to step 7. - If the voltage is not as specified, check for: a short in the YEL/BLK wire to ground. - an open in the YEL/BLK or BLK wire. - poor ground (G551). 8. Turn the ignition switch OFF. Remove the No.9 BACK UP (10A) fuse from the under-hood fuse/relay box for at least 10 seconds, then reinstall it. Page 7813 21. Leave the key in the cylinder. Reinstall the plastic retainer and spring if you removed them in step 16. Hold the plastic retainer and spring on the housing, and insert the inner cylinder. Rotate it left and right to engage the spring to the inner cylinder. Make sure the spring is properly seated to the inner cylinder. 22. Install the arm with a new cylinder rod clip and a new E-clip. 23. Make sure the key can be inserted and removed easily, and that the cylinder turns with the key. Page 1235 ^ 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 40 Keyless Entry Module: Testing and Inspection Control Unit Input Test 1. Before testing, troubleshoot the multiplex control system. 2. Remove the dashboard lower cover. 3. Disconnect the under-dash fuse/relay box connectors. NOTE: All connectors are wire side of female terminals. 4. Inspect the connector and socket terminals to be sure they are all making good contact. - If the terminals are bent, loose or corroded, repair them as necessary, and recheck the system. - If the terminals look OK, go to step 5. Page 4702 Page 1385 5. If 4 numbers or marks (1 to 4 or V to VVVV) are printed around the outside of the filter, use the following procedure to tighten the filter. ^ Spin the filter on until its seal lightly seats against the block, and note which number or mark is at the bottom. ^ Tighten the filter by turning it clockwise 3 numbers or marks from the one you noted. For example, if number 2 is at the bottom when the seal is seated, tighten the filter until the number 1 comes around the bottom. 6. After installation, fill the engine with oil up to the specified level, run the engine for more than 3 minutes, then check for oil leakage. 7/8-turn type 1. Remove the oil filter with the special oil filter wrench. 2. Inspect the threads (A) and rubber seal (B) on the new filter. Wipe off the seat on the engine block, then apply a light coat of oil to the filter rubber seal. Use only filters with a built-in bypass system. 3. Install the oil filter by hand. 4. After the rubber seal seats, tighten the oil filter clockwise with the special tool. Tighten: 7/8 turn clockwise. Tightening torque: 22 Nm (2.2 kgf-cm, 16 ft. lbs.) Continuously Variable Transmission Transmission Position Switch/Sensor: Testing and Inspection Continuously Variable Transmission Transmission Range Switch Test 1. Disconnect the transmission range switch connector. 2. Check for continuity between terminals at the switch connector. There should be continuity between terminals below listed for each switch position. 3. If there is no continuity between any terminals, adjust the transmission range switch installation. If the transmission range switch installation is OK, replace the transmission range switch. 4. If the transmission range switch continuity check was OK, replace the faulty transmission harness. Page 2327 228. ECM/PCM Part 3 228. ECM/PCM Part 4 Page 5312 Transmission Speed Sensor: Diagrams 105. CVT Drive Pulley Speed Sensor 106. CVT Driven Pulley Speed Sensor 107. CVT Speed Sensor 1 108. CVT Speed Sensor 2 Page 3199 Diodes Light Emitting Diode (LED) Motor Pressure Sensor Locations Blower Motor Relay: Locations Under-hood Fuse/Relay Box Page 4190 143. Park Pin/Shift Switch (A/T) Page 6860 12. Watch the SRS indicator: ^ If the indicator blinks twice and then goes off, the OPDS unit is initialized. Turn the ignition switch to LOCK (0), and disconnect the HDS. ^ If the indicator blinks twice and then stays on, the OPDS unit is initialized, but SRS DTCs need to be cleared. Go to step 13. ^ If the indicator stays on without first blinking, the OPDS unit is not initialized. Repeat steps 3 thru 12. 13. Turn the ignition switch to LOCK (0), then disconnect the HDS. 14. Reconnect the SCS service connector to the MES connector. Do not use a jumper wire. 15. Turn the ignition switch to ON (II). 16. Watch the SRS indicator. (It comes on for about 6 seconds and then goes off.) Disconnect the SCS service connector from the MES connector within 4 seconds after the indicator goes off. 17. When the SRS indicator comes on again, connect the SCS service connector to the MES connector within 4 seconds after the indicator comes on. 18. When the SRS indicator goes off, disconnect the SCS service connector from the MES connector within 4 seconds. (The SRS indicator blinks twice to indicate that the memory has been cleared.) 19. Turn the ignition switch to LOCK (0), and wait for 10 seconds. 20. Turn the ignition switch to ON (II). (The SRS is OK if the SRS indicator comes on for 6 seconds and then goes off.) If the DTC clearing fails, repeat the process two more times. If the DTC clearing fails again, check for set SRS DTCs, and troubleshoot them with the appropriate service manual. REPAIR PROCEDURE B: OPDS SENSOR REPLACEMENT 1. Remove the seat-back cover from the front passenger's seat: ^ Using the appropriate service manual, go to section 20 (Body), and do the removal steps under Front Seat Cover Replacement, or ^ Online, enter keyword SEAT COVER, then select Front Seat Cover Replacement from the list, and do the removal steps in the procedure. 2. Slide the seat-back cushion (foam) off the seat-back frame. (The OPDS sensor is built into the seat-back cushion.) 3. Slide a new seat-back cushion over the seat-back frame. Make sure the cushion is centered. 4. Install the seat-back cover: ^ Using the appropriate service manual, go to section 20 (Body), and do the installation step under Front Seat Cover Replacement, or ^ Online, enter keyword SEAT COVER, then select Front Seat Cover Replacement from the list, and do the installation step in the procedure. 5. Initialize the OPDS unit: ^ To initialize with the HDS, go to Initializing the OPDS Unit: HDS Method in this service bulletin. ^ To initialize with the SCS service connector, go to Initializing the OPDS Unit: Manual Mode in this service bulletin. Disclaimer Page 3278 Variable Valve Timing Pressure Switch: Service and Repair VTEC Oil Pressure Switch Replacement 1. Remove the resonator (see step 5). 2. Remove the bolt (A) and loosen the bolt (B) securing the VTEC solenoid valve, then remove the harness bracket (C) from the VTEC solenoid valve. 3. Remove the harness clamp (D) from the connecting pipe. 4. Disconnect the VTEC oil pressure switch connector, then remove the VTEC oil Pressure switch (A). 5. Install the VTEC oil pressure switch using a new O-ring (B). Locations Impact Sensor: Locations SRS Component Location Index Page 3550 39. Left Side Of Engine Compartment Page 5444 Brake Caliper: Service and Repair Disassembly and Reassembly Overhaul CAUTION: Frequent inhalation of brake pad dust, regardless of material composition, could be hazardous to your health. ^ Avoid breathing dust particles. ^ Never use an air hose or brush to clean brake assemblies. Use an OSHA-approved vacuum cleaner. Remove, disassemble, inspect, reassemble, and install the caliper, and note these items: ^ Do not spill brake fluid on the vehicle; it may damage the paint; if brake fluid gets on the paint, wash it off immediately with water. ^ To prevent dripping, cover disconnected hose joints with rags or shop towels. ^ Clean all parts in brake fluid and air dry; blow out all passages with compressed air. Before reassembling, check that all parts are free of dust and other foreign particles. ^ Replace parts with new ones as specified in the illustration. ^ Make sure no dirt or other foreign matter is allowed to contaminate the brake fluid. ^ When reusing pads, always reinstall them in their original positions to prevent loss of braking efficiency. ^ Do not reuse drained brake fluid. ^ Always use Honda DOT 3 brake fluid. Non-Honda brake fluid can cause corrosion and shorten the life of the system. Do not mix different brands of brake fluid, as they may not be compatible. ^ Coat the piston, piston seal groove, and caliper bore with clean brake fluid. Make sure no grease or oil gets on the brake discs or pads. Replace all rubber parts with new ones whenever disassembled. After installing the caliper, check the brake hose and line for leaks, interference, and twisting. Page 7339 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 3908 *MVCI: (Available through the Honda Tool and Equipment Program)* Page 1260 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. Locations Starter Relay: Locations Starting System Component Location Index Page 1723 10. Install the back cover (A), then install the camshaft pulley (B). Page 4062 4. Install the three dowel pins (D) and the gasket (E) on the torque converter housing (F). 5. Place the transmission housing (G) on the torque converter housing. 6. Install the housing bolts along with the transmission hanger (H) and connector bracket (I). Tighten the bolts in two or more steps to 44 Nm (4.5 kgf-cm, 33 ft. lbs.) in a crisscross pattern. 7. Measure the clearance between the 80 mm set ring and carrier bearing outer race with a feeler gauge. 8. If the clearance is out of standard, remove the 80 mm set ring, and measure its thickness. 9. Select and install a new set ring, then recheck the clearance and make sure it is within the standard. SET RING, 80 mm No. Part Number Thickness 1 90414-689-000 2.50 mm (0.098 inch) 2 90415-689-000 2.60 mm (0.102 inch) 3 90416-689-000 2.70 mm (0.106 inch) 4 90417-689-000 2.80 mm (0.110 inch) 5 90418-689-000 2.90 mm (0.114 inch) 6 90419-PH8-000 3.00 mm (0.118 inch) Page 8339 Vehicle Identification Number - Canada Model 4-door Page 3378 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. Specifications Page 1848 2. Insert the pilot collar (A) into the piston and connecting rod. 3. With the embossed mark facing up, place the piston assembly (B) on the special tool (C). Be sure you position the recessed flat on the piston against the lugs on the base attachment. 4. Press the pin (D) in with the pin driver (E) and a hydraulic press. Page 6727 NOTE: Multiple boxes cannot be bundled together. 5. Prior to shipment, make sure that all steps have been properly completed. All boxes must be prepared in accordance with all U.S. Department of Transportation (DOT) and FedEx Ground requirements. Incomplete or missing information will result in return to sender and delay of return credit. 6. Retain your copy of the OP-950 Hazardous Materials Certification form for at least 1 year. This is required per DOT regulations and for your proof of shipment via Tracking ID. INFLATOR PACKING AND AIR SHIPPING INSTRUCTIONS: DEALERS IN ALASKA AND HAWAII NOTE: ^ Do not deploy the original inflator. Claims for deployed inflators will be charged back to your dealership. ^ There is a 48-hour return shipment objective for the inflator. ^ Dealers in Alaska and Hawaii require Fed Ex Air shipping documents and instructions. Call the WPI administrative office at 937-642-2737 for the documents and instructions. 1. Carefully insert the original inflator into the round opening in the return shipping box (the box that the new inflator came in). 2. Close the top flap on the box, then double-tape the the box closed with 2-inch clear packing tape on the entire front seam and the side seams. Press down on the tape for good adhesion. 3. Fill in this information on the Fed Ex airbill: ^ In the From section, add your name, address, and telephone number. ^ In the Your Internal Billing Reference section, add your 6-digit dealer number and the VIN. ^ In the Does this shipment contain dangerous goods? section, check the box next to Yes per attached Shipper's Declaration. ^ In the Total Declared Value section, do not add an amount. 4. Fill in this information on the SHIPPER'S DECLARATION FOR DANGEROUS GOODS form: NOTE: If not already done, cross out the words CARGO AIRCRAFT ONLY in the TRANSPORTATION DETAILS box at the top left of the form. The shipper may reject your shipment if CARGO AIRCRAFT ONLY is not crossed out. ^ In the Shipper section, add your name and address. ^ In the Air Waybill No. section, add the 12-digit tracking number from the top of the airbill. ^ In the Page of Pages section, add 1 of 1. ^ In the lower right corner of the form, print your name and title, your city, state, and the shipment date. Then add your signature. 5. For your records, keep one copy of the shipper's declaration and the sender's copy of the airbill. Insert the completed shipper's declaration and the airbill into an adhesive FedEx envelope, then attach the envelope to the box, most likely on the bottom. Do not cover any of the hazard markings or labels on the box. 6. Attach a From label (your dealership address) and a To label (1K Holdings, Inc., as listed on the airbill) to the outside of the box. Do not cover any of the hazard markings or labels on the box. 7. Before shipment, make sure steps 1 thru 6 have been completed. Incomplete or missing information may cause the box to be returned to you. NOTE: You (the shipper) are responsible for proper packing and document completion before shipping this box. The DOT (U.S. Department of Transportation) will impose substantial fines and/or penalties on the shipper (you) if the packaging, labeling, and/or documentation is/are not properly prepared. The person signing the document must be trained, and the training records must be on file at your place of business. Retain all documents for at least 2 years. Body - Trunk Lid Hard to Close Trunk / Liftgate Lock: Customer Interest Body - Trunk Lid Hard to Close 02-061 November 5, 2004 Applies To: See VEHICLES AFFECTED Trunk Lid is Difficult to Close (Supersedes 02-061, dated July 23, 2004) Updated information is shown with asterisks. SYMPTOM The trunk lid may be difficult to close or won't latch closed. PROBABLE CAUSE The trunk lid may be misaligned, and the trunk lid opener cable, trunk lid latch, lock cylinder, lock rod, and/or the trunk lid latch striker may need adjustment or replacement. VEHICLES AFFECTED CORRECTIVE ACTION Adjust the trunk lid and/or the trunk lid latch, or replace components as needed. PARTS INFORMATION Page 1381 11. Disconnect the quick-connect fitting (A): Hold the connector (B) with one hand and squeeze the retainer tabs (C) with the other hand to release them from the locking pawls (D). Pull the connector off. NOTE: Prevent the remaining fuel in the fuel feed line or hose from flowing out with a rag or shop towel. - Be careful not to damage the line (E) or other parts. - Do not use tools. - If the connector does not move, keep the retainer tabs pressed down, and alternately pull and push the connector until it comes off easily. - Do not remove the retainer from the line; once removed, the retainer must be replaced with a new one. 12. After disconnecting the quick-connect fitting, check it for dirt or damage (see step 4). Page 990 107. Behind A/T Shift Lever (except M/T) Page 8451 NOTE: For color information, refer to PIB A05-0005, Child Seat Anchor Buttons. Click PARTS, then click PARTS LIBRARY, then click Parts Bulletins. Select Child Seat Anchor Buttons from the list. (Each part contains fabric washers, button posts, and back portions.) WARRANTY CLAIM INFORMATION In warranty: The normal warranty applies. Failed Part: 82123-SDA-305ZA Defect Code: 07801 Symptom Code: 03220 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. Remove the rear seat-back cover just enough to allow access to the opening where the button will be attached: ^ Refer to Section 20, Rear Seat-back Cover Replacement, in the appropriate service manual, or ^ Online, enter keyword SEAT COVER, and select the appropriate Rear Seat-back Cover Replacement procedure from the list. 2. Select the appropriate button from the Child Seat Anchor Service Set. 3. Attach the button to the rear seat-back cover: ^ Place a fabric washer over the button post. ^ Insert the post through the opening in the cover. ^ Snap the back portion onto the post. Page 5453 34. Left Side Of Engine Compartment Page 3828 Use the tools from Pin Tool Set. First, check the connector that you are about to repair. - If it has a secondary terminal lock, go to Connectors With a Secondary Lock. A secondary lock, found on most connectors on some models, is an additional locking device on the connector housing as a backup for the primary lock on the terminal. - If the connector does not have a secondary lock, go to Connectors Without a Secondary Lock. Connectors With a Secondary Lock All examples are shown with the connector lock facing up. The illustrations are examples of the secondary terminal locks; however, the connector you are repairing may vary in size. Identify the connector by the type of secondary lock, not by the number of terminal cavities. EXAMPLE A: 1. Release the secondary lock. 2. Remove the terminal. 3. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE B: Page 3209 - 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. Troubleshooting Tests 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 test 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 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. 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 Drop Page 3153 8. Inspect the quality of the wire crimp. If it has any of the following NO GOOD crimps, cut it off and start over. 9. Insert the terminal into the connector. Make sure the wire seals are pushed all the way into the connector. Lightly pull on the wires to make sure the terminal is locked into place. 10. Close or insert the secondary terminal lock, if applicable, and reconnect the connector. How to Install Pigtail Terminals HOW TO INSTALL PIGTAIL TERMINALS Pigtail terminals (short pieces of wire with a factory crimped terminal) are used when the wire is too short or when access to the connector is too restricted to make a terminal repair. NOTE: To replace just a connector terminal, go to How to Replace Connector Terminals. IMPORTANT SAFETY INFORMATION: On some models, the SRS wires are in a separate harness. If the SRS harness is damaged, replace the harness; do not repair it. On other models, wire harnesses include yellow SRS wires. If any SRS wire is damaged, replace the entire harness; do not repair it. 1. Remove the damaged or faulty terminal from the connector. Use the proper removal tool from Pin Tool Set. Page 2799 114. FTP Sensor (except GX) Page 724 7. Remove the four screws that hold the two fuses, and remove the fuses. 8. Release the tab that holds the ELD, and pull up on the ELD to remove it. 9. Remove the bus bar from the ELD, and insert the bar into the new ELD. 10. Install the new ELD and bus bar into the fuse/relay box. 11. Reinstall the two fuses. 12. Reinstall the 3P ELD connector and the lower fusel relay box cover. 13. Reinstall the fuse/relay box onto its holder. CR-V only: Reinstall the wire harness clip onto the holder. 14. Reinstall the fuse/relay box cover. 15. Reconnect the negative battery cable. 16. Do the idle learn procedure: ^ Make sure all electrical items (A/C, audio unit, defogger, lights, etc.) are off. Page 2861 119. Knock Sensor (except GX) Page 187 8. Put the splice connector in the proper size slot in the Crimper Tool, slide it to one end (where the flare begins), and close the crimper handles far enough to hold it in place. To release the ratchet mechanism at any point after the first click, squeeze the handles slightly and push the release lever, then let the handles open. 9. Insert one of the bare wires into the splice connector end that is in the crimper jaws. Push the wire all the way into the splice connector, and squeeze the crimper handles. Keep squeezing until the jaws touch, and hold it at that position until the ratchet clicks again. 10. Crimp the other wire in the same way into the other end of the splice connector. 11. After crimping, gently pull on the wires in the opposite directions to make sure they are secure in the connector. 12. Separate the other wires in the harness from the repaired wire(s), and shield them with nonflammable material. Page 4590 156. A/T Reverse Relay (A/T, CVT) Page 5978 234. Under-dash Fuse/Relay Box Part 4 Page 598 Door Switch: Locations Entry Light Control System Component Location Index Page 1015 1. Remove and discard the plastic cover from the ignition switch key interlock solenoid. 2. Note the position of the interlock solenoid plunger; you'll need to install it the same way. 3. Remove the screw from the solenoid, but keep the solenoid attached to its electrical connector. Discard the screw. NOTE: ^ Be careful not to lose the solenoid plunger; it slides out easily. ^ Keep the plunger free of dirt and grease while it's removed from the solenoid. 4. Note the position of the interlock lever spring; you'll need to install the new spring the same way. Page 1068 Power Distribution schematics show how power is supplied from the positive battery terminal to various circuits in the vehicle. Refer to the Power Distribution diagram set to get a more detailed understanding of how picture is supplied to the circuit you're working on. Individual circuit schematics begin with a fuse. So 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 Ground Distribution Schematics This sample Ground Distribution schematic shows all of the components that share the same ground point. Page 8735 Cruise Control Switch: Diagrams 139. Cruise Control Set/Resume/Cancel Switch (except DX) 157. Cruise Control Main Switch (except DX) Page 5912 - Remove clips carefully; don't damage their locks (A). - Slip pliers (A) under the clip base and through the hole at an angle, then squeeze the expansion tabs to release the clip. - After installing harness clips, make sure the harness doesn't interfere with any moving parts. - Keep wire harnesses away from exhaust pipes and other hot parts, from sharp edges of brackets and holes, and from exposed screws and bolts. - Seat grommets in their grooves properly (A). Do not leave grommets distorted (B). Testing and Repairs - Do not use wires or harnesses with broken insulation. Replace them or repair them by wrapping the break with electrical tape. - After installing parts, make sure that no wires are pinched under them. - When using electrical test equipment, follow the manufacturer's instructions and those described. - If possible, insert the probe of the tester from the wire side (except waterproof connector). - Use back probe adaptor 07TAZ-001020A. - Refer to the instructions in the Honda Terminal Kit for identification and replacement of connector terminals. Five-Step Troubleshooting Five-Step Troubleshooting 1. Verify The Complaint M/T - Clicking Noise Driving in 2nd Gear Reverse Idler Gear: All Technical Service Bulletins M/T - Clicking Noise Driving in 2nd Gear 03-009 June 10, 2003 Applies To: 2001-03 Civic DX, LX, HX, EX with M/T - ALL 2003 Civic Hybrid - From VIN JHMES95..3S000001 thru JHMES95..3S018631 Clicking Noise While Driving in 2nd (Supersedes 03-009, dated April 1, 2003) Updated information is shown with asterisks. SYMPTOM * While driving in 2nd gear, a clicking noise occurs when turning right (DX, LX, HX, and EX) or when turning left (Civic Hybrid).* PROBABLE CAUSE The reverse idler gear is contacting the 1st/2nd hub sleeve set. CORRECTIVE ACTION Replace the reverse idler gear, the 1st/2nd synchro hub/sleeve set, and the reverse gear holder. REQUIRED MATERIALS Honda Manual Transmission Fluid (1.7 quarts required): P/N 08798-9016, H/C 4928271 Liquid Gasket: P/N 08718-0001, H/C 2963817 PARTS INFORMATION WARRANTY CLAIM INFORMATION In warranty: The normal warranty applies. Operation Number: 213110 Page 9179 Wires Page 7019 6. Install the belt and buckles in the reverse order of removal, and note these items: - Apply liquid thread lock to the anchor bolts before reinstallation. - Check that the retractor locking mechanism functions. - Assemble the washers on the center anchor bolt as shown. - Before installing the center anchor bolt, make sure there are no twists or kinks in the center belt. Page 4400 3. If there is no continuity between any terminal, remove the transmission range switch cover, and disconnect the connector (A) at the switch (B). 4. Check for continuity between terminals at the switch connector (c). There should be continuity between the terminals listed for each position. In the P position, between terminals: ^ No. 4 and No. 5 ^ No. 4 and No. 6 ^ No. 5 and No. 6 In the R position, between terminals: ^ No. 1 and No. 4 In the N position, between terminals: ^ No. 4 and No. 5 ^ No. 4 and No. 7 ^ No.5 and No.7 In the D position, between terminals: ^ No.2 and No.4 ^ No. 2 and No. 10 ^ No. 4 and No. 10 In the D3 position, between terminals: ^ No. 4 and No. 8 ^ No. 4 and No. 10 ^ No. 8 and No. 10 In the 2 position, between terminals: ^ No.3 and No.4 5. If there is no continuity between any terminals, adjust the transmission range switch installation. If the transmission range switch installation is OK, replace the switch. 6. If the transmission range switch continuity check was OK, replace the faulty transmission range switch harness. Page 1105 Transmission Speed Sensor: Diagrams 34. Output Shaft (Countershaft) Speed Sensor (A/T Except CVT) 57. Input Shaft (Mainshaft) Speed Sensor (A/T Except CVT) Page 8510 118. Driver's Door (Coupe Exc. DX, HX; Sedan Exc: DX) 121. Driver's Door (Coupe Except DX) Page 9293 Splices Components Ground - "G" Page 9227 Door Switch: Diagrams 4. Door Switch, Driver's 5. Door Switch, Front Passenger's (Sedan) 6. Door Switch, Left Rear Or Right Rear 7. Door Switch, Passenger's (Coupe) Page 2882 32. Reinstall PGM-FI main relay 2 (A). 33. Check for continuity between fuel pump 5P connector terminal No.5 and body ground. Is there continuity? YES - Replace PGM-FI main relay 2. Also replace the No.17 FUEL PUMP (15A) fuse. NO - Check the fuel pump, and replace it as necessary. Also replace the No.17 FUEL PUMP (15A) fuse. 34. Disconnect ECM/PCM connector E (31P). 35. Turn the ignition switch ON (II). 36. Measure voltage between ECM/PCM connector terminals E9 and body ground. Is there battery voltage? YES - Go to step 37. NO - Repair open in the wire between the No.17 FUEL PUMP (15A) fuse and the ECM/PCM (E9). 37. Turn the ignition switch OFF. Page 9129 Circuit Schematics Each schematic represents one circuit. A circuit's wires and components are arranged to show current flow from power at the top of the diagram 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 Page 1777 5. If the filter is not clogged, push the VTEC solenoid valve with your finger and check its movement. If the VTEC solenoid valve moves, check the engine oil pressure. Page 8180 Doors - Component Location Index - 4-door Front Door Testing and Inspection Vacuum Brake Booster: Testing and Inspection Brake Booster Test Functional Test 1. With the engine stopped, press the brake pedal several times to deplete the vacuum reservoir, then press the pedal hard and hold it for 15 seconds. If the pedal sinks, either the master cylinder is bypassing internally, or the brake system (master cylinder, lines, modulator, proportioning valve, calipers, or wheel cylinders) is leaking. 2. Start the engine with the brake pedal pressed. If the pedal sinks slightly, the vacuum booster is operating normally. If the pedal height does not vary, the booster or check valve is faulty. 3. With the engine running, press the brake pedal lightly. If the brake pedal sinks more than 10 mm (3/8 inch) in 3 minutes, the master cylinder is faulty. A slight change in pedal height when the A/C compressor cycles on and off is normal. (The A/C compressor load changes the vacuum available to the booster.) Leak Test 1. Press the brake pedal with the engine running, then stop the engine. If the pedal height does not vary while pressed for 30 seconds, the vacuum booster is OK. If the pedal rises, the booster is faulty. 2. Turn the engine off and wait 30 seconds. Press the brake pedal several times using normal pressure. When the pedal is first pressed, it should be low. On consecutive applications, the pedal height should gradually rise. If the pedal position does not vary, check the booster check valve. 3. Disconnect the brake booster vacuum hose (check valve built-in) (A) at the booster (B) side. 4. Start the engine, and let it idle. There should be vacuum available. If no vacuum is available, the check valve is not working properly. Replace the brake booster vacuum hose and check valve, and retest. 5. Start the engine, and then pinch the brake booster vacuum hose between the check valve and the booster. 6. Turn the engine off and wait 30 seconds. Press the brake pedal several times using normal pressure. When the pedal is first pressed, it should be low. On consecutive applications, the pedal height should gradually rise. ^ If the pedal position does not vary, replace the brake booster. ^ If the pedal position varies, replace the brake booster vacuum hose/check valve assembly. Page 4882 8. Reassemble the transmission; see page 13-43 (13-59 for Hybrid) of the service manual. 9. Install the new shift fork holder. Check the reverse shift fork clearance; see page 13-19 (13-34 for Hybrid) of the service manual. 10. Reinstall the transmission; see page 13-9 (13-23 for Hybrid) of the service manual. 11. Fill the transmission with MTF. 12. * Test-drive the car; make several right turns (left turns for Hybrid), and check that the clicking noise is gone.* Disclaimer Page 5533 98. Wheel Speed Sensor, Right Rear (EX, GX) Page 5745 2. Cut off the wire about an inch back from where it connects to the damaged or faulty terminal, then strip about half of the insulation off that piece. This will be used to size the wire end of the replacement pigtail terminal. NOTE: If you are not sure of the wire size, start with a large enough hole on the stripper that will not nick or cut off any strands of wires. 3. Select a pigtail terminal that matches the original wire at both ends (same kind of terminal and same diameter bare wire). 4. Select the smallest splice connector (yellow, pink, or blue) that will fit onto the stripped end of the original wire. 5. Insert the pigtail terminal into the connector cavity; push it in until it locks in place. 6. Lay the pigtail and the original wire side-by-side, and cut off both ends at once. If you are making more than one splice, do not cut each pigtail at the same location; the resulting "lump" of splice connectors would interfere with rewrapping the harness. Instead, cut the first pigtail close enough to the terminal so you will have room to make each remaining cut about 20 mm (3/4 inch) farther down on the next pigtail. 7. If you are using a yellow splice connector, strip about 6 mm (1/4 inch) of insulation off the ends of both wires. If you are using a pink or blue splice connector, strip off about 8 mm (5/16 inch) of insulation. Locations Fuel Injector: Locations PGM-FI System - Component Location Index 46. Middle of Engine (Except GX) Page 4509 4. Inspect the pressure plate (A) surface for wear, cracks, and burning. 5. Inspect the fingers of the diaphragm spring (B) for wear at the release bearing contact area. 6. Inspect for warpage using a straight edge (A) and feeler gauge (B). Measure across the pressure plate (C). If the warpage is more than the service limit, replace the pressure plate. Standard (New): 0.03 mm (0.001 inch) max. Service Limit: 0.15 mm (0.006 inch) 7. Remove the clutch disc and special tools. 8. Inspect the lining of the clutch disc for signs of slipping or oil. If the clutch disc is burned black or oil soaked, replace it. Page 7398 7. Remove the four screws that hold the two fuses, and remove the fuses. 8. Release the tab that holds the ELD, and pull up on the ELD to remove it. 9. Remove the bus bar from the ELD, and insert the bar into the new ELD. 10. Install the new ELD and bus bar into the fuse/relay box. 11. Reinstall the two fuses. 12. Reinstall the 3P ELD connector and the lower fusel relay box cover. 13. Reinstall the fuse/relay box onto its holder. CR-V only: Reinstall the wire harness clip onto the holder. 14. Reinstall the fuse/relay box cover. 15. Reconnect the negative battery cable. 16. Do the idle learn procedure: ^ Make sure all electrical items (A/C, audio unit, defogger, lights, etc.) are off. Mainshaft Speed Sensor Replacement Transmission Speed Sensor: Service and Repair Mainshaft Speed Sensor Replacement Mainshaft Speed Sensor Replacement 1. Disconnect the mainshaft speed sensor connector. 2. Remove the mainshaft speed sensor (A). 3. Install the new mainshaft speed sensor with the new O-ring (B) and mainshaft speed sensor washer (C). NOTE: The mainshaft speed sensor washer is equipped on the SLXA automatic transmission; the BMXA does not have it. 4. Check the mainshaft speed sensor connector for rust, dirt, or oil, then connect the connector securely. Page 9689 Blower Motor Relay Type 1, Type 2 Check for continuity between the terminals. - There should be continuity between the No.1 and No.3 terminals when power and ground are connected to the No.2 and No.4 terminals. - There should be no continuity between the No.1 and No.3 terminals when power is disconnected. Five-terminal type Check for continuity between the terminals. - There should be continuity between the No.1 and No.2 terminals when power and ground are connected to the No.3 and No.5 terminals. - There should be continuity between the No.1 and No.4 terminals when power is disconnected. Page 7348 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 Locations Relay And Control Unit Locations - Engine Compartment Page 3128 Splices Components Ground - "G" Locations Page 3820 - Before connecting connectors, make sure the terminals (A) are in place and not bent. - Check for loose retainer (A) and rubber seals (B). - The backs of some connectors are packed with dielectric grease. Add grease if necessary. If the grease is contaminated, replace it. - Insert the connector all the way and make sure it is securely locked. - Position wires so that the open end of the cover faces down. Handling Wires and Harnesses - Secure wires and wire harnesses to the frame with their respective wire ties at the designated locations. Page 6356 Suspension Spring ( Coil / Leaf ): Service and Repair Rear Damper/Spring Removal and Installation Removal 1. Raise the rear of the vehicle, and support it with safety stands in the proper locations. Remove the rear wheels. Page 5245 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 Locater) 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. Troubleshooting Precautions Troubleshooting Precautions Before Troubleshooting 1. Check the main fuse and the fuse 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, or you will damage the alternator diodes. - Do not attempt to crank the engine with the ground cable disconnected 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. Page 2063 8. Inspect the quality of the wire crimp. If it has any of the following NO GOOD crimps, cut it off and start over. 9. Insert the terminal into the connector. Make sure the wire seals are pushed all the way into the connector. Lightly pull on the wires to make sure the terminal is locked into place. 10. Close or insert the secondary terminal lock, if applicable, and reconnect the connector. How to Install Pigtail Terminals HOW TO INSTALL PIGTAIL TERMINALS Pigtail terminals (short pieces of wire with a factory crimped terminal) are used when the wire is too short or when access to the connector is too restricted to make a terminal repair. NOTE: To replace just a connector terminal, go to How to Replace Connector Terminals. IMPORTANT SAFETY INFORMATION: On some models, the SRS wires are in a separate harness. If the SRS harness is damaged, replace the harness; do not repair it. On other models, wire harnesses include yellow SRS wires. If any SRS wire is damaged, replace the entire harness; do not repair it. 1. Remove the damaged or faulty terminal from the connector. Use the proper removal tool from Pin Tool Set. Page 8152 Programming the Transmitter NOTES: ^ The system accepts up to four transmitters. ^ Entering the programming mode cancels all learned transmitter codes, so none of the previously programmed transmitters will work. You must reprogram all the transmitters once you're in the programming mode. 1. Turn the ignition switch to ON (II). 2. Press and hold the Valet-Disarm button on the radio (between the AM/FM and CD/TAPE buttons) to enter the programming mode. (Continue to hold the button during this procedure, or programming will be cancelled.) Check that the power door locks cycle to confirm that you're in the programming mode. 3. Within 5 seconds, press the "Lock" or "Unlock" button on the transmitter. Check that the power door locks cycle to confirm that the code was accepted. 4. Within 10 seconds, press the "Lock" or "Unlock" button on each of the remaining transmitters. 5. After all the transmitters have been programmed, release the Valet-Disarm button to exit programming mode. Ordering a Transmitter Transmitters can be ordered only by authorized Honda dealers. Order them from American Honda using normal parts ordering procedures. Batteries for the Transmitter The battery number is CR2025. Each transmitter uses one battery. 99-04 Civic, 03-04 Accord, Element, Pilot 1999-00 Civic Value Package with factory-installed keyless entry system 1999-04 Civic EX with factory-installed keyless entry system or dealer-installed security system *1999-03 Civic (except EX) with dealer-installed keyless entry system or security system 2002-04 Civic Si with factory-installed keyless entry system or dealer-installed security system 2003-04 Civic Hybrid with factory-installed keyless entry system or dealer-installed security system 2004 Civic (except LX & EX) with dealer-installed keyless entry system or security system 2004 Civic LX with factory-installed keyless entry system or dealer-installed security system Page 7080 PARTS INFORMATION TOOL INFORMATION Page 9097 1. Remove the terminal. 2. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE E: 1. Remove the terminal. 2. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE F: Page 4798 2. Cut off the wire about an inch back from where it connects to the damaged or faulty terminal, then strip about half of the insulation off that piece. This will be used to size the wire end of the replacement pigtail terminal. NOTE: If you are not sure of the wire size, start with a large enough hole on the stripper that will not nick or cut off any strands of wires. 3. Select a pigtail terminal that matches the original wire at both ends (same kind of terminal and same diameter bare wire). 4. Select the smallest splice connector (yellow, pink, or blue) that will fit onto the stripped end of the original wire. 5. Insert the pigtail terminal into the connector cavity; push it in until it locks in place. 6. Lay the pigtail and the original wire side-by-side, and cut off both ends at once. If you are making more than one splice, do not cut each pigtail at the same location; the resulting "lump" of splice connectors would interfere with rewrapping the harness. Instead, cut the first pigtail close enough to the terminal so you will have room to make each remaining cut about 20 mm (3/4 inch) farther down on the next pigtail. 7. If you are using a yellow splice connector, strip about 6 mm (1/4 inch) of insulation off the ends of both wires. If you are using a pink or blue splice connector, strip off about 8 mm (5/16 inch) of insulation. Page 8966 110. Left B Pillar (Right Similar) 111. Left C Pillar (Sedan) (Right Similar) Page 8052 9. Open the jaws with the jaws knob, and slide the original key with its flat side down into the center jaw up to the key stop. Slide the key blank with its flat side down into the right jaw up to the key stop. Close the jaws with the jaws knob to lock the keys into place. Visually inspect both keys for proper alignment in the jaws. 10. Loosen the lateral and spring tension adjustment knobs on the clamp carriage. With the clamp carriage lever, adjust the clamp carriage to position the tracer and the cutter bit over the middle of the two locked key blades. Tighten only the spring tension knob when done. NOTE: The clamp carriage has a spring system that puts lateral pressure on the tracer and cutting bit to make it easier to cut sidewinder-type keys. Do not tighten the lateral tension adjustment knob. This knob should be left loose. 11. Turn on the cutter motor with the motor start switch. [NOTICE] ^ To avoid damaging the locking jaws while cutting, keep your hand off the vertical carriage lever. Pressure on the lever will change the cutting depth. * ^ To avoid breaking the cutter bit, never back up while cutting.* ^ Wear proper eye protection (safety glasses, goggles, etc.) Page 1472 Refrigerant: Service and Repair System Charging System Charging CAUTION: - Air conditioning refrigerant or lubricant vapor can irritate your eyes, nose, or throat. - Be careful when connecting service equipment. - Do not breathe refrigerant or vapor. Use only service equipment that is U.L.-listed and is certified to meet the requirements of SAE J2210 to remove HFC-134a (R-134a) from the air conditioning system. If accidental system discharge occurs, ventilate work area before resuming service. Additional health and safety information may be obtained from the refrigerant and lubricant manufacturers. 1. Connect a R-134a refrigerant recovery/recycling/charging station (A) to the high-pressure service port (B) and the low-pressure service port (C), as shown, following the equipment manufacturer's instructions. 2. Evacuate the system. 3. Add the same amount of new refrigerant oil to the system that was removed during recovery. Use only SANDEN SP-10 refrigerant oil. 4. Charge the system with the specified amount of R-1 34a refrigerant. Do not overcharge the system; the compressor will be damaged. Select the appropriate units of measure for your refrigerant charging station. Refrigerant capacity: 500 to 550 g 0.50 to 0.55 kg 1.1 to 1.2 lbs 17.6 to 19.4 oz 5. Check for refrigerant leaks. 6. Check for system performance. Page 9327 Diagram 115-4 (Sedan EX) Page 3988 Shift Solenoid: Service and Repair Shift Solenoid Valves A and B Replacement NOTE: Shift solenoid valves A and B must be removed/ replaced as an assembly. 1. Remove the harness clamp (c) form the clamp bracket (D). 2. Remove the mounting bolts and the shift solenoid valves A and B. 3. Clean the mounting surface and fluid passage. 4. Install a new shift solenoid valves A and B with a new filter/gasket (E), and install the harness clamp on the clamp bracket. 5. Check the connector for rust, dirt, or oil, then reconnect the connector securely. Page 3194 Wire Color Abbreviations Page 2188 Radiator Cooling Fan Temperature Sensor / Switch: Service and Repair Radiator Fan Switch Replacement 1. Disconnect the radiator fan switch connector, then remove the radiator fan switch (A). 2. Install the radiator fan switch using a new O-ring (B). Page 835 Transmission Position Switch/Sensor: Service and Repair Transmission Range Switch Replacement 1. Raise the vehicle, and make sure it is securely supported. 2. Shift to the N position. 3. Remove the transmission range switch cover (A). 4. Disconnect the transmission range switch connector (B). 5. Remove the old transmission range switch, and install the new switch. 6. Make sure that the control shaft is in the N position. If necessary, move the shift lever to the N position. Page 6870 1. On Accords and Pilots, remove the front passenger's seat-back panel by prying out the bottom. Replace the two lower clips. 2. On all models except Accords and Pilots, unzip the two seat cover zippers on the back of the front passenger's seat. 3. Pull back the seat-back cover from the left side bolster to access the OPDS unit cover. 4. Remove the OPDS unit cover from the seat frame. 5. Check the part number of the installed OPDS unit. Locations Hazard Flasher Relay: Locations Turn Signal/Hazard Flasher - Component Location Index Page 6454 9. Turn the ignition switch ON (II), and check the same wires for voltage. Is there any voltage? YES - Repair any short to power in the wire(s) between the heater control panel and the recirculation control motor. This short may also damage the heater control panel. Repair the short to power before replacing the heater control panel. NO - Go to step 10. 10. Turn the ignition switch OFF. 11. Check for continuity between the following terminals of heater control panel connector A (14P) and the recirculation control motor 7P connector. 14P: 7P: No.5 No.7 No.6 No.5 Is there continuity? YES - Check for loose wires or poor connections at heater control panel connector A (14P) and at the recirculation control motor 7P connector. If the connections are good, substitute a known-good heater control panel, and recheck. If the symptom/indication goes away, replace the original heater control panel. NO - Repair any open in the wire(s) between the heater control panel and the recirculation control motor. 12. Remove the recirculation control motor. 13. Check the recirculation control linkage and doors for smooth movement. Do the recirculation control linkage and doors move smoothly? YES - Replace the recirculation control motor. NO - Repair the recirculation control linkage or doors. Page 8012 19. Using your thumb and forefinger to hold the tumblers, remove the key from the inner cylinder, being careful not to drop any tumblers and springs. 20. *Using the key code from the iN that you have written down at step 2, build a new inner cylinder with new springs, new cylinder, and tumblers from the door lock cylinder kit. Make sure you put the appropriate numbered tumbler in the proper inner cylinder cavity. Apply a thin layer of Permalube to each tumbler to help lubricate and retain it.* NOTE: ^ There are two types of tumblers. The "SUBLOCK" tumbler goes only in cavity A." The "DISC" tumbler goes in cavities "B" through "J." ^ Cavity "E" is empty on all cylinders. Page 3076 119. Knock Sensor (except GX) Page 9361 2. Remove the terminal from the female half. 3. Remove the terminal from the male half. 4. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE D: 1. Remove the secondary locks. Page 3656 87. TCC Solenoid Valve (A/T Except CVT) Refrigerant Recovery Refrigerant: Service and Repair Refrigerant Recovery Refrigerant Recovery CAUTION: - Air conditioning refrigerant or lubricant vapor can irritate your eyes, nose, or throat. - Be careful when connecting service equipment. - Do not breathe refrigerant or vapor. Use only service equipment that is U.L.-listed and is certified to meet the requirements of SAE J2210 to remove HFC-134a (R-134a) from the air conditioning system. If accidental system discharge occurs, ventilate work area before resuming service. Additional health and safety information may be obtained from the refrigerant and lubricant manufacturers. 1. Connect a R-134a refrigerant recovery/recycling/charging station (A) to the high-pressure service port (B) and the low-pressure service port (C), as shown, following the equipment manufacturer's instructions. 2. Measure the amount of refrigerant oil removed from the A/C system after the recovery process is completed. Be sure to put the same amount of new refrigerant oil back into the A/C system before charging. Page 6270 59. Apply a thin coat of grease to the inside of the special tool. 60. Install the cylinder end seal (A) onto the steering rack (B) with its grooved side (C) toward the piston (D). Make sure the gap is special tool is opposite of rack teeth. 61. Separate the cylinder end seal from the special tool, then remove the special tool. 62. Install the new backup ring (A) on the steering rack, then place the backup ring and cylinder end seal (B) against the piston (C). 63. Mark (A) a position on the steering rack surface with a felt-tip marker, 14.5 mm (0.57 inch) from the rack end edges. Page 4234 2. Insert the terminal tool into the female terminal, and then remove the terminal tool. NOTE: Make sure you do not select a terminal tool that is larger than the mating male terminal because it would spread the female terminal and cause a loose fit. 3. Compare the drag to the other terminals in the connector. If the drag is less, replace the terminal with a replacement terminal from the appropriate terminal repair kit. Page 2014 18. Remove the crankshaft position (CKP) sensor from the oil pump without disconnecting the connector. 19. Apply a force of 98 Nm (10 kgf-cm, 22 ft. lbs.) to the timing belt at the mid point between the camshaft pulley and the water pump pulley and check that the auto-tensioner move smoothly. If the auto-tensioner does not move smoothly, replace the auto-tensioner. - Inspect the auto-tensioner when replacing the timing belt. 20. Move the auto-tensioner to remove tension from the timing belt, then remove the timing belt. Installation Special Tools Required Holder handle 07JAB-001020A - Holder attachment, 50 mm, offset 07MAB-PY3010A - Socket, 19 mm 07JAA-001020A or a commercially-available 19 mm socket NOTE: If you are removing the auto-tensioner, refer to the auto-tensioner installation procedure. 1. Clean the timing belt pulleys, and the upper and lower covers. Recall - Ignition/Shift Interlock Defect Technical Service Bulletin # 10-059 Date: 101001 Recall - Ignition/Shift Interlock Defect 10-059 October 1, 2010 Applies To: See VEHICLES AFFECTED Safety Recall: Accord, Civic, and Element Ignition Switch Key Interlock BACKGROUND Under certain conditions, the interlock lever of the ignition switch may unexpectedly deform. The interlock ensures the transmission is in Park before the ignition key can be removed. Interlock failure may allow the ignition key to be removed when the shift lever is not in Park. If the driver fails to engage the parking brake, the vehicle could roll away, increasing the risk of a crash. VEHICLES AFFECTED Not all vehicles within the VIN ranges are affected by this recall. Before beginning work on a vehicle, verify its eligibility by checking at least one of these items: ^ The customer has a notification letter. Page 8766 Use the tools from Pin Tool Set. First, check the connector that you are about to repair. - If it has a secondary terminal lock, go to Connectors With a Secondary Lock. A secondary lock, found on most connectors on some models, is an additional locking device on the connector housing as a backup for the primary lock on the terminal. - If the connector does not have a secondary lock, go to Connectors Without a Secondary Lock. Connectors With a Secondary Lock All examples are shown with the connector lock facing up. The illustrations are examples of the secondary terminal locks; however, the connector you are repairing may vary in size. Identify the connector by the type of secondary lock, not by the number of terminal cavities. EXAMPLE A: 1. Release the secondary lock. 2. Remove the terminal. 3. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE B: Page 790 125. TP Sensor Page 841 93. VTEC Oil Pressure Switch (EX, HX) Alternator - A/C Compressor Belt Inspection and Adjustment Drive Belt: Testing and Inspection Alternator - A/C Compressor Belt Inspection and Adjustment Alternator - A/C Compressor Belt Inspection and Adjustment Special Tools Required Belt tension gauge 07JGG-001010A Belt Tension Gauge Method Inspection 1. Attach the belt tension gauge to the belt and measure the tension. Follow the gauge manufacturer's instructions. If the belt is worn or damaged, replace it. If the belt needs adjustment, go to step 2. Adjustment 2. Loosen the mounting bolt (A), lock bolt (B) and lower bracket mounting bolt (C). 3. Torque the mounting bolt to 20 N.m (2.0 kgf.m, 14 lbf.ft). 4. Turn the adjusting bolt (D) to obtain the proper belt tension, then retighten the lock bolt, mounting bolt and lower bracket mounting bolt. 5. Recheck the belt tension. 6. If you installed a new belt, run the engine for 5 minutes, then readjust the belt to the used belt specification. 7. Check the power steering pump belt adjustment. Deflection Method Inspection Page 9253 193. Hazard Warning Switch Page 7319 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: Automatic Transmission Shift Indicator: Testing and Inspection Automatic Transmission Indicator Input Test SRS components are located in this area. Review the SRS component locations, precautions, and procedures in the SRS section before performing repairs or service. 1. If the MIL has been reported, check for a DTC, and repair the system as indicated by DTC. 2. If the MIL does not come on, and the A/T gear position indicator P, N, or R does not come on. Turn the ignition switch off, remove the gauge assembly from the dashboard, then disconnect gauge assembly connector A (22P) and B (22P). 3. Inspect the connectors and connector terminals to be sure they are making good contact. 4. If the terminals are bent, loose, or corroded, repair them as necessary, and recheck the system. 5. Shift to the P position, and check for continuity between AS terminal (BLU/BLK) and ground. There should be continuity in the P position and no continuity in any other shift lever position. If your test results are different, check for a faulty transmission range switch or an open in the wire. 6. Shift to the N position, and check for continuity between AS terminal (BLK/RED) and ground. There should be continuity in the N position and no continuity in any other shift lever position. If your test results are different, check for a faulty transmission range switch or an open in the wire. 7. Turn the ignition switch ON (II), shift to the R position, and check for voltage between All terminal (WHT) and ground. There should be 0 V in the [A position. There should be about 5 V in any other shift lever position. If your test results are different, check for a faulty transmission range switch or an open in the wire. 8. Check for voltage between B17 terminal (YEL) and ground with the ignition switch ON (II). There should be battery voltage. If your test results are different, check for a blown No. 10 (7.5A) fuse in the under-dash fuse/relay box or an open in the wire. 9. Turn the ignition switch OFF, and check for continuity between B16 terminal (BLK) and ground under all conditions. There should be continuity. If your test results are different, check for a poor ground (G501) or an open in the wire. 10. If all input tests prove OK, but the indicator is faulty, replace the printed circuit board. Page 800 Connectors - "C" Page 3533 48. Middle Of Engine (except GX) 49. Middle Of Engine (GX) Page 6945 Page 2484 Oxygen Sensor: Description and Operation Air Fuel (A/F) Ratio Sensor Air Fuel Ratio (A/F) sensor (D17A6 engine) The A/F sensor operates over a wide air/fuel range. The A/F sensor is installed in the exhaust manifold. Front Suspension Strut / Shock Absorber: Service and Repair Front Damper/Spring Replacement Special Tools Required Strut spring compressor, Branick MST-580A or Model 7200, or equivalent, commercially available Removal 1. Raise the front of the vehicle, and support it with safety stands in the proper locations. Remove the front wheels. Page 9296 Resistor Variable Sensor Solenoid Transistors Circuit Schematics Page 2781 ECM/PCM Inputs And Outputs At Connector E (31P) Page 2773 ECM/PCM Inputs And Outputs At Connector E (31P) Page 825 3. Strip the insulation off the end of the wire so the wire fits in the new terminal as shown. (If the wire has a wire seal, replace it with a new one from the kit.) NOTE: After stripping the end of the wire, make sure you did not cut any wire strands. If you did, cut the wire off even with the insulation, and strip it again. 4. Position the terminal in the crimping tool slot with the solid portion of the terminal toward the anvil and the open section toward the former. 5. Insert the wire in the terminal to the position shown in step 3. 6. Squeeze the tool with both hands until the stops make contact. 7. Crimp the insulation crimp. - If you do not have a wire seal, then use the next larger size crimp slot. Position the crimping tool over the insulation crimp section of the terminal, then squeeze the tool with both hands until the stops make contact. - If you have a wire seal, position the insulation crimp in the 5.5 crimping slot, then carefully squeeze the crimp closed until its ends are touching and making a full-circle shape. Page 2168 8. Inspect the quality of the wire crimp. If it has any of the following NO GOOD crimps, cut it off and start over. 9. Insert the terminal into the connector. Make sure the wire seals are pushed all the way into the connector. Lightly pull on the wires to make sure the terminal is locked into place. 10. Close or insert the secondary terminal lock, if applicable, and reconnect the connector. How to Install Pigtail Terminals HOW TO INSTALL PIGTAIL TERMINALS Pigtail terminals (short pieces of wire with a factory crimped terminal) are used when the wire is too short or when access to the connector is too restricted to make a terminal repair. NOTE: To replace just a connector terminal, go to How to Replace Connector Terminals. IMPORTANT SAFETY INFORMATION: On some models, the SRS wires are in a separate harness. If the SRS harness is damaged, replace the harness; do not repair it. On other models, wire harnesses include yellow SRS wires. If any SRS wire is damaged, replace the entire harness; do not repair it. 1. Remove the damaged or faulty terminal from the connector. Use the proper removal tool from Pin Tool Set. Page 2541 2. Cut off the wire about an inch back from where it connects to the damaged or faulty terminal, then strip about half of the insulation off that piece. This will be used to size the wire end of the replacement pigtail terminal. NOTE: If you are not sure of the wire size, start with a large enough hole on the stripper that will not nick or cut off any strands of wires. 3. Select a pigtail terminal that matches the original wire at both ends (same kind of terminal and same diameter bare wire). 4. Select the smallest splice connector (yellow, pink, or blue) that will fit onto the stripped end of the original wire. 5. Insert the pigtail terminal into the connector cavity; push it in until it locks in place. 6. Lay the pigtail and the original wire side-by-side, and cut off both ends at once. If you are making more than one splice, do not cut each pigtail at the same location; the resulting "lump" of splice connectors would interfere with rewrapping the harness. Instead, cut the first pigtail close enough to the terminal so you will have room to make each remaining cut about 20 mm (3/4 inch) farther down on the next pigtail. 7. If you are using a yellow splice connector, strip about 6 mm (1/4 inch) of insulation off the ends of both wires. If you are using a pink or blue splice connector, strip off about 8 mm (5/16 inch) of insulation. Page 2753 DTC P1253 thru P1459 Page 8287 8. Release the clip, detach the hook, and remove the lock rod protector. 9. Disconnect the outer handle rod and cylinder rod. Key Beeper, Light Chime & Ceiling Light Don't Work Key Reminder Switch: Technical Service Bulletins Key Beeper, Light Chime & Ceiling Light Don't Work SOURCE: Honda Service News April 2003 TITLE: Key Beeper, Light Chime, Ceiling Light Don't Work APPLIES TO: 2001-03 Civic, 2002-03 CR-V SERVICE TIP: If the ignition key-in beeper, the headlights-on chime, the ceiling light, and the driver's-dooropen indicator are all on the fritz check the driver's door switch in the doorjamb. A faulty door switch can cause all of these symptoms. Locations Intake Air System - Component Location Index Page 2160 1. Remove the secondary lock from the male terminal half. 2. Remove the secondary lock from the female terminal half. 3. Remove the terminal (same procedure for male and female). 4. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE C: 1. Remove the secondary lock. Page 294 Engine Control Module: Testing and Inspection How to Troubleshoot Circuits At the ECM/PCM How to Troubleshoot Circuits at the ECM/PCM Special Tools Required - Digital Multimeter KS-AHM-32-003 (1) or a commercially available digital multimeter - Backprobe Set 07SAZ-001000A (2) 1. Connect the backprobe adapters (A) to the stacking patch cords (B), and connect the cords to a digital multimeter (C). 2. Using the wire insulation as a guide for the contoured tip of the backprobe adapter, gently slide the tip into the connector from the wire side until it touches the end of the wire terminal. 3. If you cannot get to the wire side of the connector or the wire side is sealed (A), disconnect the connector and probe the terminals (B) from the terminal side. Do not force the probe into the connector. NOTE: Do not puncture the insulation on a wire. Punctures can cause poor or intermittent electrical connections. Page 7223 Programming the Transmitter This transmitter is not programmable. Ordering a Transmitter This transmitter is no longer available. Batteries for the Transmitter The battery number is CR2025. Each transmitter uses two batteries. 97-99 EV Plus With Factory-Installed Security System 1997-99 EV Plus with factory-installed security system Programming the Transmitter NOTES: ^ The system accepts up to three transmitters. The transmitter codes are stored in a stacking-type memory. If a fourth transmitter code is programmed, the code for the first transmitter is erased. ^ Entering the programming mode cancels all learned transmitter codes, so none of the previously programmed transmitters will work. You must reprogram all of the transmitters once you are in the programming mode. ^ You must complete steps 1-6 within 4 seconds of the previous step to keep the system from exiting the programming mode. 1. Turn the ignition switch to ON (II). 2. Press the "Lock" or "Unlock" button on one of the transmitters. (An unprogrammed transmitter can be used for this step.) 3. Turn the ignition switch to LOCK (0). 4. Repeat steps 1, 2, and 3 two more times using the same transmitter used in step 2. 5. Turn the ignition switch to ON (II). 6. Press the "Lock" or "Unlock" button on the same transmitter. Make sure the power door locks cycle to confirm that the system is in programming mode. 7. Within 10 seconds, press the "Lock" or "Unlock" button on each transmitter. Make sure the power door locks cycle after you press each transmitter button to confirm that the system accepted the transmitter's code. 5. Turn the ignition switch to LOCK (0) to exit the programming mode. Ordering a Transmitter Transmitters can be ordered only through Tech Line. Batteries for the Transmitter The battery number is CR2025. Each transmitter uses one battery. 00-04 Insight With Factory-Installed Keyless Entry System 2000-04 Insight with factory-installed keyless entry system Page 6816 VEHICLES AFFECTED CUSTOMER NOTIFICATION All owners of affected vehicles were mailed a notification of this warranty extension. A example of the customer notification is shown in this service bulletin. CORRECTIVE ACTION Repair the vehicle as indicated by the INSPECTION PROCEDURE. If needed, replace the OPDS unit. In rare cases where an updated OPDS unit was already installed, replace the OPDS sensor. Page 3107 65. PSP Switch Page 2909 Oxygen Sensor: Description and Operation Air Fuel (A/F) Ratio Sensor Air Fuel Ratio (A/F) sensor (D17A6 engine) The A/F sensor operates over a wide air/fuel range. The A/F sensor is installed in the exhaust manifold. Page 3876 195. Tranmission Range Switch Page 3963 1. If not already done, load the latest HDS software onto the iN workstation. 2. Restart the CM Update application on the iN workstation. 3. On the right side of the screen, click on the tools button. 4. Click on HIM Self-Test Procedure. 5. Follow the on-screen instructions to run the HIM self-test. 6. If the self-test indicates a problem with the HIM, call the Special Tools hotline for repair instructions. Disclaimer Page 3357 EGR Valve: Description and Operation The EGR valve lowers peak combustion temperatures and reduces oxides of nitrogen emissions (NOx) by recirculating exhaust gas through the intake manifold and into the combustion chambers. Page 7845 WARRANTY CLAIM INFORMATION In warranty: The normal warranty applies. Failed Part: P/N 68500-S5P-A90ZZ H/C 6528640 *Defect Code: 07406* Symptom Code: 03220 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 A 1. Check the side-to-side alignment of the trunk lid latch to the striker: ^ Refer to page 20-132 of the 2001-04 Civic Service Manual. ^ In ISIS, use the keyword TRUNK ADJUST, and select Trunk Lid Adjustment from the list. 2. Make sure the gaps of the trunk lid are even on all sides. ^ If the trunk is misaligned, go to step 3. ^ If the trunk lid is properly aligned on all sides, go to REPAIR PROCEDURE B. 3. Adjust the trunk lid hinges: ^ Refer to page 20-132 of the 2001-04 Civic Service Manual. ^ In ISIS, use the keyword TRUNK ADJUST, and select Trunk Lid Adjustment from the list. 4. Check the trunk operation: ^ If the trunk opens and closes smoothly and is properly aligned, return the vehicle to the customer. ^ If the trunk lid is still difficult to close, go to REPAIR PROCEDURE B. REPAIR PROCEDURE B Locations 94. Behind Glove Box (except GX) Page 7242 Programming the Transmitter NOTES: ^ The system accepts up to four transmitters. ^ Entering the programming mode cancels all learned transmitter codes, so none of the previously programmed transmitters will work. You must reprogram all the transmitters once you're in the programming mode. 1. Turn the ignition switch to ON (II). 2. Press and hold the Valet-Disarm button on the radio (between the AM/FM and CD/TAPE buttons) to enter the programming mode. (Continue to hold the button during this procedure, or programming will be cancelled.) Check that the power door locks cycle to confirm that you're in the programming mode. 3. Within 5 seconds, press the "Lock" or "Unlock" button on the transmitter. Check that the power door locks cycle to confirm that the code was accepted. 4. Within 10 seconds, press the "Lock" or "Unlock" button on each of the remaining transmitters. 5. After all the transmitters have been programmed, release the Valet-Disarm button to exit programming mode. Ordering a Transmitter Transmitters can be ordered only by authorized Honda dealers. Order them from American Honda using normal parts ordering procedures. Batteries for the Transmitter The battery number is CR2025. Each transmitter uses one battery. 99-04 Civic, 03-04 Accord, Element, Pilot 1999-00 Civic Value Package with factory-installed keyless entry system 1999-04 Civic EX with factory-installed keyless entry system or dealer-installed security system *1999-03 Civic (except EX) with dealer-installed keyless entry system or security system 2002-04 Civic Si with factory-installed keyless entry system or dealer-installed security system 2003-04 Civic Hybrid with factory-installed keyless entry system or dealer-installed security system 2004 Civic (except LX & EX) with dealer-installed keyless entry system or security system 2004 Civic LX with factory-installed keyless entry system or dealer-installed security system Page 1759 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 Short Circuit Locator (Short Finder) 1. Remove the blown fuse. Leave the battery connected. Page 5925 1. Remove the terminal. 2. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE E: 1. Remove the terminal. 2. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE F: Page 2254 Radiator Cooling Fan Temperature Sensor / Switch: Testing and Inspection Radiator Fan Switch Test NOTE: Bleed air from the cooling system after installing the radiator fen switch. 1. Remove the radiator fan switch from the thermostat cover. 2. Suspend the radiator fan switch (A) in a container of water as shown. 3. Heat the water and check the temperature with a thermometer. Do not let the thermometer (B) touch the bottom of the hot container. 4. Measure the continuity between the A terminal (C) and B terminal (D) according to the table. Page 2692 39. Left Side Of Engine Compartment Page 5364 Diodes Light Emitting Diode (LED) Motor Pressure Sensor Front Suspension Spring ( Coil / Leaf ): Service and Repair Front Damper/Spring Replacement Special Tools Required Strut spring compressor, Branick MST-580A or Model 7200, or equivalent, commercially available Removal 1. Raise the front of the vehicle, and support it with safety stands in the proper locations. Remove the front wheels. Page 6921 104. In Front Pass. Or Pass. Seat (Side Airbag) Page 893 3. Use the clamp carriage lever to position the clamp unit so the tracer is directly over the flat surface of the code device, just ahead of the cam blades. 4. Pull the vertical carriage lever toward you until the tracer just touches the flat surface ahead of the cam blades. Watch the arrows on the keypad: ^ If the double-headed arrow in the middle of the keypad lights green, the tracer and cutter bit are properly aligned. ^ If the arrow on the left of the keypad lights red, the cutter bit is not touching the jaw. Turn the micrometric ring nut above the tracer to the left until the double-headed arrow lights green. ^ If the vertical arrow on the right of the keypad lights red, the tracer is not touching the jaw. Turn the micrometric ring nut above the tracer to the right until the double-headed arrow lights green. *5. Turn the micrometric ring nut to the right five clicks so the cutter bit is slightly higher than the tracer. The arrow on the left should light red. Raise the vertical carriage. NOTE: Setting the tracer five clicks lower than the cutter bit at this point has the effect of making the cutter bit cut the duplicated key a little shallower. This will protect the locking jaws from being damaged.* 6. Optional: Loosen the set screw, and adjust the hand rest to a comfortable position. Tighten the screw. 7. Pull the clamp carriage lever toward you until the clamp carriage clicks into its end-of-run position. 8. Clean any metal shavings or debris out of the center jaw. (A soft-bristle toothbrush is ideal for this purpose.) Then open the jaws with the jaws knob, and slide the key blank with its flat side down into the jaw up to the key stop. Close the jaw with the jaws knob to lock the key blank into place. Visually inspect the key for proper alignment in the jaw. 9. Set and lock the cam sets on the code device. ^ Starting with the left cam set, make sure the lock pin is pulled all the way out. (This releases the cams.) Page 2075 Variable Valve Timing Pressure Switch: Service and Repair VTEC Oil Pressure Switch Replacement 1. Remove the resonator (see step 5). 2. Remove the bolt (A) and loosen the bolt (B) securing the VTEC solenoid valve, then remove the harness bracket (C) from the VTEC solenoid valve. 3. Remove the harness clamp (D) from the connecting pipe. 4. Disconnect the VTEC oil pressure switch connector, then remove the VTEC oil Pressure switch (A). 5. Install the VTEC oil pressure switch using a new O-ring (B). Page 4546 Control Module: Service and Repair Updating the ECM/PCM PCM Updating and Substitution for Testing Special Tools Required Honda Interface Module (HIM) P/N EQS05A35570 Use this procedure when you have to substitute a known-good PCM in a troubleshooting procedure. Update the PCM only if the PCM does not already have the latest software loaded. NOTE: Do not turn the ignition switch OFF while updating; the PCM can be damaged. How to Update the PCM NOTE: To ensure the latest program is installed, do an PCM update whenever the PCM is substituted or replaced. - Before you update the PCM, make sure the vehicle's battery is fully charged. - To prevent PCM damage, do not operate anything electrical (audio system, brakes, A/C, power windows, moon roof, door locks, etc.) during the update. - If you need to diagnose the Honda Interface Module (HIM) because the HIM's red (#3) light came on or was flashing during the update, leave the ignition switch in the ON (II) position when you disconnect the HIM from the Data Link Connector (DLC). This will prevent PCM damage. 1. Turn the ignition switch ON (II). Do not start the engine. 2. Connect the HIM to the DLC (A) located under the driver's side of dashboard. 3. Do the PCM update procedure as described on the HIM label and in the PCM update system. If the software in the PCM is the latest version, replace the PCM. How to End a Troubleshooting Session This procedure must be done after any troubleshooting. 1. Clear the DTC(s) with the Scan Tool or HDS, or reset the PCM by removing the No. 6 (PCM) fuse in the under-hood fuse/relay box for more than 10 seconds. 2. Turn the ignition switch ON (II). 3. Start the engine in the P or N position, and warm it up to normal operating temperature (the radiator fans come on). 4. To verify that the problem is repaired, test-drive the vehicle for several minutes at speeds over 30 mph (50 km/h) or in freeze data range. Page 3710 2. Remove the terminal from the female half. 3. Remove the terminal from the male half. 4. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE D: 1. Remove the secondary locks. Adjustments Tilt Wheel Handle: Adjustments Steering Column/Tilt Lever Inspection/Adjustment On Vehicles Manufactured In Suzuka Plant: - Check the steering column ball bearing (A) and the steering joint bearings (B) for play and proper movement. If any bearing noisy or has excessive play, replace the steering column as an assembly. - Check the sliding capsules (C) for distortion and breakage. If there is distortion or breakage, replace the steering column as an assembly. On Vehicles Manufactured In Other Plants: - Check the steering column ball bearing (A) and the steering joint bearings (B) for play and proper movement. If any bearing is noisy or has excessive play, replace the steering column as an assembly. - Check the absorbing plates (C), absorbing plate guides (D), stop (E), and coating plates (F) for distortion and breakage. If there is distortion or breakage, replace the steering column as an assembly. 1. Move the tilt lever (A) from the loose position to the lock position 3 to 5 times; then measure the tilt lever preload 10 mm (0.4 inch) from the end of the tilt lever. Campaign - OPDS Unit Warranty Extension Technical Service Bulletin # 06-009 Date: 080205 Campaign - OPDS Unit Warranty Extension 06-009 February 5, 2008 Applies To: See VEHICLES AFFECTED Warranty Extension: OPDS Unit or OPDS Sensor Triggers SRS DTC(s) 15-1, 15-2, 15-3 (Supersedes 06-009, dated September 21, 2007) Updated information is shown with asterisks. BACKGROUND *NOTE: Because of a class action settlement, the warranty extension coverage for the OPDS unit and the OPDS sensor on 2002 Accords, 2002-04 Civics, 2003-04 Civic Hybrids, 2002-04 CR-Vs, 2003 Elements, 2002 Odysseys, and 2003-04 Pilots purchased or leased between April 13, 2002, and November 7, 2006, is now 10 years or 157,500 miles, whichever occurs first. For more information, refer to Service Bulletin 06-085, Warranty Extension: Vehicle Warranty Mileage.* Several vehicle models may have a problem with the OPDS (occupant position detection system) that causes the SRS indicator to stay on. Typically, one or more of these DTCs will be set: ^ SRS DTC 15-1 (faulty OPDS unit or OPDS not initialized) ^ SRS DTC 15-2 (faulty side airbag indicator circuit) ^ SRS DTC 15-3 (faulty OPDS sensor) To ensure continued reliability with the OPDS, American Honda is extending the warranty on the OPDS unit and the OPDS sensor to 10 years or 150,000 miles, whichever occurs first. This warranty extension does not apply to any vehicle that has ever been declared a total loss, or any that has been issued a salvage, branded, or similar title under any state's law. To check for vehicle eligibility, you must do a VIN status inquiry Page 1126 195. Tranmission Range Switch Specifications Firing Order: Specifications Ignition coil Firing order .......................................................................................................................................... ............................................................ 1 - 3 - 4 - 2 Page 9825 1. Remove the screw and passenger's power window switch (A) from the door panel. 2. Disconnect the 5P connector (B) from the switch. 3. Check for continuity between the terminals in each switch position according to the table. 4. If the continuity is not as specified remove the two screws and replace the switch. Page 3068 36. Left Side Of Engine Compartment (except GX) Page 9073 Wires Page 9672 Rear Window Defogger Component Location Index Page 6163 Front Steering Knuckle: Service and Repair Knuckle/Hub/Wheel Bearing Replacement Special Tools Required ^ Hub dis/assembly tool 07GAF-SE00100 ^ Ball joint remover, 28 mm 07MAC-SL00200 ^ Attachment 62 x 68 mm 07746-0010500 ^ Driver 07749-0010000 ^ Support base 07965-SD90100 1. Raise the front of the vehicle, and support it with safety stands in the proper locations. 2. Remove the wheel cap, wheel nuts, and front wheel. Page 3977 107. Behind A/T Shift Lever (except M/T) Page 7431 Multiplex Control System Component Location Index Page 8650 Front Door Window Glass Weatherstrip: Service and Repair Door Glass Outer Weatherstrip Replacement Door Glass Outer Weatherstrip Replacement 2-door NOTE: - Put on gloves to protect your hands. - Take care not to scratch the door. 1. Remove the mirror. 2. Starting at the front, pry the door glass outer weatherstrip (A) up to detach the clips (B), and release the weatherstrip from the door sash trim (C), then remove the weatherstrip. 3. Install the weatherstrip in the reverse order of removal, and replace any damaged clips. Locations Radiator Cooling Fan Temperature Sensor / Switch: Locations Page 9306 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. Circuits must be operating when checking voltage drop. 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. 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 off, 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 Self-Powered Test Light or DVOM 1. Remove the blown fuse and disconnect the battery and load. Page 935 7. From the Mode menu, select Miscellaneous Test. 8. From the Miscellaneous Test menu, select OPDS Initialization. 9. Follow the remaining screen prompts to complete the OPDS initialization. If the initialization fails repeat the process two more times. If the initialization fails again, check for SRS DTCs, then troubleshoot them using the appropriate service manual. Initializing the OPDS Unit: Manual Mode NOTE: Non-Honda seat covers will interfere with the performance of the OPDS and are not recommended. 1. Adjust the front passenger's seat-back to an upright position, then remove anything on or near the seat. 2. Turn the ignition switch to LOCK (0). 3. Connect the HDS to the vehicle's DLC (data link connector). 4. Keep the ignition switch at LOCK (0), and turn on the HDS. 5. At the screen prompts, enter the VIN and the odometer reading. 6. From the Select Mode screen, select SCS, and follow the screen prompts. Page 6600 Refrigerant: Testing and Inspection Refrigerant Leak Test Refrigerant Leak Test Special Tool Required Leak detector, Honda Tool and Equipment YGK-H-10PM, commercially available WARNING: - Compressed air mixed with R-134a forms a combustible vapor. - The vapor can burn or explode causing serious injury. - Never use compressed air to pressure test R-134a service equipment or vehicle air conditioning system. CAUTION: - Air conditioning refrigerant or lubricant vapor can irritate your eyes, nose, or throat. - Be careful when connecting service equipment. - Do not breathe refrigerant or vapor. Use only service equipment that is U.L.-listed and is certified to meet the requirements of SAE J2210 to remove HFC-134a (R-134a) from the air conditioning system. If accidental system discharge occurs, ventilate work area before resuming service. R-134a service equipment or vehicle air conditioning systems should not be pressure tested or leak tested with compressed air. Additional health and safety information may be obtained from the refrigerant and lubricant manufacturers. 1. Connect a R-134a refrigerant recovery/recycling/charging station (A) to the high-pressure service port (B) and the low-pressure service port (C), as shown, following the equipment manufacturer's instructions. 2. Open high pressure valve to charge the system to the specified capacity, then close the supply valve, and remove the charging system couplers. Select the appropriate units of measure for your refrigerant charging station. Refrigerant capacity: 500 to 550 g 0.50 to 0.55 kg 1.1 to 1.2 lbs 17.6 to 19.4 oz 3. Check the system for leaks using a R-134a refrigerant leak detector with an accuracy of 14 g (0.5 oz) per year or better. 4. If you find leaks that require the system to be opened (to repair or replace hoses, fittings, etc.), recover the system. Page 8308 ^ Incorrect: "If a Master Key is to be cut, put a five (5) in the blank space. Use a two (2) if a valet key is needed." ^ Correct: "If a Master Key is to be cut, put an M in the blank space. Use an S if a valet key is needed." Page 2, legend at the bottom: ^ Incorrect: "C. If a Master key is desired, then the number five (5) should be placed in the M/S position. Place the number two (2) in the M/S column if a Sub (Valet) key is needed." ^ Correct: "C. If a Master Key is desired, then an M should be placed in the M/S position. Place an S in the MIS column if a Sub (Valet) key is needed." Page 8500 Door Lock Cylinder Switch: Testing and Inspection Door Lock Actuator Test Driver's door: 1. Remove the driver's door panel. 2. Disconnect the 2P connector from the actuator. 3. Check actuator operation by connecting power and ground according to the table. To prevent damage to the actuator, apply battery voltage only momentarily. 4. If the actuator does not operate as specified, replace it. Passenger's door: 1. Remove the passenger's door panel. Page 3622 Spark Plug: Testing and Inspection Spark Plug Inspection 1. Inspect the electrodes and ceramic insulator. Burned or worn electrodes may be caused by: Advanced ignition timing - Loose spark plug - Plug heat range too hot - Insufficient cooling Fouled plug may be caused by: Retarded ignition timing - Oil in combustion chamber - Incorrect spark plug gap - Plug heat range too cold - Excessive idling/low speed running - Clogged air cleaner element - Deteriorated ignition coils 2. Do not adjust the gap of platinum tip plugs (A); replace the spark plug if the gap is out of specification. Page 4410 Transmission Speed Sensor: Diagrams 34. Output Shaft (Countershaft) Speed Sensor (A/T Except CVT) 57. Input Shaft (Mainshaft) Speed Sensor (A/T Except CVT) 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. Front Impact Sensor Impact Sensor: Service and Repair Front Impact Sensor Front Impact Sensor Replacement Removal NOTE: - Removal of the front sensor must be performed according to the precautions/procedures described before. - Before disconnecting the front sensor 2P connector(s), disconnect the driver's and front passenger's airbag 2P, both seat belt tensioner 2P and both seat belt buckle tensioner 2P connector(s). - Do not turn the ignition switch ON (II), and do not connect the battery cable while replacing the side impact sensor. 1. Disconnect the battery negative cable, and wait at least 3 minutes before beginning work. 2. Remove the front inner fender. 3. Disconnect the engine compartment wire harness 2P connector (A), and remove the two Torx bolts (B) using a Torx T30 bit, then remove the front impact sensor(C). Installation NOTE: - Be sure to install the harness wires so that they are not pinched or interfering with other parts. - Do not turn the ignition switch ON (II), and do not connect the battery cable while replacing the side impact sensor. 1. Install the new front impact sensor with new Torx bolts (A), then connect the engine compartment wire harness 2P connector (B) to the front sensor (C). 2. Reconnect the battery negative cable. 3. After installing the front impact sensor, confirm proper system operation: Turn the ignition switch ON (II): the SRS indicator should come on for about 6 seconds and then go off. Page 3427 Fuel Pressure Regulator: Service and Repair Fuel Pressure Regulator Replacement 1. Remove the fuel pump. 2. Remove the fuel pressure regulator (A). 3. Install the part in the reverse order of removal with a new O-ring (B) Testing and Inspection Wheels: Testing and Inspection Wheel Runout Inspection 1. Raise the vehicle, and support it with safety stands in the proper locations. 2. Check for a bent or deformed wheel. 3. Set up the dial gauge as shown, and measure the axial runout by turning the wheel. Front and Rear Wheel axial runout: Standard: Aluminum Wheel: 0 - 0.7 mm (0 - 0.03 inch) Steel Wheel: 0 - 1.0 mm (0 - 0.04 inch) Service limit: 2.0 mm (0.08 inch) 4. Reset the dial gauge to the position shown, and measure the radial runout. Front and Rear Wheel radial runout: Standard: Aluminum Wheel: 0 - 0.7 mm (0 - 0.03 inch) Steel Wheel: 0 - 1.0 mm (0 - 0.04 inch) Service limit: 1.5 mm (0.06 inch) 5. If the wheel runout is not within the specification, cheek the wheel bearing end play. 6. If the bearing end play is within the specification but the wheel runout is more than the service limit, replace the wheel. Page 2441 PGM-FI System - Component Location Index Page 4954 107. Behind A/T Shift Lever (except M/T) 2 Door Fuel Door Release Cable: Service and Repair 2 Door Trunk Lid Opener Cable/Fuel Fill Door Opener Cable Replacement 2-door SRS components are located in this area. Review the SRS component locations and the precautions and procedures before doing repairs or service. NOTE: - Put on gloves to protect your hands. - Take care not to scratch the body and related parts. 1. Remove these items from the left side of the vehicle: - Side trim panel - Door sill trim - Trunk side trim panel 2. Pull the carpet back as necessary. 3. Disconnect the trunk lid opener/fuel fill door opener cable (A) from the opener (B). 4. Release the opener cable from the clip (C). Remove the cushion tape (D), and detach the clip (E) with a clip remover. 5. Remove the fuel fill door latch (F) by turning it 90 °, and detach the opener cable junction box (G) from the body. Page 5910 Auxiliary Power Outlet: Diagnostic Aids General Troubleshooting Information General Troubleshooting Information Tips and Precautions Before Troubleshooting 1. Check applicable fuses in the appropriate fuse/relay box. 2. Check the battery for damage, state of charge, and clean and tight connections. NOTE: 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. Handling Connectors - Make sure the connectors are clean and have no loose wire terminals. - Make sure multiple cavity connectors are packed with dielectric grease (except watertight connectors). - All connectors have push-down release type locks (A). - Some connectors have a clip on their side used to attach them to a mount bracket on the body or on another component. This clip has a pull type lock. - Some mounted connectors cannot be disconnected unless you first release the lock and remove the connector from its mount bracket (A). - Never try to disconnect connectors by pulling on their wires; pull on the connector halves instead. - Always reinstall plastic covers. Page 881 Crankshaft Position Sensor: Service and Repair CKP Sensor Replacement 1. Remove the grommet (A) from the upper cover, and disconnect the camshaft position (CMP) (top dead center (TDC)) sensor connector (B). 2. Remove the upper cover (C) and lower cover (D). 3. Disconnect the crankshaft position (CKP) sensor connector, then remove the CKP sensor from the oil pump. 4. Install the CKP sensor in reverse order of removal. Page 2089 Idle Speed: Description and Operation Idle Control System When the engine is cold, the A/C compressor is on, the transmission is in gear, the brake pedal is pressed, the power steering load is high, or the alternator is charging, the ECM/PCM controls current to the Idle Air Control (IAC) valve to maintain the correct idle speed. Refer to the System Diagram to see the functional layout of the system. Idle Control System Diagram The idle speed of the engine is controlled by the idle air control (IAC) valve: - After the engine starts, the IAC valve opens for a certain amount of time. The amount of air is increased to raise the idle speed. - When the engine coolant temperature is low, the IAC valve is opened to obtain the proper fast idle speed. The amount of bypassed air is thus controlled in relation to engine coolant temperature. Page 9188 Dome Lamp: Diagnostic Aids General Troubleshooting Information General Troubleshooting Information Tips and Precautions Before Troubleshooting 1. Check applicable fuses in the appropriate fuse/relay box. 2. Check the battery for damage, state of charge, and clean and tight connections. NOTE: 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. Handling Connectors - Make sure the connectors are clean and have no loose wire terminals. - Make sure multiple cavity connectors are packed with dielectric grease (except watertight connectors). - All connectors have push-down release type locks (A). - Some connectors have a clip on their side used to attach them to a mount bracket on the body or on another component. This clip has a pull type lock. - Some mounted connectors cannot be disconnected unless you first release the lock and remove the connector from its mount bracket (A). - Never try to disconnect connectors by pulling on their wires; pull on the connector halves instead. - Always reinstall plastic covers. Component Locations Moonroof Component Location Index Page 3644 Shift Interlock Solenoid: Service and Repair Shift Lock Solenoid Replacement 1. Remove the center console panel and center console. 2. Disconnect the shift lock solenoid connector (2P), and remove it from the shift lever bracket base. 3. Push the lock tab (A), pry the shift lock solenoid (B) to clear the projected tips (C) with a screwdriver, and remove the shift lock solenoid. 4. Install the shift lock solenoid plunger (D) and plunger spring (E) in the new shift lock solenoid. 5. Install the shift lock solenoid by aligning the joint (F) of the shift lock solenoid plunger with the tip (G) of the shift lock stop. 6. Connect the shift lock solenoid connector, and install it on the shift lever bracket base. 7. Install the center console and console panel. Locations Camshaft Position Sensor: Locations PGM-FI System - Component Location Index Page 8138 system will not enter the programming mode.) 3. Within 10 seconds, close and open the door two times. 4. Turn the ignition switch to the ACC position and then to the LOCK position three times. Close and open the door. (Complete this process within 10 seconds.) Verify that the power door locks cycle once to confirm that the system is in programming mode. 5. Within 20 seconds, press the "LOCK" button on the transmitter you are programming. Verify that the door locks cycle once. 6. Within 20 seconds, press the "UNLOCK" button on the transmitter. Verify that the door locks cycle once to confirm that the system has accepted the transmitter's code. Turning the Audible Chirp On/Off (1998-99 only) NOTE: On '00-02 Passports, the audible chirp sounds only when you push the LOCK button on the transmitter a second time. 1. Open the driver's door, then insert the key in the driver's door lock. 2. Turn the key to the "LOCK" position, then to the "UNLOCK" position. Repeat this two more times. (Complete this procedure within 10 seconds.) 3. Within 10 seconds, close and open the door two times. 4. Within 10 seconds, turn the key to the "LOCK" position, and then to the "UNLOCK" position, three times. Close and open the door once. Verify that the power door locks cycle once to confirm that the chirp has been turned on/off. Ordering a Transmitter Transmitters can be ordered only by authorized Honda dealers. Order them from American Honda using normal parts ordering procedures. Batteries for the Transmitter The battery number is CR2016. Each transmitter uses two batteries. Page 5629 3. Use the clamp carriage lever to position the clamp unit so the tracer is directly over the flat surface of the code device, just ahead of the cam blades. 4. Pull the vertical carriage lever toward you until the tracer just touches the flat surface ahead of the cam blades. Watch the arrows on the keypad: ^ If the double-headed arrow in the middle of the keypad lights green, the tracer and cutter bit are properly aligned. ^ If the arrow on the left of the keypad lights red, the cutter bit is not touching the jaw. Turn the micrometric ring nut above the tracer to the left until the double-headed arrow lights green. ^ If the vertical arrow on the right of the keypad lights red, the tracer is not touching the jaw. Turn the micrometric ring nut above the tracer to the right until the double-headed arrow lights green. *5. Turn the micrometric ring nut to the right five clicks so the cutter bit is slightly higher than the tracer. The arrow on the left should light red. Raise the vertical carriage. NOTE: Setting the tracer five clicks lower than the cutter bit at this point has the effect of making the cutter bit cut the duplicated key a little shallower. This will protect the locking jaws from being damaged.* 6. Optional: Loosen the set screw, and adjust the hand rest to a comfortable position. Tighten the screw. 7. Pull the clamp carriage lever toward you until the clamp carriage clicks into its end-of-run position. 8. Clean any metal shavings or debris out of the center jaw. (A soft-bristle toothbrush is ideal for this purpose.) Then open the jaws with the jaws knob, and slide the key blank with its flat side down into the jaw up to the key stop. Close the jaw with the jaws knob to lock the key blank into place. Visually inspect the key for proper alignment in the jaw. 9. Set and lock the cam sets on the code device. ^ Starting with the left cam set, make sure the lock pin is pulled all the way out. (This releases the cams.) Page 803 Diodes Light Emitting Diode (LED) Motor Pressure Sensor Page 4631 7. Remove the shift cable guide brackets (A) and grommet (B). 8. Remove the spring clip (A), washer (B) and plastic washer (C) from the control lever (D). 9. Loosen the locknut, then remove the shift cable (E). 10. Insert the new shift cable through the grommet hole, then install the shift cable guide brackets and grommet. 11. Verify that the transmission is in the [A position on the control lever. 12. Align the socket on the shift cable with the slot in the shift cable bracket (F), then install the socket in the bracket and the shift cable end to the control lever. Do not bend the shift cable excessively. 13. Tighten the locknut. 14. Install the plastic washer then the steel washer, and install the spring clip (H) in the direction shown. 15. Install the heat shield and the exhaust pipe A, then connect the third HO2S connector. 16. Turn the ignition switch ON (II), and verify that the N position indicator light comes on. 17. Install the shift cable to the shift lever. If necessary, adjust the shift cable. Page 9395 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. Test Equipment 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. Page 5133 2. Remove the terminal (same procedure for male and female). 3. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE E: 1. Remove the secondary locks. 2. Remove the terminal (same procedure for male and female). 3. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE F: Page 4382 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. How to Replace Connector Terminals Terminal Replacement Procedure HOW TO REPLACE CONNECTOR TERMINALS The terminal repair kits provide necessary tools and materials (terminals, wire seals, and splice connectors) to repair many damaged or faulty connector terminals. However, not all terminals for all connectors are available. Refer to the labels on the lids of the repair kits for replacement terminal availability. IMPORTANT SAFETY INFORMATION: On some models, the SRS wires are in a separate harness. If the SRS harness is damaged, replace the harness; do not repair it. On other models, wire harnesses include yellow SRS wires. If any SRS wire is damaged, replace the entire harness; do not repair it. Before you begin, inspect the wire you are about to repair for damage and length. Make sure the wire will be long enough to make a terminal repair without stretching it when you reinstall the terminal in the connector. If the wire is too short, or if access to the connector is too restricted to make a terminal repair, you may need to install a pigtail terminal (a short length of wire with a factory-crimped terminal on it). Refer to HOW TO INSTALL PIGTAIL TERMINALS. Removing the Terminal Page 3891 Transmission Speed Sensor: Service and Repair Speed Sensors Replacement 1. Disconnect connectors from the drive pulley speed sensor (A), driven pulley speed sensor (B), CVT speed sensor (C), and CVT speed sensor 2 (D). 2. Remove the 6 mm bolts, then remove the speed sensors. Remove the sensor washer (E) from the vehicle speed sensor (C). 3. Replace the O-rings (F) with new ones before installing the speed sensors. 4. Install the sensor washer on the CVT speed sensor 2, and install them. 5. Install the drive pulley speed sensor, driven pulley speed sensor, and CVT speed sensor. 6. Check the speed sensor connectors for rust, dirt, or oil, then connect the connectors securely. Page 7788 9. Open the jaws with the jaws knob, and slide the original key with its flat side down into the center jaw up to the key stop. Slide the key blank with its flat side down into the right jaw up to the key stop. Close the jaws with the jaws knob to lock the keys into place. Visually inspect both keys for proper alignment in the jaws. 10. Loosen the lateral and spring tension adjustment knobs on the clamp carriage. With the clamp carriage lever, adjust the clamp carriage to position the tracer and the cutter bit over the middle of the two locked key blades. Tighten only the spring tension knob when done. NOTE: The clamp carriage has a spring system that puts lateral pressure on the tracer and cutting bit to make it easier to cut sidewinder-type keys. Do not tighten the lateral tension adjustment knob. This knob should be left loose. 11. Turn on the cutter motor with the motor start switch. [NOTICE] ^ To avoid damaging the locking jaws while cutting, keep your hand off the vertical carriage lever. Pressure on the lever will change the cutting depth. * ^ To avoid breaking the cutter bit, never back up while cutting.* ^ Wear proper eye protection (safety glasses, goggles, etc.) Page 631 29. Back-up Light Switch (M/T) Page 2610 ^ Incorrect: "If a Master Key is to be cut, put a five (5) in the blank space. Use a two (2) if a valet key is needed." ^ Correct: "If a Master Key is to be cut, put an M in the blank space. Use an S if a valet key is needed." Page 2, legend at the bottom: ^ Incorrect: "C. If a Master key is desired, then the number five (5) should be placed in the M/S position. Place the number two (2) in the M/S column if a Sub (Valet) key is needed." ^ Correct: "C. If a Master Key is desired, then an M should be placed in the M/S position. Place an S in the MIS column if a Sub (Valet) key is needed." Page 1483 6. Refill the master cylinder reservoir to the MAX (upper) level line. Locations Wiper/Washer Component Location Index 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 6514 - Replace the O-rings with new ones at each fitting, and apply a thin coat of refrigerant oil before installing them. Be sure to use the correct O-rings for HFC-134a (R-134a) to avoid leakage. - Immediately after using the oil, reinstall the cap on the container, and seal it to avoid moisture absorption. - Do not spill the refrigerant oil on the vehicle; it may damage the paint. If the refrigerant oil contacts the paint, wash it off immediately. - Be careful not to damage the radiator or the condenser fins when installing the condenser. - Charge the system. Page 772 Oxygen Sensor: Description and Operation Third Heated Oxygen Sensor (Third HO2S) Third Heated Oxygen Sensor (Third HO2S) (D17A6 engine) The third HO2S detects the oxygen content in the exhaust gas downstream of the NOX Adsorptive Three Way Catalytic Converter (NOX Adsorptive TWC) and sends signals to the ECM/PCM which varies the duration of fuel injection accordingly. To stabilize its output, the sensor has an internal heater. The third HO2S is installed behind the NOX Adsorptive TWC. Page 6474 6. Fold the carpet and pad back toward you. Remove the mounting bolts, the mounting nut, and the blower unit. 7. Install the unit in the reverse order of removal. Make sure that there is no air leakage. Page 5837 Wiper/Washer Component Location Index Page 4545 Control Module: Service and Repair How to Substitute the PCM How to Substitute the PCM 1. Remove the PCM from the vehicle. 2. Install a known-good PCM in the vehicle. 3. Rewrite the immobilizer code with the PCM replacement procedure in the Honda PGM Tester; It allows you to start the engine. 4. After completing your tests, reinstall the original PCM and rewrite the immobilizer code with the PCM replacement procedure in the HDS Tester again. Page 8630 13. After completing the right edge, push all of the cam blades to the right until they touch the cams, then trace the cam blades from back to front. (The cutter bit cuts the same contours into the left edge of the key from tip to head.) Turn off the cutter motor. 14. Release the vertical carriage lever. Push all the cam blades to the left until they touch the cams. Pull the vertical carriage lever towards you until the tracer touches the flat surface on the right side, at the front of the cams. Gently twist the lever clockwise to lock the vertical carriage at this height. Do not overtighten the lever. 15. Turn on the cutter motor, then retrace the cam blades from front to back. Push all the cam blades to the right until they touch the cams, and then retrace the cam blades from back to front (retracing cleans up the cuts on the key). Turn off the cutter motor. 16. Release the vertical carriage lever. Open the jaw and remove the key. Make sure the jaw is free of any metal shavings or debris. Turn the key over so the blank side is up, then slide it into the jaw up to the key stop. Close the jaw to lock the key in place. 17. Push all the cam blades to the left until they touch the cams. Repeat steps 10 through 15 to cut both edges on the other side of the key. 18. When you are done making the required cuts, release the vertical carriage lever. Open the jaw and remove the key. 19. Make sure the key works in the ignition switch and the locks. If the key does not work, recut the key, and try it again. 20. Depending on the type of key, code the key transponder. Equipment Service and Warranty To service the MATRIX H Key Cutting Machine, refer to section 7 of the MATRIX H Operating Manual. It tells you how to replace parts that commonly wear out such as the drive belt, the work light bulb, and the tension spring on the vertical carriage. It also covers checking and replacing fuses and replacing the printed circuit board for the setting unit keypad. If you have technical questions on the equipment, contact the Ilco Technical Assistance Department. Mail: Kaba Ilco Technical Assistance Department 400 Jeffreys Road Rocky Mount, NC 27804 Phone: 800-452-6872 Ext: 200, 384, 323, 398, 356 Fax: 252-446-4702 The MATRIX H Key Cutting Machine comes with a 3-year limited warranty. This warranty does not cover the cutter bit or the work light bulb. CODE BOOK CORRECTIONS In the code book Honda High Security key Codes, correct these errors: Pages 4 thru 51, code headings: ^ Incorrect: J H G F Z X E D C B M/S X ^ Correct: J H G F A X E D C B M/S X Page 2, last paragraph: Page 6027 Under-hood Fuse And Relay Box (4-door) Page 8582 8. Release the clip, detach the hook, and remove the lock rod protector. 9. Disconnect the outer handle rod and cylinder rod. Page 3723 Circuit Diagram Page 3558 104. CKP Sensor Page 5170 Control Module: Service and Repair Updating the ECM/PCM PCM Updating and Substitution for Testing Special Tools Required Honda Interface Module (HIM) P/N EQS05A35570 Use this procedure when you have to substitute a known-good PCM in a troubleshooting procedure. Update the PCM only if the PCM does not already have the latest software loaded. NOTE: Do not turn the ignition switch OFF while updating; the PCM can be damaged. How to Update the PCM NOTE: To ensure the latest program is installed, do an PCM update whenever the PCM is substituted or replaced. - Before you update the PCM, make sure the vehicle's battery is fully charged. - To prevent PCM damage, do not operate anything electrical (audio system, brakes, A/C, power windows, moon roof, door locks, etc.) during the update. - If you need to diagnose the Honda Interface Module (HIM) because the HIM's red (#3) light came on or was flashing during the update, leave the ignition switch in the ON (II) position when you disconnect the HIM from the Data Link Connector (DLC). This will prevent PCM damage. 1. Turn the ignition switch ON (II). Do not start the engine. 2. Connect the HIM to the DLC (A) located under the driver's side of dashboard. 3. Do the PCM update procedure as described on the HIM label and in the PCM update system. If the software in the PCM is the latest version, replace the PCM. How to End a Troubleshooting Session This procedure must be done after any troubleshooting. 1. Clear the DTC(s) with the Scan Tool or HDS, or reset the PCM by removing the No. 6 (PCM) fuse in the under-hood fuse/relay box for more than 10 seconds. 2. Turn the ignition switch ON (II). 3. Start the engine in the P or N position, and warm it up to normal operating temperature (the radiator fans come on). 4. To verify that the problem is repaired, test-drive the vehicle for several minutes at speeds over 30 mph (50 km/h) or in freeze data range. Page 3198 Terminals - "T" Shielding Switches Fuses Locations Intake Air Temperature Sensor: Locations PGM-FI System - Component Location Index Page 23 59. Under Left Side Of Dash Page 1444 Engine Oil: Service and Repair Engine Oil Replacement 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. Change interval Every 10,000 miles (16,000 km) or 12 months (Normal conditions) Every 5,000 miles (8,000 km) or 6 months (Severe conditions). 1. Warm up the engine. 2. Remove the drain bolt (A), and drain the engine oil. 3. Reinstall the drain bolt with a new washer (B). 4. Refill with the recommended oil. Capacity D17A2, D17A6 engines: 3.3 L (3.5 US qt.) at oil change. 3.5 L (3.7 US qt.) at oil change including filter. 4.2 L (4.4 US qt.) after engine overhaul. D17A1 engine: 3.0 L (3.2 US qt.) at oil change. 3.2 L (3.4 US qt.) at oil change including filter. 4.2 L (4.4 US qt.) after engine overhaul. 5. Run the engine for more than 3 minutes, then check for oil leakage. Page 3835 1. Remove the terminal. 2. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE G: 1. Remove the terminal. 2. Go to HOW TO INSTALL NEW TERMINALS. How to Install New Terminals HOW TO INSTALL NEW TERMINALS 1. Carefully match the old terminal with a new one from the terminal repair kit. Choose the correct replacement terminal based on the wire size range the terminal will accommodate. NOTE: If the replacement terminal quantities are low, reorder them by using the terminal part number listed on the inside lid of the terminal repair kit. Replacement terminals are available through your parts department using normal parts ordering procedures. 2. Depending on the size of the wire you are repairing, use the proper size slot in the crimping tool. A/T - Avoiding Fluid Contamination Fluid - CVT: Technical Service Bulletins A/T - Avoiding Fluid Contamination SOURCE: Honda Service News TITLE: Avoiding Comebacks From A/T Contamination APPLIES TO: All models SERVICE TIP: Installing a reman A/T? Here are some important tips to keep in mind to ensure a first-time fix and to avoid any come-backs: - If the vehicle has an ATF cooler, make sure you clean the cooler with the ATF Cooler Cleaner (P/N GHTTTCF6H). See S/B 89-022, ATF Cooler Cleaner, for details. - If the reman A/T kit includes an in-line filter, don't forget to install it. If the vehicle already has an in-line filter from an earlier A/T replacement, then remove the existing filter, and install the new one. - Spray the driveshaft splines with solvent and compressed air before installing them in the reman A/T. If the failed A/T had a speed sensor, make sure it's clean before you install it. Debris from the failed A/T can catch in the driveshaft splines or on the speed sensor and contaminate the reman A/T. - If the reman A/T comes with a heater/cooler, make sure you install the reman A/T with that heater/cooler. Never install the heater/cooler from the failed A/T; you could contaminate the reman A/T. Page 165 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. Below most connector numbers and component names are PHOTO and VIEW numbers. The PHOTO number refers to a photo in the back of the book that shows the connector's location on the car. The VIEW number refers to an illustration in the back of the book that shows the connector terminals, wire colors, connector cavity numbers, and other details. The connector cavity numbering sequence begins at the top left corner of the connector as seen from either of the viewpoints shown on diagram [8] . Except for the DLC (data link 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 C554, for example, means those terminals join in cavity 2 of connector C554. Power Distribution Schematics Power Distribution Schematics Locations Oil Pressure Sender: Locations Gauges Component Location Index (Part 1 Of 4) Page 5675 ^ Start the engine, and let it warm up to its normal operating temperature (the cooling fans cycle twice). ^ Let the engine idle (throttle closed and all electrical items off) for 10 minutes. Disclaimer Page 2555 93. VTEC Oil Pressure Switch (EX, HX) Page 6632 Blower Motor Relay Type 1, Type 2 Check for continuity between the terminals. - There should be continuity between the No.1 and No.3 terminals when power and ground are connected to the No.2 and No.4 terminals. - There should be no continuity between the No.1 and No.3 terminals when power is disconnected. Five-terminal type Check for continuity between the terminals. - There should be continuity between the No.1 and No.2 terminals when power and ground are connected to the No.3 and No.5 terminals. - There should be continuity between the No.1 and No.4 terminals when power is disconnected. Page 5964 Under-dash Fuse/Relay Box (4-door) Page 7324 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 4676 Transmission Cooler: Service and Repair ATF Cooler Cleaning Special Tools Required ^ ATF Cooler Cleaner GHITTCF6H ^ Magnetic Nonbypass Spin-on Filter GTHGNBP2 (Available through the Honda Tool and Equipment Program 1-888-424-6857) Before installing an overhauled or remanufactured automatic transmission, you must thoroughly clean the ATF cooler to prevent system contamination. Failure to do so could cause a repeat automatic transmission failure. The cleaning procedure involves heated ATF-Z1 delivered under high pressure (100 psi). Check the security of all hoses and connections. Always wear safety glasses or a face shield, along with gloves and protective clothing. If you get ATF in your eyes or on your skin, rinse with water immediately. WARNING: ^ Improper use of the ATF cooler cleaner can result in burns and other serious injuries. ^ Always wear eye protection and protective clothing, and follow this procedure. 1. Check the fluid in the cooler cleaner tank. (The fluid level should be 4.5 inches from the top of the filler neck.) Adjust the level if needed; do not overfill. Use only Honda ATF-Z1; do not use any additives. 2. Plug the 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; you would damage the unit. 3. Flip the HEAT toggle switch to ON; the green indicator above the toggle switch comes 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.) NOTE: If the red indicator above the HEAT toggle switch comes on, the fluid level in the tank is too low for the tank heater to work. Coupe Front Door Exterior Handle: Service and Repair Coupe Door Outer Handle Replacement 2-door NOTE: Put on gloves to protect your hands. 1. Raise the glass fully. 2. Remove these items: - Door panel - Plastic cover, as necessary 3. Use a hooked-shaped tool to remove the retainer clip (A), then remove the lock cylinder (B). Disconnect the cylinder rod (C). 4. Pull the glass run channel (A) away as necessary. Page 6876 12. Watch the SRS indicator: ^ If the indicator blinks twice and then goes off, the OPDS unit is initialized. Turn the ignition switch to LOCK (0), and disconnect the HDS. ^ If the indicator blinks twice and then stays on, the OPDS unit is initialized, but SRS DTCs need to be cleared. Go to step 13. ^ If the indicator stays on without first blinking, the OPDS unit is not initialized. Repeat steps 3 thru 12. 13. Turn the ignition switch to LOCK (0), then disconnect the HDS. 14. Reconnect the SCS service connector to the MES connector. Do not use a jumper wire. 15. Turn the ignition switch to ON (II). 16. Watch the SRS indicator. (It comes on for about 6 seconds and then goes off.) Disconnect the SCS service connector from the MES connector within 4 seconds after the indicator goes off. 17. When the SRS indicator comes on again, connect the SCS service connector to the MES connector within 4 seconds after the indicator comes on. 18. When the SRS indicator goes off, disconnect the SCS service connector from the MES connector within 4 seconds. (The SRS indicator blinks twice to indicate that the memory has been cleared.) 19. Turn the ignition switch to LOCK (0), and wait for 10 seconds. 20. Turn the ignition switch to ON (II). (The SRS is OK if the SRS indicator comes on for 6 seconds and then goes off.) If the DTC clearing fails, repeat the process two more times. If the DTC clearing fails again, check for set SRS DTCs, and troubleshoot them with the appropriate service manual. REPAIR PROCEDURE B: OPDS SENSOR REPLACEMENT 1. Remove the seat-back cover from the front passenger's seat: ^ Using the appropriate service manual, go to section 20 (Body), and do the removal steps under Front Seat Cover Replacement, or ^ Online, enter keyword SEAT COVER, then select Front Seat Cover Replacement from the list, and do the removal steps in the procedure. 2. Slide the seat-back cushion (foam) off the seat-back frame. (The OPDS sensor is built into the seat-back cushion.) 3. Slide a new seat-back cushion over the seat-back frame. Make sure the cushion is centered. 4. Install the seat-back cover: ^ Using the appropriate service manual, go to section 20 (Body), and do the installation step under Front Seat Cover Replacement, or ^ Online, enter keyword SEAT COVER, then select Front Seat Cover Replacement from the list, and do the installation step in the procedure. 5. Initialize the OPDS unit: ^ To initialize with the HDS, go to Initializing the OPDS Unit: HDS Method in this service bulletin. ^ To initialize with the SCS service connector, go to Initializing the OPDS Unit: Manual Mode in this service bulletin. Disclaimer Page 6770 233. SRS Unit Front Page 9630 Connectors - "C" Page 981 12. Pull the vertical carriage lever toward you while you position the tracer on the right edge of the original key at its head, using the clamp carriage lever. Let the cutter bit cut into the key blank, then stop. Gently twist the lever clockwise to lock the vertical carriage at this height. Do not overtighten the lever. 13. Use the clamp carriage lever and the tracer to follow the contours of the original key. (The cutter bit cuts the same contours into the key blank.) Working from right to left, follow the right edge of the original key from head to tip, then the left edge of the key from tip to head. Turn off the cutter motor. 14. Reposition the tracer on the right edge of the original key at its head, using the clamp carriage lever. Turn on the cutter motor. Retrace the key from head to tip, then from tip to head. (This retracing cleans up the cuts on the key.) Turn off the cutter motor. 15. Release the vertical carriage lever. Open the jaw and remove only the new key. Make sure the jaw is free of any metal shavings or debris, then turn the new key over and slide the key with its blank side up into the jaw up to the key stop. Close the jaw to lock the key into place. 16. Turn on the cutter motor, and repeat steps 12 thru 14 to cut both edges of the other side of the key. 17. When you are finished making the required cuts, turn off the cutter motor, and release the vertical carriage lever. Open the jaws, and remove the keys. 18. Use a wire brush to smooth the cut surfaces on the new key. 19. Make sure the key works in the ignition switch and all the locks. If the key does not work, recut the key, and try it again. 20. Depending on the type of key blank you have used, do this: ^ If you have used a Honda key blank, add the transponder code of the new key to the immobilizer system with the Honda Diagnostic System (HDS). ^ If you have used a T-5 programmable key blank ("T-5" stamped on the shank), code the key's transponder with the Ilco Immobilizer Key Code Duplicator (see S/B 99-053, Ilco Immobilizer key Code Duplicator). Cutting Procedure - By Code 1. Press the ON/OFF button in the middle of the setting unit keypad. (This powers up the keypad.) 2. Turn the clamp unit lock lever to the left to release the clamp unit, and slide it to the right until the bottom left side is flush with the base edge. Turn the lever to the right to lock the clamp unit in place. Loosen the lateral and spring tension adjustment knobs on the clamp carriage. Page 5929 2. Cut off the wire about an inch back from where it connects to the damaged or faulty terminal, then strip about half of the insulation off that piece. This will be used to size the wire end of the replacement pigtail terminal. NOTE: If you are not sure of the wire size, start with a large enough hole on the stripper that will not nick or cut off any strands of wires. 3. Select a pigtail terminal that matches the original wire at both ends (same kind of terminal and same diameter bare wire). 4. Select the smallest splice connector (yellow, pink, or blue) that will fit onto the stripped end of the original wire. 5. Insert the pigtail terminal into the connector cavity; push it in until it locks in place. 6. Lay the pigtail and the original wire side-by-side, and cut off both ends at once. If you are making more than one splice, do not cut each pigtail at the same location; the resulting "lump" of splice connectors would interfere with rewrapping the harness. Instead, cut the first pigtail close enough to the terminal so you will have room to make each remaining cut about 20 mm (3/4 inch) farther down on the next pigtail. 7. If you are using a yellow splice connector, strip about 6 mm (1/4 inch) of insulation off the ends of both wires. If you are using a pink or blue splice connector, strip off about 8 mm (5/16 inch) of insulation. Page 5914 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 Locater) 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. Troubleshooting Precautions Troubleshooting Precautions Before Troubleshooting 1. Check the main fuse and the fuse 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, or you will damage the alternator diodes. - Do not attempt to crank the engine with the ground cable disconnected 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. 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 5520 Braking Sensor/Switch: Adjustments Brake Pedal and Brake Pedal Position Switch Adjustment Pedal Height 1. Disconnect the brake pedal position switch connector, turn the brake pedal position switch (A) counterclockwise and pull it back until it is no longer touching the brake pedal. 2. Lift up the carpet (B). At the insulator cutout, measure the pedal height (C) from the middle of the right side of the pedal pad (D). Standard Pedal Height (with carpet removed): M/T: 184 mm (7 4/16 inch) A/T: 188 mm (7 6/16 inch) 3. Loosen the pushrod locknut (A), and screw the pushrod in or out with pliers until the standard pedal height from the floor is reached. After adjustment, tighten the locknut firmly. Do not adjust the pedal height with the pushrod pressed. Pedal Free Play Page 1498 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 234 Relay And Control Unit Locations - Engine Compartment Page 7108 OPDS Unit - Connectors A, B, C, D Automatic Transmission Shift Indicator: Testing and Inspection Automatic Transmission Indicator Input Test SRS components are located in this area. Review the SRS component locations, precautions, and procedures in the SRS section before performing repairs or service. 1. If the MIL has been reported, check for a DTC, and repair the system as indicated by DTC. 2. If the MIL does not come on, and the A/T gear position indicator P, N, or R does not come on. Turn the ignition switch off, remove the gauge assembly from the dashboard, then disconnect gauge assembly connector A (22P) and B (22P). 3. Inspect the connectors and connector terminals to be sure they are making good contact. 4. If the terminals are bent, loose, or corroded, repair them as necessary, and recheck the system. 5. Shift to the P position, and check for continuity between AS terminal (BLU/BLK) and ground. There should be continuity in the P position and no continuity in any other shift lever position. If your test results are different, check for a faulty transmission range switch or an open in the wire. 6. Shift to the N position, and check for continuity between AS terminal (BLK/RED) and ground. There should be continuity in the N position and no continuity in any other shift lever position. If your test results are different, check for a faulty transmission range switch or an open in the wire. 7. Turn the ignition switch ON (II), shift to the R position, and check for voltage between All terminal (WHT) and ground. There should be 0 V in the [A position. There should be about 5 V in any other shift lever position. If your test results are different, check for a faulty transmission range switch or an open in the wire. 8. Check for voltage between B17 terminal (YEL) and ground with the ignition switch ON (II). There should be battery voltage. If your test results are different, check for a blown No. 10 (7.5A) fuse in the under-dash fuse/relay box or an open in the wire. 9. Turn the ignition switch OFF, and check for continuity between B16 terminal (BLK) and ground under all conditions. There should be continuity. If your test results are different, check for a poor ground (G501) or an open in the wire. 10. If all input tests prove OK, but the indicator is faulty, replace the printed circuit board. Page 1192 5. Disconnect the 5P connector, and make these input tests. Fuel System - FTP Sensor Diagnostics/DTC P0497 Fuel Tank Pressure Sensor: Technical Service Bulletins Fuel System - FTP Sensor Diagnostics/DTC P0497 How to Tell a Bad FTP Sensor From an EVAP Leak Troubleshooting a '01-05 Civic with DTC P0497 (EVAP system low purge flow)? When the fuel tank pressure (FTP) sensor doesn't respond to vacuum testing, it's really easy to think you've got a leak in the FVAP system. Here's an simple way to tell if the problem is just a bad FTP sensor or an actual system leak: 1. Connect the HDS to the 16P DLC. Turn the ignition switch to ON (II). Turn on the HDS. 2. At the screen prompts, enter the VIN (if you're asked) and the odometer reading. 3. From the Select Mode screen, select Honda Systems. From the System Selection Menu, select PGM-FI. From the Mode Menu, select All Data List. 4. Disconnect the two FTP sensor vacuum lines. Look at the FTP Sensor value on the display screen. ^ If the value reads between 2.45 and 2.55 volts, go to step 6. ^ If the value doesn't read between 2.45 and 2.55 volts, check the electrical connections. If you find any problems, fix them, then go to step 5. If the circuits are OK, replace the FTP sensor, then go to step 5. 5. Look at the FTP Sensor value on the display screen. ^ If the value now reads between 2.45 and 2.55 volts, reconnect the vacuum lines and disconnect the HDS. Return the vehicle to your customer. ^ If the value still doesn't read between 2.45 and 2.55 volts, go to step 6. 6. Connect a vacuum pump to the larger FTP sensor hose (the smaller hose is the FTP vent) Slowly squeeze the pump handle to pull a vacuum on the FTP sensor. Look at the sensor value on the display screen. ^ If the value changes, continue troubleshooting for DTC P0497. ^ If the value stays the same, the FTP sensor has a leak. Replace the sensor. Diagrams 194. Recirc - A/C - Defogger Switch Assembly Page 4373 Power Distribution schematics show how power is supplied from the positive battery terminal to various circuits in the vehicle. Refer to the Power Distribution diagram set to get a more detailed understanding of how picture is supplied to the circuit you're working on. Individual circuit schematics begin with a fuse. So 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 Ground Distribution Schematics This sample Ground Distribution schematic shows all of the components that share the same ground point. Page 2832 2. Remove the terminal from the female half. 3. Remove the terminal from the male half. 4. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE D: 1. Remove the secondary locks. Seats With Side Airbags Air Bag(s) Arming and Disarming: Description and Operation Seats With Side Airbags Seats with Side Airbags Seats with side airbags have a tag attached to the seat-back. Because the component parts (seat-back cover, cushion, etc.) of seats with and without airbags are different, make sure you install only the correct replacement parts. Because the seats are made by more than one manufacturer, make sure you replace any seat components (seat-back cover, frame, etc.) with the correct parts. The name of the seat manufacturer is indicated on the seat-back. Moreover, the manufacturer name is indicated on the seat-back frame and the seat-back pad. Confirm the indication when you exchange these parts. * When cleaning, do not saturate the seat with liquid, and do not spray steam on the seat. * Do not repair torn or frayed seat-back covers. Replace the seat-back cover. * After a collision in which the side airbag was deployed, replace the seat-back cover and the side airbag with new parts. If the seat-back cushion is split, it must be replaced. If the seat-back frame is definitely deformed, it must be replaced. Page 9018 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 Short Circuit Locator (Short Finder) 1. Remove the blown fuse. Leave the battery connected. Page 6379 3. Loosely install the flange bolt (A) on the bottom of the damper. 4. Raise the suspension with a floor jack to load the vehicle's weight, and tighten the nuts and bolt to the specified torque values. 5. Clean the mating surface of the brake drum and the inside of the wheel, then install the rear wheel. 6. Check the wheel alignment, and adjust it if necessary. Diagram Information and Instructions Auxiliary Power Outlet: Diagram Information and Instructions Terminal Numbering System Terminal Numbering System Connector terminals are numbered according to the cavities they're in. The cavities are numbered starting from the upper left, looking at the male terminals from the terminal side or looking at the female terminals from the wire side. Both views are in the same direction so the numbers are the same. All actual cavities are numbered, even if they have no wire terminals in them. NOTE: Data Link Connector (DLC) terminals are numbered according 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 below is #6. Page 1928 -Works on most Honda applications Contact AST for pricing Assenmacher Specialty Tools 1 800 525 2943 Page 8587 ^ If no key code can be found on the iN or with the Matrix H High Security key Codes Book, remove one tumbler at a time from the old inner cylinder, and match the number stamped on the old tumbler to a new tumbler from the kit. Insert the new tumbler and spring in the appropriate new inner cylinder cavity. ^ Do not use the old inner cylinder, springs, or tumblers. ^ Using your thumb and forefinger, hold the tumblers in place, insert the key in the cylinder and verify that all tumblers are flush with the cylinder. If not, double-check the key number, the cutting key code, the tumbler numbers, and the cavity locations. NOTE: If the key cannot be inserted, check the tumbler in the "J" cavity. It may be out of position. Locations Fuel Supply System - Component Location Index Description and Operation Front Bumper: Description and Operation Door and Bumper Reinforcement Beams Door and bumper reinforcement beams used on Honda vehicles are made from a metal equivalent to High Strength Steel. If High Strength Steel is heated, the strength of the steel will be reduced. If High Strength Steel is damaged, as in a vehicle accident, where the door and bumper reinforcement beams are bent, the beams may crack if an attempt is made to straighten them. For this reason, door and bumper reinforcement beams should NEVER be repaired; they should be replaced if they are damaged. NOTE: If a door beam is damaged, the whole door panel assembly should be replaced. Page 7625 3. Use the clamp carriage lever to position the clamp unit so the tracer is directly over the flat surface of the code device, just ahead of the cam blades. 4. Pull the vertical carriage lever toward you until the tracer just touches the flat surface ahead of the cam blades. Watch the arrows on the keypad: ^ If the double-headed arrow in the middle of the keypad lights green, the tracer and cutter bit are properly aligned. ^ If the arrow on the left of the keypad lights red, the cutter bit is not touching the jaw. Turn the micrometric ring nut above the tracer to the left until the double-headed arrow lights green. ^ If the vertical arrow on the right of the keypad lights red, the tracer is not touching the jaw. Turn the micrometric ring nut above the tracer to the right until the double-headed arrow lights green. *5. Turn the micrometric ring nut to the right five clicks so the cutter bit is slightly higher than the tracer. The arrow on the left should light red. Raise the vertical carriage. NOTE: Setting the tracer five clicks lower than the cutter bit at this point has the effect of making the cutter bit cut the duplicated key a little shallower. This will protect the locking jaws from being damaged.* 6. Optional: Loosen the set screw, and adjust the hand rest to a comfortable position. Tighten the screw. 7. Pull the clamp carriage lever toward you until the clamp carriage clicks into its end-of-run position. 8. Clean any metal shavings or debris out of the center jaw. (A soft-bristle toothbrush is ideal for this purpose.) Then open the jaws with the jaws knob, and slide the key blank with its flat side down into the jaw up to the key stop. Close the jaw with the jaws knob to lock the key blank into place. Visually inspect the key for proper alignment in the jaw. 9. Set and lock the cam sets on the code device. ^ Starting with the left cam set, make sure the lock pin is pulled all the way out. (This releases the cams.) Page 1888 5. Turn the head over and drive the guide out toward the camshaft side of the head. 6. If a valve guide won't move, drill it out with a 8 mm (5/16 inch) bit, then try again. Drill out the guides only in extreme cases; you could damage the cylinder head if the guide breaks. 7. Remove the new guide(s) from the freezer, one at a time, as you need them. 8. Apply a thin coat of clean engine oil to the outside of the new valve guide. Install the guide from the camshaft side of the head; use the special tool to drive the guide in to the specified installed height (A) of the guide (B). If you have all 16 guides to do, you may have to reheat the head. Valve Guide Installed Height Intake: 17.85 - 18.35 mm (0.703 - 0.722 inch) Locations Transmission Position Switch/Sensor: Locations Component Location Index, A/T Page 7937 3. Use the clamp carriage lever to position the clamp unit so the tracer is directly over the flat surface of the code device, just ahead of the cam blades. 4. Pull the vertical carriage lever toward you until the tracer just touches the flat surface ahead of the cam blades. Watch the arrows on the keypad: ^ If the double-headed arrow in the middle of the keypad lights green, the tracer and cutter bit are properly aligned. ^ If the arrow on the left of the keypad lights red, the cutter bit is not touching the jaw. Turn the micrometric ring nut above the tracer to the left until the double-headed arrow lights green. ^ If the vertical arrow on the right of the keypad lights red, the tracer is not touching the jaw. Turn the micrometric ring nut above the tracer to the right until the double-headed arrow lights green. *5. Turn the micrometric ring nut to the right five clicks so the cutter bit is slightly higher than the tracer. The arrow on the left should light red. Raise the vertical carriage. NOTE: Setting the tracer five clicks lower than the cutter bit at this point has the effect of making the cutter bit cut the duplicated key a little shallower. This will protect the locking jaws from being damaged.* 6. Optional: Loosen the set screw, and adjust the hand rest to a comfortable position. Tighten the screw. 7. Pull the clamp carriage lever toward you until the clamp carriage clicks into its end-of-run position. 8. Clean any metal shavings or debris out of the center jaw. (A soft-bristle toothbrush is ideal for this purpose.) Then open the jaws with the jaws knob, and slide the key blank with its flat side down into the jaw up to the key stop. Close the jaw with the jaws knob to lock the key blank into place. Visually inspect the key for proper alignment in the jaw. 9. Set and lock the cam sets on the code device. ^ Starting with the left cam set, make sure the lock pin is pulled all the way out. (This releases the cams.) Locations 6. Transmission Housing (M/T) Page 7787 Disclaimer Cutting Procedure - By Copying 1. Press the ON/OFF button in the middle of the setting unit keypad. (This powers up the keypad.) 2. Turn the clamp unit lock lever to the left to release the clamp unit, and slide it all the way to the left until it stops. Turn the lever to the right to lock the clamp unit in place. 3. Use the clamp carriage lever to position the clamp unit so the tracer and cutter bit are centered directly over the base of the center and right jaws. 4. Pull the vertical carriage lever toward you until the tracer and the cutter bit just touch the base of each fixed jaw. Watch the arrows on the keypad: ^ If the double-headed arrow in the middle of the keypad lights green, the tracer and cutter bit are properly aligned. ^ If the arrow on the left of the keypad lights red, the cutter bit is not touching the fixed jaw. Turn the micrometric ring nut above the tracer to the left until the double-headed arrow lights green. ^ If the arrow on the right of the keypad lights red, the tracer is not touching the fixed jaw. Turn the micrometric ring nut above the tracer to the right until the double-headed arrow lights green. *5. Turn the micrometric ring nut to the right three clicks so the cutter bit is slightly higher than the tracer. The arrow on the left should light red. Raise the vertical carriage. NOTE: Setting the tracer three clicks lower than the cutter bit has the effect of making the cutter bit cut the duplicated key a little shallower. This will protect the locking jaws from being damaged.* 6. Optional: Loosen the setscrew, and adjust the hand rest to a comfortable position. Tighten the screw. 7. Pull the clamp carriage lever toward you until the clamp carriage clicks into its end-of-run position. Tighten both the lateral and spring tension adjustment knobs. 8. Make sure the center and right jaws are free of any metal shavings or debris. (A soft-bristle toothbrush is ideal for this purpose.) Page 1077 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. How to Replace Connector Terminals Terminal Replacement Procedure HOW TO REPLACE CONNECTOR TERMINALS The terminal repair kits provide necessary tools and materials (terminals, wire seals, and splice connectors) to repair many damaged or faulty connector terminals. However, not all terminals for all connectors are available. Refer to the labels on the lids of the repair kits for replacement terminal availability. IMPORTANT SAFETY INFORMATION: On some models, the SRS wires are in a separate harness. If the SRS harness is damaged, replace the harness; do not repair it. On other models, wire harnesses include yellow SRS wires. If any SRS wire is damaged, replace the entire harness; do not repair it. Before you begin, inspect the wire you are about to repair for damage and length. Make sure the wire will be long enough to make a terminal repair without stretching it when you reinstall the terminal in the connector. If the wire is too short, or if access to the connector is too restricted to make a terminal repair, you may need to install a pigtail terminal (a short length of wire with a factory-crimped terminal on it). Refer to HOW TO INSTALL PIGTAIL TERMINALS. Removing the Terminal Page 7811 19. Using your thumb and forefinger to hold the tumblers, remove the key from the inner cylinder, being careful not to drop any tumblers and springs. 20. *Using the key code from the iN that you have written down at step 2, build a new inner cylinder with new springs, new cylinder, and tumblers from the door lock cylinder kit. Make sure you put the appropriate numbered tumbler in the proper inner cylinder cavity. Apply a thin layer of Permalube to each tumbler to help lubricate and retain it.* NOTE: ^ There are two types of tumblers. The "SUBLOCK" tumbler goes only in cavity A." The "DISC" tumbler goes in cavities "B" through "J." ^ Cavity "E" is empty on all cylinders. Locations 98. Under Right Side Of Dash Page 1245 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 5552 *T-5 Sidewinder Key Applications ^ 2003-05 Civic ^ 2004-05 Civic Hybrid ^ 2003-05 Civic GX (CNG) ^ 2004-05 S2000 ^ 2002-06 CR-V ^ 2003-06 Element ^ 2003-04 Odyssey ^ 2003-04 Pilot Ordering Honda key blanks through normal parts ordering channels: Refer to the parts catalog for correct key(s) for your application. PROGRAMMING KEYS Depending on the type of key blank you use, do this: ^ If you have used a T-5 programmable key blank ("T-5" stamped on the shank), you must code the key's transponder with the Ilco Immobilizer Key Code Duplicator (see S/B 99-053, Ilco Immobilizer key Code Duplicator). ^ If you have used a Honda key blank, add the* transponder code of the new key to the immobilizer system with the Honda Diagnostic System (HDS). ORDERING INFORMATION *To order the MATRIX H Key Cutting Machine, replacement cutter bits, fixed jaws and mobile jaws, T-5 programmable key blanks, and practice key blanks, contact the Honda Tool and Equipment Program by calling 888-424-6857 or using the fax order form provided in your Honda Tool and Equipment Program Catalog.* Order Honda key blanks through normal parts ordering channels. WARRANTY CLAIM INFORMATION None. This service bulletin is for information only. *DETERMINING WHICH KEY TO USE T-5 keys require less time to program and should be the first choice. They can be used as long as the following requirements are met: ^ Do you have the customer's operating key? ^ Does the vehicle fall within the T-5 Sidewinder Key Applications? ^ Does your dealership have an Ilco Immobilizer Key Code Duplicator? If the answer to all three questions on the above is yes, the 1-5 key option is the easier procedure. If you answered no to any of the questions, you should order the key(s) from the parts catalogue, and program it using the HDS.* BEFORE YOU START CUTTING 1. Get the original key or the key number from your customer or from the iN. 2. Get the applicable key blank. 3. If cutting by code, look up the applicable 9-digit cutting code for the key number. Refer to the code book Honda High Security key Codes that comes with the machine. Page 6037 234. Under-dash Fuse/Relay Box Part 6 Page 6605 Refrigerant: Service and Repair System Charging System Charging CAUTION: - Air conditioning refrigerant or lubricant vapor can irritate your eyes, nose, or throat. - Be careful when connecting service equipment. - Do not breathe refrigerant or vapor. Use only service equipment that is U.L.-listed and is certified to meet the requirements of SAE J2210 to remove HFC-134a (R-134a) from the air conditioning system. If accidental system discharge occurs, ventilate work area before resuming service. Additional health and safety information may be obtained from the refrigerant and lubricant manufacturers. 1. Connect a R-134a refrigerant recovery/recycling/charging station (A) to the high-pressure service port (B) and the low-pressure service port (C), as shown, following the equipment manufacturer's instructions. 2. Evacuate the system. 3. Add the same amount of new refrigerant oil to the system that was removed during recovery. Use only SANDEN SP-10 refrigerant oil. 4. Charge the system with the specified amount of R-1 34a refrigerant. Do not overcharge the system; the compressor will be damaged. Select the appropriate units of measure for your refrigerant charging station. Refrigerant capacity: 500 to 550 g 0.50 to 0.55 kg 1.1 to 1.2 lbs 17.6 to 19.4 oz 5. Check for refrigerant leaks. 6. Check for system performance. Page 3388 Idle Speed: Testing and Inspection Idle Speed Inspection NOTE: - Leave the Idle Air Control (IAC) valve connected. - Before checking the idle speed, check these items: The Malfunction Indicator Lamp (MIL) has not been reported on. - Ignition timing - Spark plugs - Air cleaner - PCV system - On Canadian models, pull the parking brake lever up, start the engine, then check that the headlights are off. 1. Disconnect the Evaporative Emission (EVAP) canister purge valve 2P connector. 2. Connect a tachometer. 3. Start the engine. Hold the engine at 3,000 rpm with no load (in neutral) unit the radiator fan comes on, then let it idle. 4. Check the idle speed with no-load conditions: headlights, blower fan, radiator fan, and air conditioner are not operating. 5. Idle the engine for 1 minute with the heater fan switch on HI and air conditioner on, then check the idle speed. NOTE: If the idle speed is not within specification, see the Symptom Chart. 6. Reconnect the EVAP canister purge valve 2P connector. Page 9106 Brake Lamp: Electrical Diagrams Wiring Diagrams Diagram 110-12 Diagrams: Other diagrams referred to by number (See Diagram ##-#, etc.)within these diagrams can be found at Diagrams by Number. See: Diagrams/Electrical Diagrams/Diagrams By Number Locations: Location photographs (references to PHOTOS) referred to within these diagrams can be found at Locations by Photo Number. See: Page 8570 - From the wheelhouse side, plug weld the holes in the dashboard upper and damper housing extension. - Weld the front wheelhouse, damper housing, and front side - Weld the wheelhouse upper member. When replacing the front wheelhouse only, but weld the wheelhouse upper member. Page 8102 ^ Within 1 to 4 seconds, turn the ignition switch to LOCK (0). ^ Within 1 to 4 seconds, turn the ignition to ON (II). ^ Within 1 to 4 seconds, push the transmitter lock or unlock button. ^ Confirm you can hear the sound of the door lock actuators. Within 1 to 4 seconds, push the transmitter lock or unlock button again. ^ Within 10 seconds, aim the transmitters (up to two additional ones) whose codes you want to store at the receiver, and press the transmitter lock or unlock button. Confirm that you can hear the sound of the door lock actuators after each transmitter code is stored. ^ Turn the ignition switch to LOCK (0), and pull out the key. 4. Confirm proper operation of the transmitters. Disclaimer Service and Repair 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. Locations Keyless Entry Module: Locations Relay And Control Unit Locations - Dashboard 78. Under Middle of Dash (Honda Accessory) Page 9034 Shift Indicator: Electrical Diagrams Automatic Transmission Circuit Diagram Continuously Variable Transmission Page 1241 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 9808 125. Passenger's Door (Coupe except DX, HX) 126. Front Passenger's Door (Sedan except DX) 127. Left Rear Door (Sedan except DX) (Right Similar) Page 6751 10. Cutoff each connector, strip the ends of the wires, and connect the deployment tool alligator clips (A) to the wires. Place the deployment tool at least 30 feet (10 meters) away from the vehicle. NOTE: The driver's airbag and the front passenger's airbag has four wires, two yellow and two red. Twist each pair of unlike colored wires together, and connect an alligator clip to each pair. 11. Connect a 12 volt battery to the tool. - If the green light on the tool comes on, the igniter circuit is defective and cannot deploy the component. Go to Disposal of Damaged Components. - If the red light on the tool comes on, the component is ready to be deployed. 12. Push the tool's deployment switch. The airbags and tensioners should deploy (deployment is both highly audible and visible: a loud noise and rapid inflation of the bag, followed by slow deflation). If the components deploy and the green light on the tool comes on, continue with this procedure. - If an component doesn't deploy, yet the green light comes ON, its igniter is defective. Go to Disposal of Damaged Components. - During deployment the airbag can become hot enough to burn you. Wait 30 minutes after deployment before touching the airbag. 13. Dispose of the complete airbag. No part of it can be reused. Place it in a sturdy plastic bag (A), and seal it securely. Deploying the Airbags/Tensioner (Outside Vehicle) Airbag Disposal Page 9403 2. Remove the terminal from the female half. 3. Remove the terminal from the male half. 4. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE D: 1. Remove the secondary locks. Page 9804 5. Reinstall the parts in the reverse order of removal. 6. Test the operation of all windows with the power window master switch.If any of the windows do not work correctly, continue with normal troubleshooting, and do the master switch input test: ^ Refer to page 22-168 of the 2001-05 Civic Service Manual, or ^ Online, enter keyword MASTER TEST, and select Power Window Master Switch Input Test (4-door) from the list. Disclaimer Page 126 5. Make these input tests at the connector. - If any test indicates a problem, find and correct the cause, then recheck the system. - If all the input tests prove OK, the control unit must be faulty; replace it. Page 386 7. Connect the SCS service connector to the 2P MES (memory erase signal) connector, as shown. Do not use a jumper wire. 8. Turn the ignition switch to ON (II). 9. Watch the SRS indicator. (It comes on for about 6 seconds and then goes off.) Disconnect the SCS service connector from the MES connector within 4 seconds after the indicator goes off. 10. When the SRS indicator comes on again, connect the SCS service connector to the MES connector within 4 seconds after the indicator comes on. 11. When the SRS indicator goes off, disconnect the SCS service connector from the MES connector within 4 seconds. Service and Repair Locations Daytime Running Lamp Control Unit: Locations Relay And Control Unit Locations - Dashboard Page 6834 WARRANTY CLAIM INFORMATION Out of warranty: Any repairs to the SRS system for problems other than the 15-1, 15-2, and 15-3 DTCs that are done 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. INSPECTION PROCEDURE NOTE: ^ When you check for SRS DTCs with the HDS, codes other than 15-1, 15-2, and 15-3 are not covered by this warranty extension bulletin. ^ If the vehicle is covered by warranty, repair it using the normal warranty repair procedures. If the vehicle's warranty is expired, give your customer an estimate for the cost of the repair. Do the appropriate inspection, based on the DTC. SRS DTC 15-1 Clear the DTC with the HDS. ^ If DTC 15-1 does not set again, go to REPAIR PROCEDURE A: OPDS UNIT REPLACEMENT. ^ If DTC 15-1 sets again, continue with normal troubleshooting. ^ If the OPDS unit causes DTC 15-1 to set repeatedly, yet passes the other troubleshooting steps, go to REPAIR PROCEDURE A: OPDS UNIT REPLACEMENT. SRS DTC 15-2 1. Inspect the connections and the wiring in the side airbag cutoff indicator circuit. ^ If all the connections and the wiring are OK, go to step 2. ^ If any of the connections or the wiring are faulty, repair the circuit, then go to step 2. 2. Clear the DTC with the HDS. ^ If DTC 15-2 does not set again, go to REPAIR PROCEDURE A: OPDS UNIT REPLACEMENT. ^ If DTC 15-2 sets again, continue with normal troubleshooting. ^ If the OPDS unit causes DTC 15-2 to set repeatedly, yet passes the other troubleshooting steps, go to REPAIR PROCEDURE A: OPDS UNIT REPLACEMENT. SRS DTC 15-3 1. Clear the DTC with the HDS. ^ If DTC 15-3 does not set again, go to step 2. ^ If DTC 15-3 sets again, continue with normal troubleshooting. 2. Ask your customer if electrical devices such as a laptop computer or a fluorescent map light are ever used near the front passenger's seat-back. (Some electrical devices that plug into the vehicle's accessory power socket, especially those using a power inverter/converter, can interfere with the seat-back sensors and cause SRS DTC 15-3 to set.) ^ If your customer uses any of these devices operate the device near the front passenger's seat-back. If DTC 15-3 sets again, clear it, then return the vehicle to the customer. Advise the customer to avoid using the device near the front passenger's seat-back. ^ If your customer does not use any of these devices and DTC 15-3 does not set again, go to REPAIR PROCEDURE A: OPDS UNIT REPLACEMENT. REPAIR PROCEDURE A: OPDS UNIT REPLACEMENT Page 5689 7. Connect the starter to the battery as described in the diagram, and confirm that the motor starts and keeps rotating. Specifications 8. If the electric current and motor speed meet the specifications when the battery voltage is at 11.5 V, the starter is working properly. Front Wheel Bearing: Service and Repair Front Knuckle/Hub/Wheel Bearing Replacement Special Tools Required Hub dis/assembly tool 07GAF-SE00100 - Ball joint remover, 28 mm 07MAC-SL00200 - Attachment 62 x 68 mm 07746-0010500 - Driver 07749-0010000 - Support base 07965-SD90100 1. Raise the front of the vehicle, and support it with safety stands in the proper locations. 2. Remove the wheel cap, wheel nuts, and front wheel. Recall 10V041000: Air Bag Inflator Replacement Air Bag: Recalls Recall 10V041000: Air Bag Inflator Replacement VEHICLE MAKE/MODEL: MODEL YEAR(S): Acura/3.2CL 2003 Acura/3.2TL 2002-2003 Honda/Accord 2001-2002 Honda/Civic 2001-2003 Honda/CRV 2002 Honda/Odyssey 2002 Honda/Pilot 2003 MANUFACTURER: Honda (American Honda Motor Co.) MFR'S REPORT DATE: February 09, 2010 NHTSA CAMPAIGN ID NUMBER: 10V041000 NHTSA ACTION NUMBER: N/A COMPONENT: Air Bags POTENTIAL NUMBER OF UNITS AFFECTED: 379000 SUMMARY: Honda is recalling certain model year 2001-2002 Honda Accord and Civic, model year 2002 CR-V and Odyssey, model year 2002-2003 Acura 3.2TL and one vehicle for model year 2003 Honda Pilot, Civic and Acura 3.2CL passenger vehicles. The driver's airbag inflator could produce excessive internal pressure. If an affected airbag deploys, the increased internal pressure may cause the inflator to rupture. CONSEQUENCE: Metal fragments could pass through the airbag cushion material possibly causing injury or fatality to vehicle occupants. REMEDY: Dealers will replace the airbag inflator free of charge. The safety recall is expected to begin on or before February 25, 2010. Owners may contact Honda Automobile Customer Service at 1-800-999-1009. NOTES: Honda's recall No. Q96 & Acura's recall No. R13. 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 6127 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 3437 Fuel Pump Relay: Description and Operation PGM-FI Main Relay 1 and 2 The PGM-FI relay consists of two separate relays. PGM-FI main relay 1 is energized whenever the ignition switch is ON (II) which supplies battery voltage to ECM/PCM, power to the injectors, and power for PGM-FI main relay 2. PGM-FI main relay 2 is energized to supply power to the fuel pump for 2 seconds when the ignition switch is turned ON (II), and when the engine is running. Page 5427 Brake Shoe: Service and Repair Rear Brake Shoes Replacement CAUTION: Frequent inhalation of brake pad dust, regardless of material composition, could be hazardous to your health. ^ Avoid breathing dust particles. ^ Never use an air hose or brush to clean brake assemblies. Use an OSHA-approved vacuum cleaner. NOTE: Contaminated brake linings or drums reduce stopping ability. - Block the front wheels before jacking up the rear of the vehicle. Removal/Disassembly 1. Remove the brake drum. 2. Remove the tension pins (A) by pushing each retainer spring (B) and turning the pins. 3. Remove the lower return spring (A), and remove the shoe assembly over the hub. 4. Remove the upper return spring (B), and disassemble the brake shoe assembly. 5. Disconnect the parking brake cable from the parking brake lever, and remove the brake shoe. 6. Remove the U-clip (A), wave washer (B), and pivot pin (C), and separate the parking brake lever (D) from the brake shoe (E). Page 4221 Use the tools from Pin Tool Set. First, check the connector that you are about to repair. - If it has a secondary terminal lock, go to Connectors With a Secondary Lock. A secondary lock, found on most connectors on some models, is an additional locking device on the connector housing as a backup for the primary lock on the terminal. - If the connector does not have a secondary lock, go to Connectors Without a Secondary Lock. Connectors With a Secondary Lock All examples are shown with the connector lock facing up. The illustrations are examples of the secondary terminal locks; however, the connector you are repairing may vary in size. Identify the connector by the type of secondary lock, not by the number of terminal cavities. EXAMPLE A: 1. Release the secondary lock. 2. Remove the terminal. 3. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE B: Page 9027 1. Remove the terminal. 2. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE G: 1. Remove the terminal. 2. Go to HOW TO INSTALL NEW TERMINALS. How to Install New Terminals HOW TO INSTALL NEW TERMINALS 1. Carefully match the old terminal with a new one from the terminal repair kit. Choose the correct replacement terminal based on the wire size range the terminal will accommodate. NOTE: If the replacement terminal quantities are low, reorder them by using the terminal part number listed on the inside lid of the terminal repair kit. Replacement terminals are available through your parts department using normal parts ordering procedures. 2. Depending on the size of the wire you are repairing, use the proper size slot in the crimping tool. Page 8771 1. Remove the terminal. 2. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE B: 1. Remove the terminal. 2. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE C: 1. Remove the terminal. 2. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE D: Page 2993 166. PGM-FI Main Relays 1 And 2 Locations Page 4426 Clutch Disc: Service and Repair Flywheel Replacement Clutch Replacement Special Tools Required ^ Clutch alignment shaft 07LAF-PT00110 ^ Clutch alignment disc 07JAF-PM7011A ^ Remover handle 07936-3710100 ^ Ring gear holder 07LAB-PV00100 or 07924-PD20003 ^ Attachment, 57 x 40 mm 07746-0010200 ^ Driver 077 49-0010000 Flywheel Replacement NOTE: Do not disassemble the flexible plate from the flywheel. 1. Install the special tool. 2. Remove the flywheel mounting bolts in a crisscross pattern in several steps, then remove the flywheel. 3. Remove the pilot bearing (A) from the flywheel (B). 4. Drive the new bearing into the flywheel using the special tools as shown. Apply a light coat of oil to the outside of the bearing surface. Page 4269 Skill Level: Repair Technician INSPECTION PROCEDURE 1. Remove the steering column covers. Refer to section 17 of the appropriate service manual. 2. On the lower side of the ignition switch, look at the interlock cylinder cover: ^ If the cover is square, the ignition switch was already replaced with an updated part, and a key interlock repair kit is not needed. Go to step 3. ^ If the cover is round, go to REPAIR PROCEDURE. 3. Reinstall the steering column covers. 4. Center-punch a completion mark above the seventh character of the engine compartment VIN. REPAIR PROCEDURE Page 5188 5. Attach the slide hammer to the interlock lever pin, and tighten the slide hammer clamping bolt. Then use the slide hammer to remove the pin. Discard the pin, the lever, and the spring. 6. Wipe off any debris from the lever's sliding surface on the ignition switch with a clean cloth or a cotton swab. NOTE: To keep debris out of the ignition switch, do not clean it with compressed air. Page 5591 134. Alternator Locations Crankshaft Position Sensor: Locations PGM-FI System - Component Location Index Page 2374 PGM-F1 Main Relay 1, 2 Type 1, 2 Check for continuity between the terminals. - There should be continuity between the No.1 and No.2 terminals when power and ground are connected to the No.3 and No.4 terminals. - There should be no continuity between the No.1 and No.2 terminals when power is disconnected. Normally-open type B: Rear Window Defogger Relay Page 9647 Use the tools from Pin Tool Set. First, check the connector that you are about to repair. - If it has a secondary terminal lock, go to Connectors With a Secondary Lock. A secondary lock, found on most connectors on some models, is an additional locking device on the connector housing as a backup for the primary lock on the terminal. - If the connector does not have a secondary lock, go to Connectors Without a Secondary Lock. Connectors With a Secondary Lock All examples are shown with the connector lock facing up. The illustrations are examples of the secondary terminal locks; however, the connector you are repairing may vary in size. Identify the connector by the type of secondary lock, not by the number of terminal cavities. EXAMPLE A: 1. Release the secondary lock. 2. Remove the terminal. 3. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE B: Adjustments Shift Cable: Adjustments Shift Cable Adjustment 1. Shift the transmission into the N position. 2. Remove the center console panel and center console. 3. Remove the nut securing the shift cable end (A), then separate the cable end from the shift lever assembly. 4. Rotate the socket holder (A) on the shift cable (B) toward the shift lever a quarter turn, then slide the holder out to remove the shift cable from the shift cable bracket base (C). NOTE: Do not remove the shift cable by twisting the shift cable guide (D). 5. Push the shift cable until it stops, then release it. Pull the shift cable back two steps so that the shift position is in N. 6. Turn the ignition switch ON (II), and verify that the N position indicator comes on. 7. Turn the ignition switch OFF. Page 8146 Page 1013 ^ The vehicle is shown as eligible on a VIN status inquiry. In addition, check for a punch mark above the seventh character of the engine compartment VIN. A punch mark in that location means the ignition switch key interlock has already been inspected/repaired. 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 a VIN status inquiry before selling it. CUSTOMER NOTIFICATION All owners of affected vehicles will be sent a notification of this campaign. An example of the customer notification is at the end of this service bulletin. CORRECTIVE ACTION Inspect the ignition switch and, if needed, install a Key Interlock Repair Kit. PARTS INFORMATION Key Interlock Repair Kit: P/N 06351-SDA-000 REQUIRED SPECIAL TOOLS Interlock Slide Hammer: T/N 07AAC-S84A100 NOTE: ^ An initial quantity of Permalube grease to lubricate the sliding surface of the interlock lever is included with the slide hammer. To order more Permalube, use P/N 08734-0030. ^ To order a replacement clamping bolt for the slide hammer, use T/N 07AAC-S84A400. WARRANTY CLAIM INFORMATION Failed Part: P/N 35100-SDA-A31 Defect Code: 5GC00 Symptom Code: R4400 Page 9235 159. Fog Light Relays 1 And 2 (Honda Accessory) Page 5743 3. Strip the insulation off the end of the wire so the wire fits in the new terminal as shown. (If the wire has a wire seal, replace it with a new one from the kit.) NOTE: After stripping the end of the wire, make sure you did not cut any wire strands. If you did, cut the wire off even with the insulation, and strip it again. 4. Position the terminal in the crimping tool slot with the solid portion of the terminal toward the anvil and the open section toward the former. 5. Insert the wire in the terminal to the position shown in step 3. 6. Squeeze the tool with both hands until the stops make contact. 7. Crimp the insulation crimp. - If you do not have a wire seal, then use the next larger size crimp slot. Position the crimping tool over the insulation crimp section of the terminal, then squeeze the tool with both hands until the stops make contact. - If you have a wire seal, position the insulation crimp in the 5.5 crimping slot, then carefully squeeze the crimp closed until its ends are touching and making a full-circle shape. Page 8398 Sunroof / Moonroof Limit Switch: Testing and Inspection Limit Switch Test 1. Remove the headliner. 2. Disconnect the 4P connector from the moonroof limit switch. 3. Check for continuity between the terminals in each switch position according to the table. NOTE: Turn the motor by hand with the wrench. 4. If the continuity is not as specified, replace the moonroof limit switch. Page 6719 Page 8155 On the order form, you must include the serial number of the keyless control unit or the number from one of the original transmitters. If you need a transmitter shipped overnight, fill out the order form, then call Kenwood at (500) 552-4690, or fax them at (310) 595-1029 (weekdays from 5:30A.M. thru 4:00 P.M. Pacific time). You will need to give the information on the order form to the Kenwood representative. The transmitter will be sent to your dealership COD. Additional shipping and handling charges will be applied to the order. Batteries for the Transmitter The battery number is CR1220. Each transmitter uses two batteries. 94-97 Accord 5-Door EX, 95-98 Odyssey EX 1994-97 Accord 5-door EX with factory-installed keyless entry system 1995-98 Odyssey EX with factory-installed keyless entry system Programming the Transmitter NOTE: ^ The system accepts up to two transmitters. ^ Entering the programming mode cancels all learned transmitter codes, so none of the previously programmed transmitters will work. You must reprogram all of the transmitters once you are in the programming mode. 1. Open the driver's door. 2. Push the driver's power door lock switch to the unlock position and hold it. (Continue to hold the switch during this procedure.) 3. Insert the key into the ignition switch, then remove it. Repeat this four more times (five times total) within 10 seconds. (You must complete steps 3 and 4 within 10 seconds or the system will exit the programming mode.) 4. Insert the key into the ignition switch. After you insert the key, make sure the power door locks cycle to confirm that the system is in the programming mode. 5. Press the "LOCK" or "UNLOCK" button on the transmitter. All the power door locks (except the driver's door) should cycle to confirm that the system accepted the transmitter's code. 6. To program a second transmitter, press its "LOCK" or "UNLOCK" button within 10 seconds of programming the first transmitter. 7. Release the master power door lock switch to exit the programming mode. Ordering a Transmitter Transmitters can be ordered only by authorized Honda dealers. Order them from American Honda using normal parts ordering procedures. Batteries for the Transmitter The battery number is CR2016. Each transmitter uses two batteries. 96-04 Accord, CRV, DelSOL, Ody., Prelude, S2000, Insight, Pilot 1996-02 Accord with dealer-installed security system 1998-02 Accord DX & LX with dealer-installed keyless entry system Page 1386 5. If 8 numbers (1 to 8) are printed around the outside of the filter, use the following procedure to tighten the filter. ^ Spin the filter on until its seal lightly seats against the block, and note which number is at the bottom. ^ Tighten the filter by turning it clockwise 7 numbers from the one you noted. For example, if number 2 is at the bottom when the seal is seated, tighten the filter until the number 1 comes around the bottom. 6. After installation, fill the engine with oil up to the specified level, run the engine for more than 3 minutes, then check for oil leakage. Locations Relay And Control Unit Locations - Dashboard Page 1836 15. Use the wooden handle of a hammer (A) to drive out the pistons (B). 16. Reinstall the connecting rod bearing and caps after removing each piston/connecting rod assembly. 17. To avoid mix-up on reassembly, mark each piston/connecting rod assembly with its cylinder number. NOTE: The existing number on the connecting rod does not indicate its position in the engine, it indicates the rod size. Page 894 ^ Going from front to back, use the middle lock pin to set the first cam to the appropriate key code number in the code book. (The cam is properly set when the number on the cam lines up with the red scribe mark on the clamp unit.) ^ Slide the lock pin through the notch in the cam. (This locks the cam in place.) ^ Keep doing this for each of the remaining cams in the set until all the cams are set and locked, then push the lock pin all the way in. Repeat this process to set and lock the cams for the right cam set. NOTE: Make sure you set the MIS cam in the right cam set for the type of key you are cutting. For a master key, set the cam to M; for a valet key, set it to S. When you are done, push all the cam blades to the left until they touch the cams in the left cam set. 10. Pull the vertical carriage lever toward you until the tracer touches the flat surface on the right side at the front of the cams. Gently twist the lever clockwise to lock the vertical carriage at this height. Do not overtighten the lever. 11. Turn on the cutter motor with the motor start switch. [NOTICE] ^ To avoid damaging the locking jaws while cutting, keep your hand off the vertical carriage lever. Pressure on the lever will change the cutting depth. * ^ To avoid breaking the cutter bit, never back up while cutting.* ^ Wear proper eye protection (safety glasses, goggles, etc.) 12. Use the clamp carriage lever and the tracer to follow the contours of the cam blades from front to back. (The cutter bit cuts the same contours into the right edge of the key blank, from head to tip.) Page 3831 2. Remove the terminal (same procedure for male and female). 3. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE E: 1. Remove the secondary locks. 2. Remove the terminal (same procedure for male and female). 3. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE F: Locations Main Relay (Computer/Fuel System): Locations Relay And Control Unit Locations - Dashboard Page 3207 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. Test Equipment 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. Removal and Installation Seat Occupant Sensor: Service and Repair Removal and Installation OPDS Unit Replacement NOTE: Review the seat replacement procedure in the body section before performing repair or service. Removal 1. Disconnect the battery negative cable, and wait at least 3 minutes before beginning work. 2. Disconnect the side airbag harness 2P connector. 3. Remove the seat assembly and seat-back cover. 4. Remove the cover (A), then disconnect the OPDS unit harness 8P and sensor connectors (B) from the OPDS unit. 5. Remove the two screws (C) and OPDS unit (D). Installation 1. Place the new OPDS unit on the seat-back frame. Tighten the two screws, and connect the OPDS unit harness 8P and sensor connector to the OPDS unit. Reinstall the cover. 2. Install the seat-back cover. 3. Install the seat assembly, then connect the side airbag harness 2P connector. 4. Reconnect the battery negative cable. 5. Set the seat-back in the normal position, and make sure there is nothing on the front passenger's seat. 6. Initialize the OPDS unit. 7. After installing the OPDS unit, confirm proper system operation. Turn the ignition switch ON (II); the SRS indicator light should come on for about 6 seconds and then go off. Page 6134 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 2295 NOTE: Use new gaskets and self-locking nuts when reassembling. Key Beeper, Light Chime & Ceiling Light Don't Work Door Switch: Technical Service Bulletins Key Beeper, Light Chime & Ceiling Light Don't Work SOURCE: Honda Service News April 2003 TITLE: Key Beeper, Light Chime, Ceiling Light Don't Work APPLIES TO: 2001-03 Civic, 2002-03 CR-V SERVICE TIP: If the ignition key-in beeper, the headlights-on chime, the ceiling light, and the driver's-dooropen indicator are all on the fritz check the driver's door switch in the doorjamb. A faulty door switch can cause all of these symptoms. Page 4615 10. Connect the connector securely, then install the transmission range switch shaft cap (A). 11. Turn the ignition switch ON (II). Move the shift lever through all gear positions, and check the transmission range switch is synchronization with the A/T gear position indicator. 12. Raise the vehicle, and make sure it is securely supported. 13. Allow the wheels to rotate freely, then start the engine. 14. Move the shift lever through all gear positions, and verify the following: ^ The engine will not start in any position other than N or P. ^ The back-up lights come on when the shift lever is in the R position. Page 7408 28. Antenna Module (Coupe) Page 4212 Transmission Position Switch/Sensor: Diagnostic Aids General Troubleshooting Information General Troubleshooting Information Tips and Precautions Before Troubleshooting 1. Check applicable fuses in the appropriate fuse/relay box. 2. Check the battery for damage, state of charge, and clean and tight connections. NOTE: 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. Handling Connectors - Make sure the connectors are clean and have no loose wire terminals. - Make sure multiple cavity connectors are packed with dielectric grease (except watertight connectors). - All connectors have push-down release type locks (A). - Some connectors have a clip on their side used to attach them to a mount bracket on the body or on another component. This clip has a pull type lock. - Some mounted connectors cannot be disconnected unless you first release the lock and remove the connector from its mount bracket (A). - Never try to disconnect connectors by pulling on their wires; pull on the connector halves instead. - Always reinstall plastic covers. Locations 12. Middle Of Engine Page 1471 Refrigerant: Service and Repair System Evacuation System Evacuation CAUTION: - Air conditioning refrigerant or lubricant vapor can irritate your eyes, nose, or throat. - Be careful when connecting service equipment. - Do not breathe refrigerant or vapor. Use only service equipment that is U.L.-listed and is certified to meet the requirements of SAE J221 0 to remove HFC-134a (R-134a) from the air conditioning system. If accidental system discharge occurs, ventilate work area before resuming service. Additional health and safety information may be obtained from the refrigerant and lubricant manufacturers. 1. When an A/C system has been opened to the atmosphere, such as during installation or repair, it must be evacuated using a R-134a refrigerant recovery/recycling/charging station (If the system has been open for several days, the receiver/dryer should be replaced, and the system should be evacuated for several hours.) 2. Connect a R-134a refrigerant recovery/recycling/charging station (A) to the high-pressure service port (B) and the low-pressure service port (C), as shown, following the equipment manufacturer's instructions. Evacuate the system. 3. If the low-pressure does not reach more than 93.3 kPa (700 mmHg, 27.6 in.Hg) in 15 minutes, there is probably a leak in the system. Partially charge the system, and check for leaks. Page 7948 - 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. - Refer to the scrapping procedures for disposal of the damaged airbag. 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. 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. Page 9213 Diagram 114-3 (Coupe EX) Page 264 DTC P1253 thru P1459 Page 9549 Brake Light Switch: Testing and Inspection Brake Pedal Position Switch Test 1. Disconnect the 4P connector (A) from the brake pedal position switch (B). 2. Check for continuity between the No.1 and No.2 terminals. - There should be continuity when the brake pedal is pressed. - There should be no continuity when the brake pedal is released. 3. Check for continuity between the No.3 and No.4 terminals (with cruise control). - There should be no continuity when the brake pedal is pressed. - There should be continuity when the brake pedal is released. 4. If necessary, adjust or replace the switch, or adjust the pedal height. Page 5354 4. With the engine off, inspect the play (A) on the pedal pad (B) by pushing the pedal by hand. Free Play: 0.4 - 3.0 mm (0.016 - 0.118 inch) 5. If the pedal free play is out of specification, adjust the brake pedal position switch (C). If the pedal free play is insufficient, it may result in brake drag. 6. Push in the brake pedal position switch until its plunger is fully pressed (threaded end (A) touching the pad (B) on the pedal arm). Then, turn the brake pedal position switch clockwise to lock it. Make sure the brake lights go off when the pedal is released. 7. Check the brake pedal free play. Page 5449 Brake Fluid: Service and Repair For further information regarding this component and the system that it is a part of, please refer to Brake Bleeding; Service and Repair. Page 4385 2. Remove the terminal from the female half. 3. Remove the terminal from the male half. 4. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE D: 1. Remove the secondary locks. Paint Code and Color Label Location Paint: Application and ID Paint Code and Color Label Location Paint Code List Paint Code - U.S Model 4-door Paint Code - U.S Model 2-door Paint Code - Canadian Model 4-door Specifications Brake Shoe: Specifications Brake shoes Lining thickness Service Limit ........................................................................................................................................ ......................................... 4.0 mm (0.16 inch) Page 6467 Blower Motor: Locations Heating Component Location Index Locations 12. Middle Of Engine Locations Power Steering Pressure Switch: Locations Idle Control System - Component Location Index 34. Left Side Of Engine Compartment Page 7082 1. On Accords and Pilots, remove the front passenger's seat-back panel by prying out the bottom. Replace the two lower clips. 2. On all models except Accords and Pilots, unzip the two seat cover zippers on the back of the front passenger's seat. 3. Pull back the seat-back cover from the left side bolster to access the OPDS unit cover. 4. Remove the OPDS unit cover from the seat frame. 5. Check the part number of the installed OPDS unit. Page 3957 5. Confirm the control module update by Program ID and Program Part No. Make sure this corresponds with any information provided in the service bulletin for the update you are doing. Click on Yes to continue. Within a few seconds, the CM Update sofiware loads the program file onto the HDS tablet. 6. In the HDS Tablet Programming screen, click on the check mark after programming is completed. 7. In the Updating Honda Control Modules screen, click on the check mark. NOTE: To avoid permanent control module damage, do not turn the ignition switch to LOCK (0) during the update. 8. When updating is complete, follow the screen prompts to turn the ignition switch to LOCK (0), and then to ON (II). To update another system, return to the Updating Honda Control Modules screen by clicking on the exit button on the right side of the screen. UPDATING WITH THE HIM How to Remove the PCM Control Module: Service and Repair How to Remove the PCM How to Remove the PCM for Testing 1. Remove the passenger's dashboard lower cover, the right kick panel, and the glove box. 2. Remove the bolt. Cut the plastic cross brace in the glove box opening with diagonal cutters in the area shown, and discard it. 3. Remove the relays (A), then remove the bolts and the glove box frame (B). 4. Remove the gray 20P PCM wire harness connector from the PCM mounting bracket. Remove the PCM mounting bolt (A) and the bracket. 5. Remove the nuts, then remove the PCM (B). 6. Install the PCM in the reverse order of removal. Page 3949 9. Wait for the MVCI to copy the data for updating the vehicle. 10. After the MVCI has copied the files, a confirmation screen appears. Press ENTER to update the control unit/module, or press ESC to exit. 11. Wait for the MVCI to update the control unit/module. 12. After the MVCI finishes updating the control uniti module, turn the ignition switch to LOCK (0) when directed by the MVCI. 13. Turn the ignition switch back to ON (II) within 60 seconds to complete the updating procedure. NOTE: The MVCI has a countdown timer. If you do not turn the ignition switch to ON (II) within 60 seconds, the MVCI sets an error code. Page 1208 Service and Repair Crankshaft Main Bearing Seal: Service and Repair Installation - In Car Special Tools Required ^ Driver 07749-0010000 ^ Driver attachment 07948-SB00101 or 07VAD-P84010A 1. Dry the crankshaft oil seal housing. 2. Apply a light coat of grease to the crankshaft and to the lip of the seal. 3. Using the special tools, drive in the crankshaft oil seal until the driver bottoms against the engine block end cover. When the seal is in place, clean any excess grease off the crankshaft and check that the oil seal lip is not distorted. Page 9820 Power Window Switch: Testing and Inspection Master Switch Input Test Master Switch Input Test 4-door NOTE: The power window control unit is built into the power window master switch, and it only controls the driver's window operations. 1. Remove the door grip cover. 2. Disconnect the 20P connector (A) from the master switch (B). 3. Inspect the connector and socket terminals to be sure they are all making good contact. - If the terminals are bent, loose or corroded, repair them as necessary, and recheck the system. - If the terminals look OK, make the following input tests at the connector. If a test indicates a problem, find and correct the cause, then recheck the system. - If all the input tests prove OK, the power window master switch must be faulty; replace it. Page 2894 36. Left Side Of Engine Compartment (except GX) Page 5807 220. C103 (Junction Connector) 221. C104 (Junction Connector) Page 7294 1. Remove the terminal. 2. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE G: 1. Remove the terminal. 2. Go to HOW TO INSTALL NEW TERMINALS. How to Install New Terminals HOW TO INSTALL NEW TERMINALS 1. Carefully match the old terminal with a new one from the terminal repair kit. Choose the correct replacement terminal based on the wire size range the terminal will accommodate. NOTE: If the replacement terminal quantities are low, reorder them by using the terminal part number listed on the inside lid of the terminal repair kit. Replacement terminals are available through your parts department using normal parts ordering procedures. 2. Depending on the size of the wire you are repairing, use the proper size slot in the crimping tool. Page 6452 Air Door Actuator / Motor: Testing and Inspection Mode Control Motor Test Mode Control Motor Test 1. Disconnect the 7P connector from the mode control motor. 2. Connect battery power to the No.1 terminal of the mode control motor, and ground the No.2 terminal; the mode control motor should run smoothly, and stop at Vent. If it doesn't, reverse the connections; the mode control motor should run smoothly, and stop at Defrost. When the mode control motor stops running, disconnect battery power immediately. 3. If the mode control motor does not run in step 2, remove it, then check the mode control linkage and doors for smooth movement. - If the linkage and doors move smoothly, replace the mode control motor. - If the linkage or doors stick or bind, repair them as needed. - If the mode control motor runs smoothly, go to step 4. 4. Use a digital multimeter with an output of 1 mA or less at the 20 kOhm range. With the mode control motor running as in step 2, check for continuity between the No.3, 4, 5, and 6 terminals and the No.7 terminal individually. There should be continuity for a moment at each terminal. 5. If there is no continuity for a moment at each terminal, replace the mode control motor. Page 3943 GNA600: (No longer available for purchase) Page 7926 4. Remove the clip (A), and release the fasteners (B), then remove the carpet (C). 2-door: Pull the carpet out from both side trim panels. 5. Install the carpet in the reverse order of removal, and note these items: - Apply liquid thread lock to the seat mounting bolts before reinstallation. - Take care not to damage, wrinkle or twist the carpet. - Make sure the seat harnesses are routed correctly. - Slip the slit (A) in the carpet over the hook. - 2-door: Slip the carpet under the side trim panel on each side properly. - Replace the clip if it's damaged. - Reattach the cut areas under the heater around the shift lever and parking brake lever with wire ties. - When installing new carpet, cut the carpet (B) under the heater area (C), and around the shift lever (D) and parking brake lever (E). After installing the new carpet, reattach the cut areas (D, E) with wire ties. Page 5248 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 Short Circuit Locator (Short Finder) 1. Remove the blown fuse. Leave the battery connected. Page 3211 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 Short Circuit Locator (Short Finder) 1. Remove the blown fuse. Leave the battery connected. Page 3747 Control Module: Service and Repair How to Substitute the PCM How to Substitute the PCM 1. Remove the PCM from the vehicle. 2. Install a known-good PCM in the vehicle. 3. Rewrite the immobilizer code with the PCM replacement procedure in the Honda PGM Tester; It allows you to start the engine. 4. After completing your tests, reinstall the original PCM and rewrite the immobilizer code with the PCM replacement procedure in the HDS Tester again. Page 5391 2. Insert the terminal tool into the female terminal, and then remove the terminal tool. NOTE: Make sure you do not select a terminal tool that is larger than the mating male terminal because it would spread the female terminal and cause a loose fit. 3. Compare the drag to the other terminals in the connector. If the drag is less, replace the terminal with a replacement terminal from the appropriate terminal repair kit. Page 1178 169. Power Window Switch, Passenger's (Coupe Except DX, HX) 232. Power Window Master Switch Page 4241 10. Connect the connector securely, then install the transmission range switch cover. 11. Turn the ignition switch ON (II). Move the shift lever through all gear positions, and cheek the transmission range switch synchronization with the A/T gear position indicator. 12. Allow the wheels to rotate freely, then start the engine. 13. Move the shift lever through all gear positions, and verify the following: ^ The engine will not start in any position other than N or P. ^ The back-up lights come on when the shift lever is in the R position. Page 6070 234. Under-dash Fuse/Relay Box Part 5 Page 798 Wire Color Abbreviations Page 6940 WARRANTY CLAIM INFORMATION Out of warranty: Any repairs to the SRS system for problems other than the 15-1, 15-2, and 15-3 DTCs that are done 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. INSPECTION PROCEDURE NOTE: ^ When you check for SRS DTCs with the HDS, codes other than 15-1, 15-2, and 15-3 are not covered by this warranty extension bulletin. ^ If the vehicle is covered by warranty, repair it using the normal warranty repair procedures. If the vehicle's warranty is expired, give your customer an estimate for the cost of the repair. Do the appropriate inspection, based on the DTC. SRS DTC 15-1 Clear the DTC with the HDS. ^ If DTC 15-1 does not set again, go to REPAIR PROCEDURE A: OPDS UNIT REPLACEMENT. ^ If DTC 15-1 sets again, continue with normal troubleshooting. ^ If the OPDS unit causes DTC 15-1 to set repeatedly, yet passes the other troubleshooting steps, go to REPAIR PROCEDURE A: OPDS UNIT REPLACEMENT. SRS DTC 15-2 1. Inspect the connections and the wiring in the side airbag cutoff indicator circuit. ^ If all the connections and the wiring are OK, go to step 2. ^ If any of the connections or the wiring are faulty, repair the circuit, then go to step 2. 2. Clear the DTC with the HDS. ^ If DTC 15-2 does not set again, go to REPAIR PROCEDURE A: OPDS UNIT REPLACEMENT. ^ If DTC 15-2 sets again, continue with normal troubleshooting. ^ If the OPDS unit causes DTC 15-2 to set repeatedly, yet passes the other troubleshooting steps, go to REPAIR PROCEDURE A: OPDS UNIT REPLACEMENT. SRS DTC 15-3 1. Clear the DTC with the HDS. ^ If DTC 15-3 does not set again, go to step 2. ^ If DTC 15-3 sets again, continue with normal troubleshooting. 2. Ask your customer if electrical devices such as a laptop computer or a fluorescent map light are ever used near the front passenger's seat-back. (Some electrical devices that plug into the vehicle's accessory power socket, especially those using a power inverter/converter, can interfere with the seat-back sensors and cause SRS DTC 15-3 to set.) ^ If your customer uses any of these devices operate the device near the front passenger's seat-back. If DTC 15-3 sets again, clear it, then return the vehicle to the customer. Advise the customer to avoid using the device near the front passenger's seat-back. ^ If your customer does not use any of these devices and DTC 15-3 does not set again, go to REPAIR PROCEDURE A: OPDS UNIT REPLACEMENT. REPAIR PROCEDURE A: OPDS UNIT REPLACEMENT Page 3026 Crankshaft Position Sensor: Description and Operation Crankshaft Position (CKP) Sensor The CKP sensor detects engine speed, and is used by the ECM/PCM to determine ignition timing and timing for fuel injection of each cylinder. Page 2540 8. Inspect the quality of the wire crimp. If it has any of the following NO GOOD crimps, cut it off and start over. 9. Insert the terminal into the connector. Make sure the wire seals are pushed all the way into the connector. Lightly pull on the wires to make sure the terminal is locked into place. 10. Close or insert the secondary terminal lock, if applicable, and reconnect the connector. How to Install Pigtail Terminals HOW TO INSTALL PIGTAIL TERMINALS Pigtail terminals (short pieces of wire with a factory crimped terminal) are used when the wire is too short or when access to the connector is too restricted to make a terminal repair. NOTE: To replace just a connector terminal, go to How to Replace Connector Terminals. IMPORTANT SAFETY INFORMATION: On some models, the SRS wires are in a separate harness. If the SRS harness is damaged, replace the harness; do not repair it. On other models, wire harnesses include yellow SRS wires. If any SRS wire is damaged, replace the entire harness; do not repair it. 1. Remove the damaged or faulty terminal from the connector. Use the proper removal tool from Pin Tool Set. Page 6627 Under-hood Fuse/Relay Box Page 1664 Wires Locations Relay And Control Unit Locations - Engine Compartment Locations 120. Driver's Door (Sedan except DX) Page 2782 ECM/PCM Inputs And Outputs At Connector E (31P) Page 6750 Side Airbag: 6. Disconnect the 2P connector between the side airbag (A) and the floor wire harness. Seat belt tensioner: 7. Disconnect the 2P connector between the seat belt tensioner (A) and floor wire harness. Seat belt buckle tensioner: 8. Disconnect the 4P connector between the seat belt buckle tensioner (A) and floor wire harness. 9. Pull the seat belt out all the way and cut it. Page 8256 19. Using your thumb and forefinger to hold the tumblers, remove the key from the inner cylinder, being careful not to drop any tumblers and springs. 20. *Using the key code from the iN that you have written down at step 2, build a new inner cylinder with new springs, new cylinder, and tumblers from the door lock cylinder kit. Make sure you put the appropriate numbered tumbler in the proper inner cylinder cavity. Apply a thin layer of Permalube to each tumbler to help lubricate and retain it.* NOTE: ^ There are two types of tumblers. The "SUBLOCK" tumbler goes only in cavity A." The "DISC" tumbler goes in cavities "B" through "J." ^ Cavity "E" is empty on all cylinders. Fuel System - FTP Sensor Diagnostics/DTC P0497 Fuel Tank Pressure Sensor: Technical Service Bulletins Fuel System - FTP Sensor Diagnostics/DTC P0497 How to Tell a Bad FTP Sensor From an EVAP Leak Troubleshooting a '01-05 Civic with DTC P0497 (EVAP system low purge flow)? When the fuel tank pressure (FTP) sensor doesn't respond to vacuum testing, it's really easy to think you've got a leak in the FVAP system. Here's an simple way to tell if the problem is just a bad FTP sensor or an actual system leak: 1. Connect the HDS to the 16P DLC. Turn the ignition switch to ON (II). Turn on the HDS. 2. At the screen prompts, enter the VIN (if you're asked) and the odometer reading. 3. From the Select Mode screen, select Honda Systems. From the System Selection Menu, select PGM-FI. From the Mode Menu, select All Data List. 4. Disconnect the two FTP sensor vacuum lines. Look at the FTP Sensor value on the display screen. ^ If the value reads between 2.45 and 2.55 volts, go to step 6. ^ If the value doesn't read between 2.45 and 2.55 volts, check the electrical connections. If you find any problems, fix them, then go to step 5. If the circuits are OK, replace the FTP sensor, then go to step 5. 5. Look at the FTP Sensor value on the display screen. ^ If the value now reads between 2.45 and 2.55 volts, reconnect the vacuum lines and disconnect the HDS. Return the vehicle to your customer. ^ If the value still doesn't read between 2.45 and 2.55 volts, go to step 6. 6. Connect a vacuum pump to the larger FTP sensor hose (the smaller hose is the FTP vent) Slowly squeeze the pump handle to pull a vacuum on the FTP sensor. Look at the sensor value on the display screen. ^ If the value changes, continue troubleshooting for DTC P0497. ^ If the value stays the same, the FTP sensor has a leak. Replace the sensor. Locations Relay And Control Unit Locations - Dashboard Page 5859 Relay Box: Service and Repair Removal and Installation SRS components are located in this area. Review the SRS component locations and precautions and procedures in the SRS section before performing repairs or service. Removal 1. Make sure you have the anti-theft code for the radio, then write down the frequencies for the radio's preset buttons. 2. Disconnect the battery negative cable, then disconnect the positive cable, and wait at least 3 minutes. 3. Remove the dashboard lower cover. 4. Disconnect the connectors from the fuse side of the under-dash fuse/relay box. 5. Remove the mounting bolt and slide the under-dash fuse/relay box (A) down from the bracket (B). 6. Disconnect the connectors from the back side of the under-dash fuse/relay box, and remove the fuse/relay box. NOTE: The SRS connector is a spring-loaded lock type. Installation 1. Install the under-dash fuse/relay box in the reverse order of removal and connect all connectors to the under-dash fuse/relay box. 2. Install the dashboard lower cover. 3. Connect both the negative cable and positive cable to the battery. 4. Enter the anti-theft code for the radio, then enter the customer's radio station presets. 5. Confirm that all systems work properly. 6. Do the ECM/PCM idle learn procedure. Page 3179 8. Connect the GRN test harness clip (D) to the positive probe of a voltmeter. Is there 5 V or more? YES - Go to step 9. NO - Repair short or open in the BLU/WHT or WHT/GRN wire between the VSS and the cruise control unit, or the ECM/PCM. 9. Turn the ignition switch OFF. 10. Connect the other test harness connector (A) to the VSS(B). 11. Raise the front of the vehicle, and make sure it is securely supported. 12. Put the vehicle in neutral with the ignition switch ON (II). 13. Slowly rotate one wheel with the other wheel blocked. Does voltage pulse from 0 to about 5 V or more? YES - Go to step 14. NO - Replace the VSS. Page 3926 9. Click on the check mark to begin the control unit/module update. NOTE: To avoid control unit/module damage, do not interrupt the update. 10. Within 60 seconds of update completion, turn the ignition switch to LOCK (0) and then back to ON (II). 11. Once the software verifies that the control unit/module has been successfully updated, click on Yes to update another identical vehicle, or click on No to exit the update program. HIM Updating in Storage Mode NOTE: If the red No.3 on the HIM comes on or flashes during the update, go to Diagnosing HIM Error Codes. 1. If not already done, load the latest HDS PC software onto your iN workstation. For loading instructions, refer to the Tool Information publication Installation Instructions for HDS PC So ftware on ISIS. NOTE: If the latest sofiware is not loaded and you do a control unit/module update, the software may indicate the vehicle has the latest update when it doesn't. Updates not done with the latest software are not covered under warranty. 2. From the iN workstation desktop, select CM Update (ECU Rewrite). 3. Click on the tools button on the right side of the screen, and make sure the interface device is set to HIM. 4. Return to the Updating Honda Control Modules main screen, then select Storage Mode and follow the on-screen instructions. 5. Take the HIM to the vehicle, and connect it to the vehicle's DLC. 6. Turn the ignition switch to ON (II), and wait until the green No.1 LED on the HIM stays on. Turn the ignition switch to LOCK (0), and disconnect Page 5627 9. Open the jaws with the jaws knob, and slide the original key with its flat side down into the center jaw up to the key stop. Slide the key blank with its flat side down into the right jaw up to the key stop. Close the jaws with the jaws knob to lock the keys into place. Visually inspect both keys for proper alignment in the jaws. 10. Loosen the lateral and spring tension adjustment knobs on the clamp carriage. With the clamp carriage lever, adjust the clamp carriage to position the tracer and the cutter bit over the middle of the two locked key blades. Tighten only the spring tension knob when done. NOTE: The clamp carriage has a spring system that puts lateral pressure on the tracer and cutting bit to make it easier to cut sidewinder-type keys. Do not tighten the lateral tension adjustment knob. This knob should be left loose. 11. Turn on the cutter motor with the motor start switch. [NOTICE] ^ To avoid damaging the locking jaws while cutting, keep your hand off the vertical carriage lever. Pressure on the lever will change the cutting depth. * ^ To avoid breaking the cutter bit, never back up while cutting.* ^ Wear proper eye protection (safety glasses, goggles, etc.) Page 8764 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 Short Circuit Locator (Short Finder) 1. Remove the blown fuse. Leave the battery connected. Page 3411 47. Injectors Page 6657 43. Evapoator Temperature Sensor Diagrams Page 6819 1. On Accords and Pilots, remove the front passenger's seat-back panel by prying out the bottom. Replace the two lower clips. 2. On all models except Accords and Pilots, unzip the two seat cover zippers on the back of the front passenger's seat. 3. Pull back the seat-back cover from the left side bolster to access the OPDS unit cover. 4. Remove the OPDS unit cover from the seat frame. 5. Check the part number of the installed OPDS unit. Page 4510 9. Measure the clutch disc thickness. If the thickness is less than the service limit, replace the clutch disc. Standard (New): '01 model: 8.3 - 9.0 mm (0.33 - 0.35 inch) max. '02-03 models: 8.5 - 9.1 mm (0.34 - 0.36 inch) max. Service Limit: '01 model: 5.7 mm (0.22 inch) '02-03 models: 5.8 mm (0.23 inch) 10. Measure the rivet depth from the clutch disc lining surface (A) to the rivets (B) on both sides. If the rivet depth is less than the service limit, replace the clutch disc. Standard (New): 1.65 - 2.25 mm (0.065 - 0.089 inch) max. Service Limit: 0.8 mm (0.03 inch) Page 267 DTC P1679 thru P1860 Page 7330 Page 8148 Page 1035 7. Apply a small amount of Permalube grease to the base of the new lever. Then attach the slide hammer to the new lever pin, insert the lever into the ignition switch, and seat the pin with the slide hammer. 8. Check the installed height of the pin with vernier calipers. If the height is more than 5.0 mm, the pin is not seated. If needed, reattach the slide hammer, and seat the pin. NOTE: It's normal for the interlock lever to be loose, even when the pin is fully seated. 9. Install a new spring on the lever. Make sure you attach the ends of the spring correctly: ^ The right end goes into the slot on the ignition switch. Locations EVAP System - Component Location Index Diagrams 40. EVAP Bypass Solenoid Valve (except GX) Page 913 Impact Sensor: Service Precautions SRS Unit, Front Impact Sensors, and Side Impact Sensors - Be careful not to bump or impact the SRS unit, front impact sensors, or side impact sensors whenever the ignition switch is ON (II), or for at least 3 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, front impact sensors, and side impact sensors. The airbags could accidentally deploy and cause damage or injury. - After a collision in which any airbags or seat belt tensioners were deployed, replace the SRS unit, front impact sensors, and other related components. After a collision in which a side airbag was deployed, replace the side impact sensor on the deployed side 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, front impact sensors, and side impact sensors. If there is any damage, replace the SRS unit, front impact sensors and/or side impact sensors. - Do not disassemble the SRS unit, front impact sensors, or the side impact sensors. - Turn the ignition switch OFF, disconnect the battery negative cable, and wait at least 3 minutes before beginning installation or replacement of the SRS unit, or disconnecting the connectors from the SRS unit. - Be sure the SRS unit, front impact sensors, and side impact sensors are installed securely with the mounting bolts torqued to 9.8 N.m (1.0 kgf.m, 7.2 lbf.ft) - Do not spill water or oil on the SRS unit, front impact sensors, or side impact sensors, and keep them away from dust. - Store the SRS unit, front impact sensors, and side impact sensors in a cool (less than 104 °F/40 °C) and dry (less than 80 % relative humidity, no moisture) area. Page 4488 32. Clutch Interlock Switch (M/T) Page 3686 Shift Indicator: Locations Continuously Variable Transmission Component Location Index Service and Repair Sun Shade: Service and Repair Sunshade Replacement 1. Remove the drain channel 2. Slide the sunshade (A) until you can see both sunshade slider spacers (B). 3. Remove the screws, then remove both spacers. 4. While lifting the front portion of the sunshade (A), move the sunshade forward until you can see both sunshade rear hooks (B). Do not damage the sunshade and hooks. 5. Remove the screws, then remove both hooks. Page 6072 234. Under-dash Fuse/Relay Box Part 7 Page 3243 Diodes Light Emitting Diode (LED) Motor Pressure Sensor Page 1492 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 1464 Refrigerant: Technician Safety Information 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. IMPORTANT: * Always wear safety goggles and protective gloves when working on refrigerant systems. * Beware of the danger of carbon monoxide fumes caused by running the engine. * Beware of discharged refrigerant in enclosed or improperly ventilated garages. * Always disconnect the negative battery cable and discharge and recover the refrigerant whenever repairing the air conditioning system. CAUTION: Avoid breathing A/C Refrigerant-134a and lubricant vapor and mist. Exposure may irritate eyes, nose, and throat. To remove R-134a from the A/C system, use service equipment certified to meet the requirements of SAE J2210 (R-134a recycling equipment). If accidental system discharge occurs, ventilate the work area before resuming service. Additional health and safety information may be obtained from the refrigerant and lubricant manufacturers. IMPORTANT: * Do not mix R-12 refrigerant and R-134a refrigerant, even in the smallest amounts. R12 and R-134a are incompatible with each other. If the refrigerants are mixed, compressor failure is likely to occur. * Use only the specified lubricant (PAG) for the R-134a A/C system and R-134a components. If you use lubricants other than those specified, compressor failure is likely to occur. Coat all the fittings and the O-ring seals with clean 525 viscosity refrigerant oil in order to provide a leak-proof seal and in order to aid in assembly and disassembly. * Do not store or heat the refrigerant containers above 52 °C (125 °F). * Do not heat a refrigerant container with an open flame. If the container must be warmed, place the bottom of the container in a pail of warm water. * Do NOT intentionally do the following to the refrigerant containers: Drop - Puncture - Incinerate * Refrigerant will displace oxygen. Work in well ventilated areas in order to prevent suffocation. * Do NOT introduce compressed air to any refrigerant container or refrigerant component. Contamination will occur. * If you must carry a container of DOT CFR Refrigerant-134a in a vehicle, do not carry the refrigerant in the passenger compartment. All of the Refrigerant-134a disposable, blue containers are shipped with a heavy metal screw cap in order to protect the valve and the safety plug of the container from damage. Replace the cap after each use of the container in order to continue the protection. Page 158 Wires Page 1764 2. Remove the terminal (same procedure for male and female). 3. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE E: 1. Remove the secondary locks. 2. Remove the terminal (same procedure for male and female). 3. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE F: Page 3881 Transmission Position Switch/Sensor: Service and Repair Transmission Range Switch Replacement 1. Remove the intake air duct and resonator. 2. Shift to the N position. 3. Remove the transmission range switch shaft cap (A). 4. Disconnect the transmission range switch connector (A). 5. Remove the transmission range switch (B). 6. Make sure that the control lever is in the N position. Page 4988 2. Remove the terminal from the female half. 3. Remove the terminal from the male half. 4. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE D: 1. Remove the secondary locks. Front Seat Belt: Service and Repair Front Front Seat Belt Front Seat Belt Replacement SRS components are located in this area. Review the SRS component locations and the precautions and procedures, in the SRS section before performing repairs or service. NOTE: Check the front seat belts for damage, and replace them if necessary. Be careful not to damage them during removal and installation. Front Seat Belt-2-door 1. Make sure you have the anti-theft code for the radio, then write down the frequencies for the preset buttons. 2. Disconnect the negative cable from the battery, and wait at least 3 minutes before beginning work. 3. Slide the front seat forward fully. 4. '01-02 models: Remove the lower anchor bolts (A), then remove the slide bar (B). 5. '03 model: Remove the lower anchor cap (A), and remove the lower anchor bolt (B). 6. Remove the side trim panel. Page 5682 1. Cut off the female S terminal from the harness, making the cut as close to the terminal as possible. 2. Strip 6 mm of insulation from the wire using the 2.0 slot on the crimping tool. NOTE: Make sure no wire strands were removed when you stripped the insulation. If any were removed, cut the wire off even with the insulation, and strip it again. 3. Insert the wire into the new terminal so it fits as shown. 4. Using the 2.0 slot on the crimping tool, position the terminal in the tool slot with the solid portion of the terminal toward the anvil and the open section toward the former. Page 9628 Wire Color Abbreviations Page 6087 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 3658 Torque Converter Clutch Solenoid: Service and Repair Torque Converter Clutch Solenoid Valve Replacement 1. Remove the mounting bolt and the torque converter clutch solenoid valve (A). 2. Install a new torque converter clutch solenoid valve with new O-rings (B). While installing the valve, do not allow dust or other foreign particles to enter the transmission. 3. Check the connector for rust, dirt, or oil, then connect the connector securely. Page 9402 1. Remove the secondary lock from the male terminal half. 2. Remove the secondary lock from the female terminal half. 3. Remove the terminal (same procedure for male and female). 4. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE C: 1. Remove the secondary lock. Page 665 53. Steering Wheel (Airbag Inflators Removed) Shift Solenoid Valves A and B Test Shift Solenoid: Testing and Inspection Shift Solenoid Valves A and B Test Shift Solenoid Valves A and B Test 1. Disconnect the shift solenoid valves A and B connector. 2. Measure shift solenoid valve A resistance between the No. 1 terminal of the shift solenoid valves A and B connector and body ground, and measure shift solenoid valve B resistance between the No. 2 terminal and body ground. STANDARD: 12 - 25 Ohms 3. Replace the shift solenoid valves A and B if either resistance is out of standard. 4. If the resistance is within the standard, connect the No. 1 terminal of the shift solenoid valve A to the battery positive terminal. A clicking sound should be heard. Connect the No. 2 terminal to the battery positive terminal. A clicking sound should be heard. Replace the shift solenoid valves A and B if no clicking sound is heard when either terminal is connected to the battery terminal. Page 1420 Fluid - A/T: Service and Repair ATF Replacement ATF Replacement NOTE: Keep all foreign particles out of the transmission. 1. Bring the transmission up to operating temperature (the radiator fan comes on) by driving the vehicle. 2. Park the vehicle on level ground, and turn the engine off. 3. Remove the drain plug, and drain the automatic transmission fluid (ATF). NOTE: If a cooler flusher is to be used, refer to ATF Cooler Flushing. 4. Reinstall the drain plug with a new sealing washer. 5. Refill transmission with the recommended fluid into dipstick hole to the upper mark on the dipstick. Always use Honda ATF-Z1 Automatic Transmission Fluid (ATF). Using a non-Honda ATF can affect shift quality. Automatic Transmission Fluid Capacity: 2.7 L (2.9 US qt) at changing 6.0 L (6.3 US qt) at overhaul Page 7274 Resistor Variable Sensor Solenoid Transistors Circuit Schematics Page 6062 Under-hood Fuse/Relay Box (2-door) Page 5868 Rear Window Defogger Component Location Index Service and Repair Front Crankshaft Seal: Service and Repair Installation - In Car Special Tools Required Inner driver handle 07746-0030100 1. Dry the crankshaft oil seal housing. 2. Apply a light coat of grease to the crankshaft and to the lip of the seal. 3. Using the seal driver, drive in the crankshaft oil seal until the driver bottoms against the oil pump. When the seal is in place, clean any excess grease off the crankshaft and check that the oil seal lip is not distorted. Diagrams Page 5630 ^ Going from front to back, use the middle lock pin to set the first cam to the appropriate key code number in the code book. (The cam is properly set when the number on the cam lines up with the red scribe mark on the clamp unit.) ^ Slide the lock pin through the notch in the cam. (This locks the cam in place.) ^ Keep doing this for each of the remaining cams in the set until all the cams are set and locked, then push the lock pin all the way in. Repeat this process to set and lock the cams for the right cam set. NOTE: Make sure you set the MIS cam in the right cam set for the type of key you are cutting. For a master key, set the cam to M; for a valet key, set it to S. When you are done, push all the cam blades to the left until they touch the cams in the left cam set. 10. Pull the vertical carriage lever toward you until the tracer touches the flat surface on the right side at the front of the cams. Gently twist the lever clockwise to lock the vertical carriage at this height. Do not overtighten the lever. 11. Turn on the cutter motor with the motor start switch. [NOTICE] ^ To avoid damaging the locking jaws while cutting, keep your hand off the vertical carriage lever. Pressure on the lever will change the cutting depth. * ^ To avoid breaking the cutter bit, never back up while cutting.* ^ Wear proper eye protection (safety glasses, goggles, etc.) 12. Use the clamp carriage lever and the tracer to follow the contours of the cam blades from front to back. (The cutter bit cuts the same contours into the right edge of the key blank, from head to tip.) Page 317 155. A/F Sensor Relay (HX; '04-'05: DX, EX, LX) Diagram Information and Instructions Transmission Position Switch/Sensor: Diagram Information and Instructions Terminal Numbering System Terminal Numbering System Connector terminals are numbered according to the cavities they're in. The cavities are numbered starting from the upper left, looking at the male terminals from the terminal side or looking at the female terminals from the wire side. Both views are in the same direction so the numbers are the same. All actual cavities are numbered, even if they have no wire terminals in them. NOTE: Data Link Connector (DLC) terminals are numbered according 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 below is #6. Page 1340 without disconnecting the P/S hoses. 7. Remove the alternator. 8. Remove the four ignition coils. 9. Remove the throttle cable clamps (A) and harness holder (B) from the cylinder head cover. 10. Remove the cylinder head cover. 11. Hold the pulley with holder handle (A) and holder attachment (B). 12. Remove the bolt with a heavy duty 19 mm socket (C) and breaker bar. 13. Support the engine with a jack and wood block under the oil pan. Page 3231 Transmission Position Switch/Sensor: Service and Repair Transmission Range Switch Replacement 1. Raise the vehicle, and make sure it is securely supported. 2. Shift to the N position. 3. Remove the transmission range switch cover (A). 4. Disconnect the transmission range switch connector (B). 5. Remove the old transmission range switch, and install the new switch. 6. Make sure that the control shaft is in the N position. If necessary, move the shift lever to the N position. Ignition/Locks - Cutting Sidewinder-Type Keys Technical Service Bulletin # 01-077 Date: 060419 Ignition/Locks - Cutting Sidewinder-Type Keys 01-077 April 19, 2006 Applies To: Models With Sidewinder-Type Keys - All Cutting Sidewinder-Type Keys With the MATRIX H Key Cutting Machine (Supersedes 01-077, dated January 12, 2005) Updated information is noted by asterisks. MATRIX H Key Cutting Machine, manufactured by Silca and supplied by Kaba Ilco Corporation, is a portable, power-operated tool that cuts sidewinder-type automotive keys exclusively. The machine lets you cut these keys either by copying or by code. The code function is designed and built to meet the Honda code requirements. No other similar machine has this capability. This service bulletin gives you information for ordering and servicing this special tool, and guides you through the entire key cutting process from setting up the machine to cutting the key blank. TOOL INFORMATION Order through the Honda Tool and Equipment Program: MATRIX H Key Cutting Machine: Model No. ILCMATRIXSH Cutter Bit: Model No. ILCF3O Fixed Jaw: Model No. ILCMTX-H Mobile Jaw (Right Side): Model No. ILCRTMTX-H Mobile Jaw (Left Side): Model No. ILCLTMTX-H *Remanufactured Clamp Unit: Model No. ILCMATRIXHCR* PARTS INFORMATION *For some models, there are two choices for sidewinder-type key blanks: ^ T-5 sidewinder key blanks ^ Honda sidewinder key blanks For other models, only Honda sidewinder key blanks can be used. See DETERMINING WHICH KEY TO USE to determine which key blank you should choose. Ordering T-5 key blanks through the Honda Tool and Equipment Program: T-5 Programmable Key Blank (Master): P/N ILC-35111-T-5H T-5 Programmable Key Blank (Valet): P/N ILC-35112-T-5H Practice Key Blanks (five per pack): ILC-35111DEMO* NOTE: Do not use practice key blanks for replacement purposes. Practice keys do not have an immobilizer chip. Page 2739 Electric Load Sensor: Locations PGM-FI System - Component Location Index Page 5916 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. Circuits must be operating when checking voltage drop. 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. 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 off, 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 Self-Powered Test Light or DVOM 1. Remove the blown fuse and disconnect the battery and load. Page 5979 234. Under-dash Fuse/Relay Box Part 5 Page 2017 9. Clean all oil off the inside face (A) of the crankshaft pulley, and apply lubricant to the pulley bolt (B) and washer (C). 10. Install the crankshaft pulley, and hold the pulley with holder handle (A) and holder attachment (B). 11. Tighten the bolt to 20 Nm (2.0 kgf-cm, 14 ft. lbs.) with a torque wrench and 19 mm socket (C). 12. Tighten the pulley bolt an additional 90°. 13. Rotate the crankshaft pulley about five or six turns counter clockwise so that the timing belt positions on the pulleys. 14. Turn the crankshaft pulley so its TDC mark (A) lines up with the pointers (B). Page 7440 Diodes Light Emitting Diode (LED) Motor Pressure Sensor Page 6942 ^ If the OPDS unit has an original part number, go to step 6. ^ If the OPDS unit has a new part number (refer to PARTS INFORMATION) or higher, go to REPAIR PROCEDURE B: OPDS SENSOR REPLACEMENT. 6. Recline the seat-back to access the OPDS unit mounting screws. 7. Remove the mounting screws from the OPDS unit, and gently pull out the unit. 8. Disconnect the OPDS connectors, then remove the OPDS unit. 9. Install a new OPDS unit, then snap on its cover. 10. Slip the seat-back cover over the OPDS unit. 11. On Accords, check the seat-back clip attachment bosses on the seat-back panel: ^ If the attachment bosses are OK, go to step 12. ^ If the seat-back has a pocket, and the attachment bosses are deformed or damaged, do the repair procedure in S/B 02-010, Seat-Back Panel Is Loose or Detached. Then go to step 12. ^ If the seat-back does not have a pocket, and the attachment bosses are deformed or damaged, replace the seat-back. Then go to step 12. Page 5995 3. Remove the terminal (same procedure for male and female). 4. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE C: 1. Remove the secondary lock. 2. Remove the terminal from the female half. Page 7491 Rear Bumper: Service and Repair Rear Bumper Removal/Installation Special Tools Required KTC trim tool set SOJATP2014 2-door NOTE: - Have an assistant help you when removing and installing the rear bumper. - Take care not to scratch the rear bumper and body. - Use the appropriate tool from the KTC trim tool set to avoid damage when prying components. - Put on gloves to protect your hands. 1. Remove the rear bumper as shown. 2. Install the bumper in the reverse order of removal, and note these items: - Make sure the rear bumper engages the hooks of the side spacers, upper spacers and upper brackets on both sides securely. - Replace any damaged clips. Special Tools Required KTC trim tool set SOJATP2014 4-door NOTE: - Have an assistant help you when removing and installing the rear bumper. - Take care not to scratch the rear bumper and body. - Use the appropriate tool from the KTC trim tool set to avoid damage when prying components. - Put on gloves to protect your hands. Diagram Information and Instructions Body Control Systems: Diagram Information and Instructions Terminal Numbering System Terminal Numbering System Connector terminals are numbered according to the cavities they're in. The cavities are numbered starting from the upper left, looking at the male terminals from the terminal side or looking at the female terminals from the wire side. Both views are in the same direction so the numbers are the same. All actual cavities are numbered, even if they have no wire terminals in them. NOTE: Data Link Connector (DLC) terminals are numbered according 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 below is #6. Page 4995 8. Inspect the quality of the wire crimp. If it has any of the following NO GOOD crimps, cut it off and start over. 9. Insert the terminal into the connector. Make sure the wire seals are pushed all the way into the connector. Lightly pull on the wires to make sure the terminal is locked into place. 10. Close or insert the secondary terminal lock, if applicable, and reconnect the connector. How to Install Pigtail Terminals HOW TO INSTALL PIGTAIL TERMINALS Pigtail terminals (short pieces of wire with a factory crimped terminal) are used when the wire is too short or when access to the connector is too restricted to make a terminal repair. NOTE: To replace just a connector terminal, go to How to Replace Connector Terminals. IMPORTANT SAFETY INFORMATION: On some models, the SRS wires are in a separate harness. If the SRS harness is damaged, replace the harness; do not repair it. On other models, wire harnesses include yellow SRS wires. If any SRS wire is damaged, replace the entire harness; do not repair it. 1. Remove the damaged or faulty terminal from the connector. Use the proper removal tool from Pin Tool Set. Page 799 Wires Page 2271 Water Pump: Testing and Inspection Inspection 1. Remove the timing belt. 2. Turn the water pump pulley counterclockwise. Check that it turns freely. 3. Check for signs of seal leakage. A small amount of "weeping" from the bleed hole (A) is normal. Page 5259 8. Inspect the quality of the wire crimp. If it has any of the following NO GOOD crimps, cut it off and start over. 9. Insert the terminal into the connector. Make sure the wire seals are pushed all the way into the connector. Lightly pull on the wires to make sure the terminal is locked into place. 10. Close or insert the secondary terminal lock, if applicable, and reconnect the connector. How to Install Pigtail Terminals HOW TO INSTALL PIGTAIL TERMINALS Pigtail terminals (short pieces of wire with a factory crimped terminal) are used when the wire is too short or when access to the connector is too restricted to make a terminal repair. NOTE: To replace just a connector terminal, go to How to Replace Connector Terminals. IMPORTANT SAFETY INFORMATION: On some models, the SRS wires are in a separate harness. If the SRS harness is damaged, replace the harness; do not repair it. On other models, wire harnesses include yellow SRS wires. If any SRS wire is damaged, replace the entire harness; do not repair it. 1. Remove the damaged or faulty terminal from the connector. Use the proper removal tool from Pin Tool Set. Page 7455 1. Remove the secondary lock from the male terminal half. 2. Remove the secondary lock from the female terminal half. 3. Remove the terminal (same procedure for male and female). 4. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE C: 1. Remove the secondary lock. Locations Relay And Control Unit Locations - Engine Compartment Locations Relay And Control Unit Locations - Dashboard Page 3534 125. TP Sensor Page 1293 Fuel Pressure: Testing and Inspection Fuel Pressure Test Special Tools Required - Fuel pressure gauge 07406-004000A - Fuel pressure gauge set 07ZAJ-S5A0100 1. Relieve the fuel pressure. 2. Disconnect the quick-connect fitting (A). Attach the fuel pressure gauge set and fuel pressure gauge. 3. Start the engine and let it idle. - If the engine starts, go to step 5. - If the engine does not start, go to step 4. 4. Check to see if the fuel pump is running: listen to the fuel fill port with the fuel fill cap removed. The fuel pump should run for 2 seconds when the ignition switch is first turned on. If the pump runs, step 5. - If the pump does not run, perform the fuel pump circuit troubleshooting. 5. Read the pressure gauge. The pressure should be 270 - 320 kPa (2.8 - 3.3 kgf/sq.cm, 40 - 47 psi) - If the pressure is OK, the test is complete. - If the pressure is out of specification, replace the fuel pressure regulator and the fuel filter, then recheck the fuel pressure. Page 5603 14. With a hammer and the special tools, install a new front bearing in the drive-end housing. Alternator Brush Inspection 15. Measure the length of both brushes with a vernier caliper. - If either brush is shorter than the service limit, replace the rear housing assembly. - If brush length is OK, go to step 16. Rotor Slip Ring Test 16. Check that there is continuity between the slip rings(A). - If there is continuity, go to step 17. - If there is no continuity, replace the rotor assembly. 17. Check that there is no continuity between each slip ring (A) and the rotor (B) and the rotor shaft (C). - If there is no continuity, replace the rear housing assembly, go to step 18. - If there is continuity, replace the rotor assembly. Alternator Reassembly Locations Page 1816 15. Use the wooden handle of a hammer (A) to drive out the pistons (B). 16. Reinstall the connecting rod bearing and caps after removing each piston/connecting rod assembly. 17. To avoid mix-up on reassembly, mark each piston/connecting rod assembly with its cylinder number. NOTE: The existing number on the connecting rod does not indicate its position in the engine, it indicates the rod size. Page 2709 82. Under Middle Of Dash Body - Power Windows Inoperative/Intermittent Operation Power Window Switch: All Technical Service Bulletins Body - Power Windows Inoperative/Intermittent Operation 06-010 March 8, 2006 Applies To: 2001-05 Civic - All LX and EX 4-door 2003-05 Civic Hybrid - ALL 2001-05 Civic GX ALL Power Window Does Not Work or Works Intermittently SYMPTOM One or more of the power windows does not work or works intermittently from the power window master switch (in the driver's door). PROBABLE CAUSE The power window master switch is faulty. CORRECTIVE ACTION Replace the power window master switch. PARTS INFORMATION WARRANTY CLAIM INFORMATION In warranty: The normal warranty applies. Operation Number: 744100 Flat Rate Time: 0.2 hr Failed Part: P/N 35750-S5A-A01ZA H/C 6453419 Defect Code: 03217 Symptom Code: 01201 Template ID: 06-010A (Black Switch) 06-010B (Medium Taupe Switch) 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 5359 Wire Color Abbreviations Page 6144 Alignment: Service and Repair Wheel Alignment The suspension can be adjusted for front camber, front toe, and rear toe. However, each of these adjustments are interrelated to each other. For example, when you adjust toe, the camber changes. Therefore, you must adjust the front wheel alignment whenever you adjust camber or toe. Pre-Alignment Checks For proper inspection and adjustment of the wheel alignment, do these checks: 1. Release the parking brake to avoid an incorrect measurement. 2. Make sure the suspension is not modified. 3. Check the tire size and tire pressure. Tire size: Front/rear: P185/70R14 87S P185/65R15 86H P195/60R15 87H Tire pressure: Front/rear:210 kPa (2.1 kgf/cm2, 30 psi) 4. Check the runout of the wheels and tires. 5. Check the suspension ball joints. (Hold a wheel with your hands, and move it up and down and right and left to check for wobbling). 6. Bounce the vehicle up and down several times to stabilize the suspension. Front Caster Inspection Use commercially available computerized four wheel alignment equipment to measure wheel alignment (caster, camber, toe, and turning angle). Follow the equipment manufacturer's instructions. Check the caster angle. If the caster angle is not within the specification, check for bent or damaged suspension components. Front caster angle: 1°33' ± 1° for '01-02 models 2°14' ± 1° for '03-04 models Front Camber Inspection Use commercially available computerized four wheel alignment equipment to measure wheel alignment (caster, camber, toe, and turning angle). Follow the equipment manufacturer's instructions. Check the camber angle. If the camber angle is not within the specification, adjust the camber. Front camber angle: 0°00' ± 45' Front Camber Adjustment The front camber can be adjusted by exchanging one or both of the damper pinch bolts with the smaller diameter adjusting bolt(s). The difference between the adjusting bolt diameter and the pinch bolt hole diameter allows a small range of adjustment. Page 9571 72. Behind Hazard Warning Switch Page 2924 Power Steering Pressure Signal: Description and Operation Power Steering Pressure (PSP) Switch The PSP switch signals the ECM/PCM when the power steering load is high. Page 543 Brake Switch (Cruise Control): Testing and Inspection Brake Pedal Position Switch Test 1. Disconnect the 4P connector (A) from the brake pedal position switch (B). 2. Check for continuity between the No.1 and No.2 terminals. - There should be continuity when the brake pedal is pressed. - There should be no continuity when the brake pedal is released. 3. Check for continuity between the No.3 and No.4 terminals (with cruise control). - There should be no continuity when the brake pedal is pressed. - There should be continuity when the brake pedal is released. 4. If necessary, adjust or replace the switch, or adjust the pedal height. Locations Crankshaft Position Sensor: Locations PGM-FI System - Component Location Index Page 8684 15. Right Side Of Engine Compartment (Coupe: LX, EX) 16. Rt. Side Of Eng. Comp. (USA: HX; Sedan: LX, EX, GX) Page 1298 Idle Speed: Testing and Inspection Idle Speed Inspection NOTE: - Leave the Idle Air Control (IAC) valve connected. - Before checking the idle speed, check these items: The Malfunction Indicator Lamp (MIL) has not been reported on. - Ignition timing - Spark plugs - Air cleaner - PCV system - On Canadian models, pull the parking brake lever up, start the engine, then check that the headlights are off. 1. Disconnect the Evaporative Emission (EVAP) canister purge valve 2P connector. 2. Connect a tachometer. 3. Start the engine. Hold the engine at 3,000 rpm with no load (in neutral) unit the radiator fan comes on, then let it idle. 4. Check the idle speed with no-load conditions: headlights, blower fan, radiator fan, and air conditioner are not operating. 5. Idle the engine for 1 minute with the heater fan switch on HI and air conditioner on, then check the idle speed. NOTE: If the idle speed is not within specification, see the Symptom Chart. 6. Reconnect the EVAP canister purge valve 2P connector. Page 9662 Diagram 114-1 Diagrams: Other diagrams referred to by number (See Diagram ##-#, etc.)within these diagrams can be found at Diagrams by Number. See: Diagrams/Electrical Diagrams/Diagrams By Number Locations: Location photographs (references to PHOTOS) referred to within these diagrams can be found at Locations by Photo Number. See: Locations/Component Locations/Locations By Photo Number Connector Views: Connector terminal views (references to VIEWS) referred to within these diagrams can be found at Connector Views by View Number. See: Diagrams/Connector Views/Connector Views By View Number Page 5758 Under-dash Fuse/Relay Box (4-door) Page 2933 Power Steering Pressure Switch: Description and Operation Power Steering Pressure (PSP) Switch The PSP switch signals the ECM/PCM when the power steering load is high. Page 2360 Main Relay (Computer/Fuel System): Testing and Inspection Power Relay Test Use this chart to identify the type of relay, then do the test listed for it. NOTE: See the turn signal/hazard relay input test. Normally-open type A: Page 6645 Air Conditioning Switch: Service and Repair Heater Control Panel and Push Switch Assembly Removal and Installation 1. Remove the center panel. 2. Remove the dials (A), then remove the self-tapping screws and the heater control panel (B) from the center panel (C). Remove the self-tapping screws and the push switch assembly (D) from the center panel. 3. Install the control panel and the push switch assembly in the reverse order of removal. After installation, operate the control panel controls to see whether it works properly. 4. Run the self-diagnosis function to confirm that there are no problems in the system. Page 9390 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. Below most connector numbers and component names are PHOTO and VIEW numbers. The PHOTO number refers to a photo in the back of the book that shows the connector's location on the car. The VIEW number refers to an illustration in the back of the book that shows the connector terminals, wire colors, connector cavity numbers, and other details. The connector cavity numbering sequence begins at the top left corner of the connector as seen from either of the viewpoints shown on diagram [8] . Except for the DLC (data link 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 C554, for example, means those terminals join in cavity 2 of connector C554. Power Distribution Schematics Power Distribution Schematics Locations Door Lock Knob: Locations 121. Driver's Door (Coupe except DX) 122. Driver's Door (Sedan except DX) Page 4940 Skill Level: Repair Technician INSPECTION PROCEDURE 1. Remove the steering column covers. Refer to section 17 of the appropriate service manual. 2. On the lower side of the ignition switch, look at the interlock cylinder cover: ^ If the cover is square, the ignition switch was already replaced with an updated part, and a key interlock repair kit is not needed. Go to step 3. ^ If the cover is round, go to REPAIR PROCEDURE. 3. Reinstall the steering column covers. 4. Center-punch a completion mark above the seventh character of the engine compartment VIN. REPAIR PROCEDURE Page 1803 Crankshaft Main Bearing: Specifications Torque Specifications Torque the bearing cap bolts sequentially in two steps. 1st step torque: 25 Nm (2.5 kgf-m, 18 ft. lbs.) 2nd step torque: 51 Nm (5.2 kgf-m, 38 ft. lbs.) Locations Wheel Speed Sensor: Locations 145. Right Side Of Floor (EX) 159. Left Side Of Engine Compartment Page 9405 1. Remove the secondary locks. 2. Remove the terminal from the female half. 3. Remove the terminal from the male half. 4. Go to HOW TO INSTALL NEW TERMINALS. Connectors Without a Secondary Lock All examples are shown with the connector lock facing up. The illustrations are examples of connector terminals without a secondary lock; however, the connector you are repairing may vary in size and shape. EXAMPLE A: Page 6256 12. Install the feed line clamp (A) on the gearbox. Make sure that there is no interference between the feed and return lines any other parts. 13. Wipe off any grease contamination from the ball joint tapered section and threads. Then reconnect the tie-rod end (A) to the damper steering arms. Install the 10 mm nut (B) and tighten it. 14. Install the new cotter pin (C), and bend it as shown. 15. Reinstall the heater valve (A) in its original position, and connect the heater valve cable to the valve arm. Install the heater hoses on the hose clamps securely. 16. Install the air cleaner (A) and resonator (B). Page 5773 Exterior Lights Component Location Index Specifications Crankshaft: Specifications Crankshaft Main journal diameter ................................................................................................................................... 54.976 - 55.000 mm (2.1644 - 2.1654 inch) Rod journal diameter ..................................................................................................................................... 44.976 45.000 mm (1.7707 - 1.7717 inch) Rod/main journal taper Standard or New .................................................................................................................................. ................................ 0.0025 mm (0.0001 inch) Service Limit .............................................................. ........................................................................................................... 0.005 mm (0.0002 inch) Rod/main journal out-of-round Standard or New .................................................................................................................................. ................................ 0.0025 mm (0.0001 inch) Service Limit .............................................................. ........................................................................................................... 0.005 mm (0.0002 inch) End play Standard or New .................................................................................................................................................. 0.10 0.35 mm (0.004 - 0.014 inch) Service Limit ......................................................................................... .................................................................................... 0.45 mm (0.018 inch) Runout Standard or New ....................................................................................................................................................... 0.03 mm (0.001 inch) maximum Service Limit .................................................................................... ......................................................................................... 0.04 mm (0.002 inch) Page 9835 1. Remove the screw and passenger's power window switch (A) from the door panel. 2. Disconnect the 5P connector (B) from the switch. 3. Check for continuity between the terminals in each switch position according to the table. 4. If the continuity is not as specified remove the two screws and replace the switch. Page 8672 Clutch Switch: Testing and Inspection Clutch Pedal Position Switch Test 1. Disconnect the 2P connector from the clutch pedal position switch (A). 2. Remove the clutch pedal position switch. 3. Check for continuity between the terminals according to the table. - If the continuity is not as specified, replace the clutch pedal position switch. - If OK, install the clutch pedal position switch and adjust the pedal height. Page 2515 Splices Components Ground - "G" Page 3230 3. If there is no continuity between any terminal, remove the transmission range switch cover, and disconnect the connector (A) at the switch (B). 4. Check for continuity between terminals at the switch connector (c). There should be continuity between the terminals listed for each position. In the P position, between terminals: ^ No. 4 and No. 5 ^ No. 4 and No. 6 ^ No. 5 and No. 6 In the R position, between terminals: ^ No. 1 and No. 4 In the N position, between terminals: ^ No. 4 and No. 5 ^ No. 4 and No. 7 ^ No.5 and No.7 In the D position, between terminals: ^ No.2 and No.4 ^ No. 2 and No. 10 ^ No. 4 and No. 10 In the D3 position, between terminals: ^ No. 4 and No. 8 ^ No. 4 and No. 10 ^ No. 8 and No. 10 In the 2 position, between terminals: ^ No.3 and No.4 5. If there is no continuity between any terminals, adjust the transmission range switch installation. If the transmission range switch installation is OK, replace the switch. 6. If the transmission range switch continuity check was OK, replace the faulty transmission range switch harness. Page 7511 Front Door Exterior Handle: Service and Repair Sedan Front Door Outer Handle Replacement 4-door NOTE: Put on gloves to protect your hands. 1. Raise the glass fully. 2. Remove these items: - Door panel - Plastic cover, as necessary 3. Use a hooked-shaped tool to remove the retainer clip (A), then remove the lock cylinder (B). Disconnect the cylinder rod (C). 4. Disconnect the outer handle rod (A), and remove the nuts, then remove the outer handle protector (B) from the outer handle (C). 5. Pull out the outer handle (A) in the numbered sequence, and remove it. 6. Install the handle in the reverse order of removal, and note these items: - Make sure each rod is connected securely. - Make sure the door locks and opens properly. - When installing the lock cylinder, leave the outer door handle bolts loose so the inner protector does not interfere with the lock cylinder Page 7663 6. Disconnect the trunk lid opener cable (A) from the trunk lid latch (B). 7. Using a clip remover, detach the clip (C) from the body, and detach the clips (D) from the trunk lid hinge 8. Remove the trunk lid opener/fuel fill door opener cable from the vehicle. Take care not to kink the cable. 9. Install the cable in the reverse order of removal, and note these items. - Align the alignment mark of the cable to the clip on the bottom portion of the trunk lid hinge. - Replace any damaged clips. Page 2069 Variable Valve Timing Actuator: Testing and Inspection VTEC Solenoid Valve Test 1. Remove the resonator. 2. Disconnect the VTEC solenoid valve 1P connector. 3. Measure resistance between the VTEC solenoid valve 1P connector terminal No.1 and body ground. 4. If the resistance is within specifications, remove the VTEC solenoid valve assembly (A) from the cylinder head, and check the filter (B) for clogging. If there is clogging, replace the solenoid valve filter, the engine oil filter, and the engine oil. Page 7246 1997-01 CR-V with dealer-installed security system 1996-97 del Sol with dealer-installed security system 1996-98 Odyssey with dealer-installed security system *1999-04 Odyssey LX with dealer-installed keyless entry system or security system* 1996-01 Prelude with dealer-installed security system *2000-04 S2000 with dealer-installed security system 2000-04 Insight with dealer-installed security system 2003-04 Pilot LX with dealer-installed keyless entry system or security system* Programming the Transmitter NOTES: ^ The system accepts up to three transmitters. The transmitter codes are stored in a stacking-type memory. If a fourth transmitter code is programmed, the code for the first transmitter is erased. ^ Entering the programming mode cancels all learned transmitter codes, so none of the previously programmed transmitters will work. You must reprogram all of the transmitters once you are in the programming mode. ^ You must complete steps 1-6 within 4 seconds of the previous step to keep the system from exiting the programming mode. 1. Turn the ignition switch to ON (II). 2. Press the "Lock" or "Unlock" button on one of the transmitters. (An unprogrammed transmitter can be used for this step.) 3. Turn the ignition switch to LOCK (0). 4. Repeat steps 1, 2, and 3 two more times using the same transmitter used in step 2. 5. Turn the ignition switch to ON (II). 6. Press the "Lock" or "Unlock" button on the same transmitter. Make sure the power door locks cycle to confirm that the system is in programming mode. 7. Within 10 seconds, press the "Lock" or "Unlock" button on each transmitter. Make sure the power door locks cycle after you press each transmitter button to confirm that the system accepted the transmitter's code. 8. Turn the ignition switch to LOCK (0) to exit the programming mode. Ordering a Transmitter Transmitters can be ordered only by authorized Honda dealers. Order them from American Honda using normal parts ordering procedures. Batteries for the Transmitter The battery number is CR2025. Each transmitter uses one battery. Page 8774 3. Strip the insulation off the end of the wire so the wire fits in the new terminal as shown. (If the wire has a wire seal, replace it with a new one from the kit.) NOTE: After stripping the end of the wire, make sure you did not cut any wire strands. If you did, cut the wire off even with the insulation, and strip it again. 4. Position the terminal in the crimping tool slot with the solid portion of the terminal toward the anvil and the open section toward the former. 5. Insert the wire in the terminal to the position shown in step 3. 6. Squeeze the tool with both hands until the stops make contact. 7. Crimp the insulation crimp. - If you do not have a wire seal, then use the next larger size crimp slot. Position the crimping tool over the insulation crimp section of the terminal, then squeeze the tool with both hands until the stops make contact. - If you have a wire seal, position the insulation crimp in the 5.5 crimping slot, then carefully squeeze the crimp closed until its ends are touching and making a full-circle shape. Service and Repair Sunroof / Moonroof Cable: Service and Repair Drain Channel Slider and Cable Assembly Replacement 1. Remove the frame. 2. Remove these parts from the frame: - Sunshade - Moonroof motor 3. Put on gloves to protect your hands. Remove the cable tube side bracket mounting bolts (A) and the cable tube mounting screws (B), and remove the screws (C, D), then remove the slide stops (E) and cable tube rear brackets (F) from both sides of the frame (G). 4. While pushing down on the hook (A), slide the drain channel sliders (B) back on both sides. 5. Turn both cable tube side brackets (A) up, and remove the drain channel sliders (B). Page 3064 Fuel Tank Pressure Sensor: Description and Operation The FTP sensor converts fuel tank absolute pressure into an electrical input to the ECM/PCM. Page 8387 6. Release both rear sunshade base sliders (A) from the guide rail portions of the frame, then remove the sunshade. 7. Remove both front sunshade base sliders (A). 8. Install the sunshade in the reverse order of removal, and check the glass height adjustment. 9. Check for water leaks. Let the water run freely from a hose without a nozzle. Do not use a high-pressure spray. Page 4326 Shift Cable: Service and Repair Shift Cable Replacement 1. Raise the vehicle, and make sure it is securely supported. 2. Shift the transmission into the N position. 3. Remove the center console panel and center console. 4. Remove the nut securing the shift cable end (A), then separate the cable end from the shift lever assembly. 5. Rotate the socket holder (A) on the shift cable (B) toward the shift lever a quarter turn, then slide the holder out to remove the shift cable from the shift cable bracket base (C). 6. Remove the shift cable guide bracket (A) and grommet (B). Page 4974 Circuit Schematics Each schematic represents one circuit. A circuit's wires and components are arranged to show current flow from power at the top of the diagram 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 Page 1227 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 3015 124. CMP (TDC) Sensor Page 1558 Exterior Lights Component Location Index Page 4160 7. Apply a small amount of Permalube grease to the base of the new lever. Then attach the slide hammer to the new lever pin, insert the lever into the ignition switch, and seat the pin with the slide hammer. 8. Check the installed height of the pin with vernier calipers. If the height is more than 5.0 mm, the pin is not seated. If needed, reattach the slide hammer, and seat the pin. NOTE: It's normal for the interlock lever to be loose, even when the pin is fully seated. 9. Install a new spring on the lever. Make sure you attach the ends of the spring correctly: ^ The right end goes into the slot on the ignition switch. Page 9207 2. Cut off the wire about an inch back from where it connects to the damaged or faulty terminal, then strip about half of the insulation off that piece. This will be used to size the wire end of the replacement pigtail terminal. NOTE: If you are not sure of the wire size, start with a large enough hole on the stripper that will not nick or cut off any strands of wires. 3. Select a pigtail terminal that matches the original wire at both ends (same kind of terminal and same diameter bare wire). 4. Select the smallest splice connector (yellow, pink, or blue) that will fit onto the stripped end of the original wire. 5. Insert the pigtail terminal into the connector cavity; push it in until it locks in place. 6. Lay the pigtail and the original wire side-by-side, and cut off both ends at once. If you are making more than one splice, do not cut each pigtail at the same location; the resulting "lump" of splice connectors would interfere with rewrapping the harness. Instead, cut the first pigtail close enough to the terminal so you will have room to make each remaining cut about 20 mm (3/4 inch) farther down on the next pigtail. 7. If you are using a yellow splice connector, strip about 6 mm (1/4 inch) of insulation off the ends of both wires. If you are using a pink or blue splice connector, strip off about 8 mm (5/16 inch) of insulation. Page 5623 Technical Service Bulletin # 01-077 Date: 060419 Ignition/Locks - Cutting Sidewinder-Type Keys 01-077 April 19, 2006 Applies To: Models With Sidewinder-Type Keys - All Cutting Sidewinder-Type Keys With the MATRIX H Key Cutting Machine (Supersedes 01-077, dated January 12, 2005) Updated information is noted by asterisks. MATRIX H Key Cutting Machine, manufactured by Silca and supplied by Kaba Ilco Corporation, is a portable, power-operated tool that cuts sidewinder-type automotive keys exclusively. The machine lets you cut these keys either by copying or by code. The code function is designed and built to meet the Honda code requirements. No other similar machine has this capability. This service bulletin gives you information for ordering and servicing this special tool, and guides you through the entire key cutting process from setting up the machine to cutting the key blank. TOOL INFORMATION Order through the Honda Tool and Equipment Program: MATRIX H Key Cutting Machine: Model No. ILCMATRIXSH Cutter Bit: Model No. ILCF3O Fixed Jaw: Model No. ILCMTX-H Mobile Jaw (Right Side): Model No. ILCRTMTX-H Mobile Jaw (Left Side): Model No. ILCLTMTX-H *Remanufactured Clamp Unit: Model No. ILCMATRIXHCR* PARTS INFORMATION *For some models, there are two choices for sidewinder-type key blanks: ^ T-5 sidewinder key blanks ^ Honda sidewinder key blanks For other models, only Honda sidewinder key blanks can be used. See DETERMINING WHICH KEY TO USE to determine which key blank you should choose. Ordering T-5 key blanks through the Honda Tool and Equipment Program: T-5 Programmable Key Blank (Master): P/N ILC-35111-T-5H T-5 Programmable Key Blank (Valet): P/N ILC-35112-T-5H Practice Key Blanks (five per pack): ILC-35111DEMO* NOTE: Do not use practice key blanks for replacement purposes. Practice keys do not have an immobilizer chip. Page 1081 2. Remove the terminal (same procedure for male and female). 3. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE E: 1. Remove the secondary locks. 2. Remove the terminal (same procedure for male and female). 3. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE F: Locations Fuel Supply System Component Location Index Page 5820 Multiple Junction Connector: Service and Repair How to Install Pigtail Terminals HOW TO INSTALL PIGTAIL TERMINALS Pigtail terminals (short pieces of wire with a factory crimped terminal) are used when the wire is too short or when access to the connector is too restricted to make a terminal repair. NOTE: To replace just a connector terminal, go to How to Replace Connector Terminals. IMPORTANT SAFETY INFORMATION: On some models, the SRS wires are in a separate harness. If the SRS harness is damaged, replace the harness; do not repair it. On other models, wire harnesses include yellow SRS wires. If any SRS wire is damaged, replace the entire harness; do not repair it. 1. Remove the damaged or faulty terminal from the connector. Use the proper removal tool from Pin Tool Set. 2. Cut off the wire about an inch back from where it connects to the damaged or faulty terminal, then strip about half of the insulation off that piece. This will be used to size the wire end of the replacement pigtail terminal. NOTE: If you are not sure of the wire size, start with a large enough hole on the stripper that will not nick or cut off any strands of wires. 3. Select a pigtail terminal that matches the original wire at both ends (same kind of terminal and same diameter bare wire). 4. Select the smallest splice connector (yellow, pink, or blue) that will fit onto the stripped end of the original wire. 5. Insert the pigtail terminal into the connector cavity; push it in until it locks in place. 6. Lay the pigtail and the original wire side-by-side, and cut off both ends at once. If you are making more than one splice, do not cut each pigtail at Page 9387 Diodes Light Emitting Diode (LED) Motor Pressure Sensor Page 496 31. Brake Fluid Level Switch 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 3826 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 Short Circuit Locator (Short Finder) 1. Remove the blown fuse. Leave the battery connected. Page 274 ERROR: undefined OFFENDING COMMAND: f‘~ STACK: Page 2167 3. Strip the insulation off the end of the wire so the wire fits in the new terminal as shown. (If the wire has a wire seal, replace it with a new one from the kit.) NOTE: After stripping the end of the wire, make sure you did not cut any wire strands. If you did, cut the wire off even with the insulation, and strip it again. 4. Position the terminal in the crimping tool slot with the solid portion of the terminal toward the anvil and the open section toward the former. 5. Insert the wire in the terminal to the position shown in step 3. 6. Squeeze the tool with both hands until the stops make contact. 7. Crimp the insulation crimp. - If you do not have a wire seal, then use the next larger size crimp slot. Position the crimping tool over the insulation crimp section of the terminal, then squeeze the tool with both hands until the stops make contact. - If you have a wire seal, position the insulation crimp in the 5.5 crimping slot, then carefully squeeze the crimp closed until its ends are touching and making a full-circle shape. Page 8224 Trunk / Liftgate Lock: By Symptom Technical Service Bulletin # 02-061 Date: 041105 Body - Trunk Lid Hard to Close 02-061 November 5, 2004 Applies To: See VEHICLES AFFECTED Trunk Lid is Difficult to Close (Supersedes 02-061, dated July 23, 2004) Updated information is shown with asterisks. SYMPTOM The trunk lid may be difficult to close or won't latch closed. PROBABLE CAUSE The trunk lid may be misaligned, and the trunk lid opener cable, trunk lid latch, lock cylinder, lock rod, and/or the trunk lid latch striker may need adjustment or replacement. VEHICLES AFFECTED CORRECTIVE ACTION Adjust the trunk lid and/or the trunk lid latch, or replace components as needed. PARTS INFORMATION Page 6014 Charging System Component Location Index Page 2117 3. Replace the plug at the specified interval, or if the center electrode is rounded (A). Use only the spark plugs listed. 4. Apply a small quantity of anti-seize compound to the plug threads, and screw the plugs into the cylinder head finger-tight. Then torque them to 18 N.m (1.8 kgf.m, 13 lbf.ft). Page 5404 Brake Pad: Testing and Inspection Front Inspection and Replacement CAUTION: Frequent inhalation of brake pad dust, regardless of material composition, could be hazardous to your health. ^ Avoid breathing dust particles. ^ Never use an air hose or brush to clean brake assemblies. Use an OSHA-approved vacuum cleaner. Inspection 1. Raise the front of the vehicle, and support it with safety stands in the proper locations. Remove the front wheels. 2. Check the thickness of the inner pad (A) and outer pad (B). Do not include the thickness of the backing plate. Brake pad thickness: Standard: 9.5 - 10.5 mm (0.37 - 0.41 inch) Service limit: 1.6 mm (0.06 inch) 3. If the brake pad thickness is less than the service limit, replace all the pads as a set. Testing and Inspection Trunk Lamp Switch: Testing and Inspection Trunk Lid Latch Switch Test 1. Open the trunk lid. 2. Disconnect the 2P connector (A) from the trunk lid latch (B). 3. Check for continuity between the No.1 and No.2 terminals. - There should be continuity with the trunk lid open. - There should be no continuity with the trunk lid closed. 4. If the continuity is not as specified, replace the trunk lid latch switch. Emissions - OBD II DTC's And Associated Monitors Engine Control Module: Technical Service Bulletins Emissions - OBD II DTC's And Associated Monitors 03-020 April 2, 2010 Applies To: All OBD II-equipped models except Passport OBD II DTCs and Their Associated Monitors (Supersedes 03-020, dated March 29, 2003, to revise the information marked by the black bars and asterisks) *REVISION SUMMARY Numerous DTCs were added. Refer to the list for details.* Following is a list of all OBD II DTCs and their associated monitors for all Honda automobiles with OBD II. No one model has every DTC in the list. DTC P0AA6 thru P0A9E Page 5834 Rear Window Defogger Component Location Index Page 5234 Splices Components Ground - "G" Page 1119 Shift Interlock Switch: Service and Repair Park Pin Switch Replacement 1. Remove the center console panel and center console. 2. Remove the screws (A), then remove the shift lever knob (B). 3. Remove the A/T gear position indicator panel light (c) from the A/T gear position indicator panel. 4. Remove the A/T gear position indicator panel and panel bracket as an assembly (D). 5. Disconnect the park pin switch connector (4P) (E), and remove it from the shift lever bracket base (F). 6. Remove the shift lock release (G) and spring (H). 7. Open the lock tabs (A) on the shift lever bracket base, then remove the park pin switch (B). 8. Install the new park pin switch. 9. Install the removed parts in the reverse order of removal. Page 331 Main Relay (Computer/Fuel System): Description and Operation PGM-FI Main Relay 1 and 2 The PGM-FI relay consists of two separate relays. PGM-FI main relay 1 is energized whenever the ignition switch is ON (II) which supplies battery voltage to ECM/PCM, power to the injectors, and power for PGM-FI main relay 2. PGM-FI main relay 2 is energized to supply power to the fuel pump for 2 seconds when the ignition switch is turned ON (II), and when the engine is running. Page 3063 114. FTP Sensor (except GX) Electrical - DTC P1298 Stored in ECM/PCM Electric Load Sensor: All Technical Service Bulletins Electrical - DTC P1298 Stored in ECM/PCM 05-006 May 6, 2005 Updated information is noted by asterisks. Applies To: 2001-05 Civic - ALL *2002-04 CR-V - ALL* DTC P1298 Is Stored in the ECM/PCM (Supersedes 05-006, dated February 25, 2005, to change the CR-V model-year range) SYMPTOM DTC P1298 (electrical load detector (ELD) circuit high voltage) is stored in the ECM/PCM. PROBABLE CAUSE The electronic load detector (ELD) has a faulty solder joint. CORRECTIVE ACTION Replace the ELD. NOTE: Previously, if an ELD required replacement, you had to replace the under-hood fuse/relay box. To reduce repair costs, replacement ELDs are now available. PARTS INFORMATION Electronic Load Detector: P/N 38255-S5A-003, H/C 7987571 WARRANTY CLAIM INFORMATION In warranty: The normal warranty applies. Operation Number: 121195 Flat Rate Time: 0.4 hour Failed Part: Civic P/N 38250-S5A-A03 H/C 7472277 CR-V P/N 38250-S9A-A01 H/C 6890594 Defect Code: 06402 Symptom Code: 01201 Template ID: 05-006A 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 6767 SRS Component Location Index Page 9572 193. Hazard Warning Switch Page 813 - 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. Troubleshooting Tests 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 test 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 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. 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 Drop Page 547 64. Under Left Side Of Dash (M/T) Page 290 ECM/PCM Inputs And Outputs At Connector C (22P) Page 3614 119. Knock Sensor (except GX) Page 7148 Alarm Module: Description and Operation How the Circuit Works The immobilizer system is designed to prevent the car from being started without the owner's ignition key. If an attempt is made to Start the car with any other key, the immobilizer system will disable the car's fuel supply. The immobilizer system consists of the ignition key, immobilizer control unit-receiver, immobilizer indicator light, PGM-FI main relays, injector relay (GX), fuel pump (except GX), fuel tank internal solenoid valve (GX), and the ECM/PCM. With the ignition switch in ON (II) or START (III), the immobilizer control unit-receiver and the ECM/PCM receive an "ignition on" signal through fuse 6 and the PGM-FI main relay 1. The ECM/PCM then sends power to the ignition key transponder through the immobilizer control unit-receiver. The transponder then sends a coded signal back to the ECM/PCM through the receiver. If the signal is correct, the ECM/PCM will energize the car's fuel supply system by grounding the PGM-FI main relay 2 (except GX) or injector relay (GX). The immobilizer indicator light flashes a code to indicate that the correct key has been inserted. If the ignition key signal is not correct, the ECM/PCM will not energize the car's fuel supply system by not grounding the PGM-FI main relay 2 (except GX) or injector relay (GX). The immobilizer indicator light then flashes a code to indicate that an incorrect key has been inserted. Page 2804 117. IAC Valve Page 8192 6. Disconnect the M, P, K, and J connectors from the under-dash fuse/relay box, and make these input tests at the connectors. - If any test indicates a problem, find and correct the cause, then recheck the system. - If all the input tests prove OK, the multiplex control unit must be faulty. Replace the under-dash fuse/relay box assembly. Page 1579 234. Under-dash Fuse/Relay Box Part 6 Page 265 DTC P1486 thru P1585 Capacity Specifications Refrigerant: Capacity Specifications Refrigerant Capacity or system .............................................................................................................................. ................................... 500 - 550 g (17.6 - 19.4 oz) Locations 57. Under Left Side Of Dash Specifications Pressure Plate: Specifications Pressure plate Warpage .............................................................................................................................................. ............................ 0.03 mm (0.001 inch) maximum Height of diaphragm spring fingers Measure with feeler gauge and special tool .................................................................................................................. 0.6 mm (0.02 inch) maximum Torque the mounting bolts in a crisscross pattern. Tighten the bolts in several steps to prevent warping the diaphragm spring. Page 4999 2. Insert the terminal tool into the female terminal, and then remove the terminal tool. NOTE: Make sure you do not select a terminal tool that is larger than the mating male terminal because it would spread the female terminal and cause a loose fit. 3. Compare the drag to the other terminals in the connector. If the drag is less, replace the terminal with a replacement terminal from the appropriate terminal repair kit. Page 6357 2. Remove the flange bolt (A) from the bottom of the damper. 3. Remove the flange nuts (A) from the top of the damper in the trunk. 4. Remove the damper assembly from the body. Disassembly/Inspection Electrical - DTC P1298 Stored in ECM/PCM Electric Load Sensor: All Technical Service Bulletins Electrical - DTC P1298 Stored in ECM/PCM 05-006 May 6, 2005 Updated information is noted by asterisks. Applies To: 2001-05 Civic - ALL *2002-04 CR-V - ALL* DTC P1298 Is Stored in the ECM/PCM (Supersedes 05-006, dated February 25, 2005, to change the CR-V model-year range) SYMPTOM DTC P1298 (electrical load detector (ELD) circuit high voltage) is stored in the ECM/PCM. PROBABLE CAUSE The electronic load detector (ELD) has a faulty solder joint. CORRECTIVE ACTION Replace the ELD. NOTE: Previously, if an ELD required replacement, you had to replace the under-hood fuse/relay box. To reduce repair costs, replacement ELDs are now available. PARTS INFORMATION Electronic Load Detector: P/N 38255-S5A-003, H/C 7987571 WARRANTY CLAIM INFORMATION In warranty: The normal warranty applies. Operation Number: 121195 Flat Rate Time: 0.4 hour Failed Part: Civic P/N 38250-S5A-A03 H/C 7472277 CR-V P/N 38250-S9A-A01 H/C 6890594 Defect Code: 06402 Symptom Code: 01201 Template ID: 05-006A 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 1341 14. Remove the upper bracket. 15. Remove the grommet (A) from the upper cover, and disconnect the CMP (TDC) sensor connector (B). 16. Remove the upper cover (C) and lower cover (D). 17. Remove the side engine mount bracket. Page 222 Charging System Component Location Index Page 3767 7. Apply a small amount of Permalube grease to the base of the new lever. Then attach the slide hammer to the new lever pin, insert the lever into the ignition switch, and seat the pin with the slide hammer. 8. Check the installed height of the pin with vernier calipers. If the height is more than 5.0 mm, the pin is not seated. If needed, reattach the slide hammer, and seat the pin. NOTE: It's normal for the interlock lever to be loose, even when the pin is fully seated. 9. Install a new spring on the lever. Make sure you attach the ends of the spring correctly: ^ The right end goes into the slot on the ignition switch. Locations 13. Middle Of Engine (EX, HX) Page 6611 Refrigerant Oil: Service and Repair A/C Refrigerant Oil Replacement Recommended PAG oil: SANDEN SP-10: - P/N 38897-P13-A01AH: 120 ml (4 fl.oz) - P/N 38899-P13-A01: 40 ml (1 1/3 fl.oz) Page 4086 Shift Indicator: Locations Continuously Variable Transmission Component Location Index Page 7613 21. Leave the key in the cylinder. Reinstall the plastic retainer and spring if you removed them in step 16. Hold the plastic retainer and spring on the housing, and insert the inner cylinder. Rotate it left and right to engage the spring to the inner cylinder. Make sure the spring is properly seated to the inner cylinder. 22. Install the arm with a new cylinder rod clip and a new E-clip. 23. Make sure the key can be inserted and removed easily, and that the cylinder turns with the key. Page 9737 127. Left Rear Door (Sedan Except DX) (Right Similar) Page 5719 Splices Components Ground - "G" Page 8913 48. Measure voltage between PGM-FI main relay 1 4P connector terminal No.2 and body ground. Is there battery voltage? YES - Go to step 49. NO - Repair open in the wire between the No.6 ECU (ECM/PCM) (15A) fuse and the PGM-FI main relay 1. 49. Turn the ignition switch OFF. 50. Check for continuity between PGM-FI main relay 1 4P connector terminal No.1 and ECM/PCM connector terminals A2 and A3 individually. Is there continuity? YES - Replace the PGM-FI main relay 1. NO - Repair open in the wire between PGM-FI main relay 1 and the ECM/PCM (A2, A3). 51. Measure voltage between body ground and ECM/PCM connector terminals A4, A5, A23, and A24 individually. Is there less than 1.0 V? YES - Go to step 52. NO - Repair open in the wire(s) that had more than 1.0 V between G101 and the ECM/PCM (A4, A5, A23, A24). Page 8131 The 1999-00 transmitter is not interchangeable with the 2001-04 transmitter. To tell them apart, look at the FCC ID on the back. 1999-00 - FCC ID: E4EG8DN 2001-04 - FCC ID: OUCG8D-440H-A* Programming the Transmitter NOTES: ^ The system accepts up to three transmitters. The transmitter codes are stored in a stacking-type memory. If a fourth transmitter code is programmed, the code for the first transmitter is erased. ^ Entering the programming mode cancels all learned transmitter codes, so none of the previously programmed transmitters will work. You must reprogram all of the transmitters once you are in the programming mode. You must complete steps 1-6 within 4 seconds of the previous step to keep the system from exiting the programming mode. 1. Turn the ignition switch to ON (II). 2. Press the "Lock" or "Unlock" button on one of the transmitters. (An unprogrammed transmitter can be used for this step.) 3. Turn the ignition switch to LOCK (0). 4. Repeat steps 1, 2, and 3 two more times using the same transmitter used in step 2. 5. Turn the ignition switch to ON (II). 6. Press the "Lock" or "Unlock" button on the same transmitter. Make sure the power door locks cycle to confirm that the system is in programming mode. 7. Within 10 seconds, press the "Lock" or "Unlock" button on each transmitter. Make sure the power door locks cycle after you press each transmitter button to confirm that the system accepted the transmitter's code. 8. Turn the ignition switch to LOCK (0) to exit the programming mode. Ordering a Transmitter Transmitters can be ordered only by authorized Honda dealers. Order them from American Honda using normal parts ordering procedures. Batteries for the Transmitter The battery number is CR2025. Each transmitter uses one battery. 99-01 Prelude With Factory-Installed Keyless Entry System 1999-01 Prelude with factory-installed keyless entry system Page 511 Parking Brake Warning Switch: Testing and Inspection Parking Brake Switch Test 1. Remove the console, and disconnect the connector (A) from the switch (B). 2. Check for continuity between the positive terminal and body ground: ^ With the brake lever up, there should be continuity. ^ With the brake lever down, there should be no continuity. Page 6640 Blower Motor Relay Type 1, Type 2 Check for continuity between the terminals. - There should be continuity between the No.1 and No.3 terminals when power and ground are connected to the No.2 and No.4 terminals. - There should be no continuity between the No.1 and No.3 terminals when power is disconnected. Five-terminal type Check for continuity between the terminals. - There should be continuity between the No.1 and No.2 terminals when power and ground are connected to the No.3 and No.5 terminals. - There should be continuity between the No.1 and No.4 terminals when power is disconnected. Page 8342 Page 7045 145. Seat Belt Buckle Tensioner, Driver's 146. Seat Belt Buckle Tensioner, Front Passenger's (Sedan) 147. Seat Belt Buckle Tensioner, Passenger's (Coupe) Page 9220 Dome Lamp: Service and Repair Ceiling Light Test/Replacement Ceiling Light Test/Replacement 1. Turn the light switch OFF. 2. Carefully pry off the lens (A) with a small screwdriver. 3. Remove the two mounting screws. 4. Disconnect the 3P connector (B) from the housing (C). 5. Check the bulbs. If the bulbs are OK, check for continuity between the terminals in each switch position according to the table. 6. If the continuity is not as specified, replace the ceiling light. Page 1598 18. Check for continuity between body ground and PGM-FI main relay 1 4P connector terminals No.2 and No.4 individually. Is there continuity? YES - Repair short in the wire between the No.6 ECU (ECM/PCM) (15A) fuse and PGM-FI main relay 1. Also replace the No.6 ECU (ECM/PCM) (15A) fuse. NO - Go to step 19. 19. Disconnect each of the components or connectors connector below, one at a time, and check for continuity between PGM-FI main relay 1 4P connector terminal No.1 and body ground. PGM-FI main relay 2 - ECM/PCM connector A (31P) - Each injector 2P connector - Idle air control (IAC) valve 3P connector - Camshaft position (CMP) sensor (Top dead center (TDC) sensor) 3P connector - Crankshaft position (CKP) sensor 3P connector Is there continuity? YES - Go to step 20. NO - Replace the component that made continuity to body ground go away when disconnected. If the item is the ECM/PCM, update the ECM/PCM if it does not have the latest software, or substitute a known-good ECM/PCM, then recheck. If the symptom/indication goes away with a known-good ECM/PCM, replace the original ECM/PCM. Also replace the No.6 ECU (ECM/PCM) (15A) fuse. 20. Disconnect the connectors of all these components. - PGM-FI main relay 2 - ECM/PCM connector A (31P) - Injectors - Idle air control (IAC) valve - Camshaft position (CMP) sensor (Top dead center (TDC) sensor) - Crankshaft position (CKP) sensor Page 5810 2. Remove the terminal. 3. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE B: 1. Remove the secondary lock from the male terminal half. 2. Remove the secondary lock from the female terminal half. Capacity Specifications Fluid - A/T: Capacity Specifications ATF Change ................................................................................................................................................ .............................................................. 2.7L (2.9 Qt) Overhaul .......................................................... .................................................................................................................................................. 6.0L (6.3 Qt) CVT fluid Change ................................................................................................................................ .............................................................................. 3.1L (3.3 Qt) Overhaul .......................................... .............................................................................................................................................................. .... 5.6L (6.0 Qt) Page 195 Diagram 115-5 (Sedan EX) Diagrams: Other diagrams referred to by number (See Diagram ##-#, etc.)within these diagrams can be found at Diagrams by Number. See: Diagrams/Electrical Diagrams/Diagrams By Number Locations: Location photographs (references to PHOTOS) referred to within these diagrams can be found at Locations by Photo Number. See: Locations/Component Locations/Locations By Photo Number Connector Views: Connector terminal views (references to VIEWS) referred to within these diagrams can be found at Connector Views by View Number. See: Diagrams/Connector Views/Connector Views By View Number Page 8613 17. Using a small screwdriver, push down on the tip of the last tumbler to release it, then remove the cylinder from the housing, being careful not to drop any tumblers and springs. Use your thumb and forefinger to hold the tumblers in place. Then go to step 20. 18. While turning the key left and right and pushing on the rear of the inner cylinder to release the spring, slowly remove the cylinder from the housing. Page 6780 1. To reconnect, hold the pawl-side connector half, and press on the back of the sleeve-side connector half in the direction shown. As the two connector halves are pressed together, the sleeve (A) is pushed back by the pawl (C). Do not touch the sleeve. 2. When the connector halves are completely connected, the pawl is released, and the springloaded sleeve locks the connector. Side Airbag Connector: Disconnecting To release the lock, pull the spring-loaded sleeve (A) and the slider (B) while holding the opposite half of the connector. Then pull the connector halves apart. Be sure to pull on the sleeve and not on the connector half. Connecting Hold both connector halves, and press them firmly together until the projection (C) of the sleeve-side connector clicks. Locations Main Relay (Computer/Fuel System): Locations Relay And Control Unit Locations - Dashboard Page 3258 1. Remove the secondary lock from the male terminal half. 2. Remove the secondary lock from the female terminal half. 3. Remove the terminal (same procedure for male and female). 4. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE C: 1. Remove the secondary lock. Page 2532 1. Remove the secondary lock from the male terminal half. 2. Remove the secondary lock from the female terminal half. 3. Remove the terminal (same procedure for male and female). 4. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE C: 1. Remove the secondary lock. Page 2202 Radiator Cooling Fan Temperature Sensor / Switch: Service and Repair Radiator Fan Switch Replacement 1. Disconnect the radiator fan switch connector, then remove the radiator fan switch (A). 2. Install the radiator fan switch using a new O-ring (B). Page 5437 6. Refill the master cylinder reservoir to the MAX (upper) level line. Page 1286 3. Loosen the locknut (A) while holding the tie-rod arm (B). 4. Turn the tie-rod end (C) until the toe is correct. NOTE: Adjust both the right and left wheels at the same time by the same amount in opposite directions to obtain the correct toe. 5. After adjusting, tighten the locknut while holding the tie-rod arm. Make sure the toe setting does not change. Rear Toe Inspection/Adjustment Use commercially-available computerized four wheel alignment equipment to measure wheel alignment (caster, camber, toe, and turning angle). Follow the equipment manufacturer's instructions. 1. Release the parking brake. 2. Check the toe. If it is not within the specification, go to step 3. Rear toe-in: 2 [+2/-1] mm (0.08 [+0.08/-0.04] inch) 3. Loosen the self-locking nut (A) while holding the adjusting bolt (B). NOTICE: Do not loosen the special bolts (C) on the lower arm to adjust the alignment. 4. Replace the self-locking nut with a new one, and lightly tighten it. NOTE: Always use a new self-locking nut whenever you loosened it. 5. Turn the adjusting bolt until the toe is correct. 6. Tighten the self-locknut to the specified torque while holding the adjusting bolt. Turning Angle Inspection Use commercially-available computerized four wheel alignment equipment to measure wheel alignment (caster, camber, toe, and turning angle). Follow the equipment manufacturer's instructions. Page 2585 39. Left Side Of Engine Compartment Page 4601 Shift Interlock Switch: Service and Repair Park Pin Switch Replacement 1. Remove the center console panel and center console. 2. Remove the screws (A), then remove the shift lever knob (B). 3. Remove the A/T gear position indicator panel light (c) from the A/T gear position indicator panel. 4. Remove the A/T gear position indicator panel and panel bracket as an assembly (D). 5. Disconnect the park pin switch connector (4P) (E), and remove it from the shift lever bracket base (F). 6. Remove the shift lock release (G) and spring (H). 7. Open the lock tabs (A) on the shift lever bracket base, then remove the park pin switch (B). 8. Install the new park pin switch. 9. Install the removed parts in the reverse order of removal. Page 4997 8. Put the splice connector in the proper size slot in the Crimper Tool, slide it to one end (where the flare begins), and close the crimper handles far enough to hold it in place. To release the ratchet mechanism at any point after the first click, squeeze the handles slightly and push the release lever, then let the handles open. 9. Insert one of the bare wires into the splice connector end that is in the crimper jaws. Push the wire all the way into the splice connector, and squeeze the crimper handles. Keep squeezing until the jaws touch, and hold it at that position until the ratchet clicks again. 10. Crimp the other wire in the same way into the other end of the splice connector. 11. After crimping, gently pull on the wires in the opposite directions to make sure they are secure in the connector. 12. Separate the other wires in the harness from the repaired wire(s), and shield them with nonflammable material. Page 4503 4. Apply super high temp urea grease (P/N 08798-9002) to the release fork (A), the release fork bolt (B), the release bearing (C), and the release bearing guide (D) in the shaded areas. 5. With the release fork slid between the release bearing pawls, install the release bearing on the mainshaft while inserting the release fork through the hole in the clutch housing. 6. Align the detent of the release fork with the release fork bolt, then press the release fork over the release fork bolt squarely. 7. Install the release fork boot (E), make sure the boot seals around the release fork and clutch housing. 8. Move the release fork (A) right and left to make sure that it fits properly against the release bearing (B), and that the release bearing slides smoothly. Page 9645 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 Short Circuit Locator (Short Finder) 1. Remove the blown fuse. Leave the battery connected. Description and Operation Temperature Gauge: Description and Operation How the Circuit Works The indicators are controlled by relative conditions in their associated systems. For the following indicators the information supplied to the gauge assembly is received via the multiplex control unit: - Charging System - Door Indicator Light - Maintenance Required Indicator - Seat Belt Reminder - Trunk Indicator Light Refer to each associated system to see its entire schematic. Engine Coolant Temperature Gauge The engine coolant temperature gauge is controlled by the CPU built-in the gauge assembly. The CPU receives coolant temperature information from the ECM/PCM via the multiplex control unit, The ECM/PCM receives coolant temperature information from the ECT sensor. Page 118 Blower Motor Relay Type 1, Type 2 Check for continuity between the terminals. - There should be continuity between the No.1 and No.3 terminals when power and ground are connected to the No.2 and No.4 terminals. - There should be no continuity between the No.1 and No.3 terminals when power is disconnected. Five-terminal type Check for continuity between the terminals. - There should be continuity between the No.1 and No.2 terminals when power and ground are connected to the No.3 and No.5 terminals. - There should be continuity between the No.1 and No.4 terminals when power is disconnected. Page 7898 - Weld the damper housing and front side frame. - Weld the front damper extension and dashboard upper side member. - From the passenger compartment side, plug weld the holes in the dashboard lower, damper housing extension, and front damper extension. Page 5980 234. Under-dash Fuse/Relay Box Part 6 Page 51 6. Disconnect the M, P, K, and J connectors from the under-dash fuse/relay box, and make these input tests at the connectors. - If any test indicates a problem, find and correct the cause, then recheck the system. - If all the input tests prove OK, the multiplex control unit must be faulty. Replace the under-dash fuse/relay box assembly. Page 3901 Disclaimer Page 1095 3. If there is no continuity between any terminal, remove the transmission range switch cover, and disconnect the connector (A) at the switch (B). 4. Check for continuity between terminals at the switch connector (c). There should be continuity between the terminals listed for each position. In the P position, between terminals: ^ No. 4 and No. 5 ^ No. 4 and No. 6 ^ No. 5 and No. 6 In the R position, between terminals: ^ No. 1 and No. 4 In the N position, between terminals: ^ No. 4 and No. 5 ^ No. 4 and No. 7 ^ No.5 and No.7 In the D position, between terminals: ^ No.2 and No.4 ^ No. 2 and No. 10 ^ No. 4 and No. 10 In the D3 position, between terminals: ^ No. 4 and No. 8 ^ No. 4 and No. 10 ^ No. 8 and No. 10 In the 2 position, between terminals: ^ No.3 and No.4 5. If there is no continuity between any terminals, adjust the transmission range switch installation. If the transmission range switch installation is OK, replace the switch. 6. If the transmission range switch continuity check was OK, replace the faulty transmission range switch harness. Air Bag Disarming and Arming Air Bag(s) Arming and Disarming: Service and Repair Air Bag Disarming and Arming 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. Campaign - OPDS Unit Warranty Extension Technical Service Bulletin # 06-009 Date: 080205 Campaign - OPDS Unit Warranty Extension 06-009 February 5, 2008 Applies To: See VEHICLES AFFECTED Warranty Extension: OPDS Unit or OPDS Sensor Triggers SRS DTC(s) 15-1, 15-2, 15-3 (Supersedes 06-009, dated September 21, 2007) Updated information is shown with asterisks. BACKGROUND *NOTE: Because of a class action settlement, the warranty extension coverage for the OPDS unit and the OPDS sensor on 2002 Accords, 2002-04 Civics, 2003-04 Civic Hybrids, 2002-04 CR-Vs, 2003 Elements, 2002 Odysseys, and 2003-04 Pilots purchased or leased between April 13, 2002, and November 7, 2006, is now 10 years or 157,500 miles, whichever occurs first. For more information, refer to Service Bulletin 06-085, Warranty Extension: Vehicle Warranty Mileage.* Several vehicle models may have a problem with the OPDS (occupant position detection system) that causes the SRS indicator to stay on. Typically, one or more of these DTCs will be set: ^ SRS DTC 15-1 (faulty OPDS unit or OPDS not initialized) ^ SRS DTC 15-2 (faulty side airbag indicator circuit) ^ SRS DTC 15-3 (faulty OPDS sensor) To ensure continued reliability with the OPDS, American Honda is extending the warranty on the OPDS unit and the OPDS sensor to 10 years or 150,000 miles, whichever occurs first. This warranty extension does not apply to any vehicle that has ever been declared a total loss, or any that has been issued a salvage, branded, or similar title under any state's law. To check for vehicle eligibility, you must do a VIN status inquiry Page 1534 1. Right Side Of Engine Compartment Page 2994 Main Relay (Computer/Fuel System): Description and Operation PGM-FI Main Relay 1 and 2 The PGM-FI relay consists of two separate relays. PGM-FI main relay 1 is energized whenever the ignition switch is ON (II) which supplies battery voltage to ECM/PCM, power to the injectors, and power for PGM-FI main relay 2. PGM-FI main relay 2 is energized to supply power to the fuel pump for 2 seconds when the ignition switch is turned ON (II), and when the engine is running. Page 1477 Refrigerant Oil: Fluid Type Specifications Type ................................................................................................................................... SANDEN: SP-10 (P/N 38897-P13-A01AH or 38899-P13-A01) Page 5772 Air Conditioning Component Location Index Page 8984 Keyless/Power Door Lock System Component Location Index Locations Wheel Speed Sensor: Locations 145. Right Side Of Floor (EX) 159. Left Side Of Engine Compartment Page 4539 Shift Interlock Solenoid: Service and Repair Shift Lock Solenoid Replacement 1. Remove the center console panel and center console. 2. Disconnect the shift lock solenoid connector (2P), and remove it from the shift lever bracket base. 3. Push the lock tab (A), pry the shift lock solenoid (B) to clear the projected tips (C) with a screwdriver, and remove the shift lock solenoid. 4. Install the shift lock solenoid plunger (D) and plunger spring (E) in the new shift lock solenoid. 5. Install the shift lock solenoid by aligning the joint (F) of the shift lock solenoid plunger with the tip (G) of the shift lock stop. 6. Connect the shift lock solenoid connector, and install it on the shift lever bracket base. 7. Install the center console and console panel. Page 7679 2. Install the parts in the reverse order of removal, and replace any damaged clips. Page 1754 - Remove clips carefully; don't damage their locks (A). - Slip pliers (A) under the clip base and through the hole at an angle, then squeeze the expansion tabs to release the clip. - After installing harness clips, make sure the harness doesn't interfere with any moving parts. - Keep wire harnesses away from exhaust pipes and other hot parts, from sharp edges of brackets and holes, and from exposed screws and bolts. - Seat grommets in their grooves properly (A). Do not leave grommets distorted (B). Testing and Repairs - Do not use wires or harnesses with broken insulation. Replace them or repair them by wrapping the break with electrical tape. - After installing parts, make sure that no wires are pinched under them. - When using electrical test equipment, follow the manufacturer's instructions and those described. - If possible, insert the probe of the tester from the wire side (except waterproof connector). - Use back probe adaptor 07TAZ-001020A. - Refer to the instructions in the Honda Terminal Kit for identification and replacement of connector terminals. Five-Step Troubleshooting Five-Step Troubleshooting 1. Verify The Complaint Page 6184 Component Locations Shift Interlock Switch: Component Locations Component Location Index Page 2012 without disconnecting the P/S hoses. 7. Remove the alternator. 8. Remove the four ignition coils. 9. Remove the throttle cable clamps (A) and harness holder (B) from the cylinder head cover. 10. Remove the cylinder head cover. 11. Hold the pulley with holder handle (A) and holder attachment (B). 12. Remove the bolt with a heavy duty 19 mm socket (C) and breaker bar. 13. Support the engine with a jack and wood block under the oil pan. Page 618 55. In Steering Column Cover Page 7096 PARTS INFORMATION TOOL INFORMATION Page 6756 2. Remove the access panel (A) from the steering wheel, then disconnect the driver's airbag 4P connector (B) from the cable reel. 3. Remove the two Torx bolts (A) using a Torx T30 bit. Then remove the driver's airbag (B). Installation 1. Place the new driver's airbag (A) in the steering wheel, and secure it with new Torx bolts (B). 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. Diagrams 39. ECT Sensor Page 1775 Variable Valve Timing Actuator: Electrical Diagrams Diagram 31 (EX, HX) Diagrams: Other diagrams referred to by number (See Diagram ##-#, etc.)within these diagrams can be found at Diagrams by Number. See: Diagrams/Electrical Diagrams/Diagrams By Number Locations: Location photographs (references to PHOTOS) referred to within these diagrams can be found at Locations by Photo Number. See: Locations/Component Locations/Locations By Photo Number Connector Views: Connector terminal views (references to VIEWS) referred to within these diagrams can be found at Connector Views by View Number. See: Diagrams/Connector Views/Connector Views By View Number Page 8730 Clutch Switch: Testing and Inspection Clutch Pedal Position Switch Test 1. Disconnect the 2P connector from the clutch pedal position switch (A). 2. Remove the clutch pedal position switch. 3. Check for continuity between the terminals according to the table. - If the continuity is not as specified, replace the clutch pedal position switch. - If OK, install the clutch pedal position switch and adjust the pedal height. Page 5874 Under-dash Fuse/Relay Box (2-door) Page 4146 156. A/T Reverse Relay (A/T, CVT) Page 9344 Terminals - "T" Shielding Switches Fuses Page 5835 Power Windows Component Location Index Locations 77. Under Middle Of Dash Page 8644 1. At the A-pillar, remove the door checker mounting bolt (A). 2. Detach the clips (B, C, D), then remove the door weatherstrip (E). 3. Install the weatherstrip in the reverse order of removal, and note these items: - Replace any damaged clips. - Make sure the weatherstrip is installed in the holder (F) securely. - Apply liquid thread lock to the door checker mounting bolt before installation. - Check for water leaks. - Test-drive and check for wind noise. Page 5653 5. With the wire inserted in the new terminal as shown in step 3, crimp the wire by squeezing the tool with both hands until the stops make contact. 6. Crimp the insulation by positioning the 5.5 slot on the tool over the insulation crimp section of the terminal and squeezing the tool with both hands until the stops make contact. 7. Inspect the quality of the wire crimp. If it has any of the following NO GOOD crimps, cut it off and start over. 8. Clean the starter side of the S terminal as needed using electric contact cleaner and an electrical connector cleaning brush (Snap-on P/N YA385A or equivalent). Blow out any debris remaining on or around the terminal with compressed air. 9. Apply silicone dielectric grease (3M silicone paste P/N 08946, Permatex Dielectric Tune-up grease P/N 67VR, or equivalent) to the female side of the S terminal, then carefully insert the terminal into the S terminal on the starter side. 10. Slide the boot completely over the S terminal. 11. Reconnect the positive battery cable, then reconnect the negative battery cable. 12. Enter the anti-theft code for the audio unit (if applicable), then enter the customer's audio presets. Set the clock. 13. Confirm that the starter engages properly by starting the engine several times. 14. Do the idle learn procedure: ^ Make sure all electrical items (A/C, audio unit, defogger, lights, etc.) are off. Page 5370 - Before connecting connectors, make sure the terminals (A) are in place and not bent. - Check for loose retainer (A) and rubber seals (B). - The backs of some connectors are packed with dielectric grease. Add grease if necessary. If the grease is contaminated, replace it. - Insert the connector all the way and make sure it is securely locked. - Position wires so that the open end of the cover faces down. Handling Wires and Harnesses - Secure wires and wire harnesses to the frame with their respective wire ties at the designated locations. Page 5386 3. Strip the insulation off the end of the wire so the wire fits in the new terminal as shown. (If the wire has a wire seal, replace it with a new one from the kit.) NOTE: After stripping the end of the wire, make sure you did not cut any wire strands. If you did, cut the wire off even with the insulation, and strip it again. 4. Position the terminal in the crimping tool slot with the solid portion of the terminal toward the anvil and the open section toward the former. 5. Insert the wire in the terminal to the position shown in step 3. 6. Squeeze the tool with both hands until the stops make contact. 7. Crimp the insulation crimp. - If you do not have a wire seal, then use the next larger size crimp slot. Position the crimping tool over the insulation crimp section of the terminal, then squeeze the tool with both hands until the stops make contact. - If you have a wire seal, position the insulation crimp in the 5.5 crimping slot, then carefully squeeze the crimp closed until its ends are touching and making a full-circle shape. Page 9561 Door Switch: Locations Entry Light Control System Component Location Index Page 9254 Hazard Warning Switch: Testing and Inspection Hazard Warning Switch Test 1. Remove the center panel. 2. Disconnect the 10P connector (A) from the hazard warning switch (B). 3. Push out the hazard warning switch from behind the center panel (C). 4. Check for continuity between the terminals in each switch position according to the table. 5. If the continuity is not as specified, replace the illumination bulb (D) or the switch. Page 5149 Shift Indicator: Service and Repair Indicator Bulb Replacement SRS components are located in this area. Review the SRS component locations, precautions, and procedures in SRS before performing repairs or service. 1. Remove the gauge assembly. 2. Replace the bulb (A) in the gauge assembly (B). Page 9003 Connectors - "C" Page 5973 Under-hood Fuse/Relay Box Component Locations Page 2811 Wire Color Abbreviations Page 5290 Shift Interlock Switch: Testing and Inspection Park Pin Switch Test Park Pin Switch Test 1. Remove the center console panel and center console. 2. Disconnect the park pin switch connector (4P). 3. Shift to the P position, then check for continuity between the No. 3 and No. 4 terminals. There should be no continuity. 4. Shift out of the P position, and check for continuity between terminals No. 3 and No. 4. There should be continuity. 5. If the park pin switch is faulty, replace it. Page 2628 Idle Speed: Description and Operation Idle Control System When the engine is cold, the A/C compressor is on, the transmission is in gear, the brake pedal is pressed, the power steering load is high, or the alternator is charging, the ECM/PCM controls current to the Idle Air Control (IAC) valve to maintain the correct idle speed. Refer to the System Diagram to see the functional layout of the system. Idle Control System Diagram The idle speed of the engine is controlled by the idle air control (IAC) valve: - After the engine starts, the IAC valve opens for a certain amount of time. The amount of air is increased to raise the idle speed. - When the engine coolant temperature is low, the IAC valve is opened to obtain the proper fast idle speed. The amount of bypassed air is thus controlled in relation to engine coolant temperature. Page 2826 - 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. Troubleshooting Tests 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 test 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 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. 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 Drop Locations Power Steering Pressure Switch: Locations Idle Control System - Component Location Index 34. Left Side Of Engine Compartment Page 5782 1. Right Side Of Engine Compartment Page 8309 Trunk / Liftgate Lock Cylinder: Service and Repair Trunk Lid Lock Cylinder Replacement NOTE: Put on gloves to protect your hands. 1. Disconnect the cylinder rod (A). 2. Remove the bolts securing the lock cylinder (A). Then turn the trunk lid lock cylinder 45 °, and remove it. 3. Install the lock cylinder in the reverse order of removal, and note these items: - Make sure the cylinder rod is connected properly. - Make sure the trunk lid opens properly and locks securely. Page 4980 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. Test Equipment 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. Page 2477 PGM-FI System - Component Location Index Page 1979 8. Tighten each bolt two turns at a time, in the sequence shown below, to ensure that the rockers do not bind on the valves. Specified torque 8 mm bolts: 20 Nm (2.0 kgf-cm, 14 ft. lbs.) Apply engine oil to the bolt threads. 6 mm bolts: 12 Nm (1.2 kgf-cm, 8.7 ft. lbs.) Apply engine oil to the bolt threads. 6 mm bolts: (11), (12), (13), (14) 9. Align the marks (A) on the new cylinder head plug (B) with the top edge of the head, then install the cylinder head plug in the cylinder head. Page 2969 ECM/PCM Inputs And Outputs At Connector E (31P) Page 9709 5. Reinstall the parts in the reverse order of removal. 6. Test the operation of all windows with the power window master switch.If any of the windows do not work correctly, continue with normal troubleshooting, and do the master switch input test: ^ Refer to page 22-168 of the 2001-05 Civic Service Manual, or ^ Online, enter keyword MASTER TEST, and select Power Window Master Switch Input Test (4-door) from the list. Disclaimer Antitheft System - Alarm Will Not Arm/Arms By Itself Alarm Module: All Technical Service Bulletins Antitheft System - Alarm Will Not Arm/Arms By Itself 05-025 July 1, 2005 Applies To: 2001-05 Civic - ALL 2002-05 CR-V - ALL 2003-04 Element - ALL Accessory Security System Changes Modes By Itself (Supersedes 05-025, dated June 10, 2005, to update the information indicated by black bars and asterisks.) SYMPTOM The security system will not arm or it arms by itself. PROBABLE CAUSE Key switch contact chatter causes the control unit to change modes. CORRECTIVE ACTION * Civic: Replace the security control unit, and reprogram the remote(s).* * CR-V and Element: Replace the security control unit and the microphone, then reprogram the remote(s).* * NOTE: You must replace the microphone on the CR-V and Element because the security control units are matched to their microphones when they are manufactured. Using the original microphone may result in security system problems.* PARTS INFORMATION WARRANTY CLAIM INFORMATION In warranty: The normal warranty applies. Out of warranty: Any repair performed after warranty expiration may be eligible for goodwill consideration by the District Parts and Service Manager or your Zone Office. You must request consideration, and get a decision, before starting work. REPAIR PROCEDURE NOTE: Before starting, make sure you have all of the remotes (three maximum) the customer wishes to use. Page 2976 ECM/PCM Inputs And Outputs At Connector C (22P) Primary Oxygen Sensor Oxygen Sensor: Description and Operation Primary Oxygen Sensor Primary Heated Oxygen Sensor (Primary HO2S) (D17A1, D17A2 engines) The primary HO2S detects the oxygen content in the exhaust gas and sends signals to the ECM/PCM which varies the duration of fuel injection accordingly. To stabilize its output, the sensor has an internal heater. The primary HO2S is installed in the three way catalytic converter (TWC) (D17A1 engine) or in the exhaust manifold (D17A2 engine). By controlling the air fuel ratio with primary HO2S and secondary HO2S, the deterioration of the primary HO2S can be evaluated by its feedback period. When the feedback period exceeds a certain value during stable driving conditions, the sensor is considered deteriorated and the ECM/PCM sets a DTC. Page 7310 ^ Select About. - What iTunes version are you using? - What TTS software version is installed? ^ Make sure you have the customer's iPod for troubleshooting. ^ Turn on the iPod, and verify its battery is fully charged before testing. If the battery is low, the iPod will not "make up" when connected. ^ Some iPod protective cases cause the Music Link iPod connector to be installed crookedly or not fully engaged. Be sure to remove the protective case before troubleshooting. ^ Go to http//musiclink.honda.com/Tech Faq.html to view technical FAQs and troubleshooting. TROUBLESHOOTING Check mark is not shown on the iPod display screen, radio will not switch to CD-C or CD-4 mode. NOTE: Remove the iPod protective case, if installed. 1. At the Music Link interface unit, make sure both connectors are fully engaged, and the cables do not have any broken or bent pins. NOTE: To release the Music Link interface unit connectors, you must pull back on the lock sleeves. Does either cable have the connector partially disengaged, or are any pins broken or bent? Yes - Reconnect or replace the loose or damaged cable. No - Go to step 2. 2. At the audio unit, make sure the cable connectors and the connector pin fits are tight. Also check that the optional Y-bus harness (if installed) connector and connector pin fits are tight. Do the cable connections and pins fit properly? Yes - Replace the Music Link interface unit and the cable. No - Repair the faulty connection at the audio unit. Static, or weak or no volume over speakers only in Music Link mode. NOTE: Remove iPod protective case, if installed. Page 765 17. Right Side Of Engine Compartment (EX, HX) Page 2448 Fuel Tank Pressure Sensor: Locations EVAP System - Component Location Index Page 3651 Shift Solenoid: Testing and Inspection Shift Solenoid Valves A and B Test 1. Disconnect the shift solenoid valves A and B connector. 2. Measure shift solenoid valve A resistance between the No. 1 terminal of the shift solenoid valves A and B connector and body ground, and measure shift solenoid valve B resistance between the No. 2 terminal and body ground. STANDARD: 12 - 25 Ohms 3. Replace the shift solenoid valves A and B if either resistance is out of standard. 4. If the resistance is within the standard, connect the No. 1 terminal of the shift solenoid valve A to the battery positive terminal. A clicking sound should be heard. Connect the No. 2 terminal to the battery positive terminal. A clicking sound should be heard. Replace the shift solenoid valves A and B if no clicking sound is heard when either terminal is connected to the battery terminal. Page 5734 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. How to Replace Connector Terminals Terminal Replacement Procedure HOW TO REPLACE CONNECTOR TERMINALS The terminal repair kits provide necessary tools and materials (terminals, wire seals, and splice connectors) to repair many damaged or faulty connector terminals. However, not all terminals for all connectors are available. Refer to the labels on the lids of the repair kits for replacement terminal availability. IMPORTANT SAFETY INFORMATION: On some models, the SRS wires are in a separate harness. If the SRS harness is damaged, replace the harness; do not repair it. On other models, wire harnesses include yellow SRS wires. If any SRS wire is damaged, replace the entire harness; do not repair it. Before you begin, inspect the wire you are about to repair for damage and length. Make sure the wire will be long enough to make a terminal repair without stretching it when you reinstall the terminal in the connector. If the wire is too short, or if access to the connector is too restricted to make a terminal repair, you may need to install a pigtail terminal (a short length of wire with a factory-crimped terminal on it). Refer to HOW TO INSTALL PIGTAIL TERMINALS. Removing the Terminal Door Lock Knob Switch Test Power Door Lock Switch: Testing and Inspection Door Lock Knob Switch Test Door Lock Knob Switch Test 4-door 1. Remove the driver's door panel. 2. Disconnect the 3P connector from the actuator. 3. Check for continuity between the No.1 and No.2 terminals. - There should be continuity when the door lock knob switch is in the LOCKED position. - There should be no continuity when the door lock knob switch is in the UNLOCKED position. 4. If the continuity is not as specified, replace the door lock actuator. 2-door 1. Remove the driver's door panel. 2. Disconnect the 3P connector from the actuator. 3. Check for continuity between the No.1 and No.2 terminals. - There should be continuity when the door lock knob switch is in the LOCKED position. - There should be no continuity when the door lock knob switch is in the UNLOCKED position. 4. Check for continuity between the No.1 and No.3 terminals. - There should be continuity when the door lock knob switch is in the UNLOCKED position. Page 1575 234. Under-dash Fuse/Relay Box Part 2 Page 7938 ^ Going from front to back, use the middle lock pin to set the first cam to the appropriate key code number in the code book. (The cam is properly set when the number on the cam lines up with the red scribe mark on the clamp unit.) ^ Slide the lock pin through the notch in the cam. (This locks the cam in place.) ^ Keep doing this for each of the remaining cams in the set until all the cams are set and locked, then push the lock pin all the way in. Repeat this process to set and lock the cams for the right cam set. NOTE: Make sure you set the MIS cam in the right cam set for the type of key you are cutting. For a master key, set the cam to M; for a valet key, set it to S. When you are done, push all the cam blades to the left until they touch the cams in the left cam set. 10. Pull the vertical carriage lever toward you until the tracer touches the flat surface on the right side at the front of the cams. Gently twist the lever clockwise to lock the vertical carriage at this height. Do not overtighten the lever. 11. Turn on the cutter motor with the motor start switch. [NOTICE] ^ To avoid damaging the locking jaws while cutting, keep your hand off the vertical carriage lever. Pressure on the lever will change the cutting depth. * ^ To avoid breaking the cutter bit, never back up while cutting.* ^ Wear proper eye protection (safety glasses, goggles, etc.) 12. Use the clamp carriage lever and the tracer to follow the contours of the cam blades from front to back. (The cutter bit cuts the same contours into the right edge of the key blank, from head to tip.) Testing and Inspection Camshaft: Testing and Inspection Inspection NOTE: ^ Do not rotate the camshaft during inspection. ^ Remove the rocker arms and rocker shafts. 1. Put the camshaft and the camshaft holders on the cylinder head, then tighten the bolts to the specified torque. Specified torque: 8 mm bolts: 20 Nm (2.0 kgf-cm, 14 ft. lbs.) Apply engine oil to the bolt threads. 6 mm bolts: 12 Nm (1.2 kgf-cm, 8.7 ft. lbs.) Apply engine oil to the bolt threads. 6 mm bolts: (11), (12), (13), (14) 2. Seat the camshaft by pushing it away from the camshaft pulley end of the cylinder head. 3. Zero the dial indicator against the end of the camshaft, then push the camshaft back and forth and read the end play. Camshaft End Play: Standard (New): 0.05 - 0.15 mm (0.002 - 0.006 inch) Service Limit: 0.5 mm (0.02 inch) 4. Unscrew the camshaft holder bolts two turns at a time, in a crisscross pattern. Then remove the camshaft holders from the cylinder head. 5. Lift the camshaft out of the cylinder head, wipe them clean, then inspect the lift ramps. Replace the camshaft if any lobes are pitted, scored, or excessively worn. 6. Clean the camshaft journal surfaces in the cylinder head, then set the camshaft back in place. Place a plastigage strip across each journal. 7. Install the camshaft holders, then tighten the bolts to the specified torque as shown in step 1. Page 162 Diodes Light Emitting Diode (LED) Motor Pressure Sensor Page 5723 Circuit Schematics Each schematic represents one circuit. A circuit's wires and components are arranged to show current flow from power at the top of the diagram 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 Page 3915 9. Wait for the MVCI to copy the data for updating the vehicle. 10. After the MVCI has copied the files, a confirmation screen appears. Press ENTER to update the control unit/module, or press ESC to exit. 11. Wait for the MVCI to update the control unit/module. 12. After the MVCI finishes updating the control uniti module, turn the ignition switch to LOCK (0) when directed by the MVCI. 13. Turn the ignition switch back to ON (II) within 60 seconds to complete the updating procedure. NOTE: The MVCI has a countdown timer. If you do not turn the ignition switch to ON (II) within 60 seconds, the MVCI sets an error code. Page 9716 5. Reinstall the parts in the reverse order of removal. 6. Test the operation of all windows with the power window master switch.If any of the windows do not work correctly, continue with normal troubleshooting, and do the master switch input test: ^ Refer to page 22-168 of the 2001-05 Civic Service Manual, or ^ Online, enter keyword MASTER TEST, and select Power Window Master Switch Input Test (4-door) from the list. Disclaimer Page 3156 13. Plug in the heat gun, and turn it on. Start at the middle of the splice connector, and move the gun toward the ends as the tube shrinks. Apply heat evenly by rotating the curved heat spreader around the splice connector. Shrinking is complete when a small amount of sealant appears at each end of the tube. Pigtail Terminal Selection Chart PIGTAIL TERMINAL SELECTION CHART Select the proper size pigtail terminal by matching the replacement terminal part number and the wire size being repaired to the corresponding pigtail terminal part number. Then use the color (size) splice connector listed. In some instances you may also have to match the wire seal style to select the proper pigtail terminal. Pigtail terminals are available through your parts department, in quantities of 10, using normal parts ordering procedures. Checking For Poor Fir of Terminals CHECKING FOR POOR FIT OF TERMINALS Loose terminal fit can cause a number of intermittent problems in electrical circuits. By using the Terminal Inspection Feeler Tool Set you can inspect the terminal fit between the two matching connectors without removing the terminals from the connector body. 1. Find the terminal tool that best matches the male terminal in the mating connector. Page 8527 142. Moonroof Limit Switch (EX) Diagram Information and Instructions Brake Warning Indicator: Diagram Information and Instructions Terminal Numbering System Terminal Numbering System Connector terminals are numbered according to the cavities they're in. The cavities are numbered starting from the upper left, looking at the male terminals from the terminal side or looking at the female terminals from the wire side. Both views are in the same direction so the numbers are the same. All actual cavities are numbered, even if they have no wire terminals in them. NOTE: Data Link Connector (DLC) terminals are numbered according 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 below is #6. Page 2656 3. Replace the plug at the specified interval, or if the center electrode is rounded (A). Use only the spark plugs listed. 4. Apply a small quantity of anti-seize compound to the plug threads, and screw the plugs into the cylinder head finger-tight. Then torque them to 18 N.m (1.8 kgf.m, 13 lbf.ft). Mainshaft Speed Sensor Replacement Transmission Speed Sensor: Service and Repair Mainshaft Speed Sensor Replacement Mainshaft Speed Sensor Replacement 1. Disconnect the mainshaft speed sensor connector. 2. Remove the mainshaft speed sensor (A). 3. Install the new mainshaft speed sensor with the new O-ring (B) and mainshaft speed sensor washer (C). NOTE: The mainshaft speed sensor washer is equipped on the SLXA automatic transmission; the BMXA does not have it. 4. Check the mainshaft speed sensor connector for rust, dirt, or oil, then connect the connector securely. Page 2985 Engine Control Module: Service and Repair Updating the ECM/PCM ECM/PCM Updating and Substitution for Testing Special Tools Required Honda Interface Module (HIM) - P/N EQS05A35570 Use this procedure when you have to substitute a known-good ECM/PCM in a troubleshooting procedure. Update the ECM/PCM only if the ECM/PCM does not already have the latest software loaded. NOTE: Do not turn the ignition switch OFF while updating; the ECM/PCM can be damaged. How to Update the ECM/PCM NOTE: - To ensure the latest program is installed, do an ECM/PCM update whenever the ECM/PCM is substituted or replaced. - Before you update the ECM/PCM, make sure the vehicle's battery is fully charged. - To prevent ECM/PCM damage, do not operate anything electrical (audio system, brakes, A/C, power windows, moon roof, door locks, etc.) during the update. - If you need to diagnose the Honda Interface Module (HIM) because the HIM's red (#3) light came on or was flashing during the update, leave the ignition switch in the ON (II) position when you disconnect the HIM from the Data Link Connector (DLC). This will prevent ECM/PCM damage. 1. Turn the ignition switch ON (II). Do not start the engine. 2. Connect the HIM to the DLC (A) located under the driver's side of dashboard. 3. Do the ECM/PCM update procedure as described on the HIM label and in the ECM/PCM update system. If the software in the ECM/PCM is the latest version, replace the ECM/PCM. How to Substitute the ECM/PCM 1. Remove the ECM/PCM from the vehicle. 2. Install a known-good ECM/PCM in the vehicle. 3. Rewrite the immobilizer code with the ECM/PCM replacement procedure in the Honda PGM Tester; It allows you to start the engine. 4. After completing your tests, reinstall the original ECM/PCM and rewrite the immobilizer code with the ECM/PCM replacement procedure in the Honda PGM Tester again. Front Door Glass Outer Weatherstrip Replacement Front Door Window Glass Weatherstrip: Service and Repair Front Door Glass Outer Weatherstrip Replacement Front Door Glass Outer Weatherstrip Replacement 4-door NOTE: - Put on gloves to protect your hands. - Take care not to scratch the door. 1. Remove the mirror. 2. Starting at the rear, pry the door glass outer weatherstrip (A) up to detach the clips (B, C), then remove the weatherstrip. 3. Install the weatherstrip in the reverse order of removal, and replace any damaged clips. Locations Camshaft Position Sensor: Locations PGM-FI System - Component Location Index Page 1578 234. Under-dash Fuse/Relay Box Part 5 Page 3505 Blower Motor Relay Type 1, Type 2 Check for continuity between the terminals. - There should be continuity between the No.1 and No.3 terminals when power and ground are connected to the No.2 and No.4 terminals. - There should be no continuity between the No.1 and No.3 terminals when power is disconnected. Five-terminal type Check for continuity between the terminals. - There should be continuity between the No.1 and No.2 terminals when power and ground are connected to the No.3 and No.5 terminals. - There should be continuity between the No.1 and No.4 terminals when power is disconnected. Page 8027 ^ Going from front to back, use the middle lock pin to set the first cam to the appropriate key code number in the code book. (The cam is properly set when the number on the cam lines up with the red scribe mark on the clamp unit.) ^ Slide the lock pin through the notch in the cam. (This locks the cam in place.) ^ Keep doing this for each of the remaining cams in the set until all the cams are set and locked, then push the lock pin all the way in. Repeat this process to set and lock the cams for the right cam set. NOTE: Make sure you set the MIS cam in the right cam set for the type of key you are cutting. For a master key, set the cam to M; for a valet key, set it to S. When you are done, push all the cam blades to the left until they touch the cams in the left cam set. 10. Pull the vertical carriage lever toward you until the tracer touches the flat surface on the right side at the front of the cams. Gently twist the lever clockwise to lock the vertical carriage at this height. Do not overtighten the lever. 11. Turn on the cutter motor with the motor start switch. [NOTICE] ^ To avoid damaging the locking jaws while cutting, keep your hand off the vertical carriage lever. Pressure on the lever will change the cutting depth. * ^ To avoid breaking the cutter bit, never back up while cutting.* ^ Wear proper eye protection (safety glasses, goggles, etc.) 12. Use the clamp carriage lever and the tracer to follow the contours of the cam blades from front to back. (The cutter bit cuts the same contours into the right edge of the key blank, from head to tip.) Testing and Inspection Positive Crankcase Ventilation Valve: Testing and Inspection PCV Valve Inspection and Test 1. Check the PCV valve (A), hoses (B), and connections for leaks or restrictions. 2. At idle, make sure there is a clicking sound from the PCV valve when the hose between the PCV valve and intake manifold is lightly pinched (A) with your fingers or pliers. If there is no clicking sound, check the PCV valve grommet for cracks or damage. If the grommet is OK, replace the PCV valve and recheck. Page 1839 3. Measure the piston pin-to-piston clearance. Piston Pin-to-Piston Clearance Standard (New): 0.010 - 0.020 mm (0.0004 - 0.0008 inch) 4. Check the difference between the piston pin diameter and connecting rod small end diameter. Piston Pin-to-Connecting Rod Interference Standard (New): 0.016 - 0.036 mm (0.0006 - 0.0014 inch) Reassembly 1. Assemble the piston and connecting rod with the connecting rod oil hole (A) facing the "IN" mark (B). Page 9543 29. Back-up Light Switch (M/T) Page 9122 Wire Color Abbreviations Continuously Variable Transmission Transmission Position Switch/Sensor: Testing and Inspection Continuously Variable Transmission Transmission Range Switch Test 1. Disconnect the transmission range switch connector. 2. Check for continuity between terminals at the switch connector. There should be continuity between terminals below listed for each switch position. 3. If there is no continuity between any terminals, adjust the transmission range switch installation. If the transmission range switch installation is OK, replace the transmission range switch. 4. If the transmission range switch continuity check was OK, replace the faulty transmission harness. Page 4636 107. Behind A/T Shift Lever (except M/T) Page 4325 11. If improperly installed, remove the shift cable from the shift cable bracket base, and reinstall the shift cable. Do not install the shift cable end on the mounting stud while the shift cable is on the shift cable bracket base. 12. Install and tighten the nut. 13. Remove the 6.0 mm (0.24 inch) pin that was installed to hold the shift lever. 14. Move the shift lever to each position, and verify that the A/T gear position indicator follows the transmission range switch. 15. Push the shift lock release, and verify that the shift lever releases. 16. Reinstall the center console, console panel, and related parts. Page 4769 Wire Color Abbreviations Page 600 Door Switch: Diagrams 4. Door Switch, Driver's 5. Door Switch, Front Passenger's (Sedan) 6. Door Switch, Left Rear Or Right Rear 7. Door Switch, Passenger's (Coupe) Page 4741 Flex Plate: Specifications Continuously Variable Transmission Drive Plate Tighten the six bolts in a crisscross pattern. Locations 21. Transmission Housing (A/T) Page 7088 12. Watch the SRS indicator: ^ If the indicator blinks twice and then goes off, the OPDS unit is initialized. Turn the ignition switch to LOCK (0), and disconnect the HDS. ^ If the indicator blinks twice and then stays on, the OPDS unit is initialized, but SRS DTCs need to be cleared. Go to step 13. ^ If the indicator stays on without first blinking, the OPDS unit is not initialized. Repeat steps 3 thru 12. 13. Turn the ignition switch to LOCK (0), then disconnect the HDS. 14. Reconnect the SCS service connector to the MES connector. Do not use a jumper wire. 15. Turn the ignition switch to ON (II). 16. Watch the SRS indicator. (It comes on for about 6 seconds and then goes off.) Disconnect the SCS service connector from the MES connector within 4 seconds after the indicator goes off. 17. When the SRS indicator comes on again, connect the SCS service connector to the MES connector within 4 seconds after the indicator comes on. 18. When the SRS indicator goes off, disconnect the SCS service connector from the MES connector within 4 seconds. (The SRS indicator blinks twice to indicate that the memory has been cleared.) 19. Turn the ignition switch to LOCK (0), and wait for 10 seconds. 20. Turn the ignition switch to ON (II). (The SRS is OK if the SRS indicator comes on for 6 seconds and then goes off.) If the DTC clearing fails, repeat the process two more times. If the DTC clearing fails again, check for set SRS DTCs, and troubleshoot them with the appropriate service manual. REPAIR PROCEDURE B: OPDS SENSOR REPLACEMENT 1. Remove the seat-back cover from the front passenger's seat: ^ Using the appropriate service manual, go to section 20 (Body), and do the removal steps under Front Seat Cover Replacement, or ^ Online, enter keyword SEAT COVER, then select Front Seat Cover Replacement from the list, and do the removal steps in the procedure. 2. Slide the seat-back cushion (foam) off the seat-back frame. (The OPDS sensor is built into the seat-back cushion.) 3. Slide a new seat-back cushion over the seat-back frame. Make sure the cushion is centered. 4. Install the seat-back cover: ^ Using the appropriate service manual, go to section 20 (Body), and do the installation step under Front Seat Cover Replacement, or ^ Online, enter keyword SEAT COVER, then select Front Seat Cover Replacement from the list, and do the installation step in the procedure. 5. Initialize the OPDS unit: ^ To initialize with the HDS, go to Initializing the OPDS Unit: HDS Method in this service bulletin. ^ To initialize with the SCS service connector, go to Initializing the OPDS Unit: Manual Mode in this service bulletin. Disclaimer Page 8757 Brake Warning Indicator: Diagnostic Aids General Troubleshooting Information General Troubleshooting Information Tips and Precautions Before Troubleshooting 1. Check applicable fuses in the appropriate fuse/relay box. 2. Check the battery for damage, state of charge, and clean and tight connections. NOTE: 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. Handling Connectors - Make sure the connectors are clean and have no loose wire terminals. - Make sure multiple cavity connectors are packed with dielectric grease (except watertight connectors). - All connectors have push-down release type locks (A). - Some connectors have a clip on their side used to attach them to a mount bracket on the body or on another component. This clip has a pull type lock. - Some mounted connectors cannot be disconnected unless you first release the lock and remove the connector from its mount bracket (A). - Never try to disconnect connectors by pulling on their wires; pull on the connector halves instead. - Always reinstall plastic covers. Page 7776 19. Using your thumb and forefinger to hold the tumblers, remove the key from the inner cylinder, being careful not to drop any tumblers and springs. 20. *Using the key code from the iN that you have written down at step 2, build a new inner cylinder with new springs, new cylinder, and tumblers from the door lock cylinder kit. Make sure you put the appropriate numbered tumbler in the proper inner cylinder cavity. Apply a thin layer of Permalube to each tumbler to help lubricate and retain it.* NOTE: ^ There are two types of tumblers. The "SUBLOCK" tumbler goes only in cavity A." The "DISC" tumbler goes in cavities "B" through "J." ^ Cavity "E" is empty on all cylinders. Page 3668 Shift Solenoid: Diagrams 185. CVT Control Valves And Inhibitor Solenoid Assembly 73. Shift Solenoid Valve A And B (A/T Except CVT) Page 7052 4. Remove the access panel from the steering wheel (A), then disconnect the driver's airbag 4P connector (B) from the cable reel. Front Passenger's Airbag: 5. Lower the glove box, then disconnect the front passenger's airbag 4P connector (A) from dashboard wire harness B. Side Airbag: 6. Disconnect the 2P connector between the side airbag (A) and the floor wire harness. Seat belt tensioner: 7. Disconnect the 2P connector between the seat belt tensioner (A) and floor wire harness. Seat belt buckle tensioner: Page 5488 Parking Brake Warning Switch: Testing and Inspection Parking Brake Switch Test 1. Remove the console, and disconnect the connector (A) from the switch (B). 2. Check for continuity between the positive terminal and body ground: ^ With the brake lever up, there should be continuity. ^ With the brake lever down, there should be no continuity. Page 1755 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. Test Equipment 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. Page 4655 Shift Solenoid: Diagrams 185. CVT Control Valves And Inhibitor Solenoid Assembly 73. Shift Solenoid Valve A And B (A/T Except CVT) Page 7254 Programming the Transmitter NOTES: ^ The system accepts up to three transmitters. The transmitter codes are stored in a stacking-type memory. If a fourth transmitter code is programmed, the code for the first transmitter is erased. ^ Entering the programming mode cancels all learned transmitter codes, so none of the previously programmed transmitters will work. You must reprogram all of the transmitters once you are in the programming mode. ^ You must complete steps 1-6 within 4 seconds of the previous step to keep the system from exiting the programming mode. 1. Turn the ignition switch to ON (II). 2. Press the "Lock" or "Unlock" button on one of the transmitters. (An unprogrammed transmitter can be used for this step.) 3. Turn the ignition switch to LOCK (0). 4. Repeat steps 1 2, and 3 two more times using the same transmitter used in step 2. 5. Turn the ignition switch to ON (II). 6. Press the "Lock" or "Unlock" button on the same transmitter. Make sure the power door locks cycle to confirm that the system is in programming mode. 7. Within 10 seconds, press the "Lock" or "Unlock" button on each transmitter. Make sure the power door locks cycle after you press each transmitter button to confirm that the system accepted the transmitter's code. 8. Turn the ignition switch to LOCK (0) to exit the programming mode. Ordering a Transmitter Transmitters can be ordered only by authorized Honda dealers. Order them from American Honda using normal parts ordering procedures. Batteries for the Transmitter The battery number is CR2025. Each transmitter uses one battery. 94-95 Passport (Except 1995-1/2) 1994-95 Passport (except 19951A) with dealer-installed security system NOTES: ^ The system uses a stacking-type memory that accepts up to four transmitters. If you program a fifth transmitter, the memory for the first transmitter is pushed out, and it will no longer work. ^ To clear a lost or stolen transmitter from the system's memory, program a transmitter four times. This will remove the missing transmitter from memory, since only four transmitters can be accepted. Component Locations Relay Box: Component Locations Relay Box Locations Starting System Component Location Index Page 9184 Resistor Variable Sensor Solenoid Transistors Circuit Schematics Page 7322 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. Specifications Fuel Pressure: Specifications Fuel Pressure at idle .................................................................................................................................... 270 - 320 kPa (2.8 - 3.3 kgf/sq.cm, 40 - 47 psi) Trim Removal/Installation - Rear Shelf Area Rear Shelf: Service and Repair Trim Removal/Installation - Rear Shelf Area Trim Removal/Installation - Rear Shelf Area Special Tools Required KTC trim tool set SOJATP2014 4-door NOTE: - Put on gloves to protect your hands. - Use the appropriate tool from the KTC trim tool set to avoid damage when prying components. - Take care not to bend or scratch the trim and panels. 1. Remove the trim as shown. To remove the rear shelf, remove the rear seat side bolster from each side and lock cylinder trim. 2. Install the parts in the reverse order of removal, and note these items: - Replace any damaged clips. - When installing the rear shelf, slip the rear seat belts and center belt through the slits and hole in the rear shelf. - Apply liquid thread lock to the anchor bolt before installation. - Make sure the high mount brake light connector is plugged in properly. Page 4127 Shift Indicator: Service and Repair Indicator Bulb Replacement SRS components are located in this area. Review the SRS component locations, precautions, and procedures in SRS before performing repairs or service. 1. Remove the gauge assembly. 2. Replace the bulb (A) in the gauge assembly (B). Page 2200 67. Radiator Fan Switch ATF Level Check Fluid - A/T: Service and Repair ATF Level Check ATF Level Check NOTE: Keep all foreign particles out of the transmission. 1. Warm up the engine to normal operating temperature (the radiator fan comes on). 2. Park the vehicle on level ground, and turn the engine off. 3. Remove the dipstick (yellow loop) (A) from the transmission, and wipe it with a clean cloth. 4. Insert the dipstick into the transmission. 5. Remove the dipstick and check the fluid level. It should be between the upper mark (B) and lower mark (C). 6. If the level is below the lower mark, pour the recommended fluid into the dipstick hole to bring it to the upper mark. Always use Honda ATF-Z1 Automatic Transmission Fluid (ATF). Using a non Honda ATF can affect shift quality. 7. Insert the dipstick back into the transmission in the direction shown. Page 801 Splices Components Ground - "G" Page 307 94. Behind Glove Box (except GX) Page 1064 Diodes Light Emitting Diode (LED) Motor Pressure Sensor Page 9076 Terminals - "T" Shielding Switches Fuses Locations 94. Behind Glove Box (except GX) Front Seat Belt Buckles Seat Belt Buckle: Service and Repair Front Seat Belt Buckles Front Seat Belt Replacement SRS components are located in this area. Review the SRS component locations and the precautions and procedures, in the SRS section before performing repairs or service. NOTE: Check the front seat belts for damage, and replace them if necessary. Be careful not to damage them during removal and installation. Seat Belt Buckle 1. Make sure you have the anti-theft code for the radio, then write down the customer's radio station presets. 2. Disconnect the negative cable from the battery, and wait at least 3 minutes before beginning work. 3. Remove the front seat. 4. Detach the seat belt switch connector clip (A),seat belt buckle tensioner connector clip (B), and harness clips (C). 5. On the driver's seat, adjust the seat cushion to its maximum height. 6. Remove the center anchor bolt (A), and remove the seat belt buckle (B). 7. Pull the seat belt switch/tensioner harness (C) out through the space between the seat cushion and the seat linkage (driver's seat), or the hole on the seat track (passenger's seat). Page 75 Radiator Cooling Fan Motor Relay: Testing and Inspection Power Relay Test Use this chart to identify the type of relay, then do the test listed for it. NOTE: See the turn signal/hazard relay input test. Normally-open type A: Page 186 2. Cut off the wire about an inch back from where it connects to the damaged or faulty terminal, then strip about half of the insulation off that piece. This will be used to size the wire end of the replacement pigtail terminal. NOTE: If you are not sure of the wire size, start with a large enough hole on the stripper that will not nick or cut off any strands of wires. 3. Select a pigtail terminal that matches the original wire at both ends (same kind of terminal and same diameter bare wire). 4. Select the smallest splice connector (yellow, pink, or blue) that will fit onto the stripped end of the original wire. 5. Insert the pigtail terminal into the connector cavity; push it in until it locks in place. 6. Lay the pigtail and the original wire side-by-side, and cut off both ends at once. If you are making more than one splice, do not cut each pigtail at the same location; the resulting "lump" of splice connectors would interfere with rewrapping the harness. Instead, cut the first pigtail close enough to the terminal so you will have room to make each remaining cut about 20 mm (3/4 inch) farther down on the next pigtail. 7. If you are using a yellow splice connector, strip about 6 mm (1/4 inch) of insulation off the ends of both wires. If you are using a pink or blue splice connector, strip off about 8 mm (5/16 inch) of insulation. Page 5693 Starting System - Starting Overhaul Part 2 Disassembly/Reassembly - A/T Armature Inspection and Test 1. Remove the starter. 2. Disassemble the starter as shown at the beginning of this procedure. Page 9140 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. How to Replace Connector Terminals Terminal Replacement Procedure HOW TO REPLACE CONNECTOR TERMINALS The terminal repair kits provide necessary tools and materials (terminals, wire seals, and splice connectors) to repair many damaged or faulty connector terminals. However, not all terminals for all connectors are available. Refer to the labels on the lids of the repair kits for replacement terminal availability. IMPORTANT SAFETY INFORMATION: On some models, the SRS wires are in a separate harness. If the SRS harness is damaged, replace the harness; do not repair it. On other models, wire harnesses include yellow SRS wires. If any SRS wire is damaged, replace the entire harness; do not repair it. Before you begin, inspect the wire you are about to repair for damage and length. Make sure the wire will be long enough to make a terminal repair without stretching it when you reinstall the terminal in the connector. If the wire is too short, or if access to the connector is too restricted to make a terminal repair, you may need to install a pigtail terminal (a short length of wire with a factory-crimped terminal on it). Refer to HOW TO INSTALL PIGTAIL TERMINALS. Removing the Terminal Page 4258 Shift Interlock Solenoid: Testing and Inspection Shift Lock Solenoid Test 1. Remove the center console panel and center console. 2. Disconnect the shift lock solenoid connector (2P). 3. Connect the No. 1 terminal of the shift lock solenoid connector (2P) to the battery positive terminal, and connect the No. 2 terminal to the battery negative terminal. 4. Check that the shift lever can be moved from the P position. Release the battery terminals from the shift lock solenoid connector. Move the shift lever back to the P position, and make sure it locks. NOTE: Do not connect power to the No. 2 terminal (reverse polarity) or you will damage the diode inside the solenoid. 5. Check that the shift lock releases when the shift lock release is pushed, and check that it locks when the shift lock release is released. 6. If the shift lock solenoid does not work properly, replace it. Locations Daytime Running Lamp Control Unit: Locations Relay And Control Unit Locations - Dashboard Page 7939 13. After completing the right edge, push all of the cam blades to the right until they touch the cams, then trace the cam blades from back to front. (The cutter bit cuts the same contours into the left edge of the key from tip to head.) Turn off the cutter motor. 14. Release the vertical carriage lever. Push all the cam blades to the left until they touch the cams. Pull the vertical carriage lever towards you until the tracer touches the flat surface on the right side, at the front of the cams. Gently twist the lever clockwise to lock the vertical carriage at this height. Do not overtighten the lever. 15. Turn on the cutter motor, then retrace the cam blades from front to back. Push all the cam blades to the right until they touch the cams, and then retrace the cam blades from back to front (retracing cleans up the cuts on the key). Turn off the cutter motor. 16. Release the vertical carriage lever. Open the jaw and remove the key. Make sure the jaw is free of any metal shavings or debris. Turn the key over so the blank side is up, then slide it into the jaw up to the key stop. Close the jaw to lock the key in place. 17. Push all the cam blades to the left until they touch the cams. Repeat steps 10 through 15 to cut both edges on the other side of the key. 18. When you are done making the required cuts, release the vertical carriage lever. Open the jaw and remove the key. 19. Make sure the key works in the ignition switch and the locks. If the key does not work, recut the key, and try it again. 20. Depending on the type of key, code the key transponder. Equipment Service and Warranty To service the MATRIX H Key Cutting Machine, refer to section 7 of the MATRIX H Operating Manual. It tells you how to replace parts that commonly wear out such as the drive belt, the work light bulb, and the tension spring on the vertical carriage. It also covers checking and replacing fuses and replacing the printed circuit board for the setting unit keypad. If you have technical questions on the equipment, contact the Ilco Technical Assistance Department. Mail: Kaba Ilco Technical Assistance Department 400 Jeffreys Road Rocky Mount, NC 27804 Phone: 800-452-6872 Ext: 200, 384, 323, 398, 356 Fax: 252-446-4702 The MATRIX H Key Cutting Machine comes with a 3-year limited warranty. This warranty does not cover the cutter bit or the work light bulb. CODE BOOK CORRECTIONS In the code book Honda High Security key Codes, correct these errors: Pages 4 thru 51, code headings: ^ Incorrect: J H G F Z X E D C B M/S X ^ Correct: J H G F A X E D C B M/S X Page 2, last paragraph: Page 2059 1. Remove the terminal. 2. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE B: 1. Remove the terminal. 2. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE C: 1. Remove the terminal. 2. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE D: Page 1633 12. Loosen the damper pinch bolts (A) while holding the nuts (B), and remove the bolts and nuts. 13. Remove the driveshaft outboard joint (C) from the knuckle (D) by tapping the driveshaft end (E) with a plastic hammer while pulling the knuckle outward, then remove the knuckle. NOTE: Do not pull the driveshaft end outward. The driveshaft joint may come off. 14. Separate the hub (A) from the knuckle (B) using the special tool and a hydraulic press. Be careful not to deform the splash guard. Hold onto the hub to keep it from falling when pressed clear. 15. Press the wheel bearing inner race (A) out of the hub (B) using the special tool, a commercially available bearing separator (C), and a press. Page 1537 Under-hood Fuse/Relay Box (2-door) Page 3001 95. Behind Glove Box (HX; '04-'05: DX, EX, LX) Page 7956 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 2769 ECM/PCM Inputs And Outputs At Connector B (24P) Page 3150 1. Remove the terminal. 2. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE E: 1. Remove the terminal. 2. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE F: 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 1853 6. Install the top ring (A) and second ring (B) as shown The manufacturing marks (C) must be facing upward. 7. Rotate the rings in their grooves to make sure they do not bind. 8. Position the ring end gaps as shown: Page 2727 5. Remove the lower cover from the fuse/relay box. 6. Disconnect the 3P ELD connector. Page 2412 104. CKP Sensor Page 8396 138. Rear Of Roof (EX) Page 5709 Starter Solenoid: Testing and Inspection Starter Solenoid Test 1. Check the hold-in coil for continuity between the S terminal and the armature housing (ground). There should be continuity. - If there is continuity, go to step 2. - If there is no continuity, replace the solenoid. 2. Check the pull-in coil for continuity between the S terminal and M terminal. There should be continuity. - If there is continuity, the solenoid is OK. - If there is no continuity, replace the solenoid. Front Impact Sensor Impact Sensor: Service and Repair Front Impact Sensor Front Impact Sensor Replacement Removal NOTE: - Removal of the front sensor must be performed according to the precautions/procedures described before. - Before disconnecting the front sensor 2P connector(s), disconnect the driver's and front passenger's airbag 2P, both seat belt tensioner 2P and both seat belt buckle tensioner 2P connector(s). - Do not turn the ignition switch ON (II), and do not connect the battery cable while replacing the side impact sensor. 1. Disconnect the battery negative cable, and wait at least 3 minutes before beginning work. 2. Remove the front inner fender. 3. Disconnect the engine compartment wire harness 2P connector (A), and remove the two Torx bolts (B) using a Torx T30 bit, then remove the front impact sensor(C). Installation NOTE: - Be sure to install the harness wires so that they are not pinched or interfering with other parts. - Do not turn the ignition switch ON (II), and do not connect the battery cable while replacing the side impact sensor. 1. Install the new front impact sensor with new Torx bolts (A), then connect the engine compartment wire harness 2P connector (B) to the front sensor (C). 2. Reconnect the battery negative cable. 3. After installing the front impact sensor, confirm proper system operation: Turn the ignition switch ON (II): the SRS indicator should come on for about 6 seconds and then go off. Page 7574 6. Install the door panel in the reverse order of removal, and note these items: - Replace any damaged clips - Make sure the connectors are plugged in properly, and the rod is connected properly - Make sure the window operates properly. - If applicable, install the regulator handle so it points forward and up at a 45 ° angle with the glass fully closed. Ignition/Locks - Cutting Sidewinder-Type Keys Technical Service Bulletin # 01-077 Date: 060419 Ignition/Locks - Cutting Sidewinder-Type Keys 01-077 April 19, 2006 Applies To: Models With Sidewinder-Type Keys - All Cutting Sidewinder-Type Keys With the MATRIX H Key Cutting Machine (Supersedes 01-077, dated January 12, 2005) Updated information is noted by asterisks. MATRIX H Key Cutting Machine, manufactured by Silca and supplied by Kaba Ilco Corporation, is a portable, power-operated tool that cuts sidewinder-type automotive keys exclusively. The machine lets you cut these keys either by copying or by code. The code function is designed and built to meet the Honda code requirements. No other similar machine has this capability. This service bulletin gives you information for ordering and servicing this special tool, and guides you through the entire key cutting process from setting up the machine to cutting the key blank. TOOL INFORMATION Order through the Honda Tool and Equipment Program: MATRIX H Key Cutting Machine: Model No. ILCMATRIXSH Cutter Bit: Model No. ILCF3O Fixed Jaw: Model No. ILCMTX-H Mobile Jaw (Right Side): Model No. ILCRTMTX-H Mobile Jaw (Left Side): Model No. ILCLTMTX-H *Remanufactured Clamp Unit: Model No. ILCMATRIXHCR* PARTS INFORMATION *For some models, there are two choices for sidewinder-type key blanks: ^ T-5 sidewinder key blanks ^ Honda sidewinder key blanks For other models, only Honda sidewinder key blanks can be used. See DETERMINING WHICH KEY TO USE to determine which key blank you should choose. Ordering T-5 key blanks through the Honda Tool and Equipment Program: T-5 Programmable Key Blank (Master): P/N ILC-35111-T-5H T-5 Programmable Key Blank (Valet): P/N ILC-35112-T-5H Practice Key Blanks (five per pack): ILC-35111DEMO* NOTE: Do not use practice key blanks for replacement purposes. Practice keys do not have an immobilizer chip. Component Locations Shift Interlock Switch: Component Locations Component Location Index Page 1635 22. Press a new hub bearing unit (A) into the hub (B) using the special tools and a press. 23. Install the knuckle/hub/hub bearing unit in the reverse order of removal, and note these items: - Be careful not to damage the ball joint boot when installing the knuckle. - Tighten all mounting hardware to the specified torque values. - Torque the castle nut to the lower torque specification, then tighten it only far enough to align the slot with the ball joint pin hole. Do not align the castle nut by loosening it. - Install a new lock pin on the castle nut after torquing. - Use a new spindle nut on reassembly. - Before installing the new spindle nut, apply a small amount of engine oil to the seating surface of the nut. After tightening, use a drift to stake the spindle nut shoulder against the driveshaft. - Before installing the brake disc, clean the mating surface of the front hub and the inside of the brake disc. - Before installing the wheel, clean the mating surface of the brake disc and the inside of the wheel. - Check the front wheel alignment, and adjust it if necessary. Page 7143 ^ Within 1 to 4 seconds, turn the ignition switch to LOCK (0). ^ Within 1 to 4 seconds, turn the ignition to ON (II). ^ Within 1 to 4 seconds, push the transmitter lock or unlock button. ^ Confirm you can hear the sound of the door lock actuators. Within 1 to 4 seconds, push the transmitter lock or unlock button again. ^ Within 10 seconds, aim the transmitters (up to two additional ones) whose codes you want to store at the receiver, and press the transmitter lock or unlock button. Confirm that you can hear the sound of the door lock actuators after each transmitter code is stored. ^ Turn the ignition switch to LOCK (0), and pull out the key. 4. Confirm proper operation of the transmitters. Disclaimer Page 48 Keyless Entry Module: Diagrams (EX; '04: LX, GX) (Honda Accessory) Page 2026 8. Install the timing belt in a counterclockwise sequence, starting with the drive pulley. -1 Drive pulley (A). -2 Tensioner pulley (B). -3 Water pump pulley (C). -4 Camshaft pulley (D). 9. Install the tensioner spring on the tensioner bolt. 10. Rotate the crankshaft pulley two turns counterclockwise so that the timing belt positions on the pulleys. 11. Set the No. 1 piston at TDC. 12. Tighten the auto-tensioner mounting bolt (A) to 44 Nm (4.5 kgf-cm, 33 ft. lbs.), then remove the pin (B) from the auto-tensioner. 13. Install the remaining parts. Page 2267 Page 1185 4. Disconnect the 20P connector and make these input tests. 5. Reconnect the connector to the power window master switch and make these input tests. 2-door NOTE: The power window control unit is built into the power window master switch, and it only controls the driver's window operations. 1. Remove the door grip cover. Page 9708 1. Remove the driver's side grip cover: ^ Using a trim tool, pry out the front edge of the cover to release the front clip. ^ Pry out along the bottom to release the lower hooks. ^ Pry out along the top to release the upper hooks. ^ Pull the cover forward to release the rear clip. 2. Disconnect the power window master switch connector. 3. Remove the two screws that attach the power window switch base to the armrest, then remove the switch base. 4. Remove the three screws, then replace the power window master switch assembly. Page 6055 Wiper/Washer Component Location Index Page 3740 156. A/T Reverse Relay (A/T, CVT) Page 7286 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. How to Replace Connector Terminals Terminal Replacement Procedure HOW TO REPLACE CONNECTOR TERMINALS The terminal repair kits provide necessary tools and materials (terminals, wire seals, and splice connectors) to repair many damaged or faulty connector terminals. However, not all terminals for all connectors are available. Refer to the labels on the lids of the repair kits for replacement terminal availability. IMPORTANT SAFETY INFORMATION: On some models, the SRS wires are in a separate harness. If the SRS harness is damaged, replace the harness; do not repair it. On other models, wire harnesses include yellow SRS wires. If any SRS wire is damaged, replace the entire harness; do not repair it. Before you begin, inspect the wire you are about to repair for damage and length. Make sure the wire will be long enough to make a terminal repair without stretching it when you reinstall the terminal in the connector. If the wire is too short, or if access to the connector is too restricted to make a terminal repair, you may need to install a pigtail terminal (a short length of wire with a factory-crimped terminal on it). Refer to HOW TO INSTALL PIGTAIL TERMINALS. Removing the Terminal Diagram Information and Instructions Transmission Position Switch/Sensor: Diagram Information and Instructions Terminal Numbering System Terminal Numbering System Connector terminals are numbered according to the cavities they're in. The cavities are numbered starting from the upper left, looking at the male terminals from the terminal side or looking at the female terminals from the wire side. Both views are in the same direction so the numbers are the same. All actual cavities are numbered, even if they have no wire terminals in them. NOTE: Data Link Connector (DLC) terminals are numbered according 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 below is #6. Page 7792 13. After completing the right edge, push all of the cam blades to the right until they touch the cams, then trace the cam blades from back to front. (The cutter bit cuts the same contours into the left edge of the key from tip to head.) Turn off the cutter motor. 14. Release the vertical carriage lever. Push all the cam blades to the left until they touch the cams. Pull the vertical carriage lever towards you until the tracer touches the flat surface on the right side, at the front of the cams. Gently twist the lever clockwise to lock the vertical carriage at this height. Do not overtighten the lever. 15. Turn on the cutter motor, then retrace the cam blades from front to back. Push all the cam blades to the right until they touch the cams, and then retrace the cam blades from back to front (retracing cleans up the cuts on the key). Turn off the cutter motor. 16. Release the vertical carriage lever. Open the jaw and remove the key. Make sure the jaw is free of any metal shavings or debris. Turn the key over so the blank side is up, then slide it into the jaw up to the key stop. Close the jaw to lock the key in place. 17. Push all the cam blades to the left until they touch the cams. Repeat steps 10 through 15 to cut both edges on the other side of the key. 18. When you are done making the required cuts, release the vertical carriage lever. Open the jaw and remove the key. 19. Make sure the key works in the ignition switch and the locks. If the key does not work, recut the key, and try it again. 20. Depending on the type of key, code the key transponder. Equipment Service and Warranty To service the MATRIX H Key Cutting Machine, refer to section 7 of the MATRIX H Operating Manual. It tells you how to replace parts that commonly wear out such as the drive belt, the work light bulb, and the tension spring on the vertical carriage. It also covers checking and replacing fuses and replacing the printed circuit board for the setting unit keypad. If you have technical questions on the equipment, contact the Ilco Technical Assistance Department. Mail: Kaba Ilco Technical Assistance Department 400 Jeffreys Road Rocky Mount, NC 27804 Phone: 800-452-6872 Ext: 200, 384, 323, 398, 356 Fax: 252-446-4702 The MATRIX H Key Cutting Machine comes with a 3-year limited warranty. This warranty does not cover the cutter bit or the work light bulb. CODE BOOK CORRECTIONS In the code book Honda High Security key Codes, correct these errors: Pages 4 thru 51, code headings: ^ Incorrect: J H G F Z X E D C B M/S X ^ Correct: J H G F A X E D C B M/S X Page 2, last paragraph: Page 2881 26. Remove PGM-FI main relay 2 (A). 27. Check for continuity between ECM/PCM connector terminal E9 and body ground. Is there continuity? YES - Repair short in the wire between the No.17 FUEL PUMP (15A) fuse and the ECM/PCM (E9), or the No.17 FUEL PUMP (15A) fuse and the PGM-FI main relay 2. Also replace the No.17 FUEL PUMP (15A) fuse. NO - Go to step 28. 28. Remove the rear seat cushion. 29. Remove the access panel from the floor. 30. Disconnect the fuel pump 5P connector. 31. Check for continuity between fuel pump 5P connector terminal No.5 and body ground. Is there continuity? YES - Repair short in the wire between the fuel pump and the PGM-FI main relay 2. Also replace the No.17 FUEL PUMP (15A) fuse. NO - Go to step 32. Page 5134 1. Remove the secondary locks. 2. Remove the terminal from the female half. 3. Remove the terminal from the male half. 4. Go to HOW TO INSTALL NEW TERMINALS. Connectors Without a Secondary Lock All examples are shown with the connector lock facing up. The illustrations are examples of connector terminals without a secondary lock; however, the connector you are repairing may vary in size and shape. EXAMPLE A: Continuously Variable Transmission Shift Interlock Switch: Testing and Inspection Continuously Variable Transmission Park Pin Switch Test 1. Remove the center console panel and center console. 2. Disconnect the park pin switch connector (4P). 3. Shift to the P position, then check for continuity between the No. 3 and No. 4 terminals. There should be no continuity. 4. Shift out of the P position, and check for continuity between terminals No. 3 and No. 4. There should be no continuity. 5. If the park pin switch is faulty, replace it. Page 9311 2. Remove the terminal from the female half. 3. Remove the terminal from the male half. 4. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE D: 1. Remove the secondary locks. Page 1188 Power Window Switch: Testing and Inspection Passenger's Window Switch Test/Replacement Passenger's Window Switch Test/Replacement 4-door 1. Remove the door grip cover. 2. Disconnect the 5P connector (A) from the passenger's power window switch (B). 3. Check for continuity between the terminals in each switch position according to the table. 4. If the continuity is not as specified, remove the two screws and replace the switch. 2-door Page 832 Transmission Position Switch/Sensor: Electrical Diagrams Circuit Diagram Page 9142 1. Remove the secondary lock from the male terminal half. 2. Remove the secondary lock from the female terminal half. 3. Remove the terminal (same procedure for male and female). 4. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE C: 1. Remove the secondary lock. Body - Trunk Lid Hard to Close Trunk / Liftgate Latch Release Cable: All Technical Service Bulletins Body - Trunk Lid Hard to Close 02-061 November 5, 2004 Applies To: See VEHICLES AFFECTED Trunk Lid is Difficult to Close (Supersedes 02-061, dated July 23, 2004) Updated information is shown with asterisks. SYMPTOM The trunk lid may be difficult to close or won't latch closed. PROBABLE CAUSE The trunk lid may be misaligned, and the trunk lid opener cable, trunk lid latch, lock cylinder, lock rod, and/or the trunk lid latch striker may need adjustment or replacement. VEHICLES AFFECTED CORRECTIVE ACTION Adjust the trunk lid and/or the trunk lid latch, or replace components as needed. PARTS INFORMATION Page 3112 Power Steering Pressure Switch: Service and Repair Power Steering Hoses, Lines, and Pressure Switch Replacement Note these items during installation: ^ Connect each hose to the corresponding line securely until it contacts the stop on the line. Install the clamp or adjustable clamp at the specified distance from the hose end as shown. ^ Check all clamps for deterioration or deformation; replace the clamps with new ones, if necessary. ^ Add the recommended power steering fluid to the specified level on the reservoir and check for leaks. Page 5207 7. Apply a small amount of Permalube grease to the base of the new lever. Then attach the slide hammer to the new lever pin, insert the lever into the ignition switch, and seat the pin with the slide hammer. 8. Check the installed height of the pin with vernier calipers. If the height is more than 5.0 mm, the pin is not seated. If needed, reattach the slide hammer, and seat the pin. NOTE: It's normal for the interlock lever to be loose, even when the pin is fully seated. 9. Install a new spring on the lever. Make sure you attach the ends of the spring correctly: ^ The right end goes into the slot on the ignition switch. Description and Operation Rear Bumper: Description and Operation Door and Bumper Reinforcement Beams Door and bumper reinforcement beams used on Honda vehicles are made from a metal equivalent to High Strength Steel. If High Strength Steel is heated, the strength of the steel will be reduced. If High Strength Steel is damaged, as in a vehicle accident, where the door and bumper reinforcement beams are bent, the beams may crack if an attempt is made to straighten them. For this reason, door and bumper reinforcement beams should NEVER be repaired; they should be replaced if they are damaged. NOTE: If a door beam is damaged, the whole door panel assembly should be replaced. Diagrams Center Mounted Brake Lamp: Diagrams 9. High Mount Brake Light (Honda Accessory) 52. High Mount Brake Light Page 8906 YES - Repair open in the wire between the No.20 IG (40A) fuse and the gauge assembly. If the wires are OK, test the ignition switch. NO - Repair short in the wire between the No.20 IG (40A) fuse and the under-dash fuse/relay box. Also replace the No.20 IG (40A) fuse. 10. Try to start the engine. Does the engine start? YES - Go to step 11. NO - Go to step 14. 11. Turn the ignition switch OFF. 12. Connect ECM/PCM connector terminal E31 to body ground with a jumper wire. 13. Turn the ignition switch ON (II). Is the MIL on? YES - Update the ECM/PCM if it does not have the latest software, or substitute a known-good ECM/PCM, then recheck. If the symptom/indication goes away with a known-good ECM/PCM, replace the original ECM/PCM. NO - Check for an open in the wire between the ECM/PCM (E31) and the gauge assembly. Also check for a blown MIL bulb. If the wires and the bulb are OK, replace the gauge assembly. 14. Turn the ignition switch OFF. 15. Inspect the No.6 ECU (ECM/PCM) (15A) fuse in the under-hood fuse/relay box. Is the fuse OK? YES - Go to step 22. NO - Go to step 16. 16. Remove the blown No.6 ECU (ECM/PCM) (15A) fuse in the under-dash fuse/relay box 17. Remove the glove box and PGM-FI main relay 1 (A). Page 1747 Diodes Light Emitting Diode (LED) Motor Pressure Sensor Page 1697 Variable Valve Timing Actuator: Testing and Inspection VTEC Solenoid Valve Test 1. Remove the resonator. 2. Disconnect the VTEC solenoid valve 1P connector. 3. Measure resistance between the VTEC solenoid valve 1P connector terminal No.1 and body ground. 4. If the resistance is within specifications, remove the VTEC solenoid valve assembly (A) from the cylinder head, and check the filter (B) for clogging. If there is clogging, replace the solenoid valve filter, the engine oil filter, and the engine oil. Page 9398 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. Circuits must be operating when checking voltage drop. 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. 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 off, 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 Self-Powered Test Light or DVOM 1. Remove the blown fuse and disconnect the battery and load. Locations Sunroof / Moonroof Relay: Locations Relay And Control Unit Locations - Door, Roof And Seat Locations Keyless Entry Module: Locations Relay And Control Unit Locations - Dashboard 78. Under Middle of Dash (Honda Accessory) Locations EVAP System - Component Location Index Page 2222 Temperature Gauge: Testing and Inspection Coolant Temperature Gauge Troubleshooting Before testing, check the No.9 (10 A) fuse in the under-dash fuse/relay box and the No.10 (7.5 A) fuse in the under-dash fuse/relay box. 1. Start the engine, and check the Malfunction Indicator Lamp (MIL). Does the MIL come on? YES - Troubleshoot the cause of the ECM/PCM DTC, and recheck. NO - Go to step 2. 2. Check for a multiplex control unit DTC. Is a DTC indicated? YES - Troubleshooting the cause of the multiplex control unit DTC, and recheck. NO - Go to step 3. 3. Do the communication line check with the self-diagnosis procedure. Is the word "Error" indicated on the odo/trip display? YES - The gauge cannot receive the signal from the multiplex control unit and the ECM/PCM. Check for an open in the WHT/GRN wire (gauge connector terminal A5 for 03 model Visteon type, terminal A2 for other type.). NO - Go to step 4. 4. Do the gauge drive circuit check with the self-diagnosis procedure. Does the temperature gauge needle sweep from the minimum position to the maximum, then return to the minimum position? YES - Go to step 5. NO - Replace the gauge assembly. 5. Substitute a known-good ECM/PCM, and recheck. Did the symptom/indication go away? YES - Replace the ECM/PCM. NO - Substitute a known-good gauge assembly. If the symptom/indication goes away, replace the gauge assembly. Page 207 PGM-F1 Main Relay 1, 2 Type 1, 2 Check for continuity between the terminals. - There should be continuity between the No.1 and No.2 terminals when power and ground are connected to the No.3 and No.4 terminals. - There should be no continuity between the No.1 and No.2 terminals when power is disconnected. Normally-open type B: Rear Window Defogger Relay Page 4113 1. Remove the terminal. 2. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE B: 1. Remove the terminal. 2. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE C: 1. Remove the terminal. 2. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE D: Page 5869 Power Windows Component Location Index Page 1323 Spark Plug: Application and ID NGK ..................................................................................................................................................... ............................................................... PZFR6F-11 DENSO ................................................................................................................................................ ......................................................... PKJ20CR-M11 Gap ...................................................................................................................................................... ................................. 1.0 -1.1 mm (0.039 - 0.043 in) Torque ................................................................................................................................................. ...................................................... 18 N.m (13 lb.ft) Page 6832 VEHICLES AFFECTED CUSTOMER NOTIFICATION All owners of affected vehicles were mailed a notification of this warranty extension. A example of the customer notification is shown in this service bulletin. CORRECTIVE ACTION Repair the vehicle as indicated by the INSPECTION PROCEDURE. If needed, replace the OPDS unit. In rare cases where an updated OPDS unit was already installed, replace the OPDS sensor. Page 8337 Vehicle Identification Number - U.S Model 4-door Page 8159 Programming the Transmitter NOTES: ^ The system accepts up to three transmitters. The transmitter codes are stored in a stacking-type memory. If a fourth transmitter code is programmed, the code for the first transmitter is erased. ^ Entering the programming mode cancels all learned transmitter codes, so none of the previously programmed transmitters will work. You must reprogram all of the transmitters once you are in the programming mode. ^ You must complete steps 1-6 within 4 seconds of the previous step to keep the system from exiting the programming mode. 1. Turn the ignition switch to ON (II). 2. Press the "Lock" or "Unlock" button on one of the transmitters. (An unprogrammed transmitter can be used for this step.) 3. Turn the ignition switch to LOCK (0). 4. Repeat steps 1 2, and 3 two more times using the same transmitter used in step 2. 5. Turn the ignition switch to ON (II). 6. Press the "Lock" or "Unlock" button on the same transmitter. Make sure the power door locks cycle to confirm that the system is in programming mode. 7. Within 10 seconds, press the "Lock" or "Unlock" button on each transmitter. Make sure the power door locks cycle after you press each transmitter button to confirm that the system accepted the transmitter's code. 8. Turn the ignition switch to LOCK (0) to exit the programming mode. Ordering a Transmitter Transmitters can be ordered only by authorized Honda dealers. Order them from American Honda using normal parts ordering procedures. Batteries for the Transmitter The battery number is CR1616. Each transmitter uses one battery. 97-04 CR-V & 00-04 S2000 *1997-04 CR-V LX with dealer-installed keyless entry system 1998-04 CR-V EX with factory-installed keyless entry system 2000-01 CR-V SE with factory-installed keyless entry system 2000-04 S2000 with factory-installed keyless entry system 2002-04 CR-V with dealer-installed security system* Page 6877 Page 8341 Paint: Application and ID Color Chart Paint Specification Page 4120 13. Plug in the heat gun, and turn it on. Start at the middle of the splice connector, and move the gun toward the ends as the tube shrinks. Apply heat evenly by rotating the curved heat spreader around the splice connector. Shrinking is complete when a small amount of sealant appears at each end of the tube. Pigtail Terminal Selection Chart PIGTAIL TERMINAL SELECTION CHART Select the proper size pigtail terminal by matching the replacement terminal part number and the wire size being repaired to the corresponding pigtail terminal part number. Then use the color (size) splice connector listed. In some instances you may also have to match the wire seal style to select the proper pigtail terminal. Pigtail terminals are available through your parts department, in quantities of 10, using normal parts ordering procedures. Checking For Poor Fir of Terminals CHECKING FOR POOR FIT OF TERMINALS Loose terminal fit can cause a number of intermittent problems in electrical circuits. By using the Terminal Inspection Feeler Tool Set you can inspect the terminal fit between the two matching connectors without removing the terminals from the connector body. 1. Find the terminal tool that best matches the male terminal in the mating connector. Page 9371 13. Plug in the heat gun, and turn it on. Start at the middle of the splice connector, and move the gun toward the ends as the tube shrinks. Apply heat evenly by rotating the curved heat spreader around the splice connector. Shrinking is complete when a small amount of sealant appears at each end of the tube. Pigtail Terminal Selection Chart PIGTAIL TERMINAL SELECTION CHART Select the proper size pigtail terminal by matching the replacement terminal part number and the wire size being repaired to the corresponding pigtail terminal part number. Then use the color (size) splice connector listed. In some instances you may also have to match the wire seal style to select the proper pigtail terminal. Pigtail terminals are available through your parts department, in quantities of 10, using normal parts ordering procedures. Checking For Poor Fir of Terminals CHECKING FOR POOR FIT OF TERMINALS Loose terminal fit can cause a number of intermittent problems in electrical circuits. By using the Terminal Inspection Feeler Tool Set you can inspect the terminal fit between the two matching connectors without removing the terminals from the connector body. 1. Find the terminal tool that best matches the male terminal in the mating connector. Page 1370 Air Filter Element: Service and Repair Air Cleaner Element Replacement 1. Open the air cleaner housing cover (A). 2. Remove the air cleaner (B) from the air cleaner housing (C). 3. Install in the reverse order of removal. Page 9859 10. If the old quarter glass will be reinstalled (and either clip is broken off the molding), seal the body holes with pieces of urethane tape (A). Then set the quarter glass upright in the opening, and make alignment marks (B) across the quarter glass and body with a grease pencil at the three points shown. Be careful not to touch the quarter glass where adhesive will be applied. 11. Remove the quarter glass. Page 8149 Remote Transmitter Quick Reference Guide 90-93 Accord, 92-93 Civic & Prelude, 93 Del SOL 1990-93 Accord (2-door and 4-door) with dealer-installed security system 1992-93 Civic with dealer-installed security system 1993 del Sol with dealer-installed security system 1992-93 Prelude with dealer-installed security system Programming the Transmitter NOTE: Page 8729 33. Clutch Pedal Position Switch (M/T) Page 2259 Temperature Gauge: Testing and Inspection Coolant Temperature Gauge Troubleshooting Before testing, check the No.9 (10 A) fuse in the under-dash fuse/relay box and the No.10 (7.5 A) fuse in the under-dash fuse/relay box. 1. Start the engine, and check the Malfunction Indicator Lamp (MIL). Does the MIL come on? YES - Troubleshoot the cause of the ECM/PCM DTC, and recheck. NO - Go to step 2. 2. Check for a multiplex control unit DTC. Is a DTC indicated? YES - Troubleshooting the cause of the multiplex control unit DTC, and recheck. NO - Go to step 3. 3. Do the communication line check with the self-diagnosis procedure. Is the word "Error" indicated on the odo/trip display? YES - The gauge cannot receive the signal from the multiplex control unit and the ECM/PCM. Check for an open in the WHT/GRN wire (gauge connector terminal A5 for 03 model Visteon type, terminal A2 for other type.). NO - Go to step 4. 4. Do the gauge drive circuit check with the self-diagnosis procedure. Does the temperature gauge needle sweep from the minimum position to the maximum, then return to the minimum position? YES - Go to step 5. NO - Replace the gauge assembly. 5. Substitute a known-good ECM/PCM, and recheck. Did the symptom/indication go away? YES - Replace the ECM/PCM. NO - Substitute a known-good gauge assembly. If the symptom/indication goes away, replace the gauge assembly. Page 1046 107. Behind A/T Shift Lever (except M/T) Locations Main Relay (Computer/Fuel System): Locations Relay And Control Unit Locations - Dashboard Page 1680 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 Short Circuit Locator (Short Finder) 1. Remove the blown fuse. Leave the battery connected. Page 6690 Air Bag(s) Arming and Disarming: Service and Repair Connector Disconnection / Connection Disconnecting System Connectors Before removing a front airbag, side airbag, or other SRS related devices (the SRS unit, the cable reel, front sensor, the side impact sensors, the seat belt buckle tensioners, and the seat belt tensioner connector), disconnecting connectors from related devices, or removing the dashboard or the steering column, disconnect the airbag connectors or the side airbag connectors to prevent accidental deployment. Turn the ignition switch OFF, disconnect the negative cable from the battery, and wait at least 3 minutes before beginning the following procedures. - Before disconnecting SRS unit connector A (A) from the SRS unit, disconnect the driver's airbag 4P connector (C), the front passenger's airbag 4P connector (D), the driver's seat belt tensioner 2P connector (F), and the front passenger's seat belt tensioner 2P connector (G). - Before disconnecting SRS unit connector B (1) from the SRS unit, disconnect both side airbag 2P connectors (L, M) and both seat belt buckle tensioner 4P connectors (J, K). - Before disconnecting the cable reel 4P connector (B), disconnect the driver's airbag 4P connector (C). - Before disconnecting the floor wire harness 4P connector (E), disconnect both seat belt tensioner 2P connectors (F, G). 1. Disconnect the battery negative cable, and wait at least 3 minutes. Driver's Airbag Shift Solenoid Valves A and B Test Shift Solenoid: Testing and Inspection Shift Solenoid Valves A and B Test Shift Solenoid Valves A and B Test 1. Disconnect the shift solenoid valves A and B connector. 2. Measure shift solenoid valve A resistance between the No. 1 terminal of the shift solenoid valves A and B connector and body ground, and measure shift solenoid valve B resistance between the No. 2 terminal and body ground. STANDARD: 12 - 25 Ohms 3. Replace the shift solenoid valves A and B if either resistance is out of standard. 4. If the resistance is within the standard, connect the No. 1 terminal of the shift solenoid valve A to the battery positive terminal. A clicking sound should be heard. Connect the No. 2 terminal to the battery positive terminal. A clicking sound should be heard. Replace the shift solenoid valves A and B if no clicking sound is heard when either terminal is connected to the battery terminal. Page 791 Throttle Position Sensor: Description and Operation Throttle Position (TP) Sensor The TP sensor is a potentiometer connected to the throttle valve shaft. As the throttle position changes, the sensor varies the signal voltage to the ECM/PCM. The TP sensor is not replaceable apart from the throttle body. Page 5221 Shift Interlock Switch: Service and Repair Park Pin Switch Replacement 1. Remove the center console panel and center console. 2. Remove the screws (A), then remove the shift lever knob (B) 3. Remove the A/T gear position indicator panel light (c) from the A/T gear position indicator panel. 4. Remove the A/T gear position indicator panel and panel bracket as an assembly (D). 5. Disconnect the park pin switch connector (4P) (E), and remove it from the shift lever bracket base (F). 6. Remove the shift lock release (G) and spring (H). 7. Open the lock tabs (A) on the shift lever bracket base, then remove the park pin switch (B). 8. Install the new park pin switch. 9. Install the removed parts in the reverse order of removal. Page 8128 (Not interchangeable with CR-V and S2000 remote transmitter) Transmitter Identification The transmitter for the 1995-99 Accord and the 2000-02 Accord look identical, but they are not interchangeable. The 1995-99 transmitter works the doors of a 2000-02 Accord, but it does not open the trunk. If you are not sure which transmitter you have, press and hold the trunk release button while looking at the LED. The LED on the 1995-99 transmitter comes on in about 1.1 seconds. The LED on the 2000-02 transmitter comes on in about 0.5 second. Programming the Transmitter NOTES: ^ The system accepts up to three transmitters. The transmitter codes are stored in a stacking-type memory. If a fourth transmitter code is programmed, the code for the first transmitter is erased. ^ Entering the programming mode cancels all learned transmitter codes, so none of the previously programmed transmitters will work. You must reprogram all of the transmitters once you are in the programming mode. ^ You must complete steps 1-6 within 4 seconds of the previous step to keep the system from exiting the programming mode. 1. Turn the ignition switch to ON (II). 2. Press the "Lock" or "Unlock" button on one of the transmitters. (An unprogrammed transmitter can be used for this step.) 3. Turn the ignition switch to LOCK (0). 4. Repeat steps 1 2, and 3 two more times using the same transmitter used in step 2. 5. Turn the ignition switch to ON (II). 6. Press the "Lock" or "Unlock" button on the same transmitter. Make sure the power door locks cycle to confirm that the system is in programming mode. 7. Within 10 seconds, press the "Lock" or "Unlock" button on each transmitter. Make sure the power door locks cycle after you press each transmitter button to confirm that the system accepted the transmitter's code. 8. Turn the ignition switch to LOCK (0) to exit the programming mode. Ordering a Transmitter Transmitters can be ordered only by authorized Honda dealers. Order them from American Honda using normal parts ordering procedures. Batteries for the Transmitter The battery number is CR2025. Each transmitter uses one battery. 03-04 Accord LX and EX 2003-04 Accord LX and EX with factory-installed keyless entry system Page 6656 82. Under Middle Of Dash Page 299 ECT at 140 °F (60 °C) or higher. Procedure 1. Connect the scan tool to the vehicle's data link connector (DLC), and bring up the tool's generic OBD II mode. 2. Start the engine. 3. Test-drive the vehicle under stop-and-go conditions with short periods of steady cruise. During the drive, decelerate (with the throttle fully closed) for 5 seconds. After about 3.5 miles (5.6 km), the readiness code should switch from incomplete to complete. 4. If the readiness code is still set to incomplete, check for a temporary DTC. If there is no DTC, the enable criteria was probably not met; repeat the procedure. Air/Fuel Ratio (A/F) Sensor Heater Monitor Readiness Code NOTE: All readiness codes are cleared when the battery is disconnected or when the ECM/PCM is cleared with the OBD II scan tool or Honda PGM Tester. Procedure 1. Connect the scan tool to the vehicle's data link connector (DLC), and bring up the tool's generic OBD II mode. 2. Start the engine, and let it idle for 1 minute. The readiness code should switch from incomplete to complete. 3. If the readiness code is still set to incomplete, check for a temporary DTC. If there is no DTC, repeat the procedure. Misfire Monitor and Readiness Code - This readiness code is always set to available because misfiring is continuously monitored. - Monitoring pauses, and the misfire counter resets, if the vehicle is driven over a rough road. - Monitoring also pauses, and the misfire counter holds at its current value, if the throttle position changes more than a predetermined value, or if driving conditions fall outside the range of any related enable criteria. Fuel System Monitor and Readiness Code - This readiness code is always set to available because the fuel system is continuously monitored during closed loop operation. - Monitoring pauses when the catalytic converter, EVAP control system, and A/F sensor monitors are active. - Monitoring also pauses when any related enable criteria are not being met. Monitoring resumes when the enable criteria is again being met. Comprehensive Component Monitor and Readiness Code This readiness code is always set to available because the comprehensive component monitor is continuously running whenever the engine is cranking or running. EGR Monitor and Readiness Code NOTE: - Do not turn the ignition switch off during the procedure. - All readiness Codes are cleared when the battery is disconnected or when the ECM/PCM is cleared with the OBD II scan tool or Honda PGM Tester. Enable Criteria - ECT at 176 °F (80 °C) or higher Procedure 1. Connect the scan tool to the vehicle's data link connector (DLC), and bring up the tool's generic OBD II mode. 2. Start the engine. 3. Drive at a steady speed with the CVT and A/T in D position or M/T in 4th gear, 50 - 62mph (80 - 100 km/h) or above for more than 10 seconds. 4. With the CVT and A/Tin D position or M/T in 4th gear, decelerate from 62 mph (100km/h) or above by completely releasing the throttle for at least 5 seconds. If the engine is stopped during this procedure, go to step 3 and do the procedure again. 5. If the readiness code is still set to incomplete, check for a temporary DTC. If there is no DTC, the enable criteria was probably not met; repeat the procedure. Page 1812 Crankshaft: Testing and Inspection End Play Inspection Connecting Rod and Crankshaft End Play Inspection 1. Remove the oil pump. 2. Measure the connecting rod end play with a feeler gauge between the connecting rod and crankshaft. Connecting Rod End Play Standard (New): 0.15 - 0.30 mm (0.006 - 0.012 inch) Service Limit: 0.40 mm (0.016 inch) 3. If the connecting rod end play is out-of-tolerance, install a new connecting rod, and recheck. If it is still out-of-tolerance; replace the crankshaft. 4. Mount a dial indicator on the block so that its tip contacts the end of the crankshaft. 5. Push the crankshaft firmly away from the dial indicator, and zero the dial against the end of the crankshaft. Then pull the crankshaft firmly back toward the indicator; the dial reading should not exceed the service limit. Crankshaft End Play Standard (New): 0.10 - 0.35 mm (0.004 - 0.014 inch) Service Limit: 0.45 mm (0.018 inch) 6. If the end play is excessive, replace the thrust washers and recheck. If it is still out-of-tolerance, replace the crankshaft. Service and Repair Camshaft Gear/Sprocket: Service and Repair Camshaft, Rocker Arm, Camshaft Seal and Pulley Installation NOTE: To prevent the rocker arm assembly from coming apart, leave the camshaft holder bolts in the holes. 1. After wiping down the camshaft and the journals in the cylinder head, lubricate both surfaces and install the camshaft. 2. Clean and install the oil control orifice (A) with a new O-ring (B) (D17A2, D17A6 engines). 3. Clean and install the oil control orifice (C) (D17A1 engine). 4. Turn the camshaft until its keyway (D) is facing up (No.1 piston TDC). 5. Loosen all the valve adjusting screws. 6. Apply liquid gasket to the head mating surface (shaded areas) of the No. 1 and No. 5 camshaft holders. 7. Set the rocker arm assembly in place and loosely install the bolts. Make sure that the rocker arms are properly positioned on the valve stems. Page 5302 3. If there is no continuity between any terminal, remove the transmission range switch cover, and disconnect the connector (A) at the switch (B). 4. Check for continuity between terminals at the switch connector (c). There should be continuity between the terminals listed for each position. In the P position, between terminals: ^ No. 4 and No. 5 ^ No. 4 and No. 6 ^ No. 5 and No. 6 In the R position, between terminals: ^ No. 1 and No. 4 In the N position, between terminals: ^ No. 4 and No. 5 ^ No. 4 and No. 7 ^ No.5 and No.7 In the D position, between terminals: ^ No.2 and No.4 ^ No. 2 and No. 10 ^ No. 4 and No. 10 In the D3 position, between terminals: ^ No. 4 and No. 8 ^ No. 4 and No. 10 ^ No. 8 and No. 10 In the 2 position, between terminals: ^ No.3 and No.4 5. If there is no continuity between any terminals, adjust the transmission range switch installation. If the transmission range switch installation is OK, replace the switch. 6. If the transmission range switch continuity check was OK, replace the faulty transmission range switch harness. Page 1518 Under-hood Fuse/Relay Box Page 2161 2. Remove the terminal from the female half. 3. Remove the terminal from the male half. 4. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE D: 1. Remove the secondary locks. Page 8356 2. Filling/Sanding Apply putty to repair any holes or deep gouges. Apply the putty on the damaged area in 2 - 3 steps. - Glue aluminum tape on the outside of the bumper, and apply putty from the other side of the bumper. - Remove the aluminum tape after the putty dries, apply putty from the outside, and fill the hole. Use a special polyester putty and a putty knife. 3. Sanding Sand the surface evenly, particularly at the area where the PP material and putty meet. Use a flexible block and #240 - #400 - #600 sandpaper. 4. Air blowing/degreasing Use alcohol, a tack cloth, and wax and grease remover. 5. Spraying primer surfacer NOTE: Spray the bumper primer on the area where the PP material was exposed and around the putty. - Spray the primer surface wider then the putty and painted surfaces of bumper primer. - Spray 2 - 3 coats to get 20 - 30 microns of thickness. Use the 2-component type primer surfacer (gray) and a spray gun. - Follow the materials manufacturer's instructions. Drying NOTE: Take care not to let the heat lamp deform the bumper during the drying process. Page 1802 Crankshaft Main Bearing: Specifications Service Specifications Crankshaft Journals Crankshaft Main journal diameter Standard or New ...................................................................................................................................... 54.976 55.000 mm (2.1644 - 2.1654 inch) Rod journal diameter Standard or New ...................................................................................................................................... 44.976 45.000 mm (1.7707 - 1.7717 inch) Rod/main journal taper Standard or New .................................................................................................................................. ................................ 0.0025 mm (0.0001 inch) Service Limit .............................................................. ........................................................................................................... 0.005 mm (0.0002 inch) Rod/main journal out-of-round Standard or New .................................................................................................................................. ................................ 0.0025 mm (0.0001 inch) Service Limit .............................................................. ........................................................................................................... 0.005 mm (0.0002 inch) End play Standard or New .................................................................................................................................................. 0.10 0.35 mm (0.004 - 0.014 inch) Service Limit ......................................................................................... .................................................................................... 0.45 mm (0.018 inch) Runout Standard or New ....................................................................................................................................................... 0.03 mm (0.001 inch) maximum Service Limit .................................................................................... ......................................................................................... 0.04 mm (0.002 inch) Main Bearing Clearance Crankshaft bearing Main bearing-to-journal oil clearance No.1 journal; No.5 journal Standard or New .................................................................................................................................... 0.018 - 0.036 mm (0.0007 - 0.0014 inch) Service Limit ............................................................................................. .......................................................................... 0.05 mm (0.002 inch) No.2, 3 and 4 journals Standard or New .................................................................................................................................... 0.024 - 0.042 mm (0.0009 - 0.0017 inch) Service Limit ............................................................................................. .......................................................................... 0.05 mm (0.002 inch) Rod bearing clearance Standard or New .......................................................................................................................................... 0.024 0.042 mm (0.0009 - 0.0017 inch) Service Limit ................................................................................... .......................................................................................... 0.05 mm (0.002 inch) Page 5108 Shift Indicator: Locations Continuously Variable Transmission Component Location Index Page 2332 ECM/PCM Inputs And Outputs At Connector C (22P) Page 770 Oxygen Sensor: Description and Operation Air Fuel (A/F) Ratio Sensor Air Fuel Ratio (A/F) sensor (D17A6 engine) The A/F sensor operates over a wide air/fuel range. The A/F sensor is installed in the exhaust manifold. Page 2932 65. PSP Switch Page 5231 Wire Color Abbreviations Page 2885 48. Measure voltage between PGM-FI main relay 1 4P connector terminal No.2 and body ground. Is there battery voltage? YES - Go to step 49. NO - Repair open in the wire between the No.6 ECU (ECM/PCM) (15A) fuse and the PGM-FI main relay 1. 49. Turn the ignition switch OFF. 50. Check for continuity between PGM-FI main relay 1 4P connector terminal No.1 and ECM/PCM connector terminals A2 and A3 individually. Is there continuity? YES - Replace the PGM-FI main relay 1. NO - Repair open in the wire between PGM-FI main relay 1 and the ECM/PCM (A2, A3). 51. Measure voltage between body ground and ECM/PCM connector terminals A4, A5, A23, and A24 individually. Is there less than 1.0 V? YES - Go to step 52. NO - Repair open in the wire(s) that had more than 1.0 V between G101 and the ECM/PCM (A4, A5, A23, A24). Page 1399 Brake Fluid: Service and Repair For further information regarding this component and the system that it is a part of, please refer to Brake Bleeding; Service and Repair. Page 809 - Before connecting connectors, make sure the terminals (A) are in place and not bent. - Check for loose retainer (A) and rubber seals (B). - The backs of some connectors are packed with dielectric grease. Add grease if necessary. If the grease is contaminated, replace it. - Insert the connector all the way and make sure it is securely locked. - Position wires so that the open end of the cover faces down. Handling Wires and Harnesses - Secure wires and wire harnesses to the frame with their respective wire ties at the designated locations. Page 2158 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. How to Replace Connector Terminals Terminal Replacement Procedure HOW TO REPLACE CONNECTOR TERMINALS The terminal repair kits provide necessary tools and materials (terminals, wire seals, and splice connectors) to repair many damaged or faulty connector terminals. However, not all terminals for all connectors are available. Refer to the labels on the lids of the repair kits for replacement terminal availability. IMPORTANT SAFETY INFORMATION: On some models, the SRS wires are in a separate harness. If the SRS harness is damaged, replace the harness; do not repair it. On other models, wire harnesses include yellow SRS wires. If any SRS wire is damaged, replace the entire harness; do not repair it. Before you begin, inspect the wire you are about to repair for damage and length. Make sure the wire will be long enough to make a terminal repair without stretching it when you reinstall the terminal in the connector. If the wire is too short, or if access to the connector is too restricted to make a terminal repair, you may need to install a pigtail terminal (a short length of wire with a factory-crimped terminal on it). Refer to HOW TO INSTALL PIGTAIL TERMINALS. Removing the Terminal Page 5251 1. Remove the secondary lock from the male terminal half. 2. Remove the secondary lock from the female terminal half. 3. Remove the terminal (same procedure for male and female). 4. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE C: 1. Remove the secondary lock. Page 2579 125. TP Sensor Page 9819 1. Remove the screws and the power window master switch (A) from the door panel. 2. Disconnect the 14P connector (B) from the switch. 3. Check for continuity between the terminals in each switch position according to the table. Driver's Switch: The driver's switch is combined with the control unit so you cannot isolate the switch to test it. Instead, run the master switch input test procedures. If the tests are normal, the driver's switch must be faulty. 4. If the switch is faulty, remove the three screws and replace the switch. Page 2736 5. Remove the lower cover from the fuse/relay box. 6. Disconnect the 3P ELD connector. Page 8116 Removal/Installation Throttle Body: Service and Repair Removal/Installation Throttle Body Removal/installation NOTE: - Do not adjust the throttle stop screw. - After reassembly, adjust the cruise control cable and the throttle cable. - The Throttle Position (TP) sensor is not removable. Locations Cruise Control Module: Locations Cruise Control Component Location Index Page 1069 Transmission Position Switch/Sensor: Diagnostic Aids General Troubleshooting Information General Troubleshooting Information Tips and Precautions Before Troubleshooting 1. Check applicable fuses in the appropriate fuse/relay box. 2. Check the battery for damage, state of charge, and clean and tight connections. NOTE: 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. Handling Connectors - Make sure the connectors are clean and have no loose wire terminals. - Make sure multiple cavity connectors are packed with dielectric grease (except watertight connectors). - All connectors have push-down release type locks (A). - Some connectors have a clip on their side used to attach them to a mount bracket on the body or on another component. This clip has a pull type lock. - Some mounted connectors cannot be disconnected unless you first release the lock and remove the connector from its mount bracket (A). - Never try to disconnect connectors by pulling on their wires; pull on the connector halves instead. - Always reinstall plastic covers. Page 2748 DTC P0158 thru P0400 Page 3250 - Remove clips carefully; don't damage their locks (A). - Slip pliers (A) under the clip base and through the hole at an angle, then squeeze the expansion tabs to release the clip. - After installing harness clips, make sure the harness doesn't interfere with any moving parts. - Keep wire harnesses away from exhaust pipes and other hot parts, from sharp edges of brackets and holes, and from exposed screws and bolts. - Seat grommets in their grooves properly (A). Do not leave grommets distorted (B). Testing and Repairs - Do not use wires or harnesses with broken insulation. Replace them or repair them by wrapping the break with electrical tape. - After installing parts, make sure that no wires are pinched under them. - When using electrical test equipment, follow the manufacturer's instructions and those described. - If possible, insert the probe of the tester from the wire side (except waterproof connector). - Use back probe adaptor 07TAZ-001020A. - Refer to the instructions in the Honda Terminal Kit for identification and replacement of connector terminals. Five-Step Troubleshooting Five-Step Troubleshooting 1. Verify The Complaint Page 6317 12. Loosen the damper pinch bolts (A) while holding the nuts (B), and remove the bolts and nuts. 13. Remove the driveshaft outboard joint (C) from the knuckle (D) by tapping the driveshaft end (E) with a plastic hammer while pulling the knuckle outward, then remove the knuckle. NOTE: Do not pull the driveshaft end outward. The driveshaft joint may come off. 14. Separate the hub (A) from the knuckle (B) using the special tool and a hydraulic press. Be careful not to deform the splash guard. Hold onto the hub to keep it from falling when pressed clear. 15. Press the wheel bearing inner race (A) out of the hub (B) using the special tool, a commercially available bearing separator (C), and a press. Page 6507 Compressor Clutch Relay: Description and Operation Air Conditioning (A/C) Compressor Clutch Relay When the ECM/PCM receives a demand for cooling from the A/C system, it delays the compressor from being energized, and enriches the mixture to assure smooth transition to the A/C mode. Page 9271 Blower Motor Relay Type 1, Type 2 Check for continuity between the terminals. - There should be continuity between the No.1 and No.3 terminals when power and ground are connected to the No.2 and No.4 terminals. - There should be no continuity between the No.1 and No.3 terminals when power is disconnected. Five-terminal type Check for continuity between the terminals. - There should be continuity between the No.1 and No.2 terminals when power and ground are connected to the No.3 and No.5 terminals. - There should be continuity between the No.1 and No.4 terminals when power is disconnected. Page 6020 Power Windows Component Location Index Page 8719 4. With the 14P connector disconnected, make these input tests. 5. If any test indicates a problem, find and correct the cause, then recheck the system. If all the input tests prove OK, the control unit may be faulty. Substitute a known-good control unit and retest. If the system works properly, replace the control unit. Component Locations Heating Component Location Index Service and Repair Fuel Door Release Lever: Service and Repair Trunk Lid Opener/Fuel Fill Door Opener Replacement Special Tools Required KTC trim tool set SOJATP2014 NOTE: Use the appropriate tool from the KTC trim tool set to avoid damage when prying components. 1. Using a trim tool, detach the hooks (A) by prying the front side cap (B), then remove it from the front door sill trim (C), and remove the opener lock cylinder (D). 2. Loose the bolt (E) securing the fuel fill door opener. 3. Remove the door sill trim, 2-door, and/or the front door sill trim, 4-door. 4. Remove the opener (A) from the bolt (B). 5. Disconnect the trunk lid opener/fuel fill door opener cable (A), then remove the opener (B). Take care not to kink the cable. 6. Install the opener in the reverse order of removal, and note these items: - Make sure the opener cable is connected properly. - Make sure the trunk lid and fuel fill door open properly and lock securely. Locations Radiator Cooling Fan Temperature Sensor / Switch: Locations Page 5731 - 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. Troubleshooting Tests 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 test 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 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. 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 Drop Page 7753 1. Check the depth adjustment of the trunk lid: ^ Refer to page 20-132 of the 2001-04 Civic Service Manual. ^ In ISIS, use the keyword TRUNK ADJUST, and select Trunk Lid Adjustment from the list. 2. Make sure the trunk lid is flush on all sides and corners. ^ If the trunk is misaligned, go to step 3. ^ If the trunk lid is properly aligned on all sides and corners, go to REPAIR PROCEDURE C. 3. Adjust the striker depth position and the trunk lid edge cushions: ^ Refer to page 20-132 of the 2001-04 Civic Service Manual. ^ In ISIS, use the keyword TRUNK ADJUST, and select Trunk Lid Adjustment from the list. 4. Check the trunk operation: ^ If the trunk opens and closes smoothly, return the vehicle to the customer. ^ If the trunk lid is still difficult to close, go to REPAIR PROCEDURE C. REPAIR PROCEDURE C 1. Use a small screwdriver to manually set and release the trunk lid latch. Check the operation of the latch: ^ If the latch is difficult to set or release, go to step 2. ^ If the latch operates properly, go to REPAIR PROCEDURE D. 2. Replace the trunk lid latch: ^ Refer to page 20-157 of the 2001-04 Civic Service Manual. ^ In ISIS, use the keyword LID LATCH, and select Trunk Lid Latch Replacement from the list. 3. Check the trunk operation: ^ If the trunk opens and closes smoothly, return the vehicle to the customer. ^ If the trunk lid is still difficult to close, go to REPAIR PROCEDURE D. REPAIR PROCEDURE D 1. Disconnect the trunk lid opener cable from the trunk lid latch. Check the cable operation: ^ Refer to page 20-157 of the 2001-04 Civic Service Manual. ^ In ISIS, use the keyword LID LATCH, and select Trunk Lid Latch Replacement from the list. 2. Check that there is no friction or binding of the cable by holding the outside casing and pulling back and forth on the inner cable: ^ If the cable is difficult to move or binds, go to step 3. ^ If the cable operates smoothly, go to REPAIR PROCEDURE E. 3. Replace the trunk lid opener cable: ^ Refer to page 20-151 of the 2001-04 Civic Service Manual. ^ In ISIS, use the keyword LID OPEN, and select Trunk Lid Opener/Fuel Fill Door Opener Cable Replacement from the list. 4. Check the trunk operation: Page 6925 Air Bag Control Module: Testing and Inspection Initializing the OPDS (Occupant Position Detection System) Unit Special Tools Required SCS service connector 07PAZ-0010100 When the seat-back cover, seat-back cushion, and/or OPDS unit is replaced, initialize the OPDS by following the procedure below. NOTE: Make sure the passenger's seat is dry. Set the seat-back in the normal position, and make sure there is nothing on the front passenger's seat. 1. Make sure the ignition switch is OFF. 2. Connect the Honda PGM Tester/HDS (A) to the DLC (16P) (B), and follow the Tester's prompts in the "SCS" menu to ground the SCS line (see the Honda PGM Tester Operator's Manual). 3. Connect the SCS service connector (A) to the MES connector (2P) (B). Do not use a jumper wire. 4. Turn the ignition switch ON (II). 5. The SRS indicator comes on for about 6 seconds and goes off. Remove the SCS service connector from the MES connector within 4 seconds after the SRS indicator went off. 6. The SRS indicator comes on again. Reconnect the SCS service connector to the MES connector within 4 seconds after the SRS indicator comes on. 7. The SRS indicator goes off. Remove the SCS service connector from the MES connector within 4 seconds. 8. Watch the SRS indicator. - If the indicator blinks two times and then stays on, the OPDS is initialized, but the DTCs need to be erased. Go to step 9, then erase the DTCs. - If the indicator blinks two times and then goes off, the OPDS unit is initialized. Go to step 9. - If the indicator stays on without first blinking, the OPDS is not initialized. Read the DTC, if DTC 15-1 is indicated, repeat the initialization procedure. If another DTC is indicated, go to the appropriate DTC Troubleshooting Index. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Descriptions/DTC List - Supplemental Restraint System 9. Turn the ignition switch off, and disconnect the PGM Tester. Locations Combination Switch: Locations Exterior Lights Component Location Index Page 819 2. Remove the terminal from the female half. 3. Remove the terminal from the male half. 4. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE D: 1. Remove the secondary locks. Page 5158 Control Module: Service and Repair Updating the ECM/PCM PCM Updating and Substitution for Testing Special Tools Required Honda Interface Module (HIM) P/N EQS05A35570 Use this procedure when you have to substitute a known-good PCM in a troubleshooting procedure. Update the PCM only if the PCM does not already have the latest software loaded. NOTE: Do not turn the ignition switch OFF while updating; the PCM can be damaged. How to Update the PCM NOTE: To ensure the latest program is installed, do an PCM update whenever the PCM is substituted or replaced. - Before you update the PCM, make sure the vehicle's battery is fully charged. - To prevent PCM damage, do not operate anything electrical (audio system, brakes, A/C, power windows, moon roof, door locks, etc.) during the update. - If you need to diagnose the Honda Interface Module (HIM) because the HIM's red (#3) light came on or was flashing during the update, leave the ignition switch in the ON (II) position when you disconnect the HIM from the Data Link Connector (DLC). This will prevent PCM damage. 1. Turn the ignition switch ON (II). Do not start the engine. 2. Connect the HIM to the DLC (A) located under the driver's side of dashboard. 3. Do the PCM update procedure as described on the HIM label and in the PCM update system. If the software in the PCM is the latest version, replace the PCM. How to End a Troubleshooting Session This procedure must be done after any troubleshooting. 1. Clear the DTC(s) with the Scan Tool or HDS, or reset the PCM by removing the No. 6 (PCM) fuse in the under-hood fuse/relay box for more than 10 seconds. 2. Turn the ignition switch ON (II). 3. Start the engine in the P or N position, and warm it up to normal operating temperature (the radiator fans come on). 4. To verify that the problem is repaired, test-drive the vehicle for several minutes at speeds over 30 mph (50 km/h) or in freeze data range. ECM/PCM Terminal Values Engine Control Module: Testing and Inspection ECM/PCM Terminal Values ECM/PCM Inputs And Outputs At Connector A (31P) Page 4109 1. Remove the secondary lock from the male terminal half. 2. Remove the secondary lock from the female terminal half. 3. Remove the terminal (same procedure for male and female). 4. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE C: 1. Remove the secondary lock. Page 3176 128. VSS (except CVT) Page 139 Under-dash Fuse/Relay Box Page 6003 7. Crimp the insulation crimp. - If you do not have a wire seal, then use the next larger size crimp slot. Position the crimping tool over the insulation crimp section of the terminal, then squeeze the tool with both hands until the stops make contact. - If you have a wire seal, position the insulation crimp in the 5.5 crimping slot, then carefully squeeze the crimp closed until its ends are touching and making a full-circle shape. 8. Inspect the quality of the wire crimp. If it has any of the following NO GOOD crimps, cut it off and start over. 9. Insert the terminal into the connector. Make sure the wire seals are pushed all the way into the connector. Lightly pull on the wires to make sure the terminal is locked into place. 10. Close or insert the secondary terminal lock, if applicable, and reconnect the connector. Page 6501 4. Remove the bolt and holder (A), then disconnect the field coil connector (B). Loosen the clamp screw (c) to free the field coil wire. Remove the snap ring (d) with snap ring pliers, then remove the field coil (E). Be careful not to damage the field coil or the compressor. 5. Reassemble the clutch in the reverse order of disassembly, and note these items: - Install the field coil with the wire side facing down, and align the boss on the field coil with the hole in the compressor. - Clean the rotor pulley and compressor sliding surfaces with contact cleaner or other non-petroleum solvent. - Install new snap rings, note the installation direction, and make sure they are fully seated in the groove. - Make sure that the rotor pulley turns smoothly after it's reassembled. - Route and clamp the wires properly or they can be damaged by the rotor pulley. Page 1278 ^ 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 4757 4. Torque the mounting bolts in a crisscross pattern. Tighten the bolts in several steps to prevent warping the diaphragm spring. 5. Remove the special tools. 6. Make sure the diaphragm spring fingers are all the same height. Page 1056 162. Right Side Of Engine Compartment Locations Relay And Control Unit Locations - Dashboard Recall - Driver's Air Bag Replacement Air Bag: Recalls Recall - Driver's Air Bag Replacement 08-093 February 12, 2010 Applies To: See VEHICLES AFFECTED Safety Recall: Driver's Airbag Inflator Can Be Over-Pressurized (Supersedes 08-093, dated September 16, 2009, to revise the information marked by the black bars and asterisks) REVISION SUMMARY *^ Under VEHICLES AFFECTED, the VIN ranges for Civics and Accords were expanded. Also, some 2002 CR-Vs, some 2002 Odysseys, one 2003 Civic, and one 2003 Pilot were added. ^ CR-V, Odyssey, and Pilot were added under the REPAIR PROCEDURE and Example of Customer Letter headings.* BACKGROUND A manufacturing error can produce over-pressurization of the driver's (front) airbag inflator during airbag deployment. If an affected airbag deploys, the increased internal pressure may cause the inflator casing to rupture. Metal fragments could pass through the airbag cushion material, possibly causing an injury or fatality to vehicle occupants. VEHICLES AFFECTED Not all vehicles within the following VIN ranges are affected by this campaign. To verify vehicle eligibility, you must check at least one of these items: ^ The customer has a notification letter. ^ The vehicle is shown as eligible on a VIN status inquiry. In addition, check for a punch mark below the third character of the engine compartment VIN. A punch mark in that location means this campaign has already been completed. 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. Page 795 162. Right Side Of Engine Compartment Page 6175 Page 1114 107. Behind A/T Shift Lever (except M/T) Page 5243 - Remove clips carefully; don't damage their locks (A). - Slip pliers (A) under the clip base and through the hole at an angle, then squeeze the expansion tabs to release the clip. - After installing harness clips, make sure the harness doesn't interfere with any moving parts. - Keep wire harnesses away from exhaust pipes and other hot parts, from sharp edges of brackets and holes, and from exposed screws and bolts. - Seat grommets in their grooves properly (A). Do not leave grommets distorted (B). Testing and Repairs - Do not use wires or harnesses with broken insulation. Replace them or repair them by wrapping the break with electrical tape. - After installing parts, make sure that no wires are pinched under them. - When using electrical test equipment, follow the manufacturer's instructions and those described. - If possible, insert the probe of the tester from the wire side (except waterproof connector). - Use back probe adaptor 07TAZ-001020A. - Refer to the instructions in the Honda Terminal Kit for identification and replacement of connector terminals. Five-Step Troubleshooting Five-Step Troubleshooting 1. Verify The Complaint Page 573 Air Conditioning Switch: Service and Repair Heater Control Panel and Push Switch Assembly Removal and Installation 1. Remove the center panel. 2. Remove the dials (A), then remove the self-tapping screws and the heater control panel (B) from the center panel (C). Remove the self-tapping screws and the push switch assembly (D) from the center panel. 3. Install the control panel and the push switch assembly in the reverse order of removal. After installation, operate the control panel controls to see whether it works properly. 4. Run the self-diagnosis function to confirm that there are no problems in the system. Page 2084 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 2580 Throttle Position Sensor: Description and Operation Throttle Position (TP) Sensor The TP sensor is a potentiometer connected to the throttle valve shaft. As the throttle position changes, the sensor varies the signal voltage to the ECM/PCM. The TP sensor is not replaceable apart from the throttle body. Campaign - OPDS Unit Warranty Extension Technical Service Bulletin # 06-009 Date: 080205 Campaign - OPDS Unit Warranty Extension 06-009 February 5, 2008 Applies To: See VEHICLES AFFECTED Warranty Extension: OPDS Unit or OPDS Sensor Triggers SRS DTC(s) 15-1, 15-2, 15-3 (Supersedes 06-009, dated September 21, 2007) Updated information is shown with asterisks. BACKGROUND *NOTE: Because of a class action settlement, the warranty extension coverage for the OPDS unit and the OPDS sensor on 2002 Accords, 2002-04 Civics, 2003-04 Civic Hybrids, 2002-04 CR-Vs, 2003 Elements, 2002 Odysseys, and 2003-04 Pilots purchased or leased between April 13, 2002, and November 7, 2006, is now 10 years or 157,500 miles, whichever occurs first. For more information, refer to Service Bulletin 06-085, Warranty Extension: Vehicle Warranty Mileage.* Several vehicle models may have a problem with the OPDS (occupant position detection system) that causes the SRS indicator to stay on. Typically, one or more of these DTCs will be set: ^ SRS DTC 15-1 (faulty OPDS unit or OPDS not initialized) ^ SRS DTC 15-2 (faulty side airbag indicator circuit) ^ SRS DTC 15-3 (faulty OPDS sensor) To ensure continued reliability with the OPDS, American Honda is extending the warranty on the OPDS unit and the OPDS sensor to 10 years or 150,000 miles, whichever occurs first. This warranty extension does not apply to any vehicle that has ever been declared a total loss, or any that has been issued a salvage, branded, or similar title under any state's law. To check for vehicle eligibility, you must do a VIN status inquiry Locations 4. Right Side Of Engine Compartment Page 7438 Splices Components Ground - "G" Page 9681 Heated Glass Element Relay: Testing and Inspection Power Relay Test Use this chart to identify the type of relay, then do the test listed for it. NOTE: See the turn signal/hazard relay input test. Normally-open type B: Rear Window Defogger Relay Check for continuity between the terminals. - There should be continuity between the No.1 and No.3 terminals when power and ground are connected to the No.2 and No.4 terminals. - There should be no continuity between the No.1 and No.3 terminals when power is disconnected. Page 3535 Throttle Position Sensor: Description and Operation Throttle Position (TP) Sensor The TP sensor is a potentiometer connected to the throttle valve shaft. As the throttle position changes, the sensor varies the signal voltage to the ECM/PCM. The TP sensor is not replaceable apart from the throttle body. Page 7287 Use the tools from Pin Tool Set. First, check the connector that you are about to repair. - If it has a secondary terminal lock, go to Connectors With a Secondary Lock. A secondary lock, found on most connectors on some models, is an additional locking device on the connector housing as a backup for the primary lock on the terminal. - If the connector does not have a secondary lock, go to Connectors Without a Secondary Lock. Connectors With a Secondary Lock All examples are shown with the connector lock facing up. The illustrations are examples of the secondary terminal locks; however, the connector you are repairing may vary in size. Identify the connector by the type of secondary lock, not by the number of terminal cavities. EXAMPLE A: 1. Release the secondary lock. 2. Remove the terminal. 3. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE B: Power Steering Whines or Whistles Power Steering Pump: Technical Service Bulletins Power Steering Whines or Whistles SOURCE: Honda Service News April 2003 TITLE: Power Steering Whines or Whistles APPLIES TO: 2003 Accord V6s and on 200203 Civic 2-doors before VIN 1HGEM2...3L034854 SERVICE TIP: On a loose crimp in the power steering high-pressure hose can cause the silencer inside the hose to shift and make a whine or whistle. To fix this problem, replace the high-pressure hose. Page 4799 8. Put the splice connector in the proper size slot in the Crimper Tool, slide it to one end (where the flare begins), and close the crimper handles far enough to hold it in place. To release the ratchet mechanism at any point after the first click, squeeze the handles slightly and push the release lever, then let the handles open. 9. Insert one of the bare wires into the splice connector end that is in the crimper jaws. Push the wire all the way into the splice connector, and squeeze the crimper handles. Keep squeezing until the jaws touch, and hold it at that position until the ratchet clicks again. 10. Crimp the other wire in the same way into the other end of the splice connector. 11. After crimping, gently pull on the wires in the opposite directions to make sure they are secure in the connector. 12. Separate the other wires in the harness from the repaired wire(s), and shield them with nonflammable material. Page 983 ^ Going from front to back, use the middle lock pin to set the first cam to the appropriate key code number in the code book. (The cam is properly set when the number on the cam lines up with the red scribe mark on the clamp unit.) ^ Slide the lock pin through the notch in the cam. (This locks the cam in place.) ^ Keep doing this for each of the remaining cams in the set until all the cams are set and locked, then push the lock pin all the way in. Repeat this process to set and lock the cams for the right cam set. NOTE: Make sure you set the MIS cam in the right cam set for the type of key you are cutting. For a master key, set the cam to M; for a valet key, set it to S. When you are done, push all the cam blades to the left until they touch the cams in the left cam set. 10. Pull the vertical carriage lever toward you until the tracer touches the flat surface on the right side at the front of the cams. Gently twist the lever clockwise to lock the vertical carriage at this height. Do not overtighten the lever. 11. Turn on the cutter motor with the motor start switch. [NOTICE] ^ To avoid damaging the locking jaws while cutting, keep your hand off the vertical carriage lever. Pressure on the lever will change the cutting depth. * ^ To avoid breaking the cutter bit, never back up while cutting.* ^ Wear proper eye protection (safety glasses, goggles, etc.) 12. Use the clamp carriage lever and the tracer to follow the contours of the cam blades from front to back. (The cutter bit cuts the same contours into the right edge of the key blank, from head to tip.) Page 7296 8. Inspect the quality of the wire crimp. If it has any of the following NO GOOD crimps, cut it off and start over. 9. Insert the terminal into the connector. Make sure the wire seals are pushed all the way into the connector. Lightly pull on the wires to make sure the terminal is locked into place. 10. Close or insert the secondary terminal lock, if applicable, and reconnect the connector. How to Install Pigtail Terminals HOW TO INSTALL PIGTAIL TERMINALS Pigtail terminals (short pieces of wire with a factory crimped terminal) are used when the wire is too short or when access to the connector is too restricted to make a terminal repair. NOTE: To replace just a connector terminal, go to How to Replace Connector Terminals. IMPORTANT SAFETY INFORMATION: On some models, the SRS wires are in a separate harness. If the SRS harness is damaged, replace the harness; do not repair it. On other models, wire harnesses include yellow SRS wires. If any SRS wire is damaged, replace the entire harness; do not repair it. 1. Remove the damaged or faulty terminal from the connector. Use the proper removal tool from Pin Tool Set. Page 3024 159. Left Side Of Engine Compartment Locations Neutral Safety Switch: Locations Starting System Component Location Index Page 8197 Keyless/Power Door Lock System Component Location Index Page 3169 Variable Valve Timing Pressure Switch: Service and Repair VTEC Oil Pressure Switch Replacement 1. Remove the resonator (see step 5). 2. Remove the bolt (A) and loosen the bolt (B) securing the VTEC solenoid valve, then remove the harness bracket (C) from the VTEC solenoid valve. 3. Remove the harness clamp (D) from the connecting pipe. 4. Disconnect the VTEC oil pressure switch connector, then remove the VTEC oil Pressure switch (A). 5. Install the VTEC oil pressure switch using a new O-ring (B). Page 2127 10. Rotate the crankshaft 180° counterclockwise (camshaft pulley turns 90°). The "UP" mark (A) on the camshaft pulley should be toward the exhaust side of the head. 11. Check and, if necessary, adjust the valve clearance on No. 3 cylinder. 12. Rotate the crankshaft 180° counterclockwise to bring No. 4 piston to TDC. TDC marks (A) are visible again. 13. Check and, if necessary, adjust the valve clearance on No. 4 cylinder. 14. Rotate the crankshaft 180° counterclockwise to bring No. 2 piston to TDC. The "UP" mark (A) should be on the intake side of the head. 15. Check and, if necessary, adjust the valve clearance on No. 2 cylinder. 16. Install the cylinder head cover. Locations Control Assembly: Locations 74. Behind Heater Control Unit-Panel Relay And Control Unit Locations - Dashboard Page 8773 1. Remove the terminal. 2. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE G: 1. Remove the terminal. 2. Go to HOW TO INSTALL NEW TERMINALS. How to Install New Terminals HOW TO INSTALL NEW TERMINALS 1. Carefully match the old terminal with a new one from the terminal repair kit. Choose the correct replacement terminal based on the wire size range the terminal will accommodate. NOTE: If the replacement terminal quantities are low, reorder them by using the terminal part number listed on the inside lid of the terminal repair kit. Replacement terminals are available through your parts department using normal parts ordering procedures. 2. Depending on the size of the wire you are repairing, use the proper size slot in the crimping tool. Testing and Inspection Windshield Washer Control Module: Testing and Inspection Control Unit Input Test 1. Before testing, troubleshoot the multiplex control system. 2. Remove the dashboard lower cover. 3. Disconnect the under-dash fuse/relay box connectors B, G, J, X and Y. NOTE: All connectors are wire side of female terminals. 4. Inspect the connector and socket terminals to be sure they are all making good contact. - If the terminals are bent, loose or corroded, repair them as necessary, and recheck the system. - If the terminals are OK, go to step 5. 5. Reconnect the connectors, and make these input tests at the connector. - If any test indicates a problem, find and correct the cause, then recheck the system. - If all the input tests prove OK, the multiplex control unit must be faulty; replace the under-dash fuse/relay box assembly. Page 135 159. Fog Light Relays 1 And 2 (Honda Accessory) Page 1572 69. Under Left Side Of Dash 70. Under Left Side Of Dash Page 7298 8. Put the splice connector in the proper size slot in the Crimper Tool, slide it to one end (where the flare begins), and close the crimper handles far enough to hold it in place. To release the ratchet mechanism at any point after the first click, squeeze the handles slightly and push the release lever, then let the handles open. 9. Insert one of the bare wires into the splice connector end that is in the crimper jaws. Push the wire all the way into the splice connector, and squeeze the crimper handles. Keep squeezing until the jaws touch, and hold it at that position until the ratchet clicks again. 10. Crimp the other wire in the same way into the other end of the splice connector. 11. After crimping, gently pull on the wires in the opposite directions to make sure they are secure in the connector. 12. Separate the other wires in the harness from the repaired wire(s), and shield them with nonflammable material. Page 5565 107. Behind A/T Shift Lever (except M/T) Page 7448 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. Test Equipment 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. Page 1788 Connecting Rod: Specifications Connecting rod Pin-to-rod clearance Standard or New .......................................................................................................................................... 0.016 0.036 mm (0.0006 - 0.0014 inch) Small-end bore diameter Standard or new .............................................................................................................................................. 18.96 18.98 mm (0.746 - 0.747 inch) Large-end bore diameter Nominal Standard or New .................................................................................................................................. .................................. 48.0 mm (1.89 inch) End play installed on crankshaft Standard or New .................................................................................................................................................. 0.15 0.30 mm (0.006 - 0.012 inch) Service Limit ......................................................................................... .................................................................................... 0.40 mm (0.016 inch) Torque: Connecting rod bolts to ............................................................................................................................................................. 32 Nm (3.3 kgf-m, 24 ft.) Page 5765 Under-dash Fuse/Relay Box Page 3843 Transmission Position Switch/Sensor: Electrical Diagrams Circuit Diagram Page 7961 6. Disconnect both seat belt buckle tensioner 4P connectors (A). Page 1742 Wire Color Abbreviations Page 1497 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 8186 Power Door Lock Actuator: Testing and Inspection Door Lock Actuator Test Driver's door: 1. Remove the driver's door panel. 2. Disconnect the 2P connector from the actuator. 3. Check actuator operation by connecting power and ground according to the table. To prevent damage to the actuator, apply battery voltage only momentarily. 4. If the actuator does not operate as specified, replace it. Passenger's door: 1. Remove the passenger's door panel. Page 5722 Resistor Variable Sensor Solenoid Transistors Circuit Schematics Page 3202 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. Below most connector numbers and component names are PHOTO and VIEW numbers. The PHOTO number refers to a photo in the back of the book that shows the connector's location on the car. The VIEW number refers to an illustration in the back of the book that shows the connector terminals, wire colors, connector cavity numbers, and other details. The connector cavity numbering sequence begins at the top left corner of the connector as seen from either of the viewpoints shown on diagram [8] . Except for the DLC (data link 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 C554, for example, means those terminals join in cavity 2 of connector C554. Power Distribution Schematics Power Distribution Schematics Locations Clutch Switch: Locations Starting System Component Location Index Page 6914 4. Repeat steps 2 and 3 as needed for additional buttons. 5. Install the seat-back cover in the reverse order of removal. Disclaimer Page 365 1. On Accords and Pilots, remove the front passenger's seat-back panel by prying out the bottom. Replace the two lower clips. 2. On all models except Accords and Pilots, unzip the two seat cover zippers on the back of the front passenger's seat. 3. Pull back the seat-back cover from the left side bolster to access the OPDS unit cover. 4. Remove the OPDS unit cover from the seat frame. 5. Check the part number of the installed OPDS unit. Page 9729 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. DIAGNOSIS Pull up the outer edge of the windshield molding. Check if the inner lip is folded over anywhere. ^ If the inner lip is folded over, go to REPAIR PROCEDURE. ^ If the inner lip is not folded, disregard this bulletin, and look for other possible causes. REPAIR PROCEDURE 1. Protect the roof by applying a strip of 2-inch-wide masking tape along the outer edge of the windshield molding. 2. Pull up the outer edge of the molding, and use scissors or an X-Acto knife to remove its entire inner lip. Page 7800 ^ If the trunk opens and closes smoothly, return the vehicle to the customer. ^ If the trunk lid is still difficult to close, go to REPAIR PROCEDURE E. REPAIR PROCEDURE E 1. Look at the back of the lock cylinder while you turn the key from lock to unlock. ^ Refer to page 20-158 of the 2001-04 Civic Service Manual. ^ In ISIS, use the keyword LID LOCK, and select Trunk Lid Lock Cylinder Replacement from the list. 2. Check the operation of the trunk lid lock cylinder: ^ If the lock cylinder is difficult to turn or binds, go to step 3. ^ If the lock cylinder operates properly, and the trunk lid is still difficult to close, refer to the appropriate body repair manual, and check for body inaccuracies. 3. Replace the lock cylinder, and re-key the cylinder to the customer's original key; on 2-door Civics, replace the lock cylinder and the lock cylinder rod: ^ Refer to page 20-158 of the 2001-04 Civic Service Manual. ^ In ISIS, use the keyword LID LOCK, and select Trunk Lid Lock Cylinder Replacement from the list. 4. Check the trunk operation, and return the vehicle to the customer. Disclaimer Page 4551 2. Install the new bearings with the special tool and a press. Press the bearing on until it bottoms. Oil Seal Replacement Special Tools Required Driver 07749-0010000 - Driver attachment, 78 x 80 mm 07NAD-PX40100 - Driver attachment, 58 mm 07JAD-PH80101 1. Remove the oil seal (A) from the transmission housing (B). 2. Remove the oil seal (A) from the flywheel housing (B). Page 1804 Crankshaft Main Bearing: Service and Repair Main Bearing Clearance Inspection 1. To check main bearing-to-journal oil clearance, remove the main caps and bearing halves. 2. Clean each main journal and bearing half with a clean shop towel. 3. Place one strip of plastigage across each main journal. NOTE: If the engine is still in the car when you bolt the main cap down to check the clearance, the weight of the crankshaft and drive plate will flatten the plastigage further than just the torque on the cap bolt and give you an incorrect reading. For an accurate reading, support the crank with a jack under the counterweights, and check only one bearing at a time. 4. Reinstall the bearings and caps, then torque the bolts to 51 Nm (5.2 kgf-cm, 38 ft. lbs.). Do not rotate the crankshaft. 5. Remove the cap and bearing half, and measure the widest part of the plastigage. Main Bearing-to-Journal Oil Clearance Standard (New): No.1, 5: 0.018 - 0.036mm (0.0007 - 0.0014 inch) No.2, 3, 4: 0.024 - 0.042mm (0.0009 - 0.0017 inch) Service Limit: 0.05 mm (0.002 inch) 6. If the plastigage measures too wide or too narrow, (remove the engine if it's still in the car), remove the crankshaft, and remove the upper half of the bearing. Install a new, complete bearing with the same color code, and recheck the clearance. Do not file, shim, or scrape the bearings or the caps to adjust clearance. 7. If the plastigage shows the clearance is still incorrect, try the next larger or smaller bearing (the color listed above or below that one), and check again. If the proper clearance cannot be obtained by using the appropriate larger or smaller bearings, replace the crankshaft and start over. Main Bearing Selection Crankshaft Bore Code Location Letters have been stamped on the end of the block as a code for the size of each of the five main journal bores. Locations Page 2430 ^ Start the engine and let it warm up to its normal operating temperature (the cooling fans cycle twice). ^ Let the engine idle (throttle closed and all electrical items off) for 10 minutes. 17. CR-V only: Reset the power window control unit: ^ Turn the ignition switch to ON (II). ^ Make sure the driver's window is fully closed. ^ Push down and hold the window switch until the window goes all the way down. ^ Pull back and hold the window switch until the window goes all the way up, then hold the switch for at least 2 more seconds. 18. Enter the audio unit anti-theft code, and set the clock. Enter the audio presets. Disclaimer Page 4722 Page 2952 DTC P1679 thru P1860 Page 464 - There should be no continuity when the LOCKED position. 5. If the continuity is not as specified, replace the door lock actuator. Page 125 4. Make these input tests at the connector. - If any test indicates a problem, find and correct the cause, then recheck the system. - If all the input tests prove OK, the control unit must be faulty; replace it. '04 model Page 6679 - 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. - Refer to the scrapping procedures for disposal of the damaged airbag. 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. 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. Locations Under-dash Fuse/Relay Box Page 6204 Power Steering Pressure Switch: Testing and Inspection PSP Switch Signal Circuit Troubleshooting 1. Turn the ignition switch ON (II). 2. Measure voltage between ECM/PCM connector terminals A24 and E16. Is there less than 1.0 V? YES - Go to step 3. NO - Go to step 6. 3. Start the engine. 4. Turn the steering wheel to the full lock position. 5. Measure voltage between ECM/PCM connector terminals A24 and E16. Is there battery voltage? YES - The PSP switch signal is OK. NO - Go to step 13. 6. Turn the ignition switch OFF. 7. Disconnect the PSP switch 2P connector. 8. Turn the ignition switch ON (II). 9. At the harness side, connect the PSP switch 2P connector terminals No.1 and No.2 with a jumper wire. 10. Measure voltage between ECM/PCM connector terminals A24 and E16. Is there less than 1.0 V? YES - Replace the PSP switch. NO - Go to step 11. 11. Turn the ignition switch OFF. Page 6109 ^ 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 228 Power Windows Component Location Index Page 6022 67. Under Left Side Of Dash Page 5906 Resistor Variable Sensor Solenoid Transistors Circuit Schematics Page 9369 2. Cut off the wire about an inch back from where it connects to the damaged or faulty terminal, then strip about half of the insulation off that piece. This will be used to size the wire end of the replacement pigtail terminal. NOTE: If you are not sure of the wire size, start with a large enough hole on the stripper that will not nick or cut off any strands of wires. 3. Select a pigtail terminal that matches the original wire at both ends (same kind of terminal and same diameter bare wire). 4. Select the smallest splice connector (yellow, pink, or blue) that will fit onto the stripped end of the original wire. 5. Insert the pigtail terminal into the connector cavity; push it in until it locks in place. 6. Lay the pigtail and the original wire side-by-side, and cut off both ends at once. If you are making more than one splice, do not cut each pigtail at the same location; the resulting "lump" of splice connectors would interfere with rewrapping the harness. Instead, cut the first pigtail close enough to the terminal so you will have room to make each remaining cut about 20 mm (3/4 inch) farther down on the next pigtail. 7. If you are using a yellow splice connector, strip about 6 mm (1/4 inch) of insulation off the ends of both wires. If you are using a pink or blue splice connector, strip off about 8 mm (5/16 inch) of insulation. Page 2711 Data Link Connector: Testing and Inspection DLC Circuit Troubleshooting If the ECM/PCM does not communicate with the OBD II scan tool, Honda PGM Tester, or I/M test equipment, do this troubleshooting procedure. 1. Measure voltage between DLC terminal No.16 and body ground. Is there battery voltage? YES - Go to step 2. NO - Repair open in the wire between DLC terminal No.16 and the No.9 BACK UP (7.5A) fuse in the under-hood fuse/relay box. 2. Measure voltage between DLC terminals No.4 and No.16. Is there battery voltage? YES - Go to step 3. NO - Repair open in the wire between DLC terminal No.4 and body ground. 3. Measure voltage between DLC terminals No.5 and No.16. Is there battery voltage? YES - Go to step 4. NO - Repair open in the wire between DLC terminal No.5 and ECM/PCM (E3). Page 4703 Transmission Speed Sensor: Diagrams 105. CVT Drive Pulley Speed Sensor 106. CVT Driven Pulley Speed Sensor 107. CVT Speed Sensor 1 108. CVT Speed Sensor 2 Body - Door Lock Cylinders Bind Tailgate Lock Cylinder: Customer Interest Body - Door Lock Cylinders Bind 03-068 October 29, 2004 Applies To: See VEHICLES AFFECTED Door Lock Cylinder Binds (Supersedes 03-068, dated April 20, 2004) Updated information is shown with asterisks and black bars. SYMPTOM The key will not go into the door lock cylinder, or if it goes in, it will not turn. PROBABLE CAUSE The door lock tumblers are damaged or worn. VEHICLES AFFECTED CORRECTIVE ACTION Remove the door lock cylinder, and replace the inner cylinder, springs, and tumblers. Alignment Alignment: Specifications Alignment Wheel alignment Camber Front .................................................................................................................................................... ....................................................... 0°00' ± 45' Rear ........................................................................... ................................................................................................................................ -0°45' ± 45' Caster, Front '01-02 models ...................................................................................................................................... ......................................................... 1°33' ± 1° '03-04 models ........................................................... .................................................................................................................................... 2°14' ± 1° Total toe Front .................................................................................................................................................... ............................. 0 ± 3 mm (0 ± 0.12 inch) Rear ............................................................................... .................................................................................. IN 2 [2/1] mm (0.08 [0.08/0.04] inch) Front wheel turning angle Inside wheel w/o P195/60R15 tire.............................................................. ...................................................................................................... 40°00' ± 2° Inside wheel w P195/60R15 tire.................................................................................................................................... ................................... 38°00' ± 2° Outside wheel w/o P195/60R15 tire ................................................................................................................................................... 31°00' (Reference) Outside wheel w P195/60R15 tire ...................................................................................................................................................... 30°00' (Reference) Page 4223 2. Remove the terminal from the female half. 3. Remove the terminal from the male half. 4. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE D: 1. Remove the secondary locks. Page 6068 234. Under-dash Fuse/Relay Box Part 3 Page 3289 128. VSS (except CVT) Page 4453 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. DIAGNOSIS Have an assistant press the clutch pedal while you grasp the clutch line at the clutch master cylinder, and then at the slave cylinder. If you feel a vibration through the clutch line when you hear the noise or the noise stops, go to REPAIR PROCEDURE. If you feel no vibration or the noise does not stop, look for other causes. REPAIR PROCEDURE NOTICE Do not spill brake fluid on the vehicle; it may damage the paint. If brake fluid does contact the paint, wash it off immediately with water. 1. Remove the clutch master cylinder. Refer to the appropriate service manual: 2003-04 Accord (L4): page 12-6 2003-04 Accord (V6): page 12-8 2001-04 Civic: page 12-5 2002-04 Civic Si: page 12-5 2003-04 Civic Hybrid: page 13-5 2002-04 CR-V: page 12-5 2003-04 Element: page 12-6 Enter keyword CLUTCH MASTER, and select Clutch Master Cylinder Replacement from the list. 2. Install the new clutch master cylinder, but do not attach the clutch line fitting. 3. Apply a thin coat of silicone grease to the clutch line fitting and to the opening in the clutch master cylinder. Do not use silicone spray; it could damage the 0-ring. 4. Connect the clutch line fitting to the clutch master cylinder. 5. Bleed the clutch hydraulic system, then top off the reservoir with brake fluid. 6. Check to see if the noise is gone when pressing the clutch pedal. ^ If the noise is gone, the repair is complete. Service and Repair Piston Pin: Service and Repair Replacement Special Tools Required ^ Piston base 07973-6570500 ^ Piston base spring 07973-6570600 ^ Piston pin base insert 07973-PE00400 ^ Piston base head 07973-SB00100 or 07TGF-001000A ^ Pilot collar 07973-PE00200 ^ Piston pin driver shaft 07973-PE00310 ^ Piston pin driver head 07973-PE00320 Disassembly 1. Remove the piston from the cylinder block 2. Assemble the special tool as shown. 3. Assemble and adjust the length of the piston pin driver head and shaft to 53 mm (2.1 inch). Page 3890 Transmission Speed Sensor: Diagrams 105. CVT Drive Pulley Speed Sensor 106. CVT Driven Pulley Speed Sensor 107. CVT Speed Sensor 1 108. CVT Speed Sensor 2 Page 2157 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 Short Circuit Locator (Short Finder) 1. Remove the blown fuse. Leave the battery connected. Page 1961 12. Oil Pressure Switch Page 2949 DTC P1253 thru P1459 Page 9087 - 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. Troubleshooting Tests 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 test 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 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. 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 Drop Page 8972 Fuel Gauge Sender: Locations Gauges Component Location Index (Part 1 Of 4) Page 8626 9. Open the jaws with the jaws knob, and slide the original key with its flat side down into the center jaw up to the key stop. Slide the key blank with its flat side down into the right jaw up to the key stop. Close the jaws with the jaws knob to lock the keys into place. Visually inspect both keys for proper alignment in the jaws. 10. Loosen the lateral and spring tension adjustment knobs on the clamp carriage. With the clamp carriage lever, adjust the clamp carriage to position the tracer and the cutter bit over the middle of the two locked key blades. Tighten only the spring tension knob when done. NOTE: The clamp carriage has a spring system that puts lateral pressure on the tracer and cutting bit to make it easier to cut sidewinder-type keys. Do not tighten the lateral tension adjustment knob. This knob should be left loose. 11. Turn on the cutter motor with the motor start switch. [NOTICE] ^ To avoid damaging the locking jaws while cutting, keep your hand off the vertical carriage lever. Pressure on the lever will change the cutting depth. * ^ To avoid breaking the cutter bit, never back up while cutting.* ^ Wear proper eye protection (safety glasses, goggles, etc.) Page 4957 Shift Interlock Switch: Service and Repair Park Pin Switch Replacement 1. Remove the center console panel and center console. 2. Remove the screws (A), then remove the shift lever knob (B) 3. Remove the A/T gear position indicator panel light (c) from the A/T gear position indicator panel. 4. Remove the A/T gear position indicator panel and panel bracket as an assembly (D). 5. Disconnect the park pin switch connector (4P) (E), and remove it from the shift lever bracket base (F). 6. Remove the shift lock release (G) and spring (H). 7. Open the lock tabs (A) on the shift lever bracket base, then remove the park pin switch (B). 8. Install the new park pin switch. 9. Install the removed parts in the reverse order of removal. Page 636 Brake Light Switch: Description and Operation Brake Pedal Position Switch The brake pedal position switch signals the ECM/PCM when the brake pedal is pressed. Page 7582 Rear Door Weatherstrip: Service and Repair Rear Door Weatherstrip Replacement Rear Door Weatherstrip Replacement 4-door NOTE: - Take care not to scratch the door. - Use a clip remover to remove the clips. 1. At the B-pillar, remove the door checker mounting bolt (A). 2. Detach the clips (B), then remove the door weatherstrip (C). 3. Install the weatherstrip in the reverse order of removal, and note these items: - Replace any damaged clips. - Make sure the weatherstrip is installed in the holder (D) securely. - Apply liquid thread lock to the door checker mounting bolt before in5tallation. - Check for water leaks. - Test-drive and check for wind noise. Locations Relay And Control Unit Locations - Engine Compartment Page 588 Evaporator Temperature Sensor / Switch: Service and Repair Evaporator Temperature Sensor Replacement 1. Disconnect the 2P connector (A) from the evaporator temperature sensor (B), then remove the connector clip (C). Turn the evaporator temperature sensor counterclockwise to the stop, and carefully pull out it. 2. Install the sensor in the reverse order of removal. Locations Manifold Pressure/Vacuum Sensor: Locations PGM-FI System - Component Location Index Page 6139 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. Diagram Information and Instructions Interior Lighting Module: Diagram Information and Instructions Terminal Numbering System Terminal Numbering System Connector terminals are numbered according to the cavities they're in. The cavities are numbered starting from the upper left, looking at the male terminals from the terminal side or looking at the female terminals from the wire side. Both views are in the same direction so the numbers are the same. All actual cavities are numbered, even if they have no wire terminals in them. NOTE: Data Link Connector (DLC) terminals are numbered according 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 below is #6. Page 2499 Power Steering Pressure Switch: Service and Repair Power Steering Hoses, Lines, and Pressure Switch Replacement Note these items during installation: ^ Connect each hose to the corresponding line securely until it contacts the stop on the line. Install the clamp or adjustable clamp at the specified distance from the hose end as shown. ^ Check all clamps for deterioration or deformation; replace the clamps with new ones, if necessary. ^ Add the recommended power steering fluid to the specified level on the reservoir and check for leaks. Page 7537 Front Door Weatherstrip: Service and Repair Front Door Weatherstrip Replacement Front Door Weatherstrip Replacement NOTE: - Take care not to scratch the door. - Use a clip remover to remove the clips. Page 4402 7. Align the cutouts (A) on the rotary-frame with the neutral positioning cutouts (B) on the transmission range switch, then put a 2.0 mm (0.08 inch) feeler gauge blade (C) in the cutouts to hold it in the N position. NOTE: Be sure to use a 2.0 mm (0.08 inch) blade or equivalent to hold the switch in the N position. 8. Install the transmission range switch (A) gently on the control shaft (B) with holding the N position with the 2.0 mm (0.08 inch) blade (C). 9. Tighten the bolts on the transmission range switch while you continue to hold it in the N position. Do not move the transmission range switch when tightening the bolts. Remove the feeler gauge. Page 1676 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. Test Equipment 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. Page 6042 Under-hood Fuse/Relay Box 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 8009 10. Pull down on the retainer clip with a hook-shaped tool. Remove the lock cylinder. Then go to step 14. 11. Pull the glass run channel away as necessary, and remove the bolt, then remove the center lower channel by pulling it downward. 12. Remove the access seal, and disconnect the outer handle rod and the cylinder rod. Page 8888 Key Reminder Switch: Locations Entry Light Control System Component Location Index Page 2236 PGM-F1 Main Relay 1, 2 Type 1, 2 Check for continuity between the terminals. - There should be continuity between the No.1 and No.2 terminals when power and ground are connected to the No.3 and No.4 terminals. - There should be no continuity between the No.1 and No.2 terminals when power is disconnected. Normally-open type B: Rear Window Defogger Relay Page 2253 67. Radiator Fan Switch Page 3821 - Remove clips carefully; don't damage their locks (A). - Slip pliers (A) under the clip base and through the hole at an angle, then squeeze the expansion tabs to release the clip. - After installing harness clips, make sure the harness doesn't interfere with any moving parts. - Keep wire harnesses away from exhaust pipes and other hot parts, from sharp edges of brackets and holes, and from exposed screws and bolts. - Seat grommets in their grooves properly (A). Do not leave grommets distorted (B). Testing and Repairs - Do not use wires or harnesses with broken insulation. Replace them or repair them by wrapping the break with electrical tape. - After installing parts, make sure that no wires are pinched under them. - When using electrical test equipment, follow the manufacturer's instructions and those described. - If possible, insert the probe of the tester from the wire side (except waterproof connector). - Use back probe adaptor 07TAZ-001020A. - Refer to the instructions in the Honda Terminal Kit for identification and replacement of connector terminals. Five-Step Troubleshooting Five-Step Troubleshooting 1. Verify The Complaint Locations Hazard Warning Switch: Locations Turn Signal/Hazard Flasher - Component Location Index Page 233 1. Right Side Of Engine Compartment Page 6167 16. Remove the snap ring (A) and the splash guard (B) from the knuckle (C). 17. Press the wheel bearing (A) out of the knuckle (B) using the special tool and a press. 18. Wash the knuckle and hub thoroughly in high flash point solvent before reassembly. 19. Press a new wheel bearing (A) into the knuckle (B) using the old bearing (C), a steel plate (D), the special tool, and a press. Place the wheel bearing on the knuckle with the pack seal side facing (metal color) toward the inside. Be careful not to damage the sleeve of the pack seal. 20. Install the snap ring (A) securely in the knuckle (B). 21. Install the splash guard (C), and tighten the screws (D) to the specified torque. Page 6059 1. Right Side Of Engine Compartment Page 3002 155. A/F Sensor Relay (HX; '04-'05: DX, EX, LX) Page 6523 Air Conditioning Component Location Index Page 998 Power Steering Pressure Switch: Description and Operation Power Steering Pressure (PSP) Switch The PSP switch signals the ECM/PCM when the power steering load is high. Page 2780 ECM/PCM Inputs And Outputs At Connector C (22P) Page 4731 Wheel Bearing: Service and Repair Rear Hub Bearing Unit Replacement 1. Raise the rear of the vehicle, and support it with safety stands in the proper locations. 2. Remove the wheel cap, wheel nuts, and rear wheel. Page 4371 Circuit Schematics Each schematic represents one circuit. A circuit's wires and components are arranged to show current flow from power at the top of the diagram 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 M/T - Clutch Pedal Squeak/Twang or Notchy Feel Hydraulic Hose: Customer Interest M/T - Clutch Pedal Squeak/Twang or Notchy Feel 02-002 January 11, 2005 Applies To: See VEHICLES AFFECTED Squeak at the Clutch Pedal (Supersedes 02-002, dated September 21, 2004) SYMPTOM A squeak, a twang, or a notchy feel when the clutch pedal is pressed. PROBABLE CAUSE The clutch master cylinder spring is rubbing on the outer diameter of the piston when the pedal is pressed, or the master cylinder quick connect is moving. Page 9636 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. Below most connector numbers and component names are PHOTO and VIEW numbers. The PHOTO number refers to a photo in the back of the book that shows the connector's location on the car. The VIEW number refers to an illustration in the back of the book that shows the connector terminals, wire colors, connector cavity numbers, and other details. The connector cavity numbering sequence begins at the top left corner of the connector as seen from either of the viewpoints shown on diagram [8] . Except for the DLC (data link 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 C554, for example, means those terminals join in cavity 2 of connector C554. Power Distribution Schematics Power Distribution Schematics Page 8077 Keyless Entry Module: Testing and Inspection Control Unit Input Test 1. Before testing, troubleshoot the multiplex control system. 2. Remove the dashboard lower cover. 3. Disconnect the under-dash fuse/relay box connectors. NOTE: All connectors are wire side of female terminals. 4. Inspect the connector and socket terminals to be sure they are all making good contact. - If the terminals are bent, loose or corroded, repair them as necessary, and recheck the system. - If the terminals look OK, go to step 5. Trim Removal/Installation - Door Area Trim Panel: Service and Repair Trim Removal/Installation - Door Area Trim Removal/Installation - Door Area Special Tools Required KTC trim tool set SOJATP2014 2-door NOTE: - Put on gloves to protect your hands. - Use the appropriate tool from the KTC trim tool set to avoid damage when prying components. - Take care not to bend or scratch the trim and panels. 1. Remove the trim as shown: - To remove the door sill trim and B-pillar upper trim, remove the side trim panel as necessary. - To remove the front side cap and opener lock cylinder, refer to trunk lid opener/fuel fill door opener replacement. 2. Install the pants in the reverse order of removal, and note these items: - Replace any damaged clips. - Apply liquid thread lock to the anchor bolts before installation. - Before installing the anchor bolts, make sure there are no twists or kinks in the seat belts. Special Tools Required KTC trim tool set SOJATP2014 4-door NOTE: - Put on gloves to protect your hands. - Use the appropriate tool from the KTC trim tool set to avoid damage when prying components. - Take care not to bend or scratch the trim and panels. 1. Remove the trim as shown: Diagrams Speaker: Diagrams 81. Speaker, Driver's Door 82. Speaker, Front Passenger's Door (Sedan) 83. Speaker, Left Rear Or Right Rear (except GX) Page 4872 6. Replace the 1st/2nd synchro hub/sleeve, and reassemble the countershaft; see page 13-34 (13-48 for Hybrid) of the service manual. 7. Check the countershaft clearance; see page 13-30 (13-44 for Hybrid) of the service manual. Page 831 195. Tranmission Range Switch Page 8122 Programming the Transmitter NOTES: ^ The system accepts up to four transmitters. ^ Entering the programming mode cancels all learned transmitter codes, so none of the previously programmed transmitters will work. You must reprogram all the transmitters once you're in the programming mode. 1. Turn the ignition switch to ON (II). 2. Press and hold the Valet-Disarm button on the radio (between the AM/FM and CD/TAPE buttons) to enter the programming mode. (Continue to hold the button during this procedure, or programming will be cancelled.) Check that the power door locks cycle to confirm that you're in the programming mode. 3. Within 5 seconds, press the "Lock" or "Unlock" button on the transmitter. Check that the power door locks cycle to confirm that the code was accepted. 4. Within 10 seconds, press the "Lock" or "Unlock" button on each of the remaining transmitters. 5. After all the transmitters have been programmed, release the Valet-Disarm button to exit programming mode. Ordering a Transmitter Transmitters can be ordered only by authorized Honda dealers. Order them from American Honda using normal parts ordering procedures. Batteries for the Transmitter The battery number is CR2025. Each transmitter uses one battery. 99-04 Civic, 03-04 Accord, Element, Pilot 1999-00 Civic Value Package with factory-installed keyless entry system 1999-04 Civic EX with factory-installed keyless entry system or dealer-installed security system *1999-03 Civic (except EX) with dealer-installed keyless entry system or security system 2002-04 Civic Si with factory-installed keyless entry system or dealer-installed security system 2003-04 Civic Hybrid with factory-installed keyless entry system or dealer-installed security system 2004 Civic (except LX & EX) with dealer-installed keyless entry system or security system 2004 Civic LX with factory-installed keyless entry system or dealer-installed security system Component Locations Page 322 Fuel Pump Relay: Description and Operation PGM-FI Main Relay 1 and 2 The PGM-FI relay consists of two separate relays. PGM-FI main relay 1 is energized whenever the ignition switch is ON (II) which supplies battery voltage to ECM/PCM, power to the injectors, and power for PGM-FI main relay 2. PGM-FI main relay 2 is energized to supply power to the fuel pump for 2 seconds when the ignition switch is turned ON (II), and when the engine is running. Locations Crankshaft Position Sensor: Locations PGM-FI System - Component Location Index Page 6594 Refrigerant: Fluid Type Specifications Refrigerant Type ..................................................................................................................................................... ........................................... HFC-134 a (R-134 a) Page 4457 Some types Some types 4. To prevent the retaining clip (A) from coming off, pry to open the tip of the retaining clip (B) with a screwdriver. 5. Install the clutch master cylinder. Page 4784 - 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. Troubleshooting Tests 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 test 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 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. 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 Drop Page 3713 1. Remove the terminal. 2. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE B: 1. Remove the terminal. 2. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE C: 1. Remove the terminal. 2. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE D: Page 5742 1. Remove the terminal. 2. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE G: 1. Remove the terminal. 2. Go to HOW TO INSTALL NEW TERMINALS. How to Install New Terminals HOW TO INSTALL NEW TERMINALS 1. Carefully match the old terminal with a new one from the terminal repair kit. Choose the correct replacement terminal based on the wire size range the terminal will accommodate. NOTE: If the replacement terminal quantities are low, reorder them by using the terminal part number listed on the inside lid of the terminal repair kit. Replacement terminals are available through your parts department using normal parts ordering procedures. 2. Depending on the size of the wire you are repairing, use the proper size slot in the crimping tool. Page 7218 (Not interchangeable with CR-V and S2000 remote transmitter) Transmitter Identification The transmitter for the 1995-99 Accord and the 2000-02 Accord look identical, but they are not interchangeable. The 1995-99 transmitter works the doors of a 2000-02 Accord, but it does not open the trunk. If you are not sure which transmitter you have, press and hold the trunk release button while looking at the LED. The LED on the 1995-99 transmitter comes on in about 1.1 seconds. The LED on the 2000-02 transmitter comes on in about 0.5 second. Programming the Transmitter NOTES: ^ The system accepts up to three transmitters. The transmitter codes are stored in a stacking-type memory. If a fourth transmitter code is programmed, the code for the first transmitter is erased. ^ Entering the programming mode cancels all learned transmitter codes, so none of the previously programmed transmitters will work. You must reprogram all of the transmitters once you are in the programming mode. ^ You must complete steps 1-6 within 4 seconds of the previous step to keep the system from exiting the programming mode. 1. Turn the ignition switch to ON (II). 2. Press the "Lock" or "Unlock" button on one of the transmitters. (An unprogrammed transmitter can be used for this step.) 3. Turn the ignition switch to LOCK (0). 4. Repeat steps 1 2, and 3 two more times using the same transmitter used in step 2. 5. Turn the ignition switch to ON (II). 6. Press the "Lock" or "Unlock" button on the same transmitter. Make sure the power door locks cycle to confirm that the system is in programming mode. 7. Within 10 seconds, press the "Lock" or "Unlock" button on each transmitter. Make sure the power door locks cycle after you press each transmitter button to confirm that the system accepted the transmitter's code. 8. Turn the ignition switch to LOCK (0) to exit the programming mode. Ordering a Transmitter Transmitters can be ordered only by authorized Honda dealers. Order them from American Honda using normal parts ordering procedures. Batteries for the Transmitter The battery number is CR2025. Each transmitter uses one battery. 03-04 Accord LX and EX 2003-04 Accord LX and EX with factory-installed keyless entry system Page 5233 Connectors - "C" Page 2215 Heater Core: Service and Repair Heater Unit/Core Replacement SRS components are located in this area. Review the SRS component locations, and precautions and procedures in the SRS section before performing repairs or service. 1. Make sure you have the anti-theft code for the radio, then write down the frequencies for the radio's preset buttons. 2. Disconnect the negative cable from the battery. 3. With air conditioning; disconnect the suction and receiver lines from the evaporator core. 4. From under the hood, open the cable clamp (A), then disconnect the heater valve cable (B) from the heater valve arm (C). Turn the heater valve arm to the fully opened position as shown. 5. When the engine is cool, drain the engine coolant from the radiator. 6. Slide the hose clamps (A) back, then disconnect the inlet heater hose (B) and the outlet heater hose (C) from the heater core. Engine coolant will run out when the hoses are disconnected; drain it into a clean drip pan. Be sure not to let coolant spill on the electrical parts or the painted surfaces. If any coolant spills, rinse it off immediately. 7. Remove the mounting bolt and the heater valve as shown. Page 4393 2. Cut off the wire about an inch back from where it connects to the damaged or faulty terminal, then strip about half of the insulation off that piece. This will be used to size the wire end of the replacement pigtail terminal. NOTE: If you are not sure of the wire size, start with a large enough hole on the stripper that will not nick or cut off any strands of wires. 3. Select a pigtail terminal that matches the original wire at both ends (same kind of terminal and same diameter bare wire). 4. Select the smallest splice connector (yellow, pink, or blue) that will fit onto the stripped end of the original wire. 5. Insert the pigtail terminal into the connector cavity; push it in until it locks in place. 6. Lay the pigtail and the original wire side-by-side, and cut off both ends at once. If you are making more than one splice, do not cut each pigtail at the same location; the resulting "lump" of splice connectors would interfere with rewrapping the harness. Instead, cut the first pigtail close enough to the terminal so you will have room to make each remaining cut about 20 mm (3/4 inch) farther down on the next pigtail. 7. If you are using a yellow splice connector, strip about 6 mm (1/4 inch) of insulation off the ends of both wires. If you are using a pink or blue splice connector, strip off about 8 mm (5/16 inch) of insulation. Page 7806 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. Obtain the customer's key code from the iN (Key Code Inquiry). Refer to the Honda High Security key Codes book that comes with the Matrix H key cutting machine. Write down the applicable cutting code for the key code number. Make sure the corrections to the code book listed in Service Bulletin 01-077, Cutting Sidewinder-Type keys With the Matrix H key Cutting Machine, have been made. 2. Use the chart shown to write down the numbers found in the key code book. 3. Remove the door panel. Refer to the appropriate service manual or use ISIS keyword Door Panel. 4. Remove the plastic cover as necessary. 5. Raise the window glass fully. 6. Remove the lock cylinder. ^ For Civic, go to step 7. ^ For CR-V, go to step 8. ^ For Element, go to step 11. 7. Pull down on the retainer clip with a hook-shaped tool. Remove the lock cylinder and disconnect the cylinder rod. Then go to step 14. Page 8616 21. Leave the key in the cylinder. Reinstall the plastic retainer and spring if you removed them in step 16. Hold the plastic retainer and spring on the housing, and insert the inner cylinder. Rotate it left and right to engage the spring to the inner cylinder. Make sure the spring is properly seated to the inner cylinder. 22. Install the arm with a new cylinder rod clip and a new E-clip. 23. Make sure the key can be inserted and removed easily, and that the cylinder turns with the key. Page 5748 2. Insert the terminal tool into the female terminal, and then remove the terminal tool. NOTE: Make sure you do not select a terminal tool that is larger than the mating male terminal because it would spread the female terminal and cause a loose fit. 3. Compare the drag to the other terminals in the connector. If the drag is less, replace the terminal with a replacement terminal from the appropriate terminal repair kit. Page 7637 13. Push the top of the retainer clip with a flat-tip screwdriver, and hold it. Release the retainer clip with a hook-shaped tool, then remove the lock cylinder. Go to step 14. 14. With the door lock cylinder out of the door handle remove the E-clip and the arm. 15. Try to insert the key into the cylinder and turn it. ^ If you can insert and turn the key, go to step 18. ^ If you cannot insert the key or turn it, go to step 16. 16. Carefully remove the spring and plastic retainer. Page 9252 72. Behind Hazard Warning Switch Page 1854 9. After installing a new set of rings, measure the ring-to-groove clearances: Top Ring Clearance Standard (New): 0.035 - 0.060 mm (0.0014 - 0.0024 inch) Service Limit: 0.13 mm (0.005 inch) Second Ring Clearance Standard (New): 0.030 - 0.055 mm (0.0012 - 0.0022 inch) Service Limit: 0.13 mm (0.005 inch) Page 7432 Keyless/Power Door Lock System Component Location Index Page 3293 14. Disconnect the 22P connector "A" from the gauge assembly. 15. Touch a probe to the BLU/WHT wire, and connect it to body ground through a voltmeter. 16. Slowly rotate one wheel with the other wheel blocked. Does voltage pulse from 0 to about 5 V or more? YES - Replace the speedometer assembly. NO - Repair open in the BLU/WHT wire between the VSS and the speedometer. Page 9644 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. Circuits must be operating when checking voltage drop. 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. 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 off, 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 Self-Powered Test Light or DVOM 1. Remove the blown fuse and disconnect the battery and load. Page 5931 13. Plug in the heat gun, and turn it on. Start at the middle of the splice connector, and move the gun toward the ends as the tube shrinks. Apply heat evenly by rotating the curved heat spreader around the splice connector. Shrinking is complete when a small amount of sealant appears at each end of the tube. Pigtail Terminal Selection Chart PIGTAIL TERMINAL SELECTION CHART Select the proper size pigtail terminal by matching the replacement terminal part number and the wire size being repaired to the corresponding pigtail terminal part number. Then use the color (size) splice connector listed. In some instances you may also have to match the wire seal style to select the proper pigtail terminal. Pigtail terminals are available through your parts department, in quantities of 10, using normal parts ordering procedures. Checking For Poor Fir of Terminals CHECKING FOR POOR FIT OF TERMINALS Loose terminal fit can cause a number of intermittent problems in electrical circuits. By using the Terminal Inspection Feeler Tool Set you can inspect the terminal fit between the two matching connectors without removing the terminals from the connector body. 1. Find the terminal tool that best matches the male terminal in the mating connector. Page 8120 This system uses ROM chips that match the transmitter to the security system control unit. When replacing a lost or stolen transmitter, you need to use the three ROM chips (provided with the new transmitter) to match the old transmitter with the new transmitter and the control unit. 1. Remove the rear cover from the old transmitter and the new one. 2. Remove the ROM chip from the old transmitter by sliding its socket holder toward the ROM chip. 3. Insert a new ROM chip into the socket holder, then slide the socket holder toward the socket to lock the chip in place. 4. Repeat step 3 to install a ROM chip into the new transmitter. 5. Reinstall the rear covers on the transmitters. 6. Remove the security system control unit from under the driver's seat. 7. Open the access cover on the control unit, and replace the ROM chip. (Use the same procedure as in steps 2 and 3.) 8. Press the reset button next to the ROM chip. 9. Close the access cover, and reinstall the control unit. If you are replacing a damaged transmitter, don't replace the ROM chips in the transmitters and the control unit; just remove the chip from the old transmitter and install it in the new one. Ordering a Transmitter Transmitters can be ordered only by authorized Honda dealers. Order them from American Honda using normal parts ordering procedures. If your customer wants to add a third transmitter to the system, you need to order a four ROM chip set directly from Alpine Electronics of America. The Alpine part number for the four ROM chip set is 5319. This ROM chip set does not come with a transmitter. Order the additional transmitter from American Honda. If you have questions about how to order a four ROM chip set, call Alpine's parts department at (800) 421-2284, extension 8885. Batteries for the Transmitter Page 7565 8. Pull out the outer handle (A) in the numbered sequence, then remove it 9. Install the handle in the reverse order of removal, and note these items - Make sure each rod is connected securely - Make sure the door locks and opens properly - When reinstalling the door panel, make sure the plastic cover is installed properly and sealed around its outside perimeter to seal out water Page 3709 1. Remove the secondary lock from the male terminal half. 2. Remove the secondary lock from the female terminal half. 3. Remove the terminal (same procedure for male and female). 4. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE C: 1. Remove the secondary lock. Page 2025 -2 Align the TDC marks (B) on the camshaft pulley with the top edge of the head. 4. Align the holes on the tensioner pulley (A) and tensioner base (B), then insert a 3.0 mm (0.12 inch) diameter pin into the holes. 5. Install the tensioner spring (A) on the auto tensioner (B). 6. Install the auto-tensioner, then tighten the auto tensioner mounting bolt (A) to 9.8 Nm (1.0 kgf-cm, 7.2 ft. lbs.). 7. Loosen the auto-tensioner mounting bolt 180°. Page 715 7. Remove the four screws that hold the two fuses, and remove the fuses. 8. Release the tab that holds the ELD, and pull up on the ELD to remove it. 9. Remove the bus bar from the ELD, and insert the bar into the new ELD. 10. Install the new ELD and bus bar into the fuse/relay box. 11. Reinstall the two fuses. 12. Reinstall the 3P ELD connector and the lower fusel relay box cover. 13. Reinstall the fuse/relay box onto its holder. CR-V only: Reinstall the wire harness clip onto the holder. 14. Reinstall the fuse/relay box cover. 15. Reconnect the negative battery cable. 16. Do the idle learn procedure: ^ Make sure all electrical items (A/C, audio unit, defogger, lights, etc.) are off. Service and Repair Fuel Pressure Release: Service and Repair Fuel Pressure Relieving Before disconnecting fuel lines or hoses, relieve pressure from the system by disconnecting the fuel tube/quick connect fitting in the engine compartment. 1. Make sure you have the antitheft code for the radio, then write down the frequencies for the radio's preset buttons. 2. Turn the ignition switch OFF. 3. Remove the glove box, then remove the PGM-FI main relay 2 (A). 4. Start the engine, and let it idle until it is stalls. NOTE: The DTCs or Temporary DTCs P0301, P0302, P0303, P0304 may come on during this procedure. If any DTCs are stored, ignore them. 5. Turn the ignition switch OFF. 6. Remove the fuel fill cap to relieve fuel pressure in the fuel tank. 7. Disconnect the negative cable from the battery. 8. Remove the bolt (A) and the fuel feed pipe mounting bracket (B), then remove the quick-connect fining covers (C). 9. Check the fuel quick-connect fitting for dirt, and clean if necessary. 10. Place a rag or shop towel over the quick-connect fitting (D). Page 6300 Ball Joint: Service and Repair Ball Joint Boot Replacement Replacement Special Tools Required Driver attachment 07QAD-P0A0100 1. Remove the boot. 2. Pack the interior and lip (A) of a new boot with fresh grease. Do not contaminate the lower collar of the boot (B) with grease. 3. Wipe the grease off the tapered section of the pin (C), and pack fresh grease onto the base (D). 4. Install the boot onto the ball joint pin, then squeeze it gently to force out any air. Do not let dirt or other foreign materials get into the boot. 5. Press the boot with the special tool until the bottom seats on the knuckle (A) evenly around. 6. After installing a boot, wipe any grease off the exposed portion of the ball joint pin. Page 6237 Key Reminder Switch: Testing and Inspection Ignition Key Switch Test NOTE: For more key-in beeper information, refer to the circuit diagram and input test. When the ignition key is in the ignition switch the multiplex control unit senses ground through the closed ignition key switch. When you open the driver's door, the beeper circuit senses ground through the closed door switch and sounds the beeper. 1. Remove the steering column upper and lower covers. 2. Disconnect the 6P connector. 3. Check for continuity between the No.1 and No.2 terminals. - There should be continuity with the key in the ignition switch. - There should be no continuity with the key removed. 4. If the continuity is not as specified, replace the ignition switch. Page 1762 1. Remove the secondary lock from the male terminal half. 2. Remove the secondary lock from the female terminal half. 3. Remove the terminal (same procedure for male and female). 4. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE C: 1. Remove the secondary lock. Page 6923 233. SRS Unit Page 9193 - 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. Troubleshooting Tests 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 test 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 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. 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 Drop Page 610 Fuel Gauge Sender: Service and Repair Fuel Pump/Fuel Gauge Sending Unit Replacement Special Tools Required Fuel sender wrench 07XAA-001010A 1. Relieve the fuel pressure. 2. Remove the fuel fill cap. 3. Remove the seat cushion. 4. Remove the access panel (A) from the floor. 5. Disconnect the fuel pump 5P connector (B). 6. Disconnect the quick-connect fitting (C) from the fuel tank unit. 7. Using the special tool, loosen the fuel tank unit locknut (A). Page 3600 *T-5 Sidewinder Key Applications ^ 2003-05 Civic ^ 2004-05 Civic Hybrid ^ 2003-05 Civic GX (CNG) ^ 2004-05 S2000 ^ 2002-06 CR-V ^ 2003-06 Element ^ 2003-04 Odyssey ^ 2003-04 Pilot Ordering Honda key blanks through normal parts ordering channels: Refer to the parts catalog for correct key(s) for your application. PROGRAMMING KEYS Depending on the type of key blank you use, do this: ^ If you have used a T-5 programmable key blank ("T-5" stamped on the shank), you must code the key's transponder with the Ilco Immobilizer Key Code Duplicator (see S/B 99-053, Ilco Immobilizer key Code Duplicator). ^ If you have used a Honda key blank, add the* transponder code of the new key to the immobilizer system with the Honda Diagnostic System (HDS). ORDERING INFORMATION *To order the MATRIX H Key Cutting Machine, replacement cutter bits, fixed jaws and mobile jaws, T-5 programmable key blanks, and practice key blanks, contact the Honda Tool and Equipment Program by calling 888-424-6857 or using the fax order form provided in your Honda Tool and Equipment Program Catalog.* Order Honda key blanks through normal parts ordering channels. WARRANTY CLAIM INFORMATION None. This service bulletin is for information only. *DETERMINING WHICH KEY TO USE T-5 keys require less time to program and should be the first choice. They can be used as long as the following requirements are met: ^ Do you have the customer's operating key? ^ Does the vehicle fall within the T-5 Sidewinder Key Applications? ^ Does your dealership have an Ilco Immobilizer Key Code Duplicator? If the answer to all three questions on the above is yes, the 1-5 key option is the easier procedure. If you answered no to any of the questions, you should order the key(s) from the parts catalogue, and program it using the HDS.* BEFORE YOU START CUTTING 1. Get the original key or the key number from your customer or from the iN. 2. Get the applicable key blank. 3. If cutting by code, look up the applicable 9-digit cutting code for the key number. Refer to the code book Honda High Security key Codes that comes with the machine. Page 6205 12. Check for continuity between PSP switch 2P connector terminal No.2 and body ground. Is there continuity? YES - Repair open in the wire between the PSP switch and ECM/PCM (E16). NO - Repair open in the wire between the PSP switch and G201. 13. Turn the ignition switch OFF. 14. Disconnect the PSP switch 2P connector. 15. Turn the ignition switch ON (II). 16. Measure voltage between ECM/PCM connector terminals A24 and E16. Is there battery voltage? YES - Replace the PSP switch. NO - Go to step 17. 17. Turn the ignition switch OFF. 18. Disconnect ECM/PCM connector E (31P). 19. Check for continuity between body ground and ECM/PCM connector terminal E16. Is there continuity? YES - Repair short in the wire between ECM/PCM (E16) and the PSP switch. NO - Update the ECM/PCM if it does not have the latest software, or substitute a known-good ECM/PCM, then recheck. If the Page 8758 - Before connecting connectors, make sure the terminals (A) are in place and not bent. - Check for loose retainer (A) and rubber seals (B). - The backs of some connectors are packed with dielectric grease. Add grease if necessary. If the grease is contaminated, replace it. - Insert the connector all the way and make sure it is securely locked. - Position wires so that the open end of the cover faces down. Handling Wires and Harnesses - Secure wires and wire harnesses to the frame with their respective wire ties at the designated locations. Page 8272 13. After completing the right edge, push all of the cam blades to the right until they touch the cams, then trace the cam blades from back to front. (The cutter bit cuts the same contours into the left edge of the key from tip to head.) Turn off the cutter motor. 14. Release the vertical carriage lever. Push all the cam blades to the left until they touch the cams. Pull the vertical carriage lever towards you until the tracer touches the flat surface on the right side, at the front of the cams. Gently twist the lever clockwise to lock the vertical carriage at this height. Do not overtighten the lever. 15. Turn on the cutter motor, then retrace the cam blades from front to back. Push all the cam blades to the right until they touch the cams, and then retrace the cam blades from back to front (retracing cleans up the cuts on the key). Turn off the cutter motor. 16. Release the vertical carriage lever. Open the jaw and remove the key. Make sure the jaw is free of any metal shavings or debris. Turn the key over so the blank side is up, then slide it into the jaw up to the key stop. Close the jaw to lock the key in place. 17. Push all the cam blades to the left until they touch the cams. Repeat steps 10 through 15 to cut both edges on the other side of the key. 18. When you are done making the required cuts, release the vertical carriage lever. Open the jaw and remove the key. 19. Make sure the key works in the ignition switch and the locks. If the key does not work, recut the key, and try it again. 20. Depending on the type of key, code the key transponder. Equipment Service and Warranty To service the MATRIX H Key Cutting Machine, refer to section 7 of the MATRIX H Operating Manual. It tells you how to replace parts that commonly wear out such as the drive belt, the work light bulb, and the tension spring on the vertical carriage. It also covers checking and replacing fuses and replacing the printed circuit board for the setting unit keypad. If you have technical questions on the equipment, contact the Ilco Technical Assistance Department. Mail: Kaba Ilco Technical Assistance Department 400 Jeffreys Road Rocky Mount, NC 27804 Phone: 800-452-6872 Ext: 200, 384, 323, 398, 356 Fax: 252-446-4702 The MATRIX H Key Cutting Machine comes with a 3-year limited warranty. This warranty does not cover the cutter bit or the work light bulb. CODE BOOK CORRECTIONS In the code book Honda High Security key Codes, correct these errors: Pages 4 thru 51, code headings: ^ Incorrect: J H G F Z X E D C B M/S X ^ Correct: J H G F A X E D C B M/S X Page 2, last paragraph: Page 379 PARTS INFORMATION TOOL INFORMATION Page 4370 Resistor Variable Sensor Solenoid Transistors Circuit Schematics Capacity Specifications Fluid - CVT: Capacity Specifications ATF Change ................................................................................................................................................ .............................................................. 2.7L (2.9 Qt) Overhaul .......................................................... .................................................................................................................................................. 6.0L (6.3 Qt) CVT fluid Change ................................................................................................................................ .............................................................................. 3.1L (3.3 Qt) Overhaul .......................................... .............................................................................................................................................................. .... 5.6L (6.0 Qt) Ignition/Locks - Cutting Sidewinder-Type Keys Technical Service Bulletin # 01-077 Date: 060419 Ignition/Locks - Cutting Sidewinder-Type Keys 01-077 April 19, 2006 Applies To: Models With Sidewinder-Type Keys - All Cutting Sidewinder-Type Keys With the MATRIX H Key Cutting Machine (Supersedes 01-077, dated January 12, 2005) Updated information is noted by asterisks. MATRIX H Key Cutting Machine, manufactured by Silca and supplied by Kaba Ilco Corporation, is a portable, power-operated tool that cuts sidewinder-type automotive keys exclusively. The machine lets you cut these keys either by copying or by code. The code function is designed and built to meet the Honda code requirements. No other similar machine has this capability. This service bulletin gives you information for ordering and servicing this special tool, and guides you through the entire key cutting process from setting up the machine to cutting the key blank. TOOL INFORMATION Order through the Honda Tool and Equipment Program: MATRIX H Key Cutting Machine: Model No. ILCMATRIXSH Cutter Bit: Model No. ILCF3O Fixed Jaw: Model No. ILCMTX-H Mobile Jaw (Right Side): Model No. ILCRTMTX-H Mobile Jaw (Left Side): Model No. ILCLTMTX-H *Remanufactured Clamp Unit: Model No. ILCMATRIXHCR* PARTS INFORMATION *For some models, there are two choices for sidewinder-type key blanks: ^ T-5 sidewinder key blanks ^ Honda sidewinder key blanks For other models, only Honda sidewinder key blanks can be used. See DETERMINING WHICH KEY TO USE to determine which key blank you should choose. Ordering T-5 key blanks through the Honda Tool and Equipment Program: T-5 Programmable Key Blank (Master): P/N ILC-35111-T-5H T-5 Programmable Key Blank (Valet): P/N ILC-35112-T-5H Practice Key Blanks (five per pack): ILC-35111DEMO* NOTE: Do not use practice key blanks for replacement purposes. Practice keys do not have an immobilizer chip. Page 6176 Power Steering Fluid: Service and Repair Replacement Check the reservoir (A) at regular intervals, and add the recommended fluid as necessary. Always use Honda Power Steering Fluid. Using any other type of power steering fluid or automatic transmission fluid can cause increased wear and poor steering in cold weather. 1. Raise the reservoir, then disconnect the return hose (A) to drain the reservoir. Take care not to spill the fluid on the body and parts. Wipe off any spilled fluid at once. 2. Connect a hose (B) of suitable diameter to the disconnected return hose, and put the hose end in a suitable container. 3. Start the engine, let it run at idle, and turn the steering wheel from lock-to-lock several times. When fluid stops running out of the hose, shut off the engine. Discard the fluid. 4. Reinstall the return hose on the reservoir. 5. Fill the reservoir to the upper level line (C). 6. Start the engine and run it at fast idle, then turn the steering from lock-to-lock several times to bleed air from the system. 7. Recheck the fluid level and add more if necessary. Do not fill the reservoir beyond the upper level line. Page 2458 Intake Air Temperature Sensor: Service and Repair IAT Sensor Replacement 1. Disconnect the IAT sensor 2P connector. 2. Remove the IAT sensor (A). 3. Install the sensor in the reverse order of removal Page 8763 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. Circuits must be operating when checking voltage drop. 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. 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 off, 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 Self-Powered Test Light or DVOM 1. Remove the blown fuse and disconnect the battery and load. Page 1910 7. Lightly tap the end of each valve stem two or three times with a plastic mallet (A) to ensure proper seating of the valve and valve keepers. Tap the valve stem only along its axis so you do not bend the stem. Page 3495 PGM-F1 Main Relay 1, 2 Type 1, 2 Check for continuity between the terminals. - There should be continuity between the No.1 and No.2 terminals when power and ground are connected to the No.3 and No.4 terminals. - There should be no continuity between the No.1 and No.2 terminals when power is disconnected. Normally-open type B: Rear Window Defogger Relay Page 9124 Connectors - "C" Page 743 Intake Air Temperature Sensor: Description and Operation Intake Air Temperature (IAT) Sensor The IAT sensor is a temperature dependent resistor (thermistor). The resistance of the thermistor decreases as the intake air temperature increases. Page 9039 Shift Indicator: Service and Repair Indicator Bulb Replacement SRS components are located in this area. Review the SRS component locations, precautions, and procedures in SRS before performing repairs or service. 1. Remove the gauge assembly. 2. Replace the bulb (A) in the gauge assembly (B). Page 5027 Shift Interlock Switch: Service and Repair Park Pin Switch Replacement 1. Remove the center console panel and center console. 2. Remove the screws (A), then remove the shift lever knob (B). 3. Remove the A/T gear position indicator panel light (c) from the A/T gear position indicator panel. 4. Remove the A/T gear position indicator panel and panel bracket as an assembly (D). 5. Disconnect the park pin switch connector (4P) (E), and remove it from the shift lever bracket base (F). 6. Remove the shift lock release (G) and spring (H). 7. Open the lock tabs (A) on the shift lever bracket base, then remove the park pin switch (B). 8. Install the new park pin switch. 9. Install the removed parts in the reverse order of removal. Page 8772 1. Remove the terminal. 2. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE E: 1. Remove the terminal. 2. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE F: Campaign - OPDS Unit Warranty Extension Technical Service Bulletin # 06-009 Date: 080205 Campaign - OPDS Unit Warranty Extension 06-009 February 5, 2008 Applies To: See VEHICLES AFFECTED Warranty Extension: OPDS Unit or OPDS Sensor Triggers SRS DTC(s) 15-1, 15-2, 15-3 (Supersedes 06-009, dated September 21, 2007) Updated information is shown with asterisks. BACKGROUND *NOTE: Because of a class action settlement, the warranty extension coverage for the OPDS unit and the OPDS sensor on 2002 Accords, 2002-04 Civics, 2003-04 Civic Hybrids, 2002-04 CR-Vs, 2003 Elements, 2002 Odysseys, and 2003-04 Pilots purchased or leased between April 13, 2002, and November 7, 2006, is now 10 years or 157,500 miles, whichever occurs first. For more information, refer to Service Bulletin 06-085, Warranty Extension: Vehicle Warranty Mileage.* Several vehicle models may have a problem with the OPDS (occupant position detection system) that causes the SRS indicator to stay on. Typically, one or more of these DTCs will be set: ^ SRS DTC 15-1 (faulty OPDS unit or OPDS not initialized) ^ SRS DTC 15-2 (faulty side airbag indicator circuit) ^ SRS DTC 15-3 (faulty OPDS sensor) To ensure continued reliability with the OPDS, American Honda is extending the warranty on the OPDS unit and the OPDS sensor to 10 years or 150,000 miles, whichever occurs first. This warranty extension does not apply to any vehicle that has ever been declared a total loss, or any that has been issued a salvage, branded, or similar title under any state's law. To check for vehicle eligibility, you must do a VIN status inquiry Page 3025 104. CKP Sensor Page 4694 Transmission Position Switch/Sensor: Service and Repair Transmission Range Switch Replacement 1. Remove the intake air duct and resonator. 2. Shift to the N position. 3. Remove the transmission range switch shaft cap (A). 4. Disconnect the transmission range switch connector (A). 5. Remove the transmission range switch (B). 6. Make sure that the control lever is in the N position. Page 8036 8. Release the clip, detach the hook, and remove the lock rod protector. 9. Disconnect the outer handle rod and cylinder rod. Page 1962 Oil Pressure Sender: Testing and Inspection Oil Pressure Switch Test 1. Remove the YEL/RED wire (A) from the engine oil pressure switch (B). 2. Check for continuity between the positive terminal (C) and the engine (ground). There should be continuity with the engine stopped. There should be no continuity with the engine running. 3. If the switch fails to operate, check the engine oil level. If the engine oil level is OK, check the engine oil pressure. If the oil pressure is OK, replace the oil pressure switch. Page 8285 PARTS INFORMATION REQUIRED MATERIALS WARRANTY CLAIM INFORMATION In warranty: The normal warranty applies. Failed Part: P/N 72185-S9A-003 H/C 6896716 Defect Code: 00503 Symptom Code: 07902 Skill Level: Repair Technician Specifications Engine Oil Pressure: Specifications Oil pressure with oil temperature at 176°F (80°C) At idle ................................................................................................................................................... .............. 70 kPa (0.07 kgf/cm2, 10 psi) minimum At 3,000 rpm ....................................................................................................................................................... 340 kPa (3.5 kgf/cm2, 50 psi) minimum Page 2902 PGM-FI System - Component Location Index Page 4813 Fluid - M/T: Fluid Type Specifications M/T Fluid Type ........................................................................................................................................ Honda Manual Transmission Fluid (MTF): P/N 08798-9016 If not available you may use 10W-30 or 10W-40 motor oil as a temporary replacement. An API Certification seal that says "For Gasoline Engines" should be used as a temporary replacement. Replace with Honda MTF as soon as it is convenient. Using motor oil can cause stiffer shifting because it does not contain the proper additives. Locations Transmission Position Switch/Sensor: Locations Component Location Index, A/T Page 3848 10. Connect the connector securely, then install the transmission range switch cover. 11. Turn the ignition switch ON (II). Move the shift lever through all gear positions, and cheek the transmission range switch synchronization with the A/T gear position indicator. 12. Allow the wheels to rotate freely, then start the engine. 13. Move the shift lever through all gear positions, and verify the following: ^ The engine will not start in any position other than N or P. ^ The back-up lights come on when the shift lever is in the R position. Page 1685 2. Remove the terminal (same procedure for male and female). 3. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE E: 1. Remove the secondary locks. 2. Remove the terminal (same procedure for male and female). 3. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE F: Page 6104 DIAGNOSTIC WORKSHEET REPAIR PROCEDURE A Page 6121 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 5543 32. Clutch Interlock Switch (M/T) Specifications Page 9208 8. Put the splice connector in the proper size slot in the Crimper Tool, slide it to one end (where the flare begins), and close the crimper handles far enough to hold it in place. To release the ratchet mechanism at any point after the first click, squeeze the handles slightly and push the release lever, then let the handles open. 9. Insert one of the bare wires into the splice connector end that is in the crimper jaws. Push the wire all the way into the splice connector, and squeeze the crimper handles. Keep squeezing until the jaws touch, and hold it at that position until the ratchet clicks again. 10. Crimp the other wire in the same way into the other end of the splice connector. 11. After crimping, gently pull on the wires in the opposite directions to make sure they are secure in the connector. 12. Separate the other wires in the harness from the repaired wire(s), and shield them with nonflammable material. Application and ID Grounding Point: Application and ID Ground To Components Index (4-door) Locations 25. Transmission Housing (CVT) Page 2362 Blower Motor Relay Type 1, Type 2 Check for continuity between the terminals. - There should be continuity between the No.1 and No.3 terminals when power and ground are connected to the No.2 and No.4 terminals. - There should be no continuity between the No.1 and No.3 terminals when power is disconnected. Five-terminal type Check for continuity between the terminals. - There should be continuity between the No.1 and No.2 terminals when power and ground are connected to the No.3 and No.5 terminals. - There should be continuity between the No.1 and No.4 terminals when power is disconnected. Page 8599 12. Pull the vertical carriage lever toward you while you position the tracer on the right edge of the original key at its head, using the clamp carriage lever. Let the cutter bit cut into the key blank, then stop. Gently twist the lever clockwise to lock the vertical carriage at this height. Do not overtighten the lever. 13. Use the clamp carriage lever and the tracer to follow the contours of the original key. (The cutter bit cuts the same contours into the key blank.) Working from right to left, follow the right edge of the original key from head to tip, then the left edge of the key from tip to head. Turn off the cutter motor. 14. Reposition the tracer on the right edge of the original key at its head, using the clamp carriage lever. Turn on the cutter motor. Retrace the key from head to tip, then from tip to head. (This retracing cleans up the cuts on the key.) Turn off the cutter motor. 15. Release the vertical carriage lever. Open the jaw and remove only the new key. Make sure the jaw is free of any metal shavings or debris, then turn the new key over and slide the key with its blank side up into the jaw up to the key stop. Close the jaw to lock the key into place. 16. Turn on the cutter motor, and repeat steps 12 thru 14 to cut both edges of the other side of the key. 17. When you are finished making the required cuts, turn off the cutter motor, and release the vertical carriage lever. Open the jaws, and remove the keys. 18. Use a wire brush to smooth the cut surfaces on the new key. 19. Make sure the key works in the ignition switch and all the locks. If the key does not work, recut the key, and try it again. 20. Depending on the type of key blank you have used, do this: ^ If you have used a Honda key blank, add the transponder code of the new key to the immobilizer system with the Honda Diagnostic System (HDS). ^ If you have used a T-5 programmable key blank ("T-5" stamped on the shank), code the key's transponder with the Ilco Immobilizer Key Code Duplicator (see S/B 99-053, Ilco Immobilizer key Code Duplicator). Cutting Procedure - By Code 1. Press the ON/OFF button in the middle of the setting unit keypad. (This powers up the keypad.) 2. Turn the clamp unit lock lever to the left to release the clamp unit, and slide it to the right until the bottom left side is flush with the base edge. Turn the lever to the right to lock the clamp unit in place. Loosen the lateral and spring tension adjustment knobs on the clamp carriage. Locations Sunroof / Moonroof Relay: Locations Relay And Control Unit Locations - Door, Roof And Seat Page 6166 12. Loosen the damper pinch bolts (A) while holding the nuts (B), and remove the bolts and nuts. 13. Remove the driveshaft outboard joint (C) from the knuckle (D) by tapping the driveshaft end (E) with a plastic hammer while pulling the knuckle outward, then remove the knuckle. NOTE: Do not pull the driveshaft end outward. The driveshaft joint may come off. 14. Separate the hub (A) from the knuckle (B) using the special tool and a hydraulic press. Be careful not to deform the splash guard. Hold onto the hub to keep it from falling when pressed clear. 15. Press the wheel bearing inner race (A) out of the hub (B) using the special tool, a commercially available bearing separator (C), and a press. Page 5275 Transmission Speed Sensor: Locations 22. Transmission Housing (A/T Except CVT) 19. Transmission Housing (A/T Except CVT) Locations Page 2761 Engine Control Module: Locations Multiplex Control System Component Location Index Page 1427 Fluid - CVT: Fluid Type Specifications A/T Fluid Type ..................................................................................................................................................... .......................................................... Honda ATF-Z1 Honda Service News Notice: If you're replacing transmission fluid in a CVT-equipped vehicle, or just topping it off, make sure you're using the new CVT fluid (P/N 08200-9006). From here on, DON'T put ATF-Z1 in a CVT. If you're topping off a CVT that's already got ATF-Z1, there's no need for concern; this fluid is compatible with ATF-Z1. All CVT-equipped Hondas starting with the 2006 models and onward will be factory-filled with the new CVT fluid. Page 5936 Auxiliary Power Outlet: Service and Repair Test/Replacement 1. Carefully pry the accessory power socket (A) out from the center lower cover. 2. Disconnect the 2P connector (B) from the socket. 3. Inspect the connector terminals to be sure they are all making good contact. - If the terminals are bent, loose or corroded, repair them as necessary, and recheck the system. - If the terminals look OK, go to step 4. 4. Turn the ignition switch ACC (I), and check for voltage between the No.1 and No.2 terminals. - There should be battery voltage. - If there is no battery voltage, check for: poor ground (G502). - an open in the wire. - blown No.18 (15 A) fuse in the under-dash fuse/relay box. Page 7573 3. Remove the grip cover (A) 1. Using a trim tool, pry out the front edge of the cover to release the clip (B). 2. Pry out along the bottom to release the lower hooks (C). 3. Pry out along the top to release the upper hooks (D), and release the clip (E) while pulling the cover forward. 4. Remove the screws from the grip base (F). 5. Release the clips that hold the door panel (A) with a commercially available trim pad remover (B), then remove the door panel by pulling it upward, and disconnect the power window switch connector (C) (for some models). Remove the door panel with as little bending as possible to avoid creasing or breaking it. Diagrams Page 1602 38. Measure voltage between ECM/PCM connector terminal E7 and body ground. Is there battery voltage? YES - Go to step 42. NO - Go to step 39. 39. Remove PGM-FI main relay 1 (A). 40. Measure voltage between PGM-FI main relay 1 4P connector terminal No.4 and body ground. Is there battery voltage? YES - Go to step 41. NO - Repair open in the wire between the No.6 ECU (ECM/PCM) (15A) fuse and PGM-FI main relay 1. Page 2611 Ignition Switch Lock Cylinder: Technical Service Bulletins Ignition Keys Gets Warm While Driving SOURCE: Honda Service News July 2003 TITLE: Ignition Key Gets Warm While Driving APPLIES TO: 2003 Accords, 2001-03 Civics, 2002-03 CR-Vs SERVICE TIP: Are owners of complaining of the ignition key getting warm while driving? The key interlock solenoid in the ignition switch is the likely culprit. This solenoid is energized anytime the shift lever isn't in Park, so the heat from the solenoid gets transferred to the ignition key. This is a normal characteristic of the vehicle, and can't be fixed by replacing the key interlock solenoid, the ignition lockset, or any other component. Page 1215 Wiper Switch: Diagrams 209. Wiper/Washer Switch Locations Combination Switch: Locations Exterior Lights Component Location Index Page 3634 A/T - Avoiding Fluid Contamination Fluid - CVT: Technical Service Bulletins A/T - Avoiding Fluid Contamination SOURCE: Honda Service News TITLE: Avoiding Comebacks From A/T Contamination APPLIES TO: All models SERVICE TIP: Installing a reman A/T? Here are some important tips to keep in mind to ensure a first-time fix and to avoid any come-backs: - If the vehicle has an ATF cooler, make sure you clean the cooler with the ATF Cooler Cleaner (P/N GHTTTCF6H). See S/B 89-022, ATF Cooler Cleaner, for details. - If the reman A/T kit includes an in-line filter, don't forget to install it. If the vehicle already has an in-line filter from an earlier A/T replacement, then remove the existing filter, and install the new one. - Spray the driveshaft splines with solvent and compressed air before installing them in the reman A/T. If the failed A/T had a speed sensor, make sure it's clean before you install it. Debris from the failed A/T can catch in the driveshaft splines or on the speed sensor and contaminate the reman A/T. - If the reman A/T comes with a heater/cooler, make sure you install the reman A/T with that heater/cooler. Never install the heater/cooler from the failed A/T; you could contaminate the reman A/T. Page 2992 94. Behind Glove Box (except GX) Page 9758 6. Separate the master switch plate (A) from the armrest (B). 7. Remove the three screws and replace the switch. 2-door Page 1687 1. Remove the terminal. 2. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE B: 1. Remove the terminal. 2. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE C: 1. Remove the terminal. 2. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE D: Air Bag Disarming and Arming Air Bag(s) Arming and Disarming: Service and Repair Air Bag Disarming and Arming 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 485 Sunroof / Moonroof Switch: Testing and Inspection Switch Test/Replacement 1. Remove the driver's pocket. 2. Disconnect the 6P connector (A) from the moonroof switch (B), and remove the moonroof switch. 3. Check for continuity between the terminals in each switch position according to the table. 4. If the continuity is not as specified, replace the illumination bulb (C) or the moonroof switch. Page 8429 Sunroof / Moonroof Drain: Service and Repair Drain Channel Slider and Cable Assembly Replacement Drain Channel Slider and Cable Assembly Replacement 1. Remove the frame. 2. Remove these parts from the frame: - Sunshade - Moonroof motor 3. Put on gloves to protect your hands. Remove the cable tube side bracket mounting bolts (A) and the cable tube mounting screws (B), and remove the screws (C, D), then remove the slide stops (E) and cable tube rear brackets (F) from both sides of the frame (G). 4. While pushing down on the hook (A), slide the drain channel sliders (B) back on both sides. 5. Turn both cable tube side brackets (A) up, and remove the drain channel sliders (B). Page 385 Page 6795 67. Under Left Side of Dash Page 2126 7. Insert the feeler gauge (A) between the adjusting screw (B) and the end of the valve stem and slide it back and forth; you should feel a slight amount of drag. 8. If you feel too much or too little drag, loosen the locknut (A), and turn the adjusting screw (B) until the drag on the feeler gauge is correct. 9. Tighten the locknut and recheck the clearance. Repeat the adjustment, if necessary. Page 1072 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. Test Equipment 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. Page 3453 Fuel Line Inspection Part 2 Fuel Line Inspection Check the fuel system lines, hoses, and fuel filter for damage, leaks, and deterioration. Replace any damaged parts. Page 749 119. Knock Sensor (except GX) Page 5460 7. Install the hose onto the hose bracket on the body with a new hose clip (A). 8. Connect the brake line to the brake hose. 9. After installing the brake hose, bleed the brake system. 10. Do the following checks: ^ Check the brake hose and line joint for leaks, and tighten if necessary. ^ Check the brake hoses for interference and twisting. Page 8370 6. Disconnect the M, P, K, and J connectors from the under-dash fuse/relay box, and make these input tests at the connectors. - If any test indicates a problem, find and correct the cause, then recheck the system. - If all the input tests prove OK, the multiplex control unit must be faulty. Replace the under-dash fuse/relay box assembly. Diagrams 39. ECT Sensor Page 6999 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 880 Crankshaft Position Sensor: Description and Operation Crankshaft Position (CKP) Sensor The CKP sensor detects engine speed, and is used by the ECM/PCM to determine ignition timing and timing for fuel injection of each cylinder. Page 3583 39. Left Side Of Engine Compartment Page 3103 Oxygen Sensor: Service and Repair Third HO2S Replacement Third HO2S Replacement Special Tools Required O2 sensor wrench, Snap-on YA8875, SP Tools 93750, or equivalent, commercially available NOTE: The secondary HO2S and the third HO2S must be replaced together. 1. Disconnect the third HO2S 4P connector (A), then remove the third HO2S (B). 2. Install the third HO2S in the reverse order of removal. 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 9401 Use the tools from Pin Tool Set. First, check the connector that you are about to repair. - If it has a secondary terminal lock, go to Connectors With a Secondary Lock. A secondary lock, found on most connectors on some models, is an additional locking device on the connector housing as a backup for the primary lock on the terminal. - If the connector does not have a secondary lock, go to Connectors Without a Secondary Lock. Connectors With a Secondary Lock All examples are shown with the connector lock facing up. The illustrations are examples of the secondary terminal locks; however, the connector you are repairing may vary in size. Identify the connector by the type of secondary lock, not by the number of terminal cavities. EXAMPLE A: 1. Release the secondary lock. 2. Remove the terminal. 3. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE B: Page 4637 72. Shift Lock Solenoid (A/T) Page 2979 Engine Control Module: Testing and Inspection How to Troubleshoot Circuits At the ECM/PCM How to Troubleshoot Circuits at the ECM/PCM Special Tools Required - Digital Multimeter KS-AHM-32-003 (1) or a commercially available digital multimeter - Backprobe Set 07SAZ-001000A (2) 1. Connect the backprobe adapters (A) to the stacking patch cords (B), and connect the cords to a digital multimeter (C). 2. Using the wire insulation as a guide for the contoured tip of the backprobe adapter, gently slide the tip into the connector from the wire side until it touches the end of the wire terminal. 3. If you cannot get to the wire side of the connector or the wire side is sealed (A), disconnect the connector and probe the terminals (B) from the terminal side. Do not force the probe into the connector. NOTE: Do not puncture the insulation on a wire. Punctures can cause poor or intermittent electrical connections. Page 7724 6. Disconnect the trunk lid opener cable (A) from the trunk lid latch (B). 7. Using a clip remover, detach the clip (C) from the body, and detach the clips (D) from the trunk lid hinge 8. Remove the trunk lid opener/fuel fill door opener cable from the vehicle. Take care not to kink the cable. 9. Install the cable in the reverse order of removal, and note these items. - Align the alignment mark of the cable to the clip on the bottom portion of the trunk lid hinge. - Replace any damaged clips. Page 1094 Transmission Position Switch/Sensor: Testing and Inspection Transmission Range Switch Test 1. Remove the transmission range switch harness connector (A) from the connector bracket (B), then disconnect the connector. 2. Check for continuity between terminals at the harness connector. There should be continuity between the terminals listed for each switch position. In the P position, between terminals: ^ No. 1 and No. 3 ^ No. 1 and No. 8 ^ No. 3 and No. 8 In the R position, between terminals: ^ No. 1 and No. 9 In the N position and between terminals: ^ No. 1 and No. 3 ^ No. 1 and No. 10 ^ No. 3 and No. 10 In the D position, between terminals: ^ No. 1 and No. 2 ^ No. 1 and No. 4 ^ No.2 and No.4 In the D3 position, between terminals: ^ No. 1 and No. 2 ^ No. 1 and No. 5 ^ No.2 and No.5 In the 2 position, between terminals: ^ No. 1 and No. 6 Page 2382 Main Relay (Computer/Fuel System): Testing and Inspection Power Relay Test Use this chart to identify the type of relay, then do the test listed for it. NOTE: See the turn signal/hazard relay input test. Normally-open type A: Page 8418 Sunroof / Moonroof Switch: Testing and Inspection Switch Test/Replacement 1. Remove the driver's pocket. 2. Disconnect the 6P connector (A) from the moonroof switch (B), and remove the moonroof switch. 3. Check for continuity between the terminals in each switch position according to the table. 4. If the continuity is not as specified, replace the illumination bulb (C) or the moonroof switch. Page 3822 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. Test Equipment 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. Specifications Water Pump: Specifications Water pump displacement at 6,000 engine rpm ............................................................................................................................................... 130 L (137 US qt, 114 Imp qt)/minute Page 7569 6. Remove the bolt, then remove the collar (A) from the center channel (B). 7. Move the latch (A) through the gap between the center channel (B) and door, then remove it. Take care not to bend any of the rods. 8. If necessary, remove any of the rods from the latch. 9. Install the latch in the reverse order of removal, and note these items: - Make sure the connector is plugged in properly (with power door lock), and each rod is connected securely. - Make sure the door locks and opens properly. - When reinstalling the door panel, make sure the plastic cover is installed properly and sealed around its outside perimeter to seal out water. Key Beeper, Light Chime & Ceiling Light Don't Work Door Switch: Technical Service Bulletins Key Beeper, Light Chime & Ceiling Light Don't Work SOURCE: Honda Service News April 2003 TITLE: Key Beeper, Light Chime, Ceiling Light Don't Work APPLIES TO: 2001-03 Civic, 2002-03 CR-V SERVICE TIP: If the ignition key-in beeper, the headlights-on chime, the ceiling light, and the driver's-dooropen indicator are all on the fritz check the driver's door switch in the doorjamb. A faulty door switch can cause all of these symptoms. Component Locations SRS Component Location Index Page 7642 24. Remove the key. Reinstall the retainer clip in the door handle, and push the lock cylinder into place. 25. Civic: Reconnect the cylinder rod. 26. CR-V: Reconnect the cylinder rod, the outer handle rod, and the rod protector. 27. Element: Reconnect the cylinder rod, the outer handle rod, and the access seal. Reinstall the lower run channel. 28. Reinstall the plastic covering, and lower the window glass. Install the door panel. 29. Check that the door lock and handle operate smoothly. Disclaimer Page 9029 8. Inspect the quality of the wire crimp. If it has any of the following NO GOOD crimps, cut it off and start over. 9. Insert the terminal into the connector. Make sure the wire seals are pushed all the way into the connector. Lightly pull on the wires to make sure the terminal is locked into place. 10. Close or insert the secondary terminal lock, if applicable, and reconnect the connector. How to Install Pigtail Terminals HOW TO INSTALL PIGTAIL TERMINALS Pigtail terminals (short pieces of wire with a factory crimped terminal) are used when the wire is too short or when access to the connector is too restricted to make a terminal repair. NOTE: To replace just a connector terminal, go to How to Replace Connector Terminals. IMPORTANT SAFETY INFORMATION: On some models, the SRS wires are in a separate harness. If the SRS harness is damaged, replace the harness; do not repair it. On other models, wire harnesses include yellow SRS wires. If any SRS wire is damaged, replace the entire harness; do not repair it. 1. Remove the damaged or faulty terminal from the connector. Use the proper removal tool from Pin Tool Set. Page 8917 70. Measure voltage between body ground and ECM/PCM connector terminal E5. Is there about 5 V? YES - Replace the FTP sensor. NO - Go to step 71. 71. Turn the ignition switch OFF. 72. Disconnect ECM/PCM connector E (31P). 73. Check for continuity between ECM/PCM connector terminal E5 and body ground. Is there continuity? YES - Repair short in the wire between the ECM/PCM (E5) and the FTP sensor. NO - Update the ECM/PCM if it does not have the latest software, or substitute a known-good ECM/PCM, then recheck. If the symptom/indication goes away with a known-good ECM/PCM, replace the original ECM/PCM. 74. Turn the ignition switch OFF. 75. Turn the ignition switch ON (II). 76. Measure voltage between ECM/PCM connector terminal E29 and body ground. Is there about 5 V (or battery voltage)? YES - Go to step 80. Page 8486 8. 2-door: Pull back the edge of the seat-back cover (A) all the way around, and remove the clips (B), then remove the seat-back cover. 9. 4-door: Pull back the edge of the seat-back cover (A) all the way around, and release the hooks (B) of the wire (C) from the wire (D) of the pad (E), and on the left seat-back, remove the clips (F), then remove the seat-back cover. Page 6018 Rear Window Defogger Component Location Index Page 6388 Page 5699 18. Install the starter end cover (A) to retain the brush holder (B). Overrunning Clutch Inspection 19. Slide the overrunning clutch along the shaft. Replace it if it does not slide smoothly. M/T, CVT A/T 20. Rotate the overrunning clutch (A) both ways. Does it lock in one direction and rotate smoothly in reverse ? If it does not lock in either direction or it locks in both directions, replace it. 21. If the starter drive gear (B) is worn or damaged, replace the overrunning clutch assembly; the gear is not available separately. Check the condition of the flywheel or torque converter ring gear if the starter drive gear teeth are damaged. 22. Reassemble the starter in reverse order of disassembly. Page 6747 Air Bag: 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: Service and Repair Page 6684 Air Bag(s) Arming and Disarming: Description and Operation SRS Components SRS Components Airbags The SRS is a safety device which, when used 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 (A), the cable reel (B), the driver's airbag (C), the front passenger's airbag (D), seat belt tensioners (I), seat belt buckle tensioners (J), and front impact sensors (K). Since the driver's and front passenger's airbags use the same sensors, both normally inflate at the same time. However, it is possible for only one airbag to inflate. This can occur when the severity of a collision is at the margin, or threshold, that determines whether or not the airbags will deploy. In such cases, the seat belt will provide sufficient protection, and the supplemental protection offered by the airbag would be minimal. Side Airbags The side airbags (E) are in each front seat-back. They help protect the upper torso of the driver or front seat passenger during a moderate to severe side impact. Side impact sensors (F) in each door sill and in the SRS unit detect such an impact and instantly inflate the driver's or the passenger's side airbag. Only one side airbag will deploy during a side impact. If the impact is on the passenger's side, the passenger's side airbag will deploy even if there is no passenger. 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. OPDS The side airbag system also includes an occupant position detection system (OPDS). This system consists of sensors (G) and a OPDS unit (H) in the front passenger's seat-back. The OPDS unit sends occupant height and position data to the SRS unit. If the OPDS unit determines that the front passenger is of small stature (for example, a child) and the front passenger is leaning into the side airbag deployment path, the SRS unit will automatically disable the passenger's side airbag. The SRS unit will also disable the airbag when the OPDS detects certain objects on the seat. When the side airbag is disabled, the side airbag cutoff indicator on the instrument panel alerts the driver that the passenger's side airbag will not deploy in a side impact. When the object is removed, or the passenger sits upright, the Side Airbag Cutoff indicator will go off after a few seconds, alerting the driver that the passenger's side airbag will deploy in a side impact. Page 8761 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 Locater) 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. Troubleshooting Precautions Troubleshooting Precautions Before Troubleshooting 1. Check the main fuse and the fuse 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, or you will damage the alternator diodes. - Do not attempt to crank the engine with the ground cable disconnected 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. Page 5704 Starter Relay: Testing and Inspection Power Relay Test Use this chart to identify the type of relay, then do the test listed for it. NOTE: See the turn signal/hazard relay input test. Normally-open type A: Check for continuity between the terminals. - There should be continuity between the No.1 and No.2 terminals when power and ground are connected to the No.3 and No.4 terminals. - There should be no continuity between the No.1 and No.2 terminals when power is disconnected. Page 8841 Fuel Supply System - Component Location Index Page 6102 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 9734 125. Passenger's Door (Coupe except DX, HX) 126. Front Passenger's Door (Sedan except DX) 127. Left Rear Door (Sedan except DX) (Right Similar) Page 4294 Page 6481 Blower Motor Relay: Testing and Inspection Power Relay Test Use this chart to identify the type of relay, then do the test listed for it. NOTE: See the turn signal/hazard relay input test. Normally-open type B: Blower Motor Relay Type 1, Type 2 Check for continuity between the terminals. - There should be continuity between the No.1 and No.3 terminals when power and ground are connected to the No.2 and No.4 terminals. - There should be no continuity between the No.1 and No.3 terminals when power is disconnected. Suspension - Lower Ball Joint Replacement Ball Joint: Technical Service Bulletins Suspension - Lower Ball Joint Replacement 04-079 December 21, 2004 Applies To: 2001-05 Civic (except 3-Door) - ALL Lower Ball Joint Replacement BACKGROUND Previously, if a lower ball joint was worn, you had to replace the knuckle assembly. To reduce repair costs, replacement lower ball joints are now available. PARTS INFORMATION TOOL INFORMATION WARRANTY CLAIM INFORMATION In warranty: The normal warranty applies. Failed Part: P/N 51210-S5A-J20 H/C 7233885 Defect Code: 00503 Symptom Code: 07302 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. Raise the vehicle on a hoist. Diagram Information and Instructions Transmission Position Switch/Sensor: Diagram Information and Instructions Terminal Numbering System Terminal Numbering System Connector terminals are numbered according to the cavities they're in. The cavities are numbered starting from the upper left, looking at the male terminals from the terminal side or looking at the female terminals from the wire side. Both views are in the same direction so the numbers are the same. All actual cavities are numbered, even if they have no wire terminals in them. NOTE: Data Link Connector (DLC) terminals are numbered according 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 below is #6. Page 3810 Wires Campaign - OPDS Unit Warranty Extension Technical Service Bulletin # 06-009 Date: 080205 Campaign - OPDS Unit Warranty Extension 06-009 February 5, 2008 Applies To: See VEHICLES AFFECTED Warranty Extension: OPDS Unit or OPDS Sensor Triggers SRS DTC(s) 15-1, 15-2, 15-3 (Supersedes 06-009, dated September 21, 2007) Updated information is shown with asterisks. BACKGROUND *NOTE: Because of a class action settlement, the warranty extension coverage for the OPDS unit and the OPDS sensor on 2002 Accords, 2002-04 Civics, 2003-04 Civic Hybrids, 2002-04 CR-Vs, 2003 Elements, 2002 Odysseys, and 2003-04 Pilots purchased or leased between April 13, 2002, and November 7, 2006, is now 10 years or 157,500 miles, whichever occurs first. For more information, refer to Service Bulletin 06-085, Warranty Extension: Vehicle Warranty Mileage.* Several vehicle models may have a problem with the OPDS (occupant position detection system) that causes the SRS indicator to stay on. Typically, one or more of these DTCs will be set: ^ SRS DTC 15-1 (faulty OPDS unit or OPDS not initialized) ^ SRS DTC 15-2 (faulty side airbag indicator circuit) ^ SRS DTC 15-3 (faulty OPDS sensor) To ensure continued reliability with the OPDS, American Honda is extending the warranty on the OPDS unit and the OPDS sensor to 10 years or 150,000 miles, whichever occurs first. This warranty extension does not apply to any vehicle that has ever been declared a total loss, or any that has been issued a salvage, branded, or similar title under any state's law. To check for vehicle eligibility, you must do a VIN status inquiry Page 1871 Rocker Arm Assembly: Testing and Inspection VTEC Rocker Arm Test VTEC Rocker Arm Test Special Tools Required ^ Air pressure regulator 07AAJ-PNAA100 ^ Air stopper 07LAJ-PR3020B 1. Remove the resonator. 2. Remove the ignition coil cover, then remove the four ignition coils. 3. Remove the throttle cable clamps and harness holder from the cylinder head cover. 4. Remove the cylinder head cover. 5. Set the No. 1 piston at Top Dead Center (TDC). 6. Verify that the intake secondary rocker arm (A) moves independently of the intake primary rocker arm (B). ^ If the intake secondary rocker arm does not move, remove the primary and secondary rocker arms as an assembly and check that the pistons in the secondary and primary rocker arms move smoothly. If any rocker arm needs replacing, replace the primary and secondary rocker arms as an assembly, and retest. ^ If the intake secondary rocker arm moves freely, go to step 7. 7. Repeat step 6 on the remaining intake secondary rocker arms with each piston at TDC. When all the secondary rocker arms pass the test, go to step 8. 8. Check that the air pressure on the shop air compressor gauge indicates over 400 kPa (4 kgf/cm2, 57 psi). 9. Inspect the valve clearance. 10. Cover the timing belt with a shop towel to protect the belt. 11. Plug the relief hole with the air stopper. Page 3262 1. Remove the terminal. 2. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE B: 1. Remove the terminal. 2. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE C: 1. Remove the terminal. 2. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE D: Page 4345 Disclaimer Page 7278 Cellular Phone: Diagnostic Aids General Troubleshooting Information General Troubleshooting Information Tips and Precautions Before Troubleshooting 1. Check applicable fuses in the appropriate fuse/relay box. 2. Check the battery for damage, state of charge, and clean and tight connections. NOTE: 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. Handling Connectors - Make sure the connectors are clean and have no loose wire terminals. - Make sure multiple cavity connectors are packed with dielectric grease (except watertight connectors). - All connectors have push-down release type locks (A). - Some connectors have a clip on their side used to attach them to a mount bracket on the body or on another component. This clip has a pull type lock. - Some mounted connectors cannot be disconnected unless you first release the lock and remove the connector from its mount bracket (A). - Never try to disconnect connectors by pulling on their wires; pull on the connector halves instead. - Always reinstall plastic covers. Page 2469 36. Left Side Of Engine Compartment (except GX) Diagnostic Aids Radiator Cooling Fan Motor: Diagnostic Aids General Troubleshooting Information General Troubleshooting Information Tips and Precautions Before Troubleshooting 1. Check applicable fuses in the appropriate fuse/relay box. 2. Check the battery for damage, state of charge, and clean and tight connections. NOTE: 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. Handling Connectors - Make sure the connectors are clean and have no loose wire terminals. - Make sure multiple cavity connectors are packed with dielectric grease (except watertight connectors). - All connectors have push-down release type locks (A). - Some connectors have a clip on their side used to attach them to a mount bracket on the body or on another component. This clip has a pull type lock. - Some mounted connectors cannot be disconnected unless you first release the lock and remove the connector from its mount bracket (A). - Never try to disconnect connectors by pulling on their wires; pull on the connector halves instead. - Always reinstall plastic covers. Page 5266 Transmission Position Switch/Sensor: Testing and Inspection Transmission Range Switch Test 1. Remove the transmission range switch harness connector (A) from the connector bracket (B), then disconnect the connector. 2. Check for continuity between terminals at the harness connector. There should be continuity between the terminals listed for each switch position. In the P position, between terminals: ^ No. 1 and No. 3 ^ No. 1 and No. 8 ^ No. 3 and No. 8 In the R position, between terminals: ^ No. 1 and No. 9 In the N position and between terminals: ^ No. 1 and No. 3 ^ No. 1 and No. 10 ^ No. 3 and No. 10 In the D position, between terminals: ^ No. 1 and No. 2 ^ No. 1 and No. 4 ^ No.2 and No.4 In the D3 position, between terminals: ^ No. 1 and No. 2 ^ No. 1 and No. 5 ^ No.2 and No.5 In the 2 position, between terminals: ^ No. 1 and No. 6 Page 9315 1. Remove the terminal. 2. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE E: 1. Remove the terminal. 2. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE F: Page 4704 Transmission Speed Sensor: Service and Repair Speed Sensors Replacement 1. Disconnect connectors from the drive pulley speed sensor (A), driven pulley speed sensor (B), CVT speed sensor (C), and CVT speed sensor 2 (D). 2. Remove the 6 mm bolts, then remove the speed sensors. Remove the sensor washer (E) from the vehicle speed sensor (C). 3. Replace the O-rings (F) with new ones before installing the speed sensors. 4. Install the sensor washer on the CVT speed sensor 2, and install them. 5. Install the drive pulley speed sensor, driven pulley speed sensor, and CVT speed sensor. 6. Check the speed sensor connectors for rust, dirt, or oil, then connect the connectors securely. Page 3213 Use the tools from Pin Tool Set. First, check the connector that you are about to repair. - If it has a secondary terminal lock, go to Connectors With a Secondary Lock. A secondary lock, found on most connectors on some models, is an additional locking device on the connector housing as a backup for the primary lock on the terminal. - If the connector does not have a secondary lock, go to Connectors Without a Secondary Lock. Connectors With a Secondary Lock All examples are shown with the connector lock facing up. The illustrations are examples of the secondary terminal locks; however, the connector you are repairing may vary in size. Identify the connector by the type of secondary lock, not by the number of terminal cavities. EXAMPLE A: 1. Release the secondary lock. 2. Remove the terminal. 3. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE B: Page 214 Relay And Control Unit Locations - Dashboard Page 4905 Control Module: Service and Repair How to Substitute the PCM How to Substitute the PCM 1. Remove the PCM from the vehicle. 2. Install a known-good PCM in the vehicle. 3. Rewrite the immobilizer code with the PCM replacement procedure in the Honda PGM Tester; It allows you to start the engine. 4. After completing your tests, reinstall the original PCM and rewrite the immobilizer code with the PCM replacement procedure in the HDS Tester again. Page 6221 Air Bag(s) Arming and Disarming: Description and Operation SRS Operation SRS Operation The main circuit in the SRS unit senses and judges the force of impact and, if necessary, ignites the inflator charges. 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: Seat Belt Tensioners and Seat Belt Buckle Tensioners 1. A front impact sensor must activate and send electric signals to the microprocessor. 2. The microprocessor must compute the signals and send them to the tensioners. 3. The charges must ignite and deploy the tensioners. Driver's and Front Passenger's Airbag(s) 1. A front impact sensor must activate, and send electric signals to the microprocessor. 2. The microprocessor must compute the signals, and depending on the severity of the collision and whether the seat belt buckle switch is ON or OFF, it sends the appropriate signals to the airbag inflator(s). 3. The inflators that received signals must ignite and deploy the airbags. Side Airbag(s) 1. Aside impact sensor must activate, and send electric signals to the microprocessor. 2. The microprocessor must compute the signals and send them to the side airbag inflator(s). However, the microprocessor cuts off the signals to the front passenger's side airbag if the OPDS unit determines that the front passenger's head is in the deployment path of the side airbag. 3. The inflator that received the signal must ignite and deploy the side airbag. Self-diagnosis System A self-diagnosis circuit is built into the SRS unit; when the ignition switch is turned ON (II), the SRS indicator comes on and goes off after about 6 seconds if the SRS is operating normally. If the indicator does not come on, or does not go off after 6 seconds, or if it comes on while driving, it indicates an abnormality in the SRS. The SRS must be inspected and repaired as soon as possible. For better serviceability, the SRS unit memory stores a DTC that relates to the cause of the malfunction, and the unit is connected to the data link circuit. This information can be read with the Honda PGM Tester when it is connected to the data link connector (DLC). Connector Views Engine Control Module: Connector Views 228. ECM/PCM Part 1 228. ECM/PCM Part 2 Page 3249 - Before connecting connectors, make sure the terminals (A) are in place and not bent. - Check for loose retainer (A) and rubber seals (B). - The backs of some connectors are packed with dielectric grease. Add grease if necessary. If the grease is contaminated, replace it. - Insert the connector all the way and make sure it is securely locked. - Position wires so that the open end of the cover faces down. Handling Wires and Harnesses - Secure wires and wire harnesses to the frame with their respective wire ties at the designated locations. Page 2528 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. Circuits must be operating when checking voltage drop. 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. 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 off, 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 Self-Powered Test Light or DVOM 1. Remove the blown fuse and disconnect the battery and load. Page 2155 - 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. Troubleshooting Tests 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 test 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 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. 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 Drop Page 2827 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. Circuits must be operating when checking voltage drop. 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. 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 off, 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 Self-Powered Test Light or DVOM 1. Remove the blown fuse and disconnect the battery and load. Page 9318 8. Inspect the quality of the wire crimp. If it has any of the following NO GOOD crimps, cut it off and start over. 9. Insert the terminal into the connector. Make sure the wire seals are pushed all the way into the connector. Lightly pull on the wires to make sure the terminal is locked into place. 10. Close or insert the secondary terminal lock, if applicable, and reconnect the connector. How to Install Pigtail Terminals HOW TO INSTALL PIGTAIL TERMINALS Pigtail terminals (short pieces of wire with a factory crimped terminal) are used when the wire is too short or when access to the connector is too restricted to make a terminal repair. NOTE: To replace just a connector terminal, go to How to Replace Connector Terminals. IMPORTANT SAFETY INFORMATION: On some models, the SRS wires are in a separate harness. If the SRS harness is damaged, replace the harness; do not repair it. On other models, wire harnesses include yellow SRS wires. If any SRS wire is damaged, replace the entire harness; do not repair it. 1. Remove the damaged or faulty terminal from the connector. Use the proper removal tool from Pin Tool Set. Page 6458 Air Door Actuator / Motor: Service and Repair Mode Control Motor Mode Control Motor Replacement 1. Remove the ECM/PCM. 2. Disconnect the 7P connector (A) from the mode control motor (B). Remove the self-tapping screws and the mode control motor from the heater unit. 3. Install the motor in the reverse order of removal. Make sure the pins on the motor is properly engaged with the linkage. After installation, make sure the motor runs smoothly. Body - Power Windows Inoperative/Intermittent Operation Power Window Switch: Customer Interest Body - Power Windows Inoperative/Intermittent Operation 06-010 March 8, 2006 Applies To: 2001-05 Civic - All LX and EX 4-door 2003-05 Civic Hybrid - ALL 2001-05 Civic GX ALL Power Window Does Not Work or Works Intermittently SYMPTOM One or more of the power windows does not work or works intermittently from the power window master switch (in the driver's door). PROBABLE CAUSE The power window master switch is faulty. CORRECTIVE ACTION Replace the power window master switch. PARTS INFORMATION WARRANTY CLAIM INFORMATION In warranty: The normal warranty applies. Operation Number: 744100 Flat Rate Time: 0.2 hr Failed Part: P/N 35750-S5A-A01ZA H/C 6453419 Defect Code: 03217 Symptom Code: 01201 Template ID: 06-010A (Black Switch) 06-010B (Medium Taupe Switch) 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 1210 Windshield Washer Switch: Service and Repair Wiper/Washer Switch Test/Replacement 1. Remove the dashboard lower cover. 2. Remove the steering column covers. 3. Disconnect the 14P connector (A) from the wiper/washer switch (B) 4. Remove the two screws, then pull out the wiper/washer switch. 5. Inspect the connector terminals to be sure they are all making good contact. - If the terminals are bent, loose or corroded, repair them as necessary, and recheck the system. - If the terminals look OK, check for continuity between the terminals in each switch position according to the tables. If the continuity is not as specified, replace the switch. Page 7015 NOTE: Check the front seat belts for damage, and replace them if necessary. Be careful not to damage them during removal and installation. Seat Belt Buckle 1. Make sure you have the anti-theft code for the radio, then write down the customer's radio station presets. 2. Disconnect the negative cable from the battery, and wait at least 3 minutes before beginning work. 3. Remove the front seat. 4. Detach the seat belt switch connector clip (A),seat belt buckle tensioner connector clip (B), and harness clips (C). 5. On the driver's seat, adjust the seat cushion to its maximum height. 6. Remove the center anchor bolt (A), and remove the seat belt buckle (B). 7. Pull the seat belt switch/tensioner harness (C) out through the space between the seat cushion and the seat linkage (driver's seat), or the hole on the seat track (passenger's seat). Page 3226 2. Insert the terminal tool into the female terminal, and then remove the terminal tool. NOTE: Make sure you do not select a terminal tool that is larger than the mating male terminal because it would spread the female terminal and cause a loose fit. 3. Compare the drag to the other terminals in the connector. If the drag is less, replace the terminal with a replacement terminal from the appropriate terminal repair kit. Page 7327 - 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. Cruise Control Actuator Input Test Cruise Control Servo: Testing and Inspection Cruise Control Actuator Input Test Cruise Control Actuator Input Test 2-door D17A1, D17A2 engines: 1. Disconnect the 12P connector from the actuator. 2. Inspect the connector and socket terminals to be sure they are all making good contact. - If the terminals are bent, loose, or corroded, repair them as necessary, and recheck the system. - If the terminals look OK, go to step 3. Service and Repair Headlamp Bulb: Service and Repair Bulb Replacement Headlight: 1. Disconnect the 3P connector (A) from the headlight. 2. Remove the rubber cover (B). 3. Pull the retaining spring (C) away from the bulb (D), then remove the bulb. 4. Install a new bulb in the reverse order of removal. Make sure the notches in the bulb align with the tabs in the headlight. Page 3788 Page 450 2. Disconnect the 2P connector from the actuator. 3. Check actuator operation by connecting power and ground according to the table. To prevent damage to the actuator, apply battery voltage only momentarily. 4. If the actuator does not operate as specified, replace it. Page 7147 Alarm Module: Diagrams 182. Immobilizer Control Unit - Receiver 214. Security Control Unit (Optional) Page 1926 2. If you installed a new belt, run the engine for 5 minutes, then readjust the belt to the used belt specification. Adjustment 3. Loosen the power steering pump mounting nut (A) and pump locknut (B). 4. Turn the adjusting bolt (C) to get the proper belt tension, then retighten the mounting nut and locknut. 5. Start the engine and turn the steering wheel from lock-to-lock several times, then stop the engine and recheck the tension of the belt. Page 7135 1. Remove the driver's dashboard lower cover. (See the body section of the appropriate service manual.) 2. Replace the security control unit. ^ Civic: Remove the security control unit, and install the new security control unit. ^ * CR-V and Element: Remove the security control unit and microphone. Install the new security control unit and new microphone.* 3. Reprogram the keyless receiver unit. NOTE: The codes of up to three transmitters can be stored in the keyless receiver unit memory. If a fourth code is stored, the code that was input first will be erased. It is important to maintain the time limits between the steps. Make sure the doors and the trunk/tailgate/hatch are closed, and that you have all of the remotes the customer wishes to use. ^ Turn the ignition switch to ON (II). ^ Within 1 to 4 seconds, push the transmitter lock or unlock button. ^ Within 1 to 4 seconds, turn the ignition switch to LOCK (0). ^ Within 1 to 4 seconds, turn the ignition to ON (II). ^ Within 1 to 4 seconds, push the transmitter lock or unlock button. ^ Within 1 to 4 seconds, turn the ignition switch to LOCK (0). ^ Within 1 to 4 seconds, turn the ignition switch to ON (II). ^ Within 1 to 4 seconds, push the transmitter lock or unlock button. Locations 6. Transmission Housing (M/T) Locations Transmission Position Switch/Sensor: Locations Component Location Index, A/T Testing and Inspection Radiator Cap: Testing and Inspection Test 1. Remove the radiator cap (A), wet its seal with engine coolant, then install it on a commercially available pressure tester (B). 2. Apply a pressure of 93 - 123 kPa (0.95 - 1.25 kgf/cm2, 14 - 18 psi). 3. Check for a drop in pressure. 4. If the pressure drops, replace the cap. Locations Starter Relay: Locations Starting System Component Location Index Page 9796 1. Remove the driver's side grip cover: ^ Using a trim tool, pry out the front edge of the cover to release the front clip. ^ Pry out along the bottom to release the lower hooks. ^ Pry out along the top to release the upper hooks. ^ Pull the cover forward to release the rear clip. 2. Disconnect the power window master switch connector. 3. Remove the two screws that attach the power window switch base to the armrest, then remove the switch base. 4. Remove the three screws, then replace the power window master switch assembly. Camshaft, Rocker Arm, Camshaft Seal and Pulley Installation Rocker Arm Assembly: Service and Repair Camshaft, Rocker Arm, Camshaft Seal and Pulley Installation Camshaft, Rocker Arm, Camshaft Seal and Pulley Installation NOTE: To prevent the rocker arm assembly from coming apart, leave the camshaft holder bolts in the holes. 1. After wiping down the camshaft and the journals in the cylinder head, lubricate both surfaces and install the camshaft. 2. Clean and install the oil control orifice (A) with a new O-ring (B) (D17A2, D17A6 engines). 3. Clean and install the oil control orifice (C) (D17A1 engine). 4. Turn the camshaft until its keyway (D) is facing up (No.1 piston TDC). 5. Loosen all the valve adjusting screws. 6. Apply liquid gasket to the head mating surface (shaded areas) of the No. 1 and No. 5 camshaft holders. 7. Set the rocker arm assembly in place and loosely install the bolts. Make sure that the rocker arms are properly positioned on the valve stems. Page 1936 Engine Oil Pressure: Testing and Inspection Oil Pressure Test If the oil pressure warning light stays on with the engine running, check the engine oil level. If the oil level is correct: 1. Connect a tachometer or a Honda PGM Tester. 2. Remove the engine oil pressure switch, and install an oil pressure gauge (A). 3. Start the engine. Shut it off immediately if the gauge registers no oil pressure. Repair the problem before continuing. 4. Al low the engine to reach operating temperature (fan comes on at least twice). The pressure should be: Engine Oil Temperature: 176°F (80°C) Engine Oil Pressure: At Idle: 70 kPa (0.7 kgf/cm2, 10 psi) minimum At 3,000 rpm: 340 kPa (3.5 kgf/cm2, 50 psi) minimum 5. If oil pressure is NOT within specifications, inspect these items: ^ Check the oil filter for clogging. ^ Check the oil pump. Service and Repair Headliner: Service and Repair Headliner Removal/Installation Special Tools Required KTC trim tool set SOJATP2014 NOTE: - Use the appropriate tool from the KTC trim tool set to avoid damage when prying components. - When prying with a flat-tip screwdriver, wrap it with protective tape to prevent damage. - Take care not to bend and scratch the headliner. - Be careful not to damage the dashboard and other interior trim. 1. Remove these items: - A-pillar trim, both sides - B-pillar upper trim, one side, 2-door - B-pillar upper trim, both sides, 4-door - C-pillar trim, both sides, 2-door - Rearview mirror - Ceiling light/spotlights, with moon roof - Spotlights, without moonroof - Ceiling light 2. Remove the sunvisor (A) and holder (B) from both sides. - Remove the caps (C). - Remove the self-tapping ET screws. - Remove the sunvisor from the body and holder. - Using a flat-tip screwdriver, push the hook (D), and turn the holder 90, then pull it out. Page 258 DTC P0A94 thru P0157 Page 5335 Hydraulic Control Assembly - Antilock Brakes: Service and Repair ABS Modulator-Control Unit Removal and Installation NOTE: ^ Do not spill brake fluid on the vehicle; it may damage the paint; if brake fluid gets on the paint, wash it off immediately with water. ^ Be careful not to damage or deform the brake lines during removal and installation. ^ To prevent the brake fluid from flowing, plug and cover the hose ends and joints with a shop towel or equivalent material. Removal 1. Pull up the lock (C) of the ABS control unit 31P connector (B), then disconnect the connector. 2. Disconnect the six brake lines. 3. Remove the two 8 mm nuts. 4. Remove the ABS modulator-control unit (A). Installation 1. Install the ABS modulator-control unit, then tighten the two 8 mm nuts. 2. Align the connecting surface of the ABS control unit 31P connector. 3. Push in the lock of the ABS control unit 31P connector until you hear it click into place, then connect the connector. 4. Bleed the brake system, starting with the front wheels. 5. Start the engine, and check that the ABS indicator goes off. 6. Test-drive the vehicle, and check that the ABS indicator does not come on. Page 4394 8. Put the splice connector in the proper size slot in the Crimper Tool, slide it to one end (where the flare begins), and close the crimper handles far enough to hold it in place. To release the ratchet mechanism at any point after the first click, squeeze the handles slightly and push the release lever, then let the handles open. 9. Insert one of the bare wires into the splice connector end that is in the crimper jaws. Push the wire all the way into the splice connector, and squeeze the crimper handles. Keep squeezing until the jaws touch, and hold it at that position until the ratchet clicks again. 10. Crimp the other wire in the same way into the other end of the splice connector. 11. After crimping, gently pull on the wires in the opposite directions to make sure they are secure in the connector. 12. Separate the other wires in the harness from the repaired wire(s), and shield them with nonflammable material. Page 9204 1. Remove the terminal. 2. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE G: 1. Remove the terminal. 2. Go to HOW TO INSTALL NEW TERMINALS. How to Install New Terminals HOW TO INSTALL NEW TERMINALS 1. Carefully match the old terminal with a new one from the terminal repair kit. Choose the correct replacement terminal based on the wire size range the terminal will accommodate. NOTE: If the replacement terminal quantities are low, reorder them by using the terminal part number listed on the inside lid of the terminal repair kit. Replacement terminals are available through your parts department using normal parts ordering procedures. 2. Depending on the size of the wire you are repairing, use the proper size slot in the crimping tool. Page 1269 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 1039 Page 9562 110. Left B Pillar (Right Similar) 111. Left C Pillar (Sedan) (Right Similar) Page 4613 Transmission Position Switch/Sensor: Service and Repair Transmission Range Switch Replacement 1. Remove the intake air duct and resonator. 2. Shift to the N position. 3. Remove the transmission range switch shaft cap (A). 4. Disconnect the transmission range switch connector (A). 5. Remove the transmission range switch (B). 6. Make sure that the control lever is in the N position. Page 818 1. Remove the secondary lock from the male terminal half. 2. Remove the secondary lock from the female terminal half. 3. Remove the terminal (same procedure for male and female). 4. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE C: 1. Remove the secondary lock. Page 8789 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. SRS Unit, Front Sensors and Side Impact Sensors SRS Unit, Front Sensors and Side Impact Sensors Be careful not to bump or impact the SRS unit, front sensors, or the side impact sensors whenever the ignition switch is ON (II), or for at least 3 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, front sensors, and the side impact sensor. The airbags could accidentally deploy and cause damage or injury. After a collision in which any airbags or seat belt tensioners were deployed, replace the SRS unit, front sensors, and other related components. After a collision in which a side airbag was deployed, replace the side impact sensor on the deployed side 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, front sensors, 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 3 minutes before beginning installation or replacement of the SRS unit, or disconnecting 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 N.m (1.0 kgf.m, 7.2 lbf.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 °G) and dry (less than 80% relative humidity, no moisture) area. Wiring Precautions Wiring Precautions SRS wiring can be identified by special yellow outer covering (except the SRS indicator light circuit). Page 2959 ERROR: undefined OFFENDING COMMAND: f‘~ STACK: 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 4654 23. Transmission Housing (A/T) Page 7179 68. Under Left Side Of Dash Page 2331 ECM/PCM Inputs And Outputs At Connector C (22P) Page 5258 3. Strip the insulation off the end of the wire so the wire fits in the new terminal as shown. (If the wire has a wire seal, replace it with a new one from the kit.) NOTE: After stripping the end of the wire, make sure you did not cut any wire strands. If you did, cut the wire off even with the insulation, and strip it again. 4. Position the terminal in the crimping tool slot with the solid portion of the terminal toward the anvil and the open section toward the former. 5. Insert the wire in the terminal to the position shown in step 3. 6. Squeeze the tool with both hands until the stops make contact. 7. Crimp the insulation crimp. - If you do not have a wire seal, then use the next larger size crimp slot. Position the crimping tool over the insulation crimp section of the terminal, then squeeze the tool with both hands until the stops make contact. - If you have a wire seal, position the insulation crimp in the 5.5 crimping slot, then carefully squeeze the crimp closed until its ends are touching and making a full-circle shape. Page 1246 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 8535 174. Moonroof Switch (EX) Page 7180 68. Under Left Side of Dash Air Bag Disarming and Arming Air Bag(s) Arming and Disarming: Service and Repair Air Bag Disarming and Arming 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 8117 Page 458 Keyless/Power Door Lock System Component Location Index Page 5389 8. Put the splice connector in the proper size slot in the Crimper Tool, slide it to one end (where the flare begins), and close the crimper handles far enough to hold it in place. To release the ratchet mechanism at any point after the first click, squeeze the handles slightly and push the release lever, then let the handles open. 9. Insert one of the bare wires into the splice connector end that is in the crimper jaws. Push the wire all the way into the splice connector, and squeeze the crimper handles. Keep squeezing until the jaws touch, and hold it at that position until the ratchet clicks again. 10. Crimp the other wire in the same way into the other end of the splice connector. 11. After crimping, gently pull on the wires in the opposite directions to make sure they are secure in the connector. 12. Separate the other wires in the harness from the repaired wire(s), and shield them with nonflammable material. Page 5387 8. Inspect the quality of the wire crimp. If it has any of the following NO GOOD crimps, cut it off and start over. 9. Insert the terminal into the connector. Make sure the wire seals are pushed all the way into the connector. Lightly pull on the wires to make sure the terminal is locked into place. 10. Close or insert the secondary terminal lock, if applicable, and reconnect the connector. How to Install Pigtail Terminals HOW TO INSTALL PIGTAIL TERMINALS Pigtail terminals (short pieces of wire with a factory crimped terminal) are used when the wire is too short or when access to the connector is too restricted to make a terminal repair. NOTE: To replace just a connector terminal, go to How to Replace Connector Terminals. IMPORTANT SAFETY INFORMATION: On some models, the SRS wires are in a separate harness. If the SRS harness is damaged, replace the harness; do not repair it. On other models, wire harnesses include yellow SRS wires. If any SRS wire is damaged, replace the entire harness; do not repair it. 1. Remove the damaged or faulty terminal from the connector. Use the proper removal tool from Pin Tool Set. Page 7214 1991-93 Accord 5-door EX with factory-installed keyless entry or dealer-installed security system Programming the Transmitter The transmitter is not programmable. Ordering a Transmitter Transmitters can be ordered only by authorized Honda dealers. To order a transmitter, you need the vehicle's VIN, the code number from the power door lock control unit, and the ignition key code number. The power door lock code number is a five-digit number etched into the plastic case of the control unit (mounted under the driver's seat). The ignition key code number is a four-digit number stamped on the metal shank of all five original keys delivered with the car. Replacement transmitters are manufactured to match the code of the keyless entry system. The new ignition key is cut to match the vehicle's ignition switch, front door locks, tailgate lock, and glove compartment lock. To order this transmitter, use the controlled parts ordering screen on the iN system. The transmitters are manufactured in Japan; delivery takes 4 to 6 weeks. Batteries for the Transmitter The battery is not replaceable. 91-93 Accord 5-Door LX 1991-93 Accord 5-door LX with dealer-installed security system Programming the Transmitter This transmitter is not programmable. Ordering a Transmitter Transmitters can be ordered directly from Kenwood USA only by authorized Honda dealers. Send a completed order form (copy it from the Accessory Replacement Parts section of the Dealer Parts Price List) along with a dealer check for $30.00 (payable to Kenwood U.S.A. Corp.) to this address: Kenwood Service Corp. P.O. Box 22745 Long Beach, CA 90501-5745 Page 3889 Locations Manifold Pressure/Vacuum Sensor: Locations PGM-FI System - Component Location Index Page 1805 Use them, and the numbers stamped on the crankshaft (codes for main journal size), to choose the correct bearings. If the codes are indecipherable because of an accumulation of dirt and dust, do not scrub them with a wire brush or scraper. Clean them only with solvent or detergent. Main Journal Code Locations (Numbers) Page 5023 143. Park Pin/Shift Switch (A/T) Page 7199 ^ Within 1 to 4 seconds, turn the ignition switch to LOCK (0). ^ Within 1 to 4 seconds, turn the ignition to ON (II). ^ Within 1 to 4 seconds, push the transmitter lock or unlock button. ^ Confirm you can hear the sound of the door lock actuators. Within 1 to 4 seconds, push the transmitter lock or unlock button again. ^ Within 10 seconds, aim the transmitters (up to two additional ones) whose codes you want to store at the receiver, and press the transmitter lock or unlock button. Confirm that you can hear the sound of the door lock actuators after each transmitter code is stored. ^ Turn the ignition switch to LOCK (0), and pull out the key. 4. Confirm proper operation of the transmitters. Disclaimer Body - Power Windows Inoperative/Intermittent Operation Power Window Switch: All Technical Service Bulletins Body - Power Windows Inoperative/Intermittent Operation 06-010 March 8, 2006 Applies To: 2001-05 Civic - All LX and EX 4-door 2003-05 Civic Hybrid - ALL 2001-05 Civic GX ALL Power Window Does Not Work or Works Intermittently SYMPTOM One or more of the power windows does not work or works intermittently from the power window master switch (in the driver's door). PROBABLE CAUSE The power window master switch is faulty. CORRECTIVE ACTION Replace the power window master switch. PARTS INFORMATION WARRANTY CLAIM INFORMATION In warranty: The normal warranty applies. Operation Number: 744100 Flat Rate Time: 0.2 hr Failed Part: P/N 35750-S5A-A01ZA H/C 6453419 Defect Code: 03217 Symptom Code: 01201 Template ID: 06-010A (Black Switch) 06-010B (Medium Taupe Switch) 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 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 8445 4. Repeat steps 2 and 3 as needed for additional buttons. 5. Install the seat-back cover in the reverse order of removal. Disclaimer Page 4501 4. Torque the mounting bolts in a crisscross pattern. Tighten the bolts in several steps to prevent warping the diaphragm spring. 5. Remove the special tools. 6. Make sure the diaphragm spring fingers are all the same height. Page 8165 Programming the Transmitter 1. Locate the security system control unit under the driver's seat. 2. Rub your finger over the label on the top of the control unit until you find the depression. Once you find it, push your finger through the label to expose the hole underneath. Inside the hole is a square, yellow button; this is the programming button. 3. Turn the ignition switch to ON, then turn it to LOCK. 4. Press and hold the programming button. Check that the security siren emits four separate chirps followed by a five-chirp burst. This confirms that the system is in programming mode. The siren then emits prompting chirps at 3-second intervals. 5. Release the programming button. 6. After a prompting chirp, press the "LOCK" button on the transmitter. Verify that the siren emits a confirmation chirp to confirm that the transmitter's code was accepted by the control unit. If you wait more than 30 seconds after the prompting chirp before programming a transmitter, or wait more than 30 seconds between programming transmitters, the siren emits three chirps and the system exits the programming mode. 7. To program additional transmitters, wait for another prompting chirp, then press the "LOCK" button. (You can program up to four transmitters per vehicle.) 8. To exit the programming mode, turn the ignition switch to ON, then turn it to LOCK. 9. Test all the transmitters. Ordering a Transmitter Transmitters can be ordered only by authorized Honda dealers. Order them from American Honda using normal parts ordering procedures. Batteries for the Transmitter The battery number is 23-144 (Radio Shack), A-23 (Eveready), or MS-21/MN-21 (Duracell). Each transmitter uses one battery. Page 7960 2. Remove the access panel from the steering wheel, then disconnect the driver's airbag 4P connector (A) from the cable reel. Front Passenger's Airbag 3. Lower the glove box, then disconnect the front passenger's airbag 4P connector (A) from the dashboard wire harness B. Side Airbag 4. Disconnect both side airbag 2P connectors (A) from the floor wire harness. Seat Belt Tensioner 5. Disconnect both seat belt tensioner 2P connectors (A) from the floor wire harness. Seat Belt Buckle Tensioner Page 2187 Radiator Cooling Fan Temperature Sensor / Switch: Testing and Inspection Radiator Fan Switch Test NOTE: Bleed air from the cooling system after installing the radiator fen switch. 1. Remove the radiator fan switch from the thermostat cover. 2. Suspend the radiator fan switch (A) in a container of water as shown. 3. Heat the water and check the temperature with a thermometer. Do not let the thermometer (B) touch the bottom of the hot container. 4. Measure the continuity between the A terminal (C) and B terminal (D) according to the table. Service and Repair Fuel Pressure Release: Service and Repair Fuel Pressure Relieving Before disconnecting fuel lines or hoses, relieve pressure from the system by disconnecting the fuel tube/quick connect fitting in the engine compartment. 1. Make sure you have the antitheft code for the radio, then write down the frequencies for the radio's preset buttons. 2. Turn the ignition switch OFF. 3. Remove the glove box, then remove the PGM-FI main relay 2 (A). 4. Start the engine, and let it idle until it is stalls. NOTE: The DTCs or Temporary DTCs P0301, P0302, P0303, P0304 may come on during this procedure. If any DTCs are stored, ignore them. 5. Turn the ignition switch OFF. 6. Remove the fuel fill cap to relieve fuel pressure in the fuel tank. 7. Disconnect the negative cable from the battery. 8. Remove the bolt (A) and the fuel feed pipe mounting bracket (B), then remove the quick-connect fining covers (C). 9. Check the fuel quick-connect fitting for dirt, and clean if necessary. 10. Place a rag or shop towel over the quick-connect fitting (D). Page 3229 Transmission Position Switch/Sensor: Testing and Inspection Transmission Range Switch Test 1. Remove the transmission range switch harness connector (A) from the connector bracket (B), then disconnect the connector. 2. Check for continuity between terminals at the harness connector. There should be continuity between the terminals listed for each switch position. In the P position, between terminals: ^ No. 1 and No. 3 ^ No. 1 and No. 8 ^ No. 3 and No. 8 In the R position, between terminals: ^ No. 1 and No. 9 In the N position and between terminals: ^ No. 1 and No. 3 ^ No. 1 and No. 10 ^ No. 3 and No. 10 In the D position, between terminals: ^ No. 1 and No. 2 ^ No. 1 and No. 4 ^ No.2 and No.4 In the D3 position, between terminals: ^ No. 1 and No. 2 ^ No. 1 and No. 5 ^ No.2 and No.5 In the 2 position, between terminals: ^ No. 1 and No. 6 Page 3097 Oxygen Sensor: Description and Operation Air Fuel (A/F) Ratio Sensor Air Fuel Ratio (A/F) sensor (D17A6 engine) The A/F sensor operates over a wide air/fuel range. The A/F sensor is installed in the exhaust manifold. Locations Clutch Switch: Locations Cruise Control Component Location Index Page 5716 Wire Color Abbreviations Page 6065 71. Under Left Side Of Dash Under-hood Fuse/Relay Box Page 2862 Knock Sensor: Description and Operation Knock Sensor The knock control system adjusts the ignition timing to minimize knock. Page 3784 5. Attach the slide hammer to the interlock lever pin, and tighten the slide hammer clamping bolt. Then use the slide hammer to remove the pin. Discard the pin, the lever, and the spring. 6. Wipe off any debris from the lever's sliding surface on the ignition switch with a clean cloth or a cotton swab. NOTE: To keep debris out of the ignition switch, do not clean it with compressed air. Connector Views Fuse Block: Connector Views 234. Under-dash Fuse/Relay Box Part 1 Page 3994 Torque Converter Clutch Solenoid: Service and Repair Torque Converter Clutch Solenoid Valve Replacement 1. Remove the mounting bolt and the torque converter clutch solenoid valve (A). 2. Install a new torque converter clutch solenoid valve with new O-rings (B). While installing the valve, do not allow dust or other foreign particles to enter the transmission. 3. Check the connector for rust, dirt, or oil, then connect the connector securely. Page 7299 13. Plug in the heat gun, and turn it on. Start at the middle of the splice connector, and move the gun toward the ends as the tube shrinks. Apply heat evenly by rotating the curved heat spreader around the splice connector. Shrinking is complete when a small amount of sealant appears at each end of the tube. Pigtail Terminal Selection Chart PIGTAIL TERMINAL SELECTION CHART Select the proper size pigtail terminal by matching the replacement terminal part number and the wire size being repaired to the corresponding pigtail terminal part number. Then use the color (size) splice connector listed. In some instances you may also have to match the wire seal style to select the proper pigtail terminal. Pigtail terminals are available through your parts department, in quantities of 10, using normal parts ordering procedures. Checking For Poor Fir of Terminals CHECKING FOR POOR FIT OF TERMINALS Loose terminal fit can cause a number of intermittent problems in electrical circuits. By using the Terminal Inspection Feeler Tool Set you can inspect the terminal fit between the two matching connectors without removing the terminals from the connector body. 1. Find the terminal tool that best matches the male terminal in the mating connector. Page 2717 172. EGR Valve And EGR Valve Position Sensor (EX, HX; '04-'05: DX, LX) Page 3869 Shift Interlock Switch: Service and Repair Park Pin Switch Replacement 1. Remove the center console panel and center console. 2. Remove the screws (A), then remove the shift lever knob (B). 3. Remove the A/T gear position indicator panel light (c) from the A/T gear position indicator panel. 4. Remove the A/T gear position indicator panel and panel bracket as an assembly (D). 5. Disconnect the park pin switch connector (4P) (E), and remove it from the shift lever bracket base (F). 6. Remove the shift lock release (G) and spring (H). 7. Open the lock tabs (A) on the shift lever bracket base, then remove the park pin switch (B). 8. Install the new park pin switch. 9. Install the removed parts in the reverse order of removal. Page 1529 Power Windows Component Location Index Page 9392 Map Light: Diagnostic Aids General Troubleshooting Information General Troubleshooting Information Tips and Precautions Before Troubleshooting 1. Check applicable fuses in the appropriate fuse/relay box. 2. Check the battery for damage, state of charge, and clean and tight connections. NOTE: 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. Handling Connectors - Make sure the connectors are clean and have no loose wire terminals. - Make sure multiple cavity connectors are packed with dielectric grease (except watertight connectors). - All connectors have push-down release type locks (A). - Some connectors have a clip on their side used to attach them to a mount bracket on the body or on another component. This clip has a pull type lock. - Some mounted connectors cannot be disconnected unless you first release the lock and remove the connector from its mount bracket (A). - Never try to disconnect connectors by pulling on their wires; pull on the connector halves instead. - Always reinstall plastic covers. Page 4408 Transmission Speed Sensor: Locations 22. Transmission Housing (A/T Except CVT) 19. Transmission Housing (A/T Except CVT) Page 2788 ECT at 140 °F (60 °C) or higher. Procedure 1. Connect the scan tool to the vehicle's data link connector (DLC), and bring up the tool's generic OBD II mode. 2. Start the engine. 3. Test-drive the vehicle under stop-and-go conditions with short periods of steady cruise. During the drive, decelerate (with the throttle fully closed) for 5 seconds. After about 3.5 miles (5.6 km), the readiness code should switch from incomplete to complete. 4. If the readiness code is still set to incomplete, check for a temporary DTC. If there is no DTC, the enable criteria was probably not met; repeat the procedure. Air/Fuel Ratio (A/F) Sensor Heater Monitor Readiness Code NOTE: All readiness codes are cleared when the battery is disconnected or when the ECM/PCM is cleared with the OBD II scan tool or Honda PGM Tester. Procedure 1. Connect the scan tool to the vehicle's data link connector (DLC), and bring up the tool's generic OBD II mode. 2. Start the engine, and let it idle for 1 minute. The readiness code should switch from incomplete to complete. 3. If the readiness code is still set to incomplete, check for a temporary DTC. If there is no DTC, repeat the procedure. Misfire Monitor and Readiness Code - This readiness code is always set to available because misfiring is continuously monitored. - Monitoring pauses, and the misfire counter resets, if the vehicle is driven over a rough road. - Monitoring also pauses, and the misfire counter holds at its current value, if the throttle position changes more than a predetermined value, or if driving conditions fall outside the range of any related enable criteria. Fuel System Monitor and Readiness Code - This readiness code is always set to available because the fuel system is continuously monitored during closed loop operation. - Monitoring pauses when the catalytic converter, EVAP control system, and A/F sensor monitors are active. - Monitoring also pauses when any related enable criteria are not being met. Monitoring resumes when the enable criteria is again being met. Comprehensive Component Monitor and Readiness Code This readiness code is always set to available because the comprehensive component monitor is continuously running whenever the engine is cranking or running. EGR Monitor and Readiness Code NOTE: - Do not turn the ignition switch off during the procedure. - All readiness Codes are cleared when the battery is disconnected or when the ECM/PCM is cleared with the OBD II scan tool or Honda PGM Tester. Enable Criteria - ECT at 176 °F (80 °C) or higher Procedure 1. Connect the scan tool to the vehicle's data link connector (DLC), and bring up the tool's generic OBD II mode. 2. Start the engine. 3. Drive at a steady speed with the CVT and A/T in D position or M/T in 4th gear, 50 - 62mph (80 - 100 km/h) or above for more than 10 seconds. 4. With the CVT and A/Tin D position or M/T in 4th gear, decelerate from 62 mph (100km/h) or above by completely releasing the throttle for at least 5 seconds. If the engine is stopped during this procedure, go to step 3 and do the procedure again. 5. If the readiness code is still set to incomplete, check for a temporary DTC. If there is no DTC, the enable criteria was probably not met; repeat the procedure. Page 1790 Connecting Rod: Service and Repair Replacement Special Tools Required ^ Piston base 07973-6570500 ^ Piston base spring 07973-6570600 ^ Piston pin base insert 07973-PE00400 ^ Piston base head 07973-SB00100 or 07TGF-001000A ^ Pilot collar 07973-PE00200 ^ Piston pin driver shaft 07973-PE00310 ^ Piston pin driver head 07973-PE00320 Disassembly 1. Remove the piston from the cylinder block 2. Assemble the special tool as shown. 3. Assemble and adjust the length of the piston pin driver head and shaft to 53 mm (2.1 inch). Page 6155 Power Steering Pressure Switch: Testing and Inspection PSP Switch Signal Circuit Troubleshooting 1. Turn the ignition switch ON (II). 2. Measure voltage between ECM/PCM connector terminals A24 and E16. Is there less than 1.0 V? YES - Go to step 3. NO - Go to step 6. 3. Start the engine. 4. Turn the steering wheel to the full lock position. 5. Measure voltage between ECM/PCM connector terminals A24 and E16. Is there battery voltage? YES - The PSP switch signal is OK. NO - Go to step 13. 6. Turn the ignition switch OFF. 7. Disconnect the PSP switch 2P connector. 8. Turn the ignition switch ON (II). 9. At the harness side, connect the PSP switch 2P connector terminals No.1 and No.2 with a jumper wire. 10. Measure voltage between ECM/PCM connector terminals A24 and E16. Is there less than 1.0 V? YES - Replace the PSP switch. NO - Go to step 11. 11. Turn the ignition switch OFF. Page 3985 23. Transmission Housing (A/T) Page 3168 93. VTEC Oil Pressure Switch (EX, HX) Page 3241 Splices Components Ground - "G" Automatic Transmission Shift Indicator: Locations Automatic Transmission Component Location Index Page 7970 9. Open the jaws with the jaws knob, and slide the original key with its flat side down into the center jaw up to the key stop. Slide the key blank with its flat side down into the right jaw up to the key stop. Close the jaws with the jaws knob to lock the keys into place. Visually inspect both keys for proper alignment in the jaws. 10. Loosen the lateral and spring tension adjustment knobs on the clamp carriage. With the clamp carriage lever, adjust the clamp carriage to position the tracer and the cutter bit over the middle of the two locked key blades. Tighten only the spring tension knob when done. NOTE: The clamp carriage has a spring system that puts lateral pressure on the tracer and cutting bit to make it easier to cut sidewinder-type keys. Do not tighten the lateral tension adjustment knob. This knob should be left loose. 11. Turn on the cutter motor with the motor start switch. [NOTICE] ^ To avoid damaging the locking jaws while cutting, keep your hand off the vertical carriage lever. Pressure on the lever will change the cutting depth. * ^ To avoid breaking the cutter bit, never back up while cutting.* ^ Wear proper eye protection (safety glasses, goggles, etc.) Page 8949 Oil Pressure Sender: Testing and Inspection Oil Pressure Switch Test 1. Remove the YEL/RED wire (A) from the engine oil pressure switch (B). 2. Check for continuity between the positive terminal (C) and the engine (ground). There should be continuity with the engine stopped. There should be no continuity with the engine running. 3. If the switch fails to operate, check the engine oil level. If the engine oil level is OK, check the engine oil pressure. If the oil pressure is OK, replace the oil pressure switch. Page 1893 4. Insert the intake and exhaust valves in the head and measure the valve stem installed height (A). Valve Stem Installed Height Standard (New): 53.17 - 53.64 mm (2.093 - 2.112 inch) Service Limit: 53.89 mm (2.122 inch) 5. If the valve stem installed height is over the service limit, replace the valve and recheck. If it is still over the service limit, replace the cylinder head; the valve seat in the head is too deep. Page 3623 3. Replace the plug at the specified interval, or if the center electrode is rounded (A). Use only the spark plugs listed. 4. Apply a small quantity of anti-seize compound to the plug threads, and screw the plugs into the cylinder head finger-tight. Then torque them to 18 N.m (1.8 kgf.m, 13 lbf.ft). Page 9498 Use the tools from Pin Tool Set. First, check the connector that you are about to repair. - If it has a secondary terminal lock, go to Connectors With a Secondary Lock. A secondary lock, found on most connectors on some models, is an additional locking device on the connector housing as a backup for the primary lock on the terminal. - If the connector does not have a secondary lock, go to Connectors Without a Secondary Lock. Connectors With a Secondary Lock All examples are shown with the connector lock facing up. The illustrations are examples of the secondary terminal locks; however, the connector you are repairing may vary in size. Identify the connector by the type of secondary lock, not by the number of terminal cavities. EXAMPLE A: 1. Release the secondary lock. 2. Remove the terminal. 3. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE B: Description and Operation Fuel Cut Control Unit: Description and Operation Fuel Cut-off Control During deceleration with the throttle valve closed, current to the injectors is cut off to improve fuel economy at speeds over 850 rpm. Fuel cut-off action also occurs when engine speed exceeds 6,900 rpm, regardless of the position of the throttle valve, to protect the engine from over-revving. With A/T model, when the vehicle is stopped, the PCM cuts the fuel at engine speeds over 5,000 rpm. Page 8034 PARTS INFORMATION REQUIRED MATERIALS WARRANTY CLAIM INFORMATION In warranty: The normal warranty applies. Failed Part: P/N 72185-S9A-003 H/C 6896716 Defect Code: 00503 Symptom Code: 07902 Skill Level: Repair Technician Fuel System - FTP Sensor Diagnostics/DTC P0497 Fuel Tank Pressure Sensor: Technical Service Bulletins Fuel System - FTP Sensor Diagnostics/DTC P0497 How to Tell a Bad FTP Sensor From an EVAP Leak Troubleshooting a '01-05 Civic with DTC P0497 (EVAP system low purge flow)? When the fuel tank pressure (FTP) sensor doesn't respond to vacuum testing, it's really easy to think you've got a leak in the FVAP system. Here's an simple way to tell if the problem is just a bad FTP sensor or an actual system leak: 1. Connect the HDS to the 16P DLC. Turn the ignition switch to ON (II). Turn on the HDS. 2. At the screen prompts, enter the VIN (if you're asked) and the odometer reading. 3. From the Select Mode screen, select Honda Systems. From the System Selection Menu, select PGM-FI. From the Mode Menu, select All Data List. 4. Disconnect the two FTP sensor vacuum lines. Look at the FTP Sensor value on the display screen. ^ If the value reads between 2.45 and 2.55 volts, go to step 6. ^ If the value doesn't read between 2.45 and 2.55 volts, check the electrical connections. If you find any problems, fix them, then go to step 5. If the circuits are OK, replace the FTP sensor, then go to step 5. 5. Look at the FTP Sensor value on the display screen. ^ If the value now reads between 2.45 and 2.55 volts, reconnect the vacuum lines and disconnect the HDS. Return the vehicle to your customer. ^ If the value still doesn't read between 2.45 and 2.55 volts, go to step 6. 6. Connect a vacuum pump to the larger FTP sensor hose (the smaller hose is the FTP vent) Slowly squeeze the pump handle to pull a vacuum on the FTP sensor. Look at the sensor value on the display screen. ^ If the value changes, continue troubleshooting for DTC P0497. ^ If the value stays the same, the FTP sensor has a leak. Replace the sensor. Page 108 Condenser Fan Motor Relay: Testing and Inspection Power Relay Test Use this chart to identify the type of relay, then do the test listed for it. NOTE: See the turn signal/hazard relay input test. Normally-open type A: Page 5881 71. Under Left Side Of Dash Under-hood Fuse/Relay Box Page 1247 ^ 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 8430 6. Pivot the glass bracket (A) down by sliding the link lifter (B) back, then slide both glass brackets back with the link lifter 7. Slide the cable assembly (A) and both glass brackets (B) back, then remove them from the frame (C). 8. Install the slider and cable assembly in the reverse order of removal, and note these items: - Damaged parts should be replaced. - Apply multipurpose grease to the glass bracket (A) and guide rail portion of the frame (B) indicated by the arrows. - Before reinstalling the motor, make sure both link lifters are parallel, and in the fully closed position. - Before reinstalling the motor, install the frame and glass, then check the opening drag. Page 891 9. Open the jaws with the jaws knob, and slide the original key with its flat side down into the center jaw up to the key stop. Slide the key blank with its flat side down into the right jaw up to the key stop. Close the jaws with the jaws knob to lock the keys into place. Visually inspect both keys for proper alignment in the jaws. 10. Loosen the lateral and spring tension adjustment knobs on the clamp carriage. With the clamp carriage lever, adjust the clamp carriage to position the tracer and the cutter bit over the middle of the two locked key blades. Tighten only the spring tension knob when done. NOTE: The clamp carriage has a spring system that puts lateral pressure on the tracer and cutting bit to make it easier to cut sidewinder-type keys. Do not tighten the lateral tension adjustment knob. This knob should be left loose. 11. Turn on the cutter motor with the motor start switch. [NOTICE] ^ To avoid damaging the locking jaws while cutting, keep your hand off the vertical carriage lever. Pressure on the lever will change the cutting depth. * ^ To avoid breaking the cutter bit, never back up while cutting.* ^ Wear proper eye protection (safety glasses, goggles, etc.) Page 9695 Heated Glass Element Switch: Diagrams 194. Recirc - A/C - Defogger Switch Assembly Emissions - OBD II DTC's And Associated Monitors Engine Control Module: Technical Service Bulletins Emissions - OBD II DTC's And Associated Monitors 03-020 April 2, 2010 Applies To: All OBD II-equipped models except Passport OBD II DTCs and Their Associated Monitors (Supersedes 03-020, dated March 29, 2003, to revise the information marked by the black bars and asterisks) *REVISION SUMMARY Numerous DTCs were added. Refer to the list for details.* Following is a list of all OBD II DTCs and their associated monitors for all Honda automobiles with OBD II. No one model has every DTC in the list. DTC P0AA6 thru P0A9E Page 9198 1. Remove the secondary lock from the male terminal half. 2. Remove the secondary lock from the female terminal half. 3. Remove the terminal (same procedure for male and female). 4. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE C: 1. Remove the secondary lock. Page 6314 Front Steering Knuckle: Service and Repair Knuckle/Hub/Wheel Bearing Replacement Special Tools Required ^ Hub dis/assembly tool 07GAF-SE00100 ^ Ball joint remover, 28 mm 07MAC-SL00200 ^ Attachment 62 x 68 mm 07746-0010500 ^ Driver 07749-0010000 ^ Support base 07965-SD90100 1. Raise the front of the vehicle, and support it with safety stands in the proper locations. 2. Remove the wheel cap, wheel nuts, and front wheel. Page 3608 ^ Incorrect: "If a Master Key is to be cut, put a five (5) in the blank space. Use a two (2) if a valet key is needed." ^ Correct: "If a Master Key is to be cut, put an M in the blank space. Use an S if a valet key is needed." Page 2, legend at the bottom: ^ Incorrect: "C. If a Master key is desired, then the number five (5) should be placed in the M/S position. Place the number two (2) in the M/S column if a Sub (Valet) key is needed." ^ Correct: "C. If a Master Key is desired, then an M should be placed in the M/S position. Place an S in the MIS column if a Sub (Valet) key is needed." Page 2578 48. Middle Of Engine (except GX) 49. Middle Of Engine (GX) Page 8292 ^ If no key code can be found on the iN or with the Matrix H High Security key Codes Book, remove one tumbler at a time from the old inner cylinder, and match the number stamped on the old tumbler to a new tumbler from the kit. Insert the new tumbler and spring in the appropriate new inner cylinder cavity. ^ Do not use the old inner cylinder, springs, or tumblers. ^ Using your thumb and forefinger, hold the tumblers in place, insert the key in the cylinder and verify that all tumblers are flush with the cylinder. If not, double-check the key number, the cutting key code, the tumbler numbers, and the cavity locations. NOTE: If the key cannot be inserted, check the tumbler in the "J" cavity. It may be out of position. Locations Throttle Position Sensor: Locations PGM-FI System - Component Location Index Page 432 Blower Motor Relay Type 1, Type 2 Check for continuity between the terminals. - There should be continuity between the No.1 and No.3 terminals when power and ground are connected to the No.2 and No.4 terminals. - There should be no continuity between the No.1 and No.3 terminals when power is disconnected. Five-terminal type Check for continuity between the terminals. - There should be continuity between the No.1 and No.2 terminals when power and ground are connected to the No.3 and No.5 terminals. - There should be continuity between the No.1 and No.4 terminals when power is disconnected. Page 5348 6. Refill the master cylinder reservoir to the MAX (upper) level line. Page 2314 DTC P1253 thru P1459 Page 5002 Transmission Position Switch/Sensor: Testing and Inspection Transmission Range Switch Test 1. Remove the transmission range switch harness connector (A) from the connector bracket (B), then disconnect the connector. 2. Check for continuity between terminals at the harness connector. There should be continuity between the terminals listed for each switch position. In the P position, between terminals: ^ No. 1 and No. 3 ^ No. 1 and No. 8 ^ No. 3 and No. 8 In the R position, between terminals: ^ No. 1 and No. 9 In the N position and between terminals: ^ No. 1 and No. 3 ^ No. 1 and No. 10 ^ No. 3 and No. 10 In the D position, between terminals: ^ No. 1 and No. 2 ^ No. 1 and No. 4 ^ No.2 and No.4 In the D3 position, between terminals: ^ No. 1 and No. 2 ^ No. 1 and No. 5 ^ No.2 and No.5 In the 2 position, between terminals: ^ No. 1 and No. 6 Page 1599 21. Check for continuity between PGM-FI main relay 1 4P connector terminal No.1 and body ground. Is there continuity? YES - Repair short in the wire between PGM-FI main relay 1 and each item. Also replace the No.6 ECU (ECM/PCM) (15A) fuse. NO - Replace the PGM-FI main relay 1. Also replace the No 6 ECU (ECM/PCM) (15A) fuse. 22. Inspect the No.17 FUEL PUMP (15A) fuse in the under-dash fuse/relay box. Is the fuse OK? YES - Go to step 34. NO - Go to step 23. 23. Remove the blown No.17 FUEL PUMP (15A) fuse. 24. Disconnect ECM/PCM connector E (31P). 25. Check for continuity between ECM/PCM connector terminal E9 and body ground. Is there continuity? YES - Go to step 26. NO - Replace the No.17 FUEL PUMP (15A) fuse, and update the ECM/PCM if it does not have the latest software, or substitute a known-good ECM/PCM, then recheck. If the symptom/indication goes away with a known-good ECM/PCM, replace the original ECM/PCM. Page 4922 Skill Level: Repair Technician INSPECTION PROCEDURE 1. Remove the steering column covers. Refer to section 17 of the appropriate service manual. 2. On the lower side of the ignition switch, look at the interlock cylinder cover: ^ If the cover is square, the ignition switch was already replaced with an updated part, and a key interlock repair kit is not needed. Go to step 3. ^ If the cover is round, go to REPAIR PROCEDURE. 3. Reinstall the steering column covers. 4. Center-punch a completion mark above the seventh character of the engine compartment VIN. REPAIR PROCEDURE Page 4361 162. Right Side Of Engine Compartment Fuel Gauge & Low Fuel Indicator Accuracy Check Fuel Gauge: All Technical Service Bulletins Fuel Gauge & Low Fuel Indicator Accuracy Check SOURCE: Honda Service News March 2003 TITLE: Charting the Fuel Gauge and the Low Fuel Indicator APPLIES TO: 1998-03 Accord, 1996-03 Civic, or 1999-03 Odyssey SERVICE TIP: If an owner is leery of the fuel gauge or low fuel indicator accuracy and worries about running out of fuel, you may be able to restore faith in the accuracy of this hardware by charting the operation. If the fuel gauge, the low fuel indicator, or both doesn't give your customer a warm, fuzzy feeling, don't replace the fuel gauge or the sending unit until you've first charted the fuel gauge needle position and low fuel indicator status. You rarely improve accuracy by replacing fuel gauges and sending units. To chart the fuel gauge needle position and the low fuel indicator status, do this: 1. Have your customer bring in the vehicle when the fuel tank is nearly empty. 2. Drain any remaining fuel from the tank. 3. Park the vehicle on a flat surface, and add 2 gallons of fuel to the tank with the ignition switch turned to LOCK (0). 4. Start the engine, and note the fuel gauge needle position after 2 minutes. Draw a picture of the fuel gauge showing the position of the needle. Also note on your drawing if the low fuel indicator is on or off. Turn the ignition switch to LOCK (0). 5. Add 2 more gallons of fuel to the tank. Start the engine, and note the position of the needle after 2 minutes. Draw another picture of the fuel gauge showing the current position of the needle. Note the status of the low fuel indicator. Turn the ignition switch to LOCK (0). 6. Repeat step 5 until the fuel tank is full. Then give your customer all of the pictures you've drawn. They're usually enough to convince even the staunchest Doubting Thomas. Page 5557 3. Use the clamp carriage lever to position the clamp unit so the tracer is directly over the flat surface of the code device, just ahead of the cam blades. 4. Pull the vertical carriage lever toward you until the tracer just touches the flat surface ahead of the cam blades. Watch the arrows on the keypad: ^ If the double-headed arrow in the middle of the keypad lights green, the tracer and cutter bit are properly aligned. ^ If the arrow on the left of the keypad lights red, the cutter bit is not touching the jaw. Turn the micrometric ring nut above the tracer to the left until the double-headed arrow lights green. ^ If the vertical arrow on the right of the keypad lights red, the tracer is not touching the jaw. Turn the micrometric ring nut above the tracer to the right until the double-headed arrow lights green. *5. Turn the micrometric ring nut to the right five clicks so the cutter bit is slightly higher than the tracer. The arrow on the left should light red. Raise the vertical carriage. NOTE: Setting the tracer five clicks lower than the cutter bit at this point has the effect of making the cutter bit cut the duplicated key a little shallower. This will protect the locking jaws from being damaged.* 6. Optional: Loosen the set screw, and adjust the hand rest to a comfortable position. Tighten the screw. 7. Pull the clamp carriage lever toward you until the clamp carriage clicks into its end-of-run position. 8. Clean any metal shavings or debris out of the center jaw. (A soft-bristle toothbrush is ideal for this purpose.) Then open the jaws with the jaws knob, and slide the key blank with its flat side down into the jaw up to the key stop. Close the jaw with the jaws knob to lock the key blank into place. Visually inspect the key for proper alignment in the jaw. 9. Set and lock the cam sets on the code device. ^ Starting with the left cam set, make sure the lock pin is pulled all the way out. (This releases the cams.) Page 9548 Brake Light Switch: Description and Operation Brake Pedal Position Switch The brake pedal position switch signals the ECM/PCM when the brake pedal is pressed. Page 8943 Odometer: Description and Operation How the Circuit Works The indicators are controlled by relative conditions in their associated systems. For the following indicators the information supplied to the gauge assembly is received via the multiplex control unit: - Charging System - Door Indicator Light - Maintenance Required Indicator - Seat Belt Reminder - Trunk Indicator Light Refer to each associated system to see its entire schematic. Speedometer and Odometer The odometer circuit drive and the speedometer are controlled by the CPU built-in the gauge assembly. The CPU receives pulses from the vehicle speed sensor (except CVT) or PCM (CVT). The pulse rate increases as the car accelerates. The frequency and duration of these input pulses are measured by the CPU. Page 8025 12. Pull the vertical carriage lever toward you while you position the tracer on the right edge of the original key at its head, using the clamp carriage lever. Let the cutter bit cut into the key blank, then stop. Gently twist the lever clockwise to lock the vertical carriage at this height. Do not overtighten the lever. 13. Use the clamp carriage lever and the tracer to follow the contours of the original key. (The cutter bit cuts the same contours into the key blank.) Working from right to left, follow the right edge of the original key from head to tip, then the left edge of the key from tip to head. Turn off the cutter motor. 14. Reposition the tracer on the right edge of the original key at its head, using the clamp carriage lever. Turn on the cutter motor. Retrace the key from head to tip, then from tip to head. (This retracing cleans up the cuts on the key.) Turn off the cutter motor. 15. Release the vertical carriage lever. Open the jaw and remove only the new key. Make sure the jaw is free of any metal shavings or debris, then turn the new key over and slide the key with its blank side up into the jaw up to the key stop. Close the jaw to lock the key into place. 16. Turn on the cutter motor, and repeat steps 12 thru 14 to cut both edges of the other side of the key. 17. When you are finished making the required cuts, turn off the cutter motor, and release the vertical carriage lever. Open the jaws, and remove the keys. 18. Use a wire brush to smooth the cut surfaces on the new key. 19. Make sure the key works in the ignition switch and all the locks. If the key does not work, recut the key, and try it again. 20. Depending on the type of key blank you have used, do this: ^ If you have used a Honda key blank, add the transponder code of the new key to the immobilizer system with the Honda Diagnostic System (HDS). ^ If you have used a T-5 programmable key blank ("T-5" stamped on the shank), code the key's transponder with the Ilco Immobilizer Key Code Duplicator (see S/B 99-053, Ilco Immobilizer key Code Duplicator). Cutting Procedure - By Code 1. Press the ON/OFF button in the middle of the setting unit keypad. (This powers up the keypad.) 2. Turn the clamp unit lock lever to the left to release the clamp unit, and slide it to the right until the bottom left side is flush with the base edge. Turn the lever to the right to lock the clamp unit in place. Loosen the lateral and spring tension adjustment knobs on the clamp carriage. Service and Repair Fuel Pressure Release: Service and Repair Fuel Pressure Relieving Before disconnecting fuel lines or hoses, relieve pressure from the system by disconnecting the fuel tube/quick connect fitting in the engine compartment. 1. Make sure you have the antitheft code for the radio, then write down the frequencies for the radio's preset buttons. 2. Turn the ignition switch OFF. 3. Remove the glove box, then remove the PGM-FI main relay 2 (A). 4. Start the engine, and let it idle until it is stalls. NOTE: The DTCs or Temporary DTCs P0301, P0302, P0303, P0304 may come on during this procedure. If any DTCs are stored, ignore them. 5. Turn the ignition switch OFF. 6. Remove the fuel fill cap to relieve fuel pressure in the fuel tank. 7. Disconnect the negative cable from the battery. 8. Remove the bolt (A) and the fuel feed pipe mounting bracket (B), then remove the quick-connect fining covers (C). 9. Check the fuel quick-connect fitting for dirt, and clean if necessary. 10. Place a rag or shop towel over the quick-connect fitting (D). Page 827 2. Cut off the wire about an inch back from where it connects to the damaged or faulty terminal, then strip about half of the insulation off that piece. This will be used to size the wire end of the replacement pigtail terminal. NOTE: If you are not sure of the wire size, start with a large enough hole on the stripper that will not nick or cut off any strands of wires. 3. Select a pigtail terminal that matches the original wire at both ends (same kind of terminal and same diameter bare wire). 4. Select the smallest splice connector (yellow, pink, or blue) that will fit onto the stripped end of the original wire. 5. Insert the pigtail terminal into the connector cavity; push it in until it locks in place. 6. Lay the pigtail and the original wire side-by-side, and cut off both ends at once. If you are making more than one splice, do not cut each pigtail at the same location; the resulting "lump" of splice connectors would interfere with rewrapping the harness. Instead, cut the first pigtail close enough to the terminal so you will have room to make each remaining cut about 20 mm (3/4 inch) farther down on the next pigtail. 7. If you are using a yellow splice connector, strip about 6 mm (1/4 inch) of insulation off the ends of both wires. If you are using a pink or blue splice connector, strip off about 8 mm (5/16 inch) of insulation. Page 1819 20. Install the oil pump (A). -1 Install a new crankshaft oil seal in the oil pump. -2 Apply liquid gasket, part No. 08718-0001 or 08718-0003, evenly to the block mating surface of the oil pump and to the inner threads of the bolt holes. -3 Grease the lip of the oil seal and apply oil to the new O-ring (B). -4 Install the dowel pins (C), then align the inner rotor with the crankshaft and install the oil pump. -5 Clean the excess grease off the crankshaft and check the seal for distortion. 21. Install the oil screen (D) with a new gasket (E). 22. Install the oil pan: ^ Aluminum Oil Pan Type. ^ Steel Oil Pan Type. Locations Radiator Cooling Fan Motor Relay: Locations Under-hood Fuse/Relay Box Page 1228 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 Shift Indicator: Diagram Information and Instructions Terminal Numbering System Terminal Numbering System Connector terminals are numbered according to the cavities they're in. The cavities are numbered starting from the upper left, looking at the male terminals from the terminal side or looking at the female terminals from the wire side. Both views are in the same direction so the numbers are the same. All actual cavities are numbered, even if they have no wire terminals in them. NOTE: Data Link Connector (DLC) terminals are numbered according 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 below is #6. Page 7374 ^ Within 1 to 4 seconds, turn the ignition switch to LOCK (0). ^ Within 1 to 4 seconds, turn the ignition to ON (II). ^ Within 1 to 4 seconds, push the transmitter lock or unlock button. ^ Confirm you can hear the sound of the door lock actuators. Within 1 to 4 seconds, push the transmitter lock or unlock button again. ^ Within 10 seconds, aim the transmitters (up to two additional ones) whose codes you want to store at the receiver, and press the transmitter lock or unlock button. Confirm that you can hear the sound of the door lock actuators after each transmitter code is stored. ^ Turn the ignition switch to LOCK (0), and pull out the key. 4. Confirm proper operation of the transmitters. Disclaimer Page 5471 Brake Master Cylinder: Adjustments Brake Booster Pushrod Clearance Adjustment Special Tools Required Pushrod adjustment gauge 07JAG-SD40100 NOTE: Brake booster pushrod-to-piston clearance must be checked and adjustments made, if necessary, before installing the master cylinder. 1. Set the special tool (A) on the master cylinder body (B), push in the center shaft (C) until the top of it contacts the end of the secondary piston (D) by turning the adjusting nut (E). 2. Without disturbing the center shaft's position, install the special tool (A) backwards on the booster. 3. Install the master cylinder nuts (B), and tighten to the specified torque. 4. Connect the booster in-line with a vacuum gauge (C) 0 - 101 kPa (0 - 760 mm Hg, 30 inch Hg) to the booster's engine vacuum supply, and maintain an engine speed that will deliver 66 kPa (500 mm Hg, 20 inch Hg) vacuum. 5. With a feeler gauge (A), measure the clearance between the gauge body and the adjusting nut (B) as shown. If the clearance between the gauge body and the adjusting nut is 0.4 mm (0.02 inch), the pushrod-to-piston clearance is 0 mm. However, if the clearance between the gauge body and the adjusting nut is 0 mm, the pushrod-to-piston clearance is 0.4 mm (0.02 inch) or more. Therefore it must be adjusted and rechecked. Clearance: 0 - 0.4 mm (0 - 0.0015 inch) Page 2495 Power Steering Pressure Switch: Description and Operation Power Steering Pressure (PSP) Switch The PSP switch signals the ECM/PCM when the power steering load is high. Page 6336 - Replace the front damper extension, damper housing, and damper housing extension as an assembly. Installation 1. Set the new damper housing assembly, front wheelhouse, and front bulkhead into position, and measure the front compartment diagonally. Check the body dimensions. 2. Tack weld the clamped position. 3. Temporarily install the front sub-frame, and check the front side frame position. 4. Temporarily install the hood, front fender, headlight, and front bumper, and check for difference in level and clearance. Make sure the body lines flow smoothly. 5. Do the main welding. Page 1071 - Remove clips carefully; don't damage their locks (A). - Slip pliers (A) under the clip base and through the hole at an angle, then squeeze the expansion tabs to release the clip. - After installing harness clips, make sure the harness doesn't interfere with any moving parts. - Keep wire harnesses away from exhaust pipes and other hot parts, from sharp edges of brackets and holes, and from exposed screws and bolts. - Seat grommets in their grooves properly (A). Do not leave grommets distorted (B). Testing and Repairs - Do not use wires or harnesses with broken insulation. Replace them or repair them by wrapping the break with electrical tape. - After installing parts, make sure that no wires are pinched under them. - When using electrical test equipment, follow the manufacturer's instructions and those described. - If possible, insert the probe of the tester from the wire side (except waterproof connector). - Use back probe adaptor 07TAZ-001020A. - Refer to the instructions in the Honda Terminal Kit for identification and replacement of connector terminals. Five-Step Troubleshooting Five-Step Troubleshooting 1. Verify The Complaint Page 5631 13. After completing the right edge, push all of the cam blades to the right until they touch the cams, then trace the cam blades from back to front. (The cutter bit cuts the same contours into the left edge of the key from tip to head.) Turn off the cutter motor. 14. Release the vertical carriage lever. Push all the cam blades to the left until they touch the cams. Pull the vertical carriage lever towards you until the tracer touches the flat surface on the right side, at the front of the cams. Gently twist the lever clockwise to lock the vertical carriage at this height. Do not overtighten the lever. 15. Turn on the cutter motor, then retrace the cam blades from front to back. Push all the cam blades to the right until they touch the cams, and then retrace the cam blades from back to front (retracing cleans up the cuts on the key). Turn off the cutter motor. 16. Release the vertical carriage lever. Open the jaw and remove the key. Make sure the jaw is free of any metal shavings or debris. Turn the key over so the blank side is up, then slide it into the jaw up to the key stop. Close the jaw to lock the key in place. 17. Push all the cam blades to the left until they touch the cams. Repeat steps 10 through 15 to cut both edges on the other side of the key. 18. When you are done making the required cuts, release the vertical carriage lever. Open the jaw and remove the key. 19. Make sure the key works in the ignition switch and the locks. If the key does not work, recut the key, and try it again. 20. Depending on the type of key, code the key transponder. Equipment Service and Warranty To service the MATRIX H Key Cutting Machine, refer to section 7 of the MATRIX H Operating Manual. It tells you how to replace parts that commonly wear out such as the drive belt, the work light bulb, and the tension spring on the vertical carriage. It also covers checking and replacing fuses and replacing the printed circuit board for the setting unit keypad. If you have technical questions on the equipment, contact the Ilco Technical Assistance Department. Mail: Kaba Ilco Technical Assistance Department 400 Jeffreys Road Rocky Mount, NC 27804 Phone: 800-452-6872 Ext: 200, 384, 323, 398, 356 Fax: 252-446-4702 The MATRIX H Key Cutting Machine comes with a 3-year limited warranty. This warranty does not cover the cutter bit or the work light bulb. CODE BOOK CORRECTIONS In the code book Honda High Security key Codes, correct these errors: Pages 4 thru 51, code headings: ^ Incorrect: J H G F Z X E D C B M/S X ^ Correct: J H G F A X E D C B M/S X Page 2, last paragraph: Page 7918 - Replace any damaged clips. - Push the clips into place securely. Page 9095 1. Remove the secondary locks. 2. Remove the terminal from the female half. 3. Remove the terminal from the male half. 4. Go to HOW TO INSTALL NEW TERMINALS. Connectors Without a Secondary Lock All examples are shown with the connector lock facing up. The illustrations are examples of connector terminals without a secondary lock; however, the connector you are repairing may vary in size and shape. EXAMPLE A: Page 5969 Under-hood Fuse/Relay Box (2-door) Page 8526 138. Rear Of Roof (EX) Page 3947 details, refer to the MVCI User Guide on ISIS. The Database Update version appears when you select Reprogramming, then press ENTER. 1. Connect the DLC cable to the MVCI and to the vehicle's DLC. 2. Turn the ignition switch to ON (II). The MVCI automatically boots up. 3. Press the ENTER button on the MVCI to see the User Config menu. Select CM Update Mode. 4. Select Reprogramming, then press ENTER. NOTE: Use these MVCI default settings: Setting 1Destination: USA Language: American English Setting 2 - Auto Detect: Yes Continuous Mode: No For more information on these settings, refer to the MVCI User Guide. 5. The CM Update software information appears. Press ENTER to continue. Page 8062 2. Disconnect the 2P connector from the actuator. 3. Check actuator operation by connecting power and ground according to the table. To prevent damage to the actuator, apply battery voltage only momentarily. 4. If the actuator does not operate as specified, replace it. Page 9747 4. Disconnect the 20P connector and make these input tests. 5. Reconnect the connector to the power window master switch and make these input tests. 2-door NOTE: The power window control unit is built into the power window master switch, and it only controls the driver's window operations. 1. Remove the door grip cover. Page 7854 1. Check the depth adjustment of the trunk lid: ^ Refer to page 20-132 of the 2001-04 Civic Service Manual. ^ In ISIS, use the keyword TRUNK ADJUST, and select Trunk Lid Adjustment from the list. 2. Make sure the trunk lid is flush on all sides and corners. ^ If the trunk is misaligned, go to step 3. ^ If the trunk lid is properly aligned on all sides and corners, go to REPAIR PROCEDURE C. 3. Adjust the striker depth position and the trunk lid edge cushions: ^ Refer to page 20-132 of the 2001-04 Civic Service Manual. ^ In ISIS, use the keyword TRUNK ADJUST, and select Trunk Lid Adjustment from the list. 4. Check the trunk operation: ^ If the trunk opens and closes smoothly, return the vehicle to the customer. ^ If the trunk lid is still difficult to close, go to REPAIR PROCEDURE C. REPAIR PROCEDURE C 1. Use a small screwdriver to manually set and release the trunk lid latch. Check the operation of the latch: ^ If the latch is difficult to set or release, go to step 2. ^ If the latch operates properly, go to REPAIR PROCEDURE D. 2. Replace the trunk lid latch: ^ Refer to page 20-157 of the 2001-04 Civic Service Manual. ^ In ISIS, use the keyword LID LATCH, and select Trunk Lid Latch Replacement from the list. 3. Check the trunk operation: ^ If the trunk opens and closes smoothly, return the vehicle to the customer. ^ If the trunk lid is still difficult to close, go to REPAIR PROCEDURE D. REPAIR PROCEDURE D 1. Disconnect the trunk lid opener cable from the trunk lid latch. Check the cable operation: ^ Refer to page 20-157 of the 2001-04 Civic Service Manual. ^ In ISIS, use the keyword LID LATCH, and select Trunk Lid Latch Replacement from the list. 2. Check that there is no friction or binding of the cable by holding the outside casing and pulling back and forth on the inner cable: ^ If the cable is difficult to move or binds, go to step 3. ^ If the cable operates smoothly, go to REPAIR PROCEDURE E. 3. Replace the trunk lid opener cable: ^ Refer to page 20-151 of the 2001-04 Civic Service Manual. ^ In ISIS, use the keyword LID OPEN, and select Trunk Lid Opener/Fuel Fill Door Opener Cable Replacement from the list. 4. Check the trunk operation: Page 6788 7. Remove the column cover screws (A), then remove the column covers (B, C). 8. Disconnect the dashboard wire harness B 4P connector (A) from the cable reel 4P connector (B), then disconnect the dashboard wire harness B 5P connector (C) from the cable reel (D). 9. Release the tab (A), then remove the cable reel from the column. Installation 1. Before installing the steering wheel, align the front wheels straight ahead. 2. Disconnect the battery negative cable, and wait at least 3 minutes. Page 2845 Connector Views: Connector terminal views (references to VIEWS) referred to within these diagrams can be found at Connector Views by View Number. See: Diagrams/Connector Views/Connector Views By View Number Circuit Diagram - Multiplex Control System (Part 1 Of 2) Page 3417 Fuel Line Coupler: Service Precautions Fuel Line/Quick-Connect Fitting Precaution The fuel line/quick-connect fittings connect the fuel rail (A) to fuel feed line (B), the fuel feed line (B) to the fuel pipe (C), and the fuel line (D) to the fuel tank unit (E). When removing or installing the fuel feed hose, fuel tank unit or fuel tank, it is necessary to disconnect or connect the quick-connect fittings. Pay attention to the following: - The fuel feed hose (B), fuel line (D), and quick-connect fittings (E) are not heat-resistant; be careful not to damage them during welding or other heat-generating procedures. - The fuel feed hose (B), fuel line (D), and quick-connect fittings (E) are not acid-proof; do not touch them with a shop towel used for wiping battery electrolyte. Replace them if they came into contact with electrolyte or something similar. - When connecting or disconnecting the fuel feed hose (B), fuel line (D), and quick-connect fittings (E), be careful not to bend or twist them excessively. Replace them if they are damaged. A disconnected quick-connect fitting can be reconnected, but the retainer on the mating line cannot be reused once it has been removed from the line. Page 6526 PGM-F1 Main Relay 1, 2 Type 1, 2 Check for continuity between the terminals. - There should be continuity between the No.1 and No.2 terminals when power and ground are connected to the No.3 and No.4 terminals. - There should be no continuity between the No.1 and No.2 terminals when power is disconnected. Normally-open type B: Rear Window Defogger Relay Page 3071 Intake Air Temperature Sensor: Service and Repair IAT Sensor Replacement 1. Disconnect the IAT sensor 2P connector. 2. Remove the IAT sensor (A). 3. Install the sensor in the reverse order of removal Page 7709 WARRANTY CLAIM INFORMATION In warranty: The normal warranty applies. Failed Part: P/N 68500-S5P-A90ZZ H/C 6528640 *Defect Code: 07406* Symptom Code: 03220 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 A 1. Check the side-to-side alignment of the trunk lid latch to the striker: ^ Refer to page 20-132 of the 2001-04 Civic Service Manual. ^ In ISIS, use the keyword TRUNK ADJUST, and select Trunk Lid Adjustment from the list. 2. Make sure the gaps of the trunk lid are even on all sides. ^ If the trunk is misaligned, go to step 3. ^ If the trunk lid is properly aligned on all sides, go to REPAIR PROCEDURE B. 3. Adjust the trunk lid hinges: ^ Refer to page 20-132 of the 2001-04 Civic Service Manual. ^ In ISIS, use the keyword TRUNK ADJUST, and select Trunk Lid Adjustment from the list. 4. Check the trunk operation: ^ If the trunk opens and closes smoothly and is properly aligned, return the vehicle to the customer. ^ If the trunk lid is still difficult to close, go to REPAIR PROCEDURE B. REPAIR PROCEDURE B Page 9002 Wires Page 6049 Air Conditioning Component Location Index Page 2561 Vehicle Speed Sensor: Locations Gauges Component Location Index (Part 1 Of 4) Page 1679 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. Circuits must be operating when checking voltage drop. 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. 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 off, 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 Self-Powered Test Light or DVOM 1. Remove the blown fuse and disconnect the battery and load. Page 2897 Manifold Pressure/Vacuum Sensor: Service and Repair MAP Sensor Replacement 1. Disconnect the MAP sensor 3P connector. 2. Remove the MAP sensor (A). 3. Install the sensor in the reverse order of removal with a new O-ring (B). Page 7373 1. Remove the driver's dashboard lower cover. (See the body section of the appropriate service manual.) 2. Replace the security control unit. ^ Civic: Remove the security control unit, and install the new security control unit. ^ * CR-V and Element: Remove the security control unit and microphone. Install the new security control unit and new microphone.* 3. Reprogram the keyless receiver unit. NOTE: The codes of up to three transmitters can be stored in the keyless receiver unit memory. If a fourth code is stored, the code that was input first will be erased. It is important to maintain the time limits between the steps. Make sure the doors and the trunk/tailgate/hatch are closed, and that you have all of the remotes the customer wishes to use. ^ Turn the ignition switch to ON (II). ^ Within 1 to 4 seconds, push the transmitter lock or unlock button. ^ Within 1 to 4 seconds, turn the ignition switch to LOCK (0). ^ Within 1 to 4 seconds, turn the ignition to ON (II). ^ Within 1 to 4 seconds, push the transmitter lock or unlock button. ^ Within 1 to 4 seconds, turn the ignition switch to LOCK (0). ^ Within 1 to 4 seconds, turn the ignition switch to ON (II). ^ Within 1 to 4 seconds, push the transmitter lock or unlock button. Page 5688 Starter Motor: Testing and Inspection Starter Performance Test 1. Disconnect the wires from the S terminal and the M terminal. 2. Make the connections as described using as heavy a wire as possible (preferably equivalent to the wire used for the vehicle). To avoid damaging the starter, never leave the battery connected for more than 10 seconds. 3. Connect the battery as shown. Be sure to disconnect the starter motor wire from the solenoid. If the starter pinion moves out, it is working properly. 4. Disconnect the battery from the M terminal. If the pinion does not retract, the hold-in coil of the solenoid is working properly. 5. Disconnect the battery from the starter body. If the pinion retracts immediately, it is working properly. 6. Clamp the starter firmly in a vise. Front Impact Sensor Impact Sensor: Service and Repair Front Impact Sensor Front Impact Sensor Replacement Removal NOTE: - Removal of the front sensor must be performed according to the precautions/procedures described before. - Before disconnecting the front sensor 2P connector(s), disconnect the driver's and front passenger's airbag 2P, both seat belt tensioner 2P and both seat belt buckle tensioner 2P connector(s). - Do not turn the ignition switch ON (II), and do not connect the battery cable while replacing the side impact sensor. 1. Disconnect the battery negative cable, and wait at least 3 minutes before beginning work. 2. Remove the front inner fender. 3. Disconnect the engine compartment wire harness 2P connector (A), and remove the two Torx bolts (B) using a Torx T30 bit, then remove the front impact sensor(C). Installation NOTE: - Be sure to install the harness wires so that they are not pinched or interfering with other parts. - Do not turn the ignition switch ON (II), and do not connect the battery cable while replacing the side impact sensor. 1. Install the new front impact sensor with new Torx bolts (A), then connect the engine compartment wire harness 2P connector (B) to the front sensor (C). 2. Reconnect the battery negative cable. 3. After installing the front impact sensor, confirm proper system operation: Turn the ignition switch ON (II): the SRS indicator should come on for about 6 seconds and then go off. Page 4309 23. Transmission Housing (A/T) Page 3061 Fuel Tank Pressure Sensor: Locations EVAP System - Component Location Index Page 6881 Seat Occupant Sensor: Description and Operation OPDS (Occupant Position Detection System) The side airbag system also includes an Occupant Position Detection System (OPDS). This system consists of Sensors (G) and a OPDS Unit (H) in the front passenger's seat-back. The OPDS unit sends occupant height and position data to the SRS unit. If the SRS unit determines that the front passenger is of small stature (for example, a child) and the front passenger is leaning into the side airbag deployment path, it will automatically disable the airbag. The SRS unit will also disable the airbag when the OPDS detects certain objects on the seat. Side Airbag Cutoff Indicator When the side airbag is disabled, the Side Airbag Cutoff Indicator on the instrument panel alerts the driver that the passenger's side airbag will not deploy in a side impact. When the object is removed, or the passenger sits upright, the Side Airbag Cutoff indicator will go off, alerting the driver that the side airbag will deploy in a side impact. Page 2411 159. Left Side Of Engine Compartment Page 3692 Splices Components Ground - "G" Locations 94. Behind Glove Box (except GX) Page 5011 Transmission Speed Sensor: Locations 22. Transmission Housing (A/T Except CVT) 19. Transmission Housing (A/T Except CVT) Starting System - Starter Grinds While Engine Cranks Starter Cable: All Technical Service Bulletins Starting System - Starter Grinds While Engine Cranks 06-025 May 18, 2006 Applies To: 2001-05 Civic 2-door - ALL except CVI 2001-05 Civic 4-door - ALL except Hybrid and GX Starter Grinds While Cranking the Engine SYMPTOM The starter motor intermittently grinds while cranking the engine. PROBABLE CAUSE The female terminal at the starter solenoid may have spread apart, causing a loss of current to the solenoid. CORRECTIVE ACTION Replace the female terminal at the starter solenoid. PARTS INFORMATION Spade Receiver Terminal: P/N 07JAZ-001420A, H/C 8362675 TOOL INFORMATION Terminal Crimping Tool: T/N 07JAZ-001020A WARRANTY CLAIM INFORMATION In warranty: The normal warranty applies. Operation Number: 7370C3 Flat Rate Time: 0.4 hour Failed Part: P/N 31200-PLM-A51 H/C 6452429 Defect Code: 06601 Symptom Code: 09004 Template ID: 06-025A 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. DIAGNOSIS 1. If applicable, make sure you have the anti-theft code for the audio system. Write down the customer's audio unit presets. 2. Disconnect the negative cable from the battery, then disconnect the positive cable. 3. Remove the resonator: Page 6228 6. Disconnect both seat belt buckle tensioner 4P connectors (A). Page 183 1. Remove the terminal. 2. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE G: 1. Remove the terminal. 2. Go to HOW TO INSTALL NEW TERMINALS. How to Install New Terminals HOW TO INSTALL NEW TERMINALS 1. Carefully match the old terminal with a new one from the terminal repair kit. Choose the correct replacement terminal based on the wire size range the terminal will accommodate. NOTE: If the replacement terminal quantities are low, reorder them by using the terminal part number listed on the inside lid of the terminal repair kit. Replacement terminals are available through your parts department using normal parts ordering procedures. 2. Depending on the size of the wire you are repairing, use the proper size slot in the crimping tool. Page 1339 Timing Belt: Service and Repair Removal Special Tools Required Holder handle 07JAB-001020A - Holder attachment, 50 mm, offset 07MAB-PY3010A - Socket, 19 mm 07JAA-001020A or a commercially-available 19 mm socket 1. Make sure you have the anti-theft code for the radio, then write down the frequencies for the radio's preset buttons. 2. Disconnect the battery negative terminal. 3. Turn the crankshaft pulley so its Top Dead Center (TDC) mark (A) lines up with the pointers (B). 4. Remove the front tires/wheels. 5. Remove the splash shield. 6. Remove the adjust plate mounting bolt (A), locknut (B) and mounting bolt (C), then remove the power steering (P/S) pump belt (D) and pump Page 9538 Turn Signal Relay: Testing and Inspection Turn Signal/Hazard Relay Input Test 1. Remove the turn signal/hazard relay (A) from the under-dash fuse/relay box (B). 2. Inspect the relay and fuse/relay box socket terminals to be sure they are all making good contact. - If the terminals are bent, loose, or corroded, repair them as necessary, and recheck the system. - If the terminals look OK, go to step 3. 3. Make these input tests at the fuse/relay box. - If any test indicates a problem, find and correct the cause, then recheck the system. - If all the input tests prove OK, the turn signal/hazard relay must be faulty; replace it. Page 1908 4. Remove the valve seal. Page 5122 - Before connecting connectors, make sure the terminals (A) are in place and not bent. - Check for loose retainer (A) and rubber seals (B). - The backs of some connectors are packed with dielectric grease. Add grease if necessary. If the grease is contaminated, replace it. - Insert the connector all the way and make sure it is securely locked. - Position wires so that the open end of the cover faces down. Handling Wires and Harnesses - Secure wires and wire harnesses to the frame with their respective wire ties at the designated locations. Page 4824 Flat Rate Time: 4.0 hours Failed Part: P/N 24230-PLW-000 H/C 6568653 Defect Code: 042 Contention Code: B07 Template ID: 03-009A (DX, LX, EX) 03-009B (HX) 03-009C (Hybrid) 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. * Remove the transmission. See page 13-4 of the 2001-2003 Civic Service Manual; for the Hybrid, see page 13-18. Then remove the housing. See page 13-16 of the 2001-2003 Civic Service Manual; for the Hybrid, see page 13-32.* 2. * Remove the reverse idler shaft and the reverse idler gear; discard the gear. See page 13-17 (13-32 for Hybrid) of the service manual.* Rocker Arms and Shaft Inspection Rocker Arm Assembly: Testing and Inspection Rocker Arms and Shaft Inspection Inspection 1. Measure the diameter of the shaft at the first rocker location. 2. Zero the gauge (A) to the shaft diameter. 3. Measure the inside diameter of the rocker arm, and check it for an out-of-round condition. Rocker Arm-to-Shaft Clearance: Standard (New): Intake: 0.017 - 0.050 mm (0.0007 - 0.0020 inch) Exhaust: 0.018 - 0.054 mm (0.0007 - 0.0021 inch) Service Limit: 0.08 mm (0.003 inch) 4. Repeat for all rockers and both shafts. If the clearance is over the limit, replace the rocker shaft and all over tolerance rocker arms. If any VTEC intake rocker arm needs replacement, replace both rocker arms in that set (primary and secondary). Page 9537 Turn Signal/Hazard Flasher - Component Location Index Page 9751 1. Remove the screw and passenger's power window switch (A) from the door panel. 2. Disconnect the 5P connector (B) from the switch. 3. Check for continuity between the terminals in each switch position according to the table. 4. If the continuity is not as specified remove the two screws and replace the switch. Page 6023 Under-dash Fuse/Relay Box (4-door) Service and Repair Condenser HVAC: Service and Repair Condenser Replacement 1. Recover the refrigerant with a recovery/recycling/charging station. 2. Remove the front bumper. 3. Remove the bolts, then disconnect the discharge line (A) and the condenser line (B) from the condenser. Plug or cap the lines immediately after disconnecting them to avoid moisture and dust contamination. 4. Remove the mounting bolts, then remove the condenser by lifting it up. Be careful not to damage the radiator or the condenser fins when removing the condenser. 5. Install the condenser in the reverse order of removal, and note these items. - If you're installing a new condenser, add refrigerant oil (SANDEN SP-10). Page 251 Relay Box: Service and Repair Removal and Installation SRS components are located in this area. Review the SRS component locations and precautions and procedures in the SRS section before performing repairs or service. Removal 1. Make sure you have the anti-theft code for the radio, then write down the frequencies for the radio's preset buttons. 2. Disconnect the battery negative cable, then disconnect the positive cable, and wait at least 3 minutes. 3. Remove the dashboard lower cover. 4. Disconnect the connectors from the fuse side of the under-dash fuse/relay box. 5. Remove the mounting bolt and slide the under-dash fuse/relay box (A) down from the bracket (B). 6. Disconnect the connectors from the back side of the under-dash fuse/relay box, and remove the fuse/relay box. NOTE: The SRS connector is a spring-loaded lock type. Installation 1. Install the under-dash fuse/relay box in the reverse order of removal and connect all connectors to the under-dash fuse/relay box. 2. Install the dashboard lower cover. 3. Connect both the negative cable and positive cable to the battery. 4. Enter the anti-theft code for the radio, then enter the customer's radio station presets. 5. Confirm that all systems work properly. 6. Do the ECM/PCM idle learn procedure. Page 5934 Auxiliary Power Outlet: Electrical Diagrams Diagram 155 Diagrams: Other diagrams referred to by number (See Diagram ##-#, etc.)within these diagrams can be found at Diagrams by Number. See: Diagrams/Electrical Diagrams/Diagrams By Number Locations: Location photographs (references to PHOTOS) referred to within these diagrams can be found at Locations by Photo Number. See: Locations/Component Locations/Locations By Photo Number Connector Views: Connector terminal views (references to VIEWS) referred to within these diagrams can be found at Connector Views by View Number. See: Diagrams/Connector Views/Connector Views By View Number Page 8028 13. After completing the right edge, push all of the cam blades to the right until they touch the cams, then trace the cam blades from back to front. (The cutter bit cuts the same contours into the left edge of the key from tip to head.) Turn off the cutter motor. 14. Release the vertical carriage lever. Push all the cam blades to the left until they touch the cams. Pull the vertical carriage lever towards you until the tracer touches the flat surface on the right side, at the front of the cams. Gently twist the lever clockwise to lock the vertical carriage at this height. Do not overtighten the lever. 15. Turn on the cutter motor, then retrace the cam blades from front to back. Push all the cam blades to the right until they touch the cams, and then retrace the cam blades from back to front (retracing cleans up the cuts on the key). Turn off the cutter motor. 16. Release the vertical carriage lever. Open the jaw and remove the key. Make sure the jaw is free of any metal shavings or debris. Turn the key over so the blank side is up, then slide it into the jaw up to the key stop. Close the jaw to lock the key in place. 17. Push all the cam blades to the left until they touch the cams. Repeat steps 10 through 15 to cut both edges on the other side of the key. 18. When you are done making the required cuts, release the vertical carriage lever. Open the jaw and remove the key. 19. Make sure the key works in the ignition switch and the locks. If the key does not work, recut the key, and try it again. 20. Depending on the type of key, code the key transponder. Equipment Service and Warranty To service the MATRIX H Key Cutting Machine, refer to section 7 of the MATRIX H Operating Manual. It tells you how to replace parts that commonly wear out such as the drive belt, the work light bulb, and the tension spring on the vertical carriage. It also covers checking and replacing fuses and replacing the printed circuit board for the setting unit keypad. If you have technical questions on the equipment, contact the Ilco Technical Assistance Department. Mail: Kaba Ilco Technical Assistance Department 400 Jeffreys Road Rocky Mount, NC 27804 Phone: 800-452-6872 Ext: 200, 384, 323, 398, 356 Fax: 252-446-4702 The MATRIX H Key Cutting Machine comes with a 3-year limited warranty. This warranty does not cover the cutter bit or the work light bulb. CODE BOOK CORRECTIONS In the code book Honda High Security key Codes, correct these errors: Pages 4 thru 51, code headings: ^ Incorrect: J H G F Z X E D C B M/S X ^ Correct: J H G F A X E D C B M/S X Page 2, last paragraph: Locations Relay And Control Unit Locations - Engine Compartment Page 750 Knock Sensor: Description and Operation Knock Sensor The knock control system adjusts the ignition timing to minimize knock. Page 1530 Wiper/Washer Component Location Index Specifications Page 713 REPAIR PROCEDURE 1. Make sure you have the anti-theft code for the audio unit. Write down the customer's audio presets. 2. Disconnect the negative battery cable from the battery. 3. Remove the under-hood fuse/relay box cover. 4. Release the three clips, and remove the under- hood fuse/relay box from the holder. CR-V only: Release the wire harness clip from the fuse/relay box holder Page 8124 1991-93 Accord 5-door EX with factory-installed keyless entry or dealer-installed security system Programming the Transmitter The transmitter is not programmable. Ordering a Transmitter Transmitters can be ordered only by authorized Honda dealers. To order a transmitter, you need the vehicle's VIN, the code number from the power door lock control unit, and the ignition key code number. The power door lock code number is a five-digit number etched into the plastic case of the control unit (mounted under the driver's seat). The ignition key code number is a four-digit number stamped on the metal shank of all five original keys delivered with the car. Replacement transmitters are manufactured to match the code of the keyless entry system. The new ignition key is cut to match the vehicle's ignition switch, front door locks, tailgate lock, and glove compartment lock. To order this transmitter, use the controlled parts ordering screen on the iN system. The transmitters are manufactured in Japan; delivery takes 4 to 6 weeks. Batteries for the Transmitter The battery is not replaceable. 91-93 Accord 5-Door LX 1991-93 Accord 5-door LX with dealer-installed security system Programming the Transmitter This transmitter is not programmable. Ordering a Transmitter Transmitters can be ordered directly from Kenwood USA only by authorized Honda dealers. Send a completed order form (copy it from the Accessory Replacement Parts section of the Dealer Parts Price List) along with a dealer check for $30.00 (payable to Kenwood U.S.A. Corp.) to this address: Kenwood Service Corp. P.O. Box 22745 Long Beach, CA 90501-5745 Page 3715 1. Remove the terminal. 2. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE G: 1. Remove the terminal. 2. Go to HOW TO INSTALL NEW TERMINALS. How to Install New Terminals HOW TO INSTALL NEW TERMINALS 1. Carefully match the old terminal with a new one from the terminal repair kit. Choose the correct replacement terminal based on the wire size range the terminal will accommodate. NOTE: If the replacement terminal quantities are low, reorder them by using the terminal part number listed on the inside lid of the terminal repair kit. Replacement terminals are available through your parts department using normal parts ordering procedures. 2. Depending on the size of the wire you are repairing, use the proper size slot in the crimping tool. Page 4202 Wire Color Abbreviations Page 6355 3. Position the damper bottom on the knuckle, and install the damper pinch bolts (A) and nuts (B), and lightly tighten the nuts. 4. Place the floor jack under the lower arm ball joint, and raise the suspension to load it with the vehicle's weight. NOTICE: Do not place the jack against the flat section of the lower arm. Lifting the arm in this area might bend it. 5. Tighten the flange nuts on the top of the damper to the specified torque. 6. Tighten the damper pinch nuts to the specified torque. 7. Connect the tie-rod end to the steering arm, and tighten the nut (A) to the specified torque. Install the cotter pin (B) after tightening, and bend its end as shown. 8. Install the brake hose bracket and the flange bolt onto the damper, and tighten the bolt to the specified torque. 9. Clean the mating surface of the brake disc and the inside of the wheel, then install the front wheels. 10. Check the wheel alignment, and adjust it if necessary. Page 6392 3. Remove the brake hose bracket mounting bolt (A). 4. Remove the caliper bracket mounting bolts (B), and remove the caliper assembly (C) from the knuckle. To prevent damage to the caliper assembly or brake hose, use a short piece of wire to hang the caliper assembly from the undercarriage. Do not twist the brake hose with force. 5. Raise the stake (A), and remove the spindle nut (B), then remove and discard the nut. 6. Remove the brake disc retaining flat screws (A). 7. Screw two 8 x 1.25 mm bolts (B) into the disc to push it away from the hub. Turn each bolt 2 turns at a time to prevent cocking the disc excessively. Page 6050 Exterior Lights Component Location Index Page 3958 Two updating modes can be used with the HIM: Pass-Thru mode and Storage mode. Pass-Thru mode is used when the HIM can be connected to an iN workstation and the vehicle at the same time. Storage mode is used when the HIM cannot be connected to the iN workstation and the vehicle at the same time. HIM Updating in Pass-Thru Mode NOTE: If the red No.3 LED on the HIM comes on or flashes during the update, go to Diagnosing HIM Error Codes. 1. If not already done, load the latest HDS PC software onto your iN workstation. For loading instructions, refer to the Tool Information publication Installation Instructions for HDS PC Software on ISIS. NOTE: If the latest software is not loaded and you do a control unit/module update, the software may indicate the vehicle has the latest update when it doesn't. Updates not done with the latest software are not covered under warranty. 2. From the iN workstation desktop, select CM Update (ECU Rewrite). 3. Connect the PC interface cable to the iN workstation and to the HIM. 4. Return to the Updating Honda Control Modules main screen, and click on Pass-thru-Mode. 5. Connect the HIM to the vehicle's DLC. 6. Turn the ignition switch to ON (II), and wait until the green No.1 LED on the HIM stays on. Click on the check mark to continue. Each updatable vehicle system is checked to make sure it is current. Any systems needing an update are listed on the screen. Highlight the system you want to update, then click on the check mark to continue. Page 8203 - There should be no continuity when the LOCKED position. 5. If the continuity is not as specified, replace the door lock actuator. Page 1601 32. Reinstall PGM-FI main relay 2 (A). 33. Check for continuity between fuel pump 5P connector terminal No.5 and body ground. Is there continuity? YES - Replace PGM-FI main relay 2. Also replace the No.17 FUEL PUMP (15A) fuse. NO - Check the fuel pump, and replace it as necessary. Also replace the No.17 FUEL PUMP (15A) fuse. 34. Disconnect ECM/PCM connector E (31P). 35. Turn the ignition switch ON (II). 36. Measure voltage between ECM/PCM connector terminals E9 and body ground. Is there battery voltage? YES - Go to step 37. NO - Repair open in the wire between the No.17 FUEL PUMP (15A) fuse and the ECM/PCM (E9). 37. Turn the ignition switch OFF. Page 8057 ^ Incorrect: "If a Master Key is to be cut, put a five (5) in the blank space. Use a two (2) if a valet key is needed." ^ Correct: "If a Master Key is to be cut, put an M in the blank space. Use an S if a valet key is needed." Page 2, legend at the bottom: ^ Incorrect: "C. If a Master key is desired, then the number five (5) should be placed in the M/S position. Place the number two (2) in the M/S column if a Sub (Valet) key is needed." ^ Correct: "C. If a Master Key is desired, then an M should be placed in the M/S position. Place an S in the MIS column if a Sub (Valet) key is needed." Page 6838 7. From the Mode menu, select Miscellaneous Test. 8. From the Miscellaneous Test menu, select OPDS Initialization. 9. Follow the remaining screen prompts to complete the OPDS initialization. If the initialization fails repeat the process two more times. If the initialization fails again, check for SRS DTCs, then troubleshoot them using the appropriate service manual. Initializing the OPDS Unit: Manual Mode NOTE: Non-Honda seat covers will interfere with the performance of the OPDS and are not recommended. 1. Adjust the front passenger's seat-back to an upright position, then remove anything on or near the seat. 2. Turn the ignition switch to LOCK (0). 3. Connect the HDS to the vehicle's DLC (data link connector). 4. Keep the ignition switch at LOCK (0), and turn on the HDS. 5. At the screen prompts, enter the VIN and the odometer reading. 6. From the Select Mode screen, select SCS, and follow the screen prompts. Page 7722 6. Disconnect the trunk lid opener cable (A) from the trunk lid latch (B). 7. Using a clip remover, detach the clip (C) from the trunk lid, and detach the clips (D) from the trunk lid hinge. 8. Remove the trunk lid opener/fuel fill door opener cable from the vehicle. Take care not to kink the cable. 9. Install the cable in the reverse order of removal, and note these items: - Align the alignment mark of the cable to the clip on the bottom portion of the trunk lid hinge. - Replace any damaged clips. Page 9147 1. Remove the terminal. 2. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE E: 1. Remove the terminal. 2. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE F: Page 7697 1. Check the depth adjustment of the trunk lid: ^ Refer to page 20-132 of the 2001-04 Civic Service Manual. ^ In ISIS, use the keyword TRUNK ADJUST, and select Trunk Lid Adjustment from the list. 2. Make sure the trunk lid is flush on all sides and corners. ^ If the trunk is misaligned, go to step 3. ^ If the trunk lid is properly aligned on all sides and corners, go to REPAIR PROCEDURE C. 3. Adjust the striker depth position and the trunk lid edge cushions: ^ Refer to page 20-132 of the 2001-04 Civic Service Manual. ^ In ISIS, use the keyword TRUNK ADJUST, and select Trunk Lid Adjustment from the list. 4. Check the trunk operation: ^ If the trunk opens and closes smoothly, return the vehicle to the customer. ^ If the trunk lid is still difficult to close, go to REPAIR PROCEDURE C. REPAIR PROCEDURE C 1. Use a small screwdriver to manually set and release the trunk lid latch. Check the operation of the latch: ^ If the latch is difficult to set or release, go to step 2. ^ If the latch operates properly, go to REPAIR PROCEDURE D. 2. Replace the trunk lid latch: ^ Refer to page 20-157 of the 2001-04 Civic Service Manual. ^ In ISIS, use the keyword LID LATCH, and select Trunk Lid Latch Replacement from the list. 3. Check the trunk operation: ^ If the trunk opens and closes smoothly, return the vehicle to the customer. ^ If the trunk lid is still difficult to close, go to REPAIR PROCEDURE D. REPAIR PROCEDURE D 1. Disconnect the trunk lid opener cable from the trunk lid latch. Check the cable operation: ^ Refer to page 20-157 of the 2001-04 Civic Service Manual. ^ In ISIS, use the keyword LID LATCH, and select Trunk Lid Latch Replacement from the list. 2. Check that there is no friction or binding of the cable by holding the outside casing and pulling back and forth on the inner cable: ^ If the cable is difficult to move or binds, go to step 3. ^ If the cable operates smoothly, go to REPAIR PROCEDURE E. 3. Replace the trunk lid opener cable: ^ Refer to page 20-151 of the 2001-04 Civic Service Manual. ^ In ISIS, use the keyword LID OPEN, and select Trunk Lid Opener/Fuel Fill Door Opener Cable Replacement from the list. 4. Check the trunk operation: Page 3082 36. Left Side Of Engine Compartment (except GX) Locations Body Control Systems: Locations Relay And Control Unit Locations - Dashboard Page 6590 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. Primary Oxygen Sensor Oxygen Sensor: Description and Operation Primary Oxygen Sensor Primary Heated Oxygen Sensor (Primary HO2S) (D17A1, D17A2 engines) The primary HO2S detects the oxygen content in the exhaust gas and sends signals to the ECM/PCM which varies the duration of fuel injection accordingly. To stabilize its output, the sensor has an internal heater. The primary HO2S is installed in the three way catalytic converter (TWC) (D17A1 engine) or in the exhaust manifold (D17A2 engine). By controlling the air fuel ratio with primary HO2S and secondary HO2S, the deterioration of the primary HO2S can be evaluated by its feedback period. When the feedback period exceeds a certain value during stable driving conditions, the sensor is considered deteriorated and the ECM/PCM sets a DTC. Page 775 Oxygen Sensor: Service and Repair Secondary HO2S Replacement Secondary HO2S Replacement Special Tools Required O2 sensor wrench, Snap-on YA8875, SP Tools 93750, or equivalent, commercially available NOTE: The secondary HO2S and the third HO2S must be replaced together (D17A6 engine except '01 model) 1. Disconnect the secondary HO2S 4P connector (A), then remove the secondary HO2S (B). 2. Install the secondary HO2S in the reverse order of removal. Locations 94. Behind Glove Box (except GX) Page 5371 - Remove clips carefully; don't damage their locks (A). - Slip pliers (A) under the clip base and through the hole at an angle, then squeeze the expansion tabs to release the clip. - After installing harness clips, make sure the harness doesn't interfere with any moving parts. - Keep wire harnesses away from exhaust pipes and other hot parts, from sharp edges of brackets and holes, and from exposed screws and bolts. - Seat grommets in their grooves properly (A). Do not leave grommets distorted (B). Testing and Repairs - Do not use wires or harnesses with broken insulation. Replace them or repair them by wrapping the break with electrical tape. - After installing parts, make sure that no wires are pinched under them. - When using electrical test equipment, follow the manufacturer's instructions and those described. - If possible, insert the probe of the tester from the wire side (except waterproof connector). - Use back probe adaptor 07TAZ-001020A. - Refer to the instructions in the Honda Terminal Kit for identification and replacement of connector terminals. Five-Step Troubleshooting Five-Step Troubleshooting 1. Verify The Complaint Page 952 Page 9660 2. Insert the terminal tool into the female terminal, and then remove the terminal tool. NOTE: Make sure you do not select a terminal tool that is larger than the mating male terminal because it would spread the female terminal and cause a loose fit. 3. Compare the drag to the other terminals in the connector. If the drag is less, replace the terminal with a replacement terminal from the appropriate terminal repair kit. Page 626 Parking Brake Warning Switch: Testing and Inspection Parking Brake Switch Test 1. Remove the console, and disconnect the connector (A) from the switch (B). 2. Check for continuity between the positive terminal and body ground: ^ With the brake lever up, there should be continuity. ^ With the brake lever down, there should be no continuity. Page 4231 2. Cut off the wire about an inch back from where it connects to the damaged or faulty terminal, then strip about half of the insulation off that piece. This will be used to size the wire end of the replacement pigtail terminal. NOTE: If you are not sure of the wire size, start with a large enough hole on the stripper that will not nick or cut off any strands of wires. 3. Select a pigtail terminal that matches the original wire at both ends (same kind of terminal and same diameter bare wire). 4. Select the smallest splice connector (yellow, pink, or blue) that will fit onto the stripped end of the original wire. 5. Insert the pigtail terminal into the connector cavity; push it in until it locks in place. 6. Lay the pigtail and the original wire side-by-side, and cut off both ends at once. If you are making more than one splice, do not cut each pigtail at the same location; the resulting "lump" of splice connectors would interfere with rewrapping the harness. Instead, cut the first pigtail close enough to the terminal so you will have room to make each remaining cut about 20 mm (3/4 inch) farther down on the next pigtail. 7. If you are using a yellow splice connector, strip about 6 mm (1/4 inch) of insulation off the ends of both wires. If you are using a pink or blue splice connector, strip off about 8 mm (5/16 inch) of insulation. Page 872 124. CMP (TDC) Sensor Page 5923 1. Remove the secondary locks. 2. Remove the terminal from the female half. 3. Remove the terminal from the male half. 4. Go to HOW TO INSTALL NEW TERMINALS. Connectors Without a Secondary Lock All examples are shown with the connector lock facing up. The illustrations are examples of connector terminals without a secondary lock; however, the connector you are repairing may vary in size and shape. EXAMPLE A: Page 3050 5. Remove the lower cover from the fuse/relay box. 6. Disconnect the 3P ELD connector. 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. Locations 77. Under Middle Of Dash Page 956 Seat Occupant Sensor: Locations SRS Component Location Index Page 2655 Spark Plug: Testing and Inspection Spark Plug Inspection 1. Inspect the electrodes and ceramic insulator. Burned or worn electrodes may be caused by: Advanced ignition timing - Loose spark plug - Plug heat range too hot - Insufficient cooling Fouled plug may be caused by: Retarded ignition timing - Oil in combustion chamber - Incorrect spark plug gap - Plug heat range too cold - Excessive idling/low speed running - Clogged air cleaner element - Deteriorated ignition coils 2. Do not adjust the gap of platinum tip plugs (A); replace the spark plug if the gap is out of specification. M/T - Clicking Noise Driving in 2nd Gear Synchronizer Ring: Customer Interest M/T - Clicking Noise Driving in 2nd Gear 03-009 June 10, 2003 Applies To: 2001-03 Civic DX, LX, HX, EX with M/T - ALL 2003 Civic Hybrid - From VIN JHMES95..3S000001 thru JHMES95..3S018631 Clicking Noise While Driving in 2nd (Supersedes 03-009, dated April 1, 2003) Updated information is shown with asterisks. SYMPTOM * While driving in 2nd gear, a clicking noise occurs when turning right (DX, LX, HX, and EX) or when turning left (Civic Hybrid).* PROBABLE CAUSE The reverse idler gear is contacting the 1st/2nd hub sleeve set. CORRECTIVE ACTION Replace the reverse idler gear, the 1st/2nd synchro hub/sleeve set, and the reverse gear holder. REQUIRED MATERIALS Honda Manual Transmission Fluid (1.7 quarts required): P/N 08798-9016, H/C 4928271 Liquid Gasket: P/N 08718-0001, H/C 2963817 PARTS INFORMATION WARRANTY CLAIM INFORMATION In warranty: The normal warranty applies. Operation Number: 213110 Page 8976 15. Measure resistance between the No.1 and No.2 terminals with the float at E (EMPTY), 1/2 (HALF FULL), and F (FULL) positions. If you do not get the shown readings, replace the fuel gauge sending unit. NOTE: Remove the No.9 BACK UP (10A) fuse from the under-hood fuse/relay box for at least 10 seconds after completing troubleshooting, otherwise it may take up to 20 minutes for the fuel gauge to indicate the correct fuel level. Page 7103 7. Connect the SCS service connector to the 2P MES (memory erase signal) connector, as shown. Do not use a jumper wire. 8. Turn the ignition switch to ON (II). 9. Watch the SRS indicator. (It comes on for about 6 seconds and then goes off.) Disconnect the SCS service connector from the MES connector within 4 seconds after the indicator goes off. 10. When the SRS indicator comes on again, connect the SCS service connector to the MES connector within 4 seconds after the indicator comes on. 11. When the SRS indicator goes off, disconnect the SCS service connector from the MES connector within 4 seconds. Page 4399 Transmission Position Switch/Sensor: Testing and Inspection Transmission Range Switch Test 1. Remove the transmission range switch harness connector (A) from the connector bracket (B), then disconnect the connector. 2. Check for continuity between terminals at the harness connector. There should be continuity between the terminals listed for each switch position. In the P position, between terminals: ^ No. 1 and No. 3 ^ No. 1 and No. 8 ^ No. 3 and No. 8 In the R position, between terminals: ^ No. 1 and No. 9 In the N position and between terminals: ^ No. 1 and No. 3 ^ No. 1 and No. 10 ^ No. 3 and No. 10 In the D position, between terminals: ^ No. 1 and No. 2 ^ No. 1 and No. 4 ^ No.2 and No.4 In the D3 position, between terminals: ^ No. 1 and No. 2 ^ No. 1 and No. 5 ^ No.2 and No.5 In the 2 position, between terminals: ^ No. 1 and No. 6 Page 3846 Transmission Position Switch/Sensor: Service and Repair Transmission Range Switch Replacement 1. Raise the vehicle, and make sure it is securely supported. 2. Shift to the N position. 3. Remove the transmission range switch cover (A). 4. Disconnect the transmission range switch connector (B). 5. Remove the old transmission range switch, and install the new switch. 6. Make sure that the control shaft is in the N position. If necessary, move the shift lever to the N position. Page 9438 Backup Lamp Relay: Testing and Inspection Power Relay Test Use this chart to identify the type of relay, then do the test listed for it. NOTE: See the turn signal/hazard relay input test. Normally-open type A: Page 4375 - Before connecting connectors, make sure the terminals (A) are in place and not bent. - Check for loose retainer (A) and rubber seals (B). - The backs of some connectors are packed with dielectric grease. Add grease if necessary. If the grease is contaminated, replace it. - Insert the connector all the way and make sure it is securely locked. - Position wires so that the open end of the cover faces down. Handling Wires and Harnesses - Secure wires and wire harnesses to the frame with their respective wire ties at the designated locations. Page 2601 Technical Service Bulletin # 01-077 Date: 060419 Ignition/Locks - Cutting Sidewinder-Type Keys 01-077 April 19, 2006 Applies To: Models With Sidewinder-Type Keys - All Cutting Sidewinder-Type Keys With the MATRIX H Key Cutting Machine (Supersedes 01-077, dated January 12, 2005) Updated information is noted by asterisks. MATRIX H Key Cutting Machine, manufactured by Silca and supplied by Kaba Ilco Corporation, is a portable, power-operated tool that cuts sidewinder-type automotive keys exclusively. The machine lets you cut these keys either by copying or by code. The code function is designed and built to meet the Honda code requirements. No other similar machine has this capability. This service bulletin gives you information for ordering and servicing this special tool, and guides you through the entire key cutting process from setting up the machine to cutting the key blank. TOOL INFORMATION Order through the Honda Tool and Equipment Program: MATRIX H Key Cutting Machine: Model No. ILCMATRIXSH Cutter Bit: Model No. ILCF3O Fixed Jaw: Model No. ILCMTX-H Mobile Jaw (Right Side): Model No. ILCRTMTX-H Mobile Jaw (Left Side): Model No. ILCLTMTX-H *Remanufactured Clamp Unit: Model No. ILCMATRIXHCR* PARTS INFORMATION *For some models, there are two choices for sidewinder-type key blanks: ^ T-5 sidewinder key blanks ^ Honda sidewinder key blanks For other models, only Honda sidewinder key blanks can be used. See DETERMINING WHICH KEY TO USE to determine which key blank you should choose. Ordering T-5 key blanks through the Honda Tool and Equipment Program: T-5 Programmable Key Blank (Master): P/N ILC-35111-T-5H T-5 Programmable Key Blank (Valet): P/N ILC-35112-T-5H Practice Key Blanks (five per pack): ILC-35111DEMO* NOTE: Do not use practice key blanks for replacement purposes. Practice keys do not have an immobilizer chip. Front Door Glass Outer Weatherstrip Replacement Front Door Window Glass Weatherstrip: Service and Repair Front Door Glass Outer Weatherstrip Replacement Front Door Glass Outer Weatherstrip Replacement 4-door NOTE: - Put on gloves to protect your hands. - Take care not to scratch the door. 1. Remove the mirror. 2. Starting at the rear, pry the door glass outer weatherstrip (A) up to detach the clips (B, C), then remove the weatherstrip. 3. Install the weatherstrip in the reverse order of removal, and replace any damaged clips. Page 1436 Fluid - M/T: Service and Repair Transmission Fluid Inspection and Replacement 1. Park the vehicle on level ground, and turn the engine OFF. 2. Remove the oil filler plug (A) and washer (B), check the condition of the fluid, and make sure the fluid is at the proper level (C). 3. If the transmission fluid is dirty, remove the drain plug (D) and drain the fluid. 4. Reinstall the drain plug with a new washer, and refill the transmission fluid to the proper level. Oil Capacity 1.5 L (1.6 US qt) at fluid change 1.6 L (1.7 US qt) at overhaul Always use Honda Manual Transmission Fluid (MTF). Using motor oil can cause stiffer shifting because it does not contain the proper additives. 5. Reinstall the oil filler plug with anew washer. Page 4162 13. Remove the solenoid cover, and make sure the solenoid plunger groove is installed in the fork on the lever. ^ If needed, correct the position of the solenoid plunger, then go to step 14. ^ If the solenoid plunger is correctly installed, there is an electrical problem with the key interlock system; refer to the Automatic Transmission section of the appropriate service manual for troubleshooting information. Once the key interlock is working normally, go to step 14. 14. Install the solenoid cover. 15. Reinstall the steering column covers. 16. Center-punch a completion mark above the seventh character of the engine compartment VIN. Disclaimer Page 3912 Updating Honda Control Modules screen on the HDS tablet, the HDS pocket tester, or the iN workstation. MVCI:* iN Workstation: NOTE: The HDS tablet and pocket tester screens are similar. *^If the Database Update listed in the service bulletin is later than that shown by the software, please see the the procedures for software installation in the following documents in Tool Information on ISIS (go to General Publications, then Tool Information): - MVCI User Guide (see HDS MVCI Firmware Update section) - Honda Diagnostic System (HDS) Tablet Setup Instructions - Installation Instructions for HDS ( see PC Software for the GNA600, HIM or Pocket Tester ID)* ^ Do not connect an additional power supply to the updating equipment when it is connected to the vehicle; power is supplied through the DLC. ^ To ensure that the control module/unit is not permanently damaged during updating, vedfy that the vehicle's 12-volt battery is fully charged before starthg an update. NOTE: If the vehicle's 12-volt battery drops below 10 volts during the update, the programming status bar may go past 100 percent, or the updating tool may display an error message. ^ If you have a problem during an update (D4/ immobilizer indicator flashes, update tool freezes, etc.), you can minimize the chances of damaging the control unit/module by doing one or more of these actions: - CRITICAL: Keep the ignition switch in ON (II). - Connect a jumper battery (DO NOT connect a battery charger). - Disconnect the updating tool from the vehicle's DLC. - Reboot the updating tool. - Reconnect the updating tool to the vehicle's DLC, and retry the updating procedure. *UPDATING WITH THE MVCI Make sure you have the latest control module (CM) Update software loaded from your HDS PC to your MVC I. For loading instructions and other Page 5405 Brake Pad: Service and Repair Front Inspection and Replacement CAUTION: Frequent inhalation of brake pad dust, regardless of material composition, could be hazardous to your health. ^ Avoid breathing dust particles. ^ Never use an air hose or brush to clean brake assemblies. Use an OSHA-approved vacuum cleaner. Replacement 1. Remove the bolt (B), and pivot the caliper (C) up out of the way. Check the hose and pin boots for damage and deterioration. 2. Remove the pad shim (A) and pads (B). 3. Remove the pad retainers (A). 4. Clean the caliper thoroughly; remove any rust, and check for grooves and cracks. 5. Check the brake disc for damage and cracks. 6. Apply Dow Corning Molykote M77 grease to the retainers on their mating surfaces against the caliper bracket. 7. Install the pad retainers. Wipe excess grease off the retainers. Contaminated brake discs and pads reduce stopping ability. Keep grease off the discs and pads. Service and Repair Towing Information: Service and Repair Towing If the vehicle needs to be towed, call a professional towing service. Never tow the vehicle behind another vehicle with just a rope or chain. It is very dangerous. Emergency Towing There are three popular methods of towing a vehicle. Flat-bed Equipment - The operator loads the vehicle on the back of a truck. This is the best way of transporting the vehicle. To accommodate the flat-bed equipment, the vehicle is equipped with towing hooks (A) and tie down slots (B). The towing hook can be used with a winch to pull the vehicle onto the truck, and the tie down slots can be used to secure the vehicle to truck. Wheel Lift Equipment - The tow truck uses two pivoting arms that go under the tires (front or rear) and lift them off the ground. The other two wheels remain on the ground. Sling-type Equipment - The tow truck uses metal cables with hooks on the ends. These hooks go around parts of the frame or suspension and the cables lift that end of the vehicle off the ground. The vehicle's suspension and body can be seriously damaged if this method of towing is attempted. If the vehicle cannot be transported by flat-bed, it should be towed with the front wheels off the ground. If due to damage, the vehicle must be towed with the front wheels on the ground, do the following: Manual Transmission - Release the parking brake. - Shift the transmission in Neutral. Automatic Transmission and CVT - Release the parking brake. - Start the engine. - Shift to D position, then N position. Page 2505 Throttle Position Sensor: Description and Operation Throttle Position (TP) Sensor The TP sensor is a potentiometer connected to the throttle valve shaft. As the throttle position changes, the sensor varies the signal voltage to the ECM/PCM. The TP sensor is not replaceable apart from the throttle body. Page 7119 Antenna Amplifier: Testing and Inspection Window Antenna Coil Test 4-door 1. Open the trunk lid. 2. Disconnect the 1 P connector (A) and 2P connector (B) from the window antenna coil (C). 3. Check for continuity between the terminal B2 and body ground, and between terminal A1 and B1 of the antenna coil. There should be continuity. If there is no continuity, go to step 4. 4. Remove the rear shelf. 5. Loosen the two bolts, and replace the window antenna coil. Page 3847 7. Align the cutouts (A) on the rotary-frame with the neutral positioning cutouts (B) on the transmission range switch, then put a 2.0 mm (0.08 inch) feeler gauge blade (C) in the cutouts to hold it in the N position. NOTE: Be sure to use a 2.0 mm (0.08 inch) blade or equivalent to hold the switch in the N position. 8. Install the transmission range switch (A) gently on the control shaft (B) with holding the N position with the 2.0 mm (0.08 inch) blade (C). 9. Tighten the bolts on the transmission range switch while you continue to hold it in the N position. Do not move the transmission range switch when tightening the bolts. Remove the feeler gauge. Page 1353 1. Apply a force of 98 N (10 kgf, 22 lbf), and measure the deflection at the mid point (A) between the alternator and crankshaft pulley. If the belt is worn or damaged, replace it. If the belt needs adjustment, go to step 2. Adjustment 2. Loosen the mounting bolt (B), lock bolt (C) and lower bracket mounting bolt (D). 3. Torque the mounting bolt to 20 N.m (2.0 kgf.m, 14 lbf.ft). 4. Turn the adjusting bolt (E) to obtain the proper belt tension, then retighten the lock bolt, mounting bolt and lower bracket mounting bolt. 5. Recheck the belt tension. 6. If you installed a new belt, run the engine for 5 minutes, then readjust the belt to the used belt specification. 7. Check the power steering pump belt adjustment. Service and Repair Front Door Window Regulator: Service and Repair Front Door Glass and Regulator Replacement NOTE: Put on gloves to protect your hands. 1. Remove these items: - Door panel, 2-door, 4-door - Plastic cover, as necessary, 2-door, 4-door 2. Carefully raise the glass (A) until you can see the bolts, then remove them. Carefully pull the glass out through the window slot. Take care not to Page 5871 Wiper/Washer Component Location Index Page 3177 Vehicle Speed Sensor: Description and Operation Vehicle Speed Sensor (VSS) The VSS is driven by the differential. It generates a pulsed signal from an input of 1 volts. The number of pulses per minute increases/decreases with the speed of the vehicle. Antitheft System - Alarm Will Not Arm/Arms By Itself Alarm Module: Customer Interest Antitheft System - Alarm Will Not Arm/Arms By Itself 05-025 July 1, 2005 Applies To: 2001-05 Civic - ALL 2002-05 CR-V - ALL 2003-04 Element - ALL Accessory Security System Changes Modes By Itself (Supersedes 05-025, dated June 10, 2005, to update the information indicated by black bars and asterisks.) SYMPTOM The security system will not arm or it arms by itself. PROBABLE CAUSE Key switch contact chatter causes the control unit to change modes. CORRECTIVE ACTION * Civic: Replace the security control unit, and reprogram the remote(s).* * CR-V and Element: Replace the security control unit and the microphone, then reprogram the remote(s).* * NOTE: You must replace the microphone on the CR-V and Element because the security control units are matched to their microphones when they are manufactured. Using the original microphone may result in security system problems.* PARTS INFORMATION WARRANTY CLAIM INFORMATION In warranty: The normal warranty applies. Out of warranty: Any repair performed after warranty expiration may be eligible for goodwill consideration by the District Parts and Service Manager or your Zone Office. You must request consideration, and get a decision, before starting work. REPAIR PROCEDURE NOTE: Before starting, make sure you have all of the remotes (three maximum) the customer wishes to use. Page 6114 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. Brake Pedal - Click Or Pop When Depressed Brake Pedal Assy: Technical Service Bulletins Brake Pedal - Click Or Pop When Depressed SOURCE: Honda Service News November 2004 TITLE: Click or Pop When Pressing the Brake Pedal APPLIES TO: 2003-04 Accord or 2001-05 Civic SERVICE TIP: Got a 2003-04 Accord or 2001-05 Civic in your shop that clicks or pops when you press the brake pedal? The culprit could be the brake pedal position switch. The switch plunger doesn't fit squarely into the switch casing. When you press the brake pedal, the plunger rubs the side of the casing and makes noise. There's a simple fix for this problem: Just turn the switch around so the connector lock now faces the 5 o'clock position. Locations Knock Sensor: Locations PGM-FI System - Component Location Index Page 402 Control Module: Service and Repair How to Substitute the PCM How to Substitute the PCM 1. Remove the PCM from the vehicle. 2. Install a known-good PCM in the vehicle. 3. Rewrite the immobilizer code with the PCM replacement procedure in the Honda PGM Tester; It allows you to start the engine. 4. After completing your tests, reinstall the original PCM and rewrite the immobilizer code with the PCM replacement procedure in the HDS Tester again. Page 9833 1. Remove the screws and the power window master switch (A) from the door panel. 2. Disconnect the 14P connector (B) from the switch. 3. Check for continuity between the terminals in each switch position according to the table. Driver's Switch: The driver's switch is combined with the control unit so you cannot isolate the switch to test it. Instead, run the master switch input test procedures. If the tests are normal, the driver's switch must be faulty. 4. If the switch is faulty, remove the three screws and replace the switch. Page 2379 94. Behind Glove Box (except GX) Locations Heated Glass Element Switch: Locations Rear Window Defogger Component Location Index Page 2463 119. Knock Sensor (except GX) Locations Blower Motor Relay: Locations Under-hood Fuse/Relay Box Page 110 Blower Motor Relay Type 1, Type 2 Check for continuity between the terminals. - There should be continuity between the No.1 and No.3 terminals when power and ground are connected to the No.2 and No.4 terminals. - There should be no continuity between the No.1 and No.3 terminals when power is disconnected. Five-terminal type Check for continuity between the terminals. - There should be continuity between the No.1 and No.2 terminals when power and ground are connected to the No.3 and No.5 terminals. - There should be continuity between the No.1 and No.4 terminals when power is disconnected. Specifications Compressor Clutch: Specifications Pulley-to-Pressure Plate Clearance 0.020 +/- 0.006 in Page 1067 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. Below most connector numbers and component names are PHOTO and VIEW numbers. The PHOTO number refers to a photo in the back of the book that shows the connector's location on the car. The VIEW number refers to an illustration in the back of the book that shows the connector terminals, wire colors, connector cavity numbers, and other details. The connector cavity numbering sequence begins at the top left corner of the connector as seen from either of the viewpoints shown on diagram [8] . Except for the DLC (data link 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 C554, for example, means those terminals join in cavity 2 of connector C554. Power Distribution Schematics Power Distribution Schematics Page 9757 3. Check for continuity between the terminals in each switch position according to the tables. Driver's Switch: The driver's switch is combined with the control unit so you cannot isolate the switch to test it. Instead, run the master switch input test procedures. If the tests are normal, the driver's switch must be faulty. Replace the switch. 4. If the continuity is not as specified, remove the driver's door panel. 5. Remove the armrest from the door panel. Connector Views Fuse Block: Connector Views 234. Under-dash Fuse/Relay Box Part 1 Page 5642 143. Park Pin/Shift Switch (A/T) Page 3797 143. Park Pin/Shift Switch (A/T) Page 2442 111. ELD Unit (USA) Page 8061 Door Lock Cylinder Switch: Testing and Inspection Door Lock Actuator Test Driver's door: 1. Remove the driver's door panel. 2. Disconnect the 2P connector from the actuator. 3. Check actuator operation by connecting power and ground according to the table. To prevent damage to the actuator, apply battery voltage only momentarily. 4. If the actuator does not operate as specified, replace it. Passenger's door: 1. Remove the passenger's door panel. Page 5641 107. Behind A/T Shift Lever (except M/T) Page 969 Clutch Switch: Testing and Inspection Clutch Interlock Switch Test 1. Disconnect the clutch interlock switch 2P connector. 2. Remove the clutch interlock switch (A). 3. Check for continuity between the terminals according to the table. - If the continuity is not as specified, replace the clutch interlock switch. - If OK, install clutch interlock switch and adjust the pedal height. Locations Condenser Fan Motor Relay: Locations Under-hood Fuse/Relay Box Page 2877 Malfunction Indicator Lamp: Testing and Inspection MIL Circuit Troubleshooting 1. Connect an OBD II scan tool/Honda PGM Tester. 2. Turn the ignition switch ON (II) and read the OBD II scan tool/Honda PGM Tester. Does the OBD II scan tool/Honda PGM Tester communicate with the ECM/PCM? YES - Go to step 3. NO - Go to troubleshooting "DLC Circuit Troubleshooting". 3. Check the OBD II scan tool/Honda PGM Tester for DTCs. Are any DTCs indicated? YES - Go to the DTC Troubleshooting index. See: Testing and Inspection/Diagnostic Trouble Code Descriptions NO - Go to step 4. 4. Turn the ignition switch OFF. 5. Turn the ignition switch ON (II) and watch the Malfunction Indicator Lamp (MIL). Does the MIL come on and stay on for more than 20 seconds after turning the ignition switch ON (II)? YES - If the MIL always comes on and stays on, go to step 74. But if the MIL sometimes works normally, first check for these problems. An intermittent short in the wire between the ECM/PCM (E29) and the data link connector (DLC). - An intermittent short in the wire between the ECM/PCM (E31) and the gauge assembly. NO - If the MIL is always off, go to step 6. But if the MIL sometimes works normally, first check for these problems. A loose No.10 METER (7.5A) fuse in the under-dash fuse/relay box. - A loose No.20 IG (40A) fuse in the under-hood fuse/relay box. - A loose No.6 ECU (ECM/PCM) (15A) fuse in the under-hood fuse/relay box. - A loose No.17 FUEL PUMP (15A) fuse in the under-dash fuse/relay box. - A poor connection at ECM/PCM terminal E31. - An intermittent open in the GRN/ORN wire between the ECM/PCM (E31) and the gauge assembly. - An intermittent short in the wire between the ECM/PCM (A21) and the manifold absolute pressure (MAP) sensor, CVT driven pulley speed sensor (CVT), or CVT speed sensor 1 (CVT). - An intermittent short in the wire between the ECM/PCM (A20) and the throttle position (TP) sensor, knock sensor, exhaust gas recirculation (EGR) valve position sensor, CVT drive pulley speed sensor (CVT), or CVT speed sensor 2 (CVT). - An intermittent short in the wire between the ECM/PCM (A5) and the knock sensor. - An intermittent short in the wire between the ECM/PCM (E5) and the fuel tank pressure (FTP) sensor. 6. Turn the ignition switch OFF. 7. Turn the ignition switch ON (II). Is the low oil pressure light on? YES - Go to step 10. NO - Go to step 8. 8. Inspect the No.10 METER (7.5 A) fuse in the under-dash fuse/relay box. Is the fuse OK? YES - Go to step 9. NO - Repair short in the wire between No.10 METER (7.5A) fuse and the gauge assembly. Also replace the No.10 METER (7.5A) fuse. 9. Inspect the No.20 IGN (40A) fuse in the under-hood fuse/relay box. Is the fuse OK? YES - Repair open in the wire between the No.20 IG (40A) fuse and the gauge assembly. If the wires are OK, test the ignition switch. Page 8135 Programming the Transmitter 1. Locate the security system control unit under the driver's seat. 2. Rub your finger over the label on the top of the control unit until you find the depression. Once you find it, push your finger through the label to expose the hole underneath. Inside the hole is a square, yellow button; this is the programming button. 3. Turn the ignition switch to ON, then turn it to LOCK. 4. Press and hold the programming button. Check that the security siren emits four separate chirps followed by a five-chirp burst. This confirms that the system is in programming mode. The siren then emits prompting chirps at 3-second intervals. 5. Release the programming button. 6. After a prompting chirp, press the "LOCK" button on the transmitter. Verify that the siren emits a confirmation chirp to confirm that the transmitter's code was accepted by the control unit. If you wait more than 30 seconds after the prompting chirp before programming a transmitter, or wait more than 30 seconds between programming transmitters, the siren emits three chirps and the system exits the programming mode. 7. To program additional transmitters, wait for another prompting chirp, then press the "LOCK" button. (You can program up to four transmitters per vehicle.) 8. To exit the programming mode, turn the ignition switch to ON, then turn it to LOCK. 9. Test all the transmitters. Ordering a Transmitter Transmitters can be ordered only by authorized Honda dealers. Order them from American Honda using normal parts ordering procedures. Batteries for the Transmitter The battery number is 23-144 (Radio Shack), A-23 (Eveready), or MS-21/MN-21 (Duracell). Each transmitter uses one battery. Page 8584 13. Push the top of the retainer clip with a flat-tip screwdriver, and hold it. Release the retainer clip with a hook-shaped tool, then remove the lock cylinder. Go to step 14. 14. With the door lock cylinder out of the door handle remove the E-clip and the arm. 15. Try to insert the key into the cylinder and turn it. ^ If you can insert and turn the key, go to step 18. ^ If you cannot insert the key or turn it, go to step 16. 16. Carefully remove the spring and plastic retainer. Page 4023 Pressure Regulating Solenoid: Testing and Inspection A/T Clutch Pressure Control Solenoid Valves A and B Test 1. Disconnect the connectors from the A/T clutch pressure control solenoid valves A and B. 2. Measure the resistance of the A/T clutch pressure control solenoid valves A and B between the No. 1 and No. 2 terminals of each connector. STANDARD: About 5.0 Ohms 3. If the resistance of either A/T clutch pressure control solenoid is out of standard, replace the A/T clutch pressure control solenoid valves A and B. 4. Connect the No. 1 terminal of the A/T clutch pressure control solenoid valve A (and B) to the battery positive terminal, and connect the No. 2 terminal to the battery negative terminal. A clicking sound should be heard. 5. If no sound is heard, remove the A/T clutch pressure control solenoid valves A and B. 6. Check the fluid passage of the A/T clutch pressure control solenoid valve for dust and dirt. 7. Connect the No. 1 terminal of the A/T clutch pressure control solenoid valves A and B to the battery positive terminal, and connect the No. 2 terminal to the battery negative terminal. Make sure the A/T clutch pressure control solenoid valves A and B move. 8. Disconnect one of the battery terminal and check valve movement. NOTE: You can see valve movement through the fluid passage in the mounting surface of the A/T clutch pressure control solenoid valves A and B body (c). 9. If either valve binds or moves sluggishly, or if the A/T clutch pressure control solenoid does not operate, replace the A/T clutch pressure control solenoid valves A and B. Campaign - Vehicle Warranty Mileage Extension Odometer: Recalls Campaign - Vehicle Warranty Mileage Extension 06-085 May 9, 2008 Applies To: See VEHICLES AFFECTED Warranty Extension: Vehicle Warranty Mileage (Supersedes 06-085, dated January 22, 2008, to update the information marked by asterisks) BACKGROUND On December 29, 2007, a federal court provided final approval of the settlement of a class action lawsuit alleging that the odometers on certain 2002 through 2006 Honda models, and some 2007 Fit models, were overstating mileage. As part of the settlement, American Honda is extending the mileage-based coverage period of all warranties, Honda Care Service Contracts, and Honda Certified Used Vehicles by 5 percent on the above referenced vehicles. The time limits for all warranties are unchanged. VEHICLES AFFECTED The vehicles affected by this settlement include certain 2002 through 2006 Honda models and some 2007 Fit models purchased or leased between April 13, 2002, and November 7, 2006. The affected region is the United States (including the District of Columbia, Puerto Rico, and the U.S. Virgin Islands). Affected vehicles registered to customers with a military or a NATO address are also included in this settlement. The most effective way to check a vehicle's warranty coverage is by a VIN status inquiry. CUSTOMER NOTIFICATION American Honda notified affected customers by mail or publication. The notices were sent to original registered purchasers, informing them of the terms of the settlement. Notice was also published in a national newspaper. To view the content of the mailed notice, as well as other documents regarding the settlement, or for additional information, please refer to these sources: Website: www.odosettlementinfo.com Information Center: (888) 888-3082 CORRECTIVE ACTION *On affected vehicles, the settlement requires you to honor a 5 percent increase in the mileage coverage period for all warranties, all Honda Certified Used Vehicles, and those Honda Care Service Contracts purchased only by the original owners.* WARRANTY CLAIM INFORMATION Use the chart as a reference for converting most standard warranty mileage limits to the extended mileage coverage. Use the chart as a reference to all service bulletins affected by the extended mileage coverage. In addition to the 5 percent mileage increase in warranty coverage, any repair performed after warranty expiration may be eligible for goodwill Page 1198 Power Window Switch: Service and Repair Passenger's Window Switch Test/Replacement Passenger's Window Switch Test/Replacement 4-door 1. Remove the door grip cover. 2. Disconnect the 5P connector (A) from the passenger's power window switch (B). 3. Check for continuity between the terminals in each switch position according to the table. 4. If the continuity is not as specified, remove the two screws and replace the switch. 2-door Page 6962 7. Connect the SCS service connector to the 2P MES (memory erase signal) connector, as shown. Do not use a jumper wire. 8. Turn the ignition switch to ON (II). 9. Watch the SRS indicator. (It comes on for about 6 seconds and then goes off.) Disconnect the SCS service connector from the MES connector within 4 seconds after the indicator goes off. 10. When the SRS indicator comes on again, connect the SCS service connector to the MES connector within 4 seconds after the indicator comes on. 11. When the SRS indicator goes off, disconnect the SCS service connector from the MES connector within 4 seconds. Page 3078 Knock Sensor: Service and Repair Replacement 1. Remove the oil filter with the special oil filter wrench. 2. Disconnect the knock sensor connector, then remove the knock sensor. 3. Install the knock sensor and oil filter. Page 1510 Under-dash Fuse/Relay Box (4-door) Page 5663 ^ Start the engine, and let it warm up to its normal operating temperature (the cooling fans cycle twice). ^ Let the engine idle (throttle closed and all electrical items off) for 10 minutes. Disclaimer Locations 94. Behind Glove Box (except GX) Page 8614 19. Using your thumb and forefinger to hold the tumblers, remove the key from the inner cylinder, being careful not to drop any tumblers and springs. 20. *Using the key code from the iN that you have written down at step 2, build a new inner cylinder with new springs, new cylinder, and tumblers from the door lock cylinder kit. Make sure you put the appropriate numbered tumbler in the proper inner cylinder cavity. Apply a thin layer of Permalube to each tumbler to help lubricate and retain it.* NOTE: ^ There are two types of tumblers. The "SUBLOCK" tumbler goes only in cavity A." The "DISC" tumbler goes in cavities "B" through "J." ^ Cavity "E" is empty on all cylinders. Page 12 1. Remove the driver's dashboard lower cover. (See the body section of the appropriate service manual.) 2. Replace the security control unit. ^ Civic: Remove the security control unit, and install the new security control unit. ^ * CR-V and Element: Remove the security control unit and microphone. Install the new security control unit and new microphone.* 3. Reprogram the keyless receiver unit. NOTE: The codes of up to three transmitters can be stored in the keyless receiver unit memory. If a fourth code is stored, the code that was input first will be erased. It is important to maintain the time limits between the steps. Make sure the doors and the trunk/tailgate/hatch are closed, and that you have all of the remotes the customer wishes to use. ^ Turn the ignition switch to ON (II). ^ Within 1 to 4 seconds, push the transmitter lock or unlock button. ^ Within 1 to 4 seconds, turn the ignition switch to LOCK (0). ^ Within 1 to 4 seconds, turn the ignition to ON (II). ^ Within 1 to 4 seconds, push the transmitter lock or unlock button. ^ Within 1 to 4 seconds, turn the ignition switch to LOCK (0). ^ Within 1 to 4 seconds, turn the ignition switch to ON (II). ^ Within 1 to 4 seconds, push the transmitter lock or unlock button. Page 8905 Malfunction Indicator Lamp: Testing and Inspection MIL Circuit Troubleshooting 1. Connect an OBD II scan tool/Honda PGM Tester. 2. Turn the ignition switch ON (II) and read the OBD II scan tool/Honda PGM Tester. Does the OBD II scan tool/Honda PGM Tester communicate with the ECM/PCM? YES - Go to step 3. NO - Go to troubleshooting "DLC Circuit Troubleshooting". 3. Check the OBD II scan tool/Honda PGM Tester for DTCs. Are any DTCs indicated? YES - Go to the DTC Troubleshooting index. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Descriptions NO - Go to step 4. 4. Turn the ignition switch OFF. 5. Turn the ignition switch ON (II) and watch the Malfunction Indicator Lamp (MIL). Does the MIL come on and stay on for more than 20 seconds after turning the ignition switch ON (II)? YES - If the MIL always comes on and stays on, go to step 74. But if the MIL sometimes works normally, first check for these problems. An intermittent short in the wire between the ECM/PCM (E29) and the data link connector (DLC). - An intermittent short in the wire between the ECM/PCM (E31) and the gauge assembly. NO - If the MIL is always off, go to step 6. But if the MIL sometimes works normally, first check for these problems. A loose No.10 METER (7.5A) fuse in the under-dash fuse/relay box. - A loose No.20 IG (40A) fuse in the under-hood fuse/relay box. - A loose No.6 ECU (ECM/PCM) (15A) fuse in the under-hood fuse/relay box. - A loose No.17 FUEL PUMP (15A) fuse in the under-dash fuse/relay box. - A poor connection at ECM/PCM terminal E31. - An intermittent open in the GRN/ORN wire between the ECM/PCM (E31) and the gauge assembly. - An intermittent short in the wire between the ECM/PCM (A21) and the manifold absolute pressure (MAP) sensor, CVT driven pulley speed sensor (CVT), or CVT speed sensor 1 (CVT). - An intermittent short in the wire between the ECM/PCM (A20) and the throttle position (TP) sensor, knock sensor, exhaust gas recirculation (EGR) valve position sensor, CVT drive pulley speed sensor (CVT), or CVT speed sensor 2 (CVT). - An intermittent short in the wire between the ECM/PCM (A5) and the knock sensor. - An intermittent short in the wire between the ECM/PCM (E5) and the fuel tank pressure (FTP) sensor. 6. Turn the ignition switch OFF. 7. Turn the ignition switch ON (II). Is the low oil pressure light on? YES - Go to step 10. NO - Go to step 8. 8. Inspect the No.10 METER (7.5 A) fuse in the under-dash fuse/relay box. Is the fuse OK? YES - Go to step 9. NO - Repair short in the wire between No.10 METER (7.5A) fuse and the gauge assembly. Also replace the No.10 METER (7.5A) fuse. 9. Inspect the No.20 IGN (40A) fuse in the under-hood fuse/relay box. Is the fuse OK? Locations Seat Belt Buckle Switch: Locations 100. Under Driver's Seat 101. Under Front Passenger's Seat (Passenger's Similar) Page 4240 7. Align the cutouts (A) on the rotary-frame with the neutral positioning cutouts (B) on the transmission range switch, then put a 2.0 mm (0.08 inch) feeler gauge blade (C) in the cutouts to hold it in the N position. NOTE: Be sure to use a 2.0 mm (0.08 inch) blade or equivalent to hold the switch in the N position. 8. Install the transmission range switch (A) gently on the control shaft (B) with holding the N position with the 2.0 mm (0.08 inch) blade (C). 9. Tighten the bolts on the transmission range switch while you continue to hold it in the N position. Do not move the transmission range switch when tightening the bolts. Remove the feeler gauge. Page 1361 Drive Belt: Adjustments Power Steering Belt Pump Belt Inspection and Adjustment Special Tools Required Belt tension gauge, 07JGG-0010100, 07JGG-001010A, or 07TGG-001000A Belt Tension Gauge Method Inspection 1. Remove the P/S reservoir from the bracket, and set it aside. 2. Attach the belt tension gauge to the belt, and measure the tension of the belt. Follow the gauge manufacturer's instructions. If the belt is worn or damaged, replace it. NOTE: Remove the belt tension gauge carefully to avoid hitting the gauge reset lever. Tension: Used Belt: 390 - 540 N (40 - 55 kgf, 88 - 121 lbs.) New Belt: 740 - 880 N (75 - 90 kgf, 165 - 198 lbs.) 3. If you installed a new belt, run the engine for 5 minutes, then readjust the belt to the used belt specification. Adjustment 4. Loosen the power steering pump mounting nut (A.) and pump locknut (B). 5. Turn the adjusting bolt (C) to get the proper belt tension, then retighten the mounting nut and locknut. 6. Start the engine and turn the steering wheel from lock-to-lock several times, then stop the engine and recheck the tension of the belt. Deflection Method Inspection 1. Apply a force of 98 N (10 kgf, 22 lbs.) and measure the deflection between the power steering pump pulley (A) and the crankshaft pulley (B). If the belt is worn or damaged, replace it. Deflection: Used Belt: 13.0 - 16.5 mm (0.51 - 0.65 inch) New Belt: 9.0 - 11.0 mm (0.35 - 0.43 inch) Page 8680 4. With the 14P connector disconnected, make these input tests. 5. If any test indicates a problem, find and correct the cause, then recheck the system. If all the input tests prove OK, the control unit may be faulty. Substitute a known-good control unit and retest. If the system works properly, replace the control unit. Page 172 - 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. Troubleshooting Tests 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 test 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 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. 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 Drop Page 2726 REPAIR PROCEDURE 1. Make sure you have the anti-theft code for the audio unit. Write down the customer's audio presets. 2. Disconnect the negative battery cable from the battery. 3. Remove the under-hood fuse/relay box cover. 4. Release the three clips, and remove the under- hood fuse/relay box from the holder. CR-V only: Release the wire harness clip from the fuse/relay box holder Page 5950 Under-hood Fuse/Relay Box Page 4969 Connectors - "C" Page 4445 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. DIAGNOSIS Have an assistant press the clutch pedal while you grasp the clutch line at the clutch master cylinder, and then at the slave cylinder. If you feel a vibration through the clutch line when you hear the noise or the noise stops, go to REPAIR PROCEDURE. If you feel no vibration or the noise does not stop, look for other causes. REPAIR PROCEDURE NOTICE Do not spill brake fluid on the vehicle; it may damage the paint. If brake fluid does contact the paint, wash it off immediately with water. 1. Remove the clutch master cylinder. Refer to the appropriate service manual: 2003-04 Accord (L4): page 12-6 2003-04 Accord (V6): page 12-8 2001-04 Civic: page 12-5 2002-04 Civic Si: page 12-5 2003-04 Civic Hybrid: page 13-5 2002-04 CR-V: page 12-5 2003-04 Element: page 12-6 Enter keyword CLUTCH MASTER, and select Clutch Master Cylinder Replacement from the list. 2. Install the new clutch master cylinder, but do not attach the clutch line fitting. 3. Apply a thin coat of silicone grease to the clutch line fitting and to the opening in the clutch master cylinder. Do not use silicone spray; it could damage the 0-ring. 4. Connect the clutch line fitting to the clutch master cylinder. 5. Bleed the clutch hydraulic system, then top off the reservoir with brake fluid. 6. Check to see if the noise is gone when pressing the clutch pedal. ^ If the noise is gone, the repair is complete. Page 2100 11. Disconnect the quick-connect fitting (A): Hold the connector (B) with one hand and squeeze the retainer tabs (C) with the other hand to release them from the locking pawls (D). Pull the connector off. NOTE: Prevent the remaining fuel in the fuel feed line or hose from flowing out with a rag or shop towel. - Be careful not to damage the line (E) or other parts. - Do not use tools. - If the connector does not move, keep the retainer tabs pressed down, and alternately pull and push the connector until it comes off easily. - Do not remove the retainer from the line; once removed, the retainer must be replaced with a new one. 12. After disconnecting the quick-connect fitting, check it for dirt or damage (see step 4). Page 2344 Engine Control Module: Testing and Inspection How to Troubleshoot Circuits At the ECM/PCM How to Troubleshoot Circuits at the ECM/PCM Special Tools Required - Digital Multimeter KS-AHM-32-003 (1) or a commercially available digital multimeter - Backprobe Set 07SAZ-001000A (2) 1. Connect the backprobe adapters (A) to the stacking patch cords (B), and connect the cords to a digital multimeter (C). 2. Using the wire insulation as a guide for the contoured tip of the backprobe adapter, gently slide the tip into the connector from the wire side until it touches the end of the wire terminal. 3. If you cannot get to the wire side of the connector or the wire side is sealed (A), disconnect the connector and probe the terminals (B) from the terminal side. Do not force the probe into the connector. NOTE: Do not puncture the insulation on a wire. Punctures can cause poor or intermittent electrical connections. Page 477 Sunroof / Moonroof Limit Switch: Testing and Inspection Limit Switch Test 1. Remove the headliner. 2. Disconnect the 4P connector from the moonroof limit switch. 3. Check for continuity between the terminals in each switch position according to the table. NOTE: Turn the motor by hand with the wrench. 4. If the continuity is not as specified, replace the moonroof limit switch. Page 2966 ECM/PCM Inputs And Outputs At Connector C (22P) Specifications Engine Oil Pressure: Specifications Oil pressure with oil temperature at 176°F (80°C) At idle ................................................................................................................................................... .............. 70 kPa (0.07 kgf/cm2, 10 psi) minimum At 3,000 rpm ....................................................................................................................................................... 340 kPa (3.5 kgf/cm2, 50 psi) minimum Starting System - Starter Grinds While Engine Cranks Starter Motor: All Technical Service Bulletins Starting System - Starter Grinds While Engine Cranks 06-025 May 18, 2006 Applies To: 2001-05 Civic 2-door - ALL except CVI 2001-05 Civic 4-door - ALL except Hybrid and GX Starter Grinds While Cranking the Engine SYMPTOM The starter motor intermittently grinds while cranking the engine. PROBABLE CAUSE The female terminal at the starter solenoid may have spread apart, causing a loss of current to the solenoid. CORRECTIVE ACTION Replace the female terminal at the starter solenoid. PARTS INFORMATION Spade Receiver Terminal: P/N 07JAZ-001420A, H/C 8362675 TOOL INFORMATION Terminal Crimping Tool: T/N 07JAZ-001020A WARRANTY CLAIM INFORMATION In warranty: The normal warranty applies. Operation Number: 7370C3 Flat Rate Time: 0.4 hour Failed Part: P/N 31200-PLM-A51 H/C 6452429 Defect Code: 06601 Symptom Code: 09004 Template ID: 06-025A 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. DIAGNOSIS 1. If applicable, make sure you have the anti-theft code for the audio system. Write down the customer's audio unit presets. 2. Disconnect the negative cable from the battery, then disconnect the positive cable. 3. Remove the resonator: Page 1467 Refrigerant: Testing and Inspection Refrigerant Leak Test Refrigerant Leak Test Special Tool Required Leak detector, Honda Tool and Equipment YGK-H-10PM, commercially available WARNING: - Compressed air mixed with R-134a forms a combustible vapor. - The vapor can burn or explode causing serious injury. - Never use compressed air to pressure test R-134a service equipment or vehicle air conditioning system. CAUTION: - Air conditioning refrigerant or lubricant vapor can irritate your eyes, nose, or throat. - Be careful when connecting service equipment. - Do not breathe refrigerant or vapor. Use only service equipment that is U.L.-listed and is certified to meet the requirements of SAE J2210 to remove HFC-134a (R-134a) from the air conditioning system. If accidental system discharge occurs, ventilate work area before resuming service. R-134a service equipment or vehicle air conditioning systems should not be pressure tested or leak tested with compressed air. Additional health and safety information may be obtained from the refrigerant and lubricant manufacturers. 1. Connect a R-134a refrigerant recovery/recycling/charging station (A) to the high-pressure service port (B) and the low-pressure service port (C), as shown, following the equipment manufacturer's instructions. 2. Open high pressure valve to charge the system to the specified capacity, then close the supply valve, and remove the charging system couplers. Select the appropriate units of measure for your refrigerant charging station. Refrigerant capacity: 500 to 550 g 0.50 to 0.55 kg 1.1 to 1.2 lbs 17.6 to 19.4 oz 3. Check the system for leaks using a R-134a refrigerant leak detector with an accuracy of 14 g (0.5 oz) per year or better. 4. If you find leaks that require the system to be opened (to repair or replace hoses, fittings, etc.), recover the system. Page 5429 6. Apply Molykote 44MA grease onto the sliding surfaces as illustrated. Wipe off any excess. Do not get grease on the brake linings. 7. Install the shoe assembly on the backing plate by fitting the top of the shoes onto the wheel cylinder pistons and the bottom of the shoes onto the locating plate. 8. Install the tension pins (A) and the retainer springs (B) by pushing in on each spring and turning each pin. 9. Install the lower return spring. 10. Install the brake drum and rear wheel. 11. If the wheel cylinder has been removed, bleed the brake system. 12. Press the brake pedal several times to set the self adjusting brake. 13. Adjust the parking brake. Page 4293 Service and Repair Back Window Glass: Service and Repair Rear Window Replacement 2-door NOTE: - Put on gloves to protect your hands. - Wear eye protection while cutting the glass adhesive with piano wire. - Cover interior surfaces to avoid damaging them. - Do not damage the rear window defogger grid lines, window antenna grid lines, and terminals. 1. Remove these items: - Trunk lid - Rear shelf 2. Disconnect the window antenna connector (A) and rear window defogger connectors (B). 3. If the old rear window will be reinstalled, make alignment marks across the glass and body with a grease pencil. 4. Pull down the rear portion of the headliner (A) by detaching the clips (B). Take care not to bend the headliner excessively, or you may crease or break it. 5. Apply protective tape along the inside and outside edges of the body. Using an awl, make a hole through the adhesive from inside the vehicle at the corner portion of the rear window. Push a piece of piano wire through the hole, and wrap each end around a piece of wood. Page 9487 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. Below most connector numbers and component names are PHOTO and VIEW numbers. The PHOTO number refers to a photo in the back of the book that shows the connector's location on the car. The VIEW number refers to an illustration in the back of the book that shows the connector terminals, wire colors, connector cavity numbers, and other details. The connector cavity numbering sequence begins at the top left corner of the connector as seen from either of the viewpoints shown on diagram [8] . Except for the DLC (data link 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 C554, for example, means those terminals join in cavity 2 of connector C554. Power Distribution Schematics Power Distribution Schematics Capacity Specifications Refrigerant Oil: Capacity Specifications Refrigerant oil Capacity of components Condenser ........................................................................................................................................... ............................................... 25 ml (5/6 fl oz) Evaporator ................................................................. .................................................................................................................... 45 ml (1 1/2 fl oz) Each line and hose ....................................................................................................................................... ..................................... 10 ml (1/3 fl oz) Receiver ............................................................................... ............................................................................................................. 10 ml (1/3 fl oz) Compressor . .............................................................................................................................................................. ..... 130 - 150 ml (4 1/3 - 5 fl oz) Automatic Transmission Shift Indicator: Testing and Inspection Automatic Transmission Indicator Input Test SRS components are located in this area. Review the SRS component locations, precautions, and procedures in the SRS section before performing repairs or service. 1. If the MIL has been reported, check for a DTC, and repair the system as indicated by DTC. 2. If the MIL does not come on, and the A/T gear position indicator P, N, or R does not come on. Turn the ignition switch off, remove the gauge assembly from the dashboard, then disconnect gauge assembly connector A (22P) and B (22P). 3. Inspect the connectors and connector terminals to be sure they are making good contact. 4. If the terminals are bent, loose, or corroded, repair them as necessary, and recheck the system. 5. Shift to the P position, and check for continuity between AS terminal (BLU/BLK) and ground. There should be continuity in the P position and no continuity in any other shift lever position. If your test results are different, check for a faulty transmission range switch or an open in the wire. 6. Shift to the N position, and check for continuity between AS terminal (BLK/RED) and ground. There should be continuity in the N position and no continuity in any other shift lever position. If your test results are different, check for a faulty transmission range switch or an open in the wire. 7. Turn the ignition switch ON (II), shift to the R position, and check for voltage between All terminal (WHT) and ground. There should be 0 V in the [A position. There should be about 5 V in any other shift lever position. If your test results are different, check for a faulty transmission range switch or an open in the wire. 8. Check for voltage between B17 terminal (YEL) and ground with the ignition switch ON (II). There should be battery voltage. If your test results are different, check for a blown No. 10 (7.5A) fuse in the under-dash fuse/relay box or an open in the wire. 9. Turn the ignition switch OFF, and check for continuity between B16 terminal (BLK) and ground under all conditions. There should be continuity. If your test results are different, check for a poor ground (G501) or an open in the wire. 10. If all input tests prove OK, but the indicator is faulty, replace the printed circuit board. Locations Relay And Control Unit Locations - Dashboard Page 4730 22. Press a new hub bearing unit (A) into the hub (B) using the special tools and a press. 23. Install the knuckle/hub/hub bearing unit in the reverse order of removal, and note these items: - Be careful not to damage the ball joint boot when installing the knuckle. - Tighten all mounting hardware to the specified torque values. - Torque the castle nut to the lower torque specification, then tighten it only far enough to align the slot with the ball joint pin hole. Do not align the castle nut by loosening it. - Install a new lock pin on the castle nut after torquing. - Use a new spindle nut on reassembly. - Before installing the new spindle nut, apply a small amount of engine oil to the seating surface of the nut. After tightening, use a drift to stake the spindle nut shoulder against the driveshaft. - Before installing the brake disc, clean the mating surface of the front hub and the inside of the brake disc. - Before installing the wheel, clean the mating surface of the brake disc and the inside of the wheel. - Check the front wheel alignment, and adjust it if necessary. Page 4531 Shift Solenoid: Testing and Inspection Solenoid Valve Test - Continuously Variable Transmission Solenoid Valve Test 1. Disconnect solenoid harness connector (BP). 2. Measure CVT speed change control valve assembly resistance between solenoid harness connector terminals No. 3 and No. 7. STANDARD: 3.8 - 6.8 Ohms 3. Measure CVT pulley pressure control valve assembly resistance between terminals No. 2 and No. 6. STANDARD: 3.8 - 6.8 Ohms 4. Measure CVT start clutch pressure control valve assembly resistance between terminals No. 4 and No. 8. STANDARD: 3.8 - 6.8 Ohms 5. Measure the inhibitor solenoid resistance between terminal No. 5 and body ground. STANDARD: 11.7 - 21.0 Ohms 6. Replace the CVT speed change control valve assembly or CVT start clutch pressure control valve assembly, if the measurements are out of standard. Replace the lower valve body assembly, if the measurements of CVT pulley pressure control valve assembly or inhibitor solenoid are out of standard. 7. If all of the resistance are within the standard, a clicking sound should be heard when connecting the battery terminals to the solenoid harness connector terminals below. ^ CVT speed change control valve assembly No. 3 to battery positive terminal No. 7 to battery negative terminal ^ CVT pulley pressure control valve assembly No. 2 to battery positive terminal No. 6 to battery negative terminal ^ CVT start clutch pressure control valve assembly No. 4 to battery positive terminal No. 8 to battery negative terminal ^ Inhibitor solenoid No.5 to battery positive terminal and body ground to negative terminal 8. If no clicking sound is heard, remove the lower valve body assembly, and check the solenoid. Page 2529 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 Short Circuit Locator (Short Finder) 1. Remove the blown fuse. Leave the battery connected. Page 7626 ^ Going from front to back, use the middle lock pin to set the first cam to the appropriate key code number in the code book. (The cam is properly set when the number on the cam lines up with the red scribe mark on the clamp unit.) ^ Slide the lock pin through the notch in the cam. (This locks the cam in place.) ^ Keep doing this for each of the remaining cams in the set until all the cams are set and locked, then push the lock pin all the way in. Repeat this process to set and lock the cams for the right cam set. NOTE: Make sure you set the MIS cam in the right cam set for the type of key you are cutting. For a master key, set the cam to M; for a valet key, set it to S. When you are done, push all the cam blades to the left until they touch the cams in the left cam set. 10. Pull the vertical carriage lever toward you until the tracer touches the flat surface on the right side at the front of the cams. Gently twist the lever clockwise to lock the vertical carriage at this height. Do not overtighten the lever. 11. Turn on the cutter motor with the motor start switch. [NOTICE] ^ To avoid damaging the locking jaws while cutting, keep your hand off the vertical carriage lever. Pressure on the lever will change the cutting depth. * ^ To avoid breaking the cutter bit, never back up while cutting.* ^ Wear proper eye protection (safety glasses, goggles, etc.) 12. Use the clamp carriage lever and the tracer to follow the contours of the cam blades from front to back. (The cutter bit cuts the same contours into the right edge of the key blank, from head to tip.) Page 6032 Relay Box: Diagrams 234. Under-dash Fuse/Relay Box Part 1 Page 1086 3. Strip the insulation off the end of the wire so the wire fits in the new terminal as shown. (If the wire has a wire seal, replace it with a new one from the kit.) NOTE: After stripping the end of the wire, make sure you did not cut any wire strands. If you did, cut the wire off even with the insulation, and strip it again. 4. Position the terminal in the crimping tool slot with the solid portion of the terminal toward the anvil and the open section toward the former. 5. Insert the wire in the terminal to the position shown in step 3. 6. Squeeze the tool with both hands until the stops make contact. 7. Crimp the insulation crimp. - If you do not have a wire seal, then use the next larger size crimp slot. Position the crimping tool over the insulation crimp section of the terminal, then squeeze the tool with both hands until the stops make contact. - If you have a wire seal, position the insulation crimp in the 5.5 crimping slot, then carefully squeeze the crimp closed until its ends are touching and making a full-circle shape. Page 1407 Coolant: Fluid Type Specifications Coolant Type .................................................................................................................................................. Honda All Season Antifreeze/Coolant Type 2 Page 7006 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 916 Impact Sensor: Service and Repair Side Impact Sensor Side Impact Sensor Replacement Removal NOTE: - Removal of the side impact sensor must be performed according to the precautions/procedures described before. - Before disconnecting the side impact sensor 2P connector(s), disconnect the side airbag 2P connector(s). - Do not turn the ignition switch ON (II), and do not connect the battery cable while replacing the side impact sensor. 1. Disconnect the battery negative cable, and wait at least 3 minutes before beginning work. 2. 2-door: Slide the front seat forward. 4-door: Remove the seat assembly. 3. 2-door: Remove the rear seat-backs and rear seat cushion. 4-door: Remove the B-pillar lower trim panel. 4. 2-door: Remove the front seat belt lower anchor slide bar. 5. 2-door: Remove the side trim panel. 6. 2-door: Remove the middle cross-member gusset. 7. Disconnect the floor wire harness 2P connector (A) from the side impact sensor (B). 8. Remove the Torx bolt (C) using a Torx T30 bit, then remove the side impact sensor (B). Installation NOTE: - Be sure to install the harness wires so that they are not pinched or interfering with other parts. - Do not turn the ignition switch ON (II), and do not connect the battery cable while replacing the side impact sensor. 1. Install the new side impact sensor with a new Torx bolt (A) then connect the floor wire harness 2P connector (B) to the side impact sensor (C). 2. Reconnect the battery negative cable. 3. After installing the side impact sensor, confirm proper system operation: Turn the ignition switch ON (II): the SRS indicator should come on for about 6 seconds and then go off. 4. Install all remove parts. Page 2937 Power Steering Pressure Switch: Service and Repair Power Steering Hoses, Lines, and Pressure Switch Replacement Note these items during installation: ^ Connect each hose to the corresponding line securely until it contacts the stop on the line. Install the clamp or adjustable clamp at the specified distance from the hose end as shown. ^ Check all clamps for deterioration or deformation; replace the clamps with new ones, if necessary. ^ Add the recommended power steering fluid to the specified level on the reservoir and check for leaks. Page 3111 symptom/indication goes away with a known-good ECM/PCM, replace the original ECM/PCM. Page 2347 Engine Control Module: Service and Repair ECM/PCM Idle Learn Procedure ECM/PCM Idle Learn Procedure The idle learn procedure must be done so the ECM/PCM can learn the engine idle characteristics. Do the idle learn procedure whenever you do any of these actions: - Disconnect the battery. - Replace the ECM/PCM or disconnect its connector. - Reset the ECM/PCM. NOTE: Erasing DTCs with the Honda PGM Tester does not require you to do the idle learn procedure. - Remove the No.6 ECU (ECM/PCM) (15A) fuse from the under-hood fuse/relay box. - Remove the No.19 battery (80A) fuse from the under-hood fuse/relay box. - Remove PGM-FI main relay 1. - Remove any of the wires from the under-hood fuse/relay box. - Disconnect any of the connectors from the under-hood fuse/relay box. - Disconnect the connector between the engine compartment wire harness and ECM/PCM wire harness. - Disconnect the G2 terminal from the transmission housing. - Disconnect the G1 terminal from the body. - Disconnect the G101 terminal from the water passage. Procedure: 1. Make sure all electrical items (A/C, audio, rear defogger, lights, etc.) are off. 2. Start the engine, and hold it at 3,000 rpm with no load (in Park or neutral) until the radiator fan comes on, or until the engine coolant temperature reaches 194 °F (90 °C). 3. Let the engine idle for about 5 minutes with the throttle fully closed. NOTE: If the radiator fan comes on, do not include its running time in the 5 minutes Page 5778 Wiper/Washer Component Location Index Page 9396 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 Locater) 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. Troubleshooting Precautions Troubleshooting Precautions Before Troubleshooting 1. Check the main fuse and the fuse 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, or you will damage the alternator diodes. - Do not attempt to crank the engine with the ground cable disconnected 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. Adjustments Cruise Control Servo Cable: Adjustments Actuator Cable Adjustment 1. Check that the actuator cable (A) moves smoothly with no binding or sticking. 2. Measure the amount of movement of the output linkage (B) until the engine speed starts to increase. At first, the output linkage should be located at the fully closed position (C). The free play (D) should be 3.75 ± 0.5 mm (0.15 ± 0.02 in.). 3. If the free play is not within specs, loosen the locknut, and turn the adjusting nut until the free play is as specified, then retighten the locknut. Page 4785 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. Circuits must be operating when checking voltage drop. 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. 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 off, 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 Self-Powered Test Light or DVOM 1. Remove the blown fuse and disconnect the battery and load. Page 8223 ^ If the trunk opens and closes smoothly, return the vehicle to the customer. ^ If the trunk lid is still difficult to close, go to REPAIR PROCEDURE E. REPAIR PROCEDURE E 1. Look at the back of the lock cylinder while you turn the key from lock to unlock. ^ Refer to page 20-158 of the 2001-04 Civic Service Manual. ^ In ISIS, use the keyword LID LOCK, and select Trunk Lid Lock Cylinder Replacement from the list. 2. Check the operation of the trunk lid lock cylinder: ^ If the lock cylinder is difficult to turn or binds, go to step 3. ^ If the lock cylinder operates properly, and the trunk lid is still difficult to close, refer to the appropriate body repair manual, and check for body inaccuracies. 3. Replace the lock cylinder, and re-key the cylinder to the customer's original key; on 2-door Civics, replace the lock cylinder and the lock cylinder rod: ^ Refer to page 20-158 of the 2001-04 Civic Service Manual. ^ In ISIS, use the keyword LID LOCK, and select Trunk Lid Lock Cylinder Replacement from the list. 4. Check the trunk operation, and return the vehicle to the customer. Disclaimer Page 871 39. Left Side Of Engine Compartment Page 2872 Blower Motor Relay Type 1, Type 2 Check for continuity between the terminals. - There should be continuity between the No.1 and No.3 terminals when power and ground are connected to the No.2 and No.4 terminals. - There should be no continuity between the No.1 and No.3 terminals when power is disconnected. Five-terminal type Check for continuity between the terminals. - There should be continuity between the No.1 and No.2 terminals when power and ground are connected to the No.3 and No.5 terminals. - There should be continuity between the No.1 and No.4 terminals when power is disconnected. Page 5780 Under-dash Fuse/Relay Box (4-door) Page 5915 - 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. Troubleshooting Tests 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 test 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 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. 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 Drop Page 369 Page 1758 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. Circuits must be operating when checking voltage drop. 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. 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 off, 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 Self-Powered Test Light or DVOM 1. Remove the blown fuse and disconnect the battery and load. Testing and Inspection Timing Belt: Testing and Inspection Inspection 1. Remove the ignition coil cover, then remove the four ignition coils. 2. Remove the throttle cable clamps and harness holder mounting bolts. 3. Remove the cylinder head cover. 4. Inspect the timing belt for cracks and oil or coolant soaking. Replace the belt if it is oil or coolant soaked. Remove any oil or solvent that gets on the belt. 5. After inspecting, retorque the crankshaft pulley bolt. Instruments - Fuel Gauge Inaccurate Fuel Gauge: Customer Interest Instruments - Fuel Gauge Inaccurate 05-002 March 4, 2005 Applies To: 2003-04 Civic 4-Door EX and LX- VIN starts with 1HG or 2HG Inaccurate Fuel Gauge Reading SYMPTOM At any fuel level, the fuel gauge reading drops by 1/4 tank, or 3 to 4 graduation marks. In some cases, the fuel gauge indicates "E" and the low fuel warning light is on. After driving for several minutes, or cycling the ignition switch off/on, the fuel gauge returns to the correct reading. This problem is intermittent, and it affects only Civics with Visteon gauge assemblies. PROBABLE CAUSE The software specification for calculating the current fuel level is incorrect. CORRECTIVE ACTION Replace the gauge assembly. WARRANTY CLAIM INFORMATION In warranty: The normal warranty applies. Operation Number: 734101 Flat Rate Time: 0.3 hour Failed Part: Same as listed in PARTS INFORMATION Defect Code: 03214 Symptom Code: 03902 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 1147 Heated Glass Element Switch: Diagrams 194. Recirc - A/C - Defogger Switch Assembly Page 643 Combination Switch: Testing and Inspection Combination Light Switch Test/Replacement 1. Remove the dashboard lower cover. 2. Remove the steering column covers. 3. Disconnect the 16P connector (A) from the combination light switch (B). 4. Remove the two screws, then slide out the combination light switch. 5. Inspect the connector terminals to be sure they are all making good contact. - If the terminals are bent, loose or corroded, repair them as necessary, and recheck the system. - If the terminals look OK, check for continuity between the terminals in each switch position according to the tables. 6. If the continuity is not as specified, replace the switch. Page 3043 ^ Start the engine and let it warm up to its normal operating temperature (the cooling fans cycle twice). ^ Let the engine idle (throttle closed and all electrical items off) for 10 minutes. 17. CR-V only: Reset the power window control unit: ^ Turn the ignition switch to ON (II). ^ Make sure the driver's window is fully closed. ^ Push down and hold the window switch until the window goes all the way down. ^ Pull back and hold the window switch until the window goes all the way up, then hold the switch for at least 2 more seconds. 18. Enter the audio unit anti-theft code, and set the clock. Enter the audio presets. Disclaimer Campaign - OPDS Unit Warranty Extension Technical Service Bulletin # 06-009 Date: 080205 Campaign - OPDS Unit Warranty Extension 06-009 February 5, 2008 Applies To: See VEHICLES AFFECTED Warranty Extension: OPDS Unit or OPDS Sensor Triggers SRS DTC(s) 15-1, 15-2, 15-3 (Supersedes 06-009, dated September 21, 2007) Updated information is shown with asterisks. BACKGROUND *NOTE: Because of a class action settlement, the warranty extension coverage for the OPDS unit and the OPDS sensor on 2002 Accords, 2002-04 Civics, 2003-04 Civic Hybrids, 2002-04 CR-Vs, 2003 Elements, 2002 Odysseys, and 2003-04 Pilots purchased or leased between April 13, 2002, and November 7, 2006, is now 10 years or 157,500 miles, whichever occurs first. For more information, refer to Service Bulletin 06-085, Warranty Extension: Vehicle Warranty Mileage.* Several vehicle models may have a problem with the OPDS (occupant position detection system) that causes the SRS indicator to stay on. Typically, one or more of these DTCs will be set: ^ SRS DTC 15-1 (faulty OPDS unit or OPDS not initialized) ^ SRS DTC 15-2 (faulty side airbag indicator circuit) ^ SRS DTC 15-3 (faulty OPDS sensor) To ensure continued reliability with the OPDS, American Honda is extending the warranty on the OPDS unit and the OPDS sensor to 10 years or 150,000 miles, whichever occurs first. This warranty extension does not apply to any vehicle that has ever been declared a total loss, or any that has been issued a salvage, branded, or similar title under any state's law. To check for vehicle eligibility, you must do a VIN status inquiry Page 1090 13. Plug in the heat gun, and turn it on. Start at the middle of the splice connector, and move the gun toward the ends as the tube shrinks. Apply heat evenly by rotating the curved heat spreader around the splice connector. Shrinking is complete when a small amount of sealant appears at each end of the tube. Pigtail Terminal Selection Chart PIGTAIL TERMINAL SELECTION CHART Select the proper size pigtail terminal by matching the replacement terminal part number and the wire size being repaired to the corresponding pigtail terminal part number. Then use the color (size) splice connector listed. In some instances you may also have to match the wire seal style to select the proper pigtail terminal. Pigtail terminals are available through your parts department, in quantities of 10, using normal parts ordering procedures. Checking For Poor Fir of Terminals CHECKING FOR POOR FIT OF TERMINALS Loose terminal fit can cause a number of intermittent problems in electrical circuits. By using the Terminal Inspection Feeler Tool Set you can inspect the terminal fit between the two matching connectors without removing the terminals from the connector body. 1. Find the terminal tool that best matches the male terminal in the mating connector. Page 4685 156. A/T Reverse Relay (A/T, CVT) Page 599 110. Left B Pillar (Right Similar) 111. Left C Pillar (Sedan) (Right Similar) Diagrams (Honda Accessory) Page 2904 17. Right Side Of Engine Compartment (EX, HX) Page 9437 (A/T, CVT) Page 7867 1. Clean the body surface with a sponge dampened in alcohol. After cleaning, keep oil, grease and water from getting on the surface. 2. Apply the emblems where shown. Page 8494 Seat Latch: Service and Repair Rear Seat-Back Lock Cylinder Rear Seat-back Lock Cylinder Replacement Special Tools Required KTC trim tool set SOJATP2014 2-door NOTE: - Use the appropriate tool from the KTC trim tool set to avoid damage when prying components. - Take care not to scratch the interior trim. 1. Remove the rear shelf. 2. Disconnect the cylinder rods from both seat-back latches. 3. Remove the screws, then remove the seat-back lock cylinder (A) and cylinder rods (B). 4. Install the lock cylinder in the reverse order of removal, and note these items: - Make sure the cylinder rod is connected securely. - Make sure the seat-back opens properly. 4-door NOTE: - Use the appropriate tool from the KTC trim tool set to avoid damage when prying components. - Take care not to scratch the interior trim. 1. Remove the lock cylinder trim (A). 2. From trunk compartment, disconnect the cylinder rods from both seat-back latches. Page 7959 Air Bag(s) Arming and Disarming: Service and Repair Connector Disconnection / Connection Disconnecting System Connectors Before removing a front airbag, side airbag, or other SRS related devices (the SRS unit, the cable reel, front sensor, the side impact sensors, the seat belt buckle tensioners, and the seat belt tensioner connector), disconnecting connectors from related devices, or removing the dashboard or the steering column, disconnect the airbag connectors or the side airbag connectors to prevent accidental deployment. Turn the ignition switch OFF, disconnect the negative cable from the battery, and wait at least 3 minutes before beginning the following procedures. - Before disconnecting SRS unit connector A (A) from the SRS unit, disconnect the driver's airbag 4P connector (C), the front passenger's airbag 4P connector (D), the driver's seat belt tensioner 2P connector (F), and the front passenger's seat belt tensioner 2P connector (G). - Before disconnecting SRS unit connector B (1) from the SRS unit, disconnect both side airbag 2P connectors (L, M) and both seat belt buckle tensioner 4P connectors (J, K). - Before disconnecting the cable reel 4P connector (B), disconnect the driver's airbag 4P connector (C). - Before disconnecting the floor wire harness 4P connector (E), disconnect both seat belt tensioner 2P connectors (F, G). 1. Disconnect the battery negative cable, and wait at least 3 minutes. Driver's Airbag Page 5232 Wires Page 4216 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 Locater) 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. Troubleshooting Precautions Troubleshooting Precautions Before Troubleshooting 1. Check the main fuse and the fuse 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, or you will damage the alternator diodes. - Do not attempt to crank the engine with the ground cable disconnected 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. Page 9635 Circuit Schematics Each schematic represents one circuit. A circuit's wires and components are arranged to show current flow from power at the top of the diagram 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 Page 7913 Subframe: Service and Repair Subframe Replacement Subframe Torque After loosening the subframe mounting bolts, be sure to replace them with new ones Page 5955 Charging System Component Location Index Page 9028 3. Strip the insulation off the end of the wire so the wire fits in the new terminal as shown. (If the wire has a wire seal, replace it with a new one from the kit.) NOTE: After stripping the end of the wire, make sure you did not cut any wire strands. If you did, cut the wire off even with the insulation, and strip it again. 4. Position the terminal in the crimping tool slot with the solid portion of the terminal toward the anvil and the open section toward the former. 5. Insert the wire in the terminal to the position shown in step 3. 6. Squeeze the tool with both hands until the stops make contact. 7. Crimp the insulation crimp. - If you do not have a wire seal, then use the next larger size crimp slot. Position the crimping tool over the insulation crimp section of the terminal, then squeeze the tool with both hands until the stops make contact. - If you have a wire seal, position the insulation crimp in the 5.5 crimping slot, then carefully squeeze the crimp closed until its ends are touching and making a full-circle shape. Page 2121 Compression Check: Testing and Inspection Engine Compression Inspection 1. Warm up the engine to normal operating temperature (cooling fan comes on). 2. Turn the ignition switch OFF. 3. Remove the air cleaner housing. 4. Disconnect all four injector connectors. 5. Remove the four ignition coils. 6. Remove the four spark plugs. 7. Attach the compression gauge to the spark plug hole. 8. Connect a tachometer. 9. Open the throttle fully, then crank the engine with the starter motor and measure the compression. Compression Pressure: Above 930 kPa (9.5 kgf/cm2, 135 psi) 10. Measure the compression on the remaining cylinders. Maximum variation: Within 200 kPa (2.0 kgf/cm2, 28 psi) 11. If the compression is not within specifications, check the following items, then re-measure the compression. ^ Damaged or worn valves and seats ^ Damaged cylinder head gasket ^ Damaged or worn piston rings ^ Damaged or worn piston and cylinder bore Page 3917 NOTE: If the latest software is not loaded and you do a control unit/module update, the software may indicate the vehicle has the latest update when it doesn't. Updates not done with the latest software are not covered under warranty. 2. From the iN workstation desktop, select CM Update (ECU Rewrite). 3. Connect the USB PC interface cable to the iN workstation and to the GNA6OO. Click on the Tools button on the right side of the screen, and make sure the interface device is set to GNA600. 4. Return to the Updating Honda Control Modules main screen, and click on Pass-th ru-Mode. 5. Connect the DLC cable to the GNA600 and to the vehicle's DLC. 6. Turn the ignition switch to ON (II), and wait until the green No.2 LED on the GNA6OO stays on. Click on the check mark to continue. Each updatable vehicle system is checked to make sure it is current. Any systems needing an update are listed on the screen. Highlight the system you want to update, then click on the check mark to continue. NOTE: Update the systems one at a time. Page 4072 Fluid - A/T: Service and Repair ATF Replacement ATF Replacement NOTE: Keep all foreign particles out of the transmission. 1. Bring the transmission up to operating temperature (the radiator fan comes on) by driving the vehicle. 2. Park the vehicle on level ground, and turn the engine off. 3. Remove the drain plug, and drain the automatic transmission fluid (ATF). NOTE: If a cooler flusher is to be used, refer to ATF Cooler Flushing. 4. Reinstall the drain plug with a new sealing washer. 5. Refill transmission with the recommended fluid into dipstick hole to the upper mark on the dipstick. Always use Honda ATF-Z1 Automatic Transmission Fluid (ATF). Using a non-Honda ATF can affect shift quality. Automatic Transmission Fluid Capacity: 2.7 L (2.9 US qt) at changing 6.0 L (6.3 US qt) at overhaul Page 3145 1. Remove the secondary lock from the male terminal half. 2. Remove the secondary lock from the female terminal half. 3. Remove the terminal (same procedure for male and female). 4. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE C: 1. Remove the secondary lock. Diagrams Page 4773 Terminals - "T" Shielding Switches Fuses Page 1584 Under-hood Fuse/Relay Box Page 3093 Oxygen Sensor: Diagrams 130. A/F Sensor 140. HO2S, Primary (GX; '01-'03: EX, DX, LX) Or Secondary (HX) Page 93 Blower Motor Relay: Testing and Inspection Power Relay Test Use this chart to identify the type of relay, then do the test listed for it. NOTE: See the turn signal/hazard relay input test. Normally-open type B: Blower Motor Relay Type 1, Type 2 Check for continuity between the terminals. - There should be continuity between the No.1 and No.3 terminals when power and ground are connected to the No.2 and No.4 terminals. - There should be no continuity between the No.1 and No.3 terminals when power is disconnected. 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 6790 7. Align the projections on the cable reel with the holes on the steering wheel, and install the steering wheel with a new steering wheel bolt (A). 8. Install the driver's airbag. 9. Reconnect the battery negative cable. 10. After installing the cable reel, confirm proper system operation: - Turn the ignition switch ON (II); the SRS indicator should come on for about 6 seconds and then go off. - After the SRS indicator has turned off, turn the steering wheel fully left and right to confirm the SRS indicator does not come on. - Make sure the horn works. Locations Relay And Control Unit Locations - Dashboard Page 83 61. Under Left Side Of Dash Page 2512 Wire Color Abbreviations Page 9749 5. Disconnected the 14Pconnecter and, make these in put tests at the connector. Diagrams 223. ABS Modulator-Control Unit (EX, GX) Page 6681 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 5034 195. Tranmission Range Switch Page 7649 NOTE: You need to make the corrections listed in CODE BOOK CORRECTIONS at the end of this service bulletin. TRACER AND CUTTER BIT INSTALLATION 1. Turn the power switch on the back of the machine to ON. (This turns on the built-in work light.) 2. Use the Allen wrench from the built-in tool drawer to loosen the setscrew on the left sleeve of the vertical carriage. Slide the tracer all the way into the sleeve, and tighten the screw. 3. Turn the plastic shield on the right sleeve of the vertical carriage so you can access the setscrew on the sleeve. Use the Allen wrench to loosen the screw. Slide the cutter bit all the way into the sleeve, and tighten the screw. Turn the plastic shield so the open side is in the back. MACHINE COMPONENTS Service and Repair Cabin Air Filter: Service and Repair Dust and Pollen Filter Replacement (With Air Conditioning) The dust and pollen filters should be replaced every 30,000 miles (48,000 km) or 24 months whichever comes first. Replace the filters more often if the air flow is less than usual. 1. Open the glove box. Remove the glove box stop on each side, then hang the glove box down. 2. Remove the filter lid (A) from the blower unit, then pull out the first dust and pollen filter (B). Slide the second filter to the left, and pull it out. 3. Remove the filter (A) from the housing (B), and replace the filter. 4. Install the filters in the reverse order of removal. Multiplex Control System Troubleshooting Body Control Systems: Testing and Inspection Multiplex Control System Troubleshooting Troubleshooting Mode 1 Test 1. Remove the dashboard lower cover. 2. Check the No.9 (10 A) fuse in the under-hood fuse/relay box and the No.10 (7.5 A) fuse in the under-dash fuse/relay box. Are the fuses OK? YES - Go to step 2. NO - Find and repair the cause of the blown fuse. 3. Turn the ignition switch ON (II). If the driver's seatbelt is unbuckled, the seatbelt reminder will chime 6 times. 4. Set the ceiling light to the center position and close all the doors. 5. Connect the special tool to the multiplex inspection connector. 6. After about 5 seconds the spotlight and ceiling light should come on for 2 seconds, go out, then blink on for 0.2 second to show the system is now in mode 1. Did the spotlight and ceiling light indicate mode 1? YES - Go to step 8. NO - Go to step 7. 7. Check for continuity between terminal 4 of the under-dash fuse/relay box connector J and body ground. Is there continuity? YES - Replace the under-dash fuse/relay box. NO - Repair the open in the wire. If the wire is ok, repair G301. 8. If the are DTCs present, the spotlight and ceiling light will blink to indicate the DTC(s). If more than one DTC is present, the DTCs will be displayed in ascending order. If there are not DTCs the spotlight and ceiling light will no blink again after the mode 1 indication. Page 802 Terminals - "T" Shielding Switches Fuses Page 1243 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 2843 2. Insert the terminal tool into the female terminal, and then remove the terminal tool. NOTE: Make sure you do not select a terminal tool that is larger than the mating male terminal because it would spread the female terminal and cause a loose fit. 3. Compare the drag to the other terminals in the connector. If the drag is less, replace the terminal with a replacement terminal from the appropriate terminal repair kit. Page 9131 Power Distribution schematics show how power is supplied from the positive battery terminal to various circuits in the vehicle. Refer to the Power Distribution diagram set to get a more detailed understanding of how picture is supplied to the circuit you're working on. Individual circuit schematics begin with a fuse. So 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 Ground Distribution Schematics This sample Ground Distribution schematic shows all of the components that share the same ground point. Page 2547 Transmission Position Switch/Sensor: Testing and Inspection Transmission Range Switch Test 1. Remove the transmission range switch harness connector (A) from the connector bracket (B), then disconnect the connector. 2. Check for continuity between terminals at the harness connector. There should be continuity between the terminals listed for each switch position. In the P position, between terminals: ^ No. 1 and No. 3 ^ No. 1 and No. 8 ^ No. 3 and No. 8 In the R position, between terminals: ^ No. 1 and No. 9 In the N position and between terminals: ^ No. 1 and No. 3 ^ No. 1 and No. 10 ^ No. 3 and No. 10 In the D position, between terminals: ^ No. 1 and No. 2 ^ No. 1 and No. 4 ^ No.2 and No.4 In the D3 position, between terminals: ^ No. 1 and No. 2 ^ No. 1 and No. 5 ^ No.2 and No.5 In the 2 position, between terminals: ^ No. 1 and No. 6 Page 6306 Control Arm: Service and Repair Rear Suspension Removal/Installation 1. Raise the rear of the vehicle, and support it with safety stands in the proper locations. Remove the rear wheels. 2. Place a floor jack under the trailing arm, and support the suspension. 3. Remove the flange bolt (A) and wheel sensor harness bracket (B). 4. Remove the flange bolts (A), and remove the upper arm (B). 5. Install the upper arm in the reverse order of removal, and note these items: ^ First install all the suspension components and lightly tighten bolts and nuts, then place a jack under the trailing arm, and raise the suspension to load it with the vehicle's weight before fully tightening bolts and nuts to the specified torque values. ^ Tighten all the mounting hardware to the specified torque values. ^ Before installing the wheel, clean the mating surface of the brake drum and the inside of the wheel. ^ Check the wheel alignment, and adjust it if necessary. Page 826 8. Inspect the quality of the wire crimp. If it has any of the following NO GOOD crimps, cut it off and start over. 9. Insert the terminal into the connector. Make sure the wire seals are pushed all the way into the connector. Lightly pull on the wires to make sure the terminal is locked into place. 10. Close or insert the secondary terminal lock, if applicable, and reconnect the connector. How to Install Pigtail Terminals HOW TO INSTALL PIGTAIL TERMINALS Pigtail terminals (short pieces of wire with a factory crimped terminal) are used when the wire is too short or when access to the connector is too restricted to make a terminal repair. NOTE: To replace just a connector terminal, go to How to Replace Connector Terminals. IMPORTANT SAFETY INFORMATION: On some models, the SRS wires are in a separate harness. If the SRS harness is damaged, replace the harness; do not repair it. On other models, wire harnesses include yellow SRS wires. If any SRS wire is damaged, replace the entire harness; do not repair it. 1. Remove the damaged or faulty terminal from the connector. Use the proper removal tool from Pin Tool Set. Page 8715 Relay And Control Unit Locations - Dashboard Page 1973 Specifications Firing Order: Specifications Ignition coil Firing order .......................................................................................................................................... ............................................................ 1 - 3 - 4 - 2 Page 4141 Control Module: Service and Repair How to Substitute the PCM How to Substitute the PCM 1. Remove the PCM from the vehicle. 2. Install a known-good PCM in the vehicle. 3. Rewrite the immobilizer code with the PCM replacement procedure in the Honda PGM Tester; It allows you to start the engine. 4. After completing your tests, reinstall the original PCM and rewrite the immobilizer code with the PCM replacement procedure in the HDS Tester again. Page 3197 Splices Components Ground - "G" Page 2455 36. Left Side Of Engine Compartment (except GX) Page 6024 Under-dash Fuse/Relay Box (2-door) Testing and Inspection Brake Hose/Line: Testing and Inspection Brake Hoses and Lines Inspection 1. Inspect the brake hoses, for damage, deterioration, leaks, interference, and twisting. 2. Check the brake lines for damage, rusting, and leakage. Also check for bent brake lines. 3. Check for leaks at hose and line joints or connections, and retighten if necessary. 4. Check the master cylinder and ABS modulator unit (if equipped) for damage and leakage. NOTE: Replace the brake hose clip whenever the brake hose is serviced. Page 6959 12. On Accords and Pilots, install the new seat-back clips on the seat-back panel. Turn the clips so their retaining tabs are horizontal. 13. On Accords and Pilots, install the seat-back panel. 14. On all models except Accords and Pilots, zip the seat-back cover closed. 15. Initialize the OPDS unit. ^ To initialize with the HDS, go to Initializing the OPDS Unit: HDS Method. ^ To initialize with the SCS service connector, go to Initializing the OPDS Unit: Manual Mode. Initializing the OPDS Unit: HDS Method NOTE: Non-Honda seat covers will interfere with the performance of the OPDS and are not recommended. 1. Adjust the front passenger's seat-back to an upright position, then remove anything on or near the seat. 2. Turn the ignition switch to LOCK (0). 3. Connect the HDS to the vehicle's DLC (data link connector). 4. Turn the ignition switch to ON (II), then turn on the HDS. 5. At the screen prompts, enter the VIN and the odometer reading. Also verify the correct date and time. 6. From the System Selection menu, select SRS. Page 1876 10. Install the back cover (A), then install the camshaft pulley (B). Airbag Deployment and Disposal Air Bag: Service and Repair Airbag Deployment and Disposal Deploying the Airbags/Tensioner (Inside Vehicle) Airbag Disposal Special Tool Required Deployment tool 07HAZ-SG00500 Before scrapping any airbags, side airbags, seat belt tensioners or seat belt buckle tensioners (including those in a whole vehicle to be scrapped), the airbags, side airbags, seat belt tensioners or seat belt buckle tensioners must be deployed. If the vehicle is still within the warranty period, the Honda District Service Manager must give approval and/or special instruction before deploying the airbags, side airbags, seat belt tensioners or seat belt buckle tensioners. Only after the airbags, side airbags, seat belt tensioners or seat belt buckle tensioners have been deployed (as the result of vehicle collision, for example), can they be scrapped. If the airbags, side airbags, seat belt tensioners and seat belt buckle tensioners appear intact (not deployed), treat them with extreme caution. Follow this procedure. Deploying Airbags In the vehicle If an SRS equipped vehicle is to be entirely scrapped, its airbags, side airbags, seat belt tensioners and seat belt buckle tensioners should be deployed while still in the vehicle. The airbags, side airbags, seat belt tensioners and seat belt buckle tensioners should not be considered as salvageable parts and should never be installed in another vehicle. 1. Turn the ignition switch OFF, then disconnect the battery negative cable, and wait at least 3 minutes. 2. Confirm that each airbag, side airbag, and seat belt tensioner is securely mounted. 3. Confirm that the special tool is functioning properly by following the check procedure on the tool label. Driver's Airbag: 4. Remove the access panel from the steering wheel (A), then disconnect the driver's airbag 4P connector (B) from the cable reel. Front Passenger's Airbag: 5. Lower the glove box, then disconnect the front passenger's airbag 4P connector (A) from dashboard wire harness B. Specifications Timing Belt Tensioner: Specifications Tighten the auto-tensioner mounting bolt (A) to 44 Nm (4.5 kgf-cm, 33 ft. lbs.). Page 9738 Power Window Switch: Diagrams (Sedan Except DX) (Sedan Except DX) Page 5866 Exterior Lights Component Location Index Page 2366 95. Behind Glove Box (HX; '04-'05: DX, EX, LX) Page 2595 Crankshaft Position Sensor: Service and Repair CKP Sensor Replacement 1. Remove the grommet (A) from the upper cover, and disconnect the camshaft position (CMP) (top dead center (TDC)) sensor connector (B). 2. Remove the upper cover (C) and lower cover (D). 3. Disconnect the crankshaft position (CKP) sensor connector, then remove the CKP sensor from the oil pump. 4. Install the CKP sensor in reverse order of removal. Page 6428 22. Press a new hub bearing unit (A) into the hub (B) using the special tools and a press. 23. Install the knuckle/hub/hub bearing unit in the reverse order of removal, and note these items: - Be careful not to damage the ball joint boot when installing the knuckle. - Tighten all mounting hardware to the specified torque values. - Torque the castle nut to the lower torque specification, then tighten it only far enough to align the slot with the ball joint pin hole. Do not align the castle nut by loosening it. - Install a new lock pin on the castle nut after torquing. - Use a new spindle nut on reassembly. - Before installing the new spindle nut, apply a small amount of engine oil to the seating surface of the nut. After tightening, use a drift to stake the spindle nut shoulder against the driveshaft. - Before installing the brake disc, clean the mating surface of the front hub and the inside of the brake disc. - Before installing the wheel, clean the mating surface of the brake disc and the inside of the wheel. - Check the front wheel alignment, and adjust it if necessary. Page 9643 - 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. Troubleshooting Tests 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 test 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 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. 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 Drop 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 2292 EXHAUST PIPE AND MUFFLER REPLACEMENT W/ RELATED COMPONENTS Page 7847 ^ If the trunk opens and closes smoothly, return the vehicle to the customer. ^ If the trunk lid is still difficult to close, go to REPAIR PROCEDURE E. REPAIR PROCEDURE E 1. Look at the back of the lock cylinder while you turn the key from lock to unlock. ^ Refer to page 20-158 of the 2001-04 Civic Service Manual. ^ In ISIS, use the keyword LID LOCK, and select Trunk Lid Lock Cylinder Replacement from the list. 2. Check the operation of the trunk lid lock cylinder: ^ If the lock cylinder is difficult to turn or binds, go to step 3. ^ If the lock cylinder operates properly, and the trunk lid is still difficult to close, refer to the appropriate body repair manual, and check for body inaccuracies. 3. Replace the lock cylinder, and re-key the cylinder to the customer's original key; on 2-door Civics, replace the lock cylinder and the lock cylinder rod: ^ Refer to page 20-158 of the 2001-04 Civic Service Manual. ^ In ISIS, use the keyword LID LOCK, and select Trunk Lid Lock Cylinder Replacement from the list. 4. Check the trunk operation, and return the vehicle to the customer. Disclaimer Page 6878 Seat Occupant Sensor: Locations SRS Component Location Index Page 5144 Shift Indicator: Electrical Diagrams Automatic Transmission Circuit Diagram Continuously Variable Transmission Locations Heated Glass Element Switch: Locations Rear Window Defogger Component Location Index Page 8583 10. Pull down on the retainer clip with a hook-shaped tool. Remove the lock cylinder. Then go to step 14. 11. Pull the glass run channel away as necessary, and remove the bolt, then remove the center lower channel by pulling it downward. 12. Remove the access seal, and disconnect the outer handle rod and the cylinder rod. Page 3951 NOTE: If the latest software is not loaded and you do a control unit/module update, the software may indicate the vehicle has the latest update when it doesn't. Updates not done with the latest software are not covered under warranty. 2. From the iN workstation desktop, select CM Update (ECU Rewrite). 3. Connect the USB PC interface cable to the iN workstation and to the GNA6OO. Click on the Tools button on the right side of the screen, and make sure the interface device is set to GNA600. 4. Return to the Updating Honda Control Modules main screen, and click on Pass-th ru-Mode. 5. Connect the DLC cable to the GNA600 and to the vehicle's DLC. 6. Turn the ignition switch to ON (II), and wait until the green No.2 LED on the GNA6OO stays on. Click on the check mark to continue. Each updatable vehicle system is checked to make sure it is current. Any systems needing an update are listed on the screen. Highlight the system you want to update, then click on the check mark to continue. NOTE: Update the systems one at a time. Page 8601 ^ Going from front to back, use the middle lock pin to set the first cam to the appropriate key code number in the code book. (The cam is properly set when the number on the cam lines up with the red scribe mark on the clamp unit.) ^ Slide the lock pin through the notch in the cam. (This locks the cam in place.) ^ Keep doing this for each of the remaining cams in the set until all the cams are set and locked, then push the lock pin all the way in. Repeat this process to set and lock the cams for the right cam set. NOTE: Make sure you set the MIS cam in the right cam set for the type of key you are cutting. For a master key, set the cam to M; for a valet key, set it to S. When you are done, push all the cam blades to the left until they touch the cams in the left cam set. 10. Pull the vertical carriage lever toward you until the tracer touches the flat surface on the right side at the front of the cams. Gently twist the lever clockwise to lock the vertical carriage at this height. Do not overtighten the lever. 11. Turn on the cutter motor with the motor start switch. [NOTICE] ^ To avoid damaging the locking jaws while cutting, keep your hand off the vertical carriage lever. Pressure on the lever will change the cutting depth. * ^ To avoid breaking the cutter bit, never back up while cutting.* ^ Wear proper eye protection (safety glasses, goggles, etc.) 12. Use the clamp carriage lever and the tracer to follow the contours of the cam blades from front to back. (The cutter bit cuts the same contours into the right edge of the key blank, from head to tip.) Page 7313 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 4807 Shift Indicator: Service and Repair Indicator Bulb Replacement SRS components are located in this area. Review the SRS component locations, precautions, and procedures in SRS before performing repairs or service. 1. Remove the gauge assembly. 2. Replace the bulb (A) in the gauge assembly (B). Page 978 NOTE: You need to make the corrections listed in CODE BOOK CORRECTIONS at the end of this service bulletin. TRACER AND CUTTER BIT INSTALLATION 1. Turn the power switch on the back of the machine to ON. (This turns on the built-in work light.) 2. Use the Allen wrench from the built-in tool drawer to loosen the setscrew on the left sleeve of the vertical carriage. Slide the tracer all the way into the sleeve, and tighten the screw. 3. Turn the plastic shield on the right sleeve of the vertical carriage so you can access the setscrew on the sleeve. Use the Allen wrench to loosen the screw. Slide the cutter bit all the way into the sleeve, and tighten the screw. Turn the plastic shield so the open side is in the back. MACHINE COMPONENTS Page 2279 Catalytic Converter: Description and Operation Catalytic Converter System NOX Adsorptive Three Way Catalyst (NOX Adsorptive TWC) (D17A6 engine) The NOx adsorptive TWC absorbs NOx created during lean burn running when the oxygen concentration is high. Then the engine is put into a richer running mode where the oxygen concentration and NOx levels are low, and the absorbed NOx is released, keeping the average NOx emissions low. Three Way Catalytic Converter (TWC) The TWC converts hydrocarbons (HC), carbon monoxide (CO), and oxides of nitrogen (NOx) in the exhaust gas to carbon dioxide (CO2), dinitrogen (N2), and water vapor. Page 5733 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 Short Circuit Locator (Short Finder) 1. Remove the blown fuse. Leave the battery connected. Diagram Information and Instructions Variable Valve Timing Actuator: Diagram Information and Instructions Terminal Numbering System Terminal Numbering System Connector terminals are numbered according to the cavities they're in. The cavities are numbered starting from the upper left, looking at the male terminals from the terminal side or looking at the female terminals from the wire side. Both views are in the same direction so the numbers are the same. All actual cavities are numbered, even if they have no wire terminals in them. NOTE: Data Link Connector (DLC) terminals are numbered according 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 below is #6. Page 9497 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. How to Replace Connector Terminals Terminal Replacement Procedure HOW TO REPLACE CONNECTOR TERMINALS The terminal repair kits provide necessary tools and materials (terminals, wire seals, and splice connectors) to repair many damaged or faulty connector terminals. However, not all terminals for all connectors are available. Refer to the labels on the lids of the repair kits for replacement terminal availability. IMPORTANT SAFETY INFORMATION: On some models, the SRS wires are in a separate harness. If the SRS harness is damaged, replace the harness; do not repair it. On other models, wire harnesses include yellow SRS wires. If any SRS wire is damaged, replace the entire harness; do not repair it. Before you begin, inspect the wire you are about to repair for damage and length. Make sure the wire will be long enough to make a terminal repair without stretching it when you reinstall the terminal in the connector. If the wire is too short, or if access to the connector is too restricted to make a terminal repair, you may need to install a pigtail terminal (a short length of wire with a factory-crimped terminal on it). Refer to HOW TO INSTALL PIGTAIL TERMINALS. Removing the Terminal Page 2015 2. Set the crankshaft to top dead center (TDC). Align the TDC mark (A) on the timing belt drive pulley with the pointer (B) on the oil pump. 3. Clean the camshaft pulley and set it to TDC. -1 The "UP" mark (A) on the camshaft pulley should be at the top. -2 Align the TDC marks (B) on the camshaft pulley with the top edge of the head. 4. Install the timing belt in a counterclockwise sequence, starting with the drive pulley. -1 Drive pulley (A). -2 Tensioner pulley (B). -3 Water pump pulley (C). -4 Camshaft pulley (D). Page 3827 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. How to Replace Connector Terminals Terminal Replacement Procedure HOW TO REPLACE CONNECTOR TERMINALS The terminal repair kits provide necessary tools and materials (terminals, wire seals, and splice connectors) to repair many damaged or faulty connector terminals. However, not all terminals for all connectors are available. Refer to the labels on the lids of the repair kits for replacement terminal availability. IMPORTANT SAFETY INFORMATION: On some models, the SRS wires are in a separate harness. If the SRS harness is damaged, replace the harness; do not repair it. On other models, wire harnesses include yellow SRS wires. If any SRS wire is damaged, replace the entire harness; do not repair it. Before you begin, inspect the wire you are about to repair for damage and length. Make sure the wire will be long enough to make a terminal repair without stretching it when you reinstall the terminal in the connector. If the wire is too short, or if access to the connector is too restricted to make a terminal repair, you may need to install a pigtail terminal (a short length of wire with a factory-crimped terminal on it). Refer to HOW TO INSTALL PIGTAIL TERMINALS. Removing the Terminal Page 7198 1. Remove the driver's dashboard lower cover. (See the body section of the appropriate service manual.) 2. Replace the security control unit. ^ Civic: Remove the security control unit, and install the new security control unit. ^ * CR-V and Element: Remove the security control unit and microphone. Install the new security control unit and new microphone.* 3. Reprogram the keyless receiver unit. NOTE: The codes of up to three transmitters can be stored in the keyless receiver unit memory. If a fourth code is stored, the code that was input first will be erased. It is important to maintain the time limits between the steps. Make sure the doors and the trunk/tailgate/hatch are closed, and that you have all of the remotes the customer wishes to use. ^ Turn the ignition switch to ON (II). ^ Within 1 to 4 seconds, push the transmitter lock or unlock button. ^ Within 1 to 4 seconds, turn the ignition switch to LOCK (0). ^ Within 1 to 4 seconds, turn the ignition to ON (II). ^ Within 1 to 4 seconds, push the transmitter lock or unlock button. ^ Within 1 to 4 seconds, turn the ignition switch to LOCK (0). ^ Within 1 to 4 seconds, turn the ignition switch to ON (II). ^ Within 1 to 4 seconds, push the transmitter lock or unlock button. Page 2868 166. PGM-FI Main Relays 1 And 2 Page 5907 Circuit Schematics Each schematic represents one circuit. A circuit's wires and components are arranged to show current flow from power at the top of the diagram 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 Page 3832 1. Remove the secondary locks. 2. Remove the terminal from the female half. 3. Remove the terminal from the male half. 4. Go to HOW TO INSTALL NEW TERMINALS. Connectors Without a Secondary Lock All examples are shown with the connector lock facing up. The illustrations are examples of connector terminals without a secondary lock; however, the connector you are repairing may vary in size and shape. EXAMPLE A: Page 3049 REPAIR PROCEDURE 1. Make sure you have the anti-theft code for the audio unit. Write down the customer's audio presets. 2. Disconnect the negative battery cable from the battery. 3. Remove the under-hood fuse/relay box cover. 4. Release the three clips, and remove the under- hood fuse/relay box from the holder. CR-V only: Release the wire harness clip from the fuse/relay box holder Page 6496 4. Release the field coil connector from the holder, then disconnect it (01 model). Check the thermal protector for continuity. If there is no continuity, replace the thermal protector. NOTE: The thermal protector will have no continuity above 252 to 262 °F (122 to 128 °C). When the temperature drops below 241 to 219 °F (116 to 104 °C), the thermal protector will have continuity. 5. Release the field coil connector from the holder, then disconnect it. Check resistance of the field coil. If resistance is not within specifications, replace the field coil. Page 1517 Under-dash Fuse/Relay Box Page 2048 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. Test Equipment 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. Page 8947 161. Middle Of Engine Compartment Page 9592 PGM-F1 Main Relay 1, 2 Type 1, 2 Check for continuity between the terminals. - There should be continuity between the No.1 and No.2 terminals when power and ground are connected to the No.3 and No.4 terminals. - There should be no continuity between the No.1 and No.2 terminals when power is disconnected. Normally-open type B: Rear Window Defogger Relay Page 4528 Shift Solenoid: Diagrams 185. CVT Control Valves And Inhibitor Solenoid Assembly 73. Shift Solenoid Valve A And B (A/T Except CVT) Page 2869 Main Relay (Computer/Fuel System): Description and Operation PGM-FI Main Relay 1 and 2 The PGM-FI relay consists of two separate relays. PGM-FI main relay 1 is energized whenever the ignition switch is ON (II) which supplies battery voltage to ECM/PCM, power to the injectors, and power for PGM-FI main relay 2. PGM-FI main relay 2 is energized to supply power to the fuel pump for 2 seconds when the ignition switch is turned ON (II), and when the engine is running. Page 6570 Heater Core Case: Service and Repair Heater Unit/Core Replacement SRS components are located in this area. Review the SRS component locations, and precautions and procedures in the SRS section before performing repairs or service. 1. Make sure you have the anti-theft code for the radio, then write down the frequencies for the radio's preset buttons. 2. Disconnect the negative cable from the battery. 3. With air conditioning; disconnect the suction and receiver lines from the evaporator core. 4. From under the hood, open the cable clamp (A), then disconnect the heater valve cable (B) from the heater valve arm (C). Turn the heater valve arm to the fully opened position as shown. 5. When the engine is cool, drain the engine coolant from the radiator. 6. Slide the hose clamps (A) back, then disconnect the inlet heater hose (B) and the outlet heater hose (C) from the heater core. Engine coolant will run out when the hoses are disconnected; drain it into a clean drip pan. Be sure not to let coolant spill on the electrical parts or the painted surfaces. If any coolant spills, rinse it off immediately. 7. Remove the mounting bolt and the heater valve as shown. Page 3641 107. Behind A/T Shift Lever (except M/T) Antitheft System - Alarm Will Not Arm/Arms By Itself Keyless Entry Transmitter: Customer Interest Antitheft System - Alarm Will Not Arm/Arms By Itself 05-025 July 1, 2005 Applies To: 2001-05 Civic - ALL 2002-05 CR-V - ALL 2003-04 Element - ALL Accessory Security System Changes Modes By Itself (Supersedes 05-025, dated June 10, 2005, to update the information indicated by black bars and asterisks.) SYMPTOM The security system will not arm or it arms by itself. PROBABLE CAUSE Key switch contact chatter causes the control unit to change modes. CORRECTIVE ACTION * Civic: Replace the security control unit, and reprogram the remote(s).* * CR-V and Element: Replace the security control unit and the microphone, then reprogram the remote(s).* * NOTE: You must replace the microphone on the CR-V and Element because the security control units are matched to their microphones when they are manufactured. Using the original microphone may result in security system problems.* PARTS INFORMATION WARRANTY CLAIM INFORMATION In warranty: The normal warranty applies. Out of warranty: Any repair performed after warranty expiration may be eligible for goodwill consideration by the District Parts and Service Manager or your Zone Office. You must request consideration, and get a decision, before starting work. REPAIR PROCEDURE NOTE: Before starting, make sure you have all of the remotes (three maximum) the customer wishes to use. Page 9404 2. Remove the terminal (same procedure for male and female). 3. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE E: 1. Remove the secondary locks. 2. Remove the terminal (same procedure for male and female). 3. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE F: Page 8567 - Cut and remove the wheelhouse upper member, and replace the front wheelhouse. - Check the front damper extension and damper housing position, and check for damage. If necessary, remove the wheelhouse upper member, and replace the damper housing and front damper extension as an assembly, if possible. Page 3247 Power Distribution schematics show how power is supplied from the positive battery terminal to various circuits in the vehicle. Refer to the Power Distribution diagram set to get a more detailed understanding of how picture is supplied to the circuit you're working on. Individual circuit schematics begin with a fuse. So 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 Ground Distribution Schematics This sample Ground Distribution schematic shows all of the components that share the same ground point. Page 2472 Manifold Pressure/Vacuum Sensor: Service and Repair MAP Sensor Replacement 1. Disconnect the MAP sensor 3P connector. 2. Remove the MAP sensor (A). 3. Install the sensor in the reverse order of removal with a new O-ring (B). Diagrams 39. ECT Sensor Adjustments Clutch Pedal Assembly: Adjustments Clutch Pedal, Clutch Pedal Position Switch, and Clutch Interlock Switch Adjustment NOTE: ^ To check the clutch pedal position switch. ^ To check the clutch interlock switch. ^ Remove the driver's side floor mat before adjusting the clutch pedal. ^ The clutch is self-adjusting to compensate for wear. ^ If there is no clearance between the master cylinder piston and push rod, the release bearing is held against the diaphragm spring, which can result in clutch slippage or other clutch problems. 1. Loosen locknut (A), and back off the clutch pedal position switch (B) (or adjusting bolt) until it no longer touches the clutch pedal (C). 2. Loosen locknut (D), and turn the push rod (E) in or out to get the specified height (F) and stroke (G) at the clutch pedal. Clutch Pedal Stroke: 130 - 140 mm (5.1 - 5.5 inch) Clutch Pedal Height: 198 mm (7.8 inch) 3. Tighten locknut (D). 4. With the clutch pedal released, turn the clutch pedal position switch (B) in until it contacts the clutch pedal (C).. 5. Turn the clutch pedal position switch (B) in an additional 3/4 to 1 turn. 6. Tighten locknut (A). 7. Loosen locknut (H) and the clutch interlock switch (1) 8. Press the clutch pedal to the floor. 9. Release the clutch pedal 15 - 20 mm (0.59 - 0.79 inch) from the fully depressed position, and hold it there. Adjust the position of the clutch interlock switch (1) so that the engine will start with the clutch pedal in this position. 10. Tighten locknut (H). Page 7182 Keyless Entry Receiver: Testing and Inspection Keyless Receiver Unit Input Test 1. Remove the dashboard center lower cover. 2. Remove the audio unit. 3. Disconnect the 5P connector (A) from the keyless receiver unit (B). 4. Inspect the connector and socket terminals to be sure they are all making good contact. - If the terminals are bent, loose or corroded, repair them as necessary, and recheck the system. - If the terminals are OK, go to step 5. 5. With the connector still disconnected, make these input tests at the connector. - If any test indicates a problem, find and correct the cause, then recheck the system. - If all the input tests prove OK, go to step 6. 6. Reconnect the 5P connector and make these input tests at the connector. - If any test indicates a problem, find and correct the cause, then recheck the system. - If all the input tests prove OK, replace the keyless receiver unit. Page 7608 10. Pull down on the retainer clip with a hook-shaped tool. Remove the lock cylinder. Then go to step 14. 11. Pull the glass run channel away as necessary, and remove the bolt, then remove the center lower channel by pulling it downward. 12. Remove the access seal, and disconnect the outer handle rod and the cylinder rod. Page 6029 Relay Box: Connector Locations Under-dash Fuse/Relay Box Page 1089 8. Put the splice connector in the proper size slot in the Crimper Tool, slide it to one end (where the flare begins), and close the crimper handles far enough to hold it in place. To release the ratchet mechanism at any point after the first click, squeeze the handles slightly and push the release lever, then let the handles open. 9. Insert one of the bare wires into the splice connector end that is in the crimper jaws. Push the wire all the way into the splice connector, and squeeze the crimper handles. Keep squeezing until the jaws touch, and hold it at that position until the ratchet clicks again. 10. Crimp the other wire in the same way into the other end of the splice connector. 11. After crimping, gently pull on the wires in the opposite directions to make sure they are secure in the connector. 12. Separate the other wires in the harness from the repaired wire(s), and shield them with nonflammable material. Service and Repair Sunroof / Moonroof Windguard: Service and Repair Wind Deflector Replacement 02-05 models 1. Remove the screws (A, B),then remove the wind deflector (C) and the deflector arm spring (D) in the sequence shown. Take care not to scratch the roof panel. 2. Install the deflector in the reverse order of removal. Page 6879 104. In Front Passenger's or Passenger's Seat Page 5291 Shift Interlock Switch: Service and Repair Park Pin Switch Replacement 1. Remove the center console panel and center console. 2. Remove the screws (A), then remove the shift lever knob (B). 3. Remove the A/T gear position indicator panel light (c) from the A/T gear position indicator panel. 4. Remove the A/T gear position indicator panel and panel bracket as an assembly (D). 5. Disconnect the park pin switch connector (4P) (E), and remove it from the shift lever bracket base (F). 6. Remove the shift lock release (G) and spring (H). 7. Open the lock tabs (A) on the shift lever bracket base, then remove the park pin switch (B). 8. Install the new park pin switch. 9. Install the removed parts in the reverse order of removal. Page 8147 Page 2786 Engine Control Module: Service and Repair ECM/PCM Idle Learn Procedure ECM/PCM Idle Learn Procedure The idle learn procedure must be done so the ECM/PCM can learn the engine idle characteristics. Do the idle learn procedure whenever you do any of these actions: - Disconnect the battery. - Replace the ECM/PCM or disconnect its connector. - Reset the ECM/PCM. NOTE: Erasing DTCs with the Honda PGM Tester does not require you to do the idle learn procedure. - Remove the No.6 ECU (ECM/PCM) (15A) fuse from the under-hood fuse/relay box. - Remove the No.19 battery (80A) fuse from the under-hood fuse/relay box. - Remove PGM-FI main relay 1. - Remove any of the wires from the under-hood fuse/relay box. - Disconnect any of the connectors from the under-hood fuse/relay box. - Disconnect the connector between the engine compartment wire harness and ECM/PCM wire harness. - Disconnect the G2 terminal from the transmission housing. - Disconnect the G1 terminal from the body. - Disconnect the G101 terminal from the water passage. Procedure: 1. Make sure all electrical items (A/C, audio, rear defogger, lights, etc.) are off. 2. Start the engine, and hold it at 3,000 rpm with no load (in Park or neutral) until the radiator fan comes on, or until the engine coolant temperature reaches 194 °F (90 °C). 3. Let the engine idle for about 5 minutes with the throttle fully closed. NOTE: If the radiator fan comes on, do not include its running time in the 5 minutes Page 9195 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 Short Circuit Locator (Short Finder) 1. Remove the blown fuse. Leave the battery connected. 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 5924 1. Remove the terminal. 2. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE B: 1. Remove the terminal. 2. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE C: 1. Remove the terminal. 2. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE D: Page 1695 2. Insert the terminal tool into the female terminal, and then remove the terminal tool. NOTE: Make sure you do not select a terminal tool that is larger than the mating male terminal because it would spread the female terminal and cause a loose fit. 3. Compare the drag to the other terminals in the connector. If the drag is less, replace the terminal with a replacement terminal from the appropriate terminal repair kit. Page 1297 Idle Speed: Description and Operation Idle Control System When the engine is cold, the A/C compressor is on, the transmission is in gear, the brake pedal is pressed, the power steering load is high, or the alternator is charging, the ECM/PCM controls current to the Idle Air Control (IAC) valve to maintain the correct idle speed. Refer to the System Diagram to see the functional layout of the system. Idle Control System Diagram The idle speed of the engine is controlled by the idle air control (IAC) valve: - After the engine starts, the IAC valve opens for a certain amount of time. The amount of air is increased to raise the idle speed. - When the engine coolant temperature is low, the IAC valve is opened to obtain the proper fast idle speed. The amount of bypassed air is thus controlled in relation to engine coolant temperature. Page 3407 11. Disconnect the quick-connect fitting (A): Hold the connector (B) with one hand and squeeze the retainer tabs (C) with the other hand to release them from the locking pawls (D). Pull the connector off. NOTE: Prevent the remaining fuel in the fuel feed line or hose from flowing out with a rag or shop towel. - Be careful not to damage the line (E) or other parts. - Do not use tools. - If the connector does not move, keep the retainer tabs pressed down, and alternately pull and push the connector until it comes off easily. - Do not remove the retainer from the line; once removed, the retainer must be replaced with a new one. 12. After disconnecting the quick-connect fitting, check it for dirt or damage (see step 4). Page 3215 2. Remove the terminal from the female half. 3. Remove the terminal from the male half. 4. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE D: 1. Remove the secondary locks. Component Locations Front Door Window Motor: Component Locations Power Windows Component Location Index Page 4022 Pressure Regulating Solenoid: Diagrams 25. A/T Clutch Pressure Control Solenoid Valve A 26. A/T Clutch Pressure Control Solenoid Valve B Page 6660 Evaporator Temperature Sensor / Switch: Service and Repair Evaporator Temperature Sensor Replacement 1. Disconnect the 2P connector (A) from the evaporator temperature sensor (B), then remove the connector clip (C). Turn the evaporator temperature sensor counterclockwise to the stop, and carefully pull out it. 2. Install the sensor in the reverse order of removal. 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 9388 Resistor Variable Sensor Solenoid Transistors Circuit Schematics Page 3310 EVAP System - Component Location Index Locations Parking Brake Warning Switch: Locations Gauges Component Location Index (Part 1 Of 4) Locations 134. Right C Pillar (Coupe) Page 7775 17. Using a small screwdriver, push down on the tip of the last tumbler to release it, then remove the cylinder from the housing, being careful not to drop any tumblers and springs. Use your thumb and forefinger to hold the tumblers in place. Then go to step 20. 18. While turning the key left and right and pushing on the rear of the inner cylinder to release the spring, slowly remove the cylinder from the housing. Page 1160 1. Remove the driver's side grip cover: ^ Using a trim tool, pry out the front edge of the cover to release the front clip. ^ Pry out along the bottom to release the lower hooks. ^ Pry out along the top to release the upper hooks. ^ Pull the cover forward to release the rear clip. 2. Disconnect the power window master switch connector. 3. Remove the two screws that attach the power window switch base to the armrest, then remove the switch base. 4. Remove the three screws, then replace the power window master switch assembly. Page 6786 Clockspring Assembly / Spiral Cable: Adjustments 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 5612 Clutch Switch: Testing and Inspection Clutch Interlock Switch Test 1. Disconnect the clutch interlock switch 2P connector. 2. Remove the clutch interlock switch (A). 3. Check for continuity between the terminals according to the table. - If the continuity is not as specified, replace the clutch interlock switch. - If OK, install clutch interlock switch and adjust the pedal height. Page 6692 6. Disconnect both seat belt buckle tensioner 4P connectors (A). Page 3218 1. Remove the terminal. 2. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE B: 1. Remove the terminal. 2. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE C: 1. Remove the terminal. 2. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE D: Page 9019 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. How to Replace Connector Terminals Terminal Replacement Procedure HOW TO REPLACE CONNECTOR TERMINALS The terminal repair kits provide necessary tools and materials (terminals, wire seals, and splice connectors) to repair many damaged or faulty connector terminals. However, not all terminals for all connectors are available. Refer to the labels on the lids of the repair kits for replacement terminal availability. IMPORTANT SAFETY INFORMATION: On some models, the SRS wires are in a separate harness. If the SRS harness is damaged, replace the harness; do not repair it. On other models, wire harnesses include yellow SRS wires. If any SRS wire is damaged, replace the entire harness; do not repair it. Before you begin, inspect the wire you are about to repair for damage and length. Make sure the wire will be long enough to make a terminal repair without stretching it when you reinstall the terminal in the connector. If the wire is too short, or if access to the connector is too restricted to make a terminal repair, you may need to install a pigtail terminal (a short length of wire with a factory-crimped terminal on it). Refer to HOW TO INSTALL PIGTAIL TERMINALS. Removing the Terminal Page 890 Disclaimer Cutting Procedure - By Copying 1. Press the ON/OFF button in the middle of the setting unit keypad. (This powers up the keypad.) 2. Turn the clamp unit lock lever to the left to release the clamp unit, and slide it all the way to the left until it stops. Turn the lever to the right to lock the clamp unit in place. 3. Use the clamp carriage lever to position the clamp unit so the tracer and cutter bit are centered directly over the base of the center and right jaws. 4. Pull the vertical carriage lever toward you until the tracer and the cutter bit just touch the base of each fixed jaw. Watch the arrows on the keypad: ^ If the double-headed arrow in the middle of the keypad lights green, the tracer and cutter bit are properly aligned. ^ If the arrow on the left of the keypad lights red, the cutter bit is not touching the fixed jaw. Turn the micrometric ring nut above the tracer to the left until the double-headed arrow lights green. ^ If the arrow on the right of the keypad lights red, the tracer is not touching the fixed jaw. Turn the micrometric ring nut above the tracer to the right until the double-headed arrow lights green. *5. Turn the micrometric ring nut to the right three clicks so the cutter bit is slightly higher than the tracer. The arrow on the left should light red. Raise the vertical carriage. NOTE: Setting the tracer three clicks lower than the cutter bit has the effect of making the cutter bit cut the duplicated key a little shallower. This will protect the locking jaws from being damaged.* 6. Optional: Loosen the setscrew, and adjust the hand rest to a comfortable position. Tighten the screw. 7. Pull the clamp carriage lever toward you until the clamp carriage clicks into its end-of-run position. Tighten both the lateral and spring tension adjustment knobs. 8. Make sure the center and right jaws are free of any metal shavings or debris. (A soft-bristle toothbrush is ideal for this purpose.) Page 7280 - Remove clips carefully; don't damage their locks (A). - Slip pliers (A) under the clip base and through the hole at an angle, then squeeze the expansion tabs to release the clip. - After installing harness clips, make sure the harness doesn't interfere with any moving parts. - Keep wire harnesses away from exhaust pipes and other hot parts, from sharp edges of brackets and holes, and from exposed screws and bolts. - Seat grommets in their grooves properly (A). Do not leave grommets distorted (B). Testing and Repairs - Do not use wires or harnesses with broken insulation. Replace them or repair them by wrapping the break with electrical tape. - After installing parts, make sure that no wires are pinched under them. - When using electrical test equipment, follow the manufacturer's instructions and those described. - If possible, insert the probe of the tester from the wire side (except waterproof connector). - Use back probe adaptor 07TAZ-001020A. - Refer to the instructions in the Honda Terminal Kit for identification and replacement of connector terminals. Five-Step Troubleshooting Five-Step Troubleshooting 1. Verify The Complaint Page 6360 3. Loosely install the flange bolt (A) on the bottom of the damper. 4. Raise the suspension with a floor jack to load the vehicle's weight, and tighten the nuts and bolt to the specified torque values. 5. Clean the mating surface of the brake drum and the inside of the wheel, then install the rear wheel. 6. Check the wheel alignment, and adjust it if necessary. Page 4238 3. If there is no continuity between any terminal, remove the transmission range switch cover, and disconnect the connector (A) at the switch (B). 4. Check for continuity between terminals at the switch connector (c). There should be continuity between the terminals listed for each position. In the P position, between terminals: ^ No. 4 and No. 5 ^ No. 4 and No. 6 ^ No. 5 and No. 6 In the R position, between terminals: ^ No. 1 and No. 4 In the N position, between terminals: ^ No. 4 and No. 5 ^ No. 4 and No. 7 ^ No.5 and No.7 In the D position, between terminals: ^ No.2 and No.4 ^ No. 2 and No. 10 ^ No. 4 and No. 10 In the D3 position, between terminals: ^ No. 4 and No. 8 ^ No. 4 and No. 10 ^ No. 8 and No. 10 In the 2 position, between terminals: ^ No.3 and No.4 5. If there is no continuity between any terminals, adjust the transmission range switch installation. If the transmission range switch installation is OK, replace the switch. 6. If the transmission range switch continuity check was OK, replace the faulty transmission range switch harness. Page 7217 1997 Accord SE With Factory-Installed Security System 1997 Accord SE with factory-installed security system Programming the Transmitter NOTES: ^ The system accepts up to three transmitters. The transmitter codes are stored in a stacking-type memory. If a fourth transmitter code is programmed, the code for the first transmitter is erased. ^ Entering the programming mode cancels all learned transmitter codes, so none of the previously programmed transmitters will work. You must reprogram all of the transmitters once you are in the programming mode. ^ You must complete steps 1-6 within 4 seconds of the previous step to keep the system from exiting the programming mode. 1. Turn the ignition switch to ON (II). 2. Press the "Lock" or "Unlock" button on one of the transmitters. (An unprogrammed transmitter can be used for this step.) 3. Turn the ignition switch to LOCK (0). 4. Repeat steps 1, 2, and 3 two more times using the same transmitter used in step 2. 5. Turn the ignition switch to ON (II). 6. Press the "Lock" or "Unlock" button on the same transmitter. Make sure the power door locks cycle to confirm that the system is in programming mode. 7. Within 10 seconds, press the "Lock" or "Unlock" button on each transmitter. Make sure the power door locks cycle after you press each transmitter button to confirm that the system accepted the transmitter's code. 5. Turn the ignition switch to LOCK (0) to exit the programming mode. Ordering a Transmitter Transmitters can be ordered only by authorized Honda dealers. Order them from American Honda using normal parts ordering procedures. Batteries for the Transmitter The battery number is CR2025. Each transmitter uses one battery. 98-02 Accord EX & 00-02 Accord SE 1998-02 Accord EX with factory-installed security system 2000 and 2002 Accord SE with factory-installed security system Page 5003 3. If there is no continuity between any terminal, remove the transmission range switch cover, and disconnect the connector (A) at the switch (B). 4. Check for continuity between terminals at the switch connector (c). There should be continuity between the terminals listed for each position. In the P position, between terminals: ^ No. 4 and No. 5 ^ No. 4 and No. 6 ^ No. 5 and No. 6 In the R position, between terminals: ^ No. 1 and No. 4 In the N position, between terminals: ^ No. 4 and No. 5 ^ No. 4 and No. 7 ^ No.5 and No.7 In the D position, between terminals: ^ No.2 and No.4 ^ No. 2 and No. 10 ^ No. 4 and No. 10 In the D3 position, between terminals: ^ No. 4 and No. 8 ^ No. 4 and No. 10 ^ No. 8 and No. 10 In the 2 position, between terminals: ^ No.3 and No.4 5. If there is no continuity between any terminals, adjust the transmission range switch installation. If the transmission range switch installation is OK, replace the switch. 6. If the transmission range switch continuity check was OK, replace the faulty transmission range switch harness. Page 1548 234. Under-dash Fuse/Relay Box Part 6 Page 3383 11. Disconnect the quick-connect fitting (A): Hold the connector (B) with one hand and squeeze the retainer tabs (C) with the other hand to release them from the locking pawls (D). Pull the connector off. NOTE: Prevent the remaining fuel in the fuel feed line or hose from flowing out with a rag or shop towel. - Be careful not to damage the line (E) or other parts. - Do not use tools. - If the connector does not move, keep the retainer tabs pressed down, and alternately pull and push the connector until it comes off easily. - Do not remove the retainer from the line; once removed, the retainer must be replaced with a new one. 12. After disconnecting the quick-connect fitting, check it for dirt or damage (see step 4). Page 1232 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 Locations Oil Pressure Sender: Locations Gauges Component Location Index (Part 1 Of 4) Locations 13. Middle Of Engine (EX, HX) Page 4834 3. Remove and discard the shift fork. 4. Apply vinyl tape to the mainshaft splines to protect the seal, then remove the mainshaft and shift forks as an assembly from the clutch housing. 5. Disassemble the countershaft assembly; see page 13-32 (13-45 for Hybrid) of the service manual. Page 2996 PGM-F1 Main Relay 1, 2 Type 1, 2 Check for continuity between the terminals. - There should be continuity between the No.1 and No.2 terminals when power and ground are connected to the No.3 and No.4 terminals. - There should be no continuity between the No.1 and No.2 terminals when power is disconnected. Normally-open type B: Rear Window Defogger Relay Page 2324 ERROR: undefined OFFENDING COMMAND: f‘~ STACK: Page 5744 8. Inspect the quality of the wire crimp. If it has any of the following NO GOOD crimps, cut it off and start over. 9. Insert the terminal into the connector. Make sure the wire seals are pushed all the way into the connector. Lightly pull on the wires to make sure the terminal is locked into place. 10. Close or insert the secondary terminal lock, if applicable, and reconnect the connector. How to Install Pigtail Terminals HOW TO INSTALL PIGTAIL TERMINALS Pigtail terminals (short pieces of wire with a factory crimped terminal) are used when the wire is too short or when access to the connector is too restricted to make a terminal repair. NOTE: To replace just a connector terminal, go to How to Replace Connector Terminals. IMPORTANT SAFETY INFORMATION: On some models, the SRS wires are in a separate harness. If the SRS harness is damaged, replace the harness; do not repair it. On other models, wire harnesses include yellow SRS wires. If any SRS wire is damaged, replace the entire harness; do not repair it. 1. Remove the damaged or faulty terminal from the connector. Use the proper removal tool from Pin Tool Set. Locations 12. Middle Of Engine Page 6105 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 655 160. Fog Light Switch (Honda Accessory) Locations Camshaft Position Sensor: Locations PGM-FI System - Component Location Index Page 5536 Wheel Speed Sensor: Service and Repair Replacement NOTE: Install the sensors carefully to avoid twisting the wires. Locations Cruise Control Servo: Locations Cruise Control Component Location Index Page 1181 3. Check for continuity between the terminals in each switch position according to the tables. Driver's Switch: The driver's switch is combined with the control unit so you cannot isolate the switch to test it. Instead, run the master switch input test procedures. If the tests are normal, the driver's switch must be faulty. Replace the switch. 4. If the continuity is not as specified, remove the driver's door panel. 5. Remove the armrest from the door panel. Page 6873 7. From the Mode menu, select Miscellaneous Test. 8. From the Miscellaneous Test menu, select OPDS Initialization. 9. Follow the remaining screen prompts to complete the OPDS initialization. If the initialization fails repeat the process two more times. If the initialization fails again, check for SRS DTCs, then troubleshoot them using the appropriate service manual. Initializing the OPDS Unit: Manual Mode NOTE: Non-Honda seat covers will interfere with the performance of the OPDS and are not recommended. 1. Adjust the front passenger's seat-back to an upright position, then remove anything on or near the seat. 2. Turn the ignition switch to LOCK (0). 3. Connect the HDS to the vehicle's DLC (data link connector). 4. Keep the ignition switch at LOCK (0), and turn on the HDS. 5. At the screen prompts, enter the VIN and the odometer reading. 6. From the Select Mode screen, select SCS, and follow the screen prompts. Page 2680 Intake Air Temperature Sensor: Description and Operation Intake Air Temperature (IAT) Sensor The IAT sensor is a temperature dependent resistor (thermistor). The resistance of the thermistor decreases as the intake air temperature increases. Page 206 Tail Lamp Relay: Testing and Inspection Power Relay Test Use this chart to identify the type of relay, then do the test listed for it. NOTE: See the turn signal/hazard relay input test. Normally-open type A: Page 343 Relay And Control Unit Locations - Door, Roof And Seat Page 5816 1. Remove the terminal. 2. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE E: 1. Remove the terminal. 2. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE F: Page 536 67. Radiator Fan Switch Page 4777 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. Below most connector numbers and component names are PHOTO and VIEW numbers. The PHOTO number refers to a photo in the back of the book that shows the connector's location on the car. The VIEW number refers to an illustration in the back of the book that shows the connector terminals, wire colors, connector cavity numbers, and other details. The connector cavity numbering sequence begins at the top left corner of the connector as seen from either of the viewpoints shown on diagram [8] . Except for the DLC (data link 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 C554, for example, means those terminals join in cavity 2 of connector C554. Power Distribution Schematics Power Distribution Schematics Page 8168 system will not enter the programming mode.) 3. Within 10 seconds, close and open the door two times. 4. Turn the ignition switch to the ACC position and then to the LOCK position three times. Close and open the door. (Complete this process within 10 seconds.) Verify that the power door locks cycle once to confirm that the system is in programming mode. 5. Within 20 seconds, press the "LOCK" button on the transmitter you are programming. Verify that the door locks cycle once. 6. Within 20 seconds, press the "UNLOCK" button on the transmitter. Verify that the door locks cycle once to confirm that the system has accepted the transmitter's code. Turning the Audible Chirp On/Off (1998-99 only) NOTE: On '00-02 Passports, the audible chirp sounds only when you push the LOCK button on the transmitter a second time. 1. Open the driver's door, then insert the key in the driver's door lock. 2. Turn the key to the "LOCK" position, then to the "UNLOCK" position. Repeat this two more times. (Complete this procedure within 10 seconds.) 3. Within 10 seconds, close and open the door two times. 4. Within 10 seconds, turn the key to the "LOCK" position, and then to the "UNLOCK" position, three times. Close and open the door once. Verify that the power door locks cycle once to confirm that the chirp has been turned on/off. Ordering a Transmitter Transmitters can be ordered only by authorized Honda dealers. Order them from American Honda using normal parts ordering procedures. Batteries for the Transmitter The battery number is CR2016. Each transmitter uses two batteries. Page 6691 2. Remove the access panel from the steering wheel, then disconnect the driver's airbag 4P connector (A) from the cable reel. Front Passenger's Airbag 3. Lower the glove box, then disconnect the front passenger's airbag 4P connector (A) from the dashboard wire harness B. Side Airbag 4. Disconnect both side airbag 2P connectors (A) from the floor wire harness. Seat Belt Tensioner 5. Disconnect both seat belt tensioner 2P connectors (A) from the floor wire harness. Seat Belt Buckle Tensioner Page 5759 Under-dash Fuse/Relay Box (2-door) Page 9491 - Remove clips carefully; don't damage their locks (A). - Slip pliers (A) under the clip base and through the hole at an angle, then squeeze the expansion tabs to release the clip. - After installing harness clips, make sure the harness doesn't interfere with any moving parts. - Keep wire harnesses away from exhaust pipes and other hot parts, from sharp edges of brackets and holes, and from exposed screws and bolts. - Seat grommets in their grooves properly (A). Do not leave grommets distorted (B). Testing and Repairs - Do not use wires or harnesses with broken insulation. Replace them or repair them by wrapping the break with electrical tape. - After installing parts, make sure that no wires are pinched under them. - When using electrical test equipment, follow the manufacturer's instructions and those described. - If possible, insert the probe of the tester from the wire side (except waterproof connector). - Use back probe adaptor 07TAZ-001020A. - Refer to the instructions in the Honda Terminal Kit for identification and replacement of connector terminals. Five-Step Troubleshooting Five-Step Troubleshooting 1. Verify The Complaint Service and Repair Hood Latch Release Cable: Service and Repair Hood Opener Cable Replacement NOTE: - Put on gloves to protect your hands. - Take care not to scratch the body and related parts. 1. Remove these items: - Front bumper '04-05 models - Inner fender, left side - Kick panel, left side, 2-door, 4-door 2. Disconnect the hood opener cable (A) from the hood latch (B), and remove the bolts (C),then remove the hood release handle (D) from the body 3. Using a clip remover, detach the clips (E), and remove the grommet (F) from the body, then remove the hood opener cable from the vehicle. Take care not to kink the cable. 4. Install the cable in the reverse order of removal, and replace any damaged clips. Page 1347 19. Install the harness holder (A) and throttle cable clamps (B). 20. Install the ignition coils. 21. Loosely install the alternator. 22. Adjust the alternator belt tension or the alternator-compressor belt tension. 23. Loosely install the power steering (P/S) pump belt and pump. 24. Adjust the P/S pump belt. 25. Install the splash shield. 26. Install the front tires/wheels. 27. Clean the battery posts and cable terminals with sandpaper. Connect the negative cable, then positive cable and apply grease to prevent corrosion. 28. Enter the anti-theft code for the radio, then enter the customer's radio station presets. Page 2871 PGM-F1 Main Relay 1, 2 Type 1, 2 Check for continuity between the terminals. - There should be continuity between the No.1 and No.2 terminals when power and ground are connected to the No.3 and No.4 terminals. - There should be no continuity between the No.1 and No.2 terminals when power is disconnected. Normally-open type B: Rear Window Defogger Relay Page 2313 DTC P0979 thru P1193 Page 3479 Idle Speed/Throttle Actuator - Electronic: Description and Operation Idle Air Control (IAC) Valve To maintain the proper idle speed, the IAC valve changes the amount of air bypassing the throttle body in response to an electrical signal from the ECM/PCM. Page 2914 Oxygen Sensor: Service and Repair Secondary HO2S Replacement Secondary HO2S Replacement Special Tools Required O2 sensor wrench, Snap-on YA8875, SP Tools 93750, or equivalent, commercially available NOTE: The secondary HO2S and the third HO2S must be replaced together (D17A6 engine except '01 model) 1. Disconnect the secondary HO2S 4P connector (A), then remove the secondary HO2S (B). 2. Install the secondary HO2S in the reverse order of removal. Page 5812 3. Remove the terminal from the male half. 4. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE D: 1. Remove the secondary locks. 2. Remove the terminal (same procedure for male and female). 3. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE E: Page 2770 ECM/PCM Inputs And Outputs At Connector C (22P) Page 932 1. On Accords and Pilots, remove the front passenger's seat-back panel by prying out the bottom. Replace the two lower clips. 2. On all models except Accords and Pilots, unzip the two seat cover zippers on the back of the front passenger's seat. 3. Pull back the seat-back cover from the left side bolster to access the OPDS unit cover. 4. Remove the OPDS unit cover from the seat frame. 5. Check the part number of the installed OPDS unit. Component Locations Sunroof / Moonroof Switch: Component Locations Moonroof Component Location Index 57. Under Left Side Of Dash Page 3962 13. The green No.1 LED stays on, and the yellow No. 2 LED blinks. This indicates that the control uniti module is being updated. NOTE: To avoid control unit/module damage, do not interrupt the update. 14. When the yellow No.2 LED stays on, turn the ignition switch to LOCK (0). 15. Turn the ignition switch to ON (II). When the green No.1 and the yellow No.2 LEDs stay on, the control unit/module is updated. 16. Turn the ignition switch to LOCK (0), and disconnect the HIM from the vehicle. To do the same update on an identical vehicle, repeat steps 11 thru 16. Diagnosing HIM Error Codes If the red No.3 LED on the HIM came on or was flashing during the update, do this: 1. Leave the ignition switch in ON (II) while you disconnect the HIM from the vehicle's DLC. 2. If not already done, load the latest HDS sofiware onto the iN workstation. 3. Connect the HIM to the iN workstation. Connect the small end of the PC interface cable to the PC port on the HIM. 4. If not already done, connect the PC end of the blue PC interface cable to the 9P serial port on the iN workstation. 5. Connect the 110 VACIl 2 VDC power supply to the HIM and to a wall outlet. 6. Restart the CM Update application on the iN workstation. 7. On the right side of the screen, click on the view error button. 8. Click on View Error at the bottom of the screen to display the problem encountered while the HIM was connected to the vehicle. ^ If you get a Code 40 error message (usually caused by a communication error between the HIM and the workstation), do this: - Do the HIM self-test procedure (see HIM Self-Test). - Move the blue PC interface cable to another communication port on the back of the computer. - If one of the communication ports on the back of the computer has another cable connected to it, disconnect that cable, leave it disconnected during the HIM procedure, and connect the blue PC interface cable to that port. - Connect the HIM to another computer. (Some iN workstations require an internal communication port setup procedure. For help, call the iN Support Center) ^ If you get a Code 50 error message (usually caused by a communications error between the HIM and the vehicle's DLC), do this: - Diagnose and clear any DTCs. (The control unit/module must be free of DTCs before you can update it.) - Make sure there's a good connection between the HIM and the DLC. - Retry the update using the procedures in this service bulletin or on the back of the HIM. - If needed, call Tech Line for further help. HIM Self-Test If you suspect there's a problem with the HIM, review the instructions in this service bulletin to make sure you are using it correctly. If you still think there's a problem, do this self-test: Locations Fuel Supply System - Component Location Index Page 7612 ^ If no key code can be found on the iN or with the Matrix H High Security key Codes Book, remove one tumbler at a time from the old inner cylinder, and match the number stamped on the old tumbler to a new tumbler from the kit. Insert the new tumbler and spring in the appropriate new inner cylinder cavity. ^ Do not use the old inner cylinder, springs, or tumblers. ^ Using your thumb and forefinger, hold the tumblers in place, insert the key in the cylinder and verify that all tumblers are flush with the cylinder. If not, double-check the key number, the cutting key code, the tumbler numbers, and the cavity locations. NOTE: If the key cannot be inserted, check the tumbler in the "J" cavity. It may be out of position. Page 8259 24. Remove the key. Reinstall the retainer clip in the door handle, and push the lock cylinder into place. 25. Civic: Reconnect the cylinder rod. 26. CR-V: Reconnect the cylinder rod, the outer handle rod, and the rod protector. 27. Element: Reconnect the cylinder rod, the outer handle rod, and the access seal. Reinstall the lower run channel. 28. Reinstall the plastic covering, and lower the window glass. Install the door panel. 29. Check that the door lock and handle operate smoothly. Disclaimer Diagrams Page 1963 Oil Pressure Sender: Service and Repair Oil Pressure Switch Replacement 1. Remove the oil filter with the special oil filter wrench. 2. Disconnect the oil pressure switch connector, then remove the oil pressure switch. 3. Apply liquid gasket to the oil pressure switch threads, then install the oil pressure switch. 4. Install the oil filter. Page 5811 3. Remove the terminal (same procedure for male and female). 4. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE C: 1. Remove the secondary lock. 2. Remove the terminal from the female half. Page 4692 Transmission Position Switch/Sensor: Testing and Inspection Transmission Range Switch Test Transmission Range Switch Test 1. Remove the transmission range switch harness connector (A) from the connector bracket (B), then disconnect the connector. 2. Check for continuity between terminals at the harness connector. There should be continuity between the terminals listed for each switch position. In the P position, between terminals: ^ No. 1 and No. 3 ^ No. 1 and No. 8 ^ No. 3 and No. 8 In the R position, between terminals: ^ No. 1 and No. 9 In the N position and between terminals: ^ No. 1 and No. 3 ^ No. 1 and No. 10 ^ No. 3 and No. 10 In the D position, between terminals: ^ No. 1 and No. 2 ^ No. 1 and No. 4 ^ No.2 and No.4 In the D3 position, between terminals: ^ No. 1 and No. 2 ^ No. 1 and No. 5 ^ No.2 and No.5 In the 2 position, between terminals: ^ No. 1 and No. 6 Page 5056 Page 8671 33. Clutch Pedal Position Switch (M/T) 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 6943 12. On Accords and Pilots, install the new seat-back clips on the seat-back panel. Turn the clips so their retaining tabs are horizontal. 13. On Accords and Pilots, install the seat-back panel. 14. On all models except Accords and Pilots, zip the seat-back cover closed. 15. Initialize the OPDS unit. ^ To initialize with the HDS, go to Initializing the OPDS Unit: HDS Method. ^ To initialize with the SCS service connector, go to Initializing the OPDS Unit: Manual Mode. Initializing the OPDS Unit: HDS Method NOTE: Non-Honda seat covers will interfere with the performance of the OPDS and are not recommended. 1. Adjust the front passenger's seat-back to an upright position, then remove anything on or near the seat. 2. Turn the ignition switch to LOCK (0). 3. Connect the HDS to the vehicle's DLC (data link connector). 4. Turn the ignition switch to ON (II), then turn on the HDS. 5. At the screen prompts, enter the VIN and the odometer reading. Also verify the correct date and time. 6. From the System Selection menu, select SRS. Page 1276 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 6565 8. Remove the mounting nut from the heater unit. Take care not to damage or bend the fuel lines and the brake lines, etc. 9. Remove the dashboard. 10. Remove the blower unit. 11. Disconnect the drain hose (A), then remove the mounting bolts and the heater unit (B). 12. Remove the self-tapping screws and the expansion valve cover (A). With air conditioning; carefully pull out the evaporator core (B) so you don't bend the inlet and outlet pipes. Remove the self-tapping screws and the flange cover (C), then remove the grommet (D), and carefully pull out the heater core (E) so you don't bend the inlet and outlet pipes. 13. Install the heater core and the evaporator core (with A/C) in the reverse order of removal. 14. Install the heater unit in the reverse order of removal, and note these items: - Do not interchange the inlet and outlet heater hoses, and install the hose clamps securely. Page 1204 Washer Fluid Level Switch: Diagrams (Canada) 94. Washer Fluid Level Switch (Canada) Page 4478 VEHICLES AFFECTED CORRECTIVE ACTION Replace the master cylinder, and apply a thin film of silicone grease to the clutch line fitting. REQUIRED MATERIALS Silicone Grease: P/N 08C30-B0234M, H/C 6110928 Brake Fluid: P/N 08798-9008, H/C 4423802 PARTS INFORMATION Civic/Civic Hybrid Master Cylinder: P/N 46920-S5A-G04, H/C 7569452 Accord/Civic Si/CR-V/Element Master Cylinder: P/N 46920-57A-A02, H/C 7604507 WARRANTY CLAIM INFORMATION In warranty: The normal warranty applies. Operation Number: 211101 Flat Rate Time: 0.6 hour (All Civics) 0.8 hour (Accord/CR-V/Element) Failed Part: Civic/Civic Hybrid: P/N 46920-55A-G01 H/C 6571103 Accord/Civic Si/CR-V/Element: P/N 46920-S7A-A01 H/C 6729031 Defect Code: 03214 Symptom Code: 04201 Page 4614 7. Align the cutouts (A) on the rotary-frame with the neutral positioning cutouts (B) on the transmission range switch, then put a 2.0 mm (0.08 inch) feeler gauge blade (C) in the cutouts to hold it in the N Position. NOTE: Be sure to use a 2.0 mm (0.08 inch) blade or equivalent to hold the switch in the N position. 8. Install the transmission range switch (A) gently on the control shaft (B) while holding it in the N position with the 2.0 mm (0.08 inch) blade (C). 9. Tighten the bolts on the transmission range switch while you continue to hold the N position. Do not move the transmission range switch when tightening the bolts. Remove the feeler gauge. Page 8889 Keyless/Power Door Lock System Component Location Index Page 7079 VEHICLES AFFECTED CUSTOMER NOTIFICATION All owners of affected vehicles were mailed a notification of this warranty extension. A example of the customer notification is shown in this service bulletin. CORRECTIVE ACTION Repair the vehicle as indicated by the INSPECTION PROCEDURE. If needed, replace the OPDS unit. In rare cases where an updated OPDS unit was already installed, replace the OPDS sensor. M/T - Clicking Noise Driving in 2nd Gear Synchronizer Hub: Customer Interest M/T - Clicking Noise Driving in 2nd Gear 03-009 June 10, 2003 Applies To: 2001-03 Civic DX, LX, HX, EX with M/T - ALL 2003 Civic Hybrid - From VIN JHMES95..3S000001 thru JHMES95..3S018631 Clicking Noise While Driving in 2nd (Supersedes 03-009, dated April 1, 2003) Updated information is shown with asterisks. SYMPTOM * While driving in 2nd gear, a clicking noise occurs when turning right (DX, LX, HX, and EX) or when turning left (Civic Hybrid).* PROBABLE CAUSE The reverse idler gear is contacting the 1st/2nd hub sleeve set. CORRECTIVE ACTION Replace the reverse idler gear, the 1st/2nd synchro hub/sleeve set, and the reverse gear holder. REQUIRED MATERIALS Honda Manual Transmission Fluid (1.7 quarts required): P/N 08798-9016, H/C 4928271 Liquid Gasket: P/N 08718-0001, H/C 2963817 PARTS INFORMATION WARRANTY CLAIM INFORMATION In warranty: The normal warranty applies. Operation Number: 213110 Page 5521 4. With the engine off, inspect the play (A) on the pedal pad (B) by pushing the pedal by hand. Free Play: 0.4 - 3.0 mm (0.016 - 0.118 inch) 5. If the pedal free play is out of specification, adjust the brake pedal position switch (C). If the pedal free play is insufficient, it may result in brake drag. 6. Push in the brake pedal position switch until its plunger is fully pressed (threaded end (A) touching the pad (B) on the pedal arm). Then, turn the brake pedal position switch clockwise to lock it. Make sure the brake lights go off when the pedal is released. 7. Check the brake pedal free play. Locations Power Mirrors Component Location Index Page 4116 3. Strip the insulation off the end of the wire so the wire fits in the new terminal as shown. (If the wire has a wire seal, replace it with a new one from the kit.) NOTE: After stripping the end of the wire, make sure you did not cut any wire strands. If you did, cut the wire off even with the insulation, and strip it again. 4. Position the terminal in the crimping tool slot with the solid portion of the terminal toward the anvil and the open section toward the former. 5. Insert the wire in the terminal to the position shown in step 3. 6. Squeeze the tool with both hands until the stops make contact. 7. Crimp the insulation crimp. - If you do not have a wire seal, then use the next larger size crimp slot. Position the crimping tool over the insulation crimp section of the terminal, then squeeze the tool with both hands until the stops make contact. - If you have a wire seal, position the insulation crimp in the 5.5 crimping slot, then carefully squeeze the crimp closed until its ends are touching and making a full-circle shape. Page 9745 1. Remove the screws and the power window master switch (A) from the door panel. 2. Disconnect the 14P connector (B) from the switch. 3. Check for continuity between the terminals in each switch position according to the table. Driver's Switch: The driver's switch is combined with the control unit so you cannot isolate the switch to test it. Instead, run the master switch input test procedures. If the tests are normal, the driver's switch must be faulty. 4. If the switch is faulty, remove the three screws and replace the switch. Page 864 48. Middle Of Engine (except GX) 49. Middle Of Engine (GX) Page 1545 234. Under-dash Fuse/Relay Box Part 3 Page 4956 Shift Interlock Switch: Testing and Inspection Park Pin Switch Test 1. Remove the center console panel and center console. 2. Disconnect the park pin switch connector (4P). 3. Shift to the P position, then check for continuity between the No. 3 and No. 4 terminals. There should be no continuity. 4. Shift out of the P position, and check for continuity between terminals No. 3 and No. 4. There should be continuity. 5. If the park pin switch is faulty, replace it. Page 4091 Connectors - "C" Page 189 2. Insert the terminal tool into the female terminal, and then remove the terminal tool. NOTE: Make sure you do not select a terminal tool that is larger than the mating male terminal because it would spread the female terminal and cause a loose fit. 3. Compare the drag to the other terminals in the connector. If the drag is less, replace the terminal with a replacement terminal from the appropriate terminal repair kit. Page 6191 3. Hold the steering pump (A) a vise with soft jaws (B), hold the pulley (C) with the special tool (D), and remove the pulley nut (E) and pulley. Be careful not to damage the pump housing with the jaws of the vise. 4. Remove the inlet joint and O-ring. 5. Remove the pressure control valve cap, O-ring, valve spring, and pressure control valve. 6. Remove the pump housing cap, O-ring, and pump preload spring. 7. Remove the pump cover, pump cover seal, and O-ring. 8. Pull out the roll pin. 9. Remove the outer case, cam ring, rotor, vanes, and side plate. 10. Remove the rubber seal and slipper seal from the outer case. 11. Remove the O-rings from the bottom of the housing. 12. Remove the snap-ring, then remove the drive shaft by tapping the shaft end with the plastic hammer. 13. Remove the seal from the pump housing. Inspection 14. Check the pressure control valve for wear, burrs, and other damage to the edges of the grooves in the valve. 15. Inspect the bore of the pressure control valve on the pump housing for scratches and wear. 16. Slip the pressure control valve back in the pump housing, and check that it moves in and out smoothly. If OK, go to step 17; if not, replace the pump as an assembly. The pressure control valve is not available separately. Page 4972 Diodes Light Emitting Diode (LED) Motor Pressure Sensor Page 8835 Fuel Gauge: Description and Operation How the Circuit Works The indicators are controlled by relative conditions in their associated systems. For the following indicators the information supplied to the gauge assembly is received via the multiplex control unit: - Charging System - Door Indicator Light - Maintenance Required Indicator - Seat Belt Reminder - Trunk Indicator Light Refer to each associated system to see its entire schematic. Fuel Gauge and Low Fuel Indicator Light WARNING: Do not smoke while working on the fuel system. Keep open flame away from the work area. Drain fuel only into an approved container. The fuel gauge and low fuel indicator light are controlled by the CPU built-in the gauge assembly. The CPU receives fuel level information from the fuel gauge sending unit. The fuel gauge sending unit's resistance varies from about 11 - 13 ohms at full to about 130 - 132 ohms at empty. The fuel level signals current changes with the varying resistance, which enables the CPU to determine the level of the fuel. When the CPU determines that the fuel level is low, it turns the low fuel indicator light on. When you turn the ignition switch to LOCK (0), the gauge returns to the bottom of the gauge dial regardless of the fuel level. Page 2855 Information Bus: Testing and Inspection Multiplex Control Unit Input Test Multiplex Control Unit Input Test 1. Remove the dashboard lower cover. 2. Unbolt the under-dash fuse/relay box and pull it down. NOTE: All connectors are wire side of female terminals. 3. Inspect the connector and socket terminals to be sure they are all making good contact. - If the terminals are bent, loose or corroded, repair them as necessary, and recheck the system. - If the terminals look OK, go to step 4. 4. With the connectors still disconnected, make these input tests at the connector. - If any test indicates a problem, find and correct the cause, then recheck the system. - If all the input tests prove OK, go to step 5. Page 3122 162. Right Side Of Engine Compartment Page 661 Hazard Warning Switch: Testing and Inspection Hazard Warning Switch Test 1. Remove the center panel. 2. Disconnect the 10P connector (A) from the hazard warning switch (B). 3. Push out the hazard warning switch from behind the center panel (C). 4. Check for continuity between the terminals in each switch position according to the table. 5. If the continuity is not as specified, replace the illumination bulb (D) or the switch. Page 3602 Disclaimer Cutting Procedure - By Copying 1. Press the ON/OFF button in the middle of the setting unit keypad. (This powers up the keypad.) 2. Turn the clamp unit lock lever to the left to release the clamp unit, and slide it all the way to the left until it stops. Turn the lever to the right to lock the clamp unit in place. 3. Use the clamp carriage lever to position the clamp unit so the tracer and cutter bit are centered directly over the base of the center and right jaws. 4. Pull the vertical carriage lever toward you until the tracer and the cutter bit just touch the base of each fixed jaw. Watch the arrows on the keypad: ^ If the double-headed arrow in the middle of the keypad lights green, the tracer and cutter bit are properly aligned. ^ If the arrow on the left of the keypad lights red, the cutter bit is not touching the fixed jaw. Turn the micrometric ring nut above the tracer to the left until the double-headed arrow lights green. ^ If the arrow on the right of the keypad lights red, the tracer is not touching the fixed jaw. Turn the micrometric ring nut above the tracer to the right until the double-headed arrow lights green. *5. Turn the micrometric ring nut to the right three clicks so the cutter bit is slightly higher than the tracer. The arrow on the left should light red. Raise the vertical carriage. NOTE: Setting the tracer three clicks lower than the cutter bit has the effect of making the cutter bit cut the duplicated key a little shallower. This will protect the locking jaws from being damaged.* 6. Optional: Loosen the setscrew, and adjust the hand rest to a comfortable position. Tighten the screw. 7. Pull the clamp carriage lever toward you until the clamp carriage clicks into its end-of-run position. Tighten both the lateral and spring tension adjustment knobs. 8. Make sure the center and right jaws are free of any metal shavings or debris. (A soft-bristle toothbrush is ideal for this purpose.) Page 7318 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: Specifications Valve Clearance: Specifications Valve Clearance Intake ................................................................................................................................................... ...................... 0.18 - 0.22 mm (0.007 - 0.009 inch) Exhaust ............................................................... ....................................................................................................... 0.23 - 0.27 mm (0.009 - 0.011 inch) Page 5041 10. Connect the connector securely, then install the transmission range switch shaft cap (A). 11. Turn the ignition switch ON (II). Move the shift lever through all gear positions, and check the transmission range switch is synchronization with the A/T gear position indicator. 12. Raise the vehicle, and make sure it is securely supported. 13. Allow the wheels to rotate freely, then start the engine. 14. Move the shift lever through all gear positions, and verify the following: ^ The engine will not start in any position other than N or P. ^ The back-up lights come on when the shift lever is in the R position. 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 2068 Variable Valve Timing Actuator: Electrical Diagrams Diagram 31 (EX, HX) Diagrams: Other diagrams referred to by number (See Diagram ##-#, etc.)within these diagrams can be found at Diagrams by Number. See: Diagrams/Electrical Diagrams/Diagrams By Number Locations: Location photographs (references to PHOTOS) referred to within these diagrams can be found at Locations by Photo Number. See: Locations/Component Locations/Locations By Photo Number Connector Views: Connector terminal views (references to VIEWS) referred to within these diagrams can be found at Connector Views by View Number. See: Diagrams/Connector Views/Connector Views By View Number Page 1088 2. Cut off the wire about an inch back from where it connects to the damaged or faulty terminal, then strip about half of the insulation off that piece. This will be used to size the wire end of the replacement pigtail terminal. NOTE: If you are not sure of the wire size, start with a large enough hole on the stripper that will not nick or cut off any strands of wires. 3. Select a pigtail terminal that matches the original wire at both ends (same kind of terminal and same diameter bare wire). 4. Select the smallest splice connector (yellow, pink, or blue) that will fit onto the stripped end of the original wire. 5. Insert the pigtail terminal into the connector cavity; push it in until it locks in place. 6. Lay the pigtail and the original wire side-by-side, and cut off both ends at once. If you are making more than one splice, do not cut each pigtail at the same location; the resulting "lump" of splice connectors would interfere with rewrapping the harness. Instead, cut the first pigtail close enough to the terminal so you will have room to make each remaining cut about 20 mm (3/4 inch) farther down on the next pigtail. 7. If you are using a yellow splice connector, strip about 6 mm (1/4 inch) of insulation off the ends of both wires. If you are using a pink or blue splice connector, strip off about 8 mm (5/16 inch) of insulation. Page 6826 Page 1449 Power Steering Fluid: Fluid Type Specifications Power Steering Fluid Type ........................................................................................................................................................ Honda Power Steering Fluid Do not use ATF Main Switch Cruise Control Switch: Testing and Inspection Main Switch Main Switch Test/Replacement 1. Carefully pry the switch panel assembly out of the instrument panel. 2. Disconnect the 5P connector (A) from the main switch (B), then remove the switch. 3. Check for continuity between the terminals in each switch position according to the table. If the continuity is not as specified, replace the illumination bulbs (C) or the switch. Page 9194 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. Circuits must be operating when checking voltage drop. 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. 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 off, 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 Self-Powered Test Light or DVOM 1. Remove the blown fuse and disconnect the battery and load. Page 7282 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 Locater) 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. Troubleshooting Precautions Troubleshooting Precautions Before Troubleshooting 1. Check the main fuse and the fuse 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, or you will damage the alternator diodes. - Do not attempt to crank the engine with the ground cable disconnected 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. Page 4157 Skill Level: Repair Technician INSPECTION PROCEDURE 1. Remove the steering column covers. Refer to section 17 of the appropriate service manual. 2. On the lower side of the ignition switch, look at the interlock cylinder cover: ^ If the cover is square, the ignition switch was already replaced with an updated part, and a key interlock repair kit is not needed. Go to step 3. ^ If the cover is round, go to REPAIR PROCEDURE. 3. Reinstall the steering column covers. 4. Center-punch a completion mark above the seventh character of the engine compartment VIN. REPAIR PROCEDURE Page 8799 Air Bag(s) Arming and Disarming: Service and Repair Connector Disconnection / Connection Disconnecting System Connectors Before removing a front airbag, side airbag, or other SRS related devices (the SRS unit, the cable reel, front sensor, the side impact sensors, the seat belt buckle tensioners, and the seat belt tensioner connector), disconnecting connectors from related devices, or removing the dashboard or the steering column, disconnect the airbag connectors or the side airbag connectors to prevent accidental deployment. Turn the ignition switch OFF, disconnect the negative cable from the battery, and wait at least 3 minutes before beginning the following procedures. - Before disconnecting SRS unit connector A (A) from the SRS unit, disconnect the driver's airbag 4P connector (C), the front passenger's airbag 4P connector (D), the driver's seat belt tensioner 2P connector (F), and the front passenger's seat belt tensioner 2P connector (G). - Before disconnecting SRS unit connector B (1) from the SRS unit, disconnect both side airbag 2P connectors (L, M) and both seat belt buckle tensioner 4P connectors (J, K). - Before disconnecting the cable reel 4P connector (B), disconnect the driver's airbag 4P connector (C). - Before disconnecting the floor wire harness 4P connector (E), disconnect both seat belt tensioner 2P connectors (F, G). 1. Disconnect the battery negative cable, and wait at least 3 minutes. Driver's Airbag Locations Clutch Switch: Locations Starting System Component Location Index Page 6196 37. Push in the cam ring (A) from the pump housing cap hole (B) with a flat blade screwdriver, to make sure the cam ring is fully seated against the outer case. 38. Install the pump preload spring (A) in the pump housing. 39. Coat the new 12.7 mm O-ring (B) with power steering fluid, and install it on the pump housing cap (C). 40. Install the pump housing cap (C) on the pump housing, and tighten it to the specified torque. 41. Coat the pressure control valve (A) with power steering fluid, and install pressure control valve and spring (B) on the pump housing. 42. Coat the new 16.7 mm O-ring (C) with power steering fluid, and install it on the flow control valve cap (D). 43. Install the pressure control valve cap (D) on the pump housing, and tighten it to the specified torque. 44. Coat the new O-ring (A) with power steering fluid, and install it on the inlet joint (B). 45. Install the inlet joint (B) on the pump housing. Page 8794 Air Bag(s) Arming and Disarming: Description and Operation SRS Operation SRS Operation The main circuit in the SRS unit senses and judges the force of impact and, if necessary, ignites the inflator charges. 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: Seat Belt Tensioners and Seat Belt Buckle Tensioners 1. A front impact sensor must activate and send electric signals to the microprocessor. 2. The microprocessor must compute the signals and send them to the tensioners. 3. The charges must ignite and deploy the tensioners. Driver's and Front Passenger's Airbag(s) 1. A front impact sensor must activate, and send electric signals to the microprocessor. 2. The microprocessor must compute the signals, and depending on the severity of the collision and whether the seat belt buckle switch is ON or OFF, it sends the appropriate signals to the airbag inflator(s). 3. The inflators that received signals must ignite and deploy the airbags. Side Airbag(s) 1. Aside impact sensor must activate, and send electric signals to the microprocessor. 2. The microprocessor must compute the signals and send them to the side airbag inflator(s). However, the microprocessor cuts off the signals to the front passenger's side airbag if the OPDS unit determines that the front passenger's head is in the deployment path of the side airbag. 3. The inflator that received the signal must ignite and deploy the side airbag. Self-diagnosis System A self-diagnosis circuit is built into the SRS unit; when the ignition switch is turned ON (II), the SRS indicator comes on and goes off after about 6 seconds if the SRS is operating normally. If the indicator does not come on, or does not go off after 6 seconds, or if it comes on while driving, it indicates an abnormality in the SRS. The SRS must be inspected and repaired as soon as possible. For better serviceability, the SRS unit memory stores a DTC that relates to the cause of the malfunction, and the unit is connected to the data link circuit. This information can be read with the Honda PGM Tester when it is connected to the data link connector (DLC). Page 6153 65. PSP Switch Page 7288 1. Remove the secondary lock from the male terminal half. 2. Remove the secondary lock from the female terminal half. 3. Remove the terminal (same procedure for male and female). 4. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE C: 1. Remove the secondary lock. Page 5048 Transmission Speed Sensor: Diagrams 105. CVT Drive Pulley Speed Sensor 106. CVT Driven Pulley Speed Sensor 107. CVT Speed Sensor 1 108. CVT Speed Sensor 2 A/T - Do Not Remove Torque Converter From Mainshaft Torque Converter: Technical Service Bulletins A/T - Do Not Remove Torque Converter From Mainshaft SOURCE: Honda Service News TITLE: Keep Torque Converter on Mainshaft to Avoid Damage APPLIES TO: All models SERVICE TIP: We can't emphasize enough how important it is to keep the torque converter in place when you're handling or installing a reman A/T. If the torque converter slips off the mainshaft, and you don't put it back on the shaft exactly right, you could cut the O-ring. This could result in loss of lock-up control and ATF leakage. Component Locations Shift Interlock Switch: Component Locations Component Location Index Page 3712 1. Remove the secondary locks. 2. Remove the terminal from the female half. 3. Remove the terminal from the male half. 4. Go to HOW TO INSTALL NEW TERMINALS. Connectors Without a Secondary Lock All examples are shown with the connector lock facing up. The illustrations are examples of connector terminals without a secondary lock; however, the connector you are repairing may vary in size and shape. EXAMPLE A: Body/Frame - Universal Subframe Removal Adapter Subframe: Technical Service Bulletins Body/Frame - Universal Subframe Removal Adapter 05-066 November 24, 2005 Applies To: See VEHICLES AFFECTED Universal Front Subframe Removal Adapter (Replaces 01-043, Civic Front Sub frame Removal Adapter, dated September 11, 2001) The universal front subframe removal adapter is a required tool. When properly fitted to a transmission jack and the vehicle's front subframe, the adapter provides a convenient way to remove the subframe. Front subframe removal is required for transmission or engine removal. NOTE: The adapter will only support the subframe it will not support the entire powertrain assembly. Refer to the WARNING label on the adapter. VEHICLES AFFECTED 2003-06 Accord - ALL 2005-06 Accord Hybrid - ALL 2001-06 Civic - ALL 2001-06 Civic GX - ALL 2003-06 Civic Hybrid - ALL 2002-06 Civic Si - ALL 2002-06 CRV - ALL 2003-06 Element - ALL ORDERING INFORMATION The universal front subframe removal adapter is TIN VSB02C000016. To order additional adapters, call the Honda Tool and Equipment Program. USING THE ADAPTER NOTE: The adapter is designed to be used with the transmission jack, (new model number NRI-72500D), available through the Honda Tool and Equipment Program. (The old model number LSL-W93714 can still be used.). The adapter also works with many commercially available transmission jacks. 1. Loosen the four bolts that hold the adapter's adjustable arms to its center plate. Page 1690 3. Strip the insulation off the end of the wire so the wire fits in the new terminal as shown. (If the wire has a wire seal, replace it with a new one from the kit.) NOTE: After stripping the end of the wire, make sure you did not cut any wire strands. If you did, cut the wire off even with the insulation, and strip it again. 4. Position the terminal in the crimping tool slot with the solid portion of the terminal toward the anvil and the open section toward the former. 5. Insert the wire in the terminal to the position shown in step 3. 6. Squeeze the tool with both hands until the stops make contact. 7. Crimp the insulation crimp. - If you do not have a wire seal, then use the next larger size crimp slot. Position the crimping tool over the insulation crimp section of the terminal, then squeeze the tool with both hands until the stops make contact. - If you have a wire seal, position the insulation crimp in the 5.5 crimping slot, then carefully squeeze the crimp closed until its ends are touching and making a full-circle shape. Page 7605 PARTS INFORMATION REQUIRED MATERIALS WARRANTY CLAIM INFORMATION In warranty: The normal warranty applies. Failed Part: P/N 72185-S9A-003 H/C 6896716 Defect Code: 00503 Symptom Code: 07902 Skill Level: Repair Technician Locations Relay And Control Unit Locations - Dashboard Page 3138 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. Test Equipment 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. Page 2606 12. Pull the vertical carriage lever toward you while you position the tracer on the right edge of the original key at its head, using the clamp carriage lever. Let the cutter bit cut into the key blank, then stop. Gently twist the lever clockwise to lock the vertical carriage at this height. Do not overtighten the lever. 13. Use the clamp carriage lever and the tracer to follow the contours of the original key. (The cutter bit cuts the same contours into the key blank.) Working from right to left, follow the right edge of the original key from head to tip, then the left edge of the key from tip to head. Turn off the cutter motor. 14. Reposition the tracer on the right edge of the original key at its head, using the clamp carriage lever. Turn on the cutter motor. Retrace the key from head to tip, then from tip to head. (This retracing cleans up the cuts on the key.) Turn off the cutter motor. 15. Release the vertical carriage lever. Open the jaw and remove only the new key. Make sure the jaw is free of any metal shavings or debris, then turn the new key over and slide the key with its blank side up into the jaw up to the key stop. Close the jaw to lock the key into place. 16. Turn on the cutter motor, and repeat steps 12 thru 14 to cut both edges of the other side of the key. 17. When you are finished making the required cuts, turn off the cutter motor, and release the vertical carriage lever. Open the jaws, and remove the keys. 18. Use a wire brush to smooth the cut surfaces on the new key. 19. Make sure the key works in the ignition switch and all the locks. If the key does not work, recut the key, and try it again. 20. Depending on the type of key blank you have used, do this: ^ If you have used a Honda key blank, add the transponder code of the new key to the immobilizer system with the Honda Diagnostic System (HDS). ^ If you have used a T-5 programmable key blank ("T-5" stamped on the shank), code the key's transponder with the Ilco Immobilizer Key Code Duplicator (see S/B 99-053, Ilco Immobilizer key Code Duplicator). Cutting Procedure - By Code 1. Press the ON/OFF button in the middle of the setting unit keypad. (This powers up the keypad.) 2. Turn the clamp unit lock lever to the left to release the clamp unit, and slide it to the right until the bottom left side is flush with the base edge. Turn the lever to the right to lock the clamp unit in place. Loosen the lateral and spring tension adjustment knobs on the clamp carriage. Page 9100 8. Inspect the quality of the wire crimp. If it has any of the following NO GOOD crimps, cut it off and start over. 9. Insert the terminal into the connector. Make sure the wire seals are pushed all the way into the connector. Lightly pull on the wires to make sure the terminal is locked into place. 10. Close or insert the secondary terminal lock, if applicable, and reconnect the connector. How to Install Pigtail Terminals HOW TO INSTALL PIGTAIL TERMINALS Pigtail terminals (short pieces of wire with a factory crimped terminal) are used when the wire is too short or when access to the connector is too restricted to make a terminal repair. NOTE: To replace just a connector terminal, go to How to Replace Connector Terminals. IMPORTANT SAFETY INFORMATION: On some models, the SRS wires are in a separate harness. If the SRS harness is damaged, replace the harness; do not repair it. On other models, wire harnesses include yellow SRS wires. If any SRS wire is damaged, replace the entire harness; do not repair it. 1. Remove the damaged or faulty terminal from the connector. Use the proper removal tool from Pin Tool Set. Page 8717 207. Cruise Control Unit (USA: HX; Sedan: LX, EX, GX) Page 9503 1. Remove the terminal. 2. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE B: 1. Remove the terminal. 2. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE C: 1. Remove the terminal. 2. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE D: Page 7409 Antenna Control Module: Testing and Inspection Antenna Module Input Test 2-door 1. Remove the right C-Pillar trim. 2. Make sure the antenna module mounting bolt (A) is torqued to 9.8 N.m (1.0 kgf.m, 7.2 lbf.ft) 3. Disconnect the 2P connector from the antenna module (C). 4. Turn the ignition switch ON (II), turn the rear window defogger switch ON. Check for voltage between the No.2 terminal and body ground. There should be battery voltage. If there is no voltage, check for: Faulty rear window defogger relay. - Blown No.11 (40 A) fuse or No.19 (80 A) in the under-hood fuse/relay box. - An open in the BLK/YEL wire. 5. With the ignition switch ON (II), turn the radio ON, and turn to an FM station. Check for voltage between the No.1 terminal and body ground. If there is no voltage, check for: An open in the YEL/GRN wire. - A short to ground in the YEL/GRN wire. - Faulty audio unit. 6. Disconnect the rear window defogger (+B OUT) connector (D) from the antenna module. 7. With the ignition switch and the rear window defogger switch ON, check for voltage to ground. If there is no voltage, replace the antenna module. 8. Turn the ignition switch OFF. Page 5673 1. Cut off the female S terminal from the harness, making the cut as close to the terminal as possible. 2. Strip 6 mm of insulation from the wire using the 2.0 slot on the crimping tool. NOTE: Make sure no wire strands were removed when you stripped the insulation. If any were removed, cut the wire off even with the insulation, and strip it again. 3. Insert the wire into the new terminal so it fits as shown. 4. Using the 2.0 slot on the crimping tool, position the terminal in the tool slot with the solid portion of the terminal toward the anvil and the open section toward the former. Page 5884 234. Under-dash Fuse/Relay Box Part 3 Page 6145 1. Raise the front of the vehicle, and support it with safety stands in the proper locations. Remove the front wheels. 2. Loosen the damper pinch nuts and bolts (A), and adjust the camber by moving the bottom of the damper within the range of the damper pinch bolt free play 3. Tighten the bolts to the specified torque. 4. Reinstall the front wheels. Lower the front of the vehicle to the ground, and bounce the vehicle several times to stabilize the suspension. 5. Check the camber angle. If it is within the specification, check the front toe. If it is not within the specification, go to step 6. 6. Raise the front of the vehicle, and support it with safety stands in the proper locations. Remove the front wheels. 7. Replace the damper pinch bolts with the adjusting bolts (A), and adjust the camber angle. NOTE: The camber angle can be adjusted up to ± 15' (center of tolerance) by replacing one damper pinch bolt with the adjusting bolt. The camber angle can be adjusted up to ± 30' by replacing both upper and lower damper pinch bolts with the adjusting bolts. 8. Tighten the bolts to the specified torque. 9. Reinstall the front wheels. Lower the front of the vehicle to the ground, and bounce the vehicle several times to stabilize the suspension. 10. Check the camber angle. if it is within the specification, check the front toe, and adjust it if necessary. If it is not within the specification, readjust, and recheck. If the camber angle cannot be adjusted to the specification, check for bent or damaged suspension components. Rear Camber Inspection Use commercially-available computerized four wheel alignment equipment to measure wheel alignment (caster, camber, toe, and turning angle). Follow the equipment manufacturer's instructions. Check the camber angle. If the camber angle is not within the specification, check for bent or damaged suspension components. Rear camber angle: - 0°45' ± 45' Front Toe Inspection/Adjustment Use commercially-available computerized four wheel alignment equipment to measure wheel alignment (caster, camber, toe, and turning angle). Follow the equipment manufacturer's instructions. 1. Center the steering wheel spokes. 2. Check the toe. If it is not within the specification, go to step 3. Front toe-in: 0 ± 3 mm (0 ± 0.12 inch) Page 5815 1. Remove the terminal. 2. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE C: 1. Remove the terminal. 2. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE D: Page 728 111. ELD Unit (USA) Page 5909 Power Distribution schematics show how power is supplied from the positive battery terminal to various circuits in the vehicle. Refer to the Power Distribution diagram set to get a more detailed understanding of how picture is supplied to the circuit you're working on. Individual circuit schematics begin with a fuse. So 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 Ground Distribution Schematics This sample Ground Distribution schematic shows all of the components that share the same ground point. Diagrams Page 5022 107. Behind A/T Shift Lever (except M/T) Page 5525 108. Middle Of Floor Page 7624 12. Pull the vertical carriage lever toward you while you position the tracer on the right edge of the original key at its head, using the clamp carriage lever. Let the cutter bit cut into the key blank, then stop. Gently twist the lever clockwise to lock the vertical carriage at this height. Do not overtighten the lever. 13. Use the clamp carriage lever and the tracer to follow the contours of the original key. (The cutter bit cuts the same contours into the key blank.) Working from right to left, follow the right edge of the original key from head to tip, then the left edge of the key from tip to head. Turn off the cutter motor. 14. Reposition the tracer on the right edge of the original key at its head, using the clamp carriage lever. Turn on the cutter motor. Retrace the key from head to tip, then from tip to head. (This retracing cleans up the cuts on the key.) Turn off the cutter motor. 15. Release the vertical carriage lever. Open the jaw and remove only the new key. Make sure the jaw is free of any metal shavings or debris, then turn the new key over and slide the key with its blank side up into the jaw up to the key stop. Close the jaw to lock the key into place. 16. Turn on the cutter motor, and repeat steps 12 thru 14 to cut both edges of the other side of the key. 17. When you are finished making the required cuts, turn off the cutter motor, and release the vertical carriage lever. Open the jaws, and remove the keys. 18. Use a wire brush to smooth the cut surfaces on the new key. 19. Make sure the key works in the ignition switch and all the locks. If the key does not work, recut the key, and try it again. 20. Depending on the type of key blank you have used, do this: ^ If you have used a Honda key blank, add the transponder code of the new key to the immobilizer system with the Honda Diagnostic System (HDS). ^ If you have used a T-5 programmable key blank ("T-5" stamped on the shank), code the key's transponder with the Ilco Immobilizer Key Code Duplicator (see S/B 99-053, Ilco Immobilizer key Code Duplicator). Cutting Procedure - By Code 1. Press the ON/OFF button in the middle of the setting unit keypad. (This powers up the keypad.) 2. Turn the clamp unit lock lever to the left to release the clamp unit, and slide it to the right until the bottom left side is flush with the base edge. Turn the lever to the right to lock the clamp unit in place. Loosen the lateral and spring tension adjustment knobs on the clamp carriage. Page 9407 1. Remove the terminal. 2. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE E: 1. Remove the terminal. 2. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE F: Page 6033 234. Under-dash Fuse/Relay Box Part 2 Page 5732 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. Circuits must be operating when checking voltage drop. 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. 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 off, 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 Self-Powered Test Light or DVOM 1. Remove the blown fuse and disconnect the battery and load. Page 7340 ^ 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. Locations Shift Interlock Solenoid: Locations 107. Behind A/T Shift Lever (except M/T) Locations 12. Middle of Engine Page 9452 158. DRL Relay (Canada); Low Beam Cut Relay ('01-'03 Canada) Page 3839 8. Put the splice connector in the proper size slot in the Crimper Tool, slide it to one end (where the flare begins), and close the crimper handles far enough to hold it in place. To release the ratchet mechanism at any point after the first click, squeeze the handles slightly and push the release lever, then let the handles open. 9. Insert one of the bare wires into the splice connector end that is in the crimper jaws. Push the wire all the way into the splice connector, and squeeze the crimper handles. Keep squeezing until the jaws touch, and hold it at that position until the ratchet clicks again. 10. Crimp the other wire in the same way into the other end of the splice connector. 11. After crimping, gently pull on the wires in the opposite directions to make sure they are secure in the connector. 12. Separate the other wires in the harness from the repaired wire(s), and shield them with nonflammable material. Page 2821 Information Bus: Diagnostic Aids General Troubleshooting Information General Troubleshooting Information Tips and Precautions Before Troubleshooting 1. Check applicable fuses in the appropriate fuse/relay box. 2. Check the battery for damage, state of charge, and clean and tight connections. NOTE: 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. Handling Connectors - Make sure the connectors are clean and have no loose wire terminals. - Make sure multiple cavity connectors are packed with dielectric grease (except watertight connectors). - All connectors have push-down release type locks (A). - Some connectors have a clip on their side used to attach them to a mount bracket on the body or on another component. This clip has a pull type lock. - Some mounted connectors cannot be disconnected unless you first release the lock and remove the connector from its mount bracket (A). - Never try to disconnect connectors by pulling on their wires; pull on the connector halves instead. - Always reinstall plastic covers. Page 2615 160. Left Side Of Engine Compartment (except GX) Locations Shift Interlock Solenoid: Locations 107. Behind A/T Shift Lever (except M/T) Page 7344 - 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 19 1. Remove the driver's dashboard lower cover. (See the body section of the appropriate service manual.) 2. Replace the security control unit. ^ Civic: Remove the security control unit, and install the new security control unit. ^ * CR-V and Element: Remove the security control unit and microphone. Install the new security control unit and new microphone.* 3. Reprogram the keyless receiver unit. NOTE: The codes of up to three transmitters can be stored in the keyless receiver unit memory. If a fourth code is stored, the code that was input first will be erased. It is important to maintain the time limits between the steps. Make sure the doors and the trunk/tailgate/hatch are closed, and that you have all of the remotes the customer wishes to use. ^ Turn the ignition switch to ON (II). ^ Within 1 to 4 seconds, push the transmitter lock or unlock button. ^ Within 1 to 4 seconds, turn the ignition switch to LOCK (0). ^ Within 1 to 4 seconds, turn the ignition to ON (II). ^ Within 1 to 4 seconds, push the transmitter lock or unlock button. ^ Within 1 to 4 seconds, turn the ignition switch to LOCK (0). ^ Within 1 to 4 seconds, turn the ignition switch to ON (II). ^ Within 1 to 4 seconds, push the transmitter lock or unlock button. Page 853 14. Disconnect the 22P connector "A" from the gauge assembly. 15. Touch a probe to the BLU/WHT wire, and connect it to body ground through a voltmeter. 16. Slowly rotate one wheel with the other wheel blocked. Does voltage pulse from 0 to about 5 V or more? YES - Replace the speedometer assembly. NO - Repair open in the BLU/WHT wire between the VSS and the speedometer. Page 2947 DTC P0750 thru P0977 Page 3432 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 4287 Skill Level: Repair Technician INSPECTION PROCEDURE 1. Remove the steering column covers. Refer to section 17 of the appropriate service manual. 2. On the lower side of the ignition switch, look at the interlock cylinder cover: ^ If the cover is square, the ignition switch was already replaced with an updated part, and a key interlock repair kit is not needed. Go to step 3. ^ If the cover is round, go to REPAIR PROCEDURE. 3. Reinstall the steering column covers. 4. Center-punch a completion mark above the seventh character of the engine compartment VIN. REPAIR PROCEDURE Locations Page 2140 Coolant: Service and Repair Replacement 1. Start the engine. Set the heater temperature control dial to maximum heat, then turn off the ignition switch. Make sure the engine and radiator are cool to the touch. 2. Make sure you have the anti-theft code for the radio, then write down the frequencies for the radio's preset buttons. 3. Remove the battery. 4. Remove the radiator cap. 5. Loosen the drain plug (A), and drain the coolant. 6. Remove the drain bolt (A) from the rear of the cylinder block. 7. After the coolant has drained, apply liquid gasket to the drain bolt threads, then reinstall the bolt with a new washer and tighten it securely. 8. Tighten the radiator drain plug securely. Page 9092 1. Remove the secondary lock from the male terminal half. 2. Remove the secondary lock from the female terminal half. 3. Remove the terminal (same procedure for male and female). 4. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE C: 1. Remove the secondary lock. Locations Power Steering Pressure Switch: Locations Idle Control System - Component Location Index 34. Left Side Of Engine Compartment Page 4458 6. Attach the clutch line (A) to the clutch line clip (B). 7. Bleed the clutch hydraulic system. 8. Fill brake fluid up to the MAX line on the reservoir. Push back the diaphragm in the reservoir to the initial condition, and after fitting it, attach the cap. Page 8728 64. Under Left Side Of Dash (M/T) Page 3244 Resistor Variable Sensor Solenoid Transistors Circuit Schematics Page 4211 Power Distribution schematics show how power is supplied from the positive battery terminal to various circuits in the vehicle. Refer to the Power Distribution diagram set to get a more detailed understanding of how picture is supplied to the circuit you're working on. Individual circuit schematics begin with a fuse. So 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 Ground Distribution Schematics This sample Ground Distribution schematic shows all of the components that share the same ground point. Page 7341 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 535 10. Middle Of Engine Page 7219 Programming the Transmitter NOTES: ^ The system accepts up to three transmitters. The transmitter codes are stored in a stacking-type memory. If a fourth transmitter code is programmed, the code for the first transmitter is erased. ^ Entering the programming mode cancels all learned transmitter codes, so none of the previously programmed transmitters will work. You must reprogram all of the transmitters once you are in the programming mode. ^ You must complete steps 1-6 within 4 seconds of the previous step to keep the system from exiting the programming mode. 1. Turn the ignition switch to ON (II). 2. Press the "Lock" or "Unlock" button on one of the transmitters. (An unprogrammed transmitter can be used for this step.) 3. Turn the ignition switch to LOCK (0). 4. Repeat steps 1 2, and 3 two more times using the same transmitter used in step 2. 5. Turn the ignition switch to ON (II). 6. Press the "Lock" or "Unlock" button on the same transmitter. Make sure the power door locks cycle to confirm that the system is in programming mode. 7. Within 10 seconds, press the "Lock" or "Unlock" button on each transmitter. Make sure the power door locks cycle after you press each transmitter button to confirm that the system accepted the transmitter's code. 8. Turn the ignition switch to LOCK (0) to exit the programming mode. Ordering a Transmitter Transmitters can be ordered only by authorized Honda dealers. Order them from American Honda using normal parts ordering procedures. Batteries for the Transmitter The battery number is CR1616. Each transmitter uses one battery. 97-04 CR-V & 00-04 S2000 *1997-04 CR-V LX with dealer-installed keyless entry system 1998-04 CR-V EX with factory-installed keyless entry system 2000-01 CR-V SE with factory-installed keyless entry system 2000-04 S2000 with factory-installed keyless entry system 2002-04 CR-V with dealer-installed security system* Page 242 234. Under-dash Fuse/Relay Box Part 3 Testing and Inspection Low Fuel Lamp/Indicator: Testing and Inspection Low Fuel Indicator Test 1. Do the fuel gauge sending unit test. - If the system is OK, go to step 2. - If the system has any malfunction, repair it. 2. Turn the ignition switch ON (II) with the float at the E (EMPTY) position. - If the low fuel indicator is on, go to step 3. - If the low fuel indicator is not on, '01-02 model: refer to the low fuel indicator Circuit Diagram, '03 model-Nippon Seiki Type: refer to the low fuel indicator Circuit Diagram, '03 model-Visteon Type: refer to the low fuel indicator Circuit Diagram 3. Lift the float above the LOW position. - If the low fuel indicator goes off, the system is OK. - If the low fuel indicator is not on, '01-'02 model: refer to the low fuel indicator Circuit Diagram, '03 model-Nippon Seiki Type: refer to the low fuel indicator Circuit Diagram, '03 model-Visteon Type: refer to the low fuel indicator Circuit Diagram. Page 1272 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 9604 Combination Switch: Testing and Inspection Combination Light Switch Test/Replacement 1. Remove the dashboard lower cover. 2. Remove the steering column covers. 3. Disconnect the 16P connector (A) from the combination light switch (B). 4. Remove the two screws, then slide out the combination light switch. 5. Inspect the connector terminals to be sure they are all making good contact. - If the terminals are bent, loose or corroded, repair them as necessary, and recheck the system. - If the terminals look OK, check for continuity between the terminals in each switch position according to the tables. 6. If the continuity is not as specified, replace the switch. Locations Pressure Regulating Solenoid: Locations 23. Transmission Housing (A/T) Page 8699 3. Disconnect the 12P connector from the cruise control actuator. 4. Remove the three mounting bolts, and remove the cruise control actuator. 5. Install the reverse order of removal, and adjust the free play at the throttle linkage after connecting the actuator cable. Page 9515 Diagram 115-3 (Coupe EX) Locations 25. Transmission Housing (CVT) Page 5046 Transmission Speed Sensor: Locations 25. Transmission Housing (CVT) 26. Transmission Housing (CVT) Locations 57. Under Left Side Of Dash Page 9171 Daytime Running Lamp Relay: Testing and Inspection Power Relay Test Use this chart to identify the type of relay, then do the test listed for it. NOTE: See the turn signal/hazard relay input test. Normally-open type A: Check for continuity between the terminals. - There should be continuity between the No.1 and No.2 terminals when power and ground are connected to the No.3 and No.4 terminals. - There should be no continuity between the No.1 and No.2 terminals when power is disconnected. Page 5287 143. Park Pin/Shift Switch (A/T) Page 6880 OPDS Unit - Connectors A, B, C, D Page 5945 Under-hood Fuse And Relay Box (4-door) Page 3227 195. Tranmission Range Switch Locations Keyless Entry Module: Locations Relay And Control Unit Locations - Dashboard 78. Under Middle of Dash (Honda Accessory) Page 3642 72. Shift Lock Solenoid (A/T) Coupe Front Door Panel: Service and Repair Coupe Door Panel Removal/Installation Special Tools Required - KTC trim tool set SOJATP2014 - Trim pad remover. Snap-on A 177A or equivalent, commercially available 2-door NOTE: Use the appropriate tool from the KTC trim tool set to avoid damage when prying components. 1. If applicable, remove the regulator handle (A) by pulling the clip (B) out with a wire hook (C). 2. Remove the inner handle (A). Take care not to scratch the door panel. 1. Pry out on the upper portion of the cover (B) to release the hooks (C, D), then remove the cover. 2. Remove the screws. 3. Pull the inner handle forward and out half-way to release the hook (E). 4. Disconnect the inner handle rod (F) and power door lock switch connector (G) (driver's side for some models). Page 8918 NO - Go to step 77. 77. Turn the ignition switch OFF. 78. Disconnect ECM/PCM connector E (31P). 79. Check for continuity between ECM/PCM connector terminal E29 and body ground. Is there continuity? YES - Repair short in the wire between the DLC and the ECM/PCM (E29). NO - Update the ECM/PCM if it does not have the latest software, or substitute a known-good ECM/PCM, then recheck. If the symptom/indication goes away with a known-good ECM/PCM, replace the original ECM/PCM. 80. Turn the ignition switch OFF. 81. Disconnect ECM/PCM connector E (31P). 82. Turn the ignition switch ON (II). Is the MIL on? YES - Repair short in the wire between the gauge assembly and the ECM/PCM (E31). If the wires are OK, replace the gauge assembly. NO - Update the ECM/PCM if it does not have the latest software, or substitute a known-good ECM/PCM, then recheck. If the symptom/indication goes away with a known-good ECM/PCM, replace the original ECM/PCM. Page 9484 Diodes Light Emitting Diode (LED) Motor Pressure Sensor Page 6589 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 502 Braking Sensor/Switch: Description and Operation Brake Pedal Position Switch The brake pedal position switch signals the ECM/PCM when the brake pedal is pressed. Service and Repair Crankshaft Gear/Sprocket: Service and Repair Timing Belt Drive Pulley Replacement 1.Remove the timing belt. 2.Remove the crankshaft position, (CKP) sensor. 3.Remove the timing belt drive pulley. 4. Install the new timing belt drive pulley. 5. Install the CKP sensor. 6. Install the timing belt. Recall 10V364000: Ignition Interlock Defect Shift Interlock Switch: Recalls Recall 10V364000: Ignition Interlock Defect VEHICLE MAKE/MODEL: MODEL YEAR(S): Honda/Accord 2003 Honda/Civic 2003 Honda/Element 2003-2004 MANUFACTURER: Honda (American Honda Motor Co.) MFR'S REPORT DATE: August 04, 2010 NHTSA CAMPAIGN ID NUMBER: 10V364000 NHTSA ACTION NUMBER: EA09001 COMPONENT: Electrical System: Ignition POTENTIAL NUMBER OF UNITS AFFECTED: 384220 SUMMARY: Honda is recalling certain model year 2003 Honda Accord, Civic two and four door, and model year 2003-2004 Honda Element vehicles. The interlock lever of the ignition switch may unexpectedly deform, which can allow the interlock function of a vehicle with an automatic transmission to be defeated. CONSEQUENCE: Removal of the ignition key when the gear selector of a vehicle with an automatic transmission has not been shifted to the park position can allow the vehicle to roll away, increasing the risk of a crash. REMEDY: Dealers will remove the original interlock pin and lever within the ignition switch, and replace them with newly, designed components. This service will be performed free of charge. The safety recall is expected to begin on or about September 29, 2010. Owners may contact Honda at 1-800-999-1009. NOTES: Honda safety recall No. R44. 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 2822 - Before connecting connectors, make sure the terminals (A) are in place and not bent. - Check for loose retainer (A) and rubber seals (B). - The backs of some connectors are packed with dielectric grease. Add grease if necessary. If the grease is contaminated, replace it. - Insert the connector all the way and make sure it is securely locked. - Position wires so that the open end of the cover faces down. Handling Wires and Harnesses - Secure wires and wire harnesses to the frame with their respective wire ties at the designated locations. Page 9529 PGM-F1 Main Relay 1, 2 Type 1, 2 Check for continuity between the terminals. - There should be continuity between the No.1 and No.2 terminals when power and ground are connected to the No.3 and No.4 terminals. - There should be no continuity between the No.1 and No.2 terminals when power is disconnected. Normally-open type B: Rear Window Defogger Relay Page 2819 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. Below most connector numbers and component names are PHOTO and VIEW numbers. The PHOTO number refers to a photo in the back of the book that shows the connector's location on the car. The VIEW number refers to an illustration in the back of the book that shows the connector terminals, wire colors, connector cavity numbers, and other details. The connector cavity numbering sequence begins at the top left corner of the connector as seen from either of the viewpoints shown on diagram [8] . Except for the DLC (data link 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 C554, for example, means those terminals join in cavity 2 of connector C554. Power Distribution Schematics Power Distribution Schematics Page 1513 Under-hood Fuse And Relay Box (4-door) Page 3161 3. If there is no continuity between any terminal, remove the transmission range switch cover, and disconnect the connector (A) at the switch (B). 4. Check for continuity between terminals at the switch connector (c). There should be continuity between the terminals listed for each position. In the P position, between terminals: ^ No. 4 and No. 5 ^ No. 4 and No. 6 ^ No. 5 and No. 6 In the R position, between terminals: ^ No. 1 and No. 4 In the N position, between terminals: ^ No. 4 and No. 5 ^ No. 4 and No. 7 ^ No.5 and No.7 In the D position, between terminals: ^ No.2 and No.4 ^ No. 2 and No. 10 ^ No. 4 and No. 10 In the D3 position, between terminals: ^ No. 4 and No. 8 ^ No. 4 and No. 10 ^ No. 8 and No. 10 In the 2 position, between terminals: ^ No.3 and No.4 5. If there is no continuity between any terminals, adjust the transmission range switch installation. If the transmission range switch installation is OK, replace the switch. 6. If the transmission range switch continuity check was OK, replace the faulty transmission range switch harness. Page 6035 234. Under-dash Fuse/Relay Box Part 4 Page 929 VEHICLES AFFECTED CUSTOMER NOTIFICATION All owners of affected vehicles were mailed a notification of this warranty extension. A example of the customer notification is shown in this service bulletin. CORRECTIVE ACTION Repair the vehicle as indicated by the INSPECTION PROCEDURE. If needed, replace the OPDS unit. In rare cases where an updated OPDS unit was already installed, replace the OPDS sensor. Under-Dash Fuse/Relay Box Under-dash Fuse/Relay Box Page 5361 Connectors - "C" Page 168 - Before connecting connectors, make sure the terminals (A) are in place and not bent. - Check for loose retainer (A) and rubber seals (B). - The backs of some connectors are packed with dielectric grease. Add grease if necessary. If the grease is contaminated, replace it. - Insert the connector all the way and make sure it is securely locked. - Position wires so that the open end of the cover faces down. Handling Wires and Harnesses - Secure wires and wire harnesses to the frame with their respective wire ties at the designated locations. Page 9750 Power Window Switch: Testing and Inspection Passenger's Window Switch Test/Replacement Passenger's Window Switch Test/Replacement 4-door 1. Remove the door grip cover. 2. Disconnect the 5P connector (A) from the passenger's power window switch (B). 3. Check for continuity between the terminals in each switch position according to the table. 4. If the continuity is not as specified, remove the two screws and replace the switch. 2-door Page 4814 Fluid - M/T: Service and Repair Transmission Fluid Inspection and Replacement 1. Park the vehicle on level ground, and turn the engine OFF. 2. Remove the oil filler plug (A) and washer (B), check the condition of the fluid, and make sure the fluid is at the proper level (C). 3. If the transmission fluid is dirty, remove the drain plug (D) and drain the fluid. 4. Reinstall the drain plug with a new washer, and refill the transmission fluid to the proper level. Oil Capacity 1.5 L (1.6 US qt) at fluid change 1.6 L (1.7 US qt) at overhaul Always use Honda Manual Transmission Fluid (MTF). Using motor oil can cause stiffer shifting because it does not contain the proper additives. 5. Reinstall the oil filler plug with anew washer. Page 7381 ^ Within 1 to 4 seconds, turn the ignition switch to LOCK (0). ^ Within 1 to 4 seconds, turn the ignition to ON (II). ^ Within 1 to 4 seconds, push the transmitter lock or unlock button. ^ Confirm you can hear the sound of the door lock actuators. Within 1 to 4 seconds, push the transmitter lock or unlock button again. ^ Within 10 seconds, aim the transmitters (up to two additional ones) whose codes you want to store at the receiver, and press the transmitter lock or unlock button. Confirm that you can hear the sound of the door lock actuators after each transmitter code is stored. ^ Turn the ignition switch to LOCK (0), and pull out the key. 4. Confirm proper operation of the transmitters. Disclaimer Locations Intake Air System - Component Location Index Page 4235 195. Tranmission Range Switch Page 1085 1. Remove the terminal. 2. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE G: 1. Remove the terminal. 2. Go to HOW TO INSTALL NEW TERMINALS. How to Install New Terminals HOW TO INSTALL NEW TERMINALS 1. Carefully match the old terminal with a new one from the terminal repair kit. Choose the correct replacement terminal based on the wire size range the terminal will accommodate. NOTE: If the replacement terminal quantities are low, reorder them by using the terminal part number listed on the inside lid of the terminal repair kit. Replacement terminals are available through your parts department using normal parts ordering procedures. 2. Depending on the size of the wire you are repairing, use the proper size slot in the crimping tool. Page 8907 18. Check for continuity between body ground and PGM-FI main relay 1 4P connector terminals No.2 and No.4 individually. Is there continuity? YES - Repair short in the wire between the No.6 ECU (ECM/PCM) (15A) fuse and PGM-FI main relay 1. Also replace the No.6 ECU (ECM/PCM) (15A) fuse. NO - Go to step 19. 19. Disconnect each of the components or connectors connector below, one at a time, and check for continuity between PGM-FI main relay 1 4P connector terminal No.1 and body ground. PGM-FI main relay 2 - ECM/PCM connector A (31P) - Each injector 2P connector - Idle air control (IAC) valve 3P connector - Camshaft position (CMP) sensor (Top dead center (TDC) sensor) 3P connector - Crankshaft position (CKP) sensor 3P connector Is there continuity? YES - Go to step 20. NO - Replace the component that made continuity to body ground go away when disconnected. If the item is the ECM/PCM, update the ECM/PCM if it does not have the latest software, or substitute a known-good ECM/PCM, then recheck. If the symptom/indication goes away with a known-good ECM/PCM, replace the original ECM/PCM. Also replace the No.6 ECU (ECM/PCM) (15A) fuse. 20. Disconnect the connectors of all these components. - PGM-FI main relay 2 - ECM/PCM connector A (31P) - Injectors - Idle air control (IAC) valve - Camshaft position (CMP) sensor (Top dead center (TDC) sensor) - Crankshaft position (CKP) sensor Page 7337 ^ 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 2735 REPAIR PROCEDURE 1. Make sure you have the anti-theft code for the audio unit. Write down the customer's audio presets. 2. Disconnect the negative battery cable from the battery. 3. Remove the under-hood fuse/relay box cover. 4. Release the three clips, and remove the under- hood fuse/relay box from the holder. CR-V only: Release the wire harness clip from the fuse/relay box holder Page 1673 Variable Valve Timing Actuator: Diagnostic Aids General Troubleshooting Information General Troubleshooting Information Tips and Precautions Before Troubleshooting 1. Check applicable fuses in the appropriate fuse/relay box. 2. Check the battery for damage, state of charge, and clean and tight connections. NOTE: 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. Handling Connectors - Make sure the connectors are clean and have no loose wire terminals. - Make sure multiple cavity connectors are packed with dielectric grease (except watertight connectors). - All connectors have push-down release type locks (A). - Some connectors have a clip on their side used to attach them to a mount bracket on the body or on another component. This clip has a pull type lock. - Some mounted connectors cannot be disconnected unless you first release the lock and remove the connector from its mount bracket (A). - Never try to disconnect connectors by pulling on their wires; pull on the connector halves instead. - Always reinstall plastic covers. Page 9870 drop the glass inside the door. 3. Power window: Disconnect and detach the connector (A) and harness clip (B) from the door. 4. Remove the bolts (C), and loosen the bolts (D, E), then remove the regulator (F) through the hole in the door. Power window is shown, manual window is similar. 5. Apply multipurpose grease to the sliding surfaces of the regulator (A) where shown. Locations Clutch Switch: Locations Cruise Control Component Location Index Page 9144 2. Remove the terminal (same procedure for male and female). 3. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE E: 1. Remove the secondary locks. 2. Remove the terminal (same procedure for male and female). 3. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE F: Page 6066 Relay Box: Diagrams 234. Under-dash Fuse/Relay Box Part 1 Page 2836 1. Remove the terminal. 2. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE E: 1. Remove the terminal. 2. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE F: Page 1214 55. In Steering Column Cover Page 2953 DTC P1861 thru P2238 Page 1772 8. Put the splice connector in the proper size slot in the Crimper Tool, slide it to one end (where the flare begins), and close the crimper handles far enough to hold it in place. To release the ratchet mechanism at any point after the first click, squeeze the handles slightly and push the release lever, then let the handles open. 9. Insert one of the bare wires into the splice connector end that is in the crimper jaws. Push the wire all the way into the splice connector, and squeeze the crimper handles. Keep squeezing until the jaws touch, and hold it at that position until the ratchet clicks again. 10. Crimp the other wire in the same way into the other end of the splice connector. 11. After crimping, gently pull on the wires in the opposite directions to make sure they are secure in the connector. 12. Separate the other wires in the harness from the repaired wire(s), and shield them with nonflammable material. Page 2539 3. Strip the insulation off the end of the wire so the wire fits in the new terminal as shown. (If the wire has a wire seal, replace it with a new one from the kit.) NOTE: After stripping the end of the wire, make sure you did not cut any wire strands. If you did, cut the wire off even with the insulation, and strip it again. 4. Position the terminal in the crimping tool slot with the solid portion of the terminal toward the anvil and the open section toward the former. 5. Insert the wire in the terminal to the position shown in step 3. 6. Squeeze the tool with both hands until the stops make contact. 7. Crimp the insulation crimp. - If you do not have a wire seal, then use the next larger size crimp slot. Position the crimping tool over the insulation crimp section of the terminal, then squeeze the tool with both hands until the stops make contact. - If you have a wire seal, position the insulation crimp in the 5.5 crimping slot, then carefully squeeze the crimp closed until its ends are touching and making a full-circle shape. Page 1169 Power Window Switch: Locations Relay And Control Unit Locations - Door, Roof And Seat Page 9212 Dome Lamp: Electrical Diagrams Diagram 114-2 (except EX) Page 609 15. Measure resistance between the No.1 and No.2 terminals with the float at E (EMPTY), 1/2 (HALF FULL), and F (FULL) positions. If you do not get the shown readings, replace the fuel gauge sending unit. NOTE: Remove the No.9 BACK UP (10A) fuse from the under-hood fuse/relay box for at least 10 seconds after completing troubleshooting, otherwise it may take up to 20 minutes for the fuel gauge to indicate the correct fuel level. Page 4512 Pressure Plate: Service and Repair Flywheel Replacement Clutch Replacement Special Tools Required ^ Clutch alignment shaft 07LAF-PT00110 ^ Clutch alignment disc 07JAF-PM7011A ^ Remover handle 07936-3710100 ^ Ring gear holder 07LAB-PV00100 or 07924-PD20003 ^ Attachment, 57 x 40 mm 07746-0010200 ^ Driver 077 49-0010000 Flywheel Replacement NOTE: Do not disassemble the flexible plate from the flywheel. 1. Install the special tool. 2. Remove the flywheel mounting bolts in a crisscross pattern in several steps, then remove the flywheel. 3. Remove the pilot bearing (A) from the flywheel (B). 4. Drive the new bearing into the flywheel using the special tools as shown. Apply a light coat of oil to the outside of the bearing surface. Page 5749 27. Accessory Power Socket Page 920 Seat Belt Buckle Switch: Diagrams 121. Seat Belt Switch, Driver's 122. Seat Belt Switch, Front Passenger's (Sedan) 123. Seat Belt Switch, Passenger's (Coupe) Diagram Information and Instructions Cellular Phone: Diagram Information and Instructions Terminal Numbering System Terminal Numbering System Connector terminals are numbered according to the cavities they're in. The cavities are numbered starting from the upper left, looking at the male terminals from the terminal side or looking at the female terminals from the wire side. Both views are in the same direction so the numbers are the same. All actual cavities are numbered, even if they have no wire terminals in them. NOTE: Data Link Connector (DLC) terminals are numbered according 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 below is #6. Page 239 71. Under Left Side Of Dash Under-hood Fuse/Relay Box Page 6524 Relay And Control Unit Locations - Engine Compartment Service and Repair Front Door Window Regulator: Service and Repair Front Door Glass and Regulator Replacement NOTE: Put on gloves to protect your hands. 1. Remove these items: - Door panel, 2-door, 4-door - Plastic cover, as necessary, 2-door, 4-door 2. Carefully raise the glass (A) until you can see the bolts, then remove them. Carefully pull the glass out through the window slot. Take care not to Locations Shift Interlock Solenoid: Locations 107. Behind A/T Shift Lever (except M/T) Page 232 Under-dash Fuse/Relay Box (2-door) Page 1358 1. Apply a force of 98 N (10 kgf, 22 lbf), and measure the deflection at the mid point (A) between the alternator and crankshaft pulley. If the belt is worn or damaged, replace it. If the belt needs adjustment, go to step 2. Adjustment 2. Loosen the mounting bolt (B), lock bolt (C) and lower bracket mounting bolt (D). 3. Torque the mounting bolt to 20 N.m (2.0 kgf.m, 14 lbf.ft). 4. Turn the adjusting bolt (E) to obtain the proper belt tension, then retighten the lock bolt, mounting bolt and lower bracket mounting bolt. 5. Recheck the belt tension. 6. If you installed a new belt, run the engine for 5 minutes, then readjust the belt to the used belt specification. 7. Check the power steering pump belt adjustment. Page 5040 7. Align the cutouts (A) on the rotary-frame with the neutral positioning cutouts (B) on the transmission range switch, then put a 2.0 mm (0.08 inch) feeler gauge blade (C) in the cutouts to hold it in the N Position. NOTE: Be sure to use a 2.0 mm (0.08 inch) blade or equivalent to hold the switch in the N position. 8. Install the transmission range switch (A) gently on the control shaft (B) while holding it in the N position with the 2.0 mm (0.08 inch) blade (C). 9. Tighten the bolts on the transmission range switch while you continue to hold the N position. Do not move the transmission range switch when tightening the bolts. Remove the feeler gauge. Page 6453 Air Door Actuator / Motor: Testing and Inspection Recirculation Control Motor Circuit Troubleshooting Recirculation Control Motor Circuit Troubleshooting 1. Check the No.14 (10 A) fuse in the under-dash fuse/relay box. Is the fuse OK? YES - Go to step 2. NO - Replace the fuse, and recheck. 2. Disconnect the recirculation control motor 7P connector. 3. Turn the ignition switch ON (II). 4. Measure the voltage between the No.1 terminal of the recirculation control motor 7P connector and body ground. Is there battery voltage? YES - Go to step 5. NO - Repair open in the wire between the No.14 fuse in the under-dash fuse/relay box and the recirculation control motor. 5. Turn the ignition switch OFF. 6. Test the recirculation control motor. Is the recirculation control motor OK? YES - Go to step 7. NO - Go to step 12. 7. Disconnect heater control panel connector A (14P). 8. Check for continuity between the No.5 and No.6 terminals of heater control panel connector A (14P) and body ground individually. Is there continuity? YES - Repair any short to body ground in the wire(s) between the heater control panel and the recirculation control motor. NO - Go to step 9. Page 7321 5. Click Warranty Audio Order to view the Warranty Audio Order form. 6. Enter the VIN and the mileage, then click the Submit button to view the Warranty Audio Order form. Use the completed Audio/Navigation/RES Worksheet to help you answer the questions on the Warranty Audio Order form. Questions with a red asterisk (*) are required fields that you must answer to submit the form. Make sure the information is complete (17-digit VIN, etc.). This information is critical to the remanufacturing process. Screen # 2 of the form contains the problem description, condition information, and shared functions. Fill this section out with as much information as possible. Select one part number from the list provided, then click Submit. It is your responsibility to ensure the correct part number is selected based on color and application information. Page 9632 Terminals - "T" Shielding Switches Fuses Page 9146 1. Remove the terminal. 2. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE B: 1. Remove the terminal. 2. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE C: 1. Remove the terminal. 2. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE D: Page 8825 4. Remove the three mounting screws from the gauge assembly, and gently pull it away from the dashboard. Unplug the blue and green 22P connectors from the top of the assembly, then remove the gauge assembly. 5. Install the appropriate new gauge assembly listed under PARTS INFORMATION. NOTE: ^ Laws governing odometer repair, replacement, or servicing may vary from state to state. Questions concerning state law should be directed to your applicable state agency, DMV office, or an attorney. ^ Refer to the Honda Service Operations Manual (Section 2.24) for warranty policies and procedures regarding odometer servicing and replacement. 6. Reinstall all removed parts. Disclaimer Page 7136 ^ Within 1 to 4 seconds, turn the ignition switch to LOCK (0). ^ Within 1 to 4 seconds, turn the ignition to ON (II). ^ Within 1 to 4 seconds, push the transmitter lock or unlock button. ^ Confirm you can hear the sound of the door lock actuators. Within 1 to 4 seconds, push the transmitter lock or unlock button again. ^ Within 10 seconds, aim the transmitters (up to two additional ones) whose codes you want to store at the receiver, and press the transmitter lock or unlock button. Confirm that you can hear the sound of the door lock actuators after each transmitter code is stored. ^ Turn the ignition switch to LOCK (0), and pull out the key. 4. Confirm proper operation of the transmitters. Disclaimer Locations Idle Speed/Throttle Actuator - Electronic: Locations Idle Control System - Component Location Index 48. Middle Of Engine (except GX) Locations Power Door Lock Switch: Locations Doors - Component Location Index 2-door Page 9005 Terminals - "T" Shielding Switches Fuses Page 4413 Transmission Speed Sensor: Service and Repair Countershaft Speed Sensor Replacement Countershaft Speed Sensor Replacement 1. Disconnect the countershaft speed sensor connector. 2. Remove the countershaft speed sensor (A). 3. Install the new countershaft speed sensor with the new O-ring (B). 4. Check the countershaft speed sensor connector for rust, dirt, or oil, then connect the connector securely. Page 3418 Replace the retainer when - replacing the fuel rail. - replacing the fuel line. - replacing the fuel pump. - replacing the fuel filter. - replacing the fuel pressure regulator. - replacing the fuel gauge sending unit. - it has been removed from the line. - it is damaged. Page 4998 13. Plug in the heat gun, and turn it on. Start at the middle of the splice connector, and move the gun toward the ends as the tube shrinks. Apply heat evenly by rotating the curved heat spreader around the splice connector. Shrinking is complete when a small amount of sealant appears at each end of the tube. Pigtail Terminal Selection Chart PIGTAIL TERMINAL SELECTION CHART Select the proper size pigtail terminal by matching the replacement terminal part number and the wire size being repaired to the corresponding pigtail terminal part number. Then use the color (size) splice connector listed. In some instances you may also have to match the wire seal style to select the proper pigtail terminal. Pigtail terminals are available through your parts department, in quantities of 10, using normal parts ordering procedures. Checking For Poor Fir of Terminals CHECKING FOR POOR FIT OF TERMINALS Loose terminal fit can cause a number of intermittent problems in electrical circuits. By using the Terminal Inspection Feeler Tool Set you can inspect the terminal fit between the two matching connectors without removing the terminals from the connector body. 1. Find the terminal tool that best matches the male terminal in the mating connector. Page 5353 Brake Pedal Assy: Adjustments Brake Pedal and Brake Pedal Position Switch Adjustment Pedal Height 1. Disconnect the brake pedal position switch connector, turn the brake pedal position switch (A) counterclockwise and pull it back until it is no longer touching the brake pedal. 2. Lift up the carpet (B). At the insulator cutout, measure the pedal height (C) from the middle of the right side of the pedal pad (D). Standard Pedal Height (with carpet removed): M/T: 184 mm (7 4/16 inch) A/T: 188 mm (7 6/16 inch) 3. Loosen the pushrod locknut (A), and screw the pushrod in or out with pliers until the standard pedal height from the floor is reached. After adjustment, tighten the locknut firmly. Do not adjust the pedal height with the pushrod pressed. Pedal Free Play Page 2427 REPAIR PROCEDURE 1. Make sure you have the anti-theft code for the audio unit. Write down the customer's audio presets. 2. Disconnect the negative battery cable from the battery. 3. Remove the under-hood fuse/relay box cover. 4. Release the three clips, and remove the under- hood fuse/relay box from the holder. CR-V only: Release the wire harness clip from the fuse/relay box holder Page 8541 89. Trunk Latch Switch Page 5740 1. Remove the terminal. 2. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE B: 1. Remove the terminal. 2. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE C: 1. Remove the terminal. 2. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE D: Page 9424 Map Light: Service and Repair Spotlights Test/Replacement - Without Moonroof Spotlights Test/Replacement - Without Moonroof 1. Turn the light switch OFF. 2. Carefully pry off the lenses (A) with a small screwdriver. 3. Remove the two mounting screws. 4. Disconnect the 2P connector (B) from the housing (c). 5. Check the bulbs. If the bulbs are OK,check for continuity between the terminals in each switch position according to the table. 6. If the continuity is not as specified, replace the spotlights. Page 4376 - Remove clips carefully; don't damage their locks (A). - Slip pliers (A) under the clip base and through the hole at an angle, then squeeze the expansion tabs to release the clip. - After installing harness clips, make sure the harness doesn't interfere with any moving parts. - Keep wire harnesses away from exhaust pipes and other hot parts, from sharp edges of brackets and holes, and from exposed screws and bolts. - Seat grommets in their grooves properly (A). Do not leave grommets distorted (B). Testing and Repairs - Do not use wires or harnesses with broken insulation. Replace them or repair them by wrapping the break with electrical tape. - After installing parts, make sure that no wires are pinched under them. - When using electrical test equipment, follow the manufacturer's instructions and those described. - If possible, insert the probe of the tester from the wire side (except waterproof connector). - Use back probe adaptor 07TAZ-001020A. - Refer to the instructions in the Honda Terminal Kit for identification and replacement of connector terminals. Five-Step Troubleshooting Five-Step Troubleshooting 1. Verify The Complaint Specifications Page 243 234. Under-dash Fuse/Relay Box Part 4 Page 3789 Page 6095 ^ 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 7343 ^ 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 5298 195. Tranmission Range Switch Page 3220 1. Remove the terminal. 2. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE G: 1. Remove the terminal. 2. Go to HOW TO INSTALL NEW TERMINALS. How to Install New Terminals HOW TO INSTALL NEW TERMINALS 1. Carefully match the old terminal with a new one from the terminal repair kit. Choose the correct replacement terminal based on the wire size range the terminal will accommodate. NOTE: If the replacement terminal quantities are low, reorder them by using the terminal part number listed on the inside lid of the terminal repair kit. Replacement terminals are available through your parts department using normal parts ordering procedures. 2. Depending on the size of the wire you are repairing, use the proper size slot in the crimping tool. Page 4600 Shift Interlock Switch: Testing and Inspection Park Pin Switch Test Park Pin Switch Test 1. Remove the center console panel and center console. 2. Disconnect the park pin switch connector (4P). 3. Shift to the P position, then check for continuity between the No. 3 and No. 4 terminals. There should be no continuity. 4. Shift out of the P position, and check for continuity between terminals No. 3 and No. 4. There should be continuity. 5. If the park pin switch is faulty, replace it. Recall - Ignition/Shift Interlock Defect Technical Service Bulletin # 10-059 Date: 101001 Recall - Ignition/Shift Interlock Defect 10-059 October 1, 2010 Applies To: See VEHICLES AFFECTED Safety Recall: Accord, Civic, and Element Ignition Switch Key Interlock BACKGROUND Under certain conditions, the interlock lever of the ignition switch may unexpectedly deform. The interlock ensures the transmission is in Park before the ignition key can be removed. Interlock failure may allow the ignition key to be removed when the shift lever is not in Park. If the driver fails to engage the parking brake, the vehicle could roll away, increasing the risk of a crash. VEHICLES AFFECTED Not all vehicles within the VIN ranges are affected by this recall. Before beginning work on a vehicle, verify its eligibility by checking at least one of these items: ^ The customer has a notification letter. Page 6398 3. Remove the hub cap (A), raise the stake (B), and remove the spindle nut (C). 4. Screw two 8 x 1.25 mm bolts (A) into the drum to push it away from the hub. Turn each bolt 2 turns at a time to prevent cocking the drum excessively. 5. Remove the brake drum (A), and remove the hub bearing unit (B) from the spindle. If the brake drum has stuck to the hub bearing unit, pull them out together. Do not tap on the aluminum brake drum. 6. Install the hub bearing unit in the reverse order of removal, and note these items: - Tighten all mounting hardware to the specified torque values. - Before installing the brake drum, clean the mating surface of the hub and the inside of the brake drum. - Use a new spindle nut on reassembly. - Before installing the spindle nut, apply a small amount of engine oil to the seating surface of the nut. After tightening, use a drift to stake the spindle nut shoulder against the spindle. - Use a new hub cap on reassembly. - Before installing the wheel, clean the mating surface of the brake drum and the inside of the wheel. Page 7436 Wires Primary Oxygen Sensor Oxygen Sensor: Description and Operation Primary Oxygen Sensor Primary Heated Oxygen Sensor (Primary HO2S) (D17A1, D17A2 engines) The primary HO2S detects the oxygen content in the exhaust gas and sends signals to the ECM/PCM which varies the duration of fuel injection accordingly. To stabilize its output, the sensor has an internal heater. The primary HO2S is installed in the three way catalytic converter (TWC) (D17A1 engine) or in the exhaust manifold (D17A2 engine). By controlling the air fuel ratio with primary HO2S and secondary HO2S, the deterioration of the primary HO2S can be evaluated by its feedback period. When the feedback period exceeds a certain value during stable driving conditions, the sensor is considered deteriorated and the ECM/PCM sets a DTC. Page 5551 Technical Service Bulletin # 01-077 Date: 060419 Ignition/Locks - Cutting Sidewinder-Type Keys 01-077 April 19, 2006 Applies To: Models With Sidewinder-Type Keys - All Cutting Sidewinder-Type Keys With the MATRIX H Key Cutting Machine (Supersedes 01-077, dated January 12, 2005) Updated information is noted by asterisks. MATRIX H Key Cutting Machine, manufactured by Silca and supplied by Kaba Ilco Corporation, is a portable, power-operated tool that cuts sidewinder-type automotive keys exclusively. The machine lets you cut these keys either by copying or by code. The code function is designed and built to meet the Honda code requirements. No other similar machine has this capability. This service bulletin gives you information for ordering and servicing this special tool, and guides you through the entire key cutting process from setting up the machine to cutting the key blank. TOOL INFORMATION Order through the Honda Tool and Equipment Program: MATRIX H Key Cutting Machine: Model No. ILCMATRIXSH Cutter Bit: Model No. ILCF3O Fixed Jaw: Model No. ILCMTX-H Mobile Jaw (Right Side): Model No. ILCRTMTX-H Mobile Jaw (Left Side): Model No. ILCLTMTX-H *Remanufactured Clamp Unit: Model No. ILCMATRIXHCR* PARTS INFORMATION *For some models, there are two choices for sidewinder-type key blanks: ^ T-5 sidewinder key blanks ^ Honda sidewinder key blanks For other models, only Honda sidewinder key blanks can be used. See DETERMINING WHICH KEY TO USE to determine which key blank you should choose. Ordering T-5 key blanks through the Honda Tool and Equipment Program: T-5 Programmable Key Blank (Master): P/N ILC-35111-T-5H T-5 Programmable Key Blank (Valet): P/N ILC-35112-T-5H Practice Key Blanks (five per pack): ILC-35111DEMO* NOTE: Do not use practice key blanks for replacement purposes. Practice keys do not have an immobilizer chip. Page 1675 - Remove clips carefully; don't damage their locks (A). - Slip pliers (A) under the clip base and through the hole at an angle, then squeeze the expansion tabs to release the clip. - After installing harness clips, make sure the harness doesn't interfere with any moving parts. - Keep wire harnesses away from exhaust pipes and other hot parts, from sharp edges of brackets and holes, and from exposed screws and bolts. - Seat grommets in their grooves properly (A). Do not leave grommets distorted (B). Testing and Repairs - Do not use wires or harnesses with broken insulation. Replace them or repair them by wrapping the break with electrical tape. - After installing parts, make sure that no wires are pinched under them. - When using electrical test equipment, follow the manufacturer's instructions and those described. - If possible, insert the probe of the tester from the wire side (except waterproof connector). - Use back probe adaptor 07TAZ-001020A. - Refer to the instructions in the Honda Terminal Kit for identification and replacement of connector terminals. Five-Step Troubleshooting Five-Step Troubleshooting 1. Verify The Complaint Page 7095 VEHICLES AFFECTED CUSTOMER NOTIFICATION All owners of affected vehicles were mailed a notification of this warranty extension. A example of the customer notification is shown in this service bulletin. CORRECTIVE ACTION Repair the vehicle as indicated by the INSPECTION PROCEDURE. If needed, replace the OPDS unit. In rare cases where an updated OPDS unit was already installed, replace the OPDS sensor. Page 8294 24. Remove the key. Reinstall the retainer clip in the door handle, and push the lock cylinder into place. 25. Civic: Reconnect the cylinder rod. 26. CR-V: Reconnect the cylinder rod, the outer handle rod, and the rod protector. 27. Element: Reconnect the cylinder rod, the outer handle rod, and the access seal. Reinstall the lower run channel. 28. Reinstall the plastic covering, and lower the window glass. Install the door panel. 29. Check that the door lock and handle operate smoothly. Disclaimer Page 5142 13. Plug in the heat gun, and turn it on. Start at the middle of the splice connector, and move the gun toward the ends as the tube shrinks. Apply heat evenly by rotating the curved heat spreader around the splice connector. Shrinking is complete when a small amount of sealant appears at each end of the tube. Pigtail Terminal Selection Chart PIGTAIL TERMINAL SELECTION CHART Select the proper size pigtail terminal by matching the replacement terminal part number and the wire size being repaired to the corresponding pigtail terminal part number. Then use the color (size) splice connector listed. In some instances you may also have to match the wire seal style to select the proper pigtail terminal. Pigtail terminals are available through your parts department, in quantities of 10, using normal parts ordering procedures. Checking For Poor Fir of Terminals CHECKING FOR POOR FIT OF TERMINALS Loose terminal fit can cause a number of intermittent problems in electrical circuits. By using the Terminal Inspection Feeler Tool Set you can inspect the terminal fit between the two matching connectors without removing the terminals from the connector body. 1. Find the terminal tool that best matches the male terminal in the mating connector. Locations Intake Air System - Component Location Index Ignition/Locks - Cutting Sidewinder-Type Keys Technical Service Bulletin # 01-077 Date: 060419 Ignition/Locks - Cutting Sidewinder-Type Keys 01-077 April 19, 2006 Applies To: Models With Sidewinder-Type Keys - All Cutting Sidewinder-Type Keys With the MATRIX H Key Cutting Machine (Supersedes 01-077, dated January 12, 2005) Updated information is noted by asterisks. MATRIX H Key Cutting Machine, manufactured by Silca and supplied by Kaba Ilco Corporation, is a portable, power-operated tool that cuts sidewinder-type automotive keys exclusively. The machine lets you cut these keys either by copying or by code. The code function is designed and built to meet the Honda code requirements. No other similar machine has this capability. This service bulletin gives you information for ordering and servicing this special tool, and guides you through the entire key cutting process from setting up the machine to cutting the key blank. TOOL INFORMATION Order through the Honda Tool and Equipment Program: MATRIX H Key Cutting Machine: Model No. ILCMATRIXSH Cutter Bit: Model No. ILCF3O Fixed Jaw: Model No. ILCMTX-H Mobile Jaw (Right Side): Model No. ILCRTMTX-H Mobile Jaw (Left Side): Model No. ILCLTMTX-H *Remanufactured Clamp Unit: Model No. ILCMATRIXHCR* PARTS INFORMATION *For some models, there are two choices for sidewinder-type key blanks: ^ T-5 sidewinder key blanks ^ Honda sidewinder key blanks For other models, only Honda sidewinder key blanks can be used. See DETERMINING WHICH KEY TO USE to determine which key blank you should choose. Ordering T-5 key blanks through the Honda Tool and Equipment Program: T-5 Programmable Key Blank (Master): P/N ILC-35111-T-5H T-5 Programmable Key Blank (Valet): P/N ILC-35112-T-5H Practice Key Blanks (five per pack): ILC-35111DEMO* NOTE: Do not use practice key blanks for replacement purposes. Practice keys do not have an immobilizer chip. Page 4537 72. Shift Lock Solenoid (A/T) Engine - Crankshaft Pulley Service Manual Revision Harmonic Balancer - Crankshaft Pulley: Technical Service Bulletins Engine - Crankshaft Pulley Service Manual Revision SOURCE: Honda Service News October 2003 TITLE: S/M Fix: Crankshaft Pulley Installation APPLIES TO: 2001-04 Civic SERVICE TIP: You need to fix the crankshaft pulley installation procedure on page 6-13 of the 200104 Civic S/M. In your copies of the S/M, make these changes: Page 3643 Shift Interlock Solenoid: Testing and Inspection Shift Lock Solenoid Test 1. Remove the center console panel and center console. 2. Disconnect the shift lock solenoid connector (2P). 3. Connect the No. 1 terminal of the shift lock solenoid connector (2P) to the battery positive terminal, and connect the No. 2 terminal to the battery negative terminal. 4. Check that the shift lever can be moved from the P position. Release the battery terminals from the shift lock solenoid connector. Move the shift lever back to the P position, and make sure it locks. NOTE: Do not connect power to the No. 2 terminal (reverse polarity) or you will damage the diode inside the solenoid. 5. Check that the shift lock releases when the shift lock release is pushed, and check that it locks when the shift lock release is released. 6. If the shift lock solenoid does not work properly, replace it. Page 7441 Resistor Variable Sensor Solenoid Transistors Circuit Schematics Page 4752 9. Measure the clutch disc thickness. If the thickness is less than the service limit, replace the clutch disc. Standard (New): '01 model: 8.3 - 9.0 mm (0.33 - 0.35 inch) max. '02-03 models: 8.5 - 9.1 mm (0.34 - 0.36 inch) max. Service Limit: '01 model: 5.7 mm (0.22 inch) '02-03 models: 5.8 mm (0.23 inch) 10. Measure the rivet depth from the clutch disc lining surface (A) to the rivets (B) on both sides. If the rivet depth is less than the service limit, replace the clutch disc. Standard (New): 1.65 - 2.25 mm (0.065 - 0.089 inch) max. Service Limit: 0.8 mm (0.03 inch) Page 4052 Control Module: Service and Repair Updating the ECM/PCM PCM Updating and Substitution for Testing Special Tools Required Honda Interface Module (HIM) P/N EQS05A35570 Use this procedure when you have to substitute a known-good PCM in a troubleshooting procedure. Update the PCM only if the PCM does not already have the latest software loaded. NOTE: Do not turn the ignition switch OFF while updating; the PCM can be damaged. How to Update the PCM NOTE: To ensure the latest program is installed, do an PCM update whenever the PCM is substituted or replaced. - Before you update the PCM, make sure the vehicle's battery is fully charged. - To prevent PCM damage, do not operate anything electrical (audio system, brakes, A/C, power windows, moon roof, door locks, etc.) during the update. - If you need to diagnose the Honda Interface Module (HIM) because the HIM's red (#3) light came on or was flashing during the update, leave the ignition switch in the ON (II) position when you disconnect the HIM from the Data Link Connector (DLC). This will prevent PCM damage. 1. Turn the ignition switch ON (II). Do not start the engine. 2. Connect the HIM to the DLC (A) located under the driver's side of dashboard. 3. Do the PCM update procedure as described on the HIM label and in the PCM update system. If the software in the PCM is the latest version, replace the PCM. How to End a Troubleshooting Session This procedure must be done after any troubleshooting. 1. Clear the DTC(s) with the Scan Tool or HDS, or reset the PCM by removing the No. 6 (PCM) fuse in the under-hood fuse/relay box for more than 10 seconds. 2. Turn the ignition switch ON (II). 3. Start the engine in the P or N position, and warm it up to normal operating temperature (the radiator fans come on). 4. To verify that the problem is repaired, test-drive the vehicle for several minutes at speeds over 30 mph (50 km/h) or in freeze data range. Page 8199 122. Driver's Door (Sedan Except DX) Page 4446 ^ If the noise is still present, look for other causes. 7. Test-drive the vehicle to check for proper clutch operation. Disclaimer Page 1774 2. Insert the terminal tool into the female terminal, and then remove the terminal tool. NOTE: Make sure you do not select a terminal tool that is larger than the mating male terminal because it would spread the female terminal and cause a loose fit. 3. Compare the drag to the other terminals in the connector. If the drag is less, replace the terminal with a replacement terminal from the appropriate terminal repair kit. Removal and Installation Seat Occupant Sensor: Service and Repair Removal and Installation OPDS Unit Replacement NOTE: Review the seat replacement procedure in the body section before performing repair or service. Removal 1. Disconnect the battery negative cable, and wait at least 3 minutes before beginning work. 2. Disconnect the side airbag harness 2P connector. 3. Remove the seat assembly and seat-back cover. 4. Remove the cover (A), then disconnect the OPDS unit harness 8P and sensor connectors (B) from the OPDS unit. 5. Remove the two screws (C) and OPDS unit (D). Installation 1. Place the new OPDS unit on the seat-back frame. Tighten the two screws, and connect the OPDS unit harness 8P and sensor connector to the OPDS unit. Reinstall the cover. 2. Install the seat-back cover. 3. Install the seat assembly, then connect the side airbag harness 2P connector. 4. Reconnect the battery negative cable. 5. Set the seat-back in the normal position, and make sure there is nothing on the front passenger's seat. 6. Initialize the OPDS unit. 7. After installing the OPDS unit, confirm proper system operation. Turn the ignition switch ON (II); the SRS indicator light should come on for about 6 seconds and then go off. Page 1691 8. Inspect the quality of the wire crimp. If it has any of the following NO GOOD crimps, cut it off and start over. 9. Insert the terminal into the connector. Make sure the wire seals are pushed all the way into the connector. Lightly pull on the wires to make sure the terminal is locked into place. 10. Close or insert the secondary terminal lock, if applicable, and reconnect the connector. How to Install Pigtail Terminals HOW TO INSTALL PIGTAIL TERMINALS Pigtail terminals (short pieces of wire with a factory crimped terminal) are used when the wire is too short or when access to the connector is too restricted to make a terminal repair. NOTE: To replace just a connector terminal, go to How to Replace Connector Terminals. IMPORTANT SAFETY INFORMATION: On some models, the SRS wires are in a separate harness. If the SRS harness is damaged, replace the harness; do not repair it. On other models, wire harnesses include yellow SRS wires. If any SRS wire is damaged, replace the entire harness; do not repair it. 1. Remove the damaged or faulty terminal from the connector. Use the proper removal tool from Pin Tool Set. Page 742 53. IAT Sensor Page 5342 Wheel Speed Sensor: Description and Operation Wheel Sensors The wheel sensors are the magnetic contact less type. As the gear purser teeth rotate past the wheel sensor's magnetic coil, AC current is generated. The AC frequency changes in accordance with the wheel speed. The ABS control unit detects the wheel sensor signal frequency and thereby detects the wheel speed. When the wheel speed drops sharply below the vehicle speed, the outlet valve opens momentarily to reduce the caliper fluid pressure. The pump motor starts at this time. As the wheel speed is restored, the inlet valve opens momentarily to increase the caliper fluid pressure. Page 6821 12. On Accords and Pilots, install the new seat-back clips on the seat-back panel. Turn the clips so their retaining tabs are horizontal. 13. On Accords and Pilots, install the seat-back panel. 14. On all models except Accords and Pilots, zip the seat-back cover closed. 15. Initialize the OPDS unit. ^ To initialize with the HDS, go to Initializing the OPDS Unit: HDS Method. ^ To initialize with the SCS service connector, go to Initializing the OPDS Unit: Manual Mode. Initializing the OPDS Unit: HDS Method NOTE: Non-Honda seat covers will interfere with the performance of the OPDS and are not recommended. 1. Adjust the front passenger's seat-back to an upright position, then remove anything on or near the seat. 2. Turn the ignition switch to LOCK (0). 3. Connect the HDS to the vehicle's DLC (data link connector). 4. Turn the ignition switch to ON (II), then turn on the HDS. 5. At the screen prompts, enter the VIN and the odometer reading. Also verify the correct date and time. 6. From the System Selection menu, select SRS. Page 9861 15. Put the cartridge in a caulking gun, and run a bead of adhesive (A) around the edge of the quarter glass (B) as shown: - After applying the adhesive, peel the separator off the butyl tape. - Apply the adhesive within 30 minutes after applying the glass primer. Make a slightly thicker bead at each corner. 16. Use suction cups (A) to hold the quarter glass (B) over the opening, align the clips or the alignment marks (C) made in step 10, and set it down on the adhesive. Lightly push on the quarter glass until its edges are fully seated on the adhesive all the way around. Do not open or close the doors until the adhesive is dry. 17. Scrape or wipe any excess adhesive off with a putty knife or towel. To remove adhesive from a painted surface or the quarter glass, wipe with a soft shop towel dampened with alcohol. 18. Let the adhesive dry for at least 1 hour, then spray water over the quarter glass and check for leaks. Mark the leaking areas and let the quarter glass dry, then seal with sealant. Let the vehicle stand for at least 4 hours after quarter glass installation. If the vehicle has to be used within the first 4 hours, it must be driven slowly. 19. Reinstall all remaining removed parts. NOTE: Advise the customer not to do the following things for 2 to 3 days: Slam the doors with all the windows rolled up. - Twist the body excessively (such as when going in and out of driveways at an angle or driving over rough, uneven roads). Page 3834 1. Remove the terminal. 2. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE E: 1. Remove the terminal. 2. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE F: Page 2180 PGM-F1 Main Relay 1, 2 Type 1, 2 Check for continuity between the terminals. - There should be continuity between the No.1 and No.2 terminals when power and ground are connected to the No.3 and No.4 terminals. - There should be no continuity between the No.1 and No.2 terminals when power is disconnected. Normally-open type B: Rear Window Defogger Relay Page 3509 Resonator: Service and Repair Resonator Replacement 1. Remove the bolts (A). 2. Remove the throttle cable (B) from the bracket (C). 3. Remove the resonator (D). 4. Install in the reverse order of removal. Component Locations Shift Interlock Switch: Component Locations Component Location Index Page 9668 Heated Glass Element Relay: Testing and Inspection Power Relay Test Use this chart to identify the type of relay, then do the test listed for it. NOTE: See the turn signal/hazard relay input test. Normally-open type B: Rear Window Defogger Relay Check for continuity between the terminals. - There should be continuity between the No.1 and No.3 terminals when power and ground are connected to the No.2 and No.4 terminals. - There should be no continuity between the No.1 and No.3 terminals when power is disconnected. Page 5369 Brake Warning Indicator: Diagnostic Aids General Troubleshooting Information General Troubleshooting Information Tips and Precautions Before Troubleshooting 1. Check applicable fuses in the appropriate fuse/relay box. 2. Check the battery for damage, state of charge, and clean and tight connections. NOTE: 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. Handling Connectors - Make sure the connectors are clean and have no loose wire terminals. - Make sure multiple cavity connectors are packed with dielectric grease (except watertight connectors). - All connectors have push-down release type locks (A). - Some connectors have a clip on their side used to attach them to a mount bracket on the body or on another component. This clip has a pull type lock. - Some mounted connectors cannot be disconnected unless you first release the lock and remove the connector from its mount bracket (A). - Never try to disconnect connectors by pulling on their wires; pull on the connector halves instead. - Always reinstall plastic covers. Page 7239 Remote Transmitter Quick Reference Guide 90-93 Accord, 92-93 Civic & Prelude, 93 Del SOL 1990-93 Accord (2-door and 4-door) with dealer-installed security system 1992-93 Civic with dealer-installed security system 1993 del Sol with dealer-installed security system 1992-93 Prelude with dealer-installed security system Programming the Transmitter NOTE: Page 5063 107. Behind A/T Shift Lever (except M/T) Page 8485 5. Pull back the seat-back cover (A), and remove the clips (B), and release the hooks (C) 6. '04-05 models: Pull out the seat-back frame (A) from the pad (B), then pull out the headrest guides (C) while pinching the end of the guides, and remove them. The left seat-back is shown, the right seat-back is similar 7. Remove the seat-back cover and pad from the seat-back frame. Page 2888 YES - Replace the sensor that restored about 5 V when disconnected. NO - Go to step 62. 62. Turn the ignition switch OFF. 63. Disconnect the 3P connectors from the following sensors. - Exhaust gas recirculation (EGR) valve position sensor - Knock sensor - Throttle position (TP) sensor - CVT drive pulley speed sensor (CVT) - CVT speed sensor 2 (CVT) 64. Disconnect ECM/PCM connector A (31P). 65. Check for continuity between ECM/PCM connector terminal A20 and body ground. Is there continuity? YES - Repair short in the wire between the ECM/PCM (A20) and the EGR valve position sensor, knock sensor, TP sensor, CVT drive pulley speed sensor (CVT), or CVT speed sensor 2 (CVT), or repair short in the wire between the ECM/PCM (A8) and the knock sensor. NO - Update the ECM/PCM if it does not have the latest software, or substitute a known-good ECM/PCM, then recheck. If the symptom/indication goes away with a known-good ECM/PCM, replace the original ECM/PCM. 66. Measure voltage between body ground and ECM/PCM connector terminal E5. Is there about 5 V? YES - Update the ECM/PCM if it does not have the latest software, or substitute a known-good ECM/PCM, then recheck. If the symptom/indication goes away with a known-good ECM/PCM, replace the original ECM/PCM. NO - Go to step 67. 67. Turn the ignition switch OFF. 68. Disconnect the fuel tank pressure (FTP) sensor 3P connector. 69. Turn the ignition switch ON (II). Page 3118 Throttle Position Sensor: Description and Operation Throttle Position (TP) Sensor The TP sensor is a potentiometer connected to the throttle valve shaft. As the throttle position changes, the sensor varies the signal voltage to the ECM/PCM. The TP sensor is not replaceable apart from the throttle body. Page 8617 24. Remove the key. Reinstall the retainer clip in the door handle, and push the lock cylinder into place. 25. Civic: Reconnect the cylinder rod. 26. CR-V: Reconnect the cylinder rod, the outer handle rod, and the rod protector. 27. Element: Reconnect the cylinder rod, the outer handle rod, and the access seal. Reinstall the lower run channel. 28. Reinstall the plastic covering, and lower the window glass. Install the door panel. 29. Check that the door lock and handle operate smoothly. Disclaimer Page 4364 Wire Color Abbreviations Service and Repair Rear Knuckle: Service and Repair Knuckle Replacement 1. Raise the rear of the vehicle, and support it with safety stands in the proper locations. Remove the rear wheels. 2. Remove the brake drum and hub bearing unit. 3. Disconnect the brake pipe (A) from the wheel cylinder. 4. Remove the flange bolts (B) and drum brake assembly (C) from the knuckle. 5. Remove the flange bolt (A) and wheel sensor (B) from the knuckle. Do not disconnect the wheel sensor connector. 6. Remove the flange bolts (C) and brake hose bracket (D). 7. Place the floor jack under the trailing arm (A) to support it. 8. Remove the flange bolt (B), and disconnect the upper arm (C) from the knuckle. Page 5873 Under-dash Fuse/Relay Box (4-door) Page 1569 Under-hood Fuse And Relay Box (4-door) Page 1563 Wiper/Washer Component Location Index Page 2825 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 Locater) 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. Troubleshooting Precautions Troubleshooting Precautions Before Troubleshooting 1. Check the main fuse and the fuse 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, or you will damage the alternator diodes. - Do not attempt to crank the engine with the ground cable disconnected 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. Page 7718 1. Check the depth adjustment of the trunk lid: ^ Refer to page 20-132 of the 2001-04 Civic Service Manual. ^ In ISIS, use the keyword TRUNK ADJUST, and select Trunk Lid Adjustment from the list. 2. Make sure the trunk lid is flush on all sides and corners. ^ If the trunk is misaligned, go to step 3. ^ If the trunk lid is properly aligned on all sides and corners, go to REPAIR PROCEDURE C. 3. Adjust the striker depth position and the trunk lid edge cushions: ^ Refer to page 20-132 of the 2001-04 Civic Service Manual. ^ In ISIS, use the keyword TRUNK ADJUST, and select Trunk Lid Adjustment from the list. 4. Check the trunk operation: ^ If the trunk opens and closes smoothly, return the vehicle to the customer. ^ If the trunk lid is still difficult to close, go to REPAIR PROCEDURE C. REPAIR PROCEDURE C 1. Use a small screwdriver to manually set and release the trunk lid latch. Check the operation of the latch: ^ If the latch is difficult to set or release, go to step 2. ^ If the latch operates properly, go to REPAIR PROCEDURE D. 2. Replace the trunk lid latch: ^ Refer to page 20-157 of the 2001-04 Civic Service Manual. ^ In ISIS, use the keyword LID LATCH, and select Trunk Lid Latch Replacement from the list. 3. Check the trunk operation: ^ If the trunk opens and closes smoothly, return the vehicle to the customer. ^ If the trunk lid is still difficult to close, go to REPAIR PROCEDURE D. REPAIR PROCEDURE D 1. Disconnect the trunk lid opener cable from the trunk lid latch. Check the cable operation: ^ Refer to page 20-157 of the 2001-04 Civic Service Manual. ^ In ISIS, use the keyword LID LATCH, and select Trunk Lid Latch Replacement from the list. 2. Check that there is no friction or binding of the cable by holding the outside casing and pulling back and forth on the inner cable: ^ If the cable is difficult to move or binds, go to step 3. ^ If the cable operates smoothly, go to REPAIR PROCEDURE E. 3. Replace the trunk lid opener cable: ^ Refer to page 20-151 of the 2001-04 Civic Service Manual. ^ In ISIS, use the keyword LID OPEN, and select Trunk Lid Opener/Fuel Fill Door Opener Cable Replacement from the list. 4. Check the trunk operation: Specifications Clutch Disc: Specifications Pressure plate Warpage .............................................................................................................................................. ............................ 0.03 mm (0.001 inch) maximum Height of diaphragm spring fingers Measure with feeler gauge and special tool .................................................................................................................. 0.6 mm (0.02 inch) maximum Torque the mounting bolts in a crisscross pattern. Tighten the bolts in several steps to prevent warping the diaphragm spring. Page 6077 Relay Box: Service and Repair Removal and Installation SRS components are located in this area. Review the SRS component locations and precautions and procedures in the SRS section before performing repairs or service. Removal 1. Make sure you have the anti-theft code for the radio, then write down the frequencies for the radio's preset buttons. 2. Disconnect the battery negative cable, then disconnect the positive cable, and wait at least 3 minutes. 3. Remove the dashboard lower cover. 4. Disconnect the connectors from the fuse side of the under-dash fuse/relay box. 5. Remove the mounting bolt and slide the under-dash fuse/relay box (A) down from the bracket (B). 6. Disconnect the connectors from the back side of the under-dash fuse/relay box, and remove the fuse/relay box. NOTE: The SRS connector is a spring-loaded lock type. Installation 1. Install the under-dash fuse/relay box in the reverse order of removal and connect all connectors to the under-dash fuse/relay box. 2. Install the dashboard lower cover. 3. Connect both the negative cable and positive cable to the battery. 4. Enter the anti-theft code for the radio, then enter the customer's radio station presets. 5. Confirm that all systems work properly. 6. Do the ECM/PCM idle learn procedure. Page 2208 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 9368 8. Inspect the quality of the wire crimp. If it has any of the following NO GOOD crimps, cut it off and start over. 9. Insert the terminal into the connector. Make sure the wire seals are pushed all the way into the connector. Lightly pull on the wires to make sure the terminal is locked into place. 10. Close or insert the secondary terminal lock, if applicable, and reconnect the connector. How to Install Pigtail Terminals HOW TO INSTALL PIGTAIL TERMINALS Pigtail terminals (short pieces of wire with a factory crimped terminal) are used when the wire is too short or when access to the connector is too restricted to make a terminal repair. NOTE: To replace just a connector terminal, go to How to Replace Connector Terminals. IMPORTANT SAFETY INFORMATION: On some models, the SRS wires are in a separate harness. If the SRS harness is damaged, replace the harness; do not repair it. On other models, wire harnesses include yellow SRS wires. If any SRS wire is damaged, replace the entire harness; do not repair it. 1. Remove the damaged or faulty terminal from the connector. Use the proper removal tool from Pin Tool Set. Page 3433 Fuel Pressure: Testing and Inspection Fuel Pressure Test Special Tools Required - Fuel pressure gauge 07406-004000A - Fuel pressure gauge set 07ZAJ-S5A0100 1. Relieve the fuel pressure. 2. Disconnect the quick-connect fitting (A). Attach the fuel pressure gauge set and fuel pressure gauge. 3. Start the engine and let it idle. - If the engine starts, go to step 5. - If the engine does not start, go to step 4. 4. Check to see if the fuel pump is running: listen to the fuel fill port with the fuel fill cap removed. The fuel pump should run for 2 seconds when the ignition switch is first turned on. If the pump runs, step 5. - If the pump does not run, perform the fuel pump circuit troubleshooting. 5. Read the pressure gauge. The pressure should be 270 - 320 kPa (2.8 - 3.3 kgf/sq.cm, 40 - 47 psi) - If the pressure is OK, the test is complete. - If the pressure is out of specification, replace the fuel pressure regulator and the fuel filter, then recheck the fuel pressure. Continuously Variable Transmission Shift Interlock Switch: Testing and Inspection Continuously Variable Transmission Park Pin Switch Test 1. Remove the center console panel and center console. 2. Disconnect the park pin switch connector (4P). 3. Shift to the P position, then check for continuity between the No. 3 and No. 4 terminals. There should be no continuity. 4. Shift out of the P position, and check for continuity between terminals No. 3 and No. 4. There should be no continuity. 5. If the park pin switch is faulty, replace it. Page 7472 Body Control Systems: Description and Operation System Descriptions The Multiplex Control System has four internal functions: - Multiplexing (send multiple signals over shared wires) - Wake up/sleep (runs at full power only on demand to reduce battery draw) - Fail-safe (fixes or ignores faulty signals) - Self-diagnosis (Mode 1 for the system. Mode 2 for input lines) The system controls the function of these circuits: - Entry light control (ignition key light and ceiling light) - Wiper/washer (including intermittent wipe and park functions) - Interlock system - Keyless/power Door Lock - Key-in reminder - Meter assembly, temperature gauge, and indicator lights - HVAC (compressor and fan control) Multiplex Communication To reduce the number of wire harnesses, digital signals are sent via shared multiplex communication lines rather than sending normal electrical signals through individual wires. - The input signals from each switch are converted to digital signals at the central processing unit (CPU). - The digital signals are sent from the transmitting unit to the receiving unit as serial signals. - The transmitted signal is converted to a switch signal at the receiving unit, and it operates the related component or monitors a switch. - There are exclusive communication lines between the ECM/PCM, the gauge assembly, and the under-dash fuse/relay box, Wake-up and Sleep The multiplex control system has "wake-up" and "sleep" functions to decrease parasitic draw on the battery when the ignition switch is OFF. - In the sleep mode, the multiplex control unit stops functioning (communication and CPU control) when it is not necessary for the system to operate. - As soon as any operation is requested (for example, a door is unlocked), the related control unit in the sleep mode immediately wakes up and begins to function. - When the ignition switch is turned OFF, and the driver's or front passenger's door is opened, then closed, there is about a 10 second delay before the control unit goes from the wake-up mode to the sleep mode. - If any door is open, the sleep mode will not function. - If a key is in the ignition switch, the sleep mode will not function. - When in sleep mode, the draw is reduced from 70 - 80 mA to less than 10 mA. Fail-safe To prevent improper operation, the multiplex control system has a fail-safe function. In the fail-safe mode, the output signal is fixed when any part of the system malfunctions (for example a faulty control unit or communication line). Each control unit has a hardware fail-safe function that fixes the output signal when there is any CPU malfunction, and a software fail-safe function that ignores the signal from the malfunctioning control unit and allows the system to operate normally. Locations 162. Right Side Of Engine Compartment Page 8756 Power Distribution schematics show how power is supplied from the positive battery terminal to various circuits in the vehicle. Refer to the Power Distribution diagram set to get a more detailed understanding of how picture is supplied to the circuit you're working on. Individual circuit schematics begin with a fuse. So 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 Ground Distribution Schematics This sample Ground Distribution schematic shows all of the components that share the same ground point. Page 2566 8. Connect the GRN test harness clip (D) to the positive probe of a voltmeter. Is there 5 V or more? YES - Go to step 9. NO - Repair short or open in the BLU/WHT or WHT/GRN wire between the VSS and the cruise control unit, or the ECM/PCM. 9. Turn the ignition switch OFF. 10. Connect the other test harness connector (A) to the VSS(B). 11. Raise the front of the vehicle, and make sure it is securely supported. 12. Put the vehicle in neutral with the ignition switch ON (II). 13. Slowly rotate one wheel with the other wheel blocked. Does voltage pulse from 0 to about 5 V or more? YES - Go to step 14. NO - Replace the VSS. Recall - Driver's Air Bag Replacement Air Bag: All Technical Service Bulletins Recall - Driver's Air Bag Replacement 08-093 February 12, 2010 Applies To: See VEHICLES AFFECTED Safety Recall: Driver's Airbag Inflator Can Be Over-Pressurized (Supersedes 08-093, dated September 16, 2009, to revise the information marked by the black bars and asterisks) REVISION SUMMARY *^ Under VEHICLES AFFECTED, the VIN ranges for Civics and Accords were expanded. Also, some 2002 CR-Vs, some 2002 Odysseys, one 2003 Civic, and one 2003 Pilot were added. ^ CR-V, Odyssey, and Pilot were added under the REPAIR PROCEDURE and Example of Customer Letter headings.* BACKGROUND A manufacturing error can produce over-pressurization of the driver's (front) airbag inflator during airbag deployment. If an affected airbag deploys, the increased internal pressure may cause the inflator casing to rupture. Metal fragments could pass through the airbag cushion material, possibly causing an injury or fatality to vehicle occupants. VEHICLES AFFECTED Not all vehicles within the following VIN ranges are affected by this campaign. To verify vehicle eligibility, you must check at least one of these items: ^ The customer has a notification letter. ^ The vehicle is shown as eligible on a VIN status inquiry. In addition, check for a punch mark below the third character of the engine compartment VIN. A punch mark in that location means this campaign has already been completed. 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. Page 4471 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. DIAGNOSIS Have an assistant press the clutch pedal while you grasp the clutch line at the clutch master cylinder, and then at the slave cylinder. If you feel a vibration through the clutch line when you hear the noise or the noise stops, go to REPAIR PROCEDURE. If you feel no vibration or the noise does not stop, look for other causes. REPAIR PROCEDURE NOTICE Do not spill brake fluid on the vehicle; it may damage the paint. If brake fluid does contact the paint, wash it off immediately with water. 1. Remove the clutch master cylinder. Refer to the appropriate service manual: 2003-04 Accord (L4): page 12-6 2003-04 Accord (V6): page 12-8 2001-04 Civic: page 12-5 2002-04 Civic Si: page 12-5 2003-04 Civic Hybrid: page 13-5 2002-04 CR-V: page 12-5 2003-04 Element: page 12-6 Enter keyword CLUTCH MASTER, and select Clutch Master Cylinder Replacement from the list. 2. Install the new clutch master cylinder, but do not attach the clutch line fitting. 3. Apply a thin coat of silicone grease to the clutch line fitting and to the opening in the clutch master cylinder. Do not use silicone spray; it could damage the 0-ring. 4. Connect the clutch line fitting to the clutch master cylinder. 5. Bleed the clutch hydraulic system, then top off the reservoir with brake fluid. 6. Check to see if the noise is gone when pressing the clutch pedal. ^ If the noise is gone, the repair is complete. Specifications Idle Speed: Specifications Idle Speed With no-load conditions: USA model: M/T .................................................................................................................................. .................................................................................. 700 ± 50 rpm A/T, CVT .................................... ....................................................................................................................................... 700 ± 50 rpm (in Park or neutral) Canada model: M/T .............................................................................................. ...................................................................................................................... 720 ± 50 rpm A/T .......... .............................................................................................................................................................. ............. 720 ± 50 rpm (in Park or neutral) With load conditions: M/T ...................................................................................................................................................... .............................................................. 720 ± 50 rpm A/T, CVT ........................................................ ................................................................................................................... 720 ± 50 rpm (in Park or neutral) Page 4977 Transmission Position Switch/Sensor: Diagnostic Aids General Troubleshooting Information General Troubleshooting Information Tips and Precautions Before Troubleshooting 1. Check applicable fuses in the appropriate fuse/relay box. 2. Check the battery for damage, state of charge, and clean and tight connections. NOTE: 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. Handling Connectors - Make sure the connectors are clean and have no loose wire terminals. - Make sure multiple cavity connectors are packed with dielectric grease (except watertight connectors). - All connectors have push-down release type locks (A). - Some connectors have a clip on their side used to attach them to a mount bracket on the body or on another component. This clip has a pull type lock. - Some mounted connectors cannot be disconnected unless you first release the lock and remove the connector from its mount bracket (A). - Never try to disconnect connectors by pulling on their wires; pull on the connector halves instead. - Always reinstall plastic covers. Page 5789 Under-hood Fuse/Relay Box Under-Dash Fuse/Relay Box Fuse: Locations Under-Dash Fuse/Relay Box Under-dash Fuse/Relay Box Page 163 Resistor Variable Sensor Solenoid Transistors Circuit Schematics Page 7210 This system uses ROM chips that match the transmitter to the security system control unit. When replacing a lost or stolen transmitter, you need to use the three ROM chips (provided with the new transmitter) to match the old transmitter with the new transmitter and the control unit. 1. Remove the rear cover from the old transmitter and the new one. 2. Remove the ROM chip from the old transmitter by sliding its socket holder toward the ROM chip. 3. Insert a new ROM chip into the socket holder, then slide the socket holder toward the socket to lock the chip in place. 4. Repeat step 3 to install a ROM chip into the new transmitter. 5. Reinstall the rear covers on the transmitters. 6. Remove the security system control unit from under the driver's seat. 7. Open the access cover on the control unit, and replace the ROM chip. (Use the same procedure as in steps 2 and 3.) 8. Press the reset button next to the ROM chip. 9. Close the access cover, and reinstall the control unit. If you are replacing a damaged transmitter, don't replace the ROM chips in the transmitters and the control unit; just remove the chip from the old transmitter and install it in the new one. Ordering a Transmitter Transmitters can be ordered only by authorized Honda dealers. Order them from American Honda using normal parts ordering procedures. If your customer wants to add a third transmitter to the system, you need to order a four ROM chip set directly from Alpine Electronics of America. The Alpine part number for the four ROM chip set is 5319. This ROM chip set does not come with a transmitter. Order the additional transmitter from American Honda. If you have questions about how to order a four ROM chip set, call Alpine's parts department at (800) 421-2284, extension 8885. Batteries for the Transmitter Locations Crankshaft Position Sensor: Locations PGM-FI System - Component Location Index Page 3571 160. Left Side Of Engine Compartment (except GX) Page 6253 17. Pull on the steering gearbox to free it from the mounting stud (A) on the right gearbox mounting bracket (B). Remove the three mounting bolts and bracket. 18. Lower the steering gearbox, and rotate it so the pinion shaft points upward. 19. Carefully move the steering gearbox (A) and tie-rods (B) as an assembly toward the passenger's side until the pinion shaft clears the heater hoses. Remove the steering gearbox through the wheel well opening on the passenger's side. 20. Remove the pinion shaft grommet (C) from the top of the valve body unit. Steering Gearbox Installation 1. Install the pinion shaft grommet (A). 2. Pass the valve body unit side of the steering gearbox (B) together with the tie-rods (C) through the wheel well opening on the passenger's side. 3. Carefully move the steering gearbox toward the driver's side until the pinion shaft clears the heater hoses. Continue moving the gearbox toward the driver's side until the steering gearbox is in position. Page 9020 Use the tools from Pin Tool Set. First, check the connector that you are about to repair. - If it has a secondary terminal lock, go to Connectors With a Secondary Lock. A secondary lock, found on most connectors on some models, is an additional locking device on the connector housing as a backup for the primary lock on the terminal. - If the connector does not have a secondary lock, go to Connectors Without a Secondary Lock. Connectors With a Secondary Lock All examples are shown with the connector lock facing up. The illustrations are examples of the secondary terminal locks; however, the connector you are repairing may vary in size. Identify the connector by the type of secondary lock, not by the number of terminal cavities. EXAMPLE A: 1. Release the secondary lock. 2. Remove the terminal. 3. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE B: Locations Keyless Entry Module: Locations Relay And Control Unit Locations - Dashboard 78. Under Middle of Dash (Honda Accessory) Page 4014 Shift Interlock Solenoid: Testing and Inspection Shift Lock Solenoid Test 1. Remove the center console panel and center console. 2. Disconnect the shift lock solenoid connector (2P). 3. Connect the No. 1 terminal of the shift lock solenoid connector (2P) to the battery positive terminal, and connect the No. 2 terminal to the battery negative terminal. 4. Check that the shift lever can be moved from the P position. Release the battery terminals from the shift lock solenoid connector. Move the shift lever back to the P position, and make sure it locks. NOTE: Do not connect power to the No. 2 terminal (reverse polarity) or you will damage the diode inside the solenoid. 5. Check that the shift lock releases when the shift lock release is pushed, and check that it locks when the shift lock release is released. 6. If the shift lock solenoid does not work properly, replace it. Page 7283 - 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. Troubleshooting Tests 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 test 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 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. 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 Drop Service and Repair Brake Bleeding: Service and Repair Brake System Bleeding NOTE: ^ Do not spill brake fluid on the vehicle, it may damage the paint; if brake fluid does contact the paint, wash it off immediately with water. ^ The reservoir on the master cylinder must be at the MAX (upper) level mark at the start of the bleeding procedure and checked after bleeding each brake caliper. Add fluid as required. ^ Do not reuse the drained fluid. ^ Always use Honda DOT 3 brake fluid. Non-Honda brake fluid can cause corrosion and shorten the life of the system. ^ Make sure no dirt or other foreign matter is allowed to contaminate the brake fluid. 1. Make sure the brake fluid level in the reservoir is at the MAX (upper) level line (A). 2. Slide a piece of clear plastic hose over the first bleed screw, and submerge the other end in a container of new brake fluid. 3. Have someone slowly pump the brake pedal several times, then apply steady pressure. 4. Starting at the left front, loosen the brake bleed screw to allow air to escape from the system. Then tighten the bleed screw securely. 5. Repeat the procedure for each wheel in the sequence shown until air bubbles no longer appear in the fluid. Page 1825 Harmonic Balancer - Crankshaft Pulley: Service and Repair Crankshaft Pulley Removal and Installation Special Tools Required ^ Holder handle 07JAB-001020A ^ Holder attachment, 50 mm, offset 07MAB-PY3010A Socket, 19 mm 07JAA-001020A or a commercially-available 19 mm socket Removal 1. Hold the pulley with holder handle (A) and holder attachment (B). 2. Remove the bolt with a heavy duty 19 mm socket (C) and breaker bar. Installation 1. Remove any oil from the pulleys (A), guide plate (B), crankshaft (C), bolt (D), and washer (E). Clean and lubricate as shown. Locations Canister Purge Volume Control Valve: Locations EVAP System - Component Location Index Page 2165 1. Remove the terminal. 2. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE E: 1. Remove the terminal. 2. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE F: Page 1960 161. Middle Of Engine Compartment Page 9440 Blower Motor Relay Type 1, Type 2 Check for continuity between the terminals. - There should be continuity between the No.1 and No.3 terminals when power and ground are connected to the No.2 and No.4 terminals. - There should be no continuity between the No.1 and No.3 terminals when power is disconnected. Five-terminal type Check for continuity between the terminals. - There should be continuity between the No.1 and No.2 terminals when power and ground are connected to the No.3 and No.5 terminals. - There should be continuity between the No.1 and No.4 terminals when power is disconnected. Page 1283 Alignment: Specifications Trim Height Honda Motor Company does not list ride height/trim height specifications. Page 7291 1. Remove the secondary locks. 2. Remove the terminal from the female half. 3. Remove the terminal from the male half. 4. Go to HOW TO INSTALL NEW TERMINALS. Connectors Without a Secondary Lock All examples are shown with the connector lock facing up. The illustrations are examples of connector terminals without a secondary lock; however, the connector you are repairing may vary in size and shape. EXAMPLE A: Page 8854 - 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. - Refer to the scrapping procedures for disposal of the damaged airbag. 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. 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. Page 3591 104. CKP Sensor Page 9302 - Remove clips carefully; don't damage their locks (A). - Slip pliers (A) under the clip base and through the hole at an angle, then squeeze the expansion tabs to release the clip. - After installing harness clips, make sure the harness doesn't interfere with any moving parts. - Keep wire harnesses away from exhaust pipes and other hot parts, from sharp edges of brackets and holes, and from exposed screws and bolts. - Seat grommets in their grooves properly (A). Do not leave grommets distorted (B). Testing and Repairs - Do not use wires or harnesses with broken insulation. Replace them or repair them by wrapping the break with electrical tape. - After installing parts, make sure that no wires are pinched under them. - When using electrical test equipment, follow the manufacturer's instructions and those described. - If possible, insert the probe of the tester from the wire side (except waterproof connector). - Use back probe adaptor 07TAZ-001020A. - Refer to the instructions in the Honda Terminal Kit for identification and replacement of connector terminals. Five-Step Troubleshooting Five-Step Troubleshooting 1. Verify The Complaint Page 1948 5. If 4 numbers or marks (1 to 4 or V to VVVV) are printed around the outside of the filter, use the following procedure to tighten the filter. ^ Spin the filter on until its seal lightly seats against the block, and note which number or mark is at the bottom. ^ Tighten the filter by turning it clockwise 3 numbers or marks from the one you noted. For example, if number 2 is at the bottom when the seal is seated, tighten the filter until the number 1 comes around the bottom. 6. After installation, fill the engine with oil up to the specified level, run the engine for more than 3 minutes, then check for oil leakage. 7/8-turn type 1. Remove the oil filter with the special oil filter wrench. 2. Inspect the threads (A) and rubber seal (B) on the new filter. Wipe off the seat on the engine block, then apply a light coat of oil to the filter rubber seal. Use only filters with a built-in bypass system. 3. Install the oil filter by hand. 4. After the rubber seal seats, tighten the oil filter clockwise with the special tool. Tighten: 7/8 turn clockwise. Tightening torque: 22 Nm (2.2 kgf-cm, 16 ft. lbs.) Page 6411 ^ 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 2983 Engine Control Module: Service and Repair Monitors, Trips, and/or Drive Cycle (Readiness Codes) Malfunction Indicator Lamp (MIL) Indication (In relation to Readiness Codes) The vehicle has certain "readiness codes" that are part of the on-board diagnostics for the emissions systems. If the vehicle's battery has been disconnected or gone dead, if the DTCs have been cleared, or if the ECM/PCM has been reset, these codes are reset. In some states, part of the emissions testing is to make sure these codes are set to complete. If all of them are not set to complete, the vehicle may fail the emissions test, or the test cannot be finished. To check if the readiness codes are complete, turn the ignition switch ON (II), but do not start the engine. The MIL will come on for 15 - 20 seconds. If it then goes off, the readiness codes are complete. If it blinks several times, one or more readiness codes are not complete. To set readiness codes from incomplete to complete, do the procedure for the appropriate code. Catalytic Converter Monitor and Readiness Code NOTE: - Do not turn the ignition switch off during the procedure. - All readiness codes are cleared when the battery is disconnected or when the ECM/PCM is cleared with the OBD II scan tool or Honda PGM Tester. - Low ambient temperatures or excessive stop-and-go traffic may increase the drive time needed to switch the readiness code from incomplete to complete. - The readiness code will not switch to complete until all the enable criteria are met. - If a fault in the secondary HO2S system caused the MIL to come on, the readiness code cannot be set to complete until you correct the fault. Enable Criteria - ECT at 158 °F (70 °C) or higher. - Intake air temperature (IAT) at 20 °F (-7 °C) or higher. - Vehicle speed is steady, and vehicle speed sensor (VSS) reads more then 25 mph (40 km/h). Procedure 1. Connect the scan tool to the vehicle's data link connector (DLC), and bring up the tool's generic OBD II mode. 2. Start the engine. 3. Test-drive the vehicle under stop-and-go conditions with short periods of steady cruise. After about 5 miles (8 km), the readiness code should switch from incomplete to complete. 4. If the readiness code is still set to incomplete, check for a temporary DTC. If there is no DTC, one or more of the enable criteria were probably not met; repeat the procedure. Evaporative Emissions (EVAP) Control System Monitor and Readiness code NOTE: - All readiness code are cleared when the battery is disconnected or when the ECM/PCM is cleared with the OBD II scan tool or Honda PGM Tester. - The enable criteria must be repeated if the intake air temperature (IAT) drops lower then 36 °F (2 °C) from its value at engine start up. Enable Criteria - At engine start up, ECT and IAT are higher than 32 °F (O °C), but lower than 95 °F (35 °C). - At engine start up, the ECT and IAT are within 12 °F (7 °C) of each other. Procedure 1. Connect the scan tool to the vehicle's data link connector (DLC), and bring up the tool's generic OBD II mode. 2. Start the engine. 3. Test-drive the vehicle under stop-and-go conditions with short periods of steady cruise. After about 2.5 miles (4 km), the readiness code should switch from incomplete to complete. 4. If the readiness code is still set to incomplete, check for a temporary DTC. If there is no DTC, one or more of the enable criteria were probably not met; repeat the procedure. Air Fuel Ratio (A/F) Sensor Monitor and Readiness Code NOTE: - Do not turn the ignition switch off during the procedure. - All readiness codes are cleared when the battery is disconnected or when the ECM/PCM is cleared with the OBD II scan tool or Honda PGM Tester. Enable Criteria Page 4881 6. Replace the 1st/2nd synchro hub/sleeve, and reassemble the countershaft; see page 13-34 (13-48 for Hybrid) of the service manual. 7. Check the countershaft clearance; see page 13-30 (13-44 for Hybrid) of the service manual. Page 7397 5. Remove the lower cover from the fuse/relay box. 6. Disconnect the 3P ELD connector. Body - Door Lock Cylinders Bind Door Lock Cylinder: All Technical Service Bulletins Body - Door Lock Cylinders Bind 03-068 October 29, 2004 Applies To: See VEHICLES AFFECTED Door Lock Cylinder Binds (Supersedes 03-068, dated April 20, 2004) Updated information is shown with asterisks and black bars. SYMPTOM The key will not go into the door lock cylinder, or if it goes in, it will not turn. PROBABLE CAUSE The door lock tumblers are damaged or worn. VEHICLES AFFECTED CORRECTIVE ACTION Remove the door lock cylinder, and replace the inner cylinder, springs, and tumblers. Page 9732 Power Windows Component Location Index Emissions - OBD II DTC's And Associated Monitors Engine Control Module: Technical Service Bulletins Emissions - OBD II DTC's And Associated Monitors 03-020 April 2, 2010 Applies To: All OBD II-equipped models except Passport OBD II DTCs and Their Associated Monitors (Supersedes 03-020, dated March 29, 2003, to revise the information marked by the black bars and asterisks) *REVISION SUMMARY Numerous DTCs were added. Refer to the list for details.* Following is a list of all OBD II DTCs and their associated monitors for all Honda automobiles with OBD II. No one model has every DTC in the list. DTC P0AA6 thru P0A9E Page 814 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. Circuits must be operating when checking voltage drop. 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. 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 off, 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 Self-Powered Test Light or DVOM 1. Remove the blown fuse and disconnect the battery and load. Service and Repair Cowl Moulding / Trim: Service and Repair Cowl Cover Replacement 1. Remove the windshield wiper arms. 2. Using a clip remover, detach the clips (A), then remove the hood rear seal (B), and detach the clips (C) from the cowl covers. Take care not to scratch the cowl covers. 3. Detach the clip (D) or clip (E), and clips (F, G), and release the hook (H) by carefully pulling the passenger's cowl cover (I) upward, and pull the cover forward to release the hooks (J), then remove the cover. Take care not to scratch the body. 4. Detach the clips (D) or clips (E), and clips (F, G) by carefully pulling the driver's cowl cover (K) upward, and pull the cover forward to release the hooks (L), then remove the cover. Take care not to scratch the body. 5. Install the cover in the reverse order of removal, and note these items: - Replace any damaged clips. - Push the clip portions into place securely. Page 5311 Page 776 Oxygen Sensor: Service and Repair Third HO2S Replacement Third HO2S Replacement Special Tools Required O2 sensor wrench, Snap-on YA8875, SP Tools 93750, or equivalent, commercially available NOTE: The secondary HO2S and the third HO2S must be replaced together. 1. Disconnect the third HO2S 4P connector (A), then remove the third HO2S (B). 2. Install the third HO2S in the reverse order of removal. Page 8770 1. Remove the secondary locks. 2. Remove the terminal from the female half. 3. Remove the terminal from the male half. 4. Go to HOW TO INSTALL NEW TERMINALS. Connectors Without a Secondary Lock All examples are shown with the connector lock facing up. The illustrations are examples of connector terminals without a secondary lock; however, the connector you are repairing may vary in size and shape. EXAMPLE A: Tires - Tubless Tire Repair Information Tires: 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 3823 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 Locater) 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. Troubleshooting Precautions Troubleshooting Precautions Before Troubleshooting 1. Check the main fuse and the fuse 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, or you will damage the alternator diodes. - Do not attempt to crank the engine with the ground cable disconnected 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. Locations Knock Sensor: Locations PGM-FI System - Component Location Index Page 6549 Evaporator Temperature Sensor / Switch: Description and Operation How the Circuit Works The heater control panel controls the blower controls, air delivery, and A/C compressor controls automatically. With the ignition switch in ON (II), battery voltage is supplied through fuse 14. The control unit is grounded at G502. Evaporator Temperature Sensor The evaporator temperature sensor is located on the evaporator housing. If the temperature at the evaporator gets too cold, the evaporator temperature sensor sends a signal to the heater control panel to turn off the A/C compressor clutch. This prevents condensation from freezing on the evaporator fins and blocking air delivery into the passenger compartment. Page 5118 Circuit Schematics Each schematic represents one circuit. A circuit's wires and components are arranged to show current flow from power at the top of the diagram 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 Page 1489 Air Bag(s) Arming and Disarming: Vehicle Damage Warnings 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. - To prevent damage to the airbag assembly, keep free from any oil, grease, detergent, or water. - Store the removed airbag on a secure, fiat surface away from any high heat source (exceeding 200 °F / 93 °C). Page 7050 Seat Belt Buckle Tensioner Disconnect both seat belt buckle tensioner 4P connectors (A). Page 5633 Ignition Switch Lock Cylinder: Technical Service Bulletins Ignition Keys Gets Warm While Driving SOURCE: Honda Service News July 2003 TITLE: Ignition Key Gets Warm While Driving APPLIES TO: 2003 Accords, 2001-03 Civics, 2002-03 CR-Vs SERVICE TIP: Are owners of complaining of the ignition key getting warm while driving? The key interlock solenoid in the ignition switch is the likely culprit. This solenoid is energized anytime the shift lever isn't in Park, so the heat from the solenoid gets transferred to the ignition key. This is a normal characteristic of the vehicle, and can't be fixed by replacing the key interlock solenoid, the ignition lockset, or any other component. Page 4982 - 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. Troubleshooting Tests 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 test 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 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. 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 Drop Page 8645 Front Door Weatherstrip: Service and Repair Door Upper Seal Replacement Door Upper Seal Replacement 2-door NOTE: - Take care not to scratch the door. - Use a clip remover to remove the clips. 1. Remove these items: - Power mirror/manual mirror, as necessary - Door glass outer weatherstrip - Door sash trim 2. Detach the door weatherstrip clips (A, B), then remove the door upper seal (C). 3. Install the seal in the reverse order of removal, and note these items: - Replace the clip (A) if it's damaged. - Make sure the upper seal is installed in the holder (D) securely. - Check for water leaks. - Test-drive and check for wind noise. Page 8221 WARRANTY CLAIM INFORMATION In warranty: The normal warranty applies. Failed Part: P/N 68500-S5P-A90ZZ H/C 6528640 *Defect Code: 07406* Symptom Code: 03220 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 A 1. Check the side-to-side alignment of the trunk lid latch to the striker: ^ Refer to page 20-132 of the 2001-04 Civic Service Manual. ^ In ISIS, use the keyword TRUNK ADJUST, and select Trunk Lid Adjustment from the list. 2. Make sure the gaps of the trunk lid are even on all sides. ^ If the trunk is misaligned, go to step 3. ^ If the trunk lid is properly aligned on all sides, go to REPAIR PROCEDURE B. 3. Adjust the trunk lid hinges: ^ Refer to page 20-132 of the 2001-04 Civic Service Manual. ^ In ISIS, use the keyword TRUNK ADJUST, and select Trunk Lid Adjustment from the list. 4. Check the trunk operation: ^ If the trunk opens and closes smoothly and is properly aligned, return the vehicle to the customer. ^ If the trunk lid is still difficult to close, go to REPAIR PROCEDURE B. REPAIR PROCEDURE B Page 3056 Electric Load Sensor: Description and Operation Electrical Load Detector (ELD) Since the early 1990's, 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's 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 7652 12. Pull the vertical carriage lever toward you while you position the tracer on the right edge of the original key at its head, using the clamp carriage lever. Let the cutter bit cut into the key blank, then stop. Gently twist the lever clockwise to lock the vertical carriage at this height. Do not overtighten the lever. 13. Use the clamp carriage lever and the tracer to follow the contours of the original key. (The cutter bit cuts the same contours into the key blank.) Working from right to left, follow the right edge of the original key from head to tip, then the left edge of the key from tip to head. Turn off the cutter motor. 14. Reposition the tracer on the right edge of the original key at its head, using the clamp carriage lever. Turn on the cutter motor. Retrace the key from head to tip, then from tip to head. (This retracing cleans up the cuts on the key.) Turn off the cutter motor. 15. Release the vertical carriage lever. Open the jaw and remove only the new key. Make sure the jaw is free of any metal shavings or debris, then turn the new key over and slide the key with its blank side up into the jaw up to the key stop. Close the jaw to lock the key into place. 16. Turn on the cutter motor, and repeat steps 12 thru 14 to cut both edges of the other side of the key. 17. When you are finished making the required cuts, turn off the cutter motor, and release the vertical carriage lever. Open the jaws, and remove the keys. 18. Use a wire brush to smooth the cut surfaces on the new key. 19. Make sure the key works in the ignition switch and all the locks. If the key does not work, recut the key, and try it again. 20. Depending on the type of key blank you have used, do this: ^ If you have used a Honda key blank, add the transponder code of the new key to the immobilizer system with the Honda Diagnostic System (HDS). ^ If you have used a T-5 programmable key blank ("T-5" stamped on the shank), code the key's transponder with the Ilco Immobilizer Key Code Duplicator (see S/B 99-053, Ilco Immobilizer key Code Duplicator). Cutting Procedure - By Code 1. Press the ON/OFF button in the middle of the setting unit keypad. (This powers up the keypad.) 2. Turn the clamp unit lock lever to the left to release the clamp unit, and slide it to the right until the bottom left side is flush with the base edge. Turn the lever to the right to lock the clamp unit in place. Loosen the lateral and spring tension adjustment knobs on the clamp carriage. Page 5143 2. Insert the terminal tool into the female terminal, and then remove the terminal tool. NOTE: Make sure you do not select a terminal tool that is larger than the mating male terminal because it would spread the female terminal and cause a loose fit. 3. Compare the drag to the other terminals in the connector. If the drag is less, replace the terminal with a replacement terminal from the appropriate terminal repair kit. Page 8054 3. Use the clamp carriage lever to position the clamp unit so the tracer is directly over the flat surface of the code device, just ahead of the cam blades. 4. Pull the vertical carriage lever toward you until the tracer just touches the flat surface ahead of the cam blades. Watch the arrows on the keypad: ^ If the double-headed arrow in the middle of the keypad lights green, the tracer and cutter bit are properly aligned. ^ If the arrow on the left of the keypad lights red, the cutter bit is not touching the jaw. Turn the micrometric ring nut above the tracer to the left until the double-headed arrow lights green. ^ If the vertical arrow on the right of the keypad lights red, the tracer is not touching the jaw. Turn the micrometric ring nut above the tracer to the right until the double-headed arrow lights green. *5. Turn the micrometric ring nut to the right five clicks so the cutter bit is slightly higher than the tracer. The arrow on the left should light red. Raise the vertical carriage. NOTE: Setting the tracer five clicks lower than the cutter bit at this point has the effect of making the cutter bit cut the duplicated key a little shallower. This will protect the locking jaws from being damaged.* 6. Optional: Loosen the set screw, and adjust the hand rest to a comfortable position. Tighten the screw. 7. Pull the clamp carriage lever toward you until the clamp carriage clicks into its end-of-run position. 8. Clean any metal shavings or debris out of the center jaw. (A soft-bristle toothbrush is ideal for this purpose.) Then open the jaws with the jaws knob, and slide the key blank with its flat side down into the jaw up to the key stop. Close the jaw with the jaws knob to lock the key blank into place. Visually inspect the key for proper alignment in the jaw. 9. Set and lock the cam sets on the code device. ^ Starting with the left cam set, make sure the lock pin is pulled all the way out. (This releases the cams.) Page 7949 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. SRS Unit, Front Sensors and Side Impact Sensors SRS Unit, Front Sensors and Side Impact Sensors Be careful not to bump or impact the SRS unit, front sensors, or the side impact sensors whenever the ignition switch is ON (II), or for at least 3 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, front sensors, and the side impact sensor. The airbags could accidentally deploy and cause damage or injury. After a collision in which any airbags or seat belt tensioners were deployed, replace the SRS unit, front sensors, and other related components. After a collision in which a side airbag was deployed, replace the side impact sensor on the deployed side 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, front sensors, 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 3 minutes before beginning installation or replacement of the SRS unit, or disconnecting 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 N.m (1.0 kgf.m, 7.2 lbf.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 °G) and dry (less than 80% relative humidity, no moisture) area. Wiring Precautions Wiring Precautions SRS wiring can be identified by special yellow outer covering (except the SRS indicator light circuit). Page 7454 Use the tools from Pin Tool Set. First, check the connector that you are about to repair. - If it has a secondary terminal lock, go to Connectors With a Secondary Lock. A secondary lock, found on most connectors on some models, is an additional locking device on the connector housing as a backup for the primary lock on the terminal. - If the connector does not have a secondary lock, go to Connectors Without a Secondary Lock. Connectors With a Secondary Lock All examples are shown with the connector lock facing up. The illustrations are examples of the secondary terminal locks; however, the connector you are repairing may vary in size. Identify the connector by the type of secondary lock, not by the number of terminal cavities. EXAMPLE A: 1. Release the secondary lock. 2. Remove the terminal. 3. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE B: Page 5661 1. Cut off the female S terminal from the harness, making the cut as close to the terminal as possible. 2. Strip 6 mm of insulation from the wire using the 2.0 slot on the crimping tool. NOTE: Make sure no wire strands were removed when you stripped the insulation. If any were removed, cut the wire off even with the insulation, and strip it again. 3. Insert the wire into the new terminal so it fits as shown. 4. Using the 2.0 slot on the crimping tool, position the terminal in the tool slot with the solid portion of the terminal toward the anvil and the open section toward the former. Page 2333 ECM/PCM Inputs And Outputs At Connector E (31P) Page 3016 Camshaft Position Sensor: Description and Operation Camshaft Position (CMP) Sensor (Top Dead Center (TDC) Sensor) The CMP (TDC) sensor detects the position of the No.1 cylinder as a reference for sequential fuel injection to each cylinder. Page 3311 48. Middle Of Engine (except GX) Page 1062 Splices Components Ground - "G" Locations 24. Right Side Of Engine Compartment (CVT Similar) Page 2609 13. After completing the right edge, push all of the cam blades to the right until they touch the cams, then trace the cam blades from back to front. (The cutter bit cuts the same contours into the left edge of the key from tip to head.) Turn off the cutter motor. 14. Release the vertical carriage lever. Push all the cam blades to the left until they touch the cams. Pull the vertical carriage lever towards you until the tracer touches the flat surface on the right side, at the front of the cams. Gently twist the lever clockwise to lock the vertical carriage at this height. Do not overtighten the lever. 15. Turn on the cutter motor, then retrace the cam blades from front to back. Push all the cam blades to the right until they touch the cams, and then retrace the cam blades from back to front (retracing cleans up the cuts on the key). Turn off the cutter motor. 16. Release the vertical carriage lever. Open the jaw and remove the key. Make sure the jaw is free of any metal shavings or debris. Turn the key over so the blank side is up, then slide it into the jaw up to the key stop. Close the jaw to lock the key in place. 17. Push all the cam blades to the left until they touch the cams. Repeat steps 10 through 15 to cut both edges on the other side of the key. 18. When you are done making the required cuts, release the vertical carriage lever. Open the jaw and remove the key. 19. Make sure the key works in the ignition switch and the locks. If the key does not work, recut the key, and try it again. 20. Depending on the type of key, code the key transponder. Equipment Service and Warranty To service the MATRIX H Key Cutting Machine, refer to section 7 of the MATRIX H Operating Manual. It tells you how to replace parts that commonly wear out such as the drive belt, the work light bulb, and the tension spring on the vertical carriage. It also covers checking and replacing fuses and replacing the printed circuit board for the setting unit keypad. If you have technical questions on the equipment, contact the Ilco Technical Assistance Department. Mail: Kaba Ilco Technical Assistance Department 400 Jeffreys Road Rocky Mount, NC 27804 Phone: 800-452-6872 Ext: 200, 384, 323, 398, 356 Fax: 252-446-4702 The MATRIX H Key Cutting Machine comes with a 3-year limited warranty. This warranty does not cover the cutter bit or the work light bulb. CODE BOOK CORRECTIONS In the code book Honda High Security key Codes, correct these errors: Pages 4 thru 51, code headings: ^ Incorrect: J H G F Z X E D C B M/S X ^ Correct: J H G F A X E D C B M/S X Page 2, last paragraph: Page 3883 10. Connect the connector securely, then install the transmission range switch shaft cap (A). 11. Turn the ignition switch ON (II). Move the shift lever through all gear positions, and check the transmission range switch is synchronization with the A/T gear position indicator. 12. Raise the vehicle, and make sure it is securely supported. 13. Allow the wheels to rotate freely, then start the engine. 14. Move the shift lever through all gear positions, and verify the following: ^ The engine will not start in any position other than N or P. ^ The back-up lights come on when the shift lever is in the R position. Page 6094 6. Test-drive the vehicle to make sure it no longer pulls. If the steering wheel is now off-center by more than 2 mm, go to REPAIR PROCEDURE C. 7. Use your diagnosis worksheet to fill in the following table and build your 15-digit DTC. NOTE: Enter each reading in decimal degrees. Example 30' = 0.50. REPAIR PROCEDURE C 1. Make sure the steering wheel is centered. ^ Turn the steering wheel all the way to the right until it stops. ^ Turn the steering wheel all the way to the left, and count the number of revolutions until it stops. ^ Divide the number of revolutions in half, and turn the steering wheel until it is centered. For example, if it takes four revolutions of the steering wheel to go from lock to lock, then two turns is centered. ^ If the steering wheel is off-center by a large amount (20 mm or more), it may not be centered on the steering column shaft. Reinstall the steering wheel before going to step 2. 2. Place the vehicle on a lift, turn the steering wheel until it is centered, and then raise the vehicle. 3. Adjust the tie-rods. Use your measurements from question 13 of the test-drive to make your adjustment. Component Locations Heating Component Location Index Page 2974 ECM/PCM Inputs And Outputs At Connector B (24P) Page 3503 Main Relay (Computer/Fuel System): Testing and Inspection Power Relay Test Use this chart to identify the type of relay, then do the test listed for it. NOTE: See the turn signal/hazard relay input test. Normally-open type A: Page 985 ^ Incorrect: "If a Master Key is to be cut, put a five (5) in the blank space. Use a two (2) if a valet key is needed." ^ Correct: "If a Master Key is to be cut, put an M in the blank space. Use an S if a valet key is needed." Page 2, legend at the bottom: ^ Incorrect: "C. If a Master key is desired, then the number five (5) should be placed in the M/S position. Place the number two (2) in the M/S column if a Sub (Valet) key is needed." ^ Correct: "C. If a Master Key is desired, then an M should be placed in the M/S position. Place an S in the MIS column if a Sub (Valet) key is needed." Page 7418 Keyless Entry Module: Diagrams (EX; '04: LX, GX) (Honda Accessory) Page 7902 4. Install the fender fairing in the reverse order of removal, and note these items: - Replace any damaged clips. - Before installing the clips of the door upper and lower portions, install the front fender fairing (A) to the front fender (B) properly as shown. - Push the clips into place securely. Page 2153 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. Test Equipment 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. Page 938 12. Watch the SRS indicator: ^ If the indicator blinks twice and then goes off, the OPDS unit is initialized. Turn the ignition switch to LOCK (0), and disconnect the HDS. ^ If the indicator blinks twice and then stays on, the OPDS unit is initialized, but SRS DTCs need to be cleared. Go to step 13. ^ If the indicator stays on without first blinking, the OPDS unit is not initialized. Repeat steps 3 thru 12. 13. Turn the ignition switch to LOCK (0), then disconnect the HDS. 14. Reconnect the SCS service connector to the MES connector. Do not use a jumper wire. 15. Turn the ignition switch to ON (II). 16. Watch the SRS indicator. (It comes on for about 6 seconds and then goes off.) Disconnect the SCS service connector from the MES connector within 4 seconds after the indicator goes off. 17. When the SRS indicator comes on again, connect the SCS service connector to the MES connector within 4 seconds after the indicator comes on. 18. When the SRS indicator goes off, disconnect the SCS service connector from the MES connector within 4 seconds. (The SRS indicator blinks twice to indicate that the memory has been cleared.) 19. Turn the ignition switch to LOCK (0), and wait for 10 seconds. 20. Turn the ignition switch to ON (II). (The SRS is OK if the SRS indicator comes on for 6 seconds and then goes off.) If the DTC clearing fails, repeat the process two more times. If the DTC clearing fails again, check for set SRS DTCs, and troubleshoot them with the appropriate service manual. REPAIR PROCEDURE B: OPDS SENSOR REPLACEMENT 1. Remove the seat-back cover from the front passenger's seat: ^ Using the appropriate service manual, go to section 20 (Body), and do the removal steps under Front Seat Cover Replacement, or ^ Online, enter keyword SEAT COVER, then select Front Seat Cover Replacement from the list, and do the removal steps in the procedure. 2. Slide the seat-back cushion (foam) off the seat-back frame. (The OPDS sensor is built into the seat-back cushion.) 3. Slide a new seat-back cushion over the seat-back frame. Make sure the cushion is centered. 4. Install the seat-back cover: ^ Using the appropriate service manual, go to section 20 (Body), and do the installation step under Front Seat Cover Replacement, or ^ Online, enter keyword SEAT COVER, then select Front Seat Cover Replacement from the list, and do the installation step in the procedure. 5. Initialize the OPDS unit: ^ To initialize with the HDS, go to Initializing the OPDS Unit: HDS Method in this service bulletin. ^ To initialize with the SCS service connector, go to Initializing the OPDS Unit: Manual Mode in this service bulletin. Disclaimer Page 8768 2. Remove the terminal from the female half. 3. Remove the terminal from the male half. 4. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE D: 1. Remove the secondary locks. Page 2043 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. Below most connector numbers and component names are PHOTO and VIEW numbers. The PHOTO number refers to a photo in the back of the book that shows the connector's location on the car. The VIEW number refers to an illustration in the back of the book that shows the connector terminals, wire colors, connector cavity numbers, and other details. The connector cavity numbering sequence begins at the top left corner of the connector as seen from either of the viewpoints shown on diagram [8] . Except for the DLC (data link 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 C554, for example, means those terminals join in cavity 2 of connector C554. Power Distribution Schematics Power Distribution Schematics Page 954 12. Watch the SRS indicator: ^ If the indicator blinks twice and then goes off, the OPDS unit is initialized. Turn the ignition switch to LOCK (0), and disconnect the HDS. ^ If the indicator blinks twice and then stays on, the OPDS unit is initialized, but SRS DTCs need to be cleared. Go to step 13. ^ If the indicator stays on without first blinking, the OPDS unit is not initialized. Repeat steps 3 thru 12. 13. Turn the ignition switch to LOCK (0), then disconnect the HDS. 14. Reconnect the SCS service connector to the MES connector. Do not use a jumper wire. 15. Turn the ignition switch to ON (II). 16. Watch the SRS indicator. (It comes on for about 6 seconds and then goes off.) Disconnect the SCS service connector from the MES connector within 4 seconds after the indicator goes off. 17. When the SRS indicator comes on again, connect the SCS service connector to the MES connector within 4 seconds after the indicator comes on. 18. When the SRS indicator goes off, disconnect the SCS service connector from the MES connector within 4 seconds. (The SRS indicator blinks twice to indicate that the memory has been cleared.) 19. Turn the ignition switch to LOCK (0), and wait for 10 seconds. 20. Turn the ignition switch to ON (II). (The SRS is OK if the SRS indicator comes on for 6 seconds and then goes off.) If the DTC clearing fails, repeat the process two more times. If the DTC clearing fails again, check for set SRS DTCs, and troubleshoot them with the appropriate service manual. REPAIR PROCEDURE B: OPDS SENSOR REPLACEMENT 1. Remove the seat-back cover from the front passenger's seat: ^ Using the appropriate service manual, go to section 20 (Body), and do the removal steps under Front Seat Cover Replacement, or ^ Online, enter keyword SEAT COVER, then select Front Seat Cover Replacement from the list, and do the removal steps in the procedure. 2. Slide the seat-back cushion (foam) off the seat-back frame. (The OPDS sensor is built into the seat-back cushion.) 3. Slide a new seat-back cushion over the seat-back frame. Make sure the cushion is centered. 4. Install the seat-back cover: ^ Using the appropriate service manual, go to section 20 (Body), and do the installation step under Front Seat Cover Replacement, or ^ Online, enter keyword SEAT COVER, then select Front Seat Cover Replacement from the list, and do the installation step in the procedure. 5. Initialize the OPDS unit: ^ To initialize with the HDS, go to Initializing the OPDS Unit: HDS Method in this service bulletin. ^ To initialize with the SCS service connector, go to Initializing the OPDS Unit: Manual Mode in this service bulletin. Disclaimer Page 3830 2. Remove the terminal from the female half. 3. Remove the terminal from the male half. 4. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE D: 1. Remove the secondary locks. Locations SRS Component Location Index Specifications Idle Speed: Specifications Idle Speed With no-load conditions: USA model: M/T .................................................................................................................................. .................................................................................. 700 ± 50 rpm A/T, CVT .................................... ....................................................................................................................................... 700 ± 50 rpm (in Park or neutral) Canada model: M/T .............................................................................................. ...................................................................................................................... 720 ± 50 rpm A/T .......... .............................................................................................................................................................. ............. 720 ± 50 rpm (in Park or neutral) With load conditions: M/T ...................................................................................................................................................... .............................................................. 720 ± 50 rpm A/T, CVT ........................................................ ................................................................................................................... 720 ± 50 rpm (in Park or neutral) Page 8196 Doors - Component Location Index - 4-door Front Door Page 3159 Transmission Position Switch/Sensor: Electrical Diagrams Circuit Diagram Page 729 Electric Load Sensor: Description and Operation Electrical Load Detector (ELD) Since the early 1990's, 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's 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. Recall - Ignition/Shift Interlock Defect Technical Service Bulletin # 10-059 Date: 101001 Recall - Ignition/Shift Interlock Defect 10-059 October 1, 2010 Applies To: See VEHICLES AFFECTED Safety Recall: Accord, Civic, and Element Ignition Switch Key Interlock BACKGROUND Under certain conditions, the interlock lever of the ignition switch may unexpectedly deform. The interlock ensures the transmission is in Park before the ignition key can be removed. Interlock failure may allow the ignition key to be removed when the shift lever is not in Park. If the driver fails to engage the parking brake, the vehicle could roll away, increasing the risk of a crash. VEHICLES AFFECTED Not all vehicles within the VIN ranges are affected by this recall. Before beginning work on a vehicle, verify its eligibility by checking at least one of these items: ^ The customer has a notification letter. Page 227 Power Windows Component Location Index Page 8707 Cruise Control Switch: Testing and Inspection Set/Resume/Cancel Switch Set/Resume/Cancel Switch Test/Replacement 1. Remove the two screws, then remove the switch. 2. Check for continuity between the terminals in switch position according to the table. - If there is continuity, and it matches the table, but switch failure is occurred on the cruise control unit input test, check and repair the wire harness on the switch circuit. - If there is no continuity in one or both positions, replace the switch. Page 4069 Fluid - A/T: Fluid Type Specifications A/T Fluid Type ..................................................................................................................................................... .......................................................... Honda ATF-Z1 Honda Service News Notice: If you're replacing transmission fluid in a CVT-equipped vehicle, or just topping it off, make sure you're using the new CVT fluid (P/N 08200-9006). From here on, DON'T put ATF-Z1 in a CVT. If you're topping off a CVT that's already got ATF-Z1, there's no need for concern; this fluid is compatible with ATF-Z1. All CVT-equipped Hondas starting with the 2006 models and onward will be factory-filled with the new CVT fluid. Page 1922 1. Apply a force of 98 N (10 kgf, 22 lbf), and measure the deflection at the mid point (A) between the alternator and crankshaft pulley. If the belt is worn or damaged, replace it. If the belt needs adjustment, go to step 2. Adjustment 2. Loosen the mounting bolt (B), lock bolt (C) and lower bracket mounting bolt (D). 3. Torque the mounting bolt to 20 N.m (2.0 kgf.m, 14 lbf.ft). 4. Turn the adjusting bolt (E) to obtain the proper belt tension, then retighten the lock bolt, mounting bolt and lower bracket mounting bolt. 5. Recheck the belt tension. 6. If you installed a new belt, run the engine for 5 minutes, then readjust the belt to the used belt specification. 7. Check the power steering pump belt adjustment. Page 4288 1. Remove and discard the plastic cover from the ignition switch key interlock solenoid. 2. Note the position of the interlock solenoid plunger; you'll need to install it the same way. 3. Remove the screw from the solenoid, but keep the solenoid attached to its electrical connector. Discard the screw. NOTE: ^ Be careful not to lose the solenoid plunger; it slides out easily. ^ Keep the plunger free of dirt and grease while it's removed from the solenoid. 4. Note the position of the interlock lever spring; you'll need to install the new spring the same way. Page 39 Keyless Entry Module: Diagrams (EX; '04: LX, GX) (Honda Accessory) Page 3960 9. Click on the check mark to begin the control unit/module update. NOTE: To avoid control unit/module damage, do not interrupt the update. 10. Within 60 seconds of update completion, turn the ignition switch to LOCK (0) and then back to ON (II). 11. Once the software verifies that the control unit/module has been successfully updated, click on Yes to update another identical vehicle, or click on No to exit the update program. HIM Updating in Storage Mode NOTE: If the red No.3 on the HIM comes on or flashes during the update, go to Diagnosing HIM Error Codes. 1. If not already done, load the latest HDS PC software onto your iN workstation. For loading instructions, refer to the Tool Information publication Installation Instructions for HDS PC So ftware on ISIS. NOTE: If the latest sofiware is not loaded and you do a control unit/module update, the software may indicate the vehicle has the latest update when it doesn't. Updates not done with the latest software are not covered under warranty. 2. From the iN workstation desktop, select CM Update (ECU Rewrite). 3. Click on the tools button on the right side of the screen, and make sure the interface device is set to HIM. 4. Return to the Updating Honda Control Modules main screen, then select Storage Mode and follow the on-screen instructions. 5. Take the HIM to the vehicle, and connect it to the vehicle's DLC. 6. Turn the ignition switch to ON (II), and wait until the green No.1 LED on the HIM stays on. Turn the ignition switch to LOCK (0), and disconnect Page 382 ^ If the OPDS unit has an original part number, go to step 6. ^ If the OPDS unit has a new part number (refer to PARTS INFORMATION) or higher, go to REPAIR PROCEDURE B: OPDS SENSOR REPLACEMENT. 6. Recline the seat-back to access the OPDS unit mounting screws. 7. Remove the mounting screws from the OPDS unit, and gently pull out the unit. 8. Disconnect the OPDS connectors, then remove the OPDS unit. 9. Install a new OPDS unit, then snap on its cover. 10. Slip the seat-back cover over the OPDS unit. 11. On Accords, check the seat-back clip attachment bosses on the seat-back panel: ^ If the attachment bosses are OK, go to step 12. ^ If the seat-back has a pocket, and the attachment bosses are deformed or damaged, do the repair procedure in S/B 02-010, Seat-Back Panel Is Loose or Detached. Then go to step 12. ^ If the seat-back does not have a pocket, and the attachment bosses are deformed or damaged, replace the seat-back. Then go to step 12. Page 8403 59. Moonroof Motor (EX) Service and Repair Scuff Plate: Service and Repair Trim Removal/Installation - Door Area Special Tools Required KTC trim tool set SOJATP2014 2-door NOTE: - Put on gloves to protect your hands. - Use the appropriate tool from the KTC trim tool set to avoid damage when prying components. - Take care not to bend or scratch the trim and panels. 1. Remove the trim as shown: - To remove the door sill trim and B-pillar upper trim, remove the side trim panel as necessary. - To remove the front side cap and opener lock cylinder, refer to trunk lid opener/fuel fill door opener replacement. 2. Install the pants in the reverse order of removal, and note these items: - Replace any damaged clips. - Apply liquid thread lock to the anchor bolts before installation. - Before installing the anchor bolts, make sure there are no twists or kinks in the seat belts. Special Tools Required KTC trim tool set SOJATP2014 4-door NOTE: - Put on gloves to protect your hands. - Use the appropriate tool from the KTC trim tool set to avoid damage when prying components. - Take care not to bend or scratch the trim and panels. 1. Remove the trim as shown: - To remove the driver's kick panel, remove the footrest. Page 2428 5. Remove the lower cover from the fuse/relay box. 6. Disconnect the 3P ELD connector. Service and Repair Tie Rod Boot: Service and Repair Tie-rod Ball Joint Boot Replacement Special Tools Required Attachment, 42 mm 07QAD-P0A0100 1. Remove the boot from the tie-rod end, and wipe the old grease off the ball pin. 2. Pack the lower area of the ball pin (A) with fresh multipurpose grease. 3. Pack the interior of the new boot (B) and lip (C) with fresh multipurpose grease. Note these items when installing new grease: ^ Keep grease off the boot installation section (D) and the tapered section (E) if the ball pin. ^ Do not allow dust, dirt, or other foreign materials to enter the boot. 4. Install the new boot (A) using the special tool. The boot must not have a gap at the boot installation sections (B). After installing the boot, check the ball pin tapered section for grease contamination, and wipe it if necessary. Page 4695 7. Align the cutouts (A) on the rotary-frame with the neutral positioning cutouts (B) on the transmission range switch, then put a 2.0 mm (0.08 inch) feeler gauge blade (C) in the cutouts to hold it in the N Position. NOTE: Be sure to use a 2.0 mm (0.08 inch) blade or equivalent to hold the switch in the N position. 8. Install the transmission range switch (A) gently on the control shaft (B) while holding it in the N position with the 2.0 mm (0.08 inch) blade (C). 9. Tighten the bolts on the transmission range switch while you continue to hold the N position. Do not move the transmission range switch when tightening the bolts. Remove the feeler gauge. Page 2948 DTC P0979 thru P1193 Locations Wiper Switch: Locations Wiper/Washer Component Location Index 55. In Steering Column Cover Page 1546 234. Under-dash Fuse/Relay Box Part 4 Page 5303 Transmission Position Switch/Sensor: Service and Repair Transmission Range Switch Replacement 1. Remove the intake air duct and resonator. 2. Shift to the N position. 3. Remove the transmission range switch shaft cap (A). 4. Disconnect the transmission range switch connector (A). 5. Remove the transmission range switch (B). 6. Make sure that the control lever is in the N position. Page 4037 Shift Solenoid: Diagrams 185. CVT Control Valves And Inhibitor Solenoid Assembly 73. Shift Solenoid Valve A And B (A/T Except CVT) Page 5814 2. Remove the terminal from the female half. 3. Remove the terminal from the male half. 4. Go to HOW TO INSTALL NEW TERMINALS. Connectors Without a Secondary Lock All examples are shown with the connector lock facing up. The illustrations are examples of connector terminals without a secondary lock; however, the connector you are repairing may vary in size and shape. EXAMPLE A: 1. Remove the terminal. 2. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE B: Page 4665 Shifter CVT: Service and Repair Shift Lever Installation Shift Lever Installation 1. Install the shift lever assembly. 2. Connect the shift lock solenoid connector (2P) (A) and park pin switch connector (4P) (B). 3. Turn the ignition switch ON (II), and verify that the N position indicator comes on. 4. Install the shift cable to the shift lever. If necessary, adjust the shift cable. Page 3929 1. If not already done, load the latest HDS software onto the iN workstation. 2. Restart the CM Update application on the iN workstation. 3. On the right side of the screen, click on the tools button. 4. Click on HIM Self-Test Procedure. 5. Follow the on-screen instructions to run the HIM self-test. 6. If the self-test indicates a problem with the HIM, call the Special Tools hotline for repair instructions. Disclaimer Component Locations Relay Box: Component Locations Relay Box Locations Starting System Component Location Index Page 6251 8. Above the steering gearbox, remove the feed line clamp (A). 9. Disconnect the feed line (A) and return line (B) from the valve body unit. 10. Remove the cotter pin (A) from the tie-rod ball joint nut (B), and loosen the nut. 11. Separate the tie-rod ball joint and damper steering arm using the special tool. 12. Under the steering gearbox, remove the return hose clamp. Page 8967 Door Switch: Diagrams 4. Door Switch, Driver's 5. Door Switch, Front Passenger's (Sedan) 6. Door Switch, Left Rear Or Right Rear 7. Door Switch, Passenger's (Coupe) Page 6203 Power Steering Pressure Switch: Description and Operation Power Steering Pressure (PSP) Switch The PSP switch signals the ECM/PCM when the power steering load is high. Page 5771 Charging System Component Location Index Page 2312 DTC P0750 thru P0977 Component Locations Oxygen Sensor: Component Locations PGM-FI System - Component Location Index Page 9145 1. Remove the secondary locks. 2. Remove the terminal from the female half. 3. Remove the terminal from the male half. 4. Go to HOW TO INSTALL NEW TERMINALS. Connectors Without a Secondary Lock All examples are shown with the connector lock facing up. The illustrations are examples of connector terminals without a secondary lock; however, the connector you are repairing may vary in size and shape. EXAMPLE A: Page 9502 1. Remove the secondary locks. 2. Remove the terminal from the female half. 3. Remove the terminal from the male half. 4. Go to HOW TO INSTALL NEW TERMINALS. Connectors Without a Secondary Lock All examples are shown with the connector lock facing up. The illustrations are examples of connector terminals without a secondary lock; however, the connector you are repairing may vary in size and shape. EXAMPLE A: Page 8738 Cruise Control Switch: Testing and Inspection Set/Resume/Cancel Switch Set/Resume/Cancel Switch Test/Replacement 1. Remove the two screws, then remove the switch. 2. Check for continuity between the terminals in switch position according to the table. - If there is continuity, and it matches the table, but switch failure is occurred on the cruise control unit input test, check and repair the wire harness on the switch circuit. - If there is no continuity in one or both positions, replace the switch. Page 7633 PARTS INFORMATION REQUIRED MATERIALS WARRANTY CLAIM INFORMATION In warranty: The normal warranty applies. Failed Part: P/N 72185-S9A-003 H/C 6896716 Defect Code: 00503 Symptom Code: 07902 Skill Level: Repair Technician Page 4021 Page 5513 Brake Fluid Level Sensor/Switch: Testing and Inspection Brake Fluid Level Switch Test Check for continuity between the terminals (A) with the float in the down position and the up position. ^ Remove the brake fluid completely from the reservoir. With the float down, there should be continuity. ^ Fill the reservoir with brake fluid to MAX (upper) level (B). With the float up, there should be no continuity. Page 2317 DTC P1679 thru P1860 Page 6758 Air Bag: Service and Repair Front Passenger Airbag Front Passenger's Airbag Replacement Removal 1. Disconnect the battery negative cable, and wait at least 3 minutes before beginning work. 2. Lower the glove box. 3. Disconnect the front passenger's airbag 4P connector (A) from dashboard wire harness B 4P connector (B). 4. Remove the three mounting nuts (A) from the bracket. Cover the lid and dashboard with a cloth, and pry carefully with a screwdriver to lift the front passenger's airbag (B) out of the dashboard. NOTE: The airbag lid has pawls on its side which attach it to the dashboard. Installation Page 5320 Braking Sensor/Switch: Description and Operation Brake Pedal Position Switch The brake pedal position switch signals the ECM/PCM when the brake pedal is pressed. Page 7044 Seat Belt Tensioner: Diagrams 68. Seat Belt Tensioner, Driver's 69. Seat Belt Tensioner, Front Passenger's (sedan) 70. seat Belt Tensioner, Passenger's (Coupe) Page 7453 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. How to Replace Connector Terminals Terminal Replacement Procedure HOW TO REPLACE CONNECTOR TERMINALS The terminal repair kits provide necessary tools and materials (terminals, wire seals, and splice connectors) to repair many damaged or faulty connector terminals. However, not all terminals for all connectors are available. Refer to the labels on the lids of the repair kits for replacement terminal availability. IMPORTANT SAFETY INFORMATION: On some models, the SRS wires are in a separate harness. If the SRS harness is damaged, replace the harness; do not repair it. On other models, wire harnesses include yellow SRS wires. If any SRS wire is damaged, replace the entire harness; do not repair it. Before you begin, inspect the wire you are about to repair for damage and length. Make sure the wire will be long enough to make a terminal repair without stretching it when you reinstall the terminal in the connector. If the wire is too short, or if access to the connector is too restricted to make a terminal repair, you may need to install a pigtail terminal (a short length of wire with a factory-crimped terminal on it). Refer to HOW TO INSTALL PIGTAIL TERMINALS. Removing the Terminal Page 6789 3. Set the cancel sleeve (A) so that the projections (B) are aligned vertically. 4. Carefully install the cable reel (A) on the steering column shaft. Then connect the 5P connector (B) to the cable reel, and connect the 4P connector (C) to the dashboard wire harness B 4P connector (D). 5. Install the steering column covers. 6. If necessary, center the cable reel. (New replacement cable reels come centered.) Do this by first rotating the cable reel clockwise until it stops. Then rotate it counterclockwise (approximately 2 1/2 turns) until the arrow mark on the cable reel label points straight up. Page 1998 Oil Pressure Sender: Service and Repair Oil Pressure Switch Replacement 1. Remove the oil filter with the special oil filter wrench. 2. Disconnect the oil pressure switch connector, then remove the oil pressure switch. 3. Apply liquid gasket to the oil pressure switch threads, then install the oil pressure switch. 4. Install the oil filter. Page 5982 235. Under-dash Fuse/Relay Box Part 8 Page 5697 12. Check for continuity between the brushes (A). If there is no continuity, replace the armature housing (B). 13. Check for continuity between each brush (A) and the armature housing (B). If there is continuity, replace the armature housing. Starter Brush Holder Test M/T, CVT A/T 14. Check that there is no continuity between the (+) brush holder (A) and ( - ) brush holder (B). If there is no continuity, replace the brush holder assembly. Page 8181 Doors - Component Location Index - 4-door Rear Door Page 3413 12. Install the injectors into the injector base. 13. Install the fuel rail mounting nuts. 14. Connect the connectors on the injectors, the MAP sensor, the EVAP canister purge valve, and the TP sensor. 15. Connect the quick-connect fittings. 16. Install the air cleaner. 17. Turn the ignition switch ON (II), but do not operate the starter. After the fuel pump runs for about 2 seconds, the fuel pressure in the fuel line rises. Repeat this two or three times, then check for fuel leakage. Page 1170 Power Windows Component Location Index Page 9304 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 Locater) 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. Troubleshooting Precautions Troubleshooting Precautions Before Troubleshooting 1. Check the main fuse and the fuse 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, or you will damage the alternator diodes. - Do not attempt to crank the engine with the ground cable disconnected 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. Page 7550 123. Driver's Door (Coupe Exc. DX, HX; Sedan Exc. DX) Page 2535 1. Remove the secondary locks. 2. Remove the terminal from the female half. 3. Remove the terminal from the male half. 4. Go to HOW TO INSTALL NEW TERMINALS. Connectors Without a Secondary Lock All examples are shown with the connector lock facing up. The illustrations are examples of connector terminals without a secondary lock; however, the connector you are repairing may vary in size and shape. EXAMPLE A: Page 7285 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 Short Circuit Locator (Short Finder) 1. Remove the blown fuse. Leave the battery connected. Page 223 Air Conditioning Component Location Index Page 4208 Resistor Variable Sensor Solenoid Transistors Circuit Schematics Page 7971 12. Pull the vertical carriage lever toward you while you position the tracer on the right edge of the original key at its head, using the clamp carriage lever. Let the cutter bit cut into the key blank, then stop. Gently twist the lever clockwise to lock the vertical carriage at this height. Do not overtighten the lever. 13. Use the clamp carriage lever and the tracer to follow the contours of the original key. (The cutter bit cuts the same contours into the key blank.) Working from right to left, follow the right edge of the original key from head to tip, then the left edge of the key from tip to head. Turn off the cutter motor. 14. Reposition the tracer on the right edge of the original key at its head, using the clamp carriage lever. Turn on the cutter motor. Retrace the key from head to tip, then from tip to head. (This retracing cleans up the cuts on the key.) Turn off the cutter motor. 15. Release the vertical carriage lever. Open the jaw and remove only the new key. Make sure the jaw is free of any metal shavings or debris, then turn the new key over and slide the key with its blank side up into the jaw up to the key stop. Close the jaw to lock the key into place. 16. Turn on the cutter motor, and repeat steps 12 thru 14 to cut both edges of the other side of the key. 17. When you are finished making the required cuts, turn off the cutter motor, and release the vertical carriage lever. Open the jaws, and remove the keys. 18. Use a wire brush to smooth the cut surfaces on the new key. 19. Make sure the key works in the ignition switch and all the locks. If the key does not work, recut the key, and try it again. 20. Depending on the type of key blank you have used, do this: ^ If you have used a Honda key blank, add the transponder code of the new key to the immobilizer system with the Honda Diagnostic System (HDS). ^ If you have used a T-5 programmable key blank ("T-5" stamped on the shank), code the key's transponder with the Ilco Immobilizer Key Code Duplicator (see S/B 99-053, Ilco Immobilizer key Code Duplicator). Cutting Procedure - By Code 1. Press the ON/OFF button in the middle of the setting unit keypad. (This powers up the keypad.) 2. Turn the clamp unit lock lever to the left to release the clamp unit, and slide it to the right until the bottom left side is flush with the base edge. Turn the lever to the right to lock the clamp unit in place. Loosen the lateral and spring tension adjustment knobs on the clamp carriage. Page 368 7. From the Mode menu, select Miscellaneous Test. 8. From the Miscellaneous Test menu, select OPDS Initialization. 9. Follow the remaining screen prompts to complete the OPDS initialization. If the initialization fails repeat the process two more times. If the initialization fails again, check for SRS DTCs, then troubleshoot them using the appropriate service manual. Initializing the OPDS Unit: Manual Mode NOTE: Non-Honda seat covers will interfere with the performance of the OPDS and are not recommended. 1. Adjust the front passenger's seat-back to an upright position, then remove anything on or near the seat. 2. Turn the ignition switch to LOCK (0). 3. Connect the HDS to the vehicle's DLC (data link connector). 4. Keep the ignition switch at LOCK (0), and turn on the HDS. 5. At the screen prompts, enter the VIN and the odometer reading. 6. From the Select Mode screen, select SCS, and follow the screen prompts. Page 6980 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 5738 2. Remove the terminal (same procedure for male and female). 3. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE E: 1. Remove the secondary locks. 2. Remove the terminal (same procedure for male and female). 3. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE F: Page 2462 160. Left Side Of Engine Compartment (except GX) Page 4756 Flywheel: Service and Repair Clutch Disc and Pressure Plate Installation Clutch Replacement Special Tools Required ^ Clutch alignment shaft 07LAF-PT00110 ^ Clutch alignment disc 07JAF-PM7011A ^ Remover handle 07936-3710100 ^ Ring gear holder 07LAB-PV00100 or 07924-PD20003 ^ Attachment, 57 x 40 mm 07746-0010200 ^ Driver 077 49-0010000 Clutch Disc and Pressure Plate Installation 1. Install the ring gear holder. 2. Apply super high temp urea grease (P/N 08798-9002) to the splines (A) of the clutch disc (B), then install the clutch disc using the special tools. 3. Install the pressure plate (A) and the mounting bolts (B) finger-tight. Page 6103 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 2778 ECM/PCM Inputs And Outputs At Connector B (24P) Page 2284 Exhaust Manifold: Diagrams EXHAUST MANIFOLD COMPONENTS D17A2 Engine Page 6277 97. Bend the lock washer against the flat spots on the bracket with a large pair of pliers. 98. Install the cylinder lines. Note these items during reassembly: ^ Thoroughly clean the joints of the cylinder lines. The joints must be free of foreign material. ^ Install the cylinder lines by tightening the flare nuts by hand first, then tighten the flare nuts to the specified torque. 99. Adjust the rack guide screw. After adjusting, check that the rack moves smoothly by sliding it right and left. Page 2896 Manifold Pressure/Vacuum Sensor: Description and Operation Manifold Absolute Pressure (MAP) Sensor The MAP sensor converts manifold absolute pressure into electrical signals to the ECM/PCM. Page 6063 Relay Box: Connector Locations Under-dash Fuse/Relay Box Page 9314 1. Remove the terminal. 2. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE B: 1. Remove the terminal. 2. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE C: 1. Remove the terminal. 2. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE D: Page 4983 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. Circuits must be operating when checking voltage drop. 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. 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 off, 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 Self-Powered Test Light or DVOM 1. Remove the blown fuse and disconnect the battery and load. Page 6030 69. Under Left Side Of Dash 70. Under Left Side Of Dash Page 763 PGM-FI System - Component Location Index Page 8164 Programming the Transmitter NOTES: ^ The system accepts up to three transmitters. The transmitter codes are stored in a stacking-type memory. If a fourth transmitter code is programmed, the code for the first transmitter is erased. ^ Entering the programming mode cancels all learned transmitter codes, so none of the previously programmed transmitters will work. You must reprogram all of the transmitters once you are in the programming mode. ^ You must complete steps 1-6 within 4 seconds of the previous step to keep the system from exiting the programming mode. 1. Turn the ignition switch to ON (II). 2. Press the "Lock" or "Unlock" button on one of the transmitters. (An unprogrammed transmitter can be used for this step.) 3. Turn the ignition switch to LOCK (0). 4. Repeat steps 1 2, and 3 two more times using the same transmitter used in step 2. 5. Turn the ignition switch to ON (II). 6. Press the "Lock" or "Unlock" button on the same transmitter. Make sure the power door locks cycle to confirm that the system is in programming mode. 7. Within 10 seconds, press the "Lock" or "Unlock" button on each transmitter. Make sure the power door locks cycle after you press each transmitter button to confirm that the system accepted the transmitter's code. 8. Turn the ignition switch to LOCK (0) to exit the programming mode. Ordering a Transmitter Transmitters can be ordered only by authorized Honda dealers. Order them from American Honda using normal parts ordering procedures. Batteries for the Transmitter The battery number is CR2025. Each transmitter uses one battery. 94-95 Passport (Except 1995-1/2) 1994-95 Passport (except 19951A) with dealer-installed security system NOTES: ^ The system uses a stacking-type memory that accepts up to four transmitters. If you program a fifth transmitter, the memory for the first transmitter is pushed out, and it will no longer work. ^ To clear a lost or stolen transmitter from the system's memory, program a transmitter four times. This will remove the missing transmitter from memory, since only four transmitters can be accepted. Page 1789 Connecting Rod: Testing and Inspection Connecting Rod and Crankshaft End Play Inspection 1. Remove the oil pump. 2. Measure the connecting rod end play with a feeler gauge between the connecting rod and crankshaft. Connecting Rod End Play Standard (New): 0.15 - 0.30 mm (0.006 - 0.012 inch) Service Limit: 0.40 mm (0.016 inch) 3. If the connecting rod end play is out-of-tolerance, install a new connecting rod, and recheck. If it is still out-of-tolerance; replace the crankshaft. 4. Mount a dial indicator on the block so that its tip contacts the end of the crankshaft. 5. Push the crankshaft firmly away from the dial indicator, and zero the dial against the end of the crankshaft. Then pull the crankshaft firmly back toward the indicator; the dial reading should not exceed the service limit. Crankshaft End Play Standard (New): 0.10 - 0.35 mm (0.004 - 0.014 inch) Service Limit: 0.45 mm (0.018 inch) 6. If the end play is excessive, replace the thrust washers and recheck. If it is still out-of-tolerance, replace the crankshaft. Page 8973 Fuel Supply System - Component Location Index Page 6064 69. Under Left Side Of Dash 70. Under Left Side Of Dash Page 8160 Programming the Transmitter NOTES: ^ The system accepts up to three transmitters. The transmitter codes are stored in a stacking-type memory. If a fourth transmitter code is programmed, the code for the first transmitter is erased. ^ Entering the programming mode cancels all learned transmitter codes, so none of the previously programmed transmitters will work. You must reprogram all of the transmitters once you are in the programming mode. ^ You must complete each step within 4 seconds of the previous step to keep the system from exiting the programming mode. Program the transmitters within 10 seconds. 1. Turn the ignition switch to ON (II). 2. Press the "Lock" or "Unlock" button on one of the transmitters. (An unprogrammed transmitter can be used for this step.) 3. Turn the ignition switch to LOCK (0). 4. Repeat steps 1 2, and 3 two more times using the same transmitter used in step 2. 5. Turn the ignition switch to ON (II). 6. Press the "Lock" or "Unlock" button on the same transmitter. Make sure the power door locks cycle to confirm that the system is in programming mode. 7. Within 10 seconds, press the "Lock" or "Unlock" button on each transmitter. Make sure the power door locks cycle after you press each transmitter button to confirm that the system accepted the transmitter's code. 8. Turn the ignition switch to LOCK (0) to exit the programming mode. Ordering a Transmitter Transmitters can be ordered only by authorized Honda dealers. Order them from American Honda using normal parts ordering procedures. Batteries for the Transmitter The battery number is CR2025. Each transmitter uses one battery. 99-04 Odyssey EX 1999-00 Odyssey EX with factory-installed keyless entry system or dealer-installed security system *2001-04 Odyssey EX models with factory- installed security system* *Transmitter Identification Page 2404 Camshaft Position Sensor: Service and Repair CMP (TDC) Sensor Replacement 1. Remove the grommet (A) from the upper cover, and disconnect the camshaft position (CMP) (top dead center (TDC)) sensor connector (B). 2. Remove the upper cover (C). 3. Remove the CMP (TDC) sensor from the cylinder head. 4. Install the CMP (TDC) sensor in reverse order of removal. Page 1925 Drive Belt: Adjustments Power Steering Belt Pump Belt Inspection and Adjustment Special Tools Required Belt tension gauge, 07JGG-0010100, 07JGG-001010A, or 07TGG-001000A Belt Tension Gauge Method Inspection 1. Remove the P/S reservoir from the bracket, and set it aside. 2. Attach the belt tension gauge to the belt, and measure the tension of the belt. Follow the gauge manufacturer's instructions. If the belt is worn or damaged, replace it. NOTE: Remove the belt tension gauge carefully to avoid hitting the gauge reset lever. Tension: Used Belt: 390 - 540 N (40 - 55 kgf, 88 - 121 lbs.) New Belt: 740 - 880 N (75 - 90 kgf, 165 - 198 lbs.) 3. If you installed a new belt, run the engine for 5 minutes, then readjust the belt to the used belt specification. Adjustment 4. Loosen the power steering pump mounting nut (A.) and pump locknut (B). 5. Turn the adjusting bolt (C) to get the proper belt tension, then retighten the mounting nut and locknut. 6. Start the engine and turn the steering wheel from lock-to-lock several times, then stop the engine and recheck the tension of the belt. Deflection Method Inspection 1. Apply a force of 98 N (10 kgf, 22 lbs.) and measure the deflection between the power steering pump pulley (A) and the crankshaft pulley (B). If the belt is worn or damaged, replace it. Deflection: Used Belt: 13.0 - 16.5 mm (0.51 - 0.65 inch) New Belt: 9.0 - 11.0 mm (0.35 - 0.43 inch) Page 146 Blower Motor Relay Type 1, Type 2 Check for continuity between the terminals. - There should be continuity between the No.1 and No.3 terminals when power and ground are connected to the No.2 and No.4 terminals. - There should be no continuity between the No.1 and No.3 terminals when power is disconnected. Five-terminal type Check for continuity between the terminals. - There should be continuity between the No.1 and No.2 terminals when power and ground are connected to the No.3 and No.5 terminals. - There should be continuity between the No.1 and No.4 terminals when power is disconnected. Page 1870 5. Inspect the rocker arm piston (A). Push it manually. If it does not move smoothly, replace the rocker arm set. NOTE: ^ When reassembling the primary rocker arm (B), carefully apply air pressure to its oil passage. ^ Apply oil to the pistons when reassembling. Page 316 95. Behind Glove Box (HX; '04-'05: DX, EX, LX) Page 3440 Blower Motor Relay Type 1, Type 2 Check for continuity between the terminals. - There should be continuity between the No.1 and No.3 terminals when power and ground are connected to the No.2 and No.4 terminals. - There should be no continuity between the No.1 and No.3 terminals when power is disconnected. Five-terminal type Check for continuity between the terminals. - There should be continuity between the No.1 and No.2 terminals when power and ground are connected to the No.3 and No.5 terminals. - There should be continuity between the No.1 and No.4 terminals when power is disconnected. Page 605 Fuel Gauge Sender: Locations Gauges Component Location Index (Part 1 Of 4) Page 2201 Radiator Cooling Fan Temperature Sensor / Switch: Testing and Inspection Radiator Fan Switch Test NOTE: Bleed air from the cooling system after installing the radiator fen switch. 1. Remove the radiator fan switch from the thermostat cover. 2. Suspend the radiator fan switch (A) in a container of water as shown. 3. Heat the water and check the temperature with a thermometer. Do not let the thermometer (B) touch the bottom of the hot container. 4. Measure the continuity between the A terminal (C) and B terminal (D) according to the table. Page 5887 234. Under-dash Fuse/Relay Box Part 6 Page 3716 3. Strip the insulation off the end of the wire so the wire fits in the new terminal as shown. (If the wire has a wire seal, replace it with a new one from the kit.) NOTE: After stripping the end of the wire, make sure you did not cut any wire strands. If you did, cut the wire off even with the insulation, and strip it again. 4. Position the terminal in the crimping tool slot with the solid portion of the terminal toward the anvil and the open section toward the former. 5. Insert the wire in the terminal to the position shown in step 3. 6. Squeeze the tool with both hands until the stops make contact. 7. Crimp the insulation crimp. - If you do not have a wire seal, then use the next larger size crimp slot. Position the crimping tool over the insulation crimp section of the terminal, then squeeze the tool with both hands until the stops make contact. - If you have a wire seal, position the insulation crimp in the 5.5 crimping slot, then carefully squeeze the crimp closed until its ends are touching and making a full-circle shape. Page 9413 13. Plug in the heat gun, and turn it on. Start at the middle of the splice connector, and move the gun toward the ends as the tube shrinks. Apply heat evenly by rotating the curved heat spreader around the splice connector. Shrinking is complete when a small amount of sealant appears at each end of the tube. Pigtail Terminal Selection Chart PIGTAIL TERMINAL SELECTION CHART Select the proper size pigtail terminal by matching the replacement terminal part number and the wire size being repaired to the corresponding pigtail terminal part number. Then use the color (size) splice connector listed. In some instances you may also have to match the wire seal style to select the proper pigtail terminal. Pigtail terminals are available through your parts department, in quantities of 10, using normal parts ordering procedures. Checking For Poor Fir of Terminals CHECKING FOR POOR FIT OF TERMINALS Loose terminal fit can cause a number of intermittent problems in electrical circuits. By using the Terminal Inspection Feeler Tool Set you can inspect the terminal fit between the two matching connectors without removing the terminals from the connector body. 1. Find the terminal tool that best matches the male terminal in the mating connector. Locations 12. Middle Of Engine Page 1860 7. Insert the feeler gauge (A) between the adjusting screw (B) and the end of the valve stem and slide it back and forth; you should feel a slight amount of drag. 8. If you feel too much or too little drag, loosen the locknut (A), and turn the adjusting screw (B) until the drag on the feeler gauge is correct. 9. Tighten the locknut and recheck the clearance. Repeat the adjustment, if necessary. Page 2878 NO - Repair short in the wire between the No.20 IG (40A) fuse and the under-dash fuse/relay box. Also replace the No.20 IG (40A) fuse. 10. Try to start the engine. Does the engine start? YES - Go to step 11. NO - Go to step 14. 11. Turn the ignition switch OFF. 12. Connect ECM/PCM connector terminal E31 to body ground with a jumper wire. 13. Turn the ignition switch ON (II). Is the MIL on? YES - Update the ECM/PCM if it does not have the latest software, or substitute a known-good ECM/PCM, then recheck. If the symptom/indication goes away with a known-good ECM/PCM, replace the original ECM/PCM. NO - Check for an open in the wire between the ECM/PCM (E31) and the gauge assembly. Also check for a blown MIL bulb. If the wires and the bulb are OK, replace the gauge assembly. 14. Turn the ignition switch OFF. 15. Inspect the No.6 ECU (ECM/PCM) (15A) fuse in the under-hood fuse/relay box. Is the fuse OK? YES - Go to step 22. NO - Go to step 16. 16. Remove the blown No.6 ECU (ECM/PCM) (15A) fuse in the under-dash fuse/relay box 17. Remove the glove box and PGM-FI main relay 1 (A). Page 3961 the HIM from the vehicle. 7. Connect the PC interface cable to the iN workstation and to the HIM. Connect the power supply unit and power supply cord to the HIM. After several seconds, the green and yellow LEDs flash. Each updatable vehicle system is checked to make sure it is current. Any systems needing an update are listed on the screen. Highlight the system you want to update, then click on the check mark to continue. NOTE: Update the systems one at a time. 8. Verify that the Program ID and the Program Part No. are correct, then click on the check mark. 9. Confirm the control module update by Program ID and Program Part No. Make sure this corresponds with any information provided in the service bulletin for the update you are doing. Click on Yes to continue. Within a few seconds, the CM Update software loads the program file onto the HIM. 10. Disconnect the HIM from the PC interface cable. 11. Reconnect the HIM to the vehicle's DLC. 12. Turn the ignition switch to ON (II), and wait until the green No.1 LED on the HIM stays on. Press and release the ENTER button on the HIM. Page 1671 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. Below most connector numbers and component names are PHOTO and VIEW numbers. The PHOTO number refers to a photo in the back of the book that shows the connector's location on the car. The VIEW number refers to an illustration in the back of the book that shows the connector terminals, wire colors, connector cavity numbers, and other details. The connector cavity numbering sequence begins at the top left corner of the connector as seen from either of the viewpoints shown on diagram [8] . Except for the DLC (data link 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 C554, for example, means those terminals join in cavity 2 of connector C554. Power Distribution Schematics Power Distribution Schematics Page 8288 10. Pull down on the retainer clip with a hook-shaped tool. Remove the lock cylinder. Then go to step 14. 11. Pull the glass run channel away as necessary, and remove the bolt, then remove the center lower channel by pulling it downward. 12. Remove the access seal, and disconnect the outer handle rod and the cylinder rod. Page 9841 12. Attach the clips to the rear window opening flange. 13. Set the rear window in the opening, and center it. Make alignment marks (A) across the rear window and body with a grease pencil at the four points shown. Be careful not to touch the rear window where adhesive will be applied. 14. Remove the rear window. 15. With a sponge, apply a light coat of glass primer along the edge of the rear window (A) and molding (B) as shown, then lightly wipe it off with gauze or cheesecloth: Do not apply body primer to the rear window, and do not get body and glass primer sponges mixed up. - Never touch the primed surfaces with your hands. If you do, the adhesive may not bond to the rear window properly, causing a leak after the rear window is installed. - Keep water, dust, and abrasive materials away from the primed surfaces. Page 7209 Remote Transmitter Quick Reference Guide 90-93 Accord, 92-93 Civic & Prelude, 93 Del SOL 1990-93 Accord (2-door and 4-door) with dealer-installed security system 1992-93 Civic with dealer-installed security system 1993 del Sol with dealer-installed security system 1992-93 Prelude with dealer-installed security system Programming the Transmitter NOTE: Diagrams 42. EVAP Canister Vent Shut Valve (except GX) Page 503 Braking Sensor/Switch: Testing and Inspection Brake Pedal Position Switch Signal Circuit Troubleshooting 1. Check the brake lights. Are the brake lights on without pressing the brake pedal? YES - Inspect the brake pedal position switch. NO - Go to step 2. 2. Press the brake pedal. Do the brake lights come on? YES - Go to step 3. NO - Go to step 4. 3. Measure voltage between ECM/PCM connector terminals A24 and E22 with the brake pedal pressed. Is there battery voltage? YES - The brake pedal position switch signal is OK. NO - Repair open in the wire between the ECM/PCM (E22) and the brake pedal position switch. 4. Inspect the No.7 HORN, STOP (15A) fuse in the under-hood fuse/relay box. Is the fuse OK? YES - Repair open in the wire between the brake pedal position switch and the No.7 HORN, STOP (15A) fuse. Inspect the brake pedal position switch. NO - Repair short in the wire between the ECM/PCM (E22) and the No.7 HORN, STOP (15A) fuse. Replace the No.7 HORN, STOP (15A) fuse. Page 2968 ECM/PCM Inputs And Outputs At Connector E (31P) Page 5867 Rear Window Defogger Component Location Index 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 2480 Oxygen Sensor: Diagrams 130. A/F Sensor 140. HO2S, Primary (GX; '01-'03: EX, DX, LX) Or Secondary (HX) Recall 10V364000: Ignition Interlock Defect Shift Interlock Switch: All Technical Service Bulletins Recall 10V364000: Ignition Interlock Defect VEHICLE MAKE/MODEL: MODEL YEAR(S): Honda/Accord 2003 Honda/Civic 2003 Honda/Element 2003-2004 MANUFACTURER: Honda (American Honda Motor Co.) MFR'S REPORT DATE: August 04, 2010 NHTSA CAMPAIGN ID NUMBER: 10V364000 NHTSA ACTION NUMBER: EA09001 COMPONENT: Electrical System: Ignition POTENTIAL NUMBER OF UNITS AFFECTED: 384220 SUMMARY: Honda is recalling certain model year 2003 Honda Accord, Civic two and four door, and model year 2003-2004 Honda Element vehicles. The interlock lever of the ignition switch may unexpectedly deform, which can allow the interlock function of a vehicle with an automatic transmission to be defeated. CONSEQUENCE: Removal of the ignition key when the gear selector of a vehicle with an automatic transmission has not been shifted to the park position can allow the vehicle to roll away, increasing the risk of a crash. REMEDY: Dealers will remove the original interlock pin and lever within the ignition switch, and replace them with newly, designed components. This service will be performed free of charge. The safety recall is expected to begin on or about September 29, 2010. Owners may contact Honda at 1-800-999-1009. NOTES: Honda safety recall No. R44. 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 7270 Connectors - "C" Page 3812 Splices Components Ground - "G" Page 5651 ^ Refer to page 11-199 of the 2001-2005 Civic Service Manual, or ^ Online, enter keyword RESONATOR, and select Resonator Removal/Replacement from the list. 4. Disconnect the female terminal (BLK/WHT wire) from the S terminal of the starter solenoid. NOTE: A/T is shown. M/T is similar 5. Pull the boot back from the female S terminal, and check the terminal for signs of arcing. 6. Check the male S terminal at the starter for signs of arcing. 7. If either terminal has signs of arcing, go to REPAIR PROCEDURE. If neither terminal has signs of arcing, continue your diagnosis using the appropriate service manual. REPAIR PROCEDURE Page 7789 12. Pull the vertical carriage lever toward you while you position the tracer on the right edge of the original key at its head, using the clamp carriage lever. Let the cutter bit cut into the key blank, then stop. Gently twist the lever clockwise to lock the vertical carriage at this height. Do not overtighten the lever. 13. Use the clamp carriage lever and the tracer to follow the contours of the original key. (The cutter bit cuts the same contours into the key blank.) Working from right to left, follow the right edge of the original key from head to tip, then the left edge of the key from tip to head. Turn off the cutter motor. 14. Reposition the tracer on the right edge of the original key at its head, using the clamp carriage lever. Turn on the cutter motor. Retrace the key from head to tip, then from tip to head. (This retracing cleans up the cuts on the key.) Turn off the cutter motor. 15. Release the vertical carriage lever. Open the jaw and remove only the new key. Make sure the jaw is free of any metal shavings or debris, then turn the new key over and slide the key with its blank side up into the jaw up to the key stop. Close the jaw to lock the key into place. 16. Turn on the cutter motor, and repeat steps 12 thru 14 to cut both edges of the other side of the key. 17. When you are finished making the required cuts, turn off the cutter motor, and release the vertical carriage lever. Open the jaws, and remove the keys. 18. Use a wire brush to smooth the cut surfaces on the new key. 19. Make sure the key works in the ignition switch and all the locks. If the key does not work, recut the key, and try it again. 20. Depending on the type of key blank you have used, do this: ^ If you have used a Honda key blank, add the transponder code of the new key to the immobilizer system with the Honda Diagnostic System (HDS). ^ If you have used a T-5 programmable key blank ("T-5" stamped on the shank), code the key's transponder with the Ilco Immobilizer Key Code Duplicator (see S/B 99-053, Ilco Immobilizer key Code Duplicator). Cutting Procedure - By Code 1. Press the ON/OFF button in the middle of the setting unit keypad. (This powers up the keypad.) 2. Turn the clamp unit lock lever to the left to release the clamp unit, and slide it to the right until the bottom left side is flush with the base edge. Turn the lever to the right to lock the clamp unit in place. Loosen the lateral and spring tension adjustment knobs on the clamp carriage. Page 7031 Seat Belt Buckle Switch: Diagrams 121. Seat Belt Switch, Driver's 122. Seat Belt Switch, Front Passenger's (Sedan) 123. Seat Belt Switch, Passenger's (Coupe) Page 714 5. Remove the lower cover from the fuse/relay box. 6. Disconnect the 3P ELD connector. Page 7772 8. Release the clip, detach the hook, and remove the lock rod protector. 9. Disconnect the outer handle rod and cylinder rod. Page 3946 Updating Honda Control Modules screen on the HDS tablet, the HDS pocket tester, or the iN workstation. MVCI:* iN Workstation: NOTE: The HDS tablet and pocket tester screens are similar. *^If the Database Update listed in the service bulletin is later than that shown by the software, please see the the procedures for software installation in the following documents in Tool Information on ISIS (go to General Publications, then Tool Information): - MVCI User Guide (see HDS MVCI Firmware Update section) - Honda Diagnostic System (HDS) Tablet Setup Instructions - Installation Instructions for HDS ( see PC Software for the GNA600, HIM or Pocket Tester ID)* ^ Do not connect an additional power supply to the updating equipment when it is connected to the vehicle; power is supplied through the DLC. ^ To ensure that the control module/unit is not permanently damaged during updating, vedfy that the vehicle's 12-volt battery is fully charged before starthg an update. NOTE: If the vehicle's 12-volt battery drops below 10 volts during the update, the programming status bar may go past 100 percent, or the updating tool may display an error message. ^ If you have a problem during an update (D4/ immobilizer indicator flashes, update tool freezes, etc.), you can minimize the chances of damaging the control unit/module by doing one or more of these actions: - CRITICAL: Keep the ignition switch in ON (II). - Connect a jumper battery (DO NOT connect a battery charger). - Disconnect the updating tool from the vehicle's DLC. - Reboot the updating tool. - Reconnect the updating tool to the vehicle's DLC, and retry the updating procedure. *UPDATING WITH THE MVCI Make sure you have the latest control module (CM) Update software loaded from your HDS PC to your MVC I. For loading instructions and other Page 4232 8. Put the splice connector in the proper size slot in the Crimper Tool, slide it to one end (where the flare begins), and close the crimper handles far enough to hold it in place. To release the ratchet mechanism at any point after the first click, squeeze the handles slightly and push the release lever, then let the handles open. 9. Insert one of the bare wires into the splice connector end that is in the crimper jaws. Push the wire all the way into the splice connector, and squeeze the crimper handles. Keep squeezing until the jaws touch, and hold it at that position until the ratchet clicks again. 10. Crimp the other wire in the same way into the other end of the splice connector. 11. After crimping, gently pull on the wires in the opposite directions to make sure they are secure in the connector. 12. Separate the other wires in the harness from the repaired wire(s), and shield them with nonflammable material. Page 2549 Transmission Position Switch/Sensor: Service and Repair Transmission Range Switch Replacement 1. Raise the vehicle, and make sure it is securely supported. 2. Shift to the N position. 3. Remove the transmission range switch cover (A). 4. Disconnect the transmission range switch connector (B). 5. Remove the old transmission range switch, and install the new switch. 6. Make sure that the control shaft is in the N position. If necessary, move the shift lever to the N position. Page 2777 ECM/PCM Inputs And Outputs At Connector A (31P) Page 3151 1. Remove the terminal. 2. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE G: 1. Remove the terminal. 2. Go to HOW TO INSTALL NEW TERMINALS. How to Install New Terminals HOW TO INSTALL NEW TERMINALS 1. Carefully match the old terminal with a new one from the terminal repair kit. Choose the correct replacement terminal based on the wire size range the terminal will accommodate. NOTE: If the replacement terminal quantities are low, reorder them by using the terminal part number listed on the inside lid of the terminal repair kit. Replacement terminals are available through your parts department using normal parts ordering procedures. 2. Depending on the size of the wire you are repairing, use the proper size slot in the crimping tool. Page 4119 8. Put the splice connector in the proper size slot in the Crimper Tool, slide it to one end (where the flare begins), and close the crimper handles far enough to hold it in place. To release the ratchet mechanism at any point after the first click, squeeze the handles slightly and push the release lever, then let the handles open. 9. Insert one of the bare wires into the splice connector end that is in the crimper jaws. Push the wire all the way into the splice connector, and squeeze the crimper handles. Keep squeezing until the jaws touch, and hold it at that position until the ratchet clicks again. 10. Crimp the other wire in the same way into the other end of the splice connector. 11. After crimping, gently pull on the wires in the opposite directions to make sure they are secure in the connector. 12. Separate the other wires in the harness from the repaired wire(s), and shield them with nonflammable material. Page 5561 Ignition Switch Lock Cylinder: Technical Service Bulletins Ignition Keys Gets Warm While Driving SOURCE: Honda Service News July 2003 TITLE: Ignition Key Gets Warm While Driving APPLIES TO: 2003 Accords, 2001-03 Civics, 2002-03 CR-Vs SERVICE TIP: Are owners of complaining of the ignition key getting warm while driving? The key interlock solenoid in the ignition switch is the likely culprit. This solenoid is energized anytime the shift lever isn't in Park, so the heat from the solenoid gets transferred to the ignition key. This is a normal characteristic of the vehicle, and can't be fixed by replacing the key interlock solenoid, the ignition lockset, or any other component. Page 3763 ^ The vehicle is shown as eligible on a VIN status inquiry. In addition, check for a punch mark above the seventh character of the engine compartment VIN. A punch mark in that location means the ignition switch key interlock has already been inspected/repaired. 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 a VIN status inquiry before selling it. CUSTOMER NOTIFICATION All owners of affected vehicles will be sent a notification of this campaign. An example of the customer notification is at the end of this service bulletin. CORRECTIVE ACTION Inspect the ignition switch and, if needed, install a Key Interlock Repair Kit. PARTS INFORMATION Key Interlock Repair Kit: P/N 06351-SDA-000 REQUIRED SPECIAL TOOLS Interlock Slide Hammer: T/N 07AAC-S84A100 NOTE: ^ An initial quantity of Permalube grease to lubricate the sliding surface of the interlock lever is included with the slide hammer. To order more Permalube, use P/N 08734-0030. ^ To order a replacement clamping bolt for the slide hammer, use T/N 07AAC-S84A400. WARRANTY CLAIM INFORMATION Failed Part: P/N 35100-SDA-A31 Defect Code: 5GC00 Symptom Code: R4400 Page 5518 Braking Sensor/Switch: Description and Operation Brake Pedal Position Switch The brake pedal position switch signals the ECM/PCM when the brake pedal is pressed. Page 4099 Shift Indicator: Diagnostic Aids General Troubleshooting Information General Troubleshooting Information Tips and Precautions Before Troubleshooting 1. Check applicable fuses in the appropriate fuse/relay box. 2. Check the battery for damage, state of charge, and clean and tight connections. NOTE: 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. Handling Connectors - Make sure the connectors are clean and have no loose wire terminals. - Make sure multiple cavity connectors are packed with dielectric grease (except watertight connectors). - All connectors have push-down release type locks (A). - Some connectors have a clip on their side used to attach them to a mount bracket on the body or on another component. This clip has a pull type lock. - Some mounted connectors cannot be disconnected unless you first release the lock and remove the connector from its mount bracket (A). - Never try to disconnect connectors by pulling on their wires; pull on the connector halves instead. - Always reinstall plastic covers. Locations Locations Keyless/Power Door Lock System Component Location Index Page 8629 ^ Going from front to back, use the middle lock pin to set the first cam to the appropriate key code number in the code book. (The cam is properly set when the number on the cam lines up with the red scribe mark on the clamp unit.) ^ Slide the lock pin through the notch in the cam. (This locks the cam in place.) ^ Keep doing this for each of the remaining cams in the set until all the cams are set and locked, then push the lock pin all the way in. Repeat this process to set and lock the cams for the right cam set. NOTE: Make sure you set the MIS cam in the right cam set for the type of key you are cutting. For a master key, set the cam to M; for a valet key, set it to S. When you are done, push all the cam blades to the left until they touch the cams in the left cam set. 10. Pull the vertical carriage lever toward you until the tracer touches the flat surface on the right side at the front of the cams. Gently twist the lever clockwise to lock the vertical carriage at this height. Do not overtighten the lever. 11. Turn on the cutter motor with the motor start switch. [NOTICE] ^ To avoid damaging the locking jaws while cutting, keep your hand off the vertical carriage lever. Pressure on the lever will change the cutting depth. * ^ To avoid breaking the cutter bit, never back up while cutting.* ^ Wear proper eye protection (safety glasses, goggles, etc.) 12. Use the clamp carriage lever and the tracer to follow the contours of the cam blades from front to back. (The cutter bit cuts the same contours into the right edge of the key blank, from head to tip.) Ignition/Locks - Cutting Sidewinder-Type Keys Technical Service Bulletin # 01-077 Date: 060419 Ignition/Locks - Cutting Sidewinder-Type Keys 01-077 April 19, 2006 Applies To: Models With Sidewinder-Type Keys - All Cutting Sidewinder-Type Keys With the MATRIX H Key Cutting Machine (Supersedes 01-077, dated January 12, 2005) Updated information is noted by asterisks. MATRIX H Key Cutting Machine, manufactured by Silca and supplied by Kaba Ilco Corporation, is a portable, power-operated tool that cuts sidewinder-type automotive keys exclusively. The machine lets you cut these keys either by copying or by code. The code function is designed and built to meet the Honda code requirements. No other similar machine has this capability. This service bulletin gives you information for ordering and servicing this special tool, and guides you through the entire key cutting process from setting up the machine to cutting the key blank. TOOL INFORMATION Order through the Honda Tool and Equipment Program: MATRIX H Key Cutting Machine: Model No. ILCMATRIXSH Cutter Bit: Model No. ILCF3O Fixed Jaw: Model No. ILCMTX-H Mobile Jaw (Right Side): Model No. ILCRTMTX-H Mobile Jaw (Left Side): Model No. ILCLTMTX-H *Remanufactured Clamp Unit: Model No. ILCMATRIXHCR* PARTS INFORMATION *For some models, there are two choices for sidewinder-type key blanks: ^ T-5 sidewinder key blanks ^ Honda sidewinder key blanks For other models, only Honda sidewinder key blanks can be used. See DETERMINING WHICH KEY TO USE to determine which key blank you should choose. Ordering T-5 key blanks through the Honda Tool and Equipment Program: T-5 Programmable Key Blank (Master): P/N ILC-35111-T-5H T-5 Programmable Key Blank (Valet): P/N ILC-35112-T-5H Practice Key Blanks (five per pack): ILC-35111DEMO* NOTE: Do not use practice key blanks for replacement purposes. Practice keys do not have an immobilizer chip. Continuously Variable Transmission Shift Interlock Switch: Testing and Inspection Continuously Variable Transmission Park Pin Switch Test 1. Remove the center console panel and center console. 2. Disconnect the park pin switch connector (4P). 3. Shift to the P position, then check for continuity between the No. 3 and No. 4 terminals. There should be no continuity. 4. Shift out of the P position, and check for continuity between terminals No. 3 and No. 4. There should be no continuity. 5. If the park pin switch is faulty, replace it. Page 9495 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. Circuits must be operating when checking voltage drop. 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. 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 off, 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 Self-Powered Test Light or DVOM 1. Remove the blown fuse and disconnect the battery and load. Page 784 symptom/indication goes away with a known-good ECM/PCM, replace the original ECM/PCM. Page 2588 Camshaft Position Sensor: Service and Repair CMP (TDC) Sensor Replacement 1. Remove the grommet (A) from the upper cover, and disconnect the camshaft position (CMP) (top dead center (TDC)) sensor connector (B). 2. Remove the upper cover (C). 3. Remove the CMP (TDC) sensor from the cylinder head. 4. Install the CMP (TDC) sensor in reverse order of removal. Page 3152 3. Strip the insulation off the end of the wire so the wire fits in the new terminal as shown. (If the wire has a wire seal, replace it with a new one from the kit.) NOTE: After stripping the end of the wire, make sure you did not cut any wire strands. If you did, cut the wire off even with the insulation, and strip it again. 4. Position the terminal in the crimping tool slot with the solid portion of the terminal toward the anvil and the open section toward the former. 5. Insert the wire in the terminal to the position shown in step 3. 6. Squeeze the tool with both hands until the stops make contact. 7. Crimp the insulation crimp. - If you do not have a wire seal, then use the next larger size crimp slot. Position the crimping tool over the insulation crimp section of the terminal, then squeeze the tool with both hands until the stops make contact. - If you have a wire seal, position the insulation crimp in the 5.5 crimping slot, then carefully squeeze the crimp closed until its ends are touching and making a full-circle shape. Locations Crankshaft Position Sensor: Locations PGM-FI System - Component Location Index Page 3604 12. Pull the vertical carriage lever toward you while you position the tracer on the right edge of the original key at its head, using the clamp carriage lever. Let the cutter bit cut into the key blank, then stop. Gently twist the lever clockwise to lock the vertical carriage at this height. Do not overtighten the lever. 13. Use the clamp carriage lever and the tracer to follow the contours of the original key. (The cutter bit cuts the same contours into the key blank.) Working from right to left, follow the right edge of the original key from head to tip, then the left edge of the key from tip to head. Turn off the cutter motor. 14. Reposition the tracer on the right edge of the original key at its head, using the clamp carriage lever. Turn on the cutter motor. Retrace the key from head to tip, then from tip to head. (This retracing cleans up the cuts on the key.) Turn off the cutter motor. 15. Release the vertical carriage lever. Open the jaw and remove only the new key. Make sure the jaw is free of any metal shavings or debris, then turn the new key over and slide the key with its blank side up into the jaw up to the key stop. Close the jaw to lock the key into place. 16. Turn on the cutter motor, and repeat steps 12 thru 14 to cut both edges of the other side of the key. 17. When you are finished making the required cuts, turn off the cutter motor, and release the vertical carriage lever. Open the jaws, and remove the keys. 18. Use a wire brush to smooth the cut surfaces on the new key. 19. Make sure the key works in the ignition switch and all the locks. If the key does not work, recut the key, and try it again. 20. Depending on the type of key blank you have used, do this: ^ If you have used a Honda key blank, add the transponder code of the new key to the immobilizer system with the Honda Diagnostic System (HDS). ^ If you have used a T-5 programmable key blank ("T-5" stamped on the shank), code the key's transponder with the Ilco Immobilizer Key Code Duplicator (see S/B 99-053, Ilco Immobilizer key Code Duplicator). Cutting Procedure - By Code 1. Press the ON/OFF button in the middle of the setting unit keypad. (This powers up the keypad.) 2. Turn the clamp unit lock lever to the left to release the clamp unit, and slide it to the right until the bottom left side is flush with the base edge. Turn the lever to the right to lock the clamp unit in place. Loosen the lateral and spring tension adjustment knobs on the clamp carriage. Page 8806 Door Switch: Locations Entry Light Control System Component Location Index Page 912 78. Side Impact Sensor, Front Passenger's (Sedan) 79. Side Impact Sensor, Passenger's (Coupe) Page 5838 67. Under Left Side Of Dash Page 6854 1. On Accords and Pilots, remove the front passenger's seat-back panel by prying out the bottom. Replace the two lower clips. 2. On all models except Accords and Pilots, unzip the two seat cover zippers on the back of the front passenger's seat. 3. Pull back the seat-back cover from the left side bolster to access the OPDS unit cover. 4. Remove the OPDS unit cover from the seat frame. 5. Check the part number of the installed OPDS unit. Page 1333 Valve Clearance: Adjustments Adjustment NOTE: Adjust the valves only when the cylinder head temperature is less than 100°F (38°C). 1. Remove the ignition coil cover, then remove the four ignition coils. 2. Remove the throttle cable clamps and harness holder from the cylinder head cover. 3. Remove the cylinder head cover. 4. Remove the grommet from the upper cover, and disconnect the camshaft position (CMP) (top dead center (TDC)) sensor connector. Remove the upper cover. 5. Set the No. 1 piston at TDC. The "UP" mark (A) on the camshaft pulley should be at the top, and the TDC marks (B) on the pulley should line up with the top edge of the head. 6. Select the correct thickness feeler gauge for the valves you're going to check. Intake: 0.18 - 0.22 mm (0.007 - 0.009 inch) Exhaust: 0.23 - 0.27 mm (0.009 - 0.011 inch) Adjusting screw location: Page 7018 2. Remove the center anchor bolts (A), and remove the seat belt buckles (B). 3. Remove the rear shelf, 2-door, 4-door. 4. Remove the retractor mounting self-tapping ET screw (A), and the retractor bolt (B), then remove the center belt (C) and retractor (D). 5. Remove the protector (A). Page 7700 Trunk / Liftgate Latch: Service and Repair Trunk Lid Latch Replacement NOTE: Put on gloves to protect your hands. 1. Disconnect the cylinder rod from the lock cylinder. 2. Disconnect the trunk lid opener cable (A), and remove the bolts securing the trunk lid latch (B). Take care not to kink the opener cable. 3. Disconnect the trunk lid latch switch connector (C). 4. Pull the trunk lid latch (A) out with the cylinder rod (B), and disconnect the cylinder rod from the trunk lid latch. Take care not to bend or kink the cylinder rod. 5. Install the latch in the reverse order of removal, and note these items. - Make sure the connector is plugged in properly and the opener cable is connected properly. - Make sure the cable actuates the latch before you close the trunk lid. - Make sure the trunk lid opens properly and locks securely. Page 1526 Rear Window Defogger Component Location Index Page 3135 Transmission Position Switch/Sensor: Diagnostic Aids General Troubleshooting Information General Troubleshooting Information Tips and Precautions Before Troubleshooting 1. Check applicable fuses in the appropriate fuse/relay box. 2. Check the battery for damage, state of charge, and clean and tight connections. NOTE: 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. Handling Connectors - Make sure the connectors are clean and have no loose wire terminals. - Make sure multiple cavity connectors are packed with dielectric grease (except watertight connectors). - All connectors have push-down release type locks (A). - Some connectors have a clip on their side used to attach them to a mount bracket on the body or on another component. This clip has a pull type lock. - Some mounted connectors cannot be disconnected unless you first release the lock and remove the connector from its mount bracket (A). - Never try to disconnect connectors by pulling on their wires; pull on the connector halves instead. - Always reinstall plastic covers. Page 3836 3. Strip the insulation off the end of the wire so the wire fits in the new terminal as shown. (If the wire has a wire seal, replace it with a new one from the kit.) NOTE: After stripping the end of the wire, make sure you did not cut any wire strands. If you did, cut the wire off even with the insulation, and strip it again. 4. Position the terminal in the crimping tool slot with the solid portion of the terminal toward the anvil and the open section toward the former. 5. Insert the wire in the terminal to the position shown in step 3. 6. Squeeze the tool with both hands until the stops make contact. 7. Crimp the insulation crimp. - If you do not have a wire seal, then use the next larger size crimp slot. Position the crimping tool over the insulation crimp section of the terminal, then squeeze the tool with both hands until the stops make contact. - If you have a wire seal, position the insulation crimp in the 5.5 crimping slot, then carefully squeeze the crimp closed until its ends are touching and making a full-circle shape. Page 5192 Locations Camshaft Position Sensor: Locations PGM-FI System - Component Location Index Page 8130 Programming the Transmitter NOTES: ^ The system accepts up to three transmitters. The transmitter codes are stored in a stacking-type memory. If a fourth transmitter code is programmed, the code for the first transmitter is erased. ^ Entering the programming mode cancels all learned transmitter codes, so none of the previously programmed transmitters will work. You must reprogram all of the transmitters once you are in the programming mode. ^ You must complete each step within 4 seconds of the previous step to keep the system from exiting the programming mode. Program the transmitters within 10 seconds. 1. Turn the ignition switch to ON (II). 2. Press the "Lock" or "Unlock" button on one of the transmitters. (An unprogrammed transmitter can be used for this step.) 3. Turn the ignition switch to LOCK (0). 4. Repeat steps 1 2, and 3 two more times using the same transmitter used in step 2. 5. Turn the ignition switch to ON (II). 6. Press the "Lock" or "Unlock" button on the same transmitter. Make sure the power door locks cycle to confirm that the system is in programming mode. 7. Within 10 seconds, press the "Lock" or "Unlock" button on each transmitter. Make sure the power door locks cycle after you press each transmitter button to confirm that the system accepted the transmitter's code. 8. Turn the ignition switch to LOCK (0) to exit the programming mode. Ordering a Transmitter Transmitters can be ordered only by authorized Honda dealers. Order them from American Honda using normal parts ordering procedures. Batteries for the Transmitter The battery number is CR2025. Each transmitter uses one battery. 99-04 Odyssey EX 1999-00 Odyssey EX with factory-installed keyless entry system or dealer-installed security system *2001-04 Odyssey EX models with factory- installed security system* *Transmitter Identification Page 7361 84. Speaker, Passenger's Door (Coupe) 92. Tweeter, Left Or Right (Coupe EX; '05 Sedan: SE) Page 13 ^ Within 1 to 4 seconds, turn the ignition switch to LOCK (0). ^ Within 1 to 4 seconds, turn the ignition to ON (II). ^ Within 1 to 4 seconds, push the transmitter lock or unlock button. ^ Confirm you can hear the sound of the door lock actuators. Within 1 to 4 seconds, push the transmitter lock or unlock button again. ^ Within 10 seconds, aim the transmitters (up to two additional ones) whose codes you want to store at the receiver, and press the transmitter lock or unlock button. Confirm that you can hear the sound of the door lock actuators after each transmitter code is stored. ^ Turn the ignition switch to LOCK (0), and pull out the key. 4. Confirm proper operation of the transmitters. Disclaimer Page 1016 5. Attach the slide hammer to the interlock lever pin, and tighten the slide hammer clamping bolt. Then use the slide hammer to remove the pin. Discard the pin, the lever, and the spring. 6. Wipe off any debris from the lever's sliding surface on the ignition switch with a clean cloth or a cotton swab. NOTE: To keep debris out of the ignition switch, do not clean it with compressed air. Page 5698 15. Insert the brush (A) into the brush holder, and bring the brush into contact with the commutator, then attach a spring scale (B) to the spring (C). Measure the spring tension at the moment the spring lifts off the brush. 16. Pry back each brush spring with a screwdriver, then position the brush about halfway out of its holder, and release the spring to hold it there. 17. Install the armature in the housing, and install the brush holder. Next, pry back each brush spring again, and push the brush down until it seats against the commutator, then release the spring against the end of the brush. NOTE: To seat new brushes, slip a strip of # 500 or # 600 sandpaper, with the grit side up, between the commutator and each brush, and smoothly rotate the armature. The contact surface of the brushes will be sanded to the same contour as the commutator. Page 5762 Under-hood Fuse/Relay Box (2-door) Page 1034 5. Attach the slide hammer to the interlock lever pin, and tighten the slide hammer clamping bolt. Then use the slide hammer to remove the pin. Discard the pin, the lever, and the spring. 6. Wipe off any debris from the lever's sliding surface on the ignition switch with a clean cloth or a cotton swab. NOTE: To keep debris out of the ignition switch, do not clean it with compressed air. Page 9014 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. Test Equipment 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. Page 6271 64. Apply multipurpose grease to the steering rack teeth, then insert the steering rack (A) into the cylinder (B). Be careful not to damage to inner surface of the cylinder wall and bushing with the rack edges. 65. Set the cylinder (A) in a press, then press the cylinder end seal (B) into the bottom of the cylinder until the mark (C) on the rack meets the edges (D) of the cylinder. 66. Coat the inside and outside surfaces of the new cylinder end seal (A) with power steering fluid. 67. Install the cylinder end seal onto the steering rack (B) with its grooved side (C) toward the piston. Push in the cylinder end seal with your finger. 68. Place the backup ring (D) on the cylinder end seal with its flat side facing upward. Then drive the backup ring in with the appropriate size socket wrench until the its surface is below the circlip groove (E). install the snap ring (F) in the groove. Page 9366 1. Remove the terminal. 2. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE G: 1. Remove the terminal. 2. Go to HOW TO INSTALL NEW TERMINALS. How to Install New Terminals HOW TO INSTALL NEW TERMINALS 1. Carefully match the old terminal with a new one from the terminal repair kit. Choose the correct replacement terminal based on the wire size range the terminal will accommodate. NOTE: If the replacement terminal quantities are low, reorder them by using the terminal part number listed on the inside lid of the terminal repair kit. Replacement terminals are available through your parts department using normal parts ordering procedures. 2. Depending on the size of the wire you are repairing, use the proper size slot in the crimping tool. Page 7331 NOTE: It is very important that you fill out this form fully and accurately. An accurate explanation of the problem and conditions helps the manufacturer to duplicate the problem, speeding the repair, and reducing the number of No Trouble Found" (NTF) units. Disclaimer Page 2457 Intake Air Temperature Sensor: Description and Operation Intake Air Temperature (IAT) Sensor The IAT sensor is a temperature dependent resistor (thermistor). The resistance of the thermistor decreases as the intake air temperature increases. Page 7235 Page 4728 12. Loosen the damper pinch bolts (A) while holding the nuts (B), and remove the bolts and nuts. 13. Remove the driveshaft outboard joint (C) from the knuckle (D) by tapping the driveshaft end (E) with a plastic hammer while pulling the knuckle outward, then remove the knuckle. NOTE: Do not pull the driveshaft end outward. The driveshaft joint may come off. 14. Separate the hub (A) from the knuckle (B) using the special tool and a hydraulic press. Be careful not to deform the splash guard. Hold onto the hub to keep it from falling when pressed clear. 15. Press the wheel bearing inner race (A) out of the hub (B) using the special tool, a commercially available bearing separator (C), and a press. Page 9211 Dome Lamp: Connector Views 102. Ceiling Light (EX), Rear 103. Ceiling Light (except EX) 137. Ceiling Light/spotlights (EX) Technician Safety Information Fuel: Technician Safety Information WARNING: Do not smoke while working on the fuel system. Keep open flames or sparks away from your work area. Be sure to relieve fuel pressure while the ignition switch is off. Page 170 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. Test Equipment 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. Valves, Springs and Valve Seals Removal Valve: Service and Repair Valves, Springs and Valve Seals Removal Removal Identify the valves and valve springs as they are removed, so that each item can be reinstalled in its original position. 1. Using an appropriate-sized socket (A) and plastic mallet (B), lightly tap the valve retainer to loosen the valve keepers. 2. Install the spring compressor. Compress the spring and remove the valve keepers. 3. Install the valve guide seal remover. Page 9563 Door Switch: Diagrams 4. Door Switch, Driver's 5. Door Switch, Front Passenger's (Sedan) 6. Door Switch, Left Rear Or Right Rear 7. Door Switch, Passenger's (Coupe) Locations Gasoline Page 5535 Wheel Speed Sensor: Testing and Inspection Inspection 1. Inspect the front and rear pursers for chipped or damaged teeth. 2. Measure the air gap between the wheel sensor and the purser all the way around while rotating the purser. Remove the rear brake disc to measure the gap on the rear wheel sensor. If the gap exceeds 1.0 mm (0.04 inch), check for a bent suspension arm. Standard: Front: 0.4 - 1.0 mm (0.02 - 0.04 inch) Rear: 0.2 - 1.0 mm (0.01 - 0.04 inch) Page 2816 Diodes Light Emitting Diode (LED) Motor Pressure Sensor Page 8911 38. Measure voltage between ECM/PCM connector terminal E7 and body ground. Is there battery voltage? YES - Go to step 42. NO - Go to step 39. 39. Remove PGM-FI main relay 1 (A). 40. Measure voltage between PGM-FI main relay 1 4P connector terminal No.4 and body ground. Is there battery voltage? YES - Go to step 41. NO - Repair open in the wire between the No.6 ECU (ECM/PCM) (15A) fuse and PGM-FI main relay 1. Ignition/Locks - Cutting Sidewinder-Type Keys Technical Service Bulletin # 01-077 Date: 060419 Ignition/Locks - Cutting Sidewinder-Type Keys 01-077 April 19, 2006 Applies To: Models With Sidewinder-Type Keys - All Cutting Sidewinder-Type Keys With the MATRIX H Key Cutting Machine (Supersedes 01-077, dated January 12, 2005) Updated information is noted by asterisks. MATRIX H Key Cutting Machine, manufactured by Silca and supplied by Kaba Ilco Corporation, is a portable, power-operated tool that cuts sidewinder-type automotive keys exclusively. The machine lets you cut these keys either by copying or by code. The code function is designed and built to meet the Honda code requirements. No other similar machine has this capability. This service bulletin gives you information for ordering and servicing this special tool, and guides you through the entire key cutting process from setting up the machine to cutting the key blank. TOOL INFORMATION Order through the Honda Tool and Equipment Program: MATRIX H Key Cutting Machine: Model No. ILCMATRIXSH Cutter Bit: Model No. ILCF3O Fixed Jaw: Model No. ILCMTX-H Mobile Jaw (Right Side): Model No. ILCRTMTX-H Mobile Jaw (Left Side): Model No. ILCLTMTX-H *Remanufactured Clamp Unit: Model No. ILCMATRIXHCR* PARTS INFORMATION *For some models, there are two choices for sidewinder-type key blanks: ^ T-5 sidewinder key blanks ^ Honda sidewinder key blanks For other models, only Honda sidewinder key blanks can be used. See DETERMINING WHICH KEY TO USE to determine which key blank you should choose. Ordering T-5 key blanks through the Honda Tool and Equipment Program: T-5 Programmable Key Blank (Master): P/N ILC-35111-T-5H T-5 Programmable Key Blank (Valet): P/N ILC-35112-T-5H Practice Key Blanks (five per pack): ILC-35111DEMO* NOTE: Do not use practice key blanks for replacement purposes. Practice keys do not have an immobilizer chip. Page 2152 - Remove clips carefully; don't damage their locks (A). - Slip pliers (A) under the clip base and through the hole at an angle, then squeeze the expansion tabs to release the clip. - After installing harness clips, make sure the harness doesn't interfere with any moving parts. - Keep wire harnesses away from exhaust pipes and other hot parts, from sharp edges of brackets and holes, and from exposed screws and bolts. - Seat grommets in their grooves properly (A). Do not leave grommets distorted (B). Testing and Repairs - Do not use wires or harnesses with broken insulation. Replace them or repair them by wrapping the break with electrical tape. - After installing parts, make sure that no wires are pinched under them. - When using electrical test equipment, follow the manufacturer's instructions and those described. - If possible, insert the probe of the tester from the wire side (except waterproof connector). - Use back probe adaptor 07TAZ-001020A. - Refer to the instructions in the Honda Terminal Kit for identification and replacement of connector terminals. Five-Step Troubleshooting Five-Step Troubleshooting 1. Verify The Complaint Page 7260 Keyless Entry Transmitter: Service and Repair Transmitter Programming Storing transmitter codes: The codes of up to three transmitters can be read into the keyless receiver unit memory. (If a fourth code is stored, the code which was input first will be erased.) NOTE: It is important to maintain the time limits between the steps. Make sure the doors and the trunk are closed. 1. Turn the ignition switch ON (II). 2. Within 1 to 4 sec., push the transmitter lock or unlock button with the transmitter aimed at the receiver in the multiplex control unit behind the driver's side of the dash. 3. Within 1 to 4 sec., turn the ignition switch OFF. 4. Within 1 to 4 sec., turn the ignition switch ON (II). 5. Within 1 to 4 sec., push the transmitter lock or unlock button with the transmitter aimed at the receiver in the multiplex control unit behind the driver's side of the dash. 6. Within 1 to 4 sec., turn the ignition switch OFF. 7. Within 4 sec., turn the ignition switch ON (II). 8. Within 1 to 4 sec., push the transmitter lock or unlock button with the transmitter aimed at the receiver in the multiplex control unit behind the driver's side of the dash. 9. Within 1 to 4 sec., turn the ignition switch OFF. 10. Within 4 sec., turn the ignition switch ON (II). 11. Within 1 to 4 sec., push the transmitter lock or unlock button with the transmitter aimed at the receiver in the multiplex control unit behind the driver's side of the dash. 12. Confirm you can hear the sound of the door lock actuators. Within 1 to 4 sec., push the transmitter lock or unlock button again. 13. Within 10 sec., aim the transmitters (up to two additional ones) whose codes you want to store at the receiver, and press the transmitter lock or unlock buttons. Confirm that you can hear the sound of the door lock actuators after each transmitter code is stored. 14. Turn the ignition switch OFF, and pull out the key. 15. Confirm proper operation of the transmitter. Page 8767 1. Remove the secondary lock from the male terminal half. 2. Remove the secondary lock from the female terminal half. 3. Remove the terminal (same procedure for male and female). 4. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE C: 1. Remove the secondary lock. Page 7805 PARTS INFORMATION REQUIRED MATERIALS WARRANTY CLAIM INFORMATION In warranty: The normal warranty applies. Failed Part: P/N 72185-S9A-003 H/C 6896716 Defect Code: 00503 Symptom Code: 07902 Skill Level: Repair Technician Body - Trunk Lid Hard to Close Trunk / Liftgate Latch: Customer Interest Body - Trunk Lid Hard to Close 02-061 November 5, 2004 Applies To: See VEHICLES AFFECTED Trunk Lid is Difficult to Close (Supersedes 02-061, dated July 23, 2004) Updated information is shown with asterisks. SYMPTOM The trunk lid may be difficult to close or won't latch closed. PROBABLE CAUSE The trunk lid may be misaligned, and the trunk lid opener cable, trunk lid latch, lock cylinder, lock rod, and/or the trunk lid latch striker may need adjustment or replacement. VEHICLES AFFECTED CORRECTIVE ACTION Adjust the trunk lid and/or the trunk lid latch, or replace components as needed. PARTS INFORMATION Page 6258 Steering Gear: Service and Repair Overhaul Steering Gearbox Overhaul Special Tools Required ^ Cylinder end seal remover attachment 07NAD-SR30200 or 07NAD-SR3020A ^ Driver, 27 mm 07ZAF-S5A0100 ^ Valve seal ring sizing tool 07NAG-SR30900 or 07NAD-SR3020A ^ Sleeve seal ring guide 07YAG-S2X0100 ^ Sleeve seal ring sizing tool, 36 mm 07ZAG-S5A0100 ^ Attachment, 32 x 35 mm 07746-0010100 ^ Driver 07749-0010000 ^ Piston seal ring guide 07GAG-SD40100 or 07GAG-SD4010A ^ Piston seal ring sizing tool 07GAG-SD40200 or 07GAG-SD4020A ^ Pilot collar 07GAF-PH70100 ^ Locknut wrench 07ZAA-S5A0100 ^ Driver handle 07NAD-SR30101 ^ Seal slider 07974-6890801 ^ Valve seal ring guide 07ZAG-S5A0200 ^ Pincers, Oetiker 1098 or equivalent, commercially available. Page 4910 156. A/T Reverse Relay (A/T, CVT) 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 7476 9. Troubleshoot the DTC(s) in the order indicated using the shown charts. If a faulty control unit is suspected, substitute it with a known good part and recheck for DTCs. - If the DTC(s) is still present, go to the next step instead for the DTC. - If the DTC(s) is no longer present, replace the original part. Note: Before replacing a Faulty ECM/PCM make sure it has the latest software revision. Update if necessary before swapping or replacing. Made 2 Test 1. From Mode 1, disconnect the special tool from the multiplex inspection connector for 5 to 10 seconds, and then reconnect it. 2. The spotlight and ceiling light should come on for 2 seconds, go out, then blink twice, 0.2 seconds each time. The system is now in mode 2. Page 2728 7. Remove the four screws that hold the two fuses, and remove the fuses. 8. Release the tab that holds the ELD, and pull up on the ELD to remove it. 9. Remove the bus bar from the ELD, and insert the bar into the new ELD. 10. Install the new ELD and bus bar into the fuse/relay box. 11. Reinstall the two fuses. 12. Reinstall the 3P ELD connector and the lower fusel relay box cover. 13. Reinstall the fuse/relay box onto its holder. CR-V only: Reinstall the wire harness clip onto the holder. 14. Reinstall the fuse/relay box cover. 15. Reconnect the negative battery cable. 16. Do the idle learn procedure: ^ Make sure all electrical items (A/C, audio unit, defogger, lights, etc.) are off. Page 3559 Crankshaft Position Sensor: Description and Operation Crankshaft Position (CKP) Sensor The CKP sensor detects engine speed, and is used by the ECM/PCM to determine ignition timing and timing for fuel injection of each cylinder. Page 3478 117. IAC Valve Page 1859 Valve Clearance: Adjustments Adjustment NOTE: Adjust the valves only when the cylinder head temperature is less than 100°F (38°C). 1. Remove the ignition coil cover, then remove the four ignition coils. 2. Remove the throttle cable clamps and harness holder from the cylinder head cover. 3. Remove the cylinder head cover. 4. Remove the grommet from the upper cover, and disconnect the camshaft position (CMP) (top dead center (TDC)) sensor connector. Remove the upper cover. 5. Set the No. 1 piston at TDC. The "UP" mark (A) on the camshaft pulley should be at the top, and the TDC marks (B) on the pulley should line up with the top edge of the head. 6. Select the correct thickness feeler gauge for the valves you're going to check. Intake: 0.18 - 0.22 mm (0.007 - 0.009 inch) Exhaust: 0.23 - 0.27 mm (0.009 - 0.011 inch) Adjusting screw location: How to Remove the PCM Control Module: Service and Repair How to Remove the PCM How to Remove the PCM for Testing 1. Remove the passenger's dashboard lower cover, the right kick panel, and the glove box. 2. Remove the bolt. Cut the plastic cross brace in the glove box opening with diagonal cutters in the area shown, and discard it. 3. Remove the relays (A), then remove the bolts and the glove box frame (B). 4. Remove the gray 20P PCM wire harness connector from the PCM mounting bracket. Remove the PCM mounting bolt (A) and the bracket. 5. Remove the nuts, then remove the PCM (B). 6. Install the PCM in the reverse order of removal. Page 7466 13. Plug in the heat gun, and turn it on. Start at the middle of the splice connector, and move the gun toward the ends as the tube shrinks. Apply heat evenly by rotating the curved heat spreader around the splice connector. Shrinking is complete when a small amount of sealant appears at each end of the tube. Pigtail Terminal Selection Chart PIGTAIL TERMINAL SELECTION CHART Select the proper size pigtail terminal by matching the replacement terminal part number and the wire size being repaired to the corresponding pigtail terminal part number. Then use the color (size) splice connector listed. In some instances you may also have to match the wire seal style to select the proper pigtail terminal. Pigtail terminals are available through your parts department, in quantities of 10, using normal parts ordering procedures. Checking For Poor Fir of Terminals CHECKING FOR POOR FIT OF TERMINALS Loose terminal fit can cause a number of intermittent problems in electrical circuits. By using the Terminal Inspection Feeler Tool Set you can inspect the terminal fit between the two matching connectors without removing the terminals from the connector body. 1. Find the terminal tool that best matches the male terminal in the mating connector. Page 8427 Sunroof / Moonroof Drain: Service and Repair Frame and Drain Tube Replacement Frame and Drain Tube Replacement 1. Remove these items: - Headliner - Moonroof glass 2. Put on gloves to protect your hands. Disconnect the motor connector (A), open/close-tilt/close switch connector (B), and the drain tubes (C), and remove the moonroof relays (D). 3. Remove the interior harness (E) by detaching the harness clips (F). 4. With an assistant holding the frame (G), remove the bolts, starting at the rear, and release the rear hooks (H) by moving the frame forward, then remove the frame. 5. With the help of an assistant, carefully remove the frame through the front door opening. Take care not to scratch the interior trim and body, or tear the seat covers. 6. To remove a front drain valve (A) from the body, remove the kick panel, left or right, 2-door, 4-door. Tie a string to the end of the drain tube, then pull the front drain tube (B) down out of the A-pillar. Page 4561 Fluid - CVT: Fluid Type Specifications A/T Fluid Type ..................................................................................................................................................... .......................................................... Honda ATF-Z1 Honda Service News Notice: If you're replacing transmission fluid in a CVT-equipped vehicle, or just topping it off, make sure you're using the new CVT fluid (P/N 08200-9006). From here on, DON'T put ATF-Z1 in a CVT. If you're topping off a CVT that's already got ATF-Z1, there's no need for concern; this fluid is compatible with ATF-Z1. All CVT-equipped Hondas starting with the 2006 models and onward will be factory-filled with the new CVT fluid. Page 6571 8. Remove the mounting nut from the heater unit. Take care not to damage or bend the fuel lines and the brake lines, etc. 9. Remove the dashboard. 10. Remove the blower unit. 11. Disconnect the drain hose (A), then remove the mounting bolts and the heater unit (B). 12. Remove the self-tapping screws and the expansion valve cover (A). With air conditioning; carefully pull out the evaporator core (B) so you don't bend the inlet and outlet pipes. Remove the self-tapping screws and the flange cover (C), then remove the grommet (D), and carefully pull out the heater core (E) so you don't bend the inlet and outlet pipes. 13. Install the heater core and the evaporator core (with A/C) in the reverse order of removal. 14. Install the heater unit in the reverse order of removal, and note these items: - Do not interchange the inlet and outlet heater hoses, and install the hose clamps securely. Page 2372 Fuel Pump Relay: Description and Operation PGM-FI Main Relay 1 and 2 The PGM-FI relay consists of two separate relays. PGM-FI main relay 1 is energized whenever the ignition switch is ON (II) which supplies battery voltage to ECM/PCM, power to the injectors, and power for PGM-FI main relay 2. PGM-FI main relay 2 is energized to supply power to the fuel pump for 2 seconds when the ignition switch is turned ON (II), and when the engine is running. Page 5853 234. Under-dash Fuse/Relay Box Part 6 Page 3865 143. Park Pin/Shift Switch (A/T) Page 690 Camshaft Position Sensor: Service and Repair CMP (TDC) Sensor Replacement 1. Remove the grommet (A) from the upper cover, and disconnect the camshaft position (CMP) (top dead center (TDC)) sensor connector (B). 2. Remove the upper cover (C). 3. Remove the CMP (TDC) sensor from the cylinder head. 4. Install the CMP (TDC) sensor in reverse order of removal. Page 2318 DTC P1861 thru P2238 Page 4251 Transmission Speed Sensor: Service and Repair Countershaft Speed Sensor Replacement Countershaft Speed Sensor Replacement 1. Disconnect the countershaft speed sensor connector. 2. Remove the countershaft speed sensor (A). 3. Install the new countershaft speed sensor with the new O-ring (B). 4. Check the countershaft speed sensor connector for rust, dirt, or oil, then connect the connector securely. Page 8853 Air Bag(s) Arming and Disarming: Vehicle Damage Warnings 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. - To prevent damage to the airbag assembly, keep free from any oil, grease, detergent, or water. - Store the removed airbag on a secure, fiat surface away from any high heat source (exceeding 200 °F / 93 °C). Page 8352 Paint: Service and Repair Plastic Parts Paint Features of Plastic Material Features of Plastic Material Locations Brake Fluid Level Sensor/Switch: Locations Gauges Component Location Index (Part 1 Of 4) Page 5487 13. Parking Brake Switch Page 6983 Air Bag(s) Arming and Disarming: Service and Repair Connector Disconnection / Connection Disconnecting System Connectors Before removing a front airbag, side airbag, or other SRS related devices (the SRS unit, the cable reel, front sensor, the side impact sensors, the seat belt buckle tensioners, and the seat belt tensioner connector), disconnecting connectors from related devices, or removing the dashboard or the steering column, disconnect the airbag connectors or the side airbag connectors to prevent accidental deployment. Turn the ignition switch OFF, disconnect the negative cable from the battery, and wait at least 3 minutes before beginning the following procedures. - Before disconnecting SRS unit connector A (A) from the SRS unit, disconnect the driver's airbag 4P connector (C), the front passenger's airbag 4P connector (D), the driver's seat belt tensioner 2P connector (F), and the front passenger's seat belt tensioner 2P connector (G). - Before disconnecting SRS unit connector B (1) from the SRS unit, disconnect both side airbag 2P connectors (L, M) and both seat belt buckle tensioner 4P connectors (J, K). - Before disconnecting the cable reel 4P connector (B), disconnect the driver's airbag 4P connector (C). - Before disconnecting the floor wire harness 4P connector (E), disconnect both seat belt tensioner 2P connectors (F, G). 1. Disconnect the battery negative cable, and wait at least 3 minutes. Driver's Airbag Page 6510 Blower Motor Relay Type 1, Type 2 Check for continuity between the terminals. - There should be continuity between the No.1 and No.3 terminals when power and ground are connected to the No.2 and No.4 terminals. - There should be no continuity between the No.1 and No.3 terminals when power is disconnected. Five-terminal type Check for continuity between the terminals. - There should be continuity between the No.1 and No.2 terminals when power and ground are connected to the No.3 and No.5 terminals. - There should be continuity between the No.1 and No.4 terminals when power is disconnected. Page 1274 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 1735 Rocker Arm Assembly: Service and Repair Rocker Arms and Shafts Disassembly/Reassembly Disassembly/Reassembly NOTE: ^ Identify parts as they are removed to ensure reinstallation in original location. ^ Inspect the rocker shafts and rocker arms. ^ The rocker arms must be installed in the same positions if reused. ^ When removing or installing the rocker arm assembly, do not remove the camshaft holder bolts. The bolts will keep the holders, springs and rocker arms on the shaft. ^ Prior to reassembling, clean all the parts in solvent, dry them, and apply lubricant to any contact points. ^ Bundle the intake rocker arm assemblies with rubber bands to keep them together as a set. Page 9191 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. Test Equipment 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. Page 50 Part 1 5. Reconnect all connections to the under-dash fuse/relay box, and make these input tests at the appropriate connectors on the under-dash fuse/relay box. If any test indicates a problem, find and correct the cause, then recheck the system. - If all the input tests prove OK, go to step 6. Part 2 Page 2694 Camshaft Position Sensor: Description and Operation Camshaft Position (CMP) Sensor (Top Dead Center (TDC) Sensor) The CMP (TDC) sensor detects the position of the No.1 cylinder as a reference for sequential fuel injection to each cylinder. Key Beeper, Light Chime & Ceiling Light Don't Work Key Reminder Switch: Technical Service Bulletins Key Beeper, Light Chime & Ceiling Light Don't Work SOURCE: Honda Service News April 2003 TITLE: Key Beeper, Light Chime, Ceiling Light Don't Work APPLIES TO: 2001-03 Civic, 2002-03 CR-V SERVICE TIP: If the ignition key-in beeper, the headlights-on chime, the ceiling light, and the driver's-dooropen indicator are all on the fritz check the driver's door switch in the doorjamb. A faulty door switch can cause all of these symptoms. Description and Operation Fuel Cut Control Unit: Description and Operation Fuel Cut-off Control During deceleration with the throttle valve closed, current to the injectors is cut off to improve fuel economy at speeds over 850 rpm. Fuel cut-off action also occurs when engine speed exceeds 6,900 rpm, regardless of the position of the throttle valve, to protect the engine from over-revving. With A/T model, when the vehicle is stopped, the PCM cuts the fuel at engine speeds over 5,000 rpm. Page 8775 8. Inspect the quality of the wire crimp. If it has any of the following NO GOOD crimps, cut it off and start over. 9. Insert the terminal into the connector. Make sure the wire seals are pushed all the way into the connector. Lightly pull on the wires to make sure the terminal is locked into place. 10. Close or insert the secondary terminal lock, if applicable, and reconnect the connector. How to Install Pigtail Terminals HOW TO INSTALL PIGTAIL TERMINALS Pigtail terminals (short pieces of wire with a factory crimped terminal) are used when the wire is too short or when access to the connector is too restricted to make a terminal repair. NOTE: To replace just a connector terminal, go to How to Replace Connector Terminals. IMPORTANT SAFETY INFORMATION: On some models, the SRS wires are in a separate harness. If the SRS harness is damaged, replace the harness; do not repair it. On other models, wire harnesses include yellow SRS wires. If any SRS wire is damaged, replace the entire harness; do not repair it. 1. Remove the damaged or faulty terminal from the connector. Use the proper removal tool from Pin Tool Set. Page 160 Splices Components Ground - "G" Air Bag Disarming and Arming Air Bag(s) Arming and Disarming: Service and Repair Air Bag Disarming and Arming 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. Specifications Brake Drum: Specifications Brake drum I.D. Service Limit ................................................................................................................................................... 199.9 - 200.0 mm (7.870 - 7.874 inch) Page 5799 Fuse Block: Service and Repair Removal and Installation SRS components are located in this area. Review the SRS component locations and precautions and procedures in the SRS section before performing repairs or service. Removal 1. Make sure you have the anti-theft code for the radio, then write down the frequencies for the radio's preset buttons. 2. Disconnect the battery negative cable, then disconnect the positive cable, and wait at least 3 minutes. 3. Remove the dashboard lower cover. 4. Disconnect the connectors from the fuse side of the under-dash fuse/relay box. 5. Remove the mounting bolt and slide the under-dash fuse/relay box (A) down from the bracket (B). 6. Disconnect the connectors from the back side of the under-dash fuse/relay box, and remove the fuse/relay box. NOTE: The SRS connector is a spring-loaded lock type. Installation 1. Install the under-dash fuse/relay box in the reverse order of removal and connect all connectors to the under-dash fuse/relay box. 2. Install the dashboard lower cover. 3. Connect both the negative cable and positive cable to the battery. 4. Enter the anti-theft code for the radio, then enter the customer's radio station presets. 5. Confirm that all systems work properly. 6. Do the ECM/PCM idle learn procedure. Page 5099 72. Shift Lock Solenoid (A/T) Page 5877 Under-hood Fuse And Relay Box (4-door) Page 6337 - Weld the damper housing and front side frame. - Weld the front damper extension and dashboard upper side member. - From the passenger compartment side, plug weld the holes in the dashboard lower, damper housing extension, and front damper extension. Page 1263 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 5037 Transmission Position Switch/Sensor: Testing and Inspection Transmission Range Switch Test Transmission Range Switch Test 1. Remove the transmission range switch harness connector (A) from the connector bracket (B), then disconnect the connector. 2. Check for continuity between terminals at the harness connector. There should be continuity between the terminals listed for each switch position. In the P position, between terminals: ^ No. 1 and No. 3 ^ No. 1 and No. 8 ^ No. 3 and No. 8 In the R position, between terminals: ^ No. 1 and No. 9 In the N position and between terminals: ^ No. 1 and No. 3 ^ No. 1 and No. 10 ^ No. 3 and No. 10 In the D position, between terminals: ^ No. 1 and No. 2 ^ No. 1 and No. 4 ^ No.2 and No.4 In the D3 position, between terminals: ^ No. 1 and No. 2 ^ No. 1 and No. 5 ^ No.2 and No.5 In the 2 position, between terminals: ^ No. 1 and No. 6 Page 586 Evaporator Temperature Sensor / Switch: Description and Operation How the Circuit Works The heater control panel controls the blower controls, air delivery, and A/C compressor controls automatically. With the ignition switch in ON (II), battery voltage is supplied through fuse 14. The control unit is grounded at G502. Evaporator Temperature Sensor The evaporator temperature sensor is located on the evaporator housing. If the temperature at the evaporator gets too cold, the evaporator temperature sensor sends a signal to the heater control panel to turn off the A/C compressor clutch. This prevents condensation from freezing on the evaporator fins and blocking air delivery into the passenger compartment. Page 9245 Hazard Flasher Relay: Testing and Inspection Turn Signal/Hazard Relay Input Test 1. Remove the turn signal/hazard relay (A) from the under-dash fuse/relay box (B). 2. Inspect the relay and fuse/relay box socket terminals to be sure they are all making good contact. - If the terminals are bent, loose, or corroded, repair them as necessary, and recheck the system. - If the terminals look OK, go to step 3. 3. Make these input tests at the fuse/relay box. - If any test indicates a problem, find and correct the cause, then recheck the system. - If all the input tests prove OK, the turn signal/hazard relay must be faulty; replace it. Page 1648 Be sure to first disconnect the negative cable from the vehicle with the discharged battery. Page 8293 21. Leave the key in the cylinder. Reinstall the plastic retainer and spring if you removed them in step 16. Hold the plastic retainer and spring on the housing, and insert the inner cylinder. Rotate it left and right to engage the spring to the inner cylinder. Make sure the spring is properly seated to the inner cylinder. 22. Install the arm with a new cylinder rod clip and a new E-clip. 23. Make sure the key can be inserted and removed easily, and that the cylinder turns with the key. Page 5341 98. Wheel Speed Sensor, Right Rear (EX, GX) Page 247 235. Under-dash Fuse/Relay Box Part 8 Page 1753 - Before connecting connectors, make sure the terminals (A) are in place and not bent. - Check for loose retainer (A) and rubber seals (B). - The backs of some connectors are packed with dielectric grease. Add grease if necessary. If the grease is contaminated, replace it. - Insert the connector all the way and make sure it is securely locked. - Position wires so that the open end of the cover faces down. Handling Wires and Harnesses - Secure wires and wire harnesses to the frame with their respective wire ties at the designated locations. Page 3349 4. Disconnect the vacuum hoses (A) from the EVAP canister (B), then plug the ports with plugs (C). 5. Disconnect the vacuum hose ID, from the EVAP canister vent shut valve (E), and connect a vacuum pump to the vacuum hose. 6. Pump the vacuum pump 80 times. - If the vacuum holds, go to step 7. - If the vacuum does not hold, go to step 10. 7. Connect a second vacuum pump to the fuel tank vapor signal tube (A). 8. Apply vacuum (1 pump) to the fuel tank vapor signal tube (A), then check the vacuum on the pump in step 6. - If the vacuum holds, replace the fuel tank vapor control valve. - If the vacuum is released, go to step 9. 9. Fill the fuel tank with fuel, then check for fuel in the EVAP two way valve (A), and fuel tank vapor recirculation hose (B). NOTE: At either location, tiny droplets of fuel are normal. Page 6090 DIAGNOSTIC WORKSHEET REPAIR PROCEDURE A Page 8090 68. Under Left Side of Dash Page 6536 Control Assembly: Service and Repair Heater Control Panel and Push Switch Assembly Removal and Installation 1. Remove the center panel. 2. Remove the dials (A), then remove the self-tapping screws and the heater control panel (B) from the center panel (C). Remove the self-tapping screws and the push switch assembly (D) from the center panel. 3. Install the control panel and the push switch assembly in the reverse order of removal. After installation, operate the control panel controls to see whether it works properly. 4. Run the self-diagnosis function to confirm that there are no problems in the system. Page 7238 Diagrams Page 6263 19. Set the cylinder housing (A) in a press so the cylinder side points downward, then press the cylinder end seal (B) and steering rack (C) out of the cylinder. Hold the rack to keep it from falling when pressed clear. 20. Remove the cylinder end seal from the steering rack. 21. Insert the special tools into the cylinder. Make sure the attachment (A) of the special tools is securely positioned on the bushing edges (B). 22. Place the cylinder in a press, then remove the cylinder end seal (C), backup ring (D), and bushing (B) from the cylinder by pressing on the special tool end. Note the items when pressing the cylinder end seal: ^ Keep the tool straight to avoid damaging the cylinder wall. Check the tool angle, and correct it, if necessary, when removing the cylinder end seal. ^ Use a press to remove the cylinder end seal. Do not try to remove the seal by striking the tool; striking the tool would break the cylinder end seal, and the seal would remain in the cylinder. Page 9638 Vanity Lamp: Diagnostic Aids General Troubleshooting Information General Troubleshooting Information Tips and Precautions Before Troubleshooting 1. Check applicable fuses in the appropriate fuse/relay box. 2. Check the battery for damage, state of charge, and clean and tight connections. NOTE: 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. Handling Connectors - Make sure the connectors are clean and have no loose wire terminals. - Make sure multiple cavity connectors are packed with dielectric grease (except watertight connectors). - All connectors have push-down release type locks (A). - Some connectors have a clip on their side used to attach them to a mount bracket on the body or on another component. This clip has a pull type lock. - Some mounted connectors cannot be disconnected unless you first release the lock and remove the connector from its mount bracket (A). - Never try to disconnect connectors by pulling on their wires; pull on the connector halves instead. - Always reinstall plastic covers. Page 9226 110. Left B Pillar (Right Similar) 111. Left C Pillar (Sedan) (Right Similar) Page 4312 Shift Solenoid: Service and Repair Shift Solenoid Valves A and B Replacement NOTE: Shift solenoid valves A and B must be removed/ replaced as an assembly. 1. Remove the harness clamp (c) form the clamp bracket (D). 2. Remove the mounting bolts and the shift solenoid valves A and B. 3. Clean the mounting surface and fluid passage. 4. Install a new shift solenoid valves A and B with a new filter/gasket (E), and install the harness clamp on the clamp bracket. 5. Check the connector for rust, dirt, or oil, then reconnect the connector securely. Page 3466 9. Install a 2 Ohms resistor between fuel pump 5P connector terminals No.1 and No.2, then turn the ignition switch ON (II). 10. Check that the pointer of the fuel gauge indicates "F". - If the pointer of the fuel gauge does not indicates "F", replace the gauge. - If the gauge is OK, inspect the fuel gauge sending unit. NOTE: The pointer of the fuel gauge returns to the bottom on the gauge dial when the ignition switch is OFF, regardless of the fuel level. 11. Relieve the fuel pressure. 12. Remove the fuel fill cap. 13. Disconnect the quick-connect fittings from the fuel pump. 14. Using the special tool, loosen the fuel tank unit locknut (A). Page 2903 Oxygen Sensor: Connector Locations 10. Middle Of Engine 11. Middle Of Engine (except EX) Testing and Inspection Radiator: Testing and Inspection Test 1. Wait until the engine is cool, then carefully remove the radiator cap and fill the radiator with engine coolant to the top of the filler neck. 2. Attach a commercially-available pressure tester (A) to the radiator and apply a pressure of 93 123 kPa (0.95 - 1.25 kgf/cm2, 14 - 18 psi). 3. Inspect for engine coolant leaks and a drop in pressure. 4. Remove the tester and reinstall the radiator cap. 5. Check for engine oil in the coolant and/or coolant in the engine oil. Page 1478 Refrigerant Oil: Service and Repair A/C Refrigerant Oil Replacement Recommended PAG oil: SANDEN SP-10: - P/N 38897-P13-A01AH: 120 ml (4 fl.oz) - P/N 38899-P13-A01: 40 ml (1 1/3 fl.oz) Page 2440 Electric Load Sensor: Locations PGM-FI System - Component Location Index Capacity Specifications Power Steering Fluid: Capacity Specifications Power steering fluid Capacity For fluid change ................................................................................................................................... ......................................... 0.4 L (0.42 US qt.) For system overhaul .................................................... ................................................................................................................... 1.0 L (1.06 US qt.) Page 9376 License Plate Lamp: Service and Repair License Plate Lights Replacement 1. Remove the license plate cover. 2. Pull the license plate light assembly out, and disconnect the 2P connector (A) from the light. 3. Separate the lens (B) and housing (C), then remove the bulb. 4. Install the light in the reverse order of removal. Page 9333 Key Cylinder Lamp: Testing and Inspection Ignition Key Light Test 1. Remove the steering column upper and lower covers. 2. Disconnect the 6P connector. 3. The LED should come on when power is connected to the No.6 terminal and ground is connected to No.5 terminal. 4. If the LED does not come on, replace the ignition switch. Locations Compressor Clutch Relay: Locations Air Conditioning Component Location Index Page 1087 8. Inspect the quality of the wire crimp. If it has any of the following NO GOOD crimps, cut it off and start over. 9. Insert the terminal into the connector. Make sure the wire seals are pushed all the way into the connector. Lightly pull on the wires to make sure the terminal is locked into place. 10. Close or insert the secondary terminal lock, if applicable, and reconnect the connector. How to Install Pigtail Terminals HOW TO INSTALL PIGTAIL TERMINALS Pigtail terminals (short pieces of wire with a factory crimped terminal) are used when the wire is too short or when access to the connector is too restricted to make a terminal repair. NOTE: To replace just a connector terminal, go to How to Replace Connector Terminals. IMPORTANT SAFETY INFORMATION: On some models, the SRS wires are in a separate harness. If the SRS harness is damaged, replace the harness; do not repair it. On other models, wire harnesses include yellow SRS wires. If any SRS wire is damaged, replace the entire harness; do not repair it. 1. Remove the damaged or faulty terminal from the connector. Use the proper removal tool from Pin Tool Set. Page 6424 3. Remove the brake hose bracket mounting bolt (A). 4. Remove the caliper bracket mounting bolts (B), and remove the caliper assembly (C) from the knuckle. To prevent damage to the caliper assembly or brake hose, use a short piece of wire to hang the caliper assembly from the undercarriage. Do not twist the brake hose with force. 5. Raise the stake (A), and remove the spindle nut (B), then remove and discard the nut. 6. Remove the brake disc retaining flat screws (A). 7. Screw two 8 x 1.25 mm bolts (B) into the disc to push it away from the hub. Turn each bolt 2 turns at a time to prevent cocking the disc excessively. Page 8129 Programming the Transmitter NOTES: ^ The system accepts up to three transmitters. The transmitter codes are stored in a stacking-type memory. If a fourth transmitter code is programmed, the code for the first transmitter is erased. ^ Entering the programming mode cancels all learned transmitter codes, so none of the previously programmed transmitters will work. You must reprogram all of the transmitters once you are in the programming mode. ^ You must complete steps 1-6 within 4 seconds of the previous step to keep the system from exiting the programming mode. 1. Turn the ignition switch to ON (II). 2. Press the "Lock" or "Unlock" button on one of the transmitters. (An unprogrammed transmitter can be used for this step.) 3. Turn the ignition switch to LOCK (0). 4. Repeat steps 1 2, and 3 two more times using the same transmitter used in step 2. 5. Turn the ignition switch to ON (II). 6. Press the "Lock" or "Unlock" button on the same transmitter. Make sure the power door locks cycle to confirm that the system is in programming mode. 7. Within 10 seconds, press the "Lock" or "Unlock" button on each transmitter. Make sure the power door locks cycle after you press each transmitter button to confirm that the system accepted the transmitter's code. 8. Turn the ignition switch to LOCK (0) to exit the programming mode. Ordering a Transmitter Transmitters can be ordered only by authorized Honda dealers. Order them from American Honda using normal parts ordering procedures. Batteries for the Transmitter The battery number is CR1616. Each transmitter uses one battery. 97-04 CR-V & 00-04 S2000 *1997-04 CR-V LX with dealer-installed keyless entry system 1998-04 CR-V EX with factory-installed keyless entry system 2000-01 CR-V SE with factory-installed keyless entry system 2000-04 S2000 with factory-installed keyless entry system 2002-04 CR-V with dealer-installed security system* Page 6000 1. Remove the terminal. 2. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE E: 1. Remove the terminal. 2. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE F: Page 1527 Rear Window Defogger Component Location Index Page 310 Main Relay (Computer/Fuel System): Testing and Inspection Power Relay Test Use this chart to identify the type of relay, then do the test listed for it. NOTE: See the turn signal/hazard relay input test. Normally-open type A: Page 4973 Resistor Variable Sensor Solenoid Transistors Circuit Schematics Service and Repair Rear Door Striker: Service and Repair Rear Door Hook Pin and Catch Replacement 4-door 1. With a T40 Torx bit, remove the door hook pin (A) from the door. 2. With a T40 Torx bit, remove the bolts, then remove the door catch (A) from the body. 3. Install the hook pin and catch in the reverse order of removal, and apply liquid thread lock to the threads of the door hook pin. Page 8734 53. Steering Wheel (Airbag Inflators Removed) 57. Under Left Side Of Dash Page 4857 8. Reassemble the transmission; see page 13-43 (13-59 for Hybrid) of the service manual. 9. Install the new shift fork holder. Check the reverse shift fork clearance; see page 13-19 (13-34 for Hybrid) of the service manual. 10. Reinstall the transmission; see page 13-9 (13-23 for Hybrid) of the service manual. 11. Fill the transmission with MTF. 12. * Test-drive the car; make several right turns (left turns for Hybrid), and check that the clicking noise is gone.* Disclaimer Page 1020 A/T - Vehicle Won't Move/MIL ON/DTC P0730 PROM - Programmable Read Only Memory: Customer Interest A/T - Vehicle Won't Move/MIL ON/DTC P0730 04-036 January 7, 2005 Applies To: See VEHICLES AFFECTED Vehicle Does Not Move in Drive; MIL Comes On or D Indicator Blinks With A/T DTC P0730 (Supersedes 04-036, dated September 24, 2004) SYMPTOM The vehicle does not move when you select Drive. The MIL comes on ('01-03 models) or the D indicator blinks ('04 models) with "A" DTC P0730 (shift control system) set. PROBABLE CAUSE Excessive wear in the 2nd clutch. VEHICLES AFFECTED CORRECTIVE ACTION Replace the A/T. Use the Honda Interface Module (HIM) to update the PGM software ('01-03 models only). TOOL INFORMATION To do the repair procedure, you need these items: ^ Interactive Network (iN) CD (July '04 or later) ^ iN Workstation ^ Honda Interface Module (HIM): T/N EQS05A35570 ^ PC Interface Cable (RS232): T/N VET-02002832 [This is the same cable you use to connect the PCM Tester to the iN workstation when updating software or when downloading DTCs to American Honda. The cable is blue with an attached adapter.] ^ AC Adapter (110 VAC/12 VDC Power Supply): T/N VET-02002426 (This is the same adapter used by the PGM Tester.) To order additional HIMs, interface cables, or A/C adapters, call the Honda Tool and Equipment Program or use the fax order form provided in your Honda Tool and Equipment Program Catalog. Phone lines are open Monday through Friday from 7:30 a.m. to 7:00 p.m., Central Time. You can also order through the iN. Click on SERVICE, Service Bay, and then Tool and Equipment, or click on eMail and then Tool and Equipment Program. Page 3031 172. EGR Valve And EGR Valve Position Sensor (EX, HX; '04-'05: DX, LX) Page 1872 12. Remove the sealing bolt (A) from the inspection hole (B), and connect an air pressure regulator with a 0 - 100 psi gauge (C). 13. Loosen the valve on the regulator, and apply the specified air pressure. Specified Air Pressure: 250 kPa (2.5 kgf/cm2, 36 psi) NOTE: If the synchronizing piston does not move after applying air pressure, move the primary or secondary rocker arm up and down manually by rotating the crankshaft counterclockwise. 14. Move the intake secondary rocker arm (A) for the No. 1 cylinder. The primary rocker arm (B) and secondary rocker arm should move together. ^ If the intake primary rocker arm does not move, remove the primary and secondary rocker arms as an assembly and check that the pistons in the secondary and primary rocker arms move smoothly. If any rocker arm needs replacing, replace the primary and secondary rocker arms as an assembly, and retest. 15. Remove the special tools. Page 9616 Relay And Control Unit Locations - Dashboard Page 1363 Drive Belt: Tools and Equipment Honda Serpintine Belt Wrench AST tool# HON1419 -Lightweight and slim design -Equipped with 14mm and 19mm, 12 point securing attachments Page 6622 Relay And Control Unit Locations - Engine Compartment Page 8336 Paint Code - Canadian Model 2-door Color Label Location Page 7461 1. Remove the terminal. 2. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE G: 1. Remove the terminal. 2. Go to HOW TO INSTALL NEW TERMINALS. How to Install New Terminals HOW TO INSTALL NEW TERMINALS 1. Carefully match the old terminal with a new one from the terminal repair kit. Choose the correct replacement terminal based on the wire size range the terminal will accommodate. NOTE: If the replacement terminal quantities are low, reorder them by using the terminal part number listed on the inside lid of the terminal repair kit. Replacement terminals are available through your parts department using normal parts ordering procedures. 2. Depending on the size of the wire you are repairing, use the proper size slot in the crimping tool. Page 4215 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. Test Equipment 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. Page 6752 Special Tool Required Deployment tool 07HAZ-SG00500 Before scrapping any airbags, side airbags, seat belt tensioners or seat belt buckle tensioners (including those in a whole vehicle to be scrapped), the airbags, side airbags, seat belt tensioners or seat belt buckle tensioners must be deployed. If the vehicle is still within the warranty period, the Honda District Service Manager must give approval and/or special instruction before deploying the airbags, side airbags, seat belt tensioners or seat belt buckle tensioners. Only after the airbags, side airbags, seat belt tensioners or seat belt buckle tensioners have been deployed (as the result of vehicle collision, for example), can they be scrapped. If the airbags, side airbags, seat belt tensioners and seat belt buckle tensioners appear intact (not deployed), treat them with extreme caution. Follow this procedure. Deploying the Components Out of the Vehicle If an intact airbag or tensioner has been removed from a scrapped vehicle, or has been found defective or damaged during transit, storage, or service, it should be deployed as follows: 1. Confirm that the special tool is functioning properly by following the check procedure or on the tool label. 2. Position the airbag face up, outdoors on flat ground at least 30 feet (10 meters) from any obstacles or people. 3. Follow steps 10, 11, and 12 of the in-vehicle deployment procedure. 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 3650 Shift Solenoid: Diagrams 185. CVT Control Valves And Inhibitor Solenoid Assembly 73. Shift Solenoid Valve A And B (A/T Except CVT) Page 4317 5. Disconnect the shift lock solenoid connector (2P) (A) and park pin switch connector (4P) (B). 6. Remove the four bolts, then remove the shift lever assembly. Service and Repair Cabin Air Filter: Service and Repair Dust and Pollen Filter Replacement (With Air Conditioning) The dust and pollen filters should be replaced every 30,000 miles (48,000 km) or 24 months whichever comes first. Replace the filters more often if the air flow is less than usual. 1. Open the glove box. Remove the glove box stop on each side, then hang the glove box down. 2. Remove the filter lid (A) from the blower unit, then pull out the first dust and pollen filter (B). Slide the second filter to the left, and pull it out. 3. Remove the filter (A) from the housing (B), and replace the filter. 4. Install the filters in the reverse order of removal. Page 997 65. PSP Switch Specifications Fluid Pan: Specifications CVT ATF pan/bolts Page 5406 8. Apply Dow Corning Molykote M77 or Daikalub 528D grease to both sides of the pad shim (A), the back of the pads (B), and the other areas indicated by the arrows. Wipe excess grease off the shim. Contaminated brake discs and pads reduce stopping ability. Keep grease off the discs and pads. 9. Install the brake pads and pad shim correctly. Install the pads with the wear indicators (C) on the inside. If you are reusing the pads, always reinstall the brake pads in their original positions to prevent a momentary loss of braking efficiency. 10. Push in the piston (A) so the caliper will fit over the pads. Make sure the piston boot is in position to prevent damaging it when pivoting the caliper down. 11. Pivot the caliper down into position. Being careful not to damage the pin boots, install the bolt (B), and tighten it to the specified torque. 12. Press the brake pedal several times to make sure the brake works, then test-drive. NOTE: Engagement of the brake may require a greater pedal stroke immediately after the brake pads have been replaced as a set. Several applications of the brake pedal will restore the normal pedal stroke. 13. After installation, check for leaks at hose and line joints or connections, and retighten if necessary. Page 4246 Transmission Speed Sensor: Locations 22. Transmission Housing (A/T Except CVT) 19. Transmission Housing (A/T Except CVT) Page 9053 Temperature Gauge: Testing and Inspection Coolant Temperature Gauge Troubleshooting Before testing, check the No.9 (10 A) fuse in the under-dash fuse/relay box and the No.10 (7.5 A) fuse in the under-dash fuse/relay box. 1. Start the engine, and check the Malfunction Indicator Lamp (MIL). Does the MIL come on? YES - Troubleshoot the cause of the ECM/PCM DTC, and recheck. NO - Go to step 2. 2. Check for a multiplex control unit DTC. Is a DTC indicated? YES - Troubleshooting the cause of the multiplex control unit DTC, and recheck. NO - Go to step 3. 3. Do the communication line check with the self-diagnosis procedure. Is the word "Error" indicated on the odo/trip display? YES - The gauge cannot receive the signal from the multiplex control unit and the ECM/PCM. Check for an open in the WHT/GRN wire (gauge connector terminal A5 for 03 model Visteon type, terminal A2 for other type.). NO - Go to step 4. 4. Do the gauge drive circuit check with the self-diagnosis procedure. Does the temperature gauge needle sweep from the minimum position to the maximum, then return to the minimum position? YES - Go to step 5. NO - Replace the gauge assembly. 5. Substitute a known-good ECM/PCM, and recheck. Did the symptom/indication go away? YES - Replace the ECM/PCM. NO - Substitute a known-good gauge assembly. If the symptom/indication goes away, replace the gauge assembly. Page 3228 Transmission Position Switch/Sensor: Electrical Diagrams Circuit Diagram Testing and Inspection Valve Guide: Testing and Inspection Inspection 1. Slide the valve out of its guide about 10 mm, then measure the guide-to-stem clearance with a dial indicator while rocking the stem in the direction of normal thrust (wobble method). ^ If the measurement exceeds the service limit, recheck it using a new valve. ^ If the measurement is now within the service limit, reassemble using a new valve. ^ If the measurement with a new valve still exceeds the service limit, go to step 2. Intake Valve Stem-to-Guide Clearance Standard (New): 0.04 - 0.10 mm (0.002 - 0.004 inch) Service Limit: 0.16 mm (0.006 inch) Exhaust Valve Stem-to-Guide Clearance Standard (New): 0.10 - 0.16 mm (0.004 0.006 inch) Service Limit: 0.22 mm (0.009 inch) 2. Subtract the O.D. of the valve stem, measured with a micrometer, from the I.D. of the valve guide, measured with an inside micrometer or ball gauge. Take the measurements in three places along the valve stem and three places inside the valve guide. The difference between the largest guide measurement and the smallest stem measurement should not exceed the service limit. Intake Valve Stem-to-Guide Clearance Standard (New): 0.02 - 0.05 mm (0.0008 - 0.0020 inch) Service Limit: 0.08 mm (0.003 inch) Exhaust Valve Stem-to-Guide Clearance Standard (New): 0.05 - 0.08 mm (0.0020 - 0.0031 inch) Service Limit: 0.11 mm (0.004 inch) Locations Hazard Warning Switch: Locations Turn Signal/Hazard Flasher - Component Location Index Page 8631 ^ Incorrect: "If a Master Key is to be cut, put a five (5) in the blank space. Use a two (2) if a valet key is needed." ^ Correct: "If a Master Key is to be cut, put an M in the blank space. Use an S if a valet key is needed." Page 2, legend at the bottom: ^ Incorrect: "C. If a Master key is desired, then the number five (5) should be placed in the M/S position. Place the number two (2) in the M/S column if a Sub (Valet) key is needed." ^ Correct: "C. If a Master Key is desired, then an M should be placed in the M/S position. Place an S in the MIS column if a Sub (Valet) key is needed." Page 6052 Rear Window Defogger Component Location Index 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 5926 1. Remove the terminal. 2. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE G: 1. Remove the terminal. 2. Go to HOW TO INSTALL NEW TERMINALS. How to Install New Terminals HOW TO INSTALL NEW TERMINALS 1. Carefully match the old terminal with a new one from the terminal repair kit. Choose the correct replacement terminal based on the wire size range the terminal will accommodate. NOTE: If the replacement terminal quantities are low, reorder them by using the terminal part number listed on the inside lid of the terminal repair kit. Replacement terminals are available through your parts department using normal parts ordering procedures. 2. Depending on the size of the wire you are repairing, use the proper size slot in the crimping tool. Page 2151 - Before connecting connectors, make sure the terminals (A) are in place and not bent. - Check for loose retainer (A) and rubber seals (B). - The backs of some connectors are packed with dielectric grease. Add grease if necessary. If the grease is contaminated, replace it. - Insert the connector all the way and make sure it is securely locked. - Position wires so that the open end of the cover faces down. Handling Wires and Harnesses - Secure wires and wire harnesses to the frame with their respective wire ties at the designated locations. Page 5848 Relay Box: Diagrams 234. Under-dash Fuse/Relay Box Part 1 Page 4077 Fluid Line/Hose: Service and Repair ATF Cooler Hoses Replacement 1. Connect the cooler hoses (A) to the lines (B) and the ATF cooler, and secure them with the clips (C) as shown. 2. Install the clamp (D) on the cooler hoses. Page 9602 54. In Steering Column Cover Diagrams Page 3328 Evaporative Check Valve: Description and Operation EVAP Two Way Valve and EVAP Bypass Solenoid Valve The EVAP two way valve is installed between the fuel tank and the EVAP canister line. The EVAP Two way valve sends fuel vapor to the EVAP canister corresponding to the pressure inside the fuel tank and prevents excessive vacuum in the fuel tank by drawing in fresh air through the EVAP canister. The EVAP bypass solenoid valve opens to bypass the two way valve when doing the EVAP leak check. Page 6768 104. In Front Pass. Or Pass. Seat (Side Airbag) Page 1591 Maintenance Required Lamp/Indicator: Service and Repair 1. Turn off the engine. 2. Press and hold the Select/Reset button in the instrument panel, then turn the ignition switch ON (Position II). 3. Hold the button for at least 10 seconds, until the indicator resets. Page 2490 Oxygen Sensor: Service and Repair Third HO2S Replacement Third HO2S Replacement Special Tools Required O2 sensor wrench, Snap-on YA8875, SP Tools 93750, or equivalent, commercially available NOTE: The secondary HO2S and the third HO2S must be replaced together. 1. Disconnect the third HO2S 4P connector (A), then remove the third HO2S (B). 2. Install the third HO2S in the reverse order of removal. Replacement Starter Motor: Service and Repair Replacement Starter Replacement 1. Make sure you have the anti-theft code for the radio, then write down the frequencies for the radio's preset buttons. 2. Disconnect the negative cable from the battery, then disconnect the positive cable. 3. Remove the resonator. M/T, CVT A/T 4. Disconnect the starter cable (A) from the B terminal on the solenoid, then disconnect the BLK/WHT wire (B) from the S terminal. 5. Remove the two bolts holding the starter, then remove the starter. 6. Install in the reverse order of removal. Make sure the crimped side of the ring terminal (A) is facing out. 7. Connect the battery positive cable and negative cable to the battery. 8. Start the engine to make sure the start works properly. 9. Enter the anti-theft code for the radio, then enter the customer's radio station presets. 10. Set the clock. 11. Perform the engine control module (ECM)/powertrain control module (PCM) idle learn procedure. Page 9307 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 Short Circuit Locator (Short Finder) 1. Remove the blown fuse. Leave the battery connected. Page 6551 Evaporator Temperature Sensor / Switch: Service and Repair Evaporator Temperature Sensor Replacement 1. Disconnect the 2P connector (A) from the evaporator temperature sensor (B), then remove the connector clip (C). Turn the evaporator temperature sensor counterclockwise to the stop, and carefully pull out it. 2. Install the sensor in the reverse order of removal. Page 3529 Throttle Cable/Linkage: Service and Repair Throttle Cable Removal/Installation 1. Fully open the throttle valve, then remove the throttle cable (A) from the throttle link (B). 2. Remove the cable housing (C) from the cable bracket (D). 3. Remove the throttle cable (A) from the accelerator pedal (B). 4. Install in the reverse order of removal. 5. Start the engine. Hold the engine at 3,000 rpm with no load (in park or neutral) until the radiator fan comes on, then let it idle. 6. Hold the cable, removing all slack from it. 7. Set the locknut on the cable bracket (A). Adjust the adjusting nut (B) so that its free play is 0 mm. 8. Remove the cable from the cable bracket (A). Reset the adjusting nut and tighten the locknut (C). 9. With the cable properly adjusted, check the throttle valve to be sure it opens fully when you push the accelerator pedal to the floor. Also check the throttle valve to be sure it returns to the idle position whenever you release the accelerator pedal. Page 483 138. Rear of Roof (EX) Page 5625 NOTE: You need to make the corrections listed in CODE BOOK CORRECTIONS at the end of this service bulletin. TRACER AND CUTTER BIT INSTALLATION 1. Turn the power switch on the back of the machine to ON. (This turns on the built-in work light.) 2. Use the Allen wrench from the built-in tool drawer to loosen the setscrew on the left sleeve of the vertical carriage. Slide the tracer all the way into the sleeve, and tighten the screw. 3. Turn the plastic shield on the right sleeve of the vertical carriage so you can access the setscrew on the sleeve. Use the Allen wrench to loosen the screw. Slide the cutter bit all the way into the sleeve, and tighten the screw. Turn the plastic shield so the open side is in the back. MACHINE COMPONENTS Page 8808 Door Switch: Diagrams 4. Door Switch, Driver's 5. Door Switch, Front Passenger's (Sedan) 6. Door Switch, Left Rear Or Right Rear 7. Door Switch, Passenger's (Coupe) Page 8170 Keyless Entry Transmitter: Service and Repair Transmitter Programming Storing transmitter codes: The codes of up to three transmitters can be read into the keyless receiver unit memory. (If a fourth code is stored, the code which was input first will be erased.) NOTE: It is important to maintain the time limits between the steps. Make sure the doors and the trunk are closed. 1. Turn the ignition switch ON (II). 2. Within 1 to 4 sec., push the transmitter lock or unlock button with the transmitter aimed at the receiver in the multiplex control unit behind the driver's side of the dash. 3. Within 1 to 4 sec., turn the ignition switch OFF. 4. Within 1 to 4 sec., turn the ignition switch ON (II). 5. Within 1 to 4 sec., push the transmitter lock or unlock button with the transmitter aimed at the receiver in the multiplex control unit behind the driver's side of the dash. 6. Within 1 to 4 sec., turn the ignition switch OFF. 7. Within 4 sec., turn the ignition switch ON (II). 8. Within 1 to 4 sec., push the transmitter lock or unlock button with the transmitter aimed at the receiver in the multiplex control unit behind the driver's side of the dash. 9. Within 1 to 4 sec., turn the ignition switch OFF. 10. Within 4 sec., turn the ignition switch ON (II). 11. Within 1 to 4 sec., push the transmitter lock or unlock button with the transmitter aimed at the receiver in the multiplex control unit behind the driver's side of the dash. 12. Confirm you can hear the sound of the door lock actuators. Within 1 to 4 sec., push the transmitter lock or unlock button again. 13. Within 10 sec., aim the transmitters (up to two additional ones) whose codes you want to store at the receiver, and press the transmitter lock or unlock buttons. Confirm that you can hear the sound of the door lock actuators after each transmitter code is stored. 14. Turn the ignition switch OFF, and pull out the key. 15. Confirm proper operation of the transmitter. Service and Repair Trunk / Liftgate Interior Trim Panel: Service and Repair Trim Removal/Installation - Trunk Area Special Tools Required KTC trim tool set SOJATP2014 2-door NOTE: - Put on gloves to protect your hands. - Use the appropriate tool from the KTC trim tool set to avoid damage when prying components. - Take care not to bend or scratch the trim and panels. 1. Remove the trim as shown. To remove the trunk side trim panel, remove the side trim panel as necessary. 2. Install the parts in the reverse order of removal, and replace any damaged clips. 4-door NOTE: - Put on gloves to protect your hands. - Use the appropriate tool from the KTC trim tool set to avoid damage when prying components. - Take care not to bend or scratch the trim and panels. 1. Remove the trim as shown. Page 7421 6. Disconnect the M, P, K, and J connectors from the under-dash fuse/relay box, and make these input tests at the connectors. - If any test indicates a problem, find and correct the cause, then recheck the system. - If all the input tests prove OK, the multiplex control unit must be faulty. Replace the under-dash fuse/relay box assembly. Page 2603 NOTE: You need to make the corrections listed in CODE BOOK CORRECTIONS at the end of this service bulletin. TRACER AND CUTTER BIT INSTALLATION 1. Turn the power switch on the back of the machine to ON. (This turns on the built-in work light.) 2. Use the Allen wrench from the built-in tool drawer to loosen the setscrew on the left sleeve of the vertical carriage. Slide the tracer all the way into the sleeve, and tighten the screw. 3. Turn the plastic shield on the right sleeve of the vertical carriage so you can access the setscrew on the sleeve. Use the Allen wrench to loosen the screw. Slide the cutter bit all the way into the sleeve, and tighten the screw. Turn the plastic shield so the open side is in the back. MACHINE COMPONENTS Page 823 1. Remove the terminal. 2. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE E: 1. Remove the terminal. 2. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE F: Page 5511 34. Left Side Of Engine Compartment Page 6800 105. Left B Pillar (Right Similar) 155. Behind Left Side Of Front Bumper Locations Idle Speed/Throttle Actuator - Electronic: Locations Idle Control System - Component Location Index 48. Middle Of Engine (except GX) Page 8464 14. Remove the three nuts and washers from the inboard link and the inboard seat track. Remove and discard the old bushings. 15. 2001-02 Models: Remove and discard the spacer from the inboard link. 16. Install the new bushings. 17. Install three spacers on the rear mounting stud for the seat track. 18. Reassemble the inboard side of the seat track in the reverse order of removal using new nuts. Torque the seat track mounting nuts to 24 N.m (17 lb-ft). Torque the seat belt buckle mounting bolt to 32 N.m (23 lb-ft). Page 1168 5. Reinstall the parts in the reverse order of removal. 6. Test the operation of all windows with the power window master switch.If any of the windows do not work correctly, continue with normal troubleshooting, and do the master switch input test: ^ Refer to page 22-168 of the 2001-05 Civic Service Manual, or ^ Online, enter keyword MASTER TEST, and select Power Window Master Switch Input Test (4-door) from the list. Disclaimer Page 8515 - There should be no continuity when the LOCKED position. 5. If the continuity is not as specified, replace the door lock actuator. Page 6820 ^ If the OPDS unit has an original part number, go to step 6. ^ If the OPDS unit has a new part number (refer to PARTS INFORMATION) or higher, go to REPAIR PROCEDURE B: OPDS SENSOR REPLACEMENT. 6. Recline the seat-back to access the OPDS unit mounting screws. 7. Remove the mounting screws from the OPDS unit, and gently pull out the unit. 8. Disconnect the OPDS connectors, then remove the OPDS unit. 9. Install a new OPDS unit, then snap on its cover. 10. Slip the seat-back cover over the OPDS unit. 11. On Accords, check the seat-back clip attachment bosses on the seat-back panel: ^ If the attachment bosses are OK, go to step 12. ^ If the seat-back has a pocket, and the attachment bosses are deformed or damaged, do the repair procedure in S/B 02-010, Seat-Back Panel Is Loose or Detached. Then go to step 12. ^ If the seat-back does not have a pocket, and the attachment bosses are deformed or damaged, replace the seat-back. Then go to step 12. Page 9349 Power Distribution schematics show how power is supplied from the positive battery terminal to various circuits in the vehicle. Refer to the Power Distribution diagram set to get a more detailed understanding of how picture is supplied to the circuit you're working on. Individual circuit schematics begin with a fuse. So 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 Ground Distribution Schematics This sample Ground Distribution schematic shows all of the components that share the same ground point. Page 2294 Page 1344 5. Install the crankshaft position (CKP) sensor. 6. Install the ail bolts loosely, then tighten the mounting bolts as the numbered sequence shown. 7. Install the lower cover. 8. Clean the pulley bolt and washer. Page 9415 Map Light: Connector Views 85. Spotlights (except EX) 137. Ceiling Light/spotlights (EX) Page 9488 Power Distribution schematics show how power is supplied from the positive battery terminal to various circuits in the vehicle. Refer to the Power Distribution diagram set to get a more detailed understanding of how picture is supplied to the circuit you're working on. Individual circuit schematics begin with a fuse. So 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 Ground Distribution Schematics This sample Ground Distribution schematic shows all of the components that share the same ground point. Page 1151 Service and Repair Clutch Slave Cylinder: Service and Repair Slave Cylinder Replacement NOTE: Do not spill brake fluid on the vehicle, it may damage the paint, if brake does contact the paint, wash it off immediately water. 1. Remove the mounting bolts (A) and the slave cylinder (B). 2. Remove the roll pins (C). Disconnect the clutch line (D), and remove the O-ring (E). Plug the end of the clutch line with a shop towel to prevent brake fluid coming out. 3. Install the slave cylinder in the reverse order of removal. Install the new O-ring (A). 4. Pull the boot (B) back, and apply brake assembly lube to the boot and slave cylinder rod (C). Reinstall the boot. 5. Apply super high temp urea grease (P/N 08798-9002) to the push rod of the slave cylinder. Tighten the slave cylinder mounting bolts to 22 Nm (2.2 kgf-cm, 16 ft. lbs.). 6. Bleed the clutch hydraulic system. ^ Attach a hose to the bleeder screw (A), and suspended the hose in a container of brake fluid. ^ Make sure there is an adequate supply of fluid at the clutch master cylinder, then slowly pump the clutch pedal until no more bubbles appear at the bleeder hose. ^ Tighten the bleed screw to 8 Nm (0.8 kgf-cm, 6 ft. lbs.); do not overtighten it. ^ Refill the clutch master cylinder with fluid when done. Always use only Honda DOT 3 brake fluid. Page 6597 Refrigerant: Technician Safety Information 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. IMPORTANT: * Always wear safety goggles and protective gloves when working on refrigerant systems. * Beware of the danger of carbon monoxide fumes caused by running the engine. * Beware of discharged refrigerant in enclosed or improperly ventilated garages. * Always disconnect the negative battery cable and discharge and recover the refrigerant whenever repairing the air conditioning system. CAUTION: Avoid breathing A/C Refrigerant-134a and lubricant vapor and mist. Exposure may irritate eyes, nose, and throat. To remove R-134a from the A/C system, use service equipment certified to meet the requirements of SAE J2210 (R-134a recycling equipment). If accidental system discharge occurs, ventilate the work area before resuming service. Additional health and safety information may be obtained from the refrigerant and lubricant manufacturers. IMPORTANT: * Do not mix R-12 refrigerant and R-134a refrigerant, even in the smallest amounts. R12 and R-134a are incompatible with each other. If the refrigerants are mixed, compressor failure is likely to occur. * Use only the specified lubricant (PAG) for the R-134a A/C system and R-134a components. If you use lubricants other than those specified, compressor failure is likely to occur. Coat all the fittings and the O-ring seals with clean 525 viscosity refrigerant oil in order to provide a leak-proof seal and in order to aid in assembly and disassembly. * Do not store or heat the refrigerant containers above 52 °C (125 °F). * Do not heat a refrigerant container with an open flame. If the container must be warmed, place the bottom of the container in a pail of warm water. * Do NOT intentionally do the following to the refrigerant containers: Drop - Puncture - Incinerate * Refrigerant will displace oxygen. Work in well ventilated areas in order to prevent suffocation. * Do NOT introduce compressed air to any refrigerant container or refrigerant component. Contamination will occur. * If you must carry a container of DOT CFR Refrigerant-134a in a vehicle, do not carry the refrigerant in the passenger compartment. All of the Refrigerant-134a disposable, blue containers are shipped with a heavy metal screw cap in order to protect the valve and the safety plug of the container from damage. Replace the cap after each use of the container in order to continue the protection. Page 2997 Blower Motor Relay Type 1, Type 2 Check for continuity between the terminals. - There should be continuity between the No.1 and No.3 terminals when power and ground are connected to the No.2 and No.4 terminals. - There should be no continuity between the No.1 and No.3 terminals when power is disconnected. Five-terminal type Check for continuity between the terminals. - There should be continuity between the No.1 and No.2 terminals when power and ground are connected to the No.3 and No.5 terminals. - There should be continuity between the No.1 and No.4 terminals when power is disconnected. Page 7810 17. Using a small screwdriver, push down on the tip of the last tumbler to release it, then remove the cylinder from the housing, being careful not to drop any tumblers and springs. Use your thumb and forefinger to hold the tumblers in place. Then go to step 20. 18. While turning the key left and right and pushing on the rear of the inner cylinder to release the spring, slowly remove the cylinder from the housing. Page 1665 Connectors - "C" Page 9077 Diodes Light Emitting Diode (LED) Motor Pressure Sensor Page 4786 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 Short Circuit Locator (Short Finder) 1. Remove the blown fuse. Leave the battery connected. Locations Daytime Running Lamp Control Unit: Locations Relay And Control Unit Locations - Dashboard Page 6944 7. From the Mode menu, select Miscellaneous Test. 8. From the Miscellaneous Test menu, select OPDS Initialization. 9. Follow the remaining screen prompts to complete the OPDS initialization. If the initialization fails repeat the process two more times. If the initialization fails again, check for SRS DTCs, then troubleshoot them using the appropriate service manual. Initializing the OPDS Unit: Manual Mode NOTE: Non-Honda seat covers will interfere with the performance of the OPDS and are not recommended. 1. Adjust the front passenger's seat-back to an upright position, then remove anything on or near the seat. 2. Turn the ignition switch to LOCK (0). 3. Connect the HDS to the vehicle's DLC (data link connector). 4. Keep the ignition switch at LOCK (0), and turn on the HDS. 5. At the screen prompts, enter the VIN and the odometer reading. 6. From the Select Mode screen, select SCS, and follow the screen prompts. Page 5960 Power Windows Component Location Index Page 2011 Timing Belt: Service and Repair Removal Special Tools Required Holder handle 07JAB-001020A - Holder attachment, 50 mm, offset 07MAB-PY3010A - Socket, 19 mm 07JAA-001020A or a commercially-available 19 mm socket 1. Make sure you have the anti-theft code for the radio, then write down the frequencies for the radio's preset buttons. 2. Disconnect the battery negative terminal. 3. Turn the crankshaft pulley so its Top Dead Center (TDC) mark (A) lines up with the pointers (B). 4. Remove the front tires/wheels. 5. Remove the splash shield. 6. Remove the adjust plate mounting bolt (A), locknut (B) and mounting bolt (C), then remove the power steering (P/S) pump belt (D) and pump Under-Dash Fuse/Relay Box Fuse: Application and ID Under-Dash Fuse/Relay Box Under-dash Fuse/Relay Box Page 910 157. Behind Left Side Of Front Bumper Page 2350 Engine Control Module: Service and Repair Updating the ECM/PCM ECM/PCM Updating and Substitution for Testing Special Tools Required Honda Interface Module (HIM) - P/N EQS05A35570 Use this procedure when you have to substitute a known-good ECM/PCM in a troubleshooting procedure. Update the ECM/PCM only if the ECM/PCM does not already have the latest software loaded. NOTE: Do not turn the ignition switch OFF while updating; the ECM/PCM can be damaged. How to Update the ECM/PCM NOTE: - To ensure the latest program is installed, do an ECM/PCM update whenever the ECM/PCM is substituted or replaced. - Before you update the ECM/PCM, make sure the vehicle's battery is fully charged. - To prevent ECM/PCM damage, do not operate anything electrical (audio system, brakes, A/C, power windows, moon roof, door locks, etc.) during the update. - If you need to diagnose the Honda Interface Module (HIM) because the HIM's red (#3) light came on or was flashing during the update, leave the ignition switch in the ON (II) position when you disconnect the HIM from the Data Link Connector (DLC). This will prevent ECM/PCM damage. 1. Turn the ignition switch ON (II). Do not start the engine. 2. Connect the HIM to the DLC (A) located under the driver's side of dashboard. 3. Do the ECM/PCM update procedure as described on the HIM label and in the ECM/PCM update system. If the software in the ECM/PCM is the latest version, replace the ECM/PCM. How to Substitute the ECM/PCM 1. Remove the ECM/PCM from the vehicle. 2. Install a known-good ECM/PCM in the vehicle. 3. Rewrite the immobilizer code with the ECM/PCM replacement procedure in the Honda PGM Tester; It allows you to start the engine. 4. After completing your tests, reinstall the original ECM/PCM and rewrite the immobilizer code with the ECM/PCM replacement procedure in the Honda PGM Tester again. Locations Radiator Cooling Fan Temperature Sensor / Switch: Locations Page 2315 DTC P1486 thru P1585 Rear Door Upper Seal Replacement Rear Door Weatherstrip: Service and Repair Rear Door Upper Seal Replacement Rear Door Upper Seal Replacement 4-door NOTE: - Take care not to scratch the door. - Use a clip remover to remove the clips. 1. Remove the door sash trim. 2. Detach the door weatherstrip clip (A), then remove the door upper seal (B). 3. Install the seal in the reverse order of removal, and note these items: - Replace the clip if it's damaged. - Make sure the upper seal is installed in the holder (C) securely. - Check for water leaks. - Test-drive and check for wind noise. Page 3553 Camshaft Position Sensor: Service and Repair CMP (TDC) Sensor Replacement 1. Remove the grommet (A) from the upper cover, and disconnect the camshaft position (CMP) (top dead center (TDC)) sensor connector (B). 2. Remove the upper cover (C). 3. Remove the CMP (TDC) sensor from the cylinder head. 4. Install the CMP (TDC) sensor in reverse order of removal. Page 6977 Air Bag(s) Arming and Disarming: Description and Operation SRS Components SRS Components Airbags The SRS is a safety device which, when used 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 (A), the cable reel (B), the driver's airbag (C), the front passenger's airbag (D), seat belt tensioners (I), seat belt buckle tensioners (J), and front impact sensors (K). Since the driver's and front passenger's airbags use the same sensors, both normally inflate at the same time. However, it is possible for only one airbag to inflate. This can occur when the severity of a collision is at the margin, or threshold, that determines whether or not the airbags will deploy. In such cases, the seat belt will provide sufficient protection, and the supplemental protection offered by the airbag would be minimal. Side Airbags The side airbags (E) are in each front seat-back. They help protect the upper torso of the driver or front seat passenger during a moderate to severe side impact. Side impact sensors (F) in each door sill and in the SRS unit detect such an impact and instantly inflate the driver's or the passenger's side airbag. Only one side airbag will deploy during a side impact. If the impact is on the passenger's side, the passenger's side airbag will deploy even if there is no passenger. 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. OPDS The side airbag system also includes an occupant position detection system (OPDS). This system consists of sensors (G) and a OPDS unit (H) in the front passenger's seat-back. The OPDS unit sends occupant height and position data to the SRS unit. If the OPDS unit determines that the front passenger is of small stature (for example, a child) and the front passenger is leaning into the side airbag deployment path, the SRS unit will automatically disable the passenger's side airbag. The SRS unit will also disable the airbag when the OPDS detects certain objects on the seat. When the side airbag is disabled, the side airbag cutoff indicator on the instrument panel alerts the driver that the passenger's side airbag will not deploy in a side impact. When the object is removed, or the passenger sits upright, the Side Airbag Cutoff indicator will go off after a few seconds, alerting the driver that the passenger's side airbag will deploy in a side impact. Page 3447 Fuel Return Line: Testing and Inspection Fuel Line Inspection Part 1 Page 6158 Power Steering Pressure Switch: Service and Repair Power Steering Hoses, Lines, and Pressure Switch Replacement Note these items during installation: ^ Connect each hose to the corresponding line securely until it contacts the stop on the line. Install the clamp or adjustable clamp at the specified distance from the hose end as shown. ^ Check all clamps for deterioration or deformation; replace the clamps with new ones, if necessary. ^ Add the recommended power steering fluid to the specified level on the reservoir and check for leaks. Page 3695 Resistor Variable Sensor Solenoid Transistors Circuit Schematics Page 3672 Shift Solenoid: Service and Repair Shift Solenoid Valves A and B Replacement NOTE: Shift solenoid valves A and B must be removed/ replaced as an assembly. 1. Remove the harness clamp (c) form the clamp bracket (D). 2. Remove the mounting bolts and the shift solenoid valves A and B. 3. Clean the mounting surface and fluid passage. 4. Install a new shift solenoid valves A and B with a new filter/gasket (E), and install the harness clamp on the clamp bracket. 5. Check the connector for rust, dirt, or oil, then reconnect the connector securely. Page 8991 108. Middle Of Floor Page 244 234. Under-dash Fuse/Relay Box Part 5 Page 7947 Air Bag(s) Arming and Disarming: Vehicle Damage Warnings 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. - To prevent damage to the airbag assembly, keep free from any oil, grease, detergent, or water. - Store the removed airbag on a secure, fiat surface away from any high heat source (exceeding 200 °F / 93 °C). Page 9143 2. Remove the terminal from the female half. 3. Remove the terminal from the male half. 4. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE D: 1. Remove the secondary locks. Locations 21. Transmission Housing (A/T) Page 7746 1. Check the depth adjustment of the trunk lid: ^ Refer to page 20-132 of the 2001-04 Civic Service Manual. ^ In ISIS, use the keyword TRUNK ADJUST, and select Trunk Lid Adjustment from the list. 2. Make sure the trunk lid is flush on all sides and corners. ^ If the trunk is misaligned, go to step 3. ^ If the trunk lid is properly aligned on all sides and corners, go to REPAIR PROCEDURE C. 3. Adjust the striker depth position and the trunk lid edge cushions: ^ Refer to page 20-132 of the 2001-04 Civic Service Manual. ^ In ISIS, use the keyword TRUNK ADJUST, and select Trunk Lid Adjustment from the list. 4. Check the trunk operation: ^ If the trunk opens and closes smoothly, return the vehicle to the customer. ^ If the trunk lid is still difficult to close, go to REPAIR PROCEDURE C. REPAIR PROCEDURE C 1. Use a small screwdriver to manually set and release the trunk lid latch. Check the operation of the latch: ^ If the latch is difficult to set or release, go to step 2. ^ If the latch operates properly, go to REPAIR PROCEDURE D. 2. Replace the trunk lid latch: ^ Refer to page 20-157 of the 2001-04 Civic Service Manual. ^ In ISIS, use the keyword LID LATCH, and select Trunk Lid Latch Replacement from the list. 3. Check the trunk operation: ^ If the trunk opens and closes smoothly, return the vehicle to the customer. ^ If the trunk lid is still difficult to close, go to REPAIR PROCEDURE D. REPAIR PROCEDURE D 1. Disconnect the trunk lid opener cable from the trunk lid latch. Check the cable operation: ^ Refer to page 20-157 of the 2001-04 Civic Service Manual. ^ In ISIS, use the keyword LID LATCH, and select Trunk Lid Latch Replacement from the list. 2. Check that there is no friction or binding of the cable by holding the outside casing and pulling back and forth on the inner cable: ^ If the cable is difficult to move or binds, go to step 3. ^ If the cable operates smoothly, go to REPAIR PROCEDURE E. 3. Replace the trunk lid opener cable: ^ Refer to page 20-151 of the 2001-04 Civic Service Manual. ^ In ISIS, use the keyword LID OPEN, and select Trunk Lid Opener/Fuel Fill Door Opener Cable Replacement from the list. 4. Check the trunk operation: Page 8724 Brake Switch (Cruise Control): Testing and Inspection Brake Pedal Position Switch Test 1. Disconnect the 4P connector (A) from the brake pedal position switch (B). 2. Check for continuity between the No.1 and No.2 terminals. - There should be continuity when the brake pedal is pressed. - There should be no continuity when the brake pedal is released. 3. Check for continuity between the No.3 and No.4 terminals (with cruise control). - There should be no continuity when the brake pedal is pressed. - There should be continuity when the brake pedal is released. 4. If necessary, adjust or replace the switch, or adjust the pedal height. Page 69 Electronic Brake Control Module: Service and Repair ABS Modulator-Control Unit Removal and Installation NOTE: ^ Do not spill brake fluid on the vehicle; it may damage the paint; if brake fluid gets on the paint, wash it off immediately with water. ^ Be careful not to damage or deform the brake lines during removal and installation. ^ To prevent the brake fluid from flowing, plug and cover the hose ends and joints with a shop towel or equivalent material. Removal 1. Pull up the lock (C) of the ABS control unit 31P connector (B), then disconnect the connector. 2. Disconnect the six brake lines. 3. Remove the two 8 mm nuts. 4. Remove the ABS modulator-control unit (A). Installation 1. Install the ABS modulator-control unit, then tighten the two 8 mm nuts. 2. Align the connecting surface of the ABS control unit 31P connector. 3. Push in the lock of the ABS control unit 31P connector until you hear it click into place, then connect the connector. 4. Bleed the brake system, starting with the front wheels. 5. Start the engine, and check that the ABS indicator goes off. 6. Test-drive the vehicle, and check that the ABS indicator does not come on. Removal and Installation Blower Motor: Service and Repair Removal and Installation Blower Unit Removal and Installation 1. Remove the passenger's dashboard lower cover, the right kick panel, and the glove box. 2. Remove the bolt, then cut the plastic cross brace in the glove box opening with diagonal cutters in the area shown. Remove and discard the plastic cross brace. 3. Remove the relays (A), then remove the bolts and the glove box frame (B). 4. Remove the ECM/PCM. 5. Disconnect the connectors (A) from the blower motor, the power transistor, and the recirculation control motor, then remove the wire harness clips (B). Page 9060 Backup Lamp Relay: Testing and Inspection Power Relay Test Use this chart to identify the type of relay, then do the test listed for it. NOTE: See the turn signal/hazard relay input test. Normally-open type A: ATF Level Check Fluid - CVT: Service and Repair ATF Level Check ATF Level Check NOTE: Keep all foreign particles out of the transmission. 1. Warm up the engine to normal operating temperature (the radiator fan comes on). 2. Park the vehicle on level ground, and turn the engine off. 3. Remove the dipstick (yellow loop) (A) from the transmission, and wipe it with a clean cloth. 4. Insert the dipstick into the transmission. 5. Remove the dipstick and check the fluid level within 60 - 90 seconds after the engine is turned off. The dipstick should read between the upper mark (A) and the lower mark (B) on the HOT side of the gauge (C). Do not check the level on the COLD side of the gauge (D) when the ATF warmed up. NOTE: Some dipsticks have only the HOT gauge, in which case they might or might not have HOT stamped into the dipstick. 6. If the level is below the lower mark (B), check for fluid leaks at the transmission, hose and line joints, and cooler lines. 7. If the level exceeds the upper mark (A), drain the fluid for proper level. 8. Pour the recommended fluid into the dipstick hole to bring it to upper mark. Always use Honda ATF-Z1 Automatic Transmission Fluid (ATF). Using non-Honda ATF can affect shift quality. 9. Insert the dipstick back into the transmission. Seats With Side Airbags Air Bag(s) Arming and Disarming: Description and Operation Seats With Side Airbags Seats with Side Airbags Seats with side airbags have a tag attached to the seat-back. Because the component parts (seat-back cover, cushion, etc.) of seats with and without airbags are different, make sure you install only the correct replacement parts. Because the seats are made by more than one manufacturer, make sure you replace any seat components (seat-back cover, frame, etc.) with the correct parts. The name of the seat manufacturer is indicated on the seat-back. Moreover, the manufacturer name is indicated on the seat-back frame and the seat-back pad. Confirm the indication when you exchange these parts. * When cleaning, do not saturate the seat with liquid, and do not spray steam on the seat. * Do not repair torn or frayed seat-back covers. Replace the seat-back cover. * After a collision in which the side airbag was deployed, replace the seat-back cover and the side airbag with new parts. If the seat-back cushion is split, it must be replaced. If the seat-back frame is definitely deformed, it must be replaced. Page 2171 13. Plug in the heat gun, and turn it on. Start at the middle of the splice connector, and move the gun toward the ends as the tube shrinks. Apply heat evenly by rotating the curved heat spreader around the splice connector. Shrinking is complete when a small amount of sealant appears at each end of the tube. Pigtail Terminal Selection Chart PIGTAIL TERMINAL SELECTION CHART Select the proper size pigtail terminal by matching the replacement terminal part number and the wire size being repaired to the corresponding pigtail terminal part number. Then use the color (size) splice connector listed. In some instances you may also have to match the wire seal style to select the proper pigtail terminal. Pigtail terminals are available through your parts department, in quantities of 10, using normal parts ordering procedures. Checking For Poor Fir of Terminals CHECKING FOR POOR FIT OF TERMINALS Loose terminal fit can cause a number of intermittent problems in electrical circuits. By using the Terminal Inspection Feeler Tool Set you can inspect the terminal fit between the two matching connectors without removing the terminals from the connector body. 1. Find the terminal tool that best matches the male terminal in the mating connector. Page 6787 Clockspring Assembly / Spiral Cable: Service and Repair Cable Reel Replacement Removal 1. Make sure the wheels are aligned straight ahead. 2. Disconnect the battery negative cable, and wait at least 3 minutes. 3. Remove the driver's airbag. 4. Disconnect the connector (A) from the cruise control set/resume switch, then remove the steering wheel bolt (B). 5. Align the front wheels straight ahead, then remove the steering wheel with a steering wheel puller. Do not tap on the steering wheel or steering column shaft when removing the steering wheel. 6. Remove the dashboard lower cover (A). Page 8419 Sunroof / Moonroof Switch: Service and Repair Switch Test/Replacement 1. Remove the driver's pocket. 2. Disconnect the 6P connector (A) from the moonroof switch (B), and remove the moonroof switch. 3. Check for continuity between the terminals in each switch position according to the table. 4. If the continuity is not as specified, replace the illumination bulb (C) or the moonroof switch. Page 2752 DTC P0979 thru P1193 Page 7211 The battery number is CR2025. Each transmitter uses one battery. 94-95 Accord, Civic, Del SOL, Prelude & 95 Odyssey 1994-95 Accord with dealer-installed security system 1994-95 Civic with dealer-installed security system 1994-95 del Sol with dealer-installed security system 1994-95 Prelude with dealer-installed security system 1995 Odyssey with dealer-installed security system Programming the Transmitter NOTES: ^ The system uses a stacking-type memory that accepts up to four transmitters. If you program a fifth transmitter, the system's memory for the first transmitter is pushed out, and it will no longer work. ^ To clear a lost or stolen transmitter from the system's memory, program a transmitter four times. This will remove the missing transmitter from memory, since only four transmitter codes can be accepted. ^ Another way to clear a lost or stolen transmitter is to erase all transmitter codes, and then reprogram them. To do this, refer to the security system owner's manual. 1. Turn the ignition switch to ON (II). 2. Press and hold the Valet-Disarm button on the dashboard lower cover. (Continue to hold the button during this procedure, or programming will be cancelled.) The LED on the upper steering column cover flashes when the system is in programming mode. 3. Press the top button on the transmitter. Check that the parking lights flash to confirm that the transmitter's code was accepted. 4. Press the top button on each of the remaining transmitters. Check that the parking lights flash after each transmitter code is accepted. 5. Release the Valet-Disarm button to exit the programming mode. Ordering a Transmitter Transmitters can be ordered only by authorized Honda dealers. Order them from American Honda using normal parts ordering procedures. Batteries for the Transmitter The battery number is CR2025. Each transmitter uses one battery. 96-98 Civic EX & Except EX, Civic 1996-98 Civic EX with factory-installed keyless entry system 1996-98 Civic (except EX) with dealer-installed keyless entry system 1996-98 Civic with dealer-installed security system Page 3468 Fuel Gauge Sender: Service and Repair Fuel Pump/Fuel Gauge Sending Unit Replacement Special Tools Required Fuel sender wrench 07XAA-001010A 1. Relieve the fuel pressure. 2. Remove the fuel fill cap. 3. Remove the seat cushion. 4. Remove the access panel (A) from the floor. 5. Disconnect the fuel pump 5P connector (B). 6. Disconnect the quick-connect fitting (C) from the fuel tank unit. 7. Using the special tool, loosen the fuel tank unit locknut (A). Page 8039 17. Using a small screwdriver, push down on the tip of the last tumbler to release it, then remove the cylinder from the housing, being careful not to drop any tumblers and springs. Use your thumb and forefinger to hold the tumblers in place. Then go to step 20. 18. While turning the key left and right and pushing on the rear of the inner cylinder to release the spring, slowly remove the cylinder from the housing. Page 5595 12. Check for continuity between body ground and ECM/PCM connector terminal B13. Is there continuity? YES - Test the alternator (see step 1). NO - Repair open in the wire between the ECM/PCM (B13) and the alternator. 13. Turn the ignition switch OFF. 14. Disconnect ECM/PCM connector B (24P) 15. Check for continuity between body ground and ECM/PCM connector terminal B13. Is there continuity? YES - Repair short in the wire between the ECM/PCM (B13) and the alternator. NO - Update the ECM/PCM jilt does not have the latest software, or substitute a known-good ECM/PCM, then recheck. If the symptom/indication goes away with a known-good ECM/PCM, replace the original ECM/PCM. Locations Shift Interlock Solenoid: Locations 107. Behind A/T Shift Lever (except M/T) Page 3298 12. Check for continuity between body ground and ECM/PCM connector terminal B13. Is there continuity? YES - Test the alternator (see step 1). NO - Repair open in the wire between the ECM/PCM (B13) and the alternator. 13. Turn the ignition switch OFF. 14. Disconnect ECM/PCM connector B (24P) 15. Check for continuity between body ground and ECM/PCM connector terminal B13. Is there continuity? YES - Repair short in the wire between the ECM/PCM (B13) and the alternator. NO - Update the ECM/PCM jilt does not have the latest software, or substitute a known-good ECM/PCM, then recheck. If the symptom/indication goes away with a known-good ECM/PCM, replace the original ECM/PCM. Page 1031 ^ The vehicle is shown as eligible on a VIN status inquiry. In addition, check for a punch mark above the seventh character of the engine compartment VIN. A punch mark in that location means the ignition switch key interlock has already been inspected/repaired. 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 a VIN status inquiry before selling it. CUSTOMER NOTIFICATION All owners of affected vehicles will be sent a notification of this campaign. An example of the customer notification is at the end of this service bulletin. CORRECTIVE ACTION Inspect the ignition switch and, if needed, install a Key Interlock Repair Kit. PARTS INFORMATION Key Interlock Repair Kit: P/N 06351-SDA-000 REQUIRED SPECIAL TOOLS Interlock Slide Hammer: T/N 07AAC-S84A100 NOTE: ^ An initial quantity of Permalube grease to lubricate the sliding surface of the interlock lever is included with the slide hammer. To order more Permalube, use P/N 08734-0030. ^ To order a replacement clamping bolt for the slide hammer, use T/N 07AAC-S84A400. WARRANTY CLAIM INFORMATION Failed Part: P/N 35100-SDA-A31 Defect Code: 5GC00 Symptom Code: R4400 Page 107 Relay And Control Unit Locations - Engine Compartment Page 8602 13. After completing the right edge, push all of the cam blades to the right until they touch the cams, then trace the cam blades from back to front. (The cutter bit cuts the same contours into the left edge of the key from tip to head.) Turn off the cutter motor. 14. Release the vertical carriage lever. Push all the cam blades to the left until they touch the cams. Pull the vertical carriage lever towards you until the tracer touches the flat surface on the right side, at the front of the cams. Gently twist the lever clockwise to lock the vertical carriage at this height. Do not overtighten the lever. 15. Turn on the cutter motor, then retrace the cam blades from front to back. Push all the cam blades to the right until they touch the cams, and then retrace the cam blades from back to front (retracing cleans up the cuts on the key). Turn off the cutter motor. 16. Release the vertical carriage lever. Open the jaw and remove the key. Make sure the jaw is free of any metal shavings or debris. Turn the key over so the blank side is up, then slide it into the jaw up to the key stop. Close the jaw to lock the key in place. 17. Push all the cam blades to the left until they touch the cams. Repeat steps 10 through 15 to cut both edges on the other side of the key. 18. When you are done making the required cuts, release the vertical carriage lever. Open the jaw and remove the key. 19. Make sure the key works in the ignition switch and the locks. If the key does not work, recut the key, and try it again. 20. Depending on the type of key, code the key transponder. Equipment Service and Warranty To service the MATRIX H Key Cutting Machine, refer to section 7 of the MATRIX H Operating Manual. It tells you how to replace parts that commonly wear out such as the drive belt, the work light bulb, and the tension spring on the vertical carriage. It also covers checking and replacing fuses and replacing the printed circuit board for the setting unit keypad. If you have technical questions on the equipment, contact the Ilco Technical Assistance Department. Mail: Kaba Ilco Technical Assistance Department 400 Jeffreys Road Rocky Mount, NC 27804 Phone: 800-452-6872 Ext: 200, 384, 323, 398, 356 Fax: 252-446-4702 The MATRIX H Key Cutting Machine comes with a 3-year limited warranty. This warranty does not cover the cutter bit or the work light bulb. CODE BOOK CORRECTIONS In the code book Honda High Security key Codes, correct these errors: Pages 4 thru 51, code headings: ^ Incorrect: J H G F Z X E D C B M/S X ^ Correct: J H G F A X E D C B M/S X Page 2, last paragraph: Page 3711 2. Remove the terminal (same procedure for male and female). 3. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE E: 1. Remove the secondary locks. 2. Remove the terminal (same procedure for male and female). 3. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE F: Diagrams Page 216 Turn Signal Relay: Testing and Inspection Turn Signal/Hazard Relay Input Test 1. Remove the turn signal/hazard relay (A) from the under-dash fuse/relay box (B). 2. Inspect the relay and fuse/relay box socket terminals to be sure they are all making good contact. - If the terminals are bent, loose, or corroded, repair them as necessary, and recheck the system. - If the terminals look OK, go to step 3. 3. Make these input tests at the fuse/relay box. - If any test indicates a problem, find and correct the cause, then recheck the system. - If all the input tests prove OK, the turn signal/hazard relay must be faulty; replace it. Page 7536 Front Door Weatherstrip: Service and Repair Front Door Upper Seal Replacement Front Door Upper Seal Replacement 4-door NOTE: - Take care not to scratch the door. - Use a clip remover to remove the clips. 1. Remove these items: - Power mirror/manual mirror, as necessary - Door sash trim 2. Detach the door weatherstrip clip (A), then remove the door upper seal (B). 3. Install the seal in the reverse order of removal, and note these items: - Replace the clip if it's damaged. - Make sure the upper seal is installed in the holder (C) securely. - Check for water leaks. - Test-drive and check for wind noise. Page 4383 Use the tools from Pin Tool Set. First, check the connector that you are about to repair. - If it has a secondary terminal lock, go to Connectors With a Secondary Lock. A secondary lock, found on most connectors on some models, is an additional locking device on the connector housing as a backup for the primary lock on the terminal. - If the connector does not have a secondary lock, go to Connectors Without a Secondary Lock. Connectors With a Secondary Lock All examples are shown with the connector lock facing up. The illustrations are examples of the secondary terminal locks; however, the connector you are repairing may vary in size. Identify the connector by the type of secondary lock, not by the number of terminal cavities. EXAMPLE A: 1. Release the secondary lock. 2. Remove the terminal. 3. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE B: Page 4015 Shift Interlock Solenoid: Service and Repair Shift Lock Solenoid Replacement 1. Remove the center console panel and center console. 2. Disconnect the shift lock solenoid connector (2P), and remove it from the shift lever bracket base. 3. Push the lock tab (A), pry the shift lock solenoid (B) to clear the projected tips (C) with a screwdriver, and remove the shift lock solenoid. 4. Install the shift lock solenoid plunger (D) and plunger spring (E) in the new shift lock solenoid. 5. Install the shift lock solenoid by aligning the joint (F) of the shift lock solenoid plunger with the tip (G) of the shift lock stop. 6. Connect the shift lock solenoid connector, and install it on the shift lever bracket base. 7. Install the center console and console panel. Locations Oil Pressure Sender: Locations Gauges Component Location Index (Part 1 Of 4) Page 4377 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. Test Equipment 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. Page 9394 - Remove clips carefully; don't damage their locks (A). - Slip pliers (A) under the clip base and through the hole at an angle, then squeeze the expansion tabs to release the clip. - After installing harness clips, make sure the harness doesn't interfere with any moving parts. - Keep wire harnesses away from exhaust pipes and other hot parts, from sharp edges of brackets and holes, and from exposed screws and bolts. - Seat grommets in their grooves properly (A). Do not leave grommets distorted (B). Testing and Repairs - Do not use wires or harnesses with broken insulation. Replace them or repair them by wrapping the break with electrical tape. - After installing parts, make sure that no wires are pinched under them. - When using electrical test equipment, follow the manufacturer's instructions and those described. - If possible, insert the probe of the tester from the wire side (except waterproof connector). - Use back probe adaptor 07TAZ-001020A. - Refer to the instructions in the Honda Terminal Kit for identification and replacement of connector terminals. Five-Step Troubleshooting Five-Step Troubleshooting 1. Verify The Complaint Page 9631 Splices Components Ground - "G" Page 6164 3. Remove the brake hose bracket mounting bolt (A). 4. Remove the caliper bracket mounting bolts (B), and remove the caliper assembly (C) from the knuckle. To prevent damage to the caliper assembly or brake hose, use a short piece of wire to hang the caliper assembly from the undercarriage. Do not twist the brake hose with force. 5. Raise the stake (A), and remove the spindle nut (B), then remove and discard the nut. 6. Remove the brake disc retaining flat screws (A). 7. Screw two 8 x 1.25 mm bolts (B) into the disc to push it away from the hub. Turn each bolt 2 turns at a time to prevent cocking the disc excessively. Page 9653 1. Remove the terminal. 2. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE E: 1. Remove the terminal. 2. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE F: Page 9486 Circuit Schematics Each schematic represents one circuit. A circuit's wires and components are arranged to show current flow from power at the top of the diagram 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 Page 1346 15. Check the camshaft pulley marks (A) - If the camshaft pulley marks are also at TDC, go to step 15. - If the camshaft pulley marks are not at TDC, remove the timing belt and repeat steps 2 through 11. 16. Install the upper cover (A), then connect the camshaft position (CMP) (top dead center (TDC)) sensor connector (B), and install the grommet (C). 17. Install the upper bracket (A), then tighten the nuts in the numbered sequence shown. 18. Install the cylinder head cover. Page 3726 Shift Indicator: Testing and Inspection Continuously Variable Transmission Indicator Input Test SRS components are located in this area. Review the SRS component locations, precautions, and procedures in the SRS section before performing repairs or service. 1. If the MIL has been reported, check for a DTC, and repair the system as indicated by DTC. 2. If the MIL does not come on, and the A/T gear position indicator P, N, or R does not come on. Turn the ignition switch off, remove the gauge assembly from the dashboard, then disconnect gauge assembly connector A (22P) and B (22P). 3. Inspect the connectors and connector terminals to be sure they are making good contact. 4. If the terminals are bent, loose, or corroded, repair them as necessary, and recheck the system. 5. Shift to the P position, and check for continuity between AS terminal (BLU/BLK) and ground. There should be continuity in the P position and no continuity in any other shift lever position. If your test results are different, check for a faulty transmission range switch or an open in the wire. 6. Shift to the N position, and check for continuity between AS terminal (BLK/RED) and ground. There should be continuity in the N position and no continuity in any-other shift lever position. If your test results are different, check for a faulty transmission range switch or an open in the wire. 7. Turn the ignition switch ON (II), shift to the R position, and check for voltage between A11 terminal (WHT) and ground. There should be 0 V in the R position. There should be about 5 V in any other shift lever position. If your test results are different, check for a faulty transmission range switch or an open in the wire. 8. Check for voltage between B17 terminal (YEL) and ground with the ignition switch ON (II). There should be battery voltage. If your test results are different, check for a blown No. 10 (7.5A) fuse in the under-dash fuse/relay box or an open in the wire. 9. Turn the ignition switch OFF, and check for continuity between B16terminal (BLK) and ground under all conditions. There should be continuity. If your test results are different, check for a poor ground (G501) or an open in the wire. 10. If all input tests prove OK, but the indicator is faulty, replace the printed circuit board. Page 6508 Compressor Clutch Relay: Testing and Inspection Power Relay Test Use this chart to identify the type of relay, then do the test listed for it. NOTE: See the turn signal/hazard relay input test. Normally-open type A: Page 8521 Power Mirror Switch: Testing and Inspection Power Mirror Switch Test 1. Remove the driver's pocket. 2. Disconnect the 13P connector (A) from the switch. 3. Remove the power mirror switch (B). 4. Check for continuity between the terminals in each switch position according to the table. 5. If the continuity is not as specified, replace the power mirror switch. Page 980 9. Open the jaws with the jaws knob, and slide the original key with its flat side down into the center jaw up to the key stop. Slide the key blank with its flat side down into the right jaw up to the key stop. Close the jaws with the jaws knob to lock the keys into place. Visually inspect both keys for proper alignment in the jaws. 10. Loosen the lateral and spring tension adjustment knobs on the clamp carriage. With the clamp carriage lever, adjust the clamp carriage to position the tracer and the cutter bit over the middle of the two locked key blades. Tighten only the spring tension knob when done. NOTE: The clamp carriage has a spring system that puts lateral pressure on the tracer and cutting bit to make it easier to cut sidewinder-type keys. Do not tighten the lateral tension adjustment knob. This knob should be left loose. 11. Turn on the cutter motor with the motor start switch. [NOTICE] ^ To avoid damaging the locking jaws while cutting, keep your hand off the vertical carriage lever. Pressure on the lever will change the cutting depth. * ^ To avoid breaking the cutter bit, never back up while cutting.* ^ Wear proper eye protection (safety glasses, goggles, etc.) Page 3502 Main Relay (Computer/Fuel System): Description and Operation PGM-FI Main Relay 1 and 2 The PGM-FI relay consists of two separate relays. PGM-FI main relay 1 is energized whenever the ignition switch is ON (II) which supplies battery voltage to ECM/PCM, power to the injectors, and power for PGM-FI main relay 2. PGM-FI main relay 2 is energized to supply power to the fuel pump for 2 seconds when the ignition switch is turned ON (II), and when the engine is running. Page 4336 Torque Converter Clutch Solenoid: Testing and Inspection Torque Converter Clutch Solenoid Valve Test 1. Disconnect the torque converter clutch solenoid valve connector. 2. Measure the resistance between the No. 1 and No. 2 terminals of the torque converter solenoid valve connector. STANDARD: 12 - 25 Ohms 3. Replace the torque converter clutch solenoid valve if the resistance is out of standard. 4. If the resistance is within the standard, connect the No. 2 terminal to the battery positive terminal, and connect the No. 1 terminal to the battery negative terminal. A clicking sound should be heard. Replace the torque converter clutch solenoid valve if no sound is heard when connecting the battery positive terminal. Page 5242 - Before connecting connectors, make sure the terminals (A) are in place and not bent. - Check for loose retainer (A) and rubber seals (B). - The backs of some connectors are packed with dielectric grease. Add grease if necessary. If the grease is contaminated, replace it. - Insert the connector all the way and make sure it is securely locked. - Position wires so that the open end of the cover faces down. Handling Wires and Harnesses - Secure wires and wire harnesses to the frame with their respective wire ties at the designated locations. Page 3108 Power Steering Pressure Switch: Description and Operation Power Steering Pressure (PSP) Switch The PSP switch signals the ECM/PCM when the power steering load is high. Page 5090 Shift Solenoid: Diagrams 185. CVT Control Valves And Inhibitor Solenoid Assembly 73. Shift Solenoid Valve A And B (A/T Except CVT) Page 201 PGM-F1 Main Relay 1, 2 Type 1, 2 Check for continuity between the terminals. - There should be continuity between the No.1 and No.2 terminals when power and ground are connected to the No.3 and No.4 terminals. - There should be no continuity between the No.1 and No.2 terminals when power is disconnected. Normally-open type B: Rear Window Defogger Relay 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 8955 13. Parking Brake Switch Page 5162 156. A/T Reverse Relay (A/T, CVT) Page 1115 143. Park Pin/Shift Switch (A/T) Locations Wiper/Washer Component Location Index Page 3770 Page 2592 159. Left Side Of Engine Compartment Page 1000 12. Check for continuity between PSP switch 2P connector terminal No.2 and body ground. Is there continuity? YES - Repair open in the wire between the PSP switch and ECM/PCM (E16). NO - Repair open in the wire between the PSP switch and G201. 13. Turn the ignition switch OFF. 14. Disconnect the PSP switch 2P connector. 15. Turn the ignition switch ON (II). 16. Measure voltage between ECM/PCM connector terminals A24 and E16. Is there battery voltage? YES - Replace the PSP switch. NO - Go to step 17. 17. Turn the ignition switch OFF. 18. Disconnect ECM/PCM connector E (31P). 19. Check for continuity between body ground and ECM/PCM connector terminal E16. Is there continuity? YES - Repair short in the wire between ECM/PCM (E16) and the PSP switch. NO - Update the ECM/PCM if it does not have the latest software, or substitute a known-good ECM/PCM, then recheck. If the Page 9078 Resistor Variable Sensor Solenoid Transistors Circuit Schematics Page 6948 Page 300 Engine Control Module: Service and Repair Updating the ECM/PCM ECM/PCM Updating and Substitution for Testing Special Tools Required Honda Interface Module (HIM) - P/N EQS05A35570 Use this procedure when you have to substitute a known-good ECM/PCM in a troubleshooting procedure. Update the ECM/PCM only if the ECM/PCM does not already have the latest software loaded. NOTE: Do not turn the ignition switch OFF while updating; the ECM/PCM can be damaged. How to Update the ECM/PCM NOTE: - To ensure the latest program is installed, do an ECM/PCM update whenever the ECM/PCM is substituted or replaced. - Before you update the ECM/PCM, make sure the vehicle's battery is fully charged. - To prevent ECM/PCM damage, do not operate anything electrical (audio system, brakes, A/C, power windows, moon roof, door locks, etc.) during the update. - If you need to diagnose the Honda Interface Module (HIM) because the HIM's red (#3) light came on or was flashing during the update, leave the ignition switch in the ON (II) position when you disconnect the HIM from the Data Link Connector (DLC). This will prevent ECM/PCM damage. 1. Turn the ignition switch ON (II). Do not start the engine. 2. Connect the HIM to the DLC (A) located under the driver's side of dashboard. 3. Do the ECM/PCM update procedure as described on the HIM label and in the ECM/PCM update system. If the software in the ECM/PCM is the latest version, replace the ECM/PCM. How to Substitute the ECM/PCM 1. Remove the ECM/PCM from the vehicle. 2. Install a known-good ECM/PCM in the vehicle. 3. Rewrite the immobilizer code with the ECM/PCM replacement procedure in the Honda PGM Tester; It allows you to start the engine. 4. After completing your tests, reinstall the original ECM/PCM and rewrite the immobilizer code with the ECM/PCM replacement procedure in the Honda PGM Tester again. Page 7062 78. Side Impact Sensor, Front Passenger's (Sedan) 79. Side Impact Sensor, Passenger's (Coupe) Page 3257 Use the tools from Pin Tool Set. First, check the connector that you are about to repair. - If it has a secondary terminal lock, go to Connectors With a Secondary Lock. A secondary lock, found on most connectors on some models, is an additional locking device on the connector housing as a backup for the primary lock on the terminal. - If the connector does not have a secondary lock, go to Connectors Without a Secondary Lock. Connectors With a Secondary Lock All examples are shown with the connector lock facing up. The illustrations are examples of the secondary terminal locks; however, the connector you are repairing may vary in size. Identify the connector by the type of secondary lock, not by the number of terminal cavities. EXAMPLE A: 1. Release the secondary lock. 2. Remove the terminal. 3. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE B: Page 5777 Power Windows Component Location Index Locations 25. Transmission Housing (CVT) Page 726 Electric Load Sensor: Locations PGM-FI System - Component Location Index Page 3200 Resistor Variable Sensor Solenoid Transistors Circuit Schematics Page 4827 8. Reassemble the transmission; see page 13-43 (13-59 for Hybrid) of the service manual. 9. Install the new shift fork holder. Check the reverse shift fork clearance; see page 13-19 (13-34 for Hybrid) of the service manual. 10. Reinstall the transmission; see page 13-9 (13-23 for Hybrid) of the service manual. 11. Fill the transmission with MTF. 12. * Test-drive the car; make several right turns (left turns for Hybrid), and check that the clicking noise is gone.* Disclaimer Fuel Gauge Sending Unit - New Wrench Available Fuel Gauge Sender: Technical Service Bulletins Fuel Gauge Sending Unit - New Wrench Available SOURCE: Honda Service News February 2003 TITLE: New Fuel Gauge Sending Unit Wrench Available APPLIES TO: All Models SERVICE TIP: There's a new fuel gauge sending unit wrench available in Honda parts stock. The new wrench T/N 07AAA-S0XA100) is a beefier version of the old one (T/N 07XAA-001010A) and supersedes it. The new wrench is much less prone to bending when you're removing a stubborn fuel pump/sender assembly locknut. Order it through normal parts ordering channels. Locations Knock Sensor: Locations PGM-FI System - Component Location Index Page 6206 symptom/indication goes away with a known-good ECM/PCM, replace the original ECM/PCM. Page 2162 2. Remove the terminal (same procedure for male and female). 3. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE E: 1. Remove the secondary locks. 2. Remove the terminal (same procedure for male and female). 3. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE F: Page 6547 82. Under Middle Of Dash Page 1234 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 8228 VEHICLES AFFECTED CORRECTIVE ACTION Adjust the trunk lid and/or the trunk lid latch, or replace components as needed. PARTS INFORMATION WARRANTY CLAIM INFORMATION In warranty: The normal warranty applies. Failed Part: P/N 68500-S5P-A90ZZ H/C 6528640 *Defect Code: 07406* Symptom Code: 03220 Page 7620 *T-5 Sidewinder Key Applications ^ 2003-05 Civic ^ 2004-05 Civic Hybrid ^ 2003-05 Civic GX (CNG) ^ 2004-05 S2000 ^ 2002-06 CR-V ^ 2003-06 Element ^ 2003-04 Odyssey ^ 2003-04 Pilot Ordering Honda key blanks through normal parts ordering channels: Refer to the parts catalog for correct key(s) for your application. PROGRAMMING KEYS Depending on the type of key blank you use, do this: ^ If you have used a T-5 programmable key blank ("T-5" stamped on the shank), you must code the key's transponder with the Ilco Immobilizer Key Code Duplicator (see S/B 99-053, Ilco Immobilizer key Code Duplicator). ^ If you have used a Honda key blank, add the* transponder code of the new key to the immobilizer system with the Honda Diagnostic System (HDS). ORDERING INFORMATION *To order the MATRIX H Key Cutting Machine, replacement cutter bits, fixed jaws and mobile jaws, T-5 programmable key blanks, and practice key blanks, contact the Honda Tool and Equipment Program by calling 888-424-6857 or using the fax order form provided in your Honda Tool and Equipment Program Catalog.* Order Honda key blanks through normal parts ordering channels. WARRANTY CLAIM INFORMATION None. This service bulletin is for information only. *DETERMINING WHICH KEY TO USE T-5 keys require less time to program and should be the first choice. They can be used as long as the following requirements are met: ^ Do you have the customer's operating key? ^ Does the vehicle fall within the T-5 Sidewinder Key Applications? ^ Does your dealership have an Ilco Immobilizer Key Code Duplicator? If the answer to all three questions on the above is yes, the 1-5 key option is the easier procedure. If you answered no to any of the questions, you should order the key(s) from the parts catalogue, and program it using the HDS.* BEFORE YOU START CUTTING 1. Get the original key or the key number from your customer or from the iN. 2. Get the applicable key blank. 3. If cutting by code, look up the applicable 9-digit cutting code for the key number. Refer to the code book Honda High Security key Codes that comes with the machine. Page 7100 12. On Accords and Pilots, install the new seat-back clips on the seat-back panel. Turn the clips so their retaining tabs are horizontal. 13. On Accords and Pilots, install the seat-back panel. 14. On all models except Accords and Pilots, zip the seat-back cover closed. 15. Initialize the OPDS unit. ^ To initialize with the HDS, go to Initializing the OPDS Unit: HDS Method. ^ To initialize with the SCS service connector, go to Initializing the OPDS Unit: Manual Mode. Initializing the OPDS Unit: HDS Method NOTE: Non-Honda seat covers will interfere with the performance of the OPDS and are not recommended. 1. Adjust the front passenger's seat-back to an upright position, then remove anything on or near the seat. 2. Turn the ignition switch to LOCK (0). 3. Connect the HDS to the vehicle's DLC (data link connector). 4. Turn the ignition switch to ON (II), then turn on the HDS. 5. At the screen prompts, enter the VIN and the odometer reading. Also verify the correct date and time. 6. From the System Selection menu, select SRS. Page 150 Horn Relay: Testing and Inspection Power Relay Test Use this chart to identify the type of relay, then do the test listed for it. NOTE: See the turn signal/hazard relay input test. Normally-open type A: Crankshaft Inspection Crankshaft: Testing and Inspection Crankshaft Inspection Straightness NOTE: ^ Clean the crankshaft oil passages with pipe cleaners or a suitable brush. ^ Check the keyway and threads. 1. Remove the crankshaft from the cylinder block. 2. Clean the crankshaft oil passages with pipe cleaners or a suitable brush. 3. Check the keyway and threads; repair as necessary. 4. Support the crankshaft with V-blocks. 5. Measure runout on all main journals to make sure the crank is not bent. Rotate the crankshaft two complete revolutions. The difference between measurements on each journal must not be more than the service limit. Crankshaft Total Indicator Runout Standard (New): 0.03 mm (0.001 inch) max. Service Limit: 0.04 mm (0.002 inch) Out-of-Round and Taper 6. Measure out-of-round at the middle of each rod and main journal in two places. The difference between measurements on each journal must not be more than the service limit. Journal Out-of-Round Standard (New): 0.0025 mm (0.0001 inch) max. Service Limit: 0.005 mm (0.0002 inch) 7. Measure taper at the edge of each rod and main journal. The difference between measurements on each journal must not be more than the service limit. Journal Taper Standard (New): 0.0025 mm (0.0001 inch) max. Page 8569 - Weld the damper housing and front side frame. - Weld the front damper extension and dashboard upper side member. - From the passenger compartment side, plug weld the holes in the dashboard lower, damper housing extension, and front damper extension. Page 419 156. A/T Reverse Relay (A/T, CVT) Service and Repair Trunk / Liftgate Release Lever: Service and Repair Trunk Lid Opener/Fuel Fill Door Opener Replacement Special Tools Required KTC trim tool set SOJATP2014 NOTE: Use the appropriate tool from the KTC trim tool set to avoid damage when prying components. 1. Using a trim tool, detach the hooks (A) by prying the front side cap (B), then remove it from the front door sill trim (C), and remove the opener lock cylinder (D). 2. Loose the bolt (E) securing the fuel fill door opener. 3. Remove the door sill trim, 2-door, and/or the front door sill trim, 4-door. 4. Remove the opener (A) from the bolt (B). 5. Disconnect the trunk lid opener/fuel fill door opener cable (A), then remove the opener (B). Take care not to kink the cable. 6. Install the opener in the reverse order of removal, and note these items: - Make sure the opener cable is connected properly. - Make sure the trunk lid and fuel fill door open properly and lock securely. Page 2751 DTC P0750 thru P0977 Page 5833 Rear Window Defogger Component Location Index Page 8595 *T-5 Sidewinder Key Applications ^ 2003-05 Civic ^ 2004-05 Civic Hybrid ^ 2003-05 Civic GX (CNG) ^ 2004-05 S2000 ^ 2002-06 CR-V ^ 2003-06 Element ^ 2003-04 Odyssey ^ 2003-04 Pilot Ordering Honda key blanks through normal parts ordering channels: Refer to the parts catalog for correct key(s) for your application. PROGRAMMING KEYS Depending on the type of key blank you use, do this: ^ If you have used a T-5 programmable key blank ("T-5" stamped on the shank), you must code the key's transponder with the Ilco Immobilizer Key Code Duplicator (see S/B 99-053, Ilco Immobilizer key Code Duplicator). ^ If you have used a Honda key blank, add the* transponder code of the new key to the immobilizer system with the Honda Diagnostic System (HDS). ORDERING INFORMATION *To order the MATRIX H Key Cutting Machine, replacement cutter bits, fixed jaws and mobile jaws, T-5 programmable key blanks, and practice key blanks, contact the Honda Tool and Equipment Program by calling 888-424-6857 or using the fax order form provided in your Honda Tool and Equipment Program Catalog.* Order Honda key blanks through normal parts ordering channels. WARRANTY CLAIM INFORMATION None. This service bulletin is for information only. *DETERMINING WHICH KEY TO USE T-5 keys require less time to program and should be the first choice. They can be used as long as the following requirements are met: ^ Do you have the customer's operating key? ^ Does the vehicle fall within the T-5 Sidewinder Key Applications? ^ Does your dealership have an Ilco Immobilizer Key Code Duplicator? If the answer to all three questions on the above is yes, the 1-5 key option is the easier procedure. If you answered no to any of the questions, you should order the key(s) from the parts catalogue, and program it using the HDS.* BEFORE YOU START CUTTING 1. Get the original key or the key number from your customer or from the iN. 2. Get the applicable key blank. 3. If cutting by code, look up the applicable 9-digit cutting code for the key number. Refer to the code book Honda High Security key Codes that comes with the machine. Pressure Plate and Clutch Disc Removal Pressure Plate: Service and Repair Pressure Plate and Clutch Disc Removal Clutch Replacement Special Tools Required ^ Clutch alignment shaft 07LAF-PT00110 ^ Clutch alignment disc 07JAF-PM7011A ^ Remover handle 07936-3710100 ^ Ring gear holder 07LAB-PV00100 or 07924-PD20003 ^ Attachment, 57 x 40 mm 07746-0010200 ^ Driver 077 49-0010000 Pressure Plate and Clutch Disc Removal 1. Check the diaphragm spring fingers for height using the special tools and a feeler gauge (A). If the height is more than the service limit, replace the pressure plate. Standard (New): 0.6 mm (0.02 inch) max. Service Limit: 1.0 mm (0.04 inch) 2. Install the special tools. 3. To prevent warping, unscrew the pressure plate mounting bolts (A) in a crisscross pattern in several steps, then remove the pressure plate (B). Component Locations Oxygen Sensor: Component Locations PGM-FI System - Component Location Index Page 3572 119. Knock Sensor (except GX) Page 2438 7. Remove the four screws that hold the two fuses, and remove the fuses. 8. Release the tab that holds the ELD, and pull up on the ELD to remove it. 9. Remove the bus bar from the ELD, and insert the bar into the new ELD. 10. Install the new ELD and bus bar into the fuse/relay box. 11. Reinstall the two fuses. 12. Reinstall the 3P ELD connector and the lower fusel relay box cover. 13. Reinstall the fuse/relay box onto its holder. CR-V only: Reinstall the wire harness clip onto the holder. 14. Reinstall the fuse/relay box cover. 15. Reconnect the negative battery cable. 16. Do the idle learn procedure: ^ Make sure all electrical items (A/C, audio unit, defogger, lights, etc.) are off. Body - Front Bumper Spoiler Loose/Detached Spoiler: All Technical Service Bulletins Body - Front Bumper Spoiler Loose/Detached 03-010 April 15, 2003 Applies To: 2001-03 Civic DX, HX, LX, EX, GX - ALL Front Bumper Air Spoiler Is Loose or Detached (Supersedes 03-010, dated March 4, 2003) SYMPTOM The front air spoiler is becoming detached from the bumper or it is loose, deformed, or shows gaps between the spoiler and the bumper. PROBABLE CAUSE The spoiler was pushed out of position when the front end of the vehicle was parked over a curb or a parking stop. CORRECTIVE ACTION If the spoiler is damaged or deformed, replace it. If it is loose or out of place, reinstall and secure it using 3M Weatherstrip Adhesive. REQUIRED MATERIALS 3M Weatherstrip Adhesive: 3M P/N 051135-08011 PARTS INFORMATION Front Bumper Air Spoiler: P/N 71110-S5A-A00ZA, H/C 6456784 WARRANTY CLAIM INFORMATION In warranty: The normal warranty applies. Operation Number: 023301 Flat Rate Time: 0.3 hour Failed Part: P/N 71110-S5A-A00ZA H/C 6456784 Defect Code: 004 Contention Code: A01 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. Remove the front bumper air spoiler. Page 5236 Diodes Light Emitting Diode (LED) Motor Pressure Sensor Page 9544 Backup Lamp Switch: Testing and Inspection Back-Up Light Switch Test 1. Disconnect the back-up light switch (A) connector. 2. Check for continuity between the back-up light switch 3P connector No. 1 and No. 2 terminals. There should be continuity when the shift lever is in reverse. 3. If necessary, replace the switch. Page 3069 53. IAT Sensor Locations 61. Under Left Side Of Dash Locations 12. Middle of Engine Page 4304 Shift Interlock Switch: Service and Repair Park Pin Switch Replacement 1. Remove the center console panel and center console. 2. Remove the screws (A), then remove the shift lever knob (B) 3. Remove the A/T gear position indicator panel light (c) from the A/T gear position indicator panel. 4. Remove the A/T gear position indicator panel and panel bracket as an assembly (D). 5. Disconnect the park pin switch connector (4P) (E), and remove it from the shift lever bracket base (F). 6. Remove the shift lock release (G) and spring (H). 7. Open the lock tabs (A) on the shift lever bracket base, then remove the park pin switch (B). 8. Install the new park pin switch. 9. Install the removed parts in the reverse order of removal. Page 6056 67. Under Left Side Of Dash Diagrams 223. ABS Modulator-Control Unit (EX, GX) Page 6998 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. Key Beeper, Light Chime & Ceiling Light Don't Work Door Switch: Technical Service Bulletins Key Beeper, Light Chime & Ceiling Light Don't Work SOURCE: Honda Service News April 2003 TITLE: Key Beeper, Light Chime, Ceiling Light Don't Work APPLIES TO: 2001-03 Civic, 2002-03 CR-V SERVICE TIP: If the ignition key-in beeper, the headlights-on chime, the ceiling light, and the driver's-dooropen indicator are all on the fritz check the driver's door switch in the doorjamb. A faulty door switch can cause all of these symptoms. Page 2834 1. Remove the secondary locks. 2. Remove the terminal from the female half. 3. Remove the terminal from the male half. 4. Go to HOW TO INSTALL NEW TERMINALS. Connectors Without a Secondary Lock All examples are shown with the connector lock facing up. The illustrations are examples of connector terminals without a secondary lock; however, the connector you are repairing may vary in size and shape. EXAMPLE A: Page 1458 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 101 PGM-F1 Main Relay 1, 2 Type 1, 2 Check for continuity between the terminals. - There should be continuity between the No.1 and No.2 terminals when power and ground are connected to the No.3 and No.4 terminals. - There should be no continuity between the No.1 and No.2 terminals when power is disconnected. Normally-open type B: Rear Window Defogger Relay Page 1577 234. Under-dash Fuse/Relay Box Part 4 Page 9731 Power Window Switch: Locations Relay And Control Unit Locations - Door, Roof And Seat Page 5946 Under-hood Fuse/Relay Box (2-door) Under-Dash Fuse/Relay Box Under-dash Fuse/Relay Box Locations Exterior Lights Component Location Index Page 5495 Vacuum Brake Booster: Service and Repair Brake Booster Replacement 1. Remove the master cylinder. 2. Disconnect the vacuum hose (A) from the brake booster. 3. Remove the air conditioner hose (B) and power steering hose (C) from their respective holders. 4. Remove the flange bolts ID) and throttle cable holder (E). 5. Remove the brake lines (A) from the ABS modulator (B). 6. Remove the under-dash cover and fuse/relay box in the passenger compartment. 7. Remove the clip (A) and the joint pin (B), and disconnect the yoke from the brake pedal. 8. Remove the brake booster mounting flange nuts (C). Page 5240 Power Distribution schematics show how power is supplied from the positive battery terminal to various circuits in the vehicle. Refer to the Power Distribution diagram set to get a more detailed understanding of how picture is supplied to the circuit you're working on. Individual circuit schematics begin with a fuse. So 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 Ground Distribution Schematics This sample Ground Distribution schematic shows all of the components that share the same ground point. Page 1767 1. Remove the terminal. 2. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE E: 1. Remove the terminal. 2. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE F: Page 4794 1. Remove the terminal. 2. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE E: 1. Remove the terminal. 2. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE F: Page 1443 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 .................................................................................................................................... Make sure the label says "For Gasoline Engines". From -20°F (-30°C) to over 100°F (40°C) .......................................................................................................................................................... SAE 5W-20 Page 3973 Pressure Regulating Solenoid: Service and Repair A/T Clutch Pressure Control Solenoid Valves A and B Replacement 1. Remove the mounting bolts and the A/T clutch pressure control solenoid valves A and B. 2. Clean the mounting surface and fluid passage of the A/T clutch pressure control solenoid valves A and B and the transmission housing. 3. Install the new filter/gasket (c) in the solenoid valve assembly body groove. 4. Install the new A/T clutch pressure control solenoid valves A and B. Do not pinch the filter/gasket. 5. Check the A/T clutch pressure control solenoid valve connectors for rust, dirt, or oil, then connect them securely. Page 6222 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 3606 ^ Going from front to back, use the middle lock pin to set the first cam to the appropriate key code number in the code book. (The cam is properly set when the number on the cam lines up with the red scribe mark on the clamp unit.) ^ Slide the lock pin through the notch in the cam. (This locks the cam in place.) ^ Keep doing this for each of the remaining cams in the set until all the cams are set and locked, then push the lock pin all the way in. Repeat this process to set and lock the cams for the right cam set. NOTE: Make sure you set the MIS cam in the right cam set for the type of key you are cutting. For a master key, set the cam to M; for a valet key, set it to S. When you are done, push all the cam blades to the left until they touch the cams in the left cam set. 10. Pull the vertical carriage lever toward you until the tracer touches the flat surface on the right side at the front of the cams. Gently twist the lever clockwise to lock the vertical carriage at this height. Do not overtighten the lever. 11. Turn on the cutter motor with the motor start switch. [NOTICE] ^ To avoid damaging the locking jaws while cutting, keep your hand off the vertical carriage lever. Pressure on the lever will change the cutting depth. * ^ To avoid breaking the cutter bit, never back up while cutting.* ^ Wear proper eye protection (safety glasses, goggles, etc.) 12. Use the clamp carriage lever and the tracer to follow the contours of the cam blades from front to back. (The cutter bit cuts the same contours into the right edge of the key blank, from head to tip.) Page 931 WARRANTY CLAIM INFORMATION Out of warranty: Any repairs to the SRS system for problems other than the 15-1, 15-2, and 15-3 DTCs that are done 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. INSPECTION PROCEDURE NOTE: ^ When you check for SRS DTCs with the HDS, codes other than 15-1, 15-2, and 15-3 are not covered by this warranty extension bulletin. ^ If the vehicle is covered by warranty, repair it using the normal warranty repair procedures. If the vehicle's warranty is expired, give your customer an estimate for the cost of the repair. Do the appropriate inspection, based on the DTC. SRS DTC 15-1 Clear the DTC with the HDS. ^ If DTC 15-1 does not set again, go to REPAIR PROCEDURE A: OPDS UNIT REPLACEMENT. ^ If DTC 15-1 sets again, continue with normal troubleshooting. ^ If the OPDS unit causes DTC 15-1 to set repeatedly, yet passes the other troubleshooting steps, go to REPAIR PROCEDURE A: OPDS UNIT REPLACEMENT. SRS DTC 15-2 1. Inspect the connections and the wiring in the side airbag cutoff indicator circuit. ^ If all the connections and the wiring are OK, go to step 2. ^ If any of the connections or the wiring are faulty, repair the circuit, then go to step 2. 2. Clear the DTC with the HDS. ^ If DTC 15-2 does not set again, go to REPAIR PROCEDURE A: OPDS UNIT REPLACEMENT. ^ If DTC 15-2 sets again, continue with normal troubleshooting. ^ If the OPDS unit causes DTC 15-2 to set repeatedly, yet passes the other troubleshooting steps, go to REPAIR PROCEDURE A: OPDS UNIT REPLACEMENT. SRS DTC 15-3 1. Clear the DTC with the HDS. ^ If DTC 15-3 does not set again, go to step 2. ^ If DTC 15-3 sets again, continue with normal troubleshooting. 2. Ask your customer if electrical devices such as a laptop computer or a fluorescent map light are ever used near the front passenger's seat-back. (Some electrical devices that plug into the vehicle's accessory power socket, especially those using a power inverter/converter, can interfere with the seat-back sensors and cause SRS DTC 15-3 to set.) ^ If your customer uses any of these devices operate the device near the front passenger's seat-back. If DTC 15-3 sets again, clear it, then return the vehicle to the customer. Advise the customer to avoid using the device near the front passenger's seat-back. ^ If your customer does not use any of these devices and DTC 15-3 does not set again, go to REPAIR PROCEDURE A: OPDS UNIT REPLACEMENT. REPAIR PROCEDURE A: OPDS UNIT REPLACEMENT Page 4835 6. Replace the 1st/2nd synchro hub/sleeve, and reassemble the countershaft; see page 13-34 (13-48 for Hybrid) of the service manual. 7. Check the countershaft clearance; see page 13-30 (13-44 for Hybrid) of the service manual. Page 4970 Splices Components Ground - "G" Locations Power Door Lock Switch: Locations Doors - Component Location Index 2-door Page 3463 Fuel Gauge Sender: Locations Gauges Component Location Index (Part 1 Of 4) Page 4856 6. Replace the 1st/2nd synchro hub/sleeve, and reassemble the countershaft; see page 13-34 (13-48 for Hybrid) of the service manual. 7. Check the countershaft clearance; see page 13-30 (13-44 for Hybrid) of the service manual. Page 7268 Wire Color Abbreviations Page 6875 7. Connect the SCS service connector to the 2P MES (memory erase signal) connector, as shown. Do not use a jumper wire. 8. Turn the ignition switch to ON (II). 9. Watch the SRS indicator. (It comes on for about 6 seconds and then goes off.) Disconnect the SCS service connector from the MES connector within 4 seconds after the indicator goes off. 10. When the SRS indicator comes on again, connect the SCS service connector to the MES connector within 4 seconds after the indicator comes on. 11. When the SRS indicator goes off, disconnect the SCS service connector from the MES connector within 4 seconds. Under-Dash Fuse/Relay Box Fuse: Application and ID Under-Dash Fuse/Relay Box Under-dash Fuse/Relay Box Page 169 - Remove clips carefully; don't damage their locks (A). - Slip pliers (A) under the clip base and through the hole at an angle, then squeeze the expansion tabs to release the clip. - After installing harness clips, make sure the harness doesn't interfere with any moving parts. - Keep wire harnesses away from exhaust pipes and other hot parts, from sharp edges of brackets and holes, and from exposed screws and bolts. - Seat grommets in their grooves properly (A). Do not leave grommets distorted (B). Testing and Repairs - Do not use wires or harnesses with broken insulation. Replace them or repair them by wrapping the break with electrical tape. - After installing parts, make sure that no wires are pinched under them. - When using electrical test equipment, follow the manufacturer's instructions and those described. - If possible, insert the probe of the tester from the wire side (except waterproof connector). - Use back probe adaptor 07TAZ-001020A. - Refer to the instructions in the Honda Terminal Kit for identification and replacement of connector terminals. Five-Step Troubleshooting Five-Step Troubleshooting 1. Verify The Complaint Page 5237 Resistor Variable Sensor Solenoid Transistors Circuit Schematics Page 5392 Page 2608 ^ Going from front to back, use the middle lock pin to set the first cam to the appropriate key code number in the code book. (The cam is properly set when the number on the cam lines up with the red scribe mark on the clamp unit.) ^ Slide the lock pin through the notch in the cam. (This locks the cam in place.) ^ Keep doing this for each of the remaining cams in the set until all the cams are set and locked, then push the lock pin all the way in. Repeat this process to set and lock the cams for the right cam set. NOTE: Make sure you set the MIS cam in the right cam set for the type of key you are cutting. For a master key, set the cam to M; for a valet key, set it to S. When you are done, push all the cam blades to the left until they touch the cams in the left cam set. 10. Pull the vertical carriage lever toward you until the tracer touches the flat surface on the right side at the front of the cams. Gently twist the lever clockwise to lock the vertical carriage at this height. Do not overtighten the lever. 11. Turn on the cutter motor with the motor start switch. [NOTICE] ^ To avoid damaging the locking jaws while cutting, keep your hand off the vertical carriage lever. Pressure on the lever will change the cutting depth. * ^ To avoid breaking the cutter bit, never back up while cutting.* ^ Wear proper eye protection (safety glasses, goggles, etc.) 12. Use the clamp carriage lever and the tracer to follow the contours of the cam blades from front to back. (The cutter bit cuts the same contours into the right edge of the key blank, from head to tip.) Page 4783 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 Locater) 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. Troubleshooting Precautions Troubleshooting Precautions Before Troubleshooting 1. Check the main fuse and the fuse 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, or you will damage the alternator diodes. - Do not attempt to crank the engine with the ground cable disconnected 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. Page 6135 DIAGNOSTIC WORKSHEET REPAIR PROCEDURE A Page 4228 1. Remove the terminal. 2. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE G: 1. Remove the terminal. 2. Go to HOW TO INSTALL NEW TERMINALS. How to Install New Terminals HOW TO INSTALL NEW TERMINALS 1. Carefully match the old terminal with a new one from the terminal repair kit. Choose the correct replacement terminal based on the wire size range the terminal will accommodate. NOTE: If the replacement terminal quantities are low, reorder them by using the terminal part number listed on the inside lid of the terminal repair kit. Replacement terminals are available through your parts department using normal parts ordering procedures. 2. Depending on the size of the wire you are repairing, use the proper size slot in the crimping tool. Page 9165 4. Make these input tests at the connector. - If any test indicates a problem, find and correct the cause, then recheck the system. - If all the input tests prove OK, the control unit must be faulty; replace it. '04 model Page 2067 2. Insert the terminal tool into the female terminal, and then remove the terminal tool. NOTE: Make sure you do not select a terminal tool that is larger than the mating male terminal because it would spread the female terminal and cause a loose fit. 3. Compare the drag to the other terminals in the connector. If the drag is less, replace the terminal with a replacement terminal from the appropriate terminal repair kit. Page 3266 8. Inspect the quality of the wire crimp. If it has any of the following NO GOOD crimps, cut it off and start over. 9. Insert the terminal into the connector. Make sure the wire seals are pushed all the way into the connector. Lightly pull on the wires to make sure the terminal is locked into place. 10. Close or insert the secondary terminal lock, if applicable, and reconnect the connector. How to Install Pigtail Terminals HOW TO INSTALL PIGTAIL TERMINALS Pigtail terminals (short pieces of wire with a factory crimped terminal) are used when the wire is too short or when access to the connector is too restricted to make a terminal repair. NOTE: To replace just a connector terminal, go to How to Replace Connector Terminals. IMPORTANT SAFETY INFORMATION: On some models, the SRS wires are in a separate harness. If the SRS harness is damaged, replace the harness; do not repair it. On other models, wire harnesses include yellow SRS wires. If any SRS wire is damaged, replace the entire harness; do not repair it. 1. Remove the damaged or faulty terminal from the connector. Use the proper removal tool from Pin Tool Set. Page 97 Under-hood Fuse/Relay Box Service and Repair Trunk / Liftgate Spring: Service and Repair Trunk Lid Torsion Bar Replacement Special Tools Required Torsion bar assembly tool 08M10-SM4-100 or 07AAE-SDAA100 1. Remove the torsion bars (A) from the torsion bar center clip (B). 2. Put on gloves to protect your hands. Remove the torsion bars with the torsion bar tool from both trunk lid hinges. First remove the right torsion bar (A), then remove the left torsion bar (B). 3. Remove the torsion bar center clip from the body. Page 1887 Valve Guide: Service and Repair Replacement Special Tools Required ^ Valve guide driver, 5.5 mm 07742-0010100 ^ Valve guide reamer, 5.5 mm 07HAH-PJ7A100 1. As illustrated below, use a commercially available air-impact valve guide driver (A) modified to fit the diameter of the valve guides. In most cases, the same procedure can be done using the special tool and a conventional hammer. 2. Select the proper replacement guides, and chill them in the freezer section of a refrigerator for about an hour. 3. Use a hot plate or oven to evenly heat the cylinder head to 300°F (150°C). Monitor the temperature with a cooking thermometer. Do not get the head hotter than 300°F (150°C); excessive heat may loosen the valve seats. 4. Working from the camshaft side, use the driver and an air hammer to drive the guide about 2 mm (0.1 inch) towards the combustion chamber. This will knock off some of the carbon and make removal easier. Hold the air hammer directly in line with the valve guide to prevent damaging the driver. Page 1231 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 8890 55. In Steering Column Cover Page 3225 13. Plug in the heat gun, and turn it on. Start at the middle of the splice connector, and move the gun toward the ends as the tube shrinks. Apply heat evenly by rotating the curved heat spreader around the splice connector. Shrinking is complete when a small amount of sealant appears at each end of the tube. Pigtail Terminal Selection Chart PIGTAIL TERMINAL SELECTION CHART Select the proper size pigtail terminal by matching the replacement terminal part number and the wire size being repaired to the corresponding pigtail terminal part number. Then use the color (size) splice connector listed. In some instances you may also have to match the wire seal style to select the proper pigtail terminal. Pigtail terminals are available through your parts department, in quantities of 10, using normal parts ordering procedures. Checking For Poor Fir of Terminals CHECKING FOR POOR FIT OF TERMINALS Loose terminal fit can cause a number of intermittent problems in electrical circuits. By using the Terminal Inspection Feeler Tool Set you can inspect the terminal fit between the two matching connectors without removing the terminals from the connector body. 1. Find the terminal tool that best matches the male terminal in the mating connector. Page 5685 24. Right Side of Engine Compartment (CVT Similar) Refrigerant Recovery Refrigerant: Service and Repair Refrigerant Recovery Refrigerant Recovery CAUTION: - Air conditioning refrigerant or lubricant vapor can irritate your eyes, nose, or throat. - Be careful when connecting service equipment. - Do not breathe refrigerant or vapor. Use only service equipment that is U.L.-listed and is certified to meet the requirements of SAE J2210 to remove HFC-134a (R-134a) from the air conditioning system. If accidental system discharge occurs, ventilate work area before resuming service. Additional health and safety information may be obtained from the refrigerant and lubricant manufacturers. 1. Connect a R-134a refrigerant recovery/recycling/charging station (A) to the high-pressure service port (B) and the low-pressure service port (C), as shown, following the equipment manufacturer's instructions. 2. Measure the amount of refrigerant oil removed from the A/C system after the recovery process is completed. Be sure to put the same amount of new refrigerant oil back into the A/C system before charging. Page 6071 234. Under-dash Fuse/Relay Box Part 6 Page 6054 Power Windows Component Location Index Page 2817 Resistor Variable Sensor Solenoid Transistors Circuit Schematics Page 116 Backup Lamp Relay: Testing and Inspection Power Relay Test Use this chart to identify the type of relay, then do the test listed for it. NOTE: See the turn signal/hazard relay input test. Normally-open type A: Page 3085 Manifold Pressure/Vacuum Sensor: Service and Repair MAP Sensor Replacement 1. Disconnect the MAP sensor 3P connector. 2. Remove the MAP sensor (A). 3. Install the sensor in the reverse order of removal with a new O-ring (B). Page 1217 Wiper Switch: Service and Repair Wiper/Washer Switch Test/Replacement 1. Remove the dashboard lower cover. 2. Remove the steering column covers. 3. Disconnect the 14P connector (A) from the wiper/washer switch (B) 4. Remove the two screws, then pull out the wiper/washer switch. 5. Inspect the connector terminals to be sure they are all making good contact. - If the terminals are bent, loose or corroded, repair them as necessary, and recheck the system. - If the terminals look OK, check for continuity between the terminals in each switch position according to the tables. If the continuity is not as specified, replace the switch. Locations 151. Middle Of Trunk Lid Page 8509 Keyless/Power Door Lock System Component Location Index Page 9210 2. Insert the terminal tool into the female terminal, and then remove the terminal tool. NOTE: Make sure you do not select a terminal tool that is larger than the mating male terminal because it would spread the female terminal and cause a loose fit. 3. Compare the drag to the other terminals in the connector. If the drag is less, replace the terminal with a replacement terminal from the appropriate terminal repair kit. Page 3564 Ignition Coil: Service and Repair Ignition Coil Removal/Installation 1. Remove the ignition coil cover (A), then remove the ignition coils (B). 2. Install the ignition coils in the reverse order of removal. Page 5577 Be sure to first disconnect the negative cable from the vehicle with the discharged battery. Page 9016 - 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. Troubleshooting Tests 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 test 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 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. 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 Drop Page 2551 10. Connect the connector securely, then install the transmission range switch cover. 11. Turn the ignition switch ON (II). Move the shift lever through all gear positions, and cheek the transmission range switch synchronization with the A/T gear position indicator. 12. Allow the wheels to rotate freely, then start the engine. 13. Move the shift lever through all gear positions, and verify the following: ^ The engine will not start in any position other than N or P. ^ The back-up lights come on when the shift lever is in the R position. Page 5390 13. Plug in the heat gun, and turn it on. Start at the middle of the splice connector, and move the gun toward the ends as the tube shrinks. Apply heat evenly by rotating the curved heat spreader around the splice connector. Shrinking is complete when a small amount of sealant appears at each end of the tube. Pigtail Terminal Selection Chart PIGTAIL TERMINAL SELECTION CHART Select the proper size pigtail terminal by matching the replacement terminal part number and the wire size being repaired to the corresponding pigtail terminal part number. Then use the color (size) splice connector listed. In some instances you may also have to match the wire seal style to select the proper pigtail terminal. Pigtail terminals are available through your parts department, in quantities of 10, using normal parts ordering procedures. Checking For Poor Fir of Terminals CHECKING FOR POOR FIT OF TERMINALS Loose terminal fit can cause a number of intermittent problems in electrical circuits. By using the Terminal Inspection Feeler Tool Set you can inspect the terminal fit between the two matching connectors without removing the terminals from the connector body. 1. Find the terminal tool that best matches the male terminal in the mating connector. Page 641 54. In Steering Column Cover Locations Shift Interlock Solenoid: Locations 107. Behind A/T Shift Lever (except M/T) Page 1883 7. Tighten the bolts in two or three steps. In the final step, tighten all bolts, in sequence, to 9.8 Nm (1.0 kgf-cm, 7.2 ft. lbs.). 8. Install the harness holder (A) and throttle cable clamps (B). 9. Install the ignition coils. 10. Check that all tubes, hoses and connectors are installed correctly. 11. After assembly, wait at least 30 minutes before filling the engine with oil. Page 7985 Rear Shelf: Service and Repair Trim Removal/Installation - Seat Side and Rear Shelf Area Trim Removal/Installation - Seat Side and Rear Shelf Area Special Tools Required KTC trim tool set SOJATP2014 2-door NOTE: - Put on gloves to protect your hands. - Use the appropriate tool from the KTC trim tool set to avoid damage when prying components. - Take care not to bend or scratch the trim and panels. 1. Remove the trim as shown. To remove the side trim panel, remove the rear seat-back and rear seat cushion. 2. Install the parts in the reverse order of removal, and note these items: - Before installing the rear shelf, remove the clips from the body, and install them to the rear shelf. - Replace any damaged clips. - When installing the rear shelf, slip the rear seat belts and center belt through the slits in the rear shelf. - Make sure the high mount brake light connector is plugged in properly. - Apply liquid thread lock to the anchor bolts before installation. Description and Operation Alarm System Transponder: Description and Operation When the key is inserted in the ignition switch and turned to the (II) position, the immobilizer receiver unit sends power to the transponder in the ignition key. The transponder then sends a coded signal back through the immobilizer receiver unit to the PCM. Page 7204 Page 7212 Programming the Transmitter NOTES: ^ The system accepts up to four transmitters. ^ Entering the programming mode cancels all learned transmitter codes, so none of the previously programmed transmitters will work. You must reprogram all the transmitters once you're in the programming mode. 1. Turn the ignition switch to ON (II). 2. Press and hold the Valet-Disarm button on the radio (between the AM/FM and CD/TAPE buttons) to enter the programming mode. (Continue to hold the button during this procedure, or programming will be cancelled.) Check that the power door locks cycle to confirm that you're in the programming mode. 3. Within 5 seconds, press the "Lock" or "Unlock" button on the transmitter. Check that the power door locks cycle to confirm that the code was accepted. 4. Within 10 seconds, press the "Lock" or "Unlock" button on each of the remaining transmitters. 5. After all the transmitters have been programmed, release the Valet-Disarm button to exit programming mode. Ordering a Transmitter Transmitters can be ordered only by authorized Honda dealers. Order them from American Honda using normal parts ordering procedures. Batteries for the Transmitter The battery number is CR2025. Each transmitter uses one battery. 99-04 Civic, 03-04 Accord, Element, Pilot 1999-00 Civic Value Package with factory-installed keyless entry system 1999-04 Civic EX with factory-installed keyless entry system or dealer-installed security system *1999-03 Civic (except EX) with dealer-installed keyless entry system or security system 2002-04 Civic Si with factory-installed keyless entry system or dealer-installed security system 2003-04 Civic Hybrid with factory-installed keyless entry system or dealer-installed security system 2004 Civic (except LX & EX) with dealer-installed keyless entry system or security system 2004 Civic LX with factory-installed keyless entry system or dealer-installed security system Page 1292 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 3233 10. Connect the connector securely, then install the transmission range switch cover. 11. Turn the ignition switch ON (II). Move the shift lever through all gear positions, and cheek the transmission range switch synchronization with the A/T gear position indicator. 12. Allow the wheels to rotate freely, then start the engine. 13. Move the shift lever through all gear positions, and verify the following: ^ The engine will not start in any position other than N or P. ^ The back-up lights come on when the shift lever is in the R position. Page 1769 3. Strip the insulation off the end of the wire so the wire fits in the new terminal as shown. (If the wire has a wire seal, replace it with a new one from the kit.) NOTE: After stripping the end of the wire, make sure you did not cut any wire strands. If you did, cut the wire off even with the insulation, and strip it again. 4. Position the terminal in the crimping tool slot with the solid portion of the terminal toward the anvil and the open section toward the former. 5. Insert the wire in the terminal to the position shown in step 3. 6. Squeeze the tool with both hands until the stops make contact. 7. Crimp the insulation crimp. - If you do not have a wire seal, then use the next larger size crimp slot. Position the crimping tool over the insulation crimp section of the terminal, then squeeze the tool with both hands until the stops make contact. - If you have a wire seal, position the insulation crimp in the 5.5 crimping slot, then carefully squeeze the crimp closed until its ends are touching and making a full-circle shape. Locations SRS Component Location Index Page 2712 4. Turn the ignition switch ON (II). 5. Measure voltage between DLC terminals No.5 and No.7. Is there 8.5 V or more? YES - Go to step 10. NO - Go to step 6. 6. Turn the ignition switch OFF. 7. Disconnect ECM/PCM connector E (31P). Make sure the OBD II scan tool or Honda PGM Tester is disconnected from the DLC. 8. Check for continuity between DLC terminal No.7 and body ground. Is there continuity? YES - Repair short to ground in the wire between DLC terminal No.7 and the ECM/PCM (E23). After repairing the wire, check the DTC with the OBD II scan tool/Honda PGM Tester and go to the DTC Troubleshooting index. See: Testing and Inspection/Diagnostic Trouble Code Descriptions NO - Go to step 9. 9. Check for continuity between DLC terminal No.7 and ECM/PCM terminal E23. Is there continuity? Page 8270 3. Use the clamp carriage lever to position the clamp unit so the tracer is directly over the flat surface of the code device, just ahead of the cam blades. 4. Pull the vertical carriage lever toward you until the tracer just touches the flat surface ahead of the cam blades. Watch the arrows on the keypad: ^ If the double-headed arrow in the middle of the keypad lights green, the tracer and cutter bit are properly aligned. ^ If the arrow on the left of the keypad lights red, the cutter bit is not touching the jaw. Turn the micrometric ring nut above the tracer to the left until the double-headed arrow lights green. ^ If the vertical arrow on the right of the keypad lights red, the tracer is not touching the jaw. Turn the micrometric ring nut above the tracer to the right until the double-headed arrow lights green. *5. Turn the micrometric ring nut to the right five clicks so the cutter bit is slightly higher than the tracer. The arrow on the left should light red. Raise the vertical carriage. NOTE: Setting the tracer five clicks lower than the cutter bit at this point has the effect of making the cutter bit cut the duplicated key a little shallower. This will protect the locking jaws from being damaged.* 6. Optional: Loosen the set screw, and adjust the hand rest to a comfortable position. Tighten the screw. 7. Pull the clamp carriage lever toward you until the clamp carriage clicks into its end-of-run position. 8. Clean any metal shavings or debris out of the center jaw. (A soft-bristle toothbrush is ideal for this purpose.) Then open the jaws with the jaws knob, and slide the key blank with its flat side down into the jaw up to the key stop. Close the jaw with the jaws knob to lock the key blank into place. Visually inspect the key for proper alignment in the jaw. 9. Set and lock the cam sets on the code device. ^ Starting with the left cam set, make sure the lock pin is pulled all the way out. (This releases the cams.) Page 9553 54. In Steering Column Cover Page 9797 5. Reinstall the parts in the reverse order of removal. 6. Test the operation of all windows with the power window master switch.If any of the windows do not work correctly, continue with normal troubleshooting, and do the master switch input test: ^ Refer to page 22-168 of the 2001-05 Civic Service Manual, or ^ Online, enter keyword MASTER TEST, and select Power Window Master Switch Input Test (4-door) from the list. Disclaimer Page 4781 - Remove clips carefully; don't damage their locks (A). - Slip pliers (A) under the clip base and through the hole at an angle, then squeeze the expansion tabs to release the clip. - After installing harness clips, make sure the harness doesn't interfere with any moving parts. - Keep wire harnesses away from exhaust pipes and other hot parts, from sharp edges of brackets and holes, and from exposed screws and bolts. - Seat grommets in their grooves properly (A). Do not leave grommets distorted (B). Testing and Repairs - Do not use wires or harnesses with broken insulation. Replace them or repair them by wrapping the break with electrical tape. - After installing parts, make sure that no wires are pinched under them. - When using electrical test equipment, follow the manufacturer's instructions and those described. - If possible, insert the probe of the tester from the wire side (except waterproof connector). - Use back probe adaptor 07TAZ-001020A. - Refer to the instructions in the Honda Terminal Kit for identification and replacement of connector terminals. Five-Step Troubleshooting Five-Step Troubleshooting 1. Verify The Complaint Page 4180 13. Remove the solenoid cover, and make sure the solenoid plunger groove is installed in the fork on the lever. ^ If needed, correct the position of the solenoid plunger, then go to step 14. ^ If the solenoid plunger is correctly installed, there is an electrical problem with the key interlock system; refer to the Automatic Transmission section of the appropriate service manual for troubleshooting information. Once the key interlock is working normally, go to step 14. 14. Install the solenoid cover. 15. Reinstall the steering column covers. 16. Center-punch a completion mark above the seventh character of the engine compartment VIN. Disclaimer Page 5730 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 Locater) 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. Troubleshooting Precautions Troubleshooting Precautions Before Troubleshooting 1. Check the main fuse and the fuse 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, or you will damage the alternator diodes. - Do not attempt to crank the engine with the ground cable disconnected 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. Diagram Information and Instructions Brake Warning Indicator: Diagram Information and Instructions Terminal Numbering System Terminal Numbering System Connector terminals are numbered according to the cavities they're in. The cavities are numbered starting from the upper left, looking at the male terminals from the terminal side or looking at the female terminals from the wire side. Both views are in the same direction so the numbers are the same. All actual cavities are numbered, even if they have no wire terminals in them. NOTE: Data Link Connector (DLC) terminals are numbered according 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 below is #6. Page 1974 Intake Manifold: Service and Repair Intake Manifold Removal and Installation Page 2995 Main Relay (Computer/Fuel System): Testing and Inspection Power Relay Test Use this chart to identify the type of relay, then do the test listed for it. NOTE: See the turn signal/hazard relay input test. Normally-open type A: Page 5961 Power Windows Component Location Index Page 8956 Parking Brake Warning Switch: Testing and Inspection Parking Brake Switch Test 1. Remove the console, and disconnect the connector (A) from the switch (B). 2. Check for continuity between the positive terminal and body ground: ^ With the brake lever up, there should be continuity. ^ With the brake lever down, there should be no continuity. Page 1362 2. If you installed a new belt, run the engine for 5 minutes, then readjust the belt to the used belt specification. Adjustment 3. Loosen the power steering pump mounting nut (A) and pump locknut (B). 4. Turn the adjusting bolt (C) to get the proper belt tension, then retighten the mounting nut and locknut. 5. Start the engine and turn the steering wheel from lock-to-lock several times, then stop the engine and recheck the tension of the belt. Page 9298 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. Below most connector numbers and component names are PHOTO and VIEW numbers. The PHOTO number refers to a photo in the back of the book that shows the connector's location on the car. The VIEW number refers to an illustration in the back of the book that shows the connector terminals, wire colors, connector cavity numbers, and other details. The connector cavity numbering sequence begins at the top left corner of the connector as seen from either of the viewpoints shown on diagram [8] . Except for the DLC (data link 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 C554, for example, means those terminals join in cavity 2 of connector C554. Power Distribution Schematics Power Distribution Schematics Page 9030 2. Cut off the wire about an inch back from where it connects to the damaged or faulty terminal, then strip about half of the insulation off that piece. This will be used to size the wire end of the replacement pigtail terminal. NOTE: If you are not sure of the wire size, start with a large enough hole on the stripper that will not nick or cut off any strands of wires. 3. Select a pigtail terminal that matches the original wire at both ends (same kind of terminal and same diameter bare wire). 4. Select the smallest splice connector (yellow, pink, or blue) that will fit onto the stripped end of the original wire. 5. Insert the pigtail terminal into the connector cavity; push it in until it locks in place. 6. Lay the pigtail and the original wire side-by-side, and cut off both ends at once. If you are making more than one splice, do not cut each pigtail at the same location; the resulting "lump" of splice connectors would interfere with rewrapping the harness. Instead, cut the first pigtail close enough to the terminal so you will have room to make each remaining cut about 20 mm (3/4 inch) farther down on the next pigtail. 7. If you are using a yellow splice connector, strip about 6 mm (1/4 inch) of insulation off the ends of both wires. If you are using a pink or blue splice connector, strip off about 8 mm (5/16 inch) of insulation. Locations Fuel Supply System - Component Location Index Page 6294 12. Insert the ball joint bore gauge into the knuckle bore in the four positions shown: ^ If the bore gauge does not fit through the bore at any point, go to step 13. ^ If the bore gauge fits through the knuckle at any point, the knuckle is not usable for ball joint replacement. Replace the knuckle. Replacement knuckles include a new ball joint. Page 2729 ^ Start the engine and let it warm up to its normal operating temperature (the cooling fans cycle twice). ^ Let the engine idle (throttle closed and all electrical items off) for 10 minutes. 17. CR-V only: Reset the power window control unit: ^ Turn the ignition switch to ON (II). ^ Make sure the driver's window is fully closed. ^ Push down and hold the window switch until the window goes all the way down. ^ Pull back and hold the window switch until the window goes all the way up, then hold the switch for at least 2 more seconds. 18. Enter the audio unit anti-theft code, and set the clock. Enter the audio presets. Disclaimer Page 2359 Main Relay (Computer/Fuel System): Description and Operation PGM-FI Main Relay 1 and 2 The PGM-FI relay consists of two separate relays. PGM-FI main relay 1 is energized whenever the ignition switch is ON (II) which supplies battery voltage to ECM/PCM, power to the injectors, and power for PGM-FI main relay 2. PGM-FI main relay 2 is energized to supply power to the fuel pump for 2 seconds when the ignition switch is turned ON (II), and when the engine is running. Page 5604 18. If you removed the pulley, put the rotor in the drive-end housing, then tighten its locknut to 111 N.m (11.3 kgf.m, 81.7 lbf.ft). 19. Remove any grease or any oil from the slip rings. 20. Push the brushes (A) in, then insert a pin or drill bit (B) (about 1.8 mm (0.77 in.) diameter) to hold them there. 21. Heat the rear bearing seat with a 1,000 W hair drier for about 5 minutes (129 140 °F, 50 - 60 °C). 22. Put the rear housing assembly (A) and drive-end housing/rotor assembly (B) together, tighten the four through bolts (C) and pull put the pin (D). 23. After assembling the alternator, turn the pulley by hand to make sure the rotor rotates smoothly and without noise. 24. Reinstall the alternator, and adjust its belt tension. Page 3707 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. How to Replace Connector Terminals Terminal Replacement Procedure HOW TO REPLACE CONNECTOR TERMINALS The terminal repair kits provide necessary tools and materials (terminals, wire seals, and splice connectors) to repair many damaged or faulty connector terminals. However, not all terminals for all connectors are available. Refer to the labels on the lids of the repair kits for replacement terminal availability. IMPORTANT SAFETY INFORMATION: On some models, the SRS wires are in a separate harness. If the SRS harness is damaged, replace the harness; do not repair it. On other models, wire harnesses include yellow SRS wires. If any SRS wire is damaged, replace the entire harness; do not repair it. Before you begin, inspect the wire you are about to repair for damage and length. Make sure the wire will be long enough to make a terminal repair without stretching it when you reinstall the terminal in the connector. If the wire is too short, or if access to the connector is too restricted to make a terminal repair, you may need to install a pigtail terminal (a short length of wire with a factory-crimped terminal on it). Refer to HOW TO INSTALL PIGTAIL TERMINALS. Removing the Terminal Description and Operation Temperature Gauge: Description and Operation How the Circuit Works The indicators are controlled by relative conditions in their associated systems. For the following indicators the information supplied to the gauge assembly is received via the multiplex control unit: - Charging System - Door Indicator Light - Maintenance Required Indicator - Seat Belt Reminder - Trunk Indicator Light Refer to each associated system to see its entire schematic. Engine Coolant Temperature Gauge The engine coolant temperature gauge is controlled by the CPU built-in the gauge assembly. The CPU receives coolant temperature information from the ECM/PCM via the multiplex control unit, The ECM/PCM receives coolant temperature information from the ECT sensor. Page 4179 ^ The left end goes behind the notch on the interlock lever. ^ Once the spring is correctly installed, make sure the lever moves freely and returns properly. 10. Insert the plunger into the interlock solenoid, then install the solenoid using a new screw. Make sure the groove of the solenoid plunger is in the fork on the lever. 11. Install a new plastic cover on the interlock solenoid. 12. Check the operation of the ignition switch key interlock: ^ Set the parking brake, and turn the ignition switch to ON (I I). ^ While pressing the brake pedal, shift the transmission to Neutral. ^ Try turning the ignition switch to LOCK (0) - If you cannot turn the switch to LOCK (0), your repair was successful; go to step 15. - If you can turn the switch to LOCK (0), the interlock is not working; go to step 13. Page 5592 Alternator: Description and Operation Alternator Control The alternator signals the Engine Control Module (ECM)/Powertrain Control Module (PCM) during charging. The ECM/PCM then controls the voltage generated at the alternator according to the electrical load determined by the Electrical Load Detector (ELD) and driving mode. This reduces engine load to improve fuel economy. Page 7980 6. Without moonroof: Remove the headliner (A). 1. 2-door: Remove the upper portion of the B-pillar upper trim (B) from one side 2. 4-door: Remove the upper portion of the C-pillar trim (C) from each side 3. Remove the remaining door opening trim (D) from each roof portion. 4. Detach the rear clips (E) by pulling the headliner down. 5. With the help of an assistant, lower the headliner. 6. Remove the cushion tape or glue (F), then remove the roof harness (G) from the headliner. 7. Remove the headliner through the passenger's door opening. 7. If necessary, remove the bolts, then remove the grab handle bracket (A). 4-door: Remove the remaining grab handle brackets, if necessary. 8. Install the headliner in the reverse order of removal, and note these items: - When reinstalling the headliner through the door opening, be careful not to fold or bend it. Also, be careful not to scratch the body. - If the threads on a visor or grab handle screws are worn out, use an oversized self tapping ET screw (P/N 90137-SOA-003) made specifically for this application. - Check that both sides of the headliner are securely attached to the trim. - Replace any clips that remain in the roof during removal. Reinstall the clips back in the headliner before installation. Page 2768 ECM/PCM Inputs And Outputs At Connector A (31P) Page 4939 ^ The vehicle is shown as eligible on a VIN status inquiry. In addition, check for a punch mark above the seventh character of the engine compartment VIN. A punch mark in that location means the ignition switch key interlock has already been inspected/repaired. 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 a VIN status inquiry before selling it. CUSTOMER NOTIFICATION All owners of affected vehicles will be sent a notification of this campaign. An example of the customer notification is at the end of this service bulletin. CORRECTIVE ACTION Inspect the ignition switch and, if needed, install a Key Interlock Repair Kit. PARTS INFORMATION Key Interlock Repair Kit: P/N 06351-SDA-000 REQUIRED SPECIAL TOOLS Interlock Slide Hammer: T/N 07AAC-S84A100 NOTE: ^ An initial quantity of Permalube grease to lubricate the sliding surface of the interlock lever is included with the slide hammer. To order more Permalube, use P/N 08734-0030. ^ To order a replacement clamping bolt for the slide hammer, use T/N 07AAC-S84A400. WARRANTY CLAIM INFORMATION Failed Part: P/N 35100-SDA-A31 Defect Code: 5GC00 Symptom Code: R4400 Page 8788 - 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. - Refer to the scrapping procedures for disposal of the damaged airbag. 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. 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. Page 9269 Low Beam Relay: Testing and Inspection Power Relay Test Use this chart to identify the type of relay, then do the test listed for it. NOTE: See the turn signal/hazard relay input test. Normally-open type A: Page 2380 166. PGM-FI Main Relays 1 And 2 Page 9360 1. Remove the secondary lock from the male terminal half. 2. Remove the secondary lock from the female terminal half. 3. Remove the terminal (same procedure for male and female). 4. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE C: 1. Remove the secondary lock. Page 1535 Relay And Control Unit Locations - Engine Compartment Page 9508 2. Cut off the wire about an inch back from where it connects to the damaged or faulty terminal, then strip about half of the insulation off that piece. This will be used to size the wire end of the replacement pigtail terminal. NOTE: If you are not sure of the wire size, start with a large enough hole on the stripper that will not nick or cut off any strands of wires. 3. Select a pigtail terminal that matches the original wire at both ends (same kind of terminal and same diameter bare wire). 4. Select the smallest splice connector (yellow, pink, or blue) that will fit onto the stripped end of the original wire. 5. Insert the pigtail terminal into the connector cavity; push it in until it locks in place. 6. Lay the pigtail and the original wire side-by-side, and cut off both ends at once. If you are making more than one splice, do not cut each pigtail at the same location; the resulting "lump" of splice connectors would interfere with rewrapping the harness. Instead, cut the first pigtail close enough to the terminal so you will have room to make each remaining cut about 20 mm (3/4 inch) farther down on the next pigtail. 7. If you are using a yellow splice connector, strip about 6 mm (1/4 inch) of insulation off the ends of both wires. If you are using a pink or blue splice connector, strip off about 8 mm (5/16 inch) of insulation. Page 1736 NOTE: ^ Identify parts as they are removed to ensure reinstallation in original location. ^ Inspect the rocker shafts and rocker arms. ^ The rocker arms must be installed in the same positions if reused. ^ When removing or installing the rocker arm assembly, do not remove the camshaft holder bolts. The bolts will keep the holders, springs and rocker arms on the shaft. ^ Prior to reassembling, clean all the parts in solvent, dry them, and apply lubricant to any contact points. Page 3717 8. Inspect the quality of the wire crimp. If it has any of the following NO GOOD crimps, cut it off and start over. 9. Insert the terminal into the connector. Make sure the wire seals are pushed all the way into the connector. Lightly pull on the wires to make sure the terminal is locked into place. 10. Close or insert the secondary terminal lock, if applicable, and reconnect the connector. How to Install Pigtail Terminals HOW TO INSTALL PIGTAIL TERMINALS Pigtail terminals (short pieces of wire with a factory crimped terminal) are used when the wire is too short or when access to the connector is too restricted to make a terminal repair. NOTE: To replace just a connector terminal, go to How to Replace Connector Terminals. IMPORTANT SAFETY INFORMATION: On some models, the SRS wires are in a separate harness. If the SRS harness is damaged, replace the harness; do not repair it. On other models, wire harnesses include yellow SRS wires. If any SRS wire is damaged, replace the entire harness; do not repair it. 1. Remove the damaged or faulty terminal from the connector. Use the proper removal tool from Pin Tool Set. Locations Oxygen Sensor Relay: Locations PGM-FI System - Component Location Index Locations 58. Under Left Side Of Dash (Honda Accessory) Page 5494 6. If the clearance is incorrect, loosen the star locknut (A), and turn the adjuster (B) in or out to adjust. ^ Adjust the clearance while the specified vacuum is applied to the booster. ^ Hold the clevis (C) while adjusting. 7. Tighten the star locknut securely. 8. Remove the special tool (D). 9. Check the pushrod length (A) as shown if the booster is removed. If the length is incorrect, loosen the pushrod locknut (B), and turn the clevis (C) in or out to adjust. 10. Install the master cylinder. Page 6275 85. Hold the gearbox housing using a C-clamp, then install the special tool on the lock screw (A). Retighten the lock screw to specified torque values. 86. Remove the special tool. Retighten the 12 mm flange bolts (A) to specified torque values. After tightening the 12 mm flange bolts, install a new lock washer (B) over one of bolt the heads (C). Be sure the tabs (D) of the lock washer are aligned with the flat surfaces (E) of the bolt head. 87. Clean off any grease or contamination from the boot installation grooves around on the housing. 88. Expand boot (A) by removing the vinyl tape, and fit the boot ends (B) in the installation grooves on the cylinder housing. 89. Close the ear portion (A) of the bands (B) with a commercially available pincers, Oetiker 1098 or equivalent (C). Page 4836 8. Reassemble the transmission; see page 13-43 (13-59 for Hybrid) of the service manual. 9. Install the new shift fork holder. Check the reverse shift fork clearance; see page 13-19 (13-34 for Hybrid) of the service manual. 10. Reinstall the transmission; see page 13-9 (13-23 for Hybrid) of the service manual. 11. Fill the transmission with MTF. 12. * Test-drive the car; make several right turns (left turns for Hybrid), and check that the clicking noise is gone.* Disclaimer Page 7181 Keyless Entry Receiver: Diagrams 163. Keyless Receiver Unit (EX; '04-'05: LX, GX) 164. Keyless Receiver Unit (Honda Accessory) Page 4928 Recall 10V364000: Ignition Interlock Defect Shift Interlock Switch: All Technical Service Bulletins Recall 10V364000: Ignition Interlock Defect VEHICLE MAKE/MODEL: MODEL YEAR(S): Honda/Accord 2003 Honda/Civic 2003 Honda/Element 2003-2004 MANUFACTURER: Honda (American Honda Motor Co.) MFR'S REPORT DATE: August 04, 2010 NHTSA CAMPAIGN ID NUMBER: 10V364000 NHTSA ACTION NUMBER: EA09001 COMPONENT: Electrical System: Ignition POTENTIAL NUMBER OF UNITS AFFECTED: 384220 SUMMARY: Honda is recalling certain model year 2003 Honda Accord, Civic two and four door, and model year 2003-2004 Honda Element vehicles. The interlock lever of the ignition switch may unexpectedly deform, which can allow the interlock function of a vehicle with an automatic transmission to be defeated. CONSEQUENCE: Removal of the ignition key when the gear selector of a vehicle with an automatic transmission has not been shifted to the park position can allow the vehicle to roll away, increasing the risk of a crash. REMEDY: Dealers will remove the original interlock pin and lever within the ignition switch, and replace them with newly, designed components. This service will be performed free of charge. The safety recall is expected to begin on or about September 29, 2010. Owners may contact Honda at 1-800-999-1009. NOTES: Honda safety recall No. R44. 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 4096 Circuit Schematics Each schematic represents one circuit. A circuit's wires and components are arranged to show current flow from power at the top of the diagram 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 Page 3735 Control Module: Service and Repair How to Substitute the PCM How to Substitute the PCM 1. Remove the PCM from the vehicle. 2. Install a known-good PCM in the vehicle. 3. Rewrite the immobilizer code with the PCM replacement procedure in the Honda PGM Tester; It allows you to start the engine. 4. After completing your tests, reinstall the original PCM and rewrite the immobilizer code with the PCM replacement procedure in the HDS Tester again. Page 6907 4. Repeat steps 2 and 3 as needed for additional buttons. 5. Install the seat-back cover in the reverse order of removal. Disclaimer Page 6583 135. Blower Power Transistor Page 8859 Air Bag(s) Arming and Disarming: Description and Operation SRS Components SRS Components Airbags The SRS is a safety device which, when used 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 (A), the cable reel (B), the driver's airbag (C), the front passenger's airbag (D), seat belt tensioners (I), seat belt buckle tensioners (J), and front impact sensors (K). Since the driver's and front passenger's airbags use the same sensors, both normally inflate at the same time. However, it is possible for only one airbag to inflate. This can occur when the severity of a collision is at the margin, or threshold, that determines whether or not the airbags will deploy. In such cases, the seat belt will provide sufficient protection, and the supplemental protection offered by the airbag would be minimal. Side Airbags The side airbags (E) are in each front seat-back. They help protect the upper torso of the driver or front seat passenger during a moderate to severe side impact. Side impact sensors (F) in each door sill and in the SRS unit detect such an impact and instantly inflate the driver's or the passenger's side airbag. Only one side airbag will deploy during a side impact. If the impact is on the passenger's side, the passenger's side airbag will deploy even if there is no passenger. 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. OPDS The side airbag system also includes an occupant position detection system (OPDS). This system consists of sensors (G) and a OPDS unit (H) in the front passenger's seat-back. The OPDS unit sends occupant height and position data to the SRS unit. If the OPDS unit determines that the front passenger is of small stature (for example, a child) and the front passenger is leaning into the side airbag deployment path, the SRS unit will automatically disable the passenger's side airbag. The SRS unit will also disable the airbag when the OPDS detects certain objects on the seat. When the side airbag is disabled, the side airbag cutoff indicator on the instrument panel alerts the driver that the passenger's side airbag will not deploy in a side impact. When the object is removed, or the passenger sits upright, the Side Airbag Cutoff indicator will go off after a few seconds, alerting the driver that the passenger's side airbag will deploy in a side impact. Page 3136 - Before connecting connectors, make sure the terminals (A) are in place and not bent. - Check for loose retainer (A) and rubber seals (B). - The backs of some connectors are packed with dielectric grease. Add grease if necessary. If the grease is contaminated, replace it. - Insert the connector all the way and make sure it is securely locked. - Position wires so that the open end of the cover faces down. Handling Wires and Harnesses - Secure wires and wire harnesses to the frame with their respective wire ties at the designated locations. Locations Radiator Cooling Fan Motor Relay: Locations Under-hood Fuse/Relay Box Page 1782 Connecting Rod Bearing: Service and Repair Rod Bearing Clearance Inspection 1. Remove the connecting rod cap and bearing half. 2. Clean the crankshaft rod journal and bearing half with a clean shop towel. 3. Place a strip of plastigage across the rod journal. 4. Reinstall the bearing half and cap, and torque the bolts to 32 Nm (3.3 kgf-cm, 24 ft. lbs.). Do not rotate the crankshaft. 5. Remove the rod cap and bearing half and measure the widest part of the plastigage. Connecting Rod Bearing-to-Journal Oil Clearance: Standard (New): 0.024 - 0.042 mm (0.0009 0.0017 inch) Service Limit: 0.05 mm (0.002 inch) 6. If the plastigage measures too wide or too narrow, remove the upper half of the bearing, install a new, complete bearing with the same color code, and recheck the clearance. Do not file, shim, or scrape the bearings or the caps to adjust clearance. 7. If the plastigage shows the clearance is still incorrect, try the next larger or smaller bearing (the color listed above or below that one), and check clearance again. If the proper clearance cannot be obtained by using the appropriate larger or smaller bearings, replace the crankshaft and start over. Rod Bearing Selection Each rod falls into one of four tolerance ranges (from 0 to 0.024 mm (0.0009 inch), in 0.006 mm (0.0002 inch) increments) depending on the size of its big-end bore. It's then stamped with a number (1, 2, 3, or 4), indicating the range. You may find any combination of 1, 2, 3, or 4 in any engine. Normal Bore Size: 43.0 mm (1.89 inch) Inspect the connecting rod for cracks and heat damage. Connecting Rod Journal Code Locations Page 3062 163. Under Left Side Of Floor (except GX) Page 190 Interior Lighting Module: Electrical Diagrams Diagram 115-0 (except EX) Page 2849 Information Bus: Description and Operation Circuit Description How the Circuit Works The conventional portion of the electrical system carries DC (or A/C) power through separate wires to each component. The multiplex portion of the system, however, sends digital signals between control units through shared wires to reduce the number and weight of wire harnesses. The signals from each switch are converted to digital signals within the receiving multiplex control unit. The digital signals are sent from one multiplex control unit to another as serial data over dedicated communication lines. When the appropriate control unit receives the digital signal, it converts it back to a switch signal and operates the related components. The multiplex control system schematic shows its power, grounds, and communication lines. The ignition key light is also shown because it is used to blink DTCs in the system's self-diagnosis function. The rest of the multiplex control system wiring is shown in the following circuit schematics: - Charging System - Horns - HVAC - Fans - Low Oil Pressure Indicator - Seat Belt Reminder - Lights-on Reminder - Key-in Reminder - Key Light Timer - Gauges and Indicators - A/T Gear Position Indicator - Wiper/Washers - Headlights - Trunk Light, Ceiling Light and Spotlights - Entry Light Control System - Power Door Locks - Keyless Security Alarm System - Interlock System Page 7216 1997-01 CR-V with dealer-installed security system 1996-97 del Sol with dealer-installed security system 1996-98 Odyssey with dealer-installed security system *1999-04 Odyssey LX with dealer-installed keyless entry system or security system* 1996-01 Prelude with dealer-installed security system *2000-04 S2000 with dealer-installed security system 2000-04 Insight with dealer-installed security system 2003-04 Pilot LX with dealer-installed keyless entry system or security system* Programming the Transmitter NOTES: ^ The system accepts up to three transmitters. The transmitter codes are stored in a stacking-type memory. If a fourth transmitter code is programmed, the code for the first transmitter is erased. ^ Entering the programming mode cancels all learned transmitter codes, so none of the previously programmed transmitters will work. You must reprogram all of the transmitters once you are in the programming mode. ^ You must complete steps 1-6 within 4 seconds of the previous step to keep the system from exiting the programming mode. 1. Turn the ignition switch to ON (II). 2. Press the "Lock" or "Unlock" button on one of the transmitters. (An unprogrammed transmitter can be used for this step.) 3. Turn the ignition switch to LOCK (0). 4. Repeat steps 1, 2, and 3 two more times using the same transmitter used in step 2. 5. Turn the ignition switch to ON (II). 6. Press the "Lock" or "Unlock" button on the same transmitter. Make sure the power door locks cycle to confirm that the system is in programming mode. 7. Within 10 seconds, press the "Lock" or "Unlock" button on each transmitter. Make sure the power door locks cycle after you press each transmitter button to confirm that the system accepted the transmitter's code. 8. Turn the ignition switch to LOCK (0) to exit the programming mode. Ordering a Transmitter Transmitters can be ordered only by authorized Honda dealers. Order them from American Honda using normal parts ordering procedures. Batteries for the Transmitter The battery number is CR2025. Each transmitter uses one battery. Page 192 Diagram 115-2 (Coupe EX) Page 3242 Terminals - "T" Shielding Switches Fuses Page 2357 94. Behind Glove Box (except GX) Component Locations Page 6929 Air Bag Control Module: Service and Repair OPDS Unit Replacement OPDS Unit Replacement NOTE: Review the seat replacement procedure in the body section before performing repair or service. Removal 1. Disconnect the battery negative cable, and wait at least 3 minutes before beginning work. 2. Disconnect the side airbag harness 2P connector. 3. Remove the seat assembly and seat-back cover. 4. Remove the cover (A), then disconnect the OPDS unit harness 8P and sensor connectors (B) from the OPDS unit. Installation 1. Place the new OPDS unit on the seat-back frame. Tighten the two screws, and connect the OPDS unit harness 8P and sensor connector to the OPDS unit. Reinstall the cover. 2. Install the seat-back cover. 3. Install the seat assembly, then connect the side airbag harness 2P connector. 4. Reconnect the battery negative cable. 5. Set the seat-back in the normal position, and make sure there is nothing on the front passenger's seat. 6. Initialize the OPDS unit. 7. After installing the OPDS unit, confirm proper system operation: Turn the ignition switch ON (II); the SRS indicator should come on for about 6 seconds and then go off. Page 865 125. TP Sensor Diagrams 39. ECT Sensor Page 5448 Brake Fluid: Service Precautions SAFETY PRECAUTIONS WARNING: Brake fluid may be irritating to the skin or eyes. In case of contact, take the following actions: * Eye Contact - rinse eyes thoroughly with water. * Skin Contact - wash skin with soap and water. Page 8844 15. Measure resistance between the No.1 and No.2 terminals with the float at E (EMPTY), 1/2 (HALF FULL), and F (FULL) positions. If you do not get the shown readings, replace the fuel gauge sending unit. NOTE: Remove the No.9 BACK UP (10A) fuse from the under-hood fuse/relay box for at least 10 seconds after completing troubleshooting, otherwise it may take up to 20 minutes for the fuel gauge to indicate the correct fuel level. Page 8347 - Mix the body filler and hardener quickly. - Apply the body filler in several thin coats, without air bubbles. - Do not try to cover the surface with one heavy coat. - Apply the body filler over the damaged area with a putty knife using light pressure. - After applying the body filler, allow 5-6 minutes of normal drying time, then force dry it with infrared lamps or other industrial dryer at 122 degrees F (50 degrees C) - 140 degrees F (60 degrees C). NOTE: Follow the body filler manufacturer's instructions for drying time. 2. Polishing The body filler is dry when a white mark appears when the surface is scratched with your finger nail. 1. Throughly sand the body filler surface. Use the double action sander and #80-#120 disc paper. 2. Sand the surface evenly, particularly the area that was filled. Use the flexible block and #120-#180 sandpaper. Page 7828 ^ Incorrect: "If a Master Key is to be cut, put a five (5) in the blank space. Use a two (2) if a valet key is needed." ^ Correct: "If a Master Key is to be cut, put an M in the blank space. Use an S if a valet key is needed." Page 2, legend at the bottom: ^ Incorrect: "C. If a Master key is desired, then the number five (5) should be placed in the M/S position. Place the number two (2) in the M/S column if a Sub (Valet) key is needed." ^ Correct: "C. If a Master Key is desired, then an M should be placed in the M/S position. Place an S in the MIS column if a Sub (Valet) key is needed." Page 7403 Alarm Module: Diagrams 182. Immobilizer Control Unit - Receiver 214. Security Control Unit (Optional) Page 549 Clutch Switch: Testing and Inspection Clutch Pedal Position Switch Test 1. Disconnect the 2P connector from the clutch pedal position switch (A). 2. Remove the clutch pedal position switch. 3. Check for continuity between the terminals according to the table. - If the continuity is not as specified, replace the clutch pedal position switch. - If OK, install the clutch pedal position switch and adjust the pedal height. Page 6637 Relay And Control Unit Locations - Engine Compartment Page 7380 1. Remove the driver's dashboard lower cover. (See the body section of the appropriate service manual.) 2. Replace the security control unit. ^ Civic: Remove the security control unit, and install the new security control unit. ^ * CR-V and Element: Remove the security control unit and microphone. Install the new security control unit and new microphone.* 3. Reprogram the keyless receiver unit. NOTE: The codes of up to three transmitters can be stored in the keyless receiver unit memory. If a fourth code is stored, the code that was input first will be erased. It is important to maintain the time limits between the steps. Make sure the doors and the trunk/tailgate/hatch are closed, and that you have all of the remotes the customer wishes to use. ^ Turn the ignition switch to ON (II). ^ Within 1 to 4 seconds, push the transmitter lock or unlock button. ^ Within 1 to 4 seconds, turn the ignition switch to LOCK (0). ^ Within 1 to 4 seconds, turn the ignition to ON (II). ^ Within 1 to 4 seconds, push the transmitter lock or unlock button. ^ Within 1 to 4 seconds, turn the ignition switch to LOCK (0). ^ Within 1 to 4 seconds, turn the ignition switch to ON (II). ^ Within 1 to 4 seconds, push the transmitter lock or unlock button. Page 3356 172. EGR Valve And EGR Valve Position Sensor (EX, HX; '04-'05: DX, LX) Page 6267 special tool up and down several times to make the valve seal ring fit in the pinion shaft groove. 39. Remove the special tool, turn it over, slide the smaller diameter end over the valve seal ring. Move it up and down several times to make the valve seal ring fit snugly in the pinion shaft groove. 40. Apply power steering fluid to the surface of the special tool. Slip two new seal rings (A) over the special tool from the smaller diameter end, and expand them. Install only two rings at a time from each end of the pinion shaft sleeve (B). Note these items when installing the seal ring: ^ Do not over-expand the seal ring. Install the resin seal rings with care so as not to damage them. After installation, be sure to contract the seal rings using the special tool (sizing tool). ^ There are two types of sleeve seal rings: black: and brown. Do not mix the different types of rings as they are not compatible. 41. Align the special tool with each groove in the sleeve, and slide a sleeve seal ring into each groove. After installation, compress the seal rings with your fingers temporarily. 42. Apply power steering fluid to the seal rings on the sleeve, and to the entire inside surface of the special tool, then slowly insert the sleeve into the special tool. 43. Move the sleeve back and forth several times to make the seal rings snugly fit in the sleeve. Be sure that the seal rings are not twisted. 44. Apply power steering fluid to the surface of the pinion shaft (A). Slide the sleeve (B) onto the pinion shaft by aligning the locating pin (C) on the inside of the sleeve with the cutout (D) in the shaft. Then install the new snap ring (E) securely in the pinion shaft groove. Be careful not to damage the valve seal ring when inserting the sleeve. Page 8049 *T-5 Sidewinder Key Applications ^ 2003-05 Civic ^ 2004-05 Civic Hybrid ^ 2003-05 Civic GX (CNG) ^ 2004-05 S2000 ^ 2002-06 CR-V ^ 2003-06 Element ^ 2003-04 Odyssey ^ 2003-04 Pilot Ordering Honda key blanks through normal parts ordering channels: Refer to the parts catalog for correct key(s) for your application. PROGRAMMING KEYS Depending on the type of key blank you use, do this: ^ If you have used a T-5 programmable key blank ("T-5" stamped on the shank), you must code the key's transponder with the Ilco Immobilizer Key Code Duplicator (see S/B 99-053, Ilco Immobilizer key Code Duplicator). ^ If you have used a Honda key blank, add the* transponder code of the new key to the immobilizer system with the Honda Diagnostic System (HDS). ORDERING INFORMATION *To order the MATRIX H Key Cutting Machine, replacement cutter bits, fixed jaws and mobile jaws, T-5 programmable key blanks, and practice key blanks, contact the Honda Tool and Equipment Program by calling 888-424-6857 or using the fax order form provided in your Honda Tool and Equipment Program Catalog.* Order Honda key blanks through normal parts ordering channels. WARRANTY CLAIM INFORMATION None. This service bulletin is for information only. *DETERMINING WHICH KEY TO USE T-5 keys require less time to program and should be the first choice. They can be used as long as the following requirements are met: ^ Do you have the customer's operating key? ^ Does the vehicle fall within the T-5 Sidewinder Key Applications? ^ Does your dealership have an Ilco Immobilizer Key Code Duplicator? If the answer to all three questions on the above is yes, the 1-5 key option is the easier procedure. If you answered no to any of the questions, you should order the key(s) from the parts catalogue, and program it using the HDS.* BEFORE YOU START CUTTING 1. Get the original key or the key number from your customer or from the iN. 2. Get the applicable key blank. 3. If cutting by code, look up the applicable 9-digit cutting code for the key number. Refer to the code book Honda High Security key Codes that comes with the machine. Page 4774 Diodes Light Emitting Diode (LED) Motor Pressure Sensor Page 7648 *T-5 Sidewinder Key Applications ^ 2003-05 Civic ^ 2004-05 Civic Hybrid ^ 2003-05 Civic GX (CNG) ^ 2004-05 S2000 ^ 2002-06 CR-V ^ 2003-06 Element ^ 2003-04 Odyssey ^ 2003-04 Pilot Ordering Honda key blanks through normal parts ordering channels: Refer to the parts catalog for correct key(s) for your application. PROGRAMMING KEYS Depending on the type of key blank you use, do this: ^ If you have used a T-5 programmable key blank ("T-5" stamped on the shank), you must code the key's transponder with the Ilco Immobilizer Key Code Duplicator (see S/B 99-053, Ilco Immobilizer key Code Duplicator). ^ If you have used a Honda key blank, add the* transponder code of the new key to the immobilizer system with the Honda Diagnostic System (HDS). ORDERING INFORMATION *To order the MATRIX H Key Cutting Machine, replacement cutter bits, fixed jaws and mobile jaws, T-5 programmable key blanks, and practice key blanks, contact the Honda Tool and Equipment Program by calling 888-424-6857 or using the fax order form provided in your Honda Tool and Equipment Program Catalog.* Order Honda key blanks through normal parts ordering channels. WARRANTY CLAIM INFORMATION None. This service bulletin is for information only. *DETERMINING WHICH KEY TO USE T-5 keys require less time to program and should be the first choice. They can be used as long as the following requirements are met: ^ Do you have the customer's operating key? ^ Does the vehicle fall within the T-5 Sidewinder Key Applications? ^ Does your dealership have an Ilco Immobilizer Key Code Duplicator? If the answer to all three questions on the above is yes, the 1-5 key option is the easier procedure. If you answered no to any of the questions, you should order the key(s) from the parts catalogue, and program it using the HDS.* BEFORE YOU START CUTTING 1. Get the original key or the key number from your customer or from the iN. 2. Get the applicable key blank. 3. If cutting by code, look up the applicable 9-digit cutting code for the key number. Refer to the code book Honda High Security key Codes that comes with the machine. Testing and Inspection Trunk Lamp Switch: Testing and Inspection Trunk Lid Latch Switch Test 1. Open the trunk lid. 2. Disconnect the 2P connector (A) from the trunk lid latch (B). 3. Check for continuity between the No.1 and No.2 terminals. - There should be continuity with the trunk lid open. - There should be no continuity with the trunk lid closed. 4. If the continuity is not as specified, replace the trunk lid latch switch. Component Locations Moonroof Component Location Index Page 9492 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. Test Equipment 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. Page 5842 Relay And Control Unit Locations - Engine Compartment Page 9775 Rear Door Window Motor: Diagrams (Sedan Except DX) 63. Power Window Motor, Left Rear Or Right Rear (Sedan Except DX) Page 6743 Air Bag: Connector Locations 53. Steering Wheel (Airbag Inflators Removed) 90. Under Right Side of Dash 100. Under Driver's Seat Page 5736 1. Remove the secondary lock from the male terminal half. 2. Remove the secondary lock from the female terminal half. 3. Remove the terminal (same procedure for male and female). 4. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE C: 1. Remove the secondary lock. Page 1059 Wire Color Abbreviations Page 9528 Tail Lamp Relay: Testing and Inspection Power Relay Test Use this chart to identify the type of relay, then do the test listed for it. NOTE: See the turn signal/hazard relay input test. Normally-open type A: Page 851 Vehicle Speed Sensor: Testing and Inspection Vehicle Speed Signal Circuit Troubleshooting Special Tools Required: Test Harness 07LAJ-PT3020A Before testing, inspect the No.4 (10 A) and No.10 (7.5 A) fuses in the under-dash fuse/relay box. 1. Disconnect the 3P connector from the vehicle speed sensor (VSS) (A). 2. Connect the test harness only to the engine wire harness. 3. Connect the RED test harness clip (B) to the positive probe of an ohmmeter. Cover the white (C) and green (D) test harness leads with protective tape (E). 4. Check for continuity between the RED test harness clip and body ground. Is there continuity? YES - Go to step 5. NO - Repair open in the BLK wire between the VSS and G101. 5. Connect the WHT test harness clip (B) to the positive probe of a voltmeter, and connect the RED test harness clip (C) to the negative probe. 6. Turn the ignition switch ON (II). Is there battery voltage? YES - Go to step 7. NO - Repair open in the BLK/YEL wire between the VSS and the under-dash fuse/relay box. 7. Disconnect the WHT test harness clip (B). Page 4947 Rear Door Upper Seal Replacement Rear Door Weatherstrip: Service and Repair Rear Door Upper Seal Replacement Rear Door Upper Seal Replacement 4-door NOTE: - Take care not to scratch the door. - Use a clip remover to remove the clips. 1. Remove the door sash trim. 2. Detach the door weatherstrip clip (A), then remove the door upper seal (B). 3. Install the seal in the reverse order of removal, and note these items: - Replace the clip if it's damaged. - Make sure the upper seal is installed in the holder (C) securely. - Check for water leaks. - Test-drive and check for wind noise. Page 6576 High Pressure Safety Valve HVAC: Service and Repair Compressor Relief Valve Replacement 1. Recover the refrigerant with a recovery/recycling/charging station. 2. Remove the cover (A), the relief valve (B), and the O-ring (C). Plug the opening to keep foreign matter from entering the system and the compressor oil from running out. 3. Clean the mating surfaces. 4. Replace the O-ring with a new one at the relief valve, and apply a thin coat of refrigerant oil before installing it. 5. Remove the plug, and install and tighten the relief valve. 6. Charge the system. Page 30 Antenna Control Module: Testing and Inspection Antenna Module Input Test 2-door 1. Remove the right C-Pillar trim. 2. Make sure the antenna module mounting bolt (A) is torqued to 9.8 N.m (1.0 kgf.m, 7.2 lbf.ft) 3. Disconnect the 2P connector from the antenna module (C). 4. Turn the ignition switch ON (II), turn the rear window defogger switch ON. Check for voltage between the No.2 terminal and body ground. There should be battery voltage. If there is no voltage, check for: Faulty rear window defogger relay. - Blown No.11 (40 A) fuse or No.19 (80 A) in the under-hood fuse/relay box. - An open in the BLK/YEL wire. 5. With the ignition switch ON (II), turn the radio ON, and turn to an FM station. Check for voltage between the No.1 terminal and body ground. If there is no voltage, check for: An open in the YEL/GRN wire. - A short to ground in the YEL/GRN wire. - Faulty audio unit. 6. Disconnect the rear window defogger (+B OUT) connector (D) from the antenna module. 7. With the ignition switch and the rear window defogger switch ON, check for voltage to ground. If there is no voltage, replace the antenna module. 8. Turn the ignition switch OFF. Page 7526 Front Door Panel: Service and Repair Sedan Front Door Panel Removal/Installation Special Tools Required - KTC trim tool set SOJATP2014 - Trim pad remover. Snap-on A 177A or equivalent, commercially available 4-door NOTE: Use the appropriate tool from the KTC trim tool set to avoid damage when prying components. 1. If applicable, remove the regulator handle (A) by pulling the clip (B) out with a wire hook (C) 2. Remove the inner handle (A). Take care not to scratch the door panel. 1. Pry out on the upper portion of the cover (B) to release the hooks (C, D), then remove the cover. 2. Remove the screws. 3. Pull the inner handle forward and out half-way to release the hook (E). 4. Disconnect the inner handle rod (F) and power door lock switch connector (G). Page 4976 Power Distribution schematics show how power is supplied from the positive battery terminal to various circuits in the vehicle. Refer to the Power Distribution diagram set to get a more detailed understanding of how picture is supplied to the circuit you're working on. Individual circuit schematics begin with a fuse. So 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 Ground Distribution Schematics This sample Ground Distribution schematic shows all of the components that share the same ground point. Page 5613 Clutch Switch: Adjustments Clutch Pedal, Clutch Pedal Position Switch, and Clutch Interlock Switch Adjustment NOTE: ^ To check the clutch pedal position switch. ^ To check the clutch interlock switch. ^ Remove the driver's side floor mat before adjusting the clutch pedal. ^ The clutch is self-adjusting to compensate for wear. ^ If there is no clearance between the master cylinder piston and push rod, the release bearing is held against the diaphragm spring, which can result in clutch slippage or other clutch problems. 1. Loosen locknut (A), and back off the clutch pedal position switch (B) (or adjusting bolt) until it no longer touches the clutch pedal (C). 2. Loosen locknut (D), and turn the push rod (E) in or out to get the specified height (F) and stroke (G) at the clutch pedal. Clutch Pedal Stroke: 130 - 140 mm (5.1 - 5.5 inch) Clutch Pedal Height: 198 mm (7.8 inch) 3. Tighten locknut (D). 4. With the clutch pedal released, turn the clutch pedal position switch (B) in until it contacts the clutch pedal (C).. 5. Turn the clutch pedal position switch (B) in an additional 3/4 to 1 turn. 6. Tighten locknut (A). 7. Loosen locknut (H) and the clutch interlock switch (1) 8. Press the clutch pedal to the floor. 9. Release the clutch pedal 15 - 20 mm (0.59 - 0.79 inch) from the fully depressed position, and hold it there. Adjust the position of the clutch interlock switch (1) so that the engine will start with the clutch pedal in this position. 10. Tighten locknut (H). Page 2586 124. CMP (TDC) Sensor Page 5797 234. Under-dash Fuse/Relay Box Part 7 Page 2853 9. Troubleshoot the DTC(s) in the order indicated using the shown charts. If a faulty control unit is suspected, substitute it with a known good part and recheck for DTCs. - If the DTC(s) is still present, go to the next step instead for the DTC. - If the DTC(s) is no longer present, replace the original part. Note: Before replacing a Faulty ECM/PCM make sure it has the latest software revision. Update if necessary before swapping or replacing. Made 2 Test 1. From Mode 1, disconnect the special tool from the multiplex inspection connector for 5 to 10 seconds, and then reconnect it. 2. The spotlight and ceiling light should come on for 2 seconds, go out, then blink twice, 0.2 seconds each time. The system is now in mode 2. Page 5466 Hydraulic Control Assembly - Antilock Brakes: Service and Repair ABS Modulator-Control Unit Removal and Installation NOTE: ^ Do not spill brake fluid on the vehicle; it may damage the paint; if brake fluid gets on the paint, wash it off immediately with water. ^ Be careful not to damage or deform the brake lines during removal and installation. ^ To prevent the brake fluid from flowing, plug and cover the hose ends and joints with a shop towel or equivalent material. Removal 1. Pull up the lock (C) of the ABS control unit 31P connector (B), then disconnect the connector. 2. Disconnect the six brake lines. 3. Remove the two 8 mm nuts. 4. Remove the ABS modulator-control unit (A). Installation 1. Install the ABS modulator-control unit, then tighten the two 8 mm nuts. 2. Align the connecting surface of the ABS control unit 31P connector. 3. Push in the lock of the ABS control unit 31P connector until you hear it click into place, then connect the connector. 4. Bleed the brake system, starting with the front wheels. 5. Start the engine, and check that the ABS indicator goes off. 6. Test-drive the vehicle, and check that the ABS indicator does not come on. Page 982 3. Use the clamp carriage lever to position the clamp unit so the tracer is directly over the flat surface of the code device, just ahead of the cam blades. 4. Pull the vertical carriage lever toward you until the tracer just touches the flat surface ahead of the cam blades. Watch the arrows on the keypad: ^ If the double-headed arrow in the middle of the keypad lights green, the tracer and cutter bit are properly aligned. ^ If the arrow on the left of the keypad lights red, the cutter bit is not touching the jaw. Turn the micrometric ring nut above the tracer to the left until the double-headed arrow lights green. ^ If the vertical arrow on the right of the keypad lights red, the tracer is not touching the jaw. Turn the micrometric ring nut above the tracer to the right until the double-headed arrow lights green. *5. Turn the micrometric ring nut to the right five clicks so the cutter bit is slightly higher than the tracer. The arrow on the left should light red. Raise the vertical carriage. NOTE: Setting the tracer five clicks lower than the cutter bit at this point has the effect of making the cutter bit cut the duplicated key a little shallower. This will protect the locking jaws from being damaged.* 6. Optional: Loosen the set screw, and adjust the hand rest to a comfortable position. Tighten the screw. 7. Pull the clamp carriage lever toward you until the clamp carriage clicks into its end-of-run position. 8. Clean any metal shavings or debris out of the center jaw. (A soft-bristle toothbrush is ideal for this purpose.) Then open the jaws with the jaws knob, and slide the key blank with its flat side down into the jaw up to the key stop. Close the jaw with the jaws knob to lock the key blank into place. Visually inspect the key for proper alignment in the jaw. 9. Set and lock the cam sets on the code device. ^ Starting with the left cam set, make sure the lock pin is pulled all the way out. (This releases the cams.) Locations Exterior Lights Component Location Index Diagrams Page 5559 13. After completing the right edge, push all of the cam blades to the right until they touch the cams, then trace the cam blades from back to front. (The cutter bit cuts the same contours into the left edge of the key from tip to head.) Turn off the cutter motor. 14. Release the vertical carriage lever. Push all the cam blades to the left until they touch the cams. Pull the vertical carriage lever towards you until the tracer touches the flat surface on the right side, at the front of the cams. Gently twist the lever clockwise to lock the vertical carriage at this height. Do not overtighten the lever. 15. Turn on the cutter motor, then retrace the cam blades from front to back. Push all the cam blades to the right until they touch the cams, and then retrace the cam blades from back to front (retracing cleans up the cuts on the key). Turn off the cutter motor. 16. Release the vertical carriage lever. Open the jaw and remove the key. Make sure the jaw is free of any metal shavings or debris. Turn the key over so the blank side is up, then slide it into the jaw up to the key stop. Close the jaw to lock the key in place. 17. Push all the cam blades to the left until they touch the cams. Repeat steps 10 through 15 to cut both edges on the other side of the key. 18. When you are done making the required cuts, release the vertical carriage lever. Open the jaw and remove the key. 19. Make sure the key works in the ignition switch and the locks. If the key does not work, recut the key, and try it again. 20. Depending on the type of key, code the key transponder. Equipment Service and Warranty To service the MATRIX H Key Cutting Machine, refer to section 7 of the MATRIX H Operating Manual. It tells you how to replace parts that commonly wear out such as the drive belt, the work light bulb, and the tension spring on the vertical carriage. It also covers checking and replacing fuses and replacing the printed circuit board for the setting unit keypad. If you have technical questions on the equipment, contact the Ilco Technical Assistance Department. Mail: Kaba Ilco Technical Assistance Department 400 Jeffreys Road Rocky Mount, NC 27804 Phone: 800-452-6872 Ext: 200, 384, 323, 398, 356 Fax: 252-446-4702 The MATRIX H Key Cutting Machine comes with a 3-year limited warranty. This warranty does not cover the cutter bit or the work light bulb. CODE BOOK CORRECTIONS In the code book Honda High Security key Codes, correct these errors: Pages 4 thru 51, code headings: ^ Incorrect: J H G F Z X E D C B M/S X ^ Correct: J H G F A X E D C B M/S X Page 2, last paragraph: Locations Relay And Control Unit Locations - Dashboard Page 5760 Fuse: Locations Under-Hood Fuse/Relay Box Under-hood Fuse/Relay Box Page 8762 - 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. Troubleshooting Tests 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 test 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 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. 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 Drop Page 9270 PGM-F1 Main Relay 1, 2 Type 1, 2 Check for continuity between the terminals. - There should be continuity between the No.1 and No.2 terminals when power and ground are connected to the No.3 and No.4 terminals. - There should be no continuity between the No.1 and No.2 terminals when power is disconnected. Normally-open type B: Rear Window Defogger Relay Page 1861 10. Rotate the crankshaft 180° counterclockwise (camshaft pulley turns 90°). The "UP" mark (A) on the camshaft pulley should be toward the exhaust side of the head. 11. Check and, if necessary, adjust the valve clearance on No. 3 cylinder. 12. Rotate the crankshaft 180° counterclockwise to bring No. 4 piston to TDC. TDC marks (A) are visible again. 13. Check and, if necessary, adjust the valve clearance on No. 4 cylinder. 14. Rotate the crankshaft 180° counterclockwise to bring No. 2 piston to TDC. The "UP" mark (A) should be on the intake side of the head. 15. Check and, if necessary, adjust the valve clearance on No. 2 cylinder. 16. Install the cylinder head cover. Locations Gasoline Locations Turn Signal/Hazard Flasher Component Location Index Page 6281 Steering Wheel: Service and Repair Removal SRS components are located in this area. Review the SRS component locations, precautions and procedures in the SRS section before performing repairs or service. 1. Make sure you have the anti-theft code for the radio, then write down the radio station presets. 2. Disconnect the negative cable from the battery. 3. Align the front wheels straight ahead, then remove the driver's airbag from the steering wheel. 4. Disconnect the horn switch connector (A) and the cruise control set/resume switch connector (B), and loosen the steering wheel bolt (C) or nut. 5. Install a commercially available steering wheel puller (A) on the steering wheel (B). Free the steering wheel from the steering column shaft by turning the pressure bolt (C) of the puller. Note these items when removing the steering wheel: ^ Do not tap on the steering wheel or the steering column shaft when removing the steering wheel. ^ If you thread the puller bolts (D) into the wheel hub more than five threads, the bolts will hit the cable reel and damage it. To prevent this, install a pair of jam nuts five threads up on each puller bolt. 6. Remove the steering wheel puller, then remove the steering wheel bolt (nut) and steering wheel from the steering column. 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 2760 Engine Control Module: Technical Service Bulletins Engine Controls - Replace ECM/PCM For DTC P1607 SOURCE: Honda Service News May 2003 TITLE: Replace ECM/PCM for DTC P1607 APPLIES TO: 2002-03 Civic SERVICE TIP If you've got a DTC P1607 (ECM/PCM internal circuit malfunction) set, you need to replace the ECM/PCM. These units may have defective printed circuit boards. Page 1824 Harmonic Balancer - Crankshaft Pulley: Specifications Crankshaft Pulley Tighten bolt to 200 Nm (148 lb.ft.). - Do not use an impact wrench. Page 2883 38. Measure voltage between ECM/PCM connector terminal E7 and body ground. Is there battery voltage? YES - Go to step 42. NO - Go to step 39. 39. Remove PGM-FI main relay 1 (A). 40. Measure voltage between PGM-FI main relay 1 4P connector terminal No.4 and body ground. Is there battery voltage? YES - Go to step 41. NO - Repair open in the wire between the No.6 ECU (ECM/PCM) (15A) fuse and PGM-FI main relay 1. Page 2593 104. CKP Sensor Door Lock Knob Switch Test Power Door Lock Switch: Testing and Inspection Door Lock Knob Switch Test Door Lock Knob Switch Test 4-door 1. Remove the driver's door panel. 2. Disconnect the 3P connector from the actuator. 3. Check for continuity between the No.1 and No.2 terminals. - There should be continuity when the door lock knob switch is in the LOCKED position. - There should be no continuity when the door lock knob switch is in the UNLOCKED position. 4. If the continuity is not as specified, replace the door lock actuator. 2-door 1. Remove the driver's door panel. 2. Disconnect the 3P connector from the actuator. 3. Check for continuity between the No.1 and No.2 terminals. - There should be continuity when the door lock knob switch is in the LOCKED position. - There should be no continuity when the door lock knob switch is in the UNLOCKED position. 4. Check for continuity between the No.1 and No.3 terminals. - There should be continuity when the door lock knob switch is in the UNLOCKED position. How to Remove the PCM Control Module: Service and Repair How to Remove the PCM How to Remove the PCM for Testing 1. Remove the passenger's dashboard lower cover, the right kick panel, and the glove box. 2. Remove the bolt. Cut the plastic cross brace in the glove box opening with diagonal cutters in the area shown, and discard it. 3. Remove the relays (A), then remove the bolts and the glove box frame (B). 4. Remove the gray 20P PCM wire harness connector from the PCM mounting bracket. Remove the PCM mounting bolt (A) and the bracket. 5. Remove the nuts, then remove the PCM (B). 6. Install the PCM in the reverse order of removal. Page 7641 21. Leave the key in the cylinder. Reinstall the plastic retainer and spring if you removed them in step 16. Hold the plastic retainer and spring on the housing, and insert the inner cylinder. Rotate it left and right to engage the spring to the inner cylinder. Make sure the spring is properly seated to the inner cylinder. 22. Install the arm with a new cylinder rod clip and a new E-clip. 23. Make sure the key can be inserted and removed easily, and that the cylinder turns with the key. Page 9132 Courtesy Lamp: Diagnostic Aids General Troubleshooting Information General Troubleshooting Information Tips and Precautions Before Troubleshooting 1. Check applicable fuses in the appropriate fuse/relay box. 2. Check the battery for damage, state of charge, and clean and tight connections. NOTE: 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. Handling Connectors - Make sure the connectors are clean and have no loose wire terminals. - Make sure multiple cavity connectors are packed with dielectric grease (except watertight connectors). - All connectors have push-down release type locks (A). - Some connectors have a clip on their side used to attach them to a mount bracket on the body or on another component. This clip has a pull type lock. - Some mounted connectors cannot be disconnected unless you first release the lock and remove the connector from its mount bracket (A). - Never try to disconnect connectors by pulling on their wires; pull on the connector halves instead. - Always reinstall plastic covers. Locations SRS Component Location Index Mainshaft Speed Sensor Replacement Transmission Speed Sensor: Service and Repair Mainshaft Speed Sensor Replacement Mainshaft Speed Sensor Replacement 1. Disconnect the mainshaft speed sensor connector. 2. Remove the mainshaft speed sensor (A). 3. Install the new mainshaft speed sensor with the new O-ring (B) and mainshaft speed sensor washer (C). NOTE: The mainshaft speed sensor washer is equipped on the SLXA automatic transmission; the BMXA does not have it. 4. Check the mainshaft speed sensor connector for rust, dirt, or oil, then connect the connector securely. Component Locations Shift Solenoid: Component Locations Electronic Controls Location Page 2287 D17A1, D17A6 engines Page 5506 Electronic Brake Control Module: Service and Repair ABS Modulator-Control Unit Removal and Installation NOTE: ^ Do not spill brake fluid on the vehicle; it may damage the paint; if brake fluid gets on the paint, wash it off immediately with water. ^ Be careful not to damage or deform the brake lines during removal and installation. ^ To prevent the brake fluid from flowing, plug and cover the hose ends and joints with a shop towel or equivalent material. Removal 1. Pull up the lock (C) of the ABS control unit 31P connector (B), then disconnect the connector. 2. Disconnect the six brake lines. 3. Remove the two 8 mm nuts. 4. Remove the ABS modulator-control unit (A). Installation 1. Install the ABS modulator-control unit, then tighten the two 8 mm nuts. 2. Align the connecting surface of the ABS control unit 31P connector. 3. Push in the lock of the ABS control unit 31P connector until you hear it click into place, then connect the connector. 4. Bleed the brake system, starting with the front wheels. 5. Start the engine, and check that the ABS indicator goes off. 6. Test-drive the vehicle, and check that the ABS indicator does not come on. Page 7325 ^ ALO/BOA - Your order has been allocated, but not released for shipment. ^ REL/BOR - Your order has been picked, packed, and shipped. ^ INV - Your order has been invoiced to your dealer parts account. CORE RETURN INFORMATION Service Technician: 1. If the customer's media (CD, CD magazine, DVD, DVD-A, or cassette tape) is stuck inside the faulty unit, fill out a Customer Media Return Label (reorder number Y0325), and attach it to the unit. The manufacturer will remove the media, and mail it back to your dealership. 2. Use the pre paid shipping label. Each audio supplier provides a prepaid shipping label with the remanufactured audio unit. Return the core using this label to ensure it is received at the appropriate location for credit. Use the pre paid shipping labels to return audio cores to authorized locations only; do not use them for any other purpose. If you need additional prepaid shipping labels, contact Remanufactured Parts Operations. ^ Complete the shipping label with your dealership information. ^ Pack one audio unit per box, and use a separate shipping label for each one. ^ On the line requesting Your Internal Reference Information, enter YOUR DEALER NUMBER and the WARRANTY CLAIM NUMBER. 3. On the repair order, write down the warranty claim number, the original part number, the serial numbers from both the faulty and remanufactured units, and the return tracking number. 4. Ship the faulty unit in the same box the remanufactured unit came in. Make sure you include this required paperwork: ^ A copy of the Core Return Update Acknowledgement from the iN. ^ A copy of the warranty audio order. NOTE: When the Remanufacturing Center gets the faulty unit, your warranty audio order will be updated to indicate that the core was received. If the core is received 31-60 days from the order date, and you have been debited a core loss charge, your dealership will be credited back, less a $250 late fee. OUT-OF-WARRANTY REPAIR (AUDIO, NAVIGATION, AND RES UNITS PRODUCED IN 1998 OR LATER) NOTE: If you are making a repair or exchange because of a service bulletin or service campaign, do not use OUT-OF-WARRANTY procedures. Refer to IN-WARRANTY EXCHANGE for more information. Service Advisor: 1. Give your customer an estimate for repairing the unit (see step 6), plus the labor cost to replace it. For an Alpine unit, your customer has the option of contacting Alpine Electronics directly. Alpine's customer service number is 800-421-2284, Ext. 860304. Service Technician: 2. Remove the failed unit: ^ Refer to the appropriate component section of the service manual or, Page 4395 13. Plug in the heat gun, and turn it on. Start at the middle of the splice connector, and move the gun toward the ends as the tube shrinks. Apply heat evenly by rotating the curved heat spreader around the splice connector. Shrinking is complete when a small amount of sealant appears at each end of the tube. Pigtail Terminal Selection Chart PIGTAIL TERMINAL SELECTION CHART Select the proper size pigtail terminal by matching the replacement terminal part number and the wire size being repaired to the corresponding pigtail terminal part number. Then use the color (size) splice connector listed. In some instances you may also have to match the wire seal style to select the proper pigtail terminal. Pigtail terminals are available through your parts department, in quantities of 10, using normal parts ordering procedures. Checking For Poor Fir of Terminals CHECKING FOR POOR FIT OF TERMINALS Loose terminal fit can cause a number of intermittent problems in electrical circuits. By using the Terminal Inspection Feeler Tool Set you can inspect the terminal fit between the two matching connectors without removing the terminals from the connector body. 1. Find the terminal tool that best matches the male terminal in the mating connector. Page 6375 Suspension Strut / Shock Absorber: Service and Repair Rear Damper/Spring Removal and Installation Removal 1. Raise the rear of the vehicle, and support it with safety stands in the proper locations. Remove the rear wheels. Page 9197 Use the tools from Pin Tool Set. First, check the connector that you are about to repair. - If it has a secondary terminal lock, go to Connectors With a Secondary Lock. A secondary lock, found on most connectors on some models, is an additional locking device on the connector housing as a backup for the primary lock on the terminal. - If the connector does not have a secondary lock, go to Connectors Without a Secondary Lock. Connectors With a Secondary Lock All examples are shown with the connector lock facing up. The illustrations are examples of the secondary terminal locks; however, the connector you are repairing may vary in size. Identify the connector by the type of secondary lock, not by the number of terminal cavities. EXAMPLE A: 1. Release the secondary lock. 2. Remove the terminal. 3. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE B: Page 6636 Air Conditioning Component Location Index Page 9507 8. Inspect the quality of the wire crimp. If it has any of the following NO GOOD crimps, cut it off and start over. 9. Insert the terminal into the connector. Make sure the wire seals are pushed all the way into the connector. Lightly pull on the wires to make sure the terminal is locked into place. 10. Close or insert the secondary terminal lock, if applicable, and reconnect the connector. How to Install Pigtail Terminals HOW TO INSTALL PIGTAIL TERMINALS Pigtail terminals (short pieces of wire with a factory crimped terminal) are used when the wire is too short or when access to the connector is too restricted to make a terminal repair. NOTE: To replace just a connector terminal, go to How to Replace Connector Terminals. IMPORTANT SAFETY INFORMATION: On some models, the SRS wires are in a separate harness. If the SRS harness is damaged, replace the harness; do not repair it. On other models, wire harnesses include yellow SRS wires. If any SRS wire is damaged, replace the entire harness; do not repair it. 1. Remove the damaged or faulty terminal from the connector. Use the proper removal tool from Pin Tool Set. Page 766 Oxygen Sensor: Diagrams 130. A/F Sensor 140. HO2S, Primary (GX; '01-'03: EX, DX, LX) Or Secondary (HX) Page 7396 REPAIR PROCEDURE 1. Make sure you have the anti-theft code for the audio unit. Write down the customer's audio presets. 2. Disconnect the negative battery cable from the battery. 3. Remove the under-hood fuse/relay box cover. 4. Release the three clips, and remove the under- hood fuse/relay box from the holder. CR-V only: Release the wire harness clip from the fuse/relay box holder Page 3815 Resistor Variable Sensor Solenoid Transistors Circuit Schematics Page 5888 234. Under-dash Fuse/Relay Box Part 7 Page 2526 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 Locater) 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. Troubleshooting Precautions Troubleshooting Precautions Before Troubleshooting 1. Check the main fuse and the fuse 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, or you will damage the alternator diodes. - Do not attempt to crank the engine with the ground cable disconnected 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. Page 6430 3. Remove the hub cap (A), raise the stake (B), and remove the spindle nut (C). 4. Screw two 8 x 1.25 mm bolts (A) into the drum to push it away from the hub. Turn each bolt 2 turns at a time to prevent cocking the drum excessively. 5. Remove the brake drum (A), and remove the hub bearing unit (B) from the spindle. If the brake drum has stuck to the hub bearing unit, pull them out together. Do not tap on the aluminum brake drum. 6. Install the hub bearing unit in the reverse order of removal, and note these items: - Tighten all mounting hardware to the specified torque values. - Before installing the brake drum, clean the mating surface of the hub and the inside of the brake drum. - Use a new spindle nut on reassembly. - Before installing the spindle nut, apply a small amount of engine oil to the seating surface of the nut. After tightening, use a drift to stake the spindle nut shoulder against the spindle. - Use a new hub cap on reassembly. - Before installing the wheel, clean the mating surface of the brake drum and the inside of the wheel. Page 3204 Transmission Position Switch/Sensor: Diagnostic Aids General Troubleshooting Information General Troubleshooting Information Tips and Precautions Before Troubleshooting 1. Check applicable fuses in the appropriate fuse/relay box. 2. Check the battery for damage, state of charge, and clean and tight connections. NOTE: 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. Handling Connectors - Make sure the connectors are clean and have no loose wire terminals. - Make sure multiple cavity connectors are packed with dielectric grease (except watertight connectors). - All connectors have push-down release type locks (A). - Some connectors have a clip on their side used to attach them to a mount bracket on the body or on another component. This clip has a pull type lock. - Some mounted connectors cannot be disconnected unless you first release the lock and remove the connector from its mount bracket (A). - Never try to disconnect connectors by pulling on their wires; pull on the connector halves instead. - Always reinstall plastic covers. Page 6371 2. Remove the cotter pin (A) from the tie-rod end ball joint, and remove the nut (B). 3. Disconnect the tie-rod end from the steering arm on the damper using the special tool. 4. Remove the bolts (A), and remove the wheel sensor harness bracket (B) and brake hose bracket (C) from the damper. Do not disconnect the wheel sensor connector. 5. Remove the damper pinch bolts (A) while holding the nuts (B). Page 3142 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 Short Circuit Locator (Short Finder) 1. Remove the blown fuse. Leave the battery connected. Page 5554 Disclaimer Cutting Procedure - By Copying 1. Press the ON/OFF button in the middle of the setting unit keypad. (This powers up the keypad.) 2. Turn the clamp unit lock lever to the left to release the clamp unit, and slide it all the way to the left until it stops. Turn the lever to the right to lock the clamp unit in place. 3. Use the clamp carriage lever to position the clamp unit so the tracer and cutter bit are centered directly over the base of the center and right jaws. 4. Pull the vertical carriage lever toward you until the tracer and the cutter bit just touch the base of each fixed jaw. Watch the arrows on the keypad: ^ If the double-headed arrow in the middle of the keypad lights green, the tracer and cutter bit are properly aligned. ^ If the arrow on the left of the keypad lights red, the cutter bit is not touching the fixed jaw. Turn the micrometric ring nut above the tracer to the left until the double-headed arrow lights green. ^ If the arrow on the right of the keypad lights red, the tracer is not touching the fixed jaw. Turn the micrometric ring nut above the tracer to the right until the double-headed arrow lights green. *5. Turn the micrometric ring nut to the right three clicks so the cutter bit is slightly higher than the tracer. The arrow on the left should light red. Raise the vertical carriage. NOTE: Setting the tracer three clicks lower than the cutter bit has the effect of making the cutter bit cut the duplicated key a little shallower. This will protect the locking jaws from being damaged.* 6. Optional: Loosen the setscrew, and adjust the hand rest to a comfortable position. Tighten the screw. 7. Pull the clamp carriage lever toward you until the clamp carriage clicks into its end-of-run position. Tighten both the lateral and spring tension adjustment knobs. 8. Make sure the center and right jaws are free of any metal shavings or debris. (A soft-bristle toothbrush is ideal for this purpose.) Page 3195 Wires Page 5662 5. With the wire inserted in the new terminal as shown in step 3, crimp the wire by squeezing the tool with both hands until the stops make contact. 6. Crimp the insulation by positioning the 5.5 slot on the tool over the insulation crimp section of the terminal and squeezing the tool with both hands until the stops make contact. 7. Inspect the quality of the wire crimp. If it has any of the following NO GOOD crimps, cut it off and start over. 8. Clean the starter side of the S terminal as needed using electric contact cleaner and an electrical connector cleaning brush (Snap-on P/N YA385A or equivalent). Blow out any debris remaining on or around the terminal with compressed air. 9. Apply silicone dielectric grease (3M silicone paste P/N 08946, Permatex Dielectric Tune-up grease P/N 67VR, or equivalent) to the female side of the S terminal, then carefully insert the terminal into the S terminal on the starter side. 10. Slide the boot completely over the S terminal. 11. Reconnect the positive battery cable, then reconnect the negative battery cable. 12. Enter the anti-theft code for the audio unit (if applicable), then enter the customer's audio presets. Set the clock. 13. Confirm that the starter engages properly by starting the engine several times. 14. Do the idle learn procedure: ^ Make sure all electrical items (A/C, audio unit, defogger, lights, etc.) are off. Page 5972 Under-dash Fuse/Relay Box Locations Cruise Control Component Location Index Page 903 Knock Sensor: Description and Operation Knock Sensor The knock control system adjusts the ignition timing to minimize knock. Page 8229 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 A 1. Check the side-to-side alignment of the trunk lid latch to the striker: ^ Refer to page 20-132 of the 2001-04 Civic Service Manual. ^ In ISIS, use the keyword TRUNK ADJUST, and select Trunk Lid Adjustment from the list. 2. Make sure the gaps of the trunk lid are even on all sides. ^ If the trunk is misaligned, go to step 3. ^ If the trunk lid is properly aligned on all sides, go to REPAIR PROCEDURE B. 3. Adjust the trunk lid hinges: ^ Refer to page 20-132 of the 2001-04 Civic Service Manual. ^ In ISIS, use the keyword TRUNK ADJUST, and select Trunk Lid Adjustment from the list. 4. Check the trunk operation: ^ If the trunk opens and closes smoothly and is properly aligned, return the vehicle to the customer. ^ If the trunk lid is still difficult to close, go to REPAIR PROCEDURE B. REPAIR PROCEDURE B 1. Check the depth adjustment of the trunk lid: ^ Refer to page 20-132 of the 2001-04 Civic Service Manual. ^ In ISIS, use the keyword TRUNK ADJUST, and select Trunk Lid Adjustment from the list. 2. Make sure the trunk lid is flush on all sides and corners. ^ If the trunk is misaligned, go to step 3. ^ If the trunk lid is properly aligned on all sides and corners, go to REPAIR PROCEDURE C. 3. Adjust the striker depth position and the trunk lid edge cushions: ^ Refer to page 20-132 of the 2001-04 Civic Service Manual. ^ In ISIS, use the keyword TRUNK ADJUST, and select Trunk Lid Adjustment from the list. 4. Check the trunk operation: ^ If the trunk opens and closes smoothly, return the vehicle to the customer. ^ If the trunk lid is still difficult to close, go to REPAIR PROCEDURE C. REPAIR PROCEDURE C 1. Use a small screwdriver to manually set and release the trunk lid latch. Check the operation of the latch: ^ If the latch is difficult to set or release, go to step 2. ^ If the latch operates properly, go to REPAIR PROCEDURE D. Page 5766 Under-hood Fuse/Relay Box Page 2518 Resistor Variable Sensor Solenoid Transistors Circuit Schematics Page 8624 NOTE: You need to make the corrections listed in CODE BOOK CORRECTIONS at the end of this service bulletin. TRACER AND CUTTER BIT INSTALLATION 1. Turn the power switch on the back of the machine to ON. (This turns on the built-in work light.) 2. Use the Allen wrench from the built-in tool drawer to loosen the setscrew on the left sleeve of the vertical carriage. Slide the tracer all the way into the sleeve, and tighten the screw. 3. Turn the plastic shield on the right sleeve of the vertical carriage so you can access the setscrew on the sleeve. Use the Allen wrench to loosen the screw. Slide the cutter bit all the way into the sleeve, and tighten the screw. Turn the plastic shield so the open side is in the back. MACHINE COMPONENTS Page 62 Sunroof / Moonroof Relay: Testing and Inspection Power Relay Test Use this chart to identify the type of relay, then do the test listed for it. NOTE: See the turn signal/hazard relay input test. Five-terminal type Check for continuity between the terminals. - There should be continuity between the No.1 and No.2 terminals when power and ground are connected to the No.3 and No.5 terminals. - There should be continuity between the No.1 and No.4 terminals when power is disconnected. Page 3620 Ignition System Component Location Index Page 6034 234. Under-dash Fuse/Relay Box Part 3 Page 6762 other parts. 5. Reconnect the battery negative cable. 6. After installing the side airbag, confirm proper system operation: Turn the ignition switch ON (II); the SRS indicator light should come on for about 6 seconds and then go off. Page 9409 3. Strip the insulation off the end of the wire so the wire fits in the new terminal as shown. (If the wire has a wire seal, replace it with a new one from the kit.) NOTE: After stripping the end of the wire, make sure you did not cut any wire strands. If you did, cut the wire off even with the insulation, and strip it again. 4. Position the terminal in the crimping tool slot with the solid portion of the terminal toward the anvil and the open section toward the former. 5. Insert the wire in the terminal to the position shown in step 3. 6. Squeeze the tool with both hands until the stops make contact. 7. Crimp the insulation crimp. - If you do not have a wire seal, then use the next larger size crimp slot. Position the crimping tool over the insulation crimp section of the terminal, then squeeze the tool with both hands until the stops make contact. - If you have a wire seal, position the insulation crimp in the 5.5 crimping slot, then carefully squeeze the crimp closed until its ends are touching and making a full-circle shape. Page 9410 8. Inspect the quality of the wire crimp. If it has any of the following NO GOOD crimps, cut it off and start over. 9. Insert the terminal into the connector. Make sure the wire seals are pushed all the way into the connector. Lightly pull on the wires to make sure the terminal is locked into place. 10. Close or insert the secondary terminal lock, if applicable, and reconnect the connector. How to Install Pigtail Terminals HOW TO INSTALL PIGTAIL TERMINALS Pigtail terminals (short pieces of wire with a factory crimped terminal) are used when the wire is too short or when access to the connector is too restricted to make a terminal repair. NOTE: To replace just a connector terminal, go to How to Replace Connector Terminals. IMPORTANT SAFETY INFORMATION: On some models, the SRS wires are in a separate harness. If the SRS harness is damaged, replace the harness; do not repair it. On other models, wire harnesses include yellow SRS wires. If any SRS wire is damaged, replace the entire harness; do not repair it. 1. Remove the damaged or faulty terminal from the connector. Use the proper removal tool from Pin Tool Set. Removal Oil Pan: Service and Repair Removal Oil Pan Removal If the engine is out of the vehicle, go to step 6. 1. Raise the vehicle on the hoist to full height. 2. Drain the engine oil. 3. D17A2 engine: Disconnect the primary heated oxygen sensor (primary HO2S) connector and secondary heated oxygen sensor (secondary HO2S) connector, then remove the exhaust pipe A/ three way catalytic converter (TWC). 4. D17A6 engine: Disconnect the third heated oxygen sensor (third HO2S) connector, remove the exhaust pipe A/TWC assembly. 5. D17A1 engine: Remove the exhaust pipe/muffler assembly. 6. Remove the bolts/nuts securing the oil pan. 7. Remove the oil pan. Page 585 43. Evapoator Temperature Sensor Locations Control Module: Locations Electronic Controls Location Page 1322 Ignition System Component Location Index Page 2513 Wires Page 4174 ^ The vehicle is shown as eligible on a VIN status inquiry. In addition, check for a punch mark above the seventh character of the engine compartment VIN. A punch mark in that location means the ignition switch key interlock has already been inspected/repaired. 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 a VIN status inquiry before selling it. CUSTOMER NOTIFICATION All owners of affected vehicles will be sent a notification of this campaign. An example of the customer notification is at the end of this service bulletin. CORRECTIVE ACTION Inspect the ignition switch and, if needed, install a Key Interlock Repair Kit. PARTS INFORMATION Key Interlock Repair Kit: P/N 06351-SDA-000 REQUIRED SPECIAL TOOLS Interlock Slide Hammer: T/N 07AAC-S84A100 NOTE: ^ An initial quantity of Permalube grease to lubricate the sliding surface of the interlock lever is included with the slide hammer. To order more Permalube, use P/N 08734-0030. ^ To order a replacement clamping bolt for the slide hammer, use T/N 07AAC-S84A400. WARRANTY CLAIM INFORMATION Failed Part: P/N 35100-SDA-A31 Defect Code: 5GC00 Symptom Code: R4400 Page 2618 Knock Sensor: Service and Repair Replacement 1. Remove the oil filter with the special oil filter wrench. 2. Disconnect the knock sensor connector, then remove the knock sensor. 3. Install the knock sensor and oil filter. Page 5864 Charging System Component Location Index Page 2058 1. Remove the secondary locks. 2. Remove the terminal from the female half. 3. Remove the terminal from the male half. 4. Go to HOW TO INSTALL NEW TERMINALS. Connectors Without a Secondary Lock All examples are shown with the connector lock facing up. The illustrations are examples of connector terminals without a secondary lock; however, the connector you are repairing may vary in size and shape. EXAMPLE A: Page 3677 72. Shift Lock Solenoid (A/T) Page 4801 2. Insert the terminal tool into the female terminal, and then remove the terminal tool. NOTE: Make sure you do not select a terminal tool that is larger than the mating male terminal because it would spread the female terminal and cause a loose fit. 3. Compare the drag to the other terminals in the connector. If the drag is less, replace the terminal with a replacement terminal from the appropriate terminal repair kit. Diagrams Locations Condenser Fan Motor Relay: Locations Under-hood Fuse/Relay Box Page 1254 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. Locations 12. Middle of Engine Page 8824 PARTS INFORMATION REPAIR PROCEDURE 1. Tilt the steering wheel all the way up. 2. Remove the three upper cover mounting screws from the lower steering column cover, then tilt the steering wheel all the way down, and remove the column covers. 3. Remove the two mounting screws from the instrument panel trim. Gently pull on the bottom of the trim to release the two clips and the two hooks. Carefully pull the trim out of the dashboard. Page 1080 2. Remove the terminal from the female half. 3. Remove the terminal from the male half. 4. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE D: 1. Remove the secondary locks. Page 3256 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. How to Replace Connector Terminals Terminal Replacement Procedure HOW TO REPLACE CONNECTOR TERMINALS The terminal repair kits provide necessary tools and materials (terminals, wire seals, and splice connectors) to repair many damaged or faulty connector terminals. However, not all terminals for all connectors are available. Refer to the labels on the lids of the repair kits for replacement terminal availability. IMPORTANT SAFETY INFORMATION: On some models, the SRS wires are in a separate harness. If the SRS harness is damaged, replace the harness; do not repair it. On other models, wire harnesses include yellow SRS wires. If any SRS wire is damaged, replace the entire harness; do not repair it. Before you begin, inspect the wire you are about to repair for damage and length. Make sure the wire will be long enough to make a terminal repair without stretching it when you reinstall the terminal in the connector. If the wire is too short, or if access to the connector is too restricted to make a terminal repair, you may need to install a pigtail terminal (a short length of wire with a factory-crimped terminal on it). Refer to HOW TO INSTALL PIGTAIL TERMINALS. Removing the Terminal Page 6874 Page 2954 DTC P2240 thru U0073 Description and Operation Fuel Cut Control Unit: Description and Operation Fuel Cut-off Control During deceleration with the throttle valve closed, current to the injectors is cut off to improve fuel economy at speeds over 850 rpm. Fuel cut-off action also occurs when engine speed exceeds 6,900 rpm, regardless of the position of the throttle valve, to protect the engine from over-revving. With A/T model, when the vehicle is stopped, the PCM cuts the fuel at engine speeds over 5,000 rpm. Page 1270 ^ 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 1167 1. Remove the driver's side grip cover: ^ Using a trim tool, pry out the front edge of the cover to release the front clip. ^ Pry out along the bottom to release the lower hooks. ^ Pry out along the top to release the upper hooks. ^ Pull the cover forward to release the rear clip. 2. Disconnect the power window master switch connector. 3. Remove the two screws that attach the power window switch base to the armrest, then remove the switch base. 4. Remove the three screws, then replace the power window master switch assembly. Page 7979 3. Lower the grab handle, then remove the caps (A). Remove the self-tapping ET screws, then remove the grab handle (B). 4-door: Remove the remaining grab handles. 4. 2-door: From the rear driver's side, remove the screw, then remove the coat hanger (A). 5. With moon roof: Remove the headliner (A). 1. Remove the socket plug (B). 2. 2-door: Remove the upper portion of the B-pillar upper trim (C) from one side 3. 4-door: Remove the upper portion of the C-pillar trim (D) from each side 4. Remove the remaining door opening trim (E) from each roof portion. 5. Detach the rear clips (F) by pulling the headliner down. 6. Gently pull down the headliner from the moonroof opening, and detach the clips (G) with a clip remover. Gently pull down on the sides of moon roof opening to release fasteners (H). Be careful not to deform the headliner. 7. With the help of an assistant, release the clips (I) of the headliner from the moonroof frame (J), and lower the headliner. 8. Remove the headliner through the passenger's door opening. Page 2840 2. Cut off the wire about an inch back from where it connects to the damaged or faulty terminal, then strip about half of the insulation off that piece. This will be used to size the wire end of the replacement pigtail terminal. NOTE: If you are not sure of the wire size, start with a large enough hole on the stripper that will not nick or cut off any strands of wires. 3. Select a pigtail terminal that matches the original wire at both ends (same kind of terminal and same diameter bare wire). 4. Select the smallest splice connector (yellow, pink, or blue) that will fit onto the stripped end of the original wire. 5. Insert the pigtail terminal into the connector cavity; push it in until it locks in place. 6. Lay the pigtail and the original wire side-by-side, and cut off both ends at once. If you are making more than one splice, do not cut each pigtail at the same location; the resulting "lump" of splice connectors would interfere with rewrapping the harness. Instead, cut the first pigtail close enough to the terminal so you will have room to make each remaining cut about 20 mm (3/4 inch) farther down on the next pigtail. 7. If you are using a yellow splice connector, strip about 6 mm (1/4 inch) of insulation off the ends of both wires. If you are using a pink or blue splice connector, strip off about 8 mm (5/16 inch) of insulation. How To Replace Connector Terminals Multiple Junction Connector: Service and Repair How To Replace Connector Terminals Terminal Replacement Procedure HOW TO REPLACE CONNECTOR TERMINALS The terminal repair kits provide necessary tools and materials (terminals, wire seals, and splice connectors) to repair many damaged or faulty connector terminals. However, not all terminals for all connectors are available. Refer to the labels on the lids of the repair kits for replacement terminal availability. IMPORTANT SAFETY INFORMATION: On some models, the SRS wires are in a separate harness. If the SRS harness is damaged, replace the harness; do not repair it. On other models, wire harnesses include yellow SRS wires. If any SRS wire is damaged, replace the entire harness; do not repair it. Before you begin, inspect the wire you are about to repair for damage and length. Make sure the wire will be long enough to make a terminal repair without stretching it when you reinstall the terminal in the connector. If the wire is too short, or if access to the connector is too restricted to make a terminal repair, you may need to install a pigtail terminal (a short length of wire with a factory-crimped terminal on it). Refer to HOW TO INSTALL PIGTAIL TERMINALS. Removing the Terminal Use the tools from Pin Tool Set. First, check the connector that you are about to repair. - If it has a secondary terminal lock, go to Connectors With a Secondary Lock. A secondary lock, found on most connectors on some models, is an additional locking device on the connector housing as a backup for the primary lock on the terminal. - If the connector does not have a secondary lock, go to Connectors Without a Secondary Lock. Connectors With a Secondary Lock All examples are shown with the connector lock facing up. The illustrations are examples of the secondary terminal locks; however, the connector you are repairing may vary in size. Identify the connector by the type of secondary lock, not by the number of terminal cavities. EXAMPLE A: 1. Release the secondary lock. Page 9603 212. Combination Light Switch Page 7426 - Turn off the engine. It is best to tow the vehicle no farther than 50 miles (80 km), and keep the speed below 35 mph (55 km/h). NOTE: - Improper towing preparation will damage the transmission. Follow the above procedure exactly. If you cannot shift the transmission or start the engine (automatic transmission), the vehicle must be transported on a flat-bed. - Trying to lift or tow the vehicle by the bumpers will cause serious damage. The bumpers are not designed to support the vehicle's weight. Page 8253 10. Pull down on the retainer clip with a hook-shaped tool. Remove the lock cylinder. Then go to step 14. 11. Pull the glass run channel away as necessary, and remove the bolt, then remove the center lower channel by pulling it downward. 12. Remove the access seal, and disconnect the outer handle rod and the cylinder rod. Page 259 DTC P0158 thru P0400 Page 8126 1997-01 CR-V with dealer-installed security system 1996-97 del Sol with dealer-installed security system 1996-98 Odyssey with dealer-installed security system *1999-04 Odyssey LX with dealer-installed keyless entry system or security system* 1996-01 Prelude with dealer-installed security system *2000-04 S2000 with dealer-installed security system 2000-04 Insight with dealer-installed security system 2003-04 Pilot LX with dealer-installed keyless entry system or security system* Programming the Transmitter NOTES: ^ The system accepts up to three transmitters. The transmitter codes are stored in a stacking-type memory. If a fourth transmitter code is programmed, the code for the first transmitter is erased. ^ Entering the programming mode cancels all learned transmitter codes, so none of the previously programmed transmitters will work. You must reprogram all of the transmitters once you are in the programming mode. ^ You must complete steps 1-6 within 4 seconds of the previous step to keep the system from exiting the programming mode. 1. Turn the ignition switch to ON (II). 2. Press the "Lock" or "Unlock" button on one of the transmitters. (An unprogrammed transmitter can be used for this step.) 3. Turn the ignition switch to LOCK (0). 4. Repeat steps 1, 2, and 3 two more times using the same transmitter used in step 2. 5. Turn the ignition switch to ON (II). 6. Press the "Lock" or "Unlock" button on the same transmitter. Make sure the power door locks cycle to confirm that the system is in programming mode. 7. Within 10 seconds, press the "Lock" or "Unlock" button on each transmitter. Make sure the power door locks cycle after you press each transmitter button to confirm that the system accepted the transmitter's code. 8. Turn the ignition switch to LOCK (0) to exit the programming mode. Ordering a Transmitter Transmitters can be ordered only by authorized Honda dealers. Order them from American Honda using normal parts ordering procedures. Batteries for the Transmitter The battery number is CR2025. Each transmitter uses one battery. Page 518 Wheel Speed Sensor: Description and Operation Wheel Sensors The wheel sensors are the magnetic contact less type. As the gear purser teeth rotate past the wheel sensor's magnetic coil, AC current is generated. The AC frequency changes in accordance with the wheel speed. The ABS control unit detects the wheel sensor signal frequency and thereby detects the wheel speed. When the wheel speed drops sharply below the vehicle speed, the outlet valve opens momentarily to reduce the caliper fluid pressure. The pump motor starts at this time. As the wheel speed is restored, the inlet valve opens momentarily to increase the caliper fluid pressure. Page 4388 1. Remove the terminal. 2. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE B: 1. Remove the terminal. 2. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE C: 1. Remove the terminal. 2. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE D: Page 8611 10. Pull down on the retainer clip with a hook-shaped tool. Remove the lock cylinder. Then go to step 14. 11. Pull the glass run channel away as necessary, and remove the bolt, then remove the center lower channel by pulling it downward. 12. Remove the access seal, and disconnect the outer handle rod and the cylinder rod. Page 5057 Pressure Regulating Solenoid: Diagrams 25. A/T Clutch Pressure Control Solenoid Valve A 26. A/T Clutch Pressure Control Solenoid Valve B Page 3603 9. Open the jaws with the jaws knob, and slide the original key with its flat side down into the center jaw up to the key stop. Slide the key blank with its flat side down into the right jaw up to the key stop. Close the jaws with the jaws knob to lock the keys into place. Visually inspect both keys for proper alignment in the jaws. 10. Loosen the lateral and spring tension adjustment knobs on the clamp carriage. With the clamp carriage lever, adjust the clamp carriage to position the tracer and the cutter bit over the middle of the two locked key blades. Tighten only the spring tension knob when done. NOTE: The clamp carriage has a spring system that puts lateral pressure on the tracer and cutting bit to make it easier to cut sidewinder-type keys. Do not tighten the lateral tension adjustment knob. This knob should be left loose. 11. Turn on the cutter motor with the motor start switch. [NOTICE] ^ To avoid damaging the locking jaws while cutting, keep your hand off the vertical carriage lever. Pressure on the lever will change the cutting depth. * ^ To avoid breaking the cutter bit, never back up while cutting.* ^ Wear proper eye protection (safety glasses, goggles, etc.) Page 8268 9. Open the jaws with the jaws knob, and slide the original key with its flat side down into the center jaw up to the key stop. Slide the key blank with its flat side down into the right jaw up to the key stop. Close the jaws with the jaws knob to lock the keys into place. Visually inspect both keys for proper alignment in the jaws. 10. Loosen the lateral and spring tension adjustment knobs on the clamp carriage. With the clamp carriage lever, adjust the clamp carriage to position the tracer and the cutter bit over the middle of the two locked key blades. Tighten only the spring tension knob when done. NOTE: The clamp carriage has a spring system that puts lateral pressure on the tracer and cutting bit to make it easier to cut sidewinder-type keys. Do not tighten the lateral tension adjustment knob. This knob should be left loose. 11. Turn on the cutter motor with the motor start switch. [NOTICE] ^ To avoid damaging the locking jaws while cutting, keep your hand off the vertical carriage lever. Pressure on the lever will change the cutting depth. * ^ To avoid breaking the cutter bit, never back up while cutting.* ^ Wear proper eye protection (safety glasses, goggles, etc.) Page 2824 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. Test Equipment 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. Keyless Entry - Remote Transmitter Information Technical Service Bulletin # 98-011 Date: 040220 Keyless Entry - Remote Transmitter Information 98-011 February 20, 2004 Applies To: ALL Keyless Remote Transmitter Information (Supersedes 98-011, dated February 6, 2003) Updated information is shown by asterisks and a black bar. This service bulletin gives you information about keyless remote transmitters for most Honda vehicles. Each procedure describes transmitter programming (if applicable), transmitter ordering, and transmitter batteries. A remote transmitter quick reference guide is shown below. Page 5470 Brake Master Cylinder: Testing and Inspection Inspection NOTE: ^ Before reassembling, check that all parts are free of dust and other foreign particles. ^ Do not try to disassemble the master cylinder assembly. Replace the master cylinder assembly with a new part if necessary. Do not allow dirt or foreign matter to contaminate the brake fluid. Page 5872 67. Under Left Side Of Dash How to Remove the PCM Control Module: Service and Repair How to Remove the PCM How to Remove the PCM for Testing 1. Remove the passenger's dashboard lower cover, the right kick panel, and the glove box. 2. Remove the bolt. Cut the plastic cross brace in the glove box opening with diagonal cutters in the area shown, and discard it. 3. Remove the relays (A), then remove the bolts and the glove box frame (B). 4. Remove the gray 20P PCM wire harness connector from the PCM mounting bracket. Remove the PCM mounting bolt (A) and the bracket. 5. Remove the nuts, then remove the PCM (B). 6. Install the PCM in the reverse order of removal. Page 109 PGM-F1 Main Relay 1, 2 Type 1, 2 Check for continuity between the terminals. - There should be continuity between the No.1 and No.2 terminals when power and ground are connected to the No.3 and No.4 terminals. - There should be no continuity between the No.1 and No.2 terminals when power is disconnected. Normally-open type B: Rear Window Defogger Relay Page 2587 Camshaft Position Sensor: Description and Operation Camshaft Position (CMP) Sensor (Top Dead Center (TDC) Sensor) The CMP (TDC) sensor detects the position of the No.1 cylinder as a reference for sequential fuel injection to each cylinder. Page 4748 Flywheel: Testing and Inspection Clutch Replacement Special Tools Required ^ Clutch alignment shaft 07LAF-PT00110 ^ Clutch alignment disc 07JAF-PM7011A ^ Remover handle 07936-3710100 ^ Ring gear holder 07LAB-PV00100 or 07924-PD20003 ^ Attachment, 57 x 40 mm 07746-0010200 ^ Driver 077 49-0010000 Flywheel Inspection 1. Inspect the ring gear teeth for wear and damage. 2. Inspect the clutch disc mating surface on the flywheel for wear, cracks and burning. 3. Measure the flywheel (A) runout using a dial indicator (B) through at least two full turns with the engine installed. Push against the flywheel each time you turn it to take up the crankshaft thrust washer clearance. If the runout is more than the service limit, replace the flywheel and recheck the runout. Standard (New): 0.06 mm (0.002 inch) max. Service Limit: 0.15 mm (0.006 inch) 4. Turn the inner race of the pilot bearing (A) with your finger. The bearing should turn smoothly and quietly. Check that the bearing outer race fits tightly in the flywheel. If the race does not turn smoothly, quietly, or fit tight in the flywheel, replace the bearing. Page 1719 8. Remove the camshaft holders. Measure the widest portion of plastigage on each journal. ^ If the camshaft-to-holder clearance is within limits, go to step 10. ^ If the camshaft-to-holder clearance is beyond the service limit and the camshaft has been replaced, replace the cylinder head.; ^ If the camshaft-to-holder clearance is beyond the service limit and the camshaft has not been replaced, go to step 9. Camshaft-to-Holder Oil Clearance: Standard (New): 0.050 - 0.089 mm (0.0020 - 0.0035 inch) Service Limit: 0.15 mm (0.006 inch) 9. Check the total runout with the camshaft supported on V-blocks. ^ If the total runout of the camshaft is within the service limit, replace the cylinder head. ^ If the total runout is beyond the service limit, replace the camshaft and recheck the camshaft-to-holder oil clearance. If the oil clearance is still out of tolerance, replace the cylinder head. Camshaft Total Runout: Standard (New): 0.03 mm (0.001 inch) max. Service Limit: 0.04 mm (0.002 inch) Page 1244 DIAGNOSTIC WORKSHEET REPAIR PROCEDURE A Page 9743 3. Check for continuity between the terminals in each switch position according to the tables. Driver's Switch: The driver's switch is combined with the control unit so you cannot isolate the switch to test it. Instead, run the master switch input test procedures. If the tests are normal, the driver's switch must be faulty. Replace the switch. 4. If the continuity is not as specified, remove the driver's door panel. 5. Remove the armrest from the door panel. Page 7468 Body Control Systems: Connector Views 241. Carlink Card Reader 242. Carlink Interface Box Antitheft System - Alarm Will Not Arm/Arms By Itself Alarm Module: All Technical Service Bulletins Antitheft System - Alarm Will Not Arm/Arms By Itself 05-025 July 1, 2005 Applies To: 2001-05 Civic - ALL 2002-05 CR-V - ALL 2003-04 Element - ALL Accessory Security System Changes Modes By Itself (Supersedes 05-025, dated June 10, 2005, to update the information indicated by black bars and asterisks.) SYMPTOM The security system will not arm or it arms by itself. PROBABLE CAUSE Key switch contact chatter causes the control unit to change modes. CORRECTIVE ACTION * Civic: Replace the security control unit, and reprogram the remote(s).* * CR-V and Element: Replace the security control unit and the microphone, then reprogram the remote(s).* * NOTE: You must replace the microphone on the CR-V and Element because the security control units are matched to their microphones when they are manufactured. Using the original microphone may result in security system problems.* PARTS INFORMATION WARRANTY CLAIM INFORMATION In warranty: The normal warranty applies. Out of warranty: Any repair performed after warranty expiration may be eligible for goodwill consideration by the District Parts and Service Manager or your Zone Office. You must request consideration, and get a decision, before starting work. REPAIR PROCEDURE NOTE: Before starting, make sure you have all of the remotes (three maximum) the customer wishes to use. Page 6707 2. Remove the driver's airbag: ^ Refer to page 23-137 of the 2001-2005 Civic Service Manual, or * ^ Refer to page 23-131 of the 2002-2004 CR-V Service Manual, or ^ Refer to page 23-368 of the 199~2004 Odyssey Service Manual, or ^ Refer to page 23-105 of the 2003-2004 Pilot Service Manual, or* ^ Online, enter keywords DRIVER AIR, and select Driver's Airbag Replacement from the list. 3. Place the airbag, face down, on a clean shop towel. 4. Using needle-nose Vise Grips, remove the four locknuts from the inflator and discard them reused. NOTE: Do not remove the inflator from the airbag until you complete step 5. 5. Use shop air to clean any debris that may be on the inflator, then remove the inflator from the airbag. NOTE: ^ Do not allow any foreign objects to enter the inflator opening in the airbag. ^ Do not deploy the inflator. The inflator must be returned to its supplier in the box the new inflator came in (see INFLATOR PACKING AND GROUND SHIPPING INSTRUCTIONS: DEALERS IN THE 48 CONTIGUOUS STATES or INFLATOR PACKING AND AIR SHIPPING INSTRUCTIONS: DEALERS IN ALASKA AND HAWAII). 6. Turn over the airbag (inflator side down), and shake it to remove any debris from the inflator opening. 7. Install the new inflator in the airbag with new locknuts. Torque the locknuts to 3.9 N.m (2.8 lb-ft, 34 lb-in). NOTE: The 55A inflator is slightly taller than the S84 inflator, but they are still interchangeable. Page 7467 2. Insert the terminal tool into the female terminal, and then remove the terminal tool. NOTE: Make sure you do not select a terminal tool that is larger than the mating male terminal because it would spread the female terminal and cause a loose fit. 3. Compare the drag to the other terminals in the connector. If the drag is less, replace the terminal with a replacement terminal from the appropriate terminal repair kit. Page 6088 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 3584 124. CMP (TDC) Sensor Recall 10V364000: Ignition Interlock Defect Shift Interlock Switch: Recalls Recall 10V364000: Ignition Interlock Defect VEHICLE MAKE/MODEL: MODEL YEAR(S): Honda/Accord 2003 Honda/Civic 2003 Honda/Element 2003-2004 MANUFACTURER: Honda (American Honda Motor Co.) MFR'S REPORT DATE: August 04, 2010 NHTSA CAMPAIGN ID NUMBER: 10V364000 NHTSA ACTION NUMBER: EA09001 COMPONENT: Electrical System: Ignition POTENTIAL NUMBER OF UNITS AFFECTED: 384220 SUMMARY: Honda is recalling certain model year 2003 Honda Accord, Civic two and four door, and model year 2003-2004 Honda Element vehicles. The interlock lever of the ignition switch may unexpectedly deform, which can allow the interlock function of a vehicle with an automatic transmission to be defeated. CONSEQUENCE: Removal of the ignition key when the gear selector of a vehicle with an automatic transmission has not been shifted to the park position can allow the vehicle to roll away, increasing the risk of a crash. REMEDY: Dealers will remove the original interlock pin and lever within the ignition switch, and replace them with newly, designed components. This service will be performed free of charge. The safety recall is expected to begin on or about September 29, 2010. Owners may contact Honda at 1-800-999-1009. NOTES: Honda safety recall No. R44. 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 3014 39. Left Side Of Engine Compartment Page 6389 Wheel Bearing: Testing and Inspection End Play Inspection 1. Raise the vehicle, and support it with safety stands in the proper locations. Remove the wheels. 2. Install suitable flat washers (A) and wheel nuts, and tighten the nuts to the specified torque to hold the brake disc or drum securely against the hub. 3. Set up the dial gauge against the hub flange as shown, and measure the bearing end play moving the brake disc or drum inward and outward. Bearing end play: Standard: Front/Rear: 0 - 0.05 mm (0 - 0.002 inch) 4. If the bearing end play is more than the standard, replace the wheel bearing. Page 520 Wheel Speed Sensor: Service and Repair Replacement NOTE: Install the sensors carefully to avoid twisting the wires. Page 7968 NOTE: You need to make the corrections listed in CODE BOOK CORRECTIONS at the end of this service bulletin. TRACER AND CUTTER BIT INSTALLATION 1. Turn the power switch on the back of the machine to ON. (This turns on the built-in work light.) 2. Use the Allen wrench from the built-in tool drawer to loosen the setscrew on the left sleeve of the vertical carriage. Slide the tracer all the way into the sleeve, and tighten the screw. 3. Turn the plastic shield on the right sleeve of the vertical carriage so you can access the setscrew on the sleeve. Use the Allen wrench to loosen the screw. Slide the cutter bit all the way into the sleeve, and tighten the screw. Turn the plastic shield so the open side is in the back. MACHINE COMPONENTS Page 6282 Disassembly/Reassembly Installation 1. Before installing the steering wheel, make sure the front wheels are aligned straight ahead, then center the cable reel (A). Do this by first rotating the cable reel clockwise until it stops. Then rotate it counterclockwise about two and a half turns. The arrow mark (B) on the cable reel label point should point straight up. 2. Position the two tabs (A) of the turn signal cancelling sleeve (B) as shown, and install the steering wheel on to the steering column shaft, making sure the steering wheel hub (C) engages the pins (D) of the cable reel and tabs of the canceling sleeve. Do not tap on the steering wheel or steering column shaft when installing the steering wheel. Page 6601 5. After checking and repairing leaks, the system must be evacuated. Page 4181 Page 7309 - 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 5119 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. Below most connector numbers and component names are PHOTO and VIEW numbers. The PHOTO number refers to a photo in the back of the book that shows the connector's location on the car. The VIEW number refers to an illustration in the back of the book that shows the connector terminals, wire colors, connector cavity numbers, and other details. The connector cavity numbering sequence begins at the top left corner of the connector as seen from either of the viewpoints shown on diagram [8] . Except for the DLC (data link 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 C554, for example, means those terminals join in cavity 2 of connector C554. Power Distribution Schematics Power Distribution Schematics Page 5930 8. Put the splice connector in the proper size slot in the Crimper Tool, slide it to one end (where the flare begins), and close the crimper handles far enough to hold it in place. To release the ratchet mechanism at any point after the first click, squeeze the handles slightly and push the release lever, then let the handles open. 9. Insert one of the bare wires into the splice connector end that is in the crimper jaws. Push the wire all the way into the splice connector, and squeeze the crimper handles. Keep squeezing until the jaws touch, and hold it at that position until the ratchet clicks again. 10. Crimp the other wire in the same way into the other end of the splice connector. 11. After crimping, gently pull on the wires in the opposite directions to make sure they are secure in the connector. 12. Separate the other wires in the harness from the repaired wire(s), and shield them with nonflammable material. Instruments - Fuel Gauge Inaccurate Fuel Gauge: All Technical Service Bulletins Instruments - Fuel Gauge Inaccurate 05-002 March 4, 2005 Applies To: 2003-04 Civic 4-Door EX and LX- VIN starts with 1HG or 2HG Inaccurate Fuel Gauge Reading SYMPTOM At any fuel level, the fuel gauge reading drops by 1/4 tank, or 3 to 4 graduation marks. In some cases, the fuel gauge indicates "E" and the low fuel warning light is on. After driving for several minutes, or cycling the ignition switch off/on, the fuel gauge returns to the correct reading. This problem is intermittent, and it affects only Civics with Visteon gauge assemblies. PROBABLE CAUSE The software specification for calculating the current fuel level is incorrect. CORRECTIVE ACTION Replace the gauge assembly. WARRANTY CLAIM INFORMATION In warranty: The normal warranty applies. Operation Number: 734101 Flat Rate Time: 0.3 hour Failed Part: Same as listed in PARTS INFORMATION Defect Code: 03214 Symptom Code: 03902 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 3288 20. Transmission Housing Page 6978 Air Bag(s) Arming and Disarming: Description and Operation SRS Operation SRS Operation The main circuit in the SRS unit senses and judges the force of impact and, if necessary, ignites the inflator charges. 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: Seat Belt Tensioners and Seat Belt Buckle Tensioners 1. A front impact sensor must activate and send electric signals to the microprocessor. 2. The microprocessor must compute the signals and send them to the tensioners. 3. The charges must ignite and deploy the tensioners. Driver's and Front Passenger's Airbag(s) 1. A front impact sensor must activate, and send electric signals to the microprocessor. 2. The microprocessor must compute the signals, and depending on the severity of the collision and whether the seat belt buckle switch is ON or OFF, it sends the appropriate signals to the airbag inflator(s). 3. The inflators that received signals must ignite and deploy the airbags. Side Airbag(s) 1. Aside impact sensor must activate, and send electric signals to the microprocessor. 2. The microprocessor must compute the signals and send them to the side airbag inflator(s). However, the microprocessor cuts off the signals to the front passenger's side airbag if the OPDS unit determines that the front passenger's head is in the deployment path of the side airbag. 3. The inflator that received the signal must ignite and deploy the side airbag. Self-diagnosis System A self-diagnosis circuit is built into the SRS unit; when the ignition switch is turned ON (II), the SRS indicator comes on and goes off after about 6 seconds if the SRS is operating normally. If the indicator does not come on, or does not go off after 6 seconds, or if it comes on while driving, it indicates an abnormality in the SRS. The SRS must be inspected and repaired as soon as possible. For better serviceability, the SRS unit memory stores a DTC that relates to the cause of the malfunction, and the unit is connected to the data link circuit. This information can be read with the Honda PGM Tester when it is connected to the data link connector (DLC). Seats With Side Airbags Air Bag(s) Arming and Disarming: Description and Operation Seats With Side Airbags Seats with Side Airbags Seats with side airbags have a tag attached to the seat-back. Because the component parts (seat-back cover, cushion, etc.) of seats with and without airbags are different, make sure you install only the correct replacement parts. Because the seats are made by more than one manufacturer, make sure you replace any seat components (seat-back cover, frame, etc.) with the correct parts. The name of the seat manufacturer is indicated on the seat-back. Moreover, the manufacturer name is indicated on the seat-back frame and the seat-back pad. Confirm the indication when you exchange these parts. * When cleaning, do not saturate the seat with liquid, and do not spray steam on the seat. * Do not repair torn or frayed seat-back covers. Replace the seat-back cover. * After a collision in which the side airbag was deployed, replace the seat-back cover and the side airbag with new parts. If the seat-back cushion is split, it must be replaced. If the seat-back frame is definitely deformed, it must be replaced. Page 2496 Power Steering Pressure Switch: Testing and Inspection PSP Switch Signal Circuit Troubleshooting 1. Turn the ignition switch ON (II). 2. Measure voltage between ECM/PCM connector terminals A24 and E16. Is there less than 1.0 V? YES - Go to step 3. NO - Go to step 6. 3. Start the engine. 4. Turn the steering wheel to the full lock position. 5. Measure voltage between ECM/PCM connector terminals A24 and E16. Is there battery voltage? YES - The PSP switch signal is OK. NO - Go to step 13. 6. Turn the ignition switch OFF. 7. Disconnect the PSP switch 2P connector. 8. Turn the ignition switch ON (II). 9. At the harness side, connect the PSP switch 2P connector terminals No.1 and No.2 with a jumper wire. 10. Measure voltage between ECM/PCM connector terminals A24 and E16. Is there less than 1.0 V? YES - Replace the PSP switch. NO - Go to step 11. 11. Turn the ignition switch OFF. Page 970 Clutch Switch: Adjustments Clutch Pedal, Clutch Pedal Position Switch, and Clutch Interlock Switch Adjustment NOTE: ^ To check the clutch pedal position switch. ^ To check the clutch interlock switch. ^ Remove the driver's side floor mat before adjusting the clutch pedal. ^ The clutch is self-adjusting to compensate for wear. ^ If there is no clearance between the master cylinder piston and push rod, the release bearing is held against the diaphragm spring, which can result in clutch slippage or other clutch problems. 1. Loosen locknut (A), and back off the clutch pedal position switch (B) (or adjusting bolt) until it no longer touches the clutch pedal (C). 2. Loosen locknut (D), and turn the push rod (E) in or out to get the specified height (F) and stroke (G) at the clutch pedal. Clutch Pedal Stroke: 130 - 140 mm (5.1 - 5.5 inch) Clutch Pedal Height: 198 mm (7.8 inch) 3. Tighten locknut (D). 4. With the clutch pedal released, turn the clutch pedal position switch (B) in until it contacts the clutch pedal (C).. 5. Turn the clutch pedal position switch (B) in an additional 3/4 to 1 turn. 6. Tighten locknut (A). 7. Loosen locknut (H) and the clutch interlock switch (1) 8. Press the clutch pedal to the floor. 9. Release the clutch pedal 15 - 20 mm (0.59 - 0.79 inch) from the fully depressed position, and hold it there. Adjust the position of the clutch interlock switch (1) so that the engine will start with the clutch pedal in this position. 10. Tighten locknut (H). Page 312 Blower Motor Relay Type 1, Type 2 Check for continuity between the terminals. - There should be continuity between the No.1 and No.3 terminals when power and ground are connected to the No.2 and No.4 terminals. - There should be no continuity between the No.1 and No.3 terminals when power is disconnected. Five-terminal type Check for continuity between the terminals. - There should be continuity between the No.1 and No.2 terminals when power and ground are connected to the No.3 and No.5 terminals. - There should be continuity between the No.1 and No.4 terminals when power is disconnected. Page 1634 16. Remove the snap ring (A) and the splash guard (B) from the knuckle (C). 17. Press the wheel bearing (A) out of the knuckle (B) using the special tool and a press. 18. Wash the knuckle and hub thoroughly in high flash point solvent before reassembly. 19. Press a new wheel bearing (A) into the knuckle (B) using the old bearing (C), a steel plate (D), the special tool, and a press. Place the wheel bearing on the knuckle with the pack seal side facing (metal color) toward the inside. Be careful not to damage the sleeve of the pack seal. 20. Install the snap ring (A) securely in the knuckle (B). 21. Install the splash guard (C), and tighten the screws (D) to the specified torque. Page 8280 ^ If the trunk opens and closes smoothly, return the vehicle to the customer. ^ If the trunk lid is still difficult to close, go to REPAIR PROCEDURE E. REPAIR PROCEDURE E 1. Look at the back of the lock cylinder while you turn the key from lock to unlock. ^ Refer to page 20-158 of the 2001-04 Civic Service Manual. ^ In ISIS, use the keyword LID LOCK, and select Trunk Lid Lock Cylinder Replacement from the list. 2. Check the operation of the trunk lid lock cylinder: ^ If the lock cylinder is difficult to turn or binds, go to step 3. ^ If the lock cylinder operates properly, and the trunk lid is still difficult to close, refer to the appropriate body repair manual, and check for body inaccuracies. 3. Replace the lock cylinder, and re-key the cylinder to the customer's original key; on 2-door Civics, replace the lock cylinder and the lock cylinder rod: ^ Refer to page 20-158 of the 2001-04 Civic Service Manual. ^ In ISIS, use the keyword LID LOCK, and select Trunk Lid Lock Cylinder Replacement from the list. 4. Check the trunk operation, and return the vehicle to the customer. Disclaimer Page 9032 13. Plug in the heat gun, and turn it on. Start at the middle of the splice connector, and move the gun toward the ends as the tube shrinks. Apply heat evenly by rotating the curved heat spreader around the splice connector. Shrinking is complete when a small amount of sealant appears at each end of the tube. Pigtail Terminal Selection Chart PIGTAIL TERMINAL SELECTION CHART Select the proper size pigtail terminal by matching the replacement terminal part number and the wire size being repaired to the corresponding pigtail terminal part number. Then use the color (size) splice connector listed. In some instances you may also have to match the wire seal style to select the proper pigtail terminal. Pigtail terminals are available through your parts department, in quantities of 10, using normal parts ordering procedures. Checking For Poor Fir of Terminals CHECKING FOR POOR FIT OF TERMINALS Loose terminal fit can cause a number of intermittent problems in electrical circuits. By using the Terminal Inspection Feeler Tool Set you can inspect the terminal fit between the two matching connectors without removing the terminals from the connector body. 1. Find the terminal tool that best matches the male terminal in the mating connector. Page 2437 5. Remove the lower cover from the fuse/relay box. 6. Disconnect the 3P ELD connector. Page 1817 Crankshaft: Service and Repair Crankshaft Installation Installation Special Tools Required ^ Handle Driver 07749-0010000 ^ Driver Attachment, 96 mm 07948-SB00101 or 07VAD-P8A010A 1. Check the connecting rod bearing clearance with plastigage. 2. Check the main bearing clearance with plastigage. 3. Apply engine oil to the main bearings and rod bearings. 4. Install the bearing halves in the cylinder block and connecting rods. 5. Hold the crankshaft so rod journal No. 2 and rod journal No. 3 are straight up, and lower the crankshaft into the block. 6. Install the thrust washers (A) on both edges of the No. 4 main bearing recess. 7. Apply engine oil to the threads of the connecting rod bolts. 8. Seat the rod journals into connecting rod No. 1 and connecting rod No. 4. Install the caps and nuts finger tight. Install the cap so the bearing recess is on the same side as the recess in the rod. 9. Rotate the crankshaft clockwise, and seat the journals into connecting rod No.2 and connecting rod No. 3. Install the connecting rod cap and bolts finger tight. 10. Tighten the connecting rod bolts to 32 Nm (3.3 kgf-m, 24 ft. lbs. ). 11. Install the bearing cap bridge. Coat the bolt threads with engine oil. 12. Torque the bearing cap bolts sequentially in two steps. 1st step torque: 25 Nm (2.5 kgf-cm, 18 ft. lbs.) 2nd step torque: 51 Nm (5.2 kgf-cm, 38 ft. lbs.) NOTE: Whenever any crankshaft or connecting rod bearing is replaced, it is necessary after reassembly to run the engine at idling speed until it reaches normal operating temperature, then continue to run it for about 15 minutes. Bearing Cap Bolts Tightening Sequence: 13. The seal mating surface on the engine block end cover should be dry. Apply a light coat of grease to the crankshaft and to the lip of the seal. Locations 94. Behind Glove Box (except GX) Front Suspension Control Arm: Service and Repair Front Suspension Lower Arm Removal/Installation Special Tools Required Ball joint remover, 28 mm 07MAC-SL00200 1. Raise the front of the vehicle, and support it with safety stands in the proper locations. Remove the front wheels. 2. Remove the flange nut (A) while holding the joint pin (B) with a hex wrench (C), and disconnect the stabilizer link (D) from the lower arm (E). 3. Remove the lock pin (A) from the lower arm ball joint, and remove the castle nut (B). NOTE: During installation, insert the lock pin into the ball joint pin the range of 180 degrees or below from the inside of the vehicle. Insert the lock pin from the inside to the outside of the vehicle. 4. Disconnect the lower arm from the knuckle using the special tool. 5. Remove the flange bolts (A), and remove the lower arm (B). 6. Install the lower arm in the reverse order of removal, and note these items: Page 5544 Clutch Switch: Testing and Inspection Clutch Interlock Switch Test 1. Disconnect the clutch interlock switch 2P connector. 2. Remove the clutch interlock switch (A). 3. Check for continuity between the terminals according to the table. - If the continuity is not as specified, replace the clutch interlock switch. - If OK, install clutch interlock switch and adjust the pedal height. Page 4292 13. Remove the solenoid cover, and make sure the solenoid plunger groove is installed in the fork on the lever. ^ If needed, correct the position of the solenoid plunger, then go to step 14. ^ If the solenoid plunger is correctly installed, there is an electrical problem with the key interlock system; refer to the Automatic Transmission section of the appropriate service manual for troubleshooting information. Once the key interlock is working normally, go to step 14. 14. Install the solenoid cover. 15. Reinstall the steering column covers. 16. Center-punch a completion mark above the seventh character of the engine compartment VIN. Disclaimer Page 5089 23. Transmission Housing (A/T) Page 2982 Engine Control Module: Service and Repair ECM/PCM Idle Learn Procedure ECM/PCM Idle Learn Procedure The idle learn procedure must be done so the ECM/PCM can learn the engine idle characteristics. Do the idle learn procedure whenever you do any of these actions: - Disconnect the battery. - Replace the ECM/PCM or disconnect its connector. - Reset the ECM/PCM. NOTE: Erasing DTCs with the Honda PGM Tester does not require you to do the idle learn procedure. - Remove the No.6 ECU (ECM/PCM) (15A) fuse from the under-hood fuse/relay box. - Remove the No.19 battery (80A) fuse from the under-hood fuse/relay box. - Remove PGM-FI main relay 1. - Remove any of the wires from the under-hood fuse/relay box. - Disconnect any of the connectors from the under-hood fuse/relay box. - Disconnect the connector between the engine compartment wire harness and ECM/PCM wire harness. - Disconnect the G2 terminal from the transmission housing. - Disconnect the G1 terminal from the body. - Disconnect the G101 terminal from the water passage. Procedure: 1. Make sure all electrical items (A/C, audio, rear defogger, lights, etc.) are off. 2. Start the engine, and hold it at 3,000 rpm with no load (in Park or neutral) until the radiator fan comes on, or until the engine coolant temperature reaches 194 °F (90 °C). 3. Let the engine idle for about 5 minutes with the throttle fully closed. NOTE: If the radiator fan comes on, do not include its running time in the 5 minutes Page 5686 Starter Motor: Diagrams Starter Overhaul For M/T, CVT Campaign - OPDS Unit Warranty Extension Technical Service Bulletin # 06-009 Date: 080205 Campaign - OPDS Unit Warranty Extension 06-009 February 5, 2008 Applies To: See VEHICLES AFFECTED Warranty Extension: OPDS Unit or OPDS Sensor Triggers SRS DTC(s) 15-1, 15-2, 15-3 (Supersedes 06-009, dated September 21, 2007) Updated information is shown with asterisks. BACKGROUND *NOTE: Because of a class action settlement, the warranty extension coverage for the OPDS unit and the OPDS sensor on 2002 Accords, 2002-04 Civics, 2003-04 Civic Hybrids, 2002-04 CR-Vs, 2003 Elements, 2002 Odysseys, and 2003-04 Pilots purchased or leased between April 13, 2002, and November 7, 2006, is now 10 years or 157,500 miles, whichever occurs first. For more information, refer to Service Bulletin 06-085, Warranty Extension: Vehicle Warranty Mileage.* Several vehicle models may have a problem with the OPDS (occupant position detection system) that causes the SRS indicator to stay on. Typically, one or more of these DTCs will be set: ^ SRS DTC 15-1 (faulty OPDS unit or OPDS not initialized) ^ SRS DTC 15-2 (faulty side airbag indicator circuit) ^ SRS DTC 15-3 (faulty OPDS sensor) To ensure continued reliability with the OPDS, American Honda is extending the warranty on the OPDS unit and the OPDS sensor to 10 years or 150,000 miles, whichever occurs first. This warranty extension does not apply to any vehicle that has ever been declared a total loss, or any that has been issued a salvage, branded, or similar title under any state's law. To check for vehicle eligibility, you must do a VIN status inquiry Page 5481 Parking Brake Cable: Adjustments Check and Adjustment Check 1. Pull the parking brake lever (A) with 196 N (20.0 kgf, 44.1 lbs.) of force to fully apply the parking brake. The parking brake lever should be locked within the specified number of clicks (B). Lever locked clicks: 6 - 7 2. Adjust the parking brake if the lever clicks are not within the specification. Adjustment NOTE: After servicing the rear brake shoes, loosen the parking brake adjusting nut, start the engine, and press the brake pedal several times to set the self-adjusting brake before adjusting the parking brake. 1. Block the front wheels, then raise the rear of the vehicle, and make sure it is securely supported. 2. Remove the console cover. 3. Pull the parking brake lever up one click. 4. Tighten the adjusting nut (A) until the parking brakes drag slightly when the rear wheels are turned. 5. Release the parking brake lever fully, and check that the parking brakes do not drag when the rear wheels are turned. Readjust if necessary. 6. Make sure the parking brakes are fully applied when the parking brake lever is pulled up fully. 7. Reinstall the console cover. Page 7606 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. Obtain the customer's key code from the iN (Key Code Inquiry). Refer to the Honda High Security key Codes book that comes with the Matrix H key cutting machine. Write down the applicable cutting code for the key code number. Make sure the corrections to the code book listed in Service Bulletin 01-077, Cutting Sidewinder-Type keys With the Matrix H key Cutting Machine, have been made. 2. Use the chart shown to write down the numbers found in the key code book. 3. Remove the door panel. Refer to the appropriate service manual or use ISIS keyword Door Panel. 4. Remove the plastic cover as necessary. 5. Raise the window glass fully. 6. Remove the lock cylinder. ^ For Civic, go to step 7. ^ For CR-V, go to step 8. ^ For Element, go to step 11. 7. Pull down on the retainer clip with a hook-shaped tool. Remove the lock cylinder and disconnect the cylinder rod. Then go to step 14. Page 8089 68. Under Left Side Of Dash Locations Turn Signal Relay: Locations Turn Signal/Hazard Flasher Component Location Index Page 9535 Under-dash Fuse/Relay Box Page 8404 Sunroof / Moonroof Motor: Testing and Inspection Motor Test 1. Remove the headliner. 2. Disconnect the 2P connector from the moonroof motor. 3. Check the motor by connecting power and ground according to the table. 4. If the motor does not run, replace it. NOTE: See closing force check for motor clutch test. Diagram Information and Instructions Transmission Position Switch/Sensor: Diagram Information and Instructions Terminal Numbering System Terminal Numbering System Connector terminals are numbered according to the cavities they're in. The cavities are numbered starting from the upper left, looking at the male terminals from the terminal side or looking at the female terminals from the wire side. Both views are in the same direction so the numbers are the same. All actual cavities are numbered, even if they have no wire terminals in them. NOTE: Data Link Connector (DLC) terminals are numbered according 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 below is #6. Page 722 REPAIR PROCEDURE 1. Make sure you have the anti-theft code for the audio unit. Write down the customer's audio presets. 2. Disconnect the negative battery cable from the battery. 3. Remove the under-hood fuse/relay box cover. 4. Release the three clips, and remove the under- hood fuse/relay box from the holder. CR-V only: Release the wire harness clip from the fuse/relay box holder Page 3621 Spark Plug: Application and ID NGK ..................................................................................................................................................... ............................................................... PZFR6F-11 DENSO ................................................................................................................................................ ......................................................... PKJ20CR-M11 Gap ...................................................................................................................................................... ................................. 1.0 -1.1 mm (0.039 - 0.043 in) Torque ................................................................................................................................................. ...................................................... 18 N.m (13 lb.ft) Page 2174 Radiator Cooling Fan Motor: Testing and Inspection Fan Motor Test 1. Disconnect the 2P connectors from the radiator fan motor (A) and condenser fan motor (B). 2. Test the motor by connecting battery power to the B terminal and the ground to the A terminal. 3. If the motor fails to run or does not run smoothly, replace it. Page 5255 1. Remove the terminal. 2. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE B: 1. Remove the terminal. 2. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE C: 1. Remove the terminal. 2. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE D: Page 4921 ^ The vehicle is shown as eligible on a VIN status inquiry. In addition, check for a punch mark above the seventh character of the engine compartment VIN. A punch mark in that location means the ignition switch key interlock has already been inspected/repaired. 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 a VIN status inquiry before selling it. CUSTOMER NOTIFICATION All owners of affected vehicles will be sent a notification of this campaign. An example of the customer notification is at the end of this service bulletin. CORRECTIVE ACTION Inspect the ignition switch and, if needed, install a Key Interlock Repair Kit. PARTS INFORMATION Key Interlock Repair Kit: P/N 06351-SDA-000 REQUIRED SPECIAL TOOLS Interlock Slide Hammer: T/N 07AAC-S84A100 NOTE: ^ An initial quantity of Permalube grease to lubricate the sliding surface of the interlock lever is included with the slide hammer. To order more Permalube, use P/N 08734-0030. ^ To order a replacement clamping bolt for the slide hammer, use T/N 07AAC-S84A400. WARRANTY CLAIM INFORMATION Failed Part: P/N 35100-SDA-A31 Defect Code: 5GC00 Symptom Code: R4400 Page 292 ECM/PCM Inputs And Outputs At Connector E (31P) Front Page 1048 Shift Interlock Switch: Testing and Inspection Park Pin Switch Test 1. Remove the center console panel and center console. 2. Disconnect the park pin switch connector (4P). 3. Shift to the P position, then check for continuity between the No. 3 and No. 4 terminals. There should be no continuity. 4. Shift out of the P position, and check for continuity between terminals No. 3 and No. 4. There should be continuity. 5. If the park pin switch is faulty, replace it. Connector Views Fuse Block: Connector Views 234. Under-dash Fuse/Relay Box Part 1 Page 8271 ^ Going from front to back, use the middle lock pin to set the first cam to the appropriate key code number in the code book. (The cam is properly set when the number on the cam lines up with the red scribe mark on the clamp unit.) ^ Slide the lock pin through the notch in the cam. (This locks the cam in place.) ^ Keep doing this for each of the remaining cams in the set until all the cams are set and locked, then push the lock pin all the way in. Repeat this process to set and lock the cams for the right cam set. NOTE: Make sure you set the MIS cam in the right cam set for the type of key you are cutting. For a master key, set the cam to M; for a valet key, set it to S. When you are done, push all the cam blades to the left until they touch the cams in the left cam set. 10. Pull the vertical carriage lever toward you until the tracer touches the flat surface on the right side at the front of the cams. Gently twist the lever clockwise to lock the vertical carriage at this height. Do not overtighten the lever. 11. Turn on the cutter motor with the motor start switch. [NOTICE] ^ To avoid damaging the locking jaws while cutting, keep your hand off the vertical carriage lever. Pressure on the lever will change the cutting depth. * ^ To avoid breaking the cutter bit, never back up while cutting.* ^ Wear proper eye protection (safety glasses, goggles, etc.) 12. Use the clamp carriage lever and the tracer to follow the contours of the cam blades from front to back. (The cutter bit cuts the same contours into the right edge of the key blank, from head to tip.) Body - Trunk Lid Hard to Close Trunk / Liftgate Latch Release Cable: Customer Interest Body - Trunk Lid Hard to Close 02-061 November 5, 2004 Applies To: See VEHICLES AFFECTED Trunk Lid is Difficult to Close (Supersedes 02-061, dated July 23, 2004) Updated information is shown with asterisks. SYMPTOM The trunk lid may be difficult to close or won't latch closed. PROBABLE CAUSE The trunk lid may be misaligned, and the trunk lid opener cable, trunk lid latch, lock cylinder, lock rod, and/or the trunk lid latch striker may need adjustment or replacement. VEHICLES AFFECTED CORRECTIVE ACTION Adjust the trunk lid and/or the trunk lid latch, or replace components as needed. PARTS INFORMATION 2 Door Trunk / Liftgate Latch Release Cable: Service and Repair 2 Door Trunk Lid Opener Cable/Fuel Fill Door Opener Cable Replacement 2-door SRS components are located in this area. Review the SRS component locations and the precautions and procedures before doing repairs or service. NOTE: - Put on gloves to protect your hands. - Take care not to scratch the body and related parts. 1. Remove these items from the left side of the vehicle: - Side trim panel - Door sill trim - Trunk side trim panel 2. Pull the carpet back as necessary. 3. Disconnect the trunk lid opener/fuel fill door opener cable (A) from the opener (B). 4. Release the opener cable from the clip (C). Remove the cushion tape (D), and detach the clip (E) with a clip remover. 5. Remove the fuel fill door latch (F) by turning it 90 °, and detach the opener cable junction box (G) from the body. Page 2546 Transmission Position Switch/Sensor: Electrical Diagrams Circuit Diagram Page 9417 Diagram 114-3 (Coupe EX) Page 1191 4. Reconnect the connector, and make these input tests at the connector. If any test indicates a problem, find and correct the cause, then recheck the system. Page 8266 NOTE: You need to make the corrections listed in CODE BOOK CORRECTIONS at the end of this service bulletin. TRACER AND CUTTER BIT INSTALLATION 1. Turn the power switch on the back of the machine to ON. (This turns on the built-in work light.) 2. Use the Allen wrench from the built-in tool drawer to loosen the setscrew on the left sleeve of the vertical carriage. Slide the tracer all the way into the sleeve, and tighten the screw. 3. Turn the plastic shield on the right sleeve of the vertical carriage so you can access the setscrew on the sleeve. Use the Allen wrench to loosen the screw. Slide the cutter bit all the way into the sleeve, and tighten the screw. Turn the plastic shield so the open side is in the back. MACHINE COMPONENTS Page 7105 Page 4806 Shift Indicator: Testing and Inspection Continuously Variable Transmission Indicator Input Test SRS components are located in this area. Review the SRS component locations, precautions, and procedures in the SRS section before performing repairs or service. 1. If the MIL has been reported, check for a DTC, and repair the system as indicated by DTC. 2. If the MIL does not come on, and the A/T gear position indicator P, N, or R does not come on. Turn the ignition switch off, remove the gauge assembly from the dashboard, then disconnect gauge assembly connector A (22P) and B (22P). 3. Inspect the connectors and connector terminals to be sure they are making good contact. 4. If the terminals are bent, loose, or corroded, repair them as necessary, and recheck the system. 5. Shift to the P position, and check for continuity between AS terminal (BLU/BLK) and ground. There should be continuity in the P position and no continuity in any other shift lever position. If your test results are different, check for a faulty transmission range switch or an open in the wire. 6. Shift to the N position, and check for continuity between AS terminal (BLK/RED) and ground. There should be continuity in the N position and no continuity in any-other shift lever position. If your test results are different, check for a faulty transmission range switch or an open in the wire. 7. Turn the ignition switch ON (II), shift to the R position, and check for voltage between A11 terminal (WHT) and ground. There should be 0 V in the R position. There should be about 5 V in any other shift lever position. If your test results are different, check for a faulty transmission range switch or an open in the wire. 8. Check for voltage between B17 terminal (YEL) and ground with the ignition switch ON (II). There should be battery voltage. If your test results are different, check for a blown No. 10 (7.5A) fuse in the under-dash fuse/relay box or an open in the wire. 9. Turn the ignition switch OFF, and check for continuity between B16terminal (BLK) and ground under all conditions. There should be continuity. If your test results are different, check for a poor ground (G501) or an open in the wire. 10. If all input tests prove OK, but the indicator is faulty, replace the printed circuit board. Page 430 Power Window Relay: Testing and Inspection Power Relay Test Use this chart to identify the type of relay, then do the test listed for it. NOTE: See the turn signal/hazard relay input test. Normally-open type A: Campaign - Vehicle Warranty Mileage Extension Odometer: All Technical Service Bulletins Campaign - Vehicle Warranty Mileage Extension 06-085 May 9, 2008 Applies To: See VEHICLES AFFECTED Warranty Extension: Vehicle Warranty Mileage (Supersedes 06-085, dated January 22, 2008, to update the information marked by asterisks) BACKGROUND On December 29, 2007, a federal court provided final approval of the settlement of a class action lawsuit alleging that the odometers on certain 2002 through 2006 Honda models, and some 2007 Fit models, were overstating mileage. As part of the settlement, American Honda is extending the mileage-based coverage period of all warranties, Honda Care Service Contracts, and Honda Certified Used Vehicles by 5 percent on the above referenced vehicles. The time limits for all warranties are unchanged. VEHICLES AFFECTED The vehicles affected by this settlement include certain 2002 through 2006 Honda models and some 2007 Fit models purchased or leased between April 13, 2002, and November 7, 2006. The affected region is the United States (including the District of Columbia, Puerto Rico, and the U.S. Virgin Islands). Affected vehicles registered to customers with a military or a NATO address are also included in this settlement. The most effective way to check a vehicle's warranty coverage is by a VIN status inquiry. CUSTOMER NOTIFICATION American Honda notified affected customers by mail or publication. The notices were sent to original registered purchasers, informing them of the terms of the settlement. Notice was also published in a national newspaper. To view the content of the mailed notice, as well as other documents regarding the settlement, or for additional information, please refer to these sources: Website: www.odosettlementinfo.com Information Center: (888) 888-3082 CORRECTIVE ACTION *On affected vehicles, the settlement requires you to honor a 5 percent increase in the mileage coverage period for all warranties, all Honda Certified Used Vehicles, and those Honda Care Service Contracts purchased only by the original owners.* WARRANTY CLAIM INFORMATION Use the chart as a reference for converting most standard warranty mileage limits to the extended mileage coverage. Use the chart as a reference to all service bulletins affected by the extended mileage coverage. In addition to the 5 percent mileage increase in warranty coverage, any repair performed after warranty expiration may be eligible for goodwill Page 3260 2. Remove the terminal (same procedure for male and female). 3. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE E: 1. Remove the secondary locks. 2. Remove the terminal (same procedure for male and female). 3. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE F: Page 3841 2. Insert the terminal tool into the female terminal, and then remove the terminal tool. NOTE: Make sure you do not select a terminal tool that is larger than the mating male terminal because it would spread the female terminal and cause a loose fit. 3. Compare the drag to the other terminals in the connector. If the drag is less, replace the terminal with a replacement terminal from the appropriate terminal repair kit. Page 821 1. Remove the secondary locks. 2. Remove the terminal from the female half. 3. Remove the terminal from the male half. 4. Go to HOW TO INSTALL NEW TERMINALS. Connectors Without a Secondary Lock All examples are shown with the connector lock facing up. The illustrations are examples of connector terminals without a secondary lock; however, the connector you are repairing may vary in size and shape. EXAMPLE A: Page 5519 Braking Sensor/Switch: Testing and Inspection Brake Pedal Position Switch Signal Circuit Troubleshooting 1. Check the brake lights. Are the brake lights on without pressing the brake pedal? YES - Inspect the brake pedal position switch. NO - Go to step 2. 2. Press the brake pedal. Do the brake lights come on? YES - Go to step 3. NO - Go to step 4. 3. Measure voltage between ECM/PCM connector terminals A24 and E22 with the brake pedal pressed. Is there battery voltage? YES - The brake pedal position switch signal is OK. NO - Repair open in the wire between the ECM/PCM (E22) and the brake pedal position switch. 4. Inspect the No.7 HORN, STOP (15A) fuse in the under-hood fuse/relay box. Is the fuse OK? YES - Repair open in the wire between the brake pedal position switch and the No.7 HORN, STOP (15A) fuse. Inspect the brake pedal position switch. NO - Repair short in the wire between the ECM/PCM (E22) and the No.7 HORN, STOP (15A) fuse. Replace the No.7 HORN, STOP (15A) fuse. Page 3694 Diodes Light Emitting Diode (LED) Motor Pressure Sensor Page 5235 Terminals - "T" Shielding Switches Fuses Page 7932 *T-5 Sidewinder Key Applications ^ 2003-05 Civic ^ 2004-05 Civic Hybrid ^ 2003-05 Civic GX (CNG) ^ 2004-05 S2000 ^ 2002-06 CR-V ^ 2003-06 Element ^ 2003-04 Odyssey ^ 2003-04 Pilot Ordering Honda key blanks through normal parts ordering channels: Refer to the parts catalog for correct key(s) for your application. PROGRAMMING KEYS Depending on the type of key blank you use, do this: ^ If you have used a T-5 programmable key blank ("T-5" stamped on the shank), you must code the key's transponder with the Ilco Immobilizer Key Code Duplicator (see S/B 99-053, Ilco Immobilizer key Code Duplicator). ^ If you have used a Honda key blank, add the* transponder code of the new key to the immobilizer system with the Honda Diagnostic System (HDS). ORDERING INFORMATION *To order the MATRIX H Key Cutting Machine, replacement cutter bits, fixed jaws and mobile jaws, T-5 programmable key blanks, and practice key blanks, contact the Honda Tool and Equipment Program by calling 888-424-6857 or using the fax order form provided in your Honda Tool and Equipment Program Catalog.* Order Honda key blanks through normal parts ordering channels. WARRANTY CLAIM INFORMATION None. This service bulletin is for information only. *DETERMINING WHICH KEY TO USE T-5 keys require less time to program and should be the first choice. They can be used as long as the following requirements are met: ^ Do you have the customer's operating key? ^ Does the vehicle fall within the T-5 Sidewinder Key Applications? ^ Does your dealership have an Ilco Immobilizer Key Code Duplicator? If the answer to all three questions on the above is yes, the 1-5 key option is the easier procedure. If you answered no to any of the questions, you should order the key(s) from the parts catalogue, and program it using the HDS.* BEFORE YOU START CUTTING 1. Get the original key or the key number from your customer or from the iN. 2. Get the applicable key blank. 3. If cutting by code, look up the applicable 9-digit cutting code for the key number. Refer to the code book Honda High Security key Codes that comes with the machine. Page 3130 Diodes Light Emitting Diode (LED) Motor Pressure Sensor Page 1763 2. Remove the terminal from the female half. 3. Remove the terminal from the male half. 4. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE D: 1. Remove the secondary locks. Page 2381 Main Relay (Computer/Fuel System): Description and Operation PGM-FI Main Relay 1 and 2 The PGM-FI relay consists of two separate relays. PGM-FI main relay 1 is energized whenever the ignition switch is ON (II) which supplies battery voltage to ECM/PCM, power to the injectors, and power for PGM-FI main relay 2. PGM-FI main relay 2 is energized to supply power to the fuel pump for 2 seconds when the ignition switch is turned ON (II), and when the engine is running. Page 9733 Power Windows Component Location Index 119. Driver's Door (Coupe except DX, HX) Page 8078 Part 1 5. Reconnect all connections to the under-dash fuse/relay box, and make these input tests at the appropriate connectors on the under-dash fuse/relay box. If any test indicates a problem, find and correct the cause, then recheck the system. - If all the input tests prove OK, go to step 6. Part 2 Page 3270 2. Insert the terminal tool into the female terminal, and then remove the terminal tool. NOTE: Make sure you do not select a terminal tool that is larger than the mating male terminal because it would spread the female terminal and cause a loose fit. 3. Compare the drag to the other terminals in the connector. If the drag is less, replace the terminal with a replacement terminal from the appropriate terminal repair kit. Page 366 ^ If the OPDS unit has an original part number, go to step 6. ^ If the OPDS unit has a new part number (refer to PARTS INFORMATION) or higher, go to REPAIR PROCEDURE B: OPDS SENSOR REPLACEMENT. 6. Recline the seat-back to access the OPDS unit mounting screws. 7. Remove the mounting screws from the OPDS unit, and gently pull out the unit. 8. Disconnect the OPDS connectors, then remove the OPDS unit. 9. Install a new OPDS unit, then snap on its cover. 10. Slip the seat-back cover over the OPDS unit. 11. On Accords, check the seat-back clip attachment bosses on the seat-back panel: ^ If the attachment bosses are OK, go to step 12. ^ If the seat-back has a pocket, and the attachment bosses are deformed or damaged, do the repair procedure in S/B 02-010, Seat-Back Panel Is Loose or Detached. Then go to step 12. ^ If the seat-back does not have a pocket, and the attachment bosses are deformed or damaged, replace the seat-back. Then go to step 12. Locations 134. Right C Pillar (Coupe) Page 3186 125. TP Sensor Page 660 193. Hazard Warning Switch Page 7047 Seat Belt Tensioner: 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. Rear Seat-Back Latch Seat Latch: Service and Repair Rear Seat-Back Latch Rear Seat-back Latch Replacement NOTE: Take care not to scratch the interior trim. 1. Remove the rear shelf, 2-door, 4-door 2. Disconnect the cylinder rod (A), and remove the bolts, then remove the seat-back latch (B). 3. Install the latch in the reverse order of removal, and note these items: - Make sure the cylinder rod is connected securely. - Make sure the seat-back locks securely and opens properly. Service and Repair Vehicle Lifting: Service and Repair Lift and Support Points NOTE: If you are going to remove heavy components such as the suspension or the fuel tank from the rear of the vehicle, first support the front of the vehicle with tall safety stands. When substantial weight is removed from the rear of the vehicle, the center of gravity can change and cause the vehicle to tip forward on the hoist. Frame Hoist 1. Position the hoist lift blocks (A), or safety stands, under the vehicle's front support points (B) and rear support points (C). 2. Raise the hoist a few inches, and rock the vehicle gently to be sure it is firmly supported. 3. Raise the hoist to full height, and inspect the lift points for solid contact with the lift blocks. Safety Stands To support the vehicle on safety stands, use the same support points (B and C) as for a frame hoist. Always use safety stands when working on or under any vehicle that is supported only by a jack. Floor Jack 1. Set the parking brake. 2. Block the wheels that are not being lifted. 3. When lifting the rear of the vehicle, put the gearshift lever in reverse (or the automatic transmission in [P] position). 4. Position the floor jack under the front jacking bracket (A) or rear jacking bracket (B), center the jacking bracket in the jack lift platform (C), and jack up the vehicle high enough to fit the safety stands under it. 5. Position the safety stands under the support points and adjust them so the vehicle will level. 6. Lower the vehicle onto the stands. Page 804 Resistor Variable Sensor Solenoid Transistors Circuit Schematics Page 7955 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 5976 234. Under-dash Fuse/Relay Box Part 2 Page 41 Part 1 5. Reconnect all connections to the under-dash fuse/relay box, and make these input tests at the appropriate connectors on the under-dash fuse/relay box. If any test indicates a problem, find and correct the cause, then recheck the system. - If all the input tests prove OK, go to step 6. Part 2 Page 6566 - Refill the cooling system with engine coolant. - Be sure to connect the drain hose securely. - Adjust the heater valve cable. - Make sure that there is no coolant leakage. - Make sure that there is no air leakage. - With air conditioning, refer to evaporator core replacement. - Do the ECM/PCM idle learn procedure. - Enter the anti-theft code for the radio, then enter the customer's radio station presets. Page 9753 4. Reconnect the connector, and make these input tests at the connector. If any test indicates a problem, find and correct the cause, then recheck the system. Page 1070 - Before connecting connectors, make sure the terminals (A) are in place and not bent. - Check for loose retainer (A) and rubber seals (B). - The backs of some connectors are packed with dielectric grease. Add grease if necessary. If the grease is contaminated, replace it. - Insert the connector all the way and make sure it is securely locked. - Position wires so that the open end of the cover faces down. Handling Wires and Harnesses - Secure wires and wire harnesses to the frame with their respective wire ties at the designated locations. Page 1544 234. Under-dash Fuse/Relay Box Part 2 Page 6939 PARTS INFORMATION TOOL INFORMATION Page 3652 Shift Solenoid: Service and Repair Shift Solenoid Valves A and B Replacement NOTE: Shift solenoid valves A and B must be removed/ replaced as an assembly. 1. Remove the harness clamp (c) form the clamp bracket (D). 2. Remove the mounting bolts and the shift solenoid valves A and B. 3. Clean the mounting surface and fluid passage. 4. Install a new shift solenoid valves A and B with a new filter/gasket (E), and install the harness clamp on the clamp bracket. 5. Check the connector for rust, dirt, or oil, then reconnect the connector securely. Service and Repair Rear Door Latch: Service and Repair Rear Door Latch Replacement 4-door NOTE: Put on gloves to protect your hands 1. Raise the glass fully. 2. Remove these items - Door panel - Plastic cover, as necessary - Rod protector 3. Remove the screws securing the latch 4. With power door lock, disconnect the actuator rod (A) and connector (B), then remove the actuator (C). 5. Disconnect the lock rod (A) from the lock crank (B) Ignition/Locks - Cutting Sidewinder-Type Keys Technical Service Bulletin # 01-077 Date: 060419 Ignition/Locks - Cutting Sidewinder-Type Keys 01-077 April 19, 2006 Applies To: Models With Sidewinder-Type Keys - All Cutting Sidewinder-Type Keys With the MATRIX H Key Cutting Machine (Supersedes 01-077, dated January 12, 2005) Updated information is noted by asterisks. MATRIX H Key Cutting Machine, manufactured by Silca and supplied by Kaba Ilco Corporation, is a portable, power-operated tool that cuts sidewinder-type automotive keys exclusively. The machine lets you cut these keys either by copying or by code. The code function is designed and built to meet the Honda code requirements. No other similar machine has this capability. This service bulletin gives you information for ordering and servicing this special tool, and guides you through the entire key cutting process from setting up the machine to cutting the key blank. TOOL INFORMATION Order through the Honda Tool and Equipment Program: MATRIX H Key Cutting Machine: Model No. ILCMATRIXSH Cutter Bit: Model No. ILCF3O Fixed Jaw: Model No. ILCMTX-H Mobile Jaw (Right Side): Model No. ILCRTMTX-H Mobile Jaw (Left Side): Model No. ILCLTMTX-H *Remanufactured Clamp Unit: Model No. ILCMATRIXHCR* PARTS INFORMATION *For some models, there are two choices for sidewinder-type key blanks: ^ T-5 sidewinder key blanks ^ Honda sidewinder key blanks For other models, only Honda sidewinder key blanks can be used. See DETERMINING WHICH KEY TO USE to determine which key blank you should choose. Ordering T-5 key blanks through the Honda Tool and Equipment Program: T-5 Programmable Key Blank (Master): P/N ILC-35111-T-5H T-5 Programmable Key Blank (Valet): P/N ILC-35112-T-5H Practice Key Blanks (five per pack): ILC-35111DEMO* NOTE: Do not use practice key blanks for replacement purposes. Practice keys do not have an immobilizer chip. Page 2602 *T-5 Sidewinder Key Applications ^ 2003-05 Civic ^ 2004-05 Civic Hybrid ^ 2003-05 Civic GX (CNG) ^ 2004-05 S2000 ^ 2002-06 CR-V ^ 2003-06 Element ^ 2003-04 Odyssey ^ 2003-04 Pilot Ordering Honda key blanks through normal parts ordering channels: Refer to the parts catalog for correct key(s) for your application. PROGRAMMING KEYS Depending on the type of key blank you use, do this: ^ If you have used a T-5 programmable key blank ("T-5" stamped on the shank), you must code the key's transponder with the Ilco Immobilizer Key Code Duplicator (see S/B 99-053, Ilco Immobilizer key Code Duplicator). ^ If you have used a Honda key blank, add the* transponder code of the new key to the immobilizer system with the Honda Diagnostic System (HDS). ORDERING INFORMATION *To order the MATRIX H Key Cutting Machine, replacement cutter bits, fixed jaws and mobile jaws, T-5 programmable key blanks, and practice key blanks, contact the Honda Tool and Equipment Program by calling 888-424-6857 or using the fax order form provided in your Honda Tool and Equipment Program Catalog.* Order Honda key blanks through normal parts ordering channels. WARRANTY CLAIM INFORMATION None. This service bulletin is for information only. *DETERMINING WHICH KEY TO USE T-5 keys require less time to program and should be the first choice. They can be used as long as the following requirements are met: ^ Do you have the customer's operating key? ^ Does the vehicle fall within the T-5 Sidewinder Key Applications? ^ Does your dealership have an Ilco Immobilizer Key Code Duplicator? If the answer to all three questions on the above is yes, the 1-5 key option is the easier procedure. If you answered no to any of the questions, you should order the key(s) from the parts catalogue, and program it using the HDS.* BEFORE YOU START CUTTING 1. Get the original key or the key number from your customer or from the iN. 2. Get the applicable key blank. 3. If cutting by code, look up the applicable 9-digit cutting code for the key number. Refer to the code book Honda High Security key Codes that comes with the machine. Page 748 160. Left Side Of Engine Compartment (except GX) Page 4751 4. Inspect the pressure plate (A) surface for wear, cracks, and burning. 5. Inspect the fingers of the diaphragm spring (B) for wear at the release bearing contact area. 6. Inspect for warpage using a straight edge (A) and feeler gauge (B). Measure across the pressure plate (C). If the warpage is more than the service limit, replace the pressure plate. Standard (New): 0.03 mm (0.001 inch) max. Service Limit: 0.15 mm (0.006 inch) 7. Remove the clutch disc and special tools. 8. Inspect the lining of the clutch disc for signs of slipping or oil. If the clutch disc is burned black or oil soaked, replace it. Page 9001 Wire Color Abbreviations Page 8568 - Replace the front damper extension, damper housing, and damper housing extension as an assembly. Installation 1. Set the new damper housing assembly, front wheelhouse, and front bulkhead into position, and measure the front compartment diagonally. Check the body dimensions. 2. Tack weld the clamped position. 3. Temporarily install the front sub-frame, and check the front side frame position. 4. Temporarily install the hood, front fender, headlight, and front bumper, and check for difference in level and clearance. Make sure the body lines flow smoothly. 5. Do the main welding. Specifications Page 2693 124. CMP (TDC) Sensor Page 24 Alarm Module: Diagrams 182. Immobilizer Control Unit - Receiver 214. Security Control Unit (Optional) Locations Clutch Switch: Locations Cruise Control Component Location Index Page 1956 2. Apply liquid gasket, PIN 08718-0001 or 08718-0003, on the oil pump and engine block end cover mating areas. NOTE: Do not install the parts if 5 minutes or more have elapsed since applying liquid gasket. Instead, reapply liquid gasket after removing old residue. 3. Apply liquid gasket, P/N 08718-0001 or 08718-0003, to the new oil pan gasket (A) at the four corners of the recesses (B), then install the oil pan (C). NOTE: Do not install the parts if 5 minutes or more have elapsed since applying liquid gasket. Instead, reapply liquid gasket after removing old residue. 4. Tighten the bolts and nuts finger tight at six points as shown. 5. Tighten all bolts and nuts, starting from nut (1), clockwise in 3 steps. In the final step, tighten all bolts, in sequence to 12 Nm (1.2 kgf-cm, 8.7 ft. lbs.). 6. After assembly, wait at least 30 minutes before filling the engine with oil. Locations Page 9294 Terminals - "T" Shielding Switches Fuses Page 4106 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 Short Circuit Locator (Short Finder) 1. Remove the blown fuse. Leave the battery connected. Page 3637 Pressure Regulating Solenoid: Service and Repair A/T Clutch Pressure Control Solenoid Valves A and B Replacement 1. Remove the mounting bolts and the A/T clutch pressure control solenoid valves A and B. 2. Clean the mounting surface and fluid passage of the A/T clutch pressure control solenoid valves A and B and the transmission housing. 3. Install the new filter/gasket (c) in the solenoid valve assembly body groove. 4. Install the new A/T clutch pressure control solenoid valves A and B. Do not pinch the filter/gasket. 5. Check the A/T clutch pressure control solenoid valve connectors for rust, dirt, or oil, then connect them securely. Page 828 8. Put the splice connector in the proper size slot in the Crimper Tool, slide it to one end (where the flare begins), and close the crimper handles far enough to hold it in place. To release the ratchet mechanism at any point after the first click, squeeze the handles slightly and push the release lever, then let the handles open. 9. Insert one of the bare wires into the splice connector end that is in the crimper jaws. Push the wire all the way into the splice connector, and squeeze the crimper handles. Keep squeezing until the jaws touch, and hold it at that position until the ratchet clicks again. 10. Crimp the other wire in the same way into the other end of the splice connector. 11. After crimping, gently pull on the wires in the opposite directions to make sure they are secure in the connector. 12. Separate the other wires in the harness from the repaired wire(s), and shield them with nonflammable material. Page 2053 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. How to Replace Connector Terminals Terminal Replacement Procedure HOW TO REPLACE CONNECTOR TERMINALS The terminal repair kits provide necessary tools and materials (terminals, wire seals, and splice connectors) to repair many damaged or faulty connector terminals. However, not all terminals for all connectors are available. Refer to the labels on the lids of the repair kits for replacement terminal availability. IMPORTANT SAFETY INFORMATION: On some models, the SRS wires are in a separate harness. If the SRS harness is damaged, replace the harness; do not repair it. On other models, wire harnesses include yellow SRS wires. If any SRS wire is damaged, replace the entire harness; do not repair it. Before you begin, inspect the wire you are about to repair for damage and length. Make sure the wire will be long enough to make a terminal repair without stretching it when you reinstall the terminal in the connector. If the wire is too short, or if access to the connector is too restricted to make a terminal repair, you may need to install a pigtail terminal (a short length of wire with a factory-crimped terminal on it). Refer to HOW TO INSTALL PIGTAIL TERMINALS. Removing the Terminal Page 235 Under-hood Fuse And Relay Box (4-door) Page 4114 1. Remove the terminal. 2. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE E: 1. Remove the terminal. 2. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE F: Page 6397 Wheel Bearing: Service and Repair Rear Hub Bearing Unit Replacement 1. Raise the rear of the vehicle, and support it with safety stands in the proper locations. 2. Remove the wheel cap, wheel nuts, and rear wheel. Locations 12. Middle of Engine Page 8409 138. Rear Of Roof (EX) Page 2334 ECM/PCM Inputs And Outputs At Connector E (31P) Page 7354 206. CD Changer (Honda Accessory) Page 9605 Combination Switch: Service and Repair Combination Light Switch Test/Replacement 1. Remove the dashboard lower cover. 2. Remove the steering column covers. 3. Disconnect the 16P connector (A) from the combination light switch (B). 4. Remove the two screws, then slide out the combination light switch. 5. Inspect the connector terminals to be sure they are all making good contact. - If the terminals are bent, loose or corroded, repair them as necessary, and recheck the system. - If the terminals look OK, check for continuity between the terminals in each switch position according to the tables. If the continuity is not as specified, replace the switch. Page 345 104. In Front Pass. Or Pass. Seat (Side Airbag) Page 2771 ECM/PCM Inputs And Outputs At Connector C (22P) Page 7614 24. Remove the key. Reinstall the retainer clip in the door handle, and push the lock cylinder into place. 25. Civic: Reconnect the cylinder rod. 26. CR-V: Reconnect the cylinder rod, the outer handle rod, and the rod protector. 27. Element: Reconnect the cylinder rod, the outer handle rod, and the access seal. Reinstall the lower run channel. 28. Reinstall the plastic covering, and lower the window glass. Install the door panel. 29. Check that the door lock and handle operate smoothly. Disclaimer Page 5512 31. Brake Fluid Level Switch Page 3952 7. Verify that the Program ID and the Program Part No. are for the vehicle you are updating, then click on the check mark. 8. Confirm the control module update by Program ID and Program Part No. Make sure this corresponds with any information provided in the service bulletin for the update you are doing. Click on Yes to continue. Within a few seconds, the CM Update software loads the program file onto the GNA600. 9. Click on the check mark to begin the control uniti module update. NOTE: To avoid control unit/module damage, do not interrupt the update. 10. Within 60 seconds of update completion, turn the ignition switch to LOCK (0) and then back to ON (II). 11. Once the software verifies that the control uniti mod ule has been successfully updated, click on Yes to update another identical vehicle, or click on No to exit the update program. GNA600 Updating in Storage Mode 1. If not already done, load the latest HDS PC software onto your iN workstation. For loading instructions, refer to the ISIS publication Installation Instructions for HDS PC Software. Page 5997 1. Remove the secondary locks. 2. Remove the terminal (same procedure for male and female). 3. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE F: 1. Remove the secondary locks. Locations Transmission Position Switch/Sensor: Locations Component Location Index, A/T Page 6130 ^ 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. Ignition/Locks - Cutting Sidewinder-Type Keys Technical Service Bulletin # 01-077 Date: 060419 Ignition/Locks - Cutting Sidewinder-Type Keys 01-077 April 19, 2006 Applies To: Models With Sidewinder-Type Keys - All Cutting Sidewinder-Type Keys With the MATRIX H Key Cutting Machine (Supersedes 01-077, dated January 12, 2005) Updated information is noted by asterisks. MATRIX H Key Cutting Machine, manufactured by Silca and supplied by Kaba Ilco Corporation, is a portable, power-operated tool that cuts sidewinder-type automotive keys exclusively. The machine lets you cut these keys either by copying or by code. The code function is designed and built to meet the Honda code requirements. No other similar machine has this capability. This service bulletin gives you information for ordering and servicing this special tool, and guides you through the entire key cutting process from setting up the machine to cutting the key blank. TOOL INFORMATION Order through the Honda Tool and Equipment Program: MATRIX H Key Cutting Machine: Model No. ILCMATRIXSH Cutter Bit: Model No. ILCF3O Fixed Jaw: Model No. ILCMTX-H Mobile Jaw (Right Side): Model No. ILCRTMTX-H Mobile Jaw (Left Side): Model No. ILCLTMTX-H *Remanufactured Clamp Unit: Model No. ILCMATRIXHCR* PARTS INFORMATION *For some models, there are two choices for sidewinder-type key blanks: ^ T-5 sidewinder key blanks ^ Honda sidewinder key blanks For other models, only Honda sidewinder key blanks can be used. See DETERMINING WHICH KEY TO USE to determine which key blank you should choose. Ordering T-5 key blanks through the Honda Tool and Equipment Program: T-5 Programmable Key Blank (Master): P/N ILC-35111-T-5H T-5 Programmable Key Blank (Valet): P/N ILC-35112-T-5H Practice Key Blanks (five per pack): ILC-35111DEMO* NOTE: Do not use practice key blanks for replacement purposes. Practice keys do not have an immobilizer chip. Page 2886 52. Measure voltage between body ground and ECM/PCM connector terminal A21. Is there about 5 V? YES - Go to step 59. NO - Go to step 53. 53. Turn the ignition switch OFF. 54. Disconnect the 3P connector from each of these sensors, one at a time, and measure voltage between body ground and ECM/PCM connector terminal A21 with the ignition switch ON (II). Manifold absolute pressure (MAP) sensor - CVT driven pulley speed sensor (CVT) - CVT speed sensor 1 (CVT) Is there about 5 V? YES - Replace the sensor that restored 5 V when disconnected. NO - Go to step 55. 55. Turn the ignition switch OFF. 56. Disconnect the 3P connector from the following sensors. - Manifold absolute pressure (MAP) sensor - CVT driven pulley speed sensor (CVT) - CVT speed sensor 1 57. Disconnect ECM/PCM connector A (31P). Page 9730 3. Using an O-ring pick or similar tool, pull up the outer edge of the molding, and apply 3M Black Super Silicone Sealant under it, along the A-pillars and the upper edge of the windshield. 4. Push down on the molding, and smooth it out until it sits flush with the roof. 5. Wait 5 minutes, then remove the masking tape. 6. Clean up any excess sealant with 3M General Purpose Adhesive Cleaner. Disclaimer Page 1450 Page 1502 2. Remove the access panel from the steering wheel, then disconnect the driver's airbag 4P connector (A) from the cable reel. Front Passenger's Airbag 3. Lower the glove box, then disconnect the front passenger's airbag 4P connector (A) from the dashboard wire harness B. Side Airbag 4. Disconnect both side airbag 2P connectors (A) from the floor wire harness. Seat Belt Tensioner 5. Disconnect both seat belt tensioner 2P connectors (A) from the floor wire harness. Seat Belt Buckle Tensioner Page 7443 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. Below most connector numbers and component names are PHOTO and VIEW numbers. The PHOTO number refers to a photo in the back of the book that shows the connector's location on the car. The VIEW number refers to an illustration in the back of the book that shows the connector terminals, wire colors, connector cavity numbers, and other details. The connector cavity numbering sequence begins at the top left corner of the connector as seen from either of the viewpoints shown on diagram [8] . Except for the DLC (data link 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 C554, for example, means those terminals join in cavity 2 of connector C554. Power Distribution Schematics Power Distribution Schematics Page 9337 150. Middle of Trunk Lid Page 4968 Wires Page 4987 1. Remove the secondary lock from the male terminal half. 2. Remove the secondary lock from the female terminal half. 3. Remove the terminal (same procedure for male and female). 4. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE C: 1. Remove the secondary lock. Page 9752 Power Window Switch: Testing and Inspection Passenger's Window Switch Input Test Passenger's Switch Input Test 1. Remove the switch panel. 2. Disconnect the 5P connector (A) from the switch (B). 3. Inspect the connector and socket terminals to be sure they are all making good contact. - If the terminals are bent, loose or corroded, repair them as necessary, and recheck the system. - If the terminals look OK, go to step 4. Page 5376 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 Short Circuit Locator (Short Finder) 1. Remove the blown fuse. Leave the battery connected. Page 7098 1. On Accords and Pilots, remove the front passenger's seat-back panel by prying out the bottom. Replace the two lower clips. 2. On all models except Accords and Pilots, unzip the two seat cover zippers on the back of the front passenger's seat. 3. Pull back the seat-back cover from the left side bolster to access the OPDS unit cover. 4. Remove the OPDS unit cover from the seat frame. 5. Check the part number of the installed OPDS unit. Page 979 Disclaimer Cutting Procedure - By Copying 1. Press the ON/OFF button in the middle of the setting unit keypad. (This powers up the keypad.) 2. Turn the clamp unit lock lever to the left to release the clamp unit, and slide it all the way to the left until it stops. Turn the lever to the right to lock the clamp unit in place. 3. Use the clamp carriage lever to position the clamp unit so the tracer and cutter bit are centered directly over the base of the center and right jaws. 4. Pull the vertical carriage lever toward you until the tracer and the cutter bit just touch the base of each fixed jaw. Watch the arrows on the keypad: ^ If the double-headed arrow in the middle of the keypad lights green, the tracer and cutter bit are properly aligned. ^ If the arrow on the left of the keypad lights red, the cutter bit is not touching the fixed jaw. Turn the micrometric ring nut above the tracer to the left until the double-headed arrow lights green. ^ If the arrow on the right of the keypad lights red, the tracer is not touching the fixed jaw. Turn the micrometric ring nut above the tracer to the right until the double-headed arrow lights green. *5. Turn the micrometric ring nut to the right three clicks so the cutter bit is slightly higher than the tracer. The arrow on the left should light red. Raise the vertical carriage. NOTE: Setting the tracer three clicks lower than the cutter bit has the effect of making the cutter bit cut the duplicated key a little shallower. This will protect the locking jaws from being damaged.* 6. Optional: Loosen the setscrew, and adjust the hand rest to a comfortable position. Tighten the screw. 7. Pull the clamp carriage lever toward you until the clamp carriage clicks into its end-of-run position. Tighten both the lateral and spring tension adjustment knobs. 8. Make sure the center and right jaws are free of any metal shavings or debris. (A soft-bristle toothbrush is ideal for this purpose.) Page 1229 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 2754 DTC P1486 thru P1585 Page 6376 2. Remove the flange bolt (A) from the bottom of the damper. 3. Remove the flange nuts (A) from the top of the damper in the trunk. 4. Remove the damper assembly from the body. Disassembly/Inspection Page 5327 Electronic Brake Control Module: Description and Operation ABS Control Unit Main Control The ABS control unit detects the wheel speed based on the wheel sensor signal it received, then it calculates the vehicle speed based on the detected wheel speed. The control unit detects the vehicle speed during deceleration based on the rate of deceleration. The ABS control unit calculates the slip rate of each wheel and transmits the control signal to the modulator unit solenoid valve when the slip rate is high. The pressure reduction control has three modes: pressure reducing, pressure retaining, and pressure intensifying. Self-diagnosis Function 1. The ABS control unit is equipped with a main CPU and a sub-CPU. Each CPU checks the other for problems. 2. The CPUs check the circuit of the system. 3. The ABS control unit turns on the ABS indicator when the unit detects a problem and the unit stops the system. 4. The self-diagnosis can be classified into these two categories: ^ Initial diagnosis ^ Regular diagnosis On-board Diagnosis Function The ABS can be diagnosed with the Honda PGM Tester. The ALB Checker cannot be used with this system. For air bleeding and checking wheel sensor signals, use the Honda PGM Tester. See the Honda PGM Tester user's manual for specific operating instructions. Page 260 DTC P0401 thru P0562 Page 1702 17. VTEC Solenoid Valve (EX, HX) Page 6354 1. Install all the parts except the self-locking nut onto the damper unit by referring to the Exploded View. Align the bottom of the spring (A) and the stepped part of the lower spring seat (B) as illustrated. The hole in the upper spring seat and the arrow on the damper mounting base must point toward the knuckle mounting area. 2. Install the damper assembly on a commercially available strut spring compressor (C). 3. Compress the damper spring with the strut spring compressor. 4. Install a new self-locking nut (A) on the damper shaft. 5. Hold the damper shaft with a hex wrench (B), and tighten the self-locking nut to the specified torque. Installation 1. Lower the lower arm, and position the damper assembly in the body. 2. Loosely install the flange nuts (A) onto the top of the damper. Body - Trunk Lid Hard to Close Trunk / Liftgate Lock: All Technical Service Bulletins Body - Trunk Lid Hard to Close 02-061 November 5, 2004 Applies To: See VEHICLES AFFECTED Trunk Lid is Difficult to Close (Supersedes 02-061, dated July 23, 2004) Updated information is shown with asterisks. SYMPTOM The trunk lid may be difficult to close or won't latch closed. PROBABLE CAUSE The trunk lid may be misaligned, and the trunk lid opener cable, trunk lid latch, lock cylinder, lock rod, and/or the trunk lid latch striker may need adjustment or replacement. VEHICLES AFFECTED CORRECTIVE ACTION Adjust the trunk lid and/or the trunk lid latch, or replace components as needed. PARTS INFORMATION Locations Fuel Supply System - Component Location Index Page 5779 67. Under Left Side Of Dash Page 2702 159. Left Side Of Engine Compartment Page 7558 6. Install the glass and regulator in the reverse order of removal, and note these items: - Roll the glass up and down to see if it moves freely without binding. - Make sure that there is no clearance between the glass and glass run channel when the glass is closed. - Adjust the position of the glass as necessary. - Check for water leaks. - Test-drive and check for wind noise and rattles. - When reinstalling the door panel, make sure the plastic cover is installed properly and sealed around its outside perimeter to seal out water. Page 1748 Resistor Variable Sensor Solenoid Transistors Circuit Schematics Page 6771 Air Bag Control Module: Description and Operation SRS Operation The main circuit in the SRS unit senses and judges the force of impact and, if necessary, ignites the inflator charges. 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: Driver's and Front Passenger's Airbag(s) 1. The frontal impact sensor must activate, and send electric signals to the microprocessor. 2. The microprocessor must compute the signals, and depending on the severity of the collision and whether the seat belt buckle switch is ON or OFF, it sends the appropriate signals to the airbag inflator(s). 3. The inflators that received signals must ignite and deploy the airbags. Side Airbag(s) 1. The side impact sensors must activate, and send electric signals to the microprocessor. 2. The microprocessor must compute the signals and send them to the side airbag inflator(s). However, the microprocessor cuts off the signals to the front passenger's side airbag if the SRS unit determines that the front passenger's head is in the deployment path of the side airbag. 3. The inflator that received the signal must ignite and deploy the side airbag. 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 6 seconds if the system is operating normally. If the indicator does not come on, or does not go off after 6 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 SRS unit memory stores a DTC that relates to the cause of the malfunction, and the unit is connected to the data link connector (DLC). This information can be read with the Honda PGM Tester when it is connected to the DLC (16P). Page 9536 Relay And Control Unit Locations - Dashboard Locations Page 947 WARRANTY CLAIM INFORMATION Out of warranty: Any repairs to the SRS system for problems other than the 15-1, 15-2, and 15-3 DTCs that are done 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. INSPECTION PROCEDURE NOTE: ^ When you check for SRS DTCs with the HDS, codes other than 15-1, 15-2, and 15-3 are not covered by this warranty extension bulletin. ^ If the vehicle is covered by warranty, repair it using the normal warranty repair procedures. If the vehicle's warranty is expired, give your customer an estimate for the cost of the repair. Do the appropriate inspection, based on the DTC. SRS DTC 15-1 Clear the DTC with the HDS. ^ If DTC 15-1 does not set again, go to REPAIR PROCEDURE A: OPDS UNIT REPLACEMENT. ^ If DTC 15-1 sets again, continue with normal troubleshooting. ^ If the OPDS unit causes DTC 15-1 to set repeatedly, yet passes the other troubleshooting steps, go to REPAIR PROCEDURE A: OPDS UNIT REPLACEMENT. SRS DTC 15-2 1. Inspect the connections and the wiring in the side airbag cutoff indicator circuit. ^ If all the connections and the wiring are OK, go to step 2. ^ If any of the connections or the wiring are faulty, repair the circuit, then go to step 2. 2. Clear the DTC with the HDS. ^ If DTC 15-2 does not set again, go to REPAIR PROCEDURE A: OPDS UNIT REPLACEMENT. ^ If DTC 15-2 sets again, continue with normal troubleshooting. ^ If the OPDS unit causes DTC 15-2 to set repeatedly, yet passes the other troubleshooting steps, go to REPAIR PROCEDURE A: OPDS UNIT REPLACEMENT. SRS DTC 15-3 1. Clear the DTC with the HDS. ^ If DTC 15-3 does not set again, go to step 2. ^ If DTC 15-3 sets again, continue with normal troubleshooting. 2. Ask your customer if electrical devices such as a laptop computer or a fluorescent map light are ever used near the front passenger's seat-back. (Some electrical devices that plug into the vehicle's accessory power socket, especially those using a power inverter/converter, can interfere with the seat-back sensors and cause SRS DTC 15-3 to set.) ^ If your customer uses any of these devices operate the device near the front passenger's seat-back. If DTC 15-3 sets again, clear it, then return the vehicle to the customer. Advise the customer to avoid using the device near the front passenger's seat-back. ^ If your customer does not use any of these devices and DTC 15-3 does not set again, go to REPAIR PROCEDURE A: OPDS UNIT REPLACEMENT. REPAIR PROCEDURE A: OPDS UNIT REPLACEMENT Page 6772 Air Bag Control Module: Testing and Inspection Initializing the OPDS (Occupant Position Detection System) Unit Special Tools Required SCS service connector 07PAZ-0010100 When the seat-back cover, seat-back cushion, and/or OPDS unit is replaced, initialize the OPDS by following the procedure below. NOTE: Make sure the passenger's seat is dry. Set the seat-back in the normal position, and make sure there is nothing on the front passenger's seat. 1. Make sure the ignition switch is OFF. 2. Connect the Honda PGM Tester/HDS (A) to the DLC (16P) (B), and follow the Tester's prompts in the "SCS" menu to ground the SCS line (see the Honda PGM Tester Operator's Manual). 3. Connect the SCS service connector (A) to the MES connector (2P) (B). Do not use a jumper wire. 4. Turn the ignition switch ON (II). 5. The SRS indicator comes on for about 6 seconds and goes off. Remove the SCS service connector from the MES connector within 4 seconds after the SRS indicator went off. 6. The SRS indicator comes on again. Reconnect the SCS service connector to the MES connector within 4 seconds after the SRS indicator comes on. 7. The SRS indicator goes off. Remove the SCS service connector from the MES connector within 4 seconds. 8. Watch the SRS indicator. - If the indicator blinks two times and then stays on, the OPDS is initialized, but the DTCs need to be erased. Go to step 9, then erase the DTCs. - If the indicator blinks two times and then goes off, the OPDS unit is initialized. Go to step 9. - If the indicator stays on without first blinking, the OPDS is not initialized. Read the DTC, if DTC 15-1 is indicated, repeat the initialization procedure. If another DTC is indicated, go to the appropriate DTC Troubleshooting Index. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Descriptions/DTC List - Supplemental Restraint System 9. Turn the ignition switch off, and disconnect the PGM Tester. Page 1002 Power Steering Pressure Switch: Service and Repair Power Steering Hoses, Lines, and Pressure Switch Replacement Note these items during installation: ^ Connect each hose to the corresponding line securely until it contacts the stop on the line. Install the clamp or adjustable clamp at the specified distance from the hose end as shown. ^ Check all clamps for deterioration or deformation; replace the clamps with new ones, if necessary. ^ Add the recommended power steering fluid to the specified level on the reservoir and check for leaks. Automatic Transmission Shift Indicator: Locations Automatic Transmission Component Location Index Page 8359 Using a buffer and compound, remove any polishing marks made from the sandpaper. Use a buffing sponge, and buffing wool and compounds. Finish up with buffing: -1. Wet sands with #2000 sandpaper and soapy water. -2. Remove moisture using compressed air. -3. Finish using fine compound and very fine compound. Polish with an electric polisher. NOTE: Polish lightly. -4. Check the finished area at an angle, and make sure there are no polishing marks. -5. Polish with ultra fine compound and a buffing sponge. -6. Wax the finished area. Use of the Repair Material Use of the Repair Material NOTE: Follow the materials manufacturer's instructions. The use of a special polyester putty for PP bumpers is described here: 1. Filler Page 953 7. Connect the SCS service connector to the 2P MES (memory erase signal) connector, as shown. Do not use a jumper wire. 8. Turn the ignition switch to ON (II). 9. Watch the SRS indicator. (It comes on for about 6 seconds and then goes off.) Disconnect the SCS service connector from the MES connector within 4 seconds after the indicator goes off. 10. When the SRS indicator comes on again, connect the SCS service connector to the MES connector within 4 seconds after the indicator comes on. 11. When the SRS indicator goes off, disconnect the SCS service connector from the MES connector within 4 seconds. Campaign - OPDS Unit Warranty Extension Technical Service Bulletin # 06-009 Date: 080205 Campaign - OPDS Unit Warranty Extension 06-009 February 5, 2008 Applies To: See VEHICLES AFFECTED Warranty Extension: OPDS Unit or OPDS Sensor Triggers SRS DTC(s) 15-1, 15-2, 15-3 (Supersedes 06-009, dated September 21, 2007) Updated information is shown with asterisks. BACKGROUND *NOTE: Because of a class action settlement, the warranty extension coverage for the OPDS unit and the OPDS sensor on 2002 Accords, 2002-04 Civics, 2003-04 Civic Hybrids, 2002-04 CR-Vs, 2003 Elements, 2002 Odysseys, and 2003-04 Pilots purchased or leased between April 13, 2002, and November 7, 2006, is now 10 years or 157,500 miles, whichever occurs first. For more information, refer to Service Bulletin 06-085, Warranty Extension: Vehicle Warranty Mileage.* Several vehicle models may have a problem with the OPDS (occupant position detection system) that causes the SRS indicator to stay on. Typically, one or more of these DTCs will be set: ^ SRS DTC 15-1 (faulty OPDS unit or OPDS not initialized) ^ SRS DTC 15-2 (faulty side airbag indicator circuit) ^ SRS DTC 15-3 (faulty OPDS sensor) To ensure continued reliability with the OPDS, American Honda is extending the warranty on the OPDS unit and the OPDS sensor to 10 years or 150,000 miles, whichever occurs first. This warranty extension does not apply to any vehicle that has ever been declared a total loss, or any that has been issued a salvage, branded, or similar title under any state's law. To check for vehicle eligibility, you must do a VIN status inquiry Page 3140 - 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. Troubleshooting Tests 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 test 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 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. 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 Drop Page 3290 Vehicle Speed Sensor: Description and Operation Vehicle Speed Sensor (VSS) The VSS is driven by the differential. It generates a pulsed signal from an input of 1 volts. The number of pulses per minute increases/decreases with the speed of the vehicle. Description and Operation Barometric Pressure Sensor: Description and Operation Barometric Pressure (BARO) Sensor The BARO sensor is inside the ECM/PCM. It converts atmospheric pressure into a voltage signal that the ECM/PCM uses to modify the basic duration of the fuel injection discharge. Page 9081 Power Distribution schematics show how power is supplied from the positive battery terminal to various circuits in the vehicle. Refer to the Power Distribution diagram set to get a more detailed understanding of how picture is supplied to the circuit you're working on. Individual circuit schematics begin with a fuse. So 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 Ground Distribution Schematics This sample Ground Distribution schematic shows all of the components that share the same ground point. Page 3206 - Remove clips carefully; don't damage their locks (A). - Slip pliers (A) under the clip base and through the hole at an angle, then squeeze the expansion tabs to release the clip. - After installing harness clips, make sure the harness doesn't interfere with any moving parts. - Keep wire harnesses away from exhaust pipes and other hot parts, from sharp edges of brackets and holes, and from exposed screws and bolts. - Seat grommets in their grooves properly (A). Do not leave grommets distorted (B). Testing and Repairs - Do not use wires or harnesses with broken insulation. Replace them or repair them by wrapping the break with electrical tape. - After installing parts, make sure that no wires are pinched under them. - When using electrical test equipment, follow the manufacturer's instructions and those described. - If possible, insert the probe of the tester from the wire side (except waterproof connector). - Use back probe adaptor 07TAZ-001020A. - Refer to the instructions in the Honda Terminal Kit for identification and replacement of connector terminals. Five-Step Troubleshooting Five-Step Troubleshooting 1. Verify The Complaint Page 568 Oil Pressure Sender: Service and Repair Oil Pressure Switch Replacement 1. Remove the oil filter with the special oil filter wrench. 2. Disconnect the oil pressure switch connector, then remove the oil pressure switch. 3. Apply liquid gasket to the oil pressure switch threads, then install the oil pressure switch. 4. Install the oil filter. Page 4644 107. Behind A/T Shift Lever (except M/T) Page 2962 228. ECM/PCM Part 3 228. ECM/PCM Part 4 Page 3909 GNA600: (No longer available for purchase) Locations Control Module: Locations Electronic Controls Location Page 8366 80. Under Middle of Dash Diagram Information and Instructions Transmission Position Switch/Sensor: Diagram Information and Instructions Terminal Numbering System Terminal Numbering System Connector terminals are numbered according to the cavities they're in. The cavities are numbered starting from the upper left, looking at the male terminals from the terminal side or looking at the female terminals from the wire side. Both views are in the same direction so the numbers are the same. All actual cavities are numbered, even if they have no wire terminals in them. NOTE: Data Link Connector (DLC) terminals are numbered according 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 below is #6. Page 4994 3. Strip the insulation off the end of the wire so the wire fits in the new terminal as shown. (If the wire has a wire seal, replace it with a new one from the kit.) NOTE: After stripping the end of the wire, make sure you did not cut any wire strands. If you did, cut the wire off even with the insulation, and strip it again. 4. Position the terminal in the crimping tool slot with the solid portion of the terminal toward the anvil and the open section toward the former. 5. Insert the wire in the terminal to the position shown in step 3. 6. Squeeze the tool with both hands until the stops make contact. 7. Crimp the insulation crimp. - If you do not have a wire seal, then use the next larger size crimp slot. Position the crimping tool over the insulation crimp section of the terminal, then squeeze the tool with both hands until the stops make contact. - If you have a wire seal, position the insulation crimp in the 5.5 crimping slot, then carefully squeeze the crimp closed until its ends are touching and making a full-circle shape. Page 403 Control Module: Service and Repair Updating the ECM/PCM PCM Updating and Substitution for Testing Special Tools Required Honda Interface Module (HIM) P/N EQS05A35570 Use this procedure when you have to substitute a known-good PCM in a troubleshooting procedure. Update the PCM only if the PCM does not already have the latest software loaded. NOTE: Do not turn the ignition switch OFF while updating; the PCM can be damaged. How to Update the PCM NOTE: To ensure the latest program is installed, do an PCM update whenever the PCM is substituted or replaced. - Before you update the PCM, make sure the vehicle's battery is fully charged. - To prevent PCM damage, do not operate anything electrical (audio system, brakes, A/C, power windows, moon roof, door locks, etc.) during the update. - If you need to diagnose the Honda Interface Module (HIM) because the HIM's red (#3) light came on or was flashing during the update, leave the ignition switch in the ON (II) position when you disconnect the HIM from the Data Link Connector (DLC). This will prevent PCM damage. 1. Turn the ignition switch ON (II). Do not start the engine. 2. Connect the HIM to the DLC (A) located under the driver's side of dashboard. 3. Do the PCM update procedure as described on the HIM label and in the PCM update system. If the software in the PCM is the latest version, replace the PCM. How to End a Troubleshooting Session This procedure must be done after any troubleshooting. 1. Clear the DTC(s) with the Scan Tool or HDS, or reset the PCM by removing the No. 6 (PCM) fuse in the under-hood fuse/relay box for more than 10 seconds. 2. Turn the ignition switch ON (II). 3. Start the engine in the P or N position, and warm it up to normal operating temperature (the radiator fans come on). 4. To verify that the problem is repaired, test-drive the vehicle for several minutes at speeds over 30 mph (50 km/h) or in freeze data range. Page 5378 Use the tools from Pin Tool Set. First, check the connector that you are about to repair. - If it has a secondary terminal lock, go to Connectors With a Secondary Lock. A secondary lock, found on most connectors on some models, is an additional locking device on the connector housing as a backup for the primary lock on the terminal. - If the connector does not have a secondary lock, go to Connectors Without a Secondary Lock. Connectors With a Secondary Lock All examples are shown with the connector lock facing up. The illustrations are examples of the secondary terminal locks; however, the connector you are repairing may vary in size. Identify the connector by the type of secondary lock, not by the number of terminal cavities. EXAMPLE A: 1. Release the secondary lock. 2. Remove the terminal. 3. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE B: Page 5374 - 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. Troubleshooting Tests 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 test 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 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. 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 Drop Page 5340 Wheel Speed Sensor: Diagrams 95. Wheel Speed Sensor, Left Front (EX, GX) 96. Wheel Speed Sensor, Left Rear (EX, GX) 97. Wheel Speed Sensor, Right Front (EX, GX) Page 7255 Programming the Transmitter 1. Locate the security system control unit under the driver's seat. 2. Rub your finger over the label on the top of the control unit until you find the depression. Once you find it, push your finger through the label to expose the hole underneath. Inside the hole is a square, yellow button; this is the programming button. 3. Turn the ignition switch to ON, then turn it to LOCK. 4. Press and hold the programming button. Check that the security siren emits four separate chirps followed by a five-chirp burst. This confirms that the system is in programming mode. The siren then emits prompting chirps at 3-second intervals. 5. Release the programming button. 6. After a prompting chirp, press the "LOCK" button on the transmitter. Verify that the siren emits a confirmation chirp to confirm that the transmitter's code was accepted by the control unit. If you wait more than 30 seconds after the prompting chirp before programming a transmitter, or wait more than 30 seconds between programming transmitters, the siren emits three chirps and the system exits the programming mode. 7. To program additional transmitters, wait for another prompting chirp, then press the "LOCK" button. (You can program up to four transmitters per vehicle.) 8. To exit the programming mode, turn the ignition switch to ON, then turn it to LOCK. 9. Test all the transmitters. Ordering a Transmitter Transmitters can be ordered only by authorized Honda dealers. Order them from American Honda using normal parts ordering procedures. Batteries for the Transmitter The battery number is 23-144 (Radio Shack), A-23 (Eveready), or MS-21/MN-21 (Duracell). Each transmitter uses one battery. Page 716 ^ Start the engine and let it warm up to its normal operating temperature (the cooling fans cycle twice). ^ Let the engine idle (throttle closed and all electrical items off) for 10 minutes. 17. CR-V only: Reset the power window control unit: ^ Turn the ignition switch to ON (II). ^ Make sure the driver's window is fully closed. ^ Push down and hold the window switch until the window goes all the way down. ^ Pull back and hold the window switch until the window goes all the way up, then hold the switch for at least 2 more seconds. 18. Enter the audio unit anti-theft code, and set the clock. Enter the audio presets. Disclaimer Diagrams 39. ECT Sensor Service and Repair Quarter Window Glass: Service and Repair Quarter Glass Replacement 2-door NOTE: - Put on gloves to protect your hands. - Wear eye protection while cutting the glass adhesive with piano wire. - Cover interior surfaces to avoid damaging them. 1. Remove these items: - C-pillar trim and side trim panel - B-pillar upper trim 2. Apply protective tape along the inside and outside edges of the body, and along the edge of the headliner. Using an awl, make a hole through the adhesive from inside the vehicle. Push a piece of piece of piano wire through the hole, and wrap each end around a piece of wood. 3. With a helper on the outside, pull the piano wire (A) back and forth in a sawing motion. Hold the piano wire as close to the quarter glass (B) as possible to prevent damage to the body, and carefully cut through the adhesive (C) around the entire quarter glass: If the quarter glass will be reinstalled, take care not to damage the molding (D). - If the molding is damaged, replace the quarter glass, molding fastener (E), and clips (F) as an assembly. - If any of the clips and fastener are broken, the quarter glass can be reinstalled using butyl tape (refer to step 8). 4. Carefully remove the quarter glass. 5. With a putty knife, scrape the old adhesive smooth to a thickness of about 2 mm (0.08 in.) on the bonding surface around the entire quarter glass opening flange: Do not scrape down to the painted surface of the body; damaged paint will interfere with proper bonding. - Remove the clips and fastener from the body. 6. Clean the body bonding surface with a sponge dampened in alcohol. After cleaning, keep oil, grease and water from getting on the surface. 7. If the old quarter glass will be reinstalled, use a putty knife to scrape off all of the old adhesive, any broken clips, and the fastener from the glass. Clean the inside face and the edge of the glass with alcohol where new adhesive will be applied. Make sure the bonding surface is kept free of water, oil and grease. Page 8596 NOTE: You need to make the corrections listed in CODE BOOK CORRECTIONS at the end of this service bulletin. TRACER AND CUTTER BIT INSTALLATION 1. Turn the power switch on the back of the machine to ON. (This turns on the built-in work light.) 2. Use the Allen wrench from the built-in tool drawer to loosen the setscrew on the left sleeve of the vertical carriage. Slide the tracer all the way into the sleeve, and tighten the screw. 3. Turn the plastic shield on the right sleeve of the vertical carriage so you can access the setscrew on the sleeve. Use the Allen wrench to loosen the screw. Slide the cutter bit all the way into the sleeve, and tighten the screw. Turn the plastic shield so the open side is in the back. MACHINE COMPONENTS Page 6535 Heater Control Panel Inputs And Outputs Page 8191 Part 1 5. Reconnect all connections to the under-dash fuse/relay box, and make these input tests at the appropriate connectors on the under-dash fuse/relay box. If any test indicates a problem, find and correct the cause, then recheck the system. - If all the input tests prove OK, go to step 6. Part 2 Page 5059 Pressure Regulating Solenoid: Service and Repair A/T Clutch Pressure Control Solenoid Valves A and B Replacement 1. Remove the mounting bolts and the A/T clutch pressure control solenoid valves A and B. 2. Clean the mounting surface and fluid passage of the A/T clutch pressure control solenoid valves A and B and the transmission housing. 3. Install the new filter/gasket (c) in the solenoid valve assembly body groove. 4. Install the new A/T clutch pressure control solenoid valves A and B. Do not pinch the filter/gasket. 5. Check the A/T clutch pressure control solenoid valve connectors for rust, dirt, or oil, then connect them securely. Page 1840 2. Insert the pilot collar (A) into the piston and connecting rod. 3. With the embossed mark facing up, place the piston assembly (B) on the special tool (C). Be sure you position the recessed flat on the piston against the lugs on the base attachment. 4. Press the pin (D) in with the pin driver (E) and a hydraulic press. Page 644 Combination Switch: Service and Repair Combination Light Switch Test/Replacement 1. Remove the dashboard lower cover. 2. Remove the steering column covers. 3. Disconnect the 16P connector (A) from the combination light switch (B). 4. Remove the two screws, then slide out the combination light switch. 5. Inspect the connector terminals to be sure they are all making good contact. - If the terminals are bent, loose or corroded, repair them as necessary, and recheck the system. - If the terminals look OK, check for continuity between the terminals in each switch position according to the tables. If the continuity is not as specified, replace the switch. Page 1133 10. Connect the connector securely, then install the transmission range switch shaft cap (A). 11. Turn the ignition switch ON (II). Move the shift lever through all gear positions, and check the transmission range switch is synchronization with the A/T gear position indicator. 12. Raise the vehicle, and make sure it is securely supported. 13. Allow the wheels to rotate freely, then start the engine. 14. Move the shift lever through all gear positions, and verify the following: ^ The engine will not start in any position other than N or P. ^ The back-up lights come on when the shift lever is in the R position. Page 4502 Clutch Release Bearing: Service and Repair Release Bearing Replacement Clutch Replacement Special Tools Required ^ Clutch alignment shaft 07LAF-PT00110 ^ Clutch alignment disc 07JAF-PM7011A ^ Remover handle 07936-3710100 ^ Ring gear holder 07LAB-PV00100 or 07924-PD20003 ^ Attachment, 57 x 40 mm 07746-0010200 ^ Driver 07749-0010000 Release Bearing Replacement 1. Remove the release fork boot (A) from the clutch housing (B). 2. Remove the release fork (C) from the clutch housing (B) by squeezing the release fork set spring (D) with pliers. Remove the release bearing (E). 3. Check the release bearing for play by spinning it by hand. If there is excessive play, replace the release bearing with a new one. NOTE: The release bearing is packed with grease. Do not wash it in solvent. Locations 25. Transmission Housing (CVT) Page 9154 2. Insert the terminal tool into the female terminal, and then remove the terminal tool. NOTE: Make sure you do not select a terminal tool that is larger than the mating male terminal because it would spread the female terminal and cause a loose fit. 3. Compare the drag to the other terminals in the connector. If the drag is less, replace the terminal with a replacement terminal from the appropriate terminal repair kit. Page 3838 2. Cut off the wire about an inch back from where it connects to the damaged or faulty terminal, then strip about half of the insulation off that piece. This will be used to size the wire end of the replacement pigtail terminal. NOTE: If you are not sure of the wire size, start with a large enough hole on the stripper that will not nick or cut off any strands of wires. 3. Select a pigtail terminal that matches the original wire at both ends (same kind of terminal and same diameter bare wire). 4. Select the smallest splice connector (yellow, pink, or blue) that will fit onto the stripped end of the original wire. 5. Insert the pigtail terminal into the connector cavity; push it in until it locks in place. 6. Lay the pigtail and the original wire side-by-side, and cut off both ends at once. If you are making more than one splice, do not cut each pigtail at the same location; the resulting "lump" of splice connectors would interfere with rewrapping the harness. Instead, cut the first pigtail close enough to the terminal so you will have room to make each remaining cut about 20 mm (3/4 inch) farther down on the next pigtail. 7. If you are using a yellow splice connector, strip about 6 mm (1/4 inch) of insulation off the ends of both wires. If you are using a pink or blue splice connector, strip off about 8 mm (5/16 inch) of insulation. Page 8244 1. Check the depth adjustment of the trunk lid: ^ Refer to page 20-132 of the 2001-04 Civic Service Manual. ^ In ISIS, use the keyword TRUNK ADJUST, and select Trunk Lid Adjustment from the list. 2. Make sure the trunk lid is flush on all sides and corners. ^ If the trunk is misaligned, go to step 3. ^ If the trunk lid is properly aligned on all sides and corners, go to REPAIR PROCEDURE C. 3. Adjust the striker depth position and the trunk lid edge cushions: ^ Refer to page 20-132 of the 2001-04 Civic Service Manual. ^ In ISIS, use the keyword TRUNK ADJUST, and select Trunk Lid Adjustment from the list. 4. Check the trunk operation: ^ If the trunk opens and closes smoothly, return the vehicle to the customer. ^ If the trunk lid is still difficult to close, go to REPAIR PROCEDURE C. REPAIR PROCEDURE C 1. Use a small screwdriver to manually set and release the trunk lid latch. Check the operation of the latch: ^ If the latch is difficult to set or release, go to step 2. ^ If the latch operates properly, go to REPAIR PROCEDURE D. 2. Replace the trunk lid latch: ^ Refer to page 20-157 of the 2001-04 Civic Service Manual. ^ In ISIS, use the keyword LID LATCH, and select Trunk Lid Latch Replacement from the list. 3. Check the trunk operation: ^ If the trunk opens and closes smoothly, return the vehicle to the customer. ^ If the trunk lid is still difficult to close, go to REPAIR PROCEDURE D. REPAIR PROCEDURE D 1. Disconnect the trunk lid opener cable from the trunk lid latch. Check the cable operation: ^ Refer to page 20-157 of the 2001-04 Civic Service Manual. ^ In ISIS, use the keyword LID LATCH, and select Trunk Lid Latch Replacement from the list. 2. Check that there is no friction or binding of the cable by holding the outside casing and pulling back and forth on the inner cable: ^ If the cable is difficult to move or binds, go to step 3. ^ If the cable operates smoothly, go to REPAIR PROCEDURE E. 3. Replace the trunk lid opener cable: ^ Refer to page 20-151 of the 2001-04 Civic Service Manual. ^ In ISIS, use the keyword LID OPEN, and select Trunk Lid Opener/Fuel Fill Door Opener Cable Replacement from the list. 4. Check the trunk operation: Page 263 DTC P0979 thru P1193 Specifications Page 4372 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. Below most connector numbers and component names are PHOTO and VIEW numbers. The PHOTO number refers to a photo in the back of the book that shows the connector's location on the car. The VIEW number refers to an illustration in the back of the book that shows the connector terminals, wire colors, connector cavity numbers, and other details. The connector cavity numbering sequence begins at the top left corner of the connector as seen from either of the viewpoints shown on diagram [8] . Except for the DLC (data link 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 C554, for example, means those terminals join in cavity 2 of connector C554. Power Distribution Schematics Power Distribution Schematics Page 6858 Page 4967 Wire Color Abbreviations Page 5377 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. How to Replace Connector Terminals Terminal Replacement Procedure HOW TO REPLACE CONNECTOR TERMINALS The terminal repair kits provide necessary tools and materials (terminals, wire seals, and splice connectors) to repair many damaged or faulty connector terminals. However, not all terminals for all connectors are available. Refer to the labels on the lids of the repair kits for replacement terminal availability. IMPORTANT SAFETY INFORMATION: On some models, the SRS wires are in a separate harness. If the SRS harness is damaged, replace the harness; do not repair it. On other models, wire harnesses include yellow SRS wires. If any SRS wire is damaged, replace the entire harness; do not repair it. Before you begin, inspect the wire you are about to repair for damage and length. Make sure the wire will be long enough to make a terminal repair without stretching it when you reinstall the terminal in the connector. If the wire is too short, or if access to the connector is too restricted to make a terminal repair, you may need to install a pigtail terminal (a short length of wire with a factory-crimped terminal on it). Refer to HOW TO INSTALL PIGTAIL TERMINALS. Removing the Terminal Replacement Alternator: Service and Repair Replacement Alternator Replacement 1. Make sure you have the anti-theft code for the radio, then write down the frequencies for the radio's preset buttons. 2. Disconnect the negative cable from the battery. 3. Remove the adjust plate mounting bolt (A), locknut (B), and mounting bolt (C), then remove the power steering (P/S) pump belt (D) and pump without disconnecting the P/S hoses. 4. Disconnect the 4P connector (A) and alternator cable (B) from the alternator. 5. Loosen the adjusting bolt (A), and remove the lock bolt (B) and mounting bolt (C), then remove the alternator belt and alternator. 6. Install in the reverse order of removal. 7. Adjust the alternator belt tension or the alternator compressor belt tension. 8. Enter the anti-theft code for the radio, then enter the customer's radio station presets. Page 977 *T-5 Sidewinder Key Applications ^ 2003-05 Civic ^ 2004-05 Civic Hybrid ^ 2003-05 Civic GX (CNG) ^ 2004-05 S2000 ^ 2002-06 CR-V ^ 2003-06 Element ^ 2003-04 Odyssey ^ 2003-04 Pilot Ordering Honda key blanks through normal parts ordering channels: Refer to the parts catalog for correct key(s) for your application. PROGRAMMING KEYS Depending on the type of key blank you use, do this: ^ If you have used a T-5 programmable key blank ("T-5" stamped on the shank), you must code the key's transponder with the Ilco Immobilizer Key Code Duplicator (see S/B 99-053, Ilco Immobilizer key Code Duplicator). ^ If you have used a Honda key blank, add the* transponder code of the new key to the immobilizer system with the Honda Diagnostic System (HDS). ORDERING INFORMATION *To order the MATRIX H Key Cutting Machine, replacement cutter bits, fixed jaws and mobile jaws, T-5 programmable key blanks, and practice key blanks, contact the Honda Tool and Equipment Program by calling 888-424-6857 or using the fax order form provided in your Honda Tool and Equipment Program Catalog.* Order Honda key blanks through normal parts ordering channels. WARRANTY CLAIM INFORMATION None. This service bulletin is for information only. *DETERMINING WHICH KEY TO USE T-5 keys require less time to program and should be the first choice. They can be used as long as the following requirements are met: ^ Do you have the customer's operating key? ^ Does the vehicle fall within the T-5 Sidewinder Key Applications? ^ Does your dealership have an Ilco Immobilizer Key Code Duplicator? If the answer to all three questions on the above is yes, the 1-5 key option is the easier procedure. If you answered no to any of the questions, you should order the key(s) from the parts catalogue, and program it using the HDS.* BEFORE YOU START CUTTING 1. Get the original key or the key number from your customer or from the iN. 2. Get the applicable key blank. 3. If cutting by code, look up the applicable 9-digit cutting code for the key number. Refer to the code book Honda High Security key Codes that comes with the machine. Locations Shift Interlock Solenoid: Locations 107. Behind A/T Shift Lever (except M/T) Page 6217 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 497 Brake Fluid Level Sensor/Switch: Testing and Inspection Brake Fluid Level Switch Test Check for continuity between the terminals (A) with the float in the down position and the up position. ^ Remove the brake fluid completely from the reservoir. With the float down, there should be continuity. ^ Fill the reservoir with brake fluid to MAX (upper) level (B). With the float up, there should be no continuity. Page 1324 Spark Plug: Testing and Inspection Spark Plug Inspection 1. Inspect the electrodes and ceramic insulator. Burned or worn electrodes may be caused by: Advanced ignition timing - Loose spark plug - Plug heat range too hot - Insufficient cooling Fouled plug may be caused by: Retarded ignition timing - Oil in combustion chamber - Incorrect spark plug gap - Plug heat range too cold - Excessive idling/low speed running - Clogged air cleaner element - Deteriorated ignition coils 2. Do not adjust the gap of platinum tip plugs (A); replace the spark plug if the gap is out of specification. Page 3110 12. Check for continuity between PSP switch 2P connector terminal No.2 and body ground. Is there continuity? YES - Repair open in the wire between the PSP switch and ECM/PCM (E16). NO - Repair open in the wire between the PSP switch and G201. 13. Turn the ignition switch OFF. 14. Disconnect the PSP switch 2P connector. 15. Turn the ignition switch ON (II). 16. Measure voltage between ECM/PCM connector terminals A24 and E16. Is there battery voltage? YES - Replace the PSP switch. NO - Go to step 17. 17. Turn the ignition switch OFF. 18. Disconnect ECM/PCM connector E (31P). 19. Check for continuity between body ground and ECM/PCM connector terminal E16. Is there continuity? YES - Repair short in the wire between ECM/PCM (E16) and the PSP switch. NO - Update the ECM/PCM if it does not have the latest software, or substitute a known-good ECM/PCM, then recheck. If the Page 946 PARTS INFORMATION TOOL INFORMATION Page 8474 19. Install the seat. 20. Confirm that the problem is resolved. If the driver's seat still rocks, look for other causes. 21. Reconnect the battery. 22. Turn the ignition switch to ON (II), and check the SRS indicator. If the indicator comes on for 6 seconds and then turns off, the SRS is OK. If the indicator stays on, check for codes, and do normal troubleshooting. 23. Enter the anti-theft code for the radio, and then enter the customer's radio station presets. 24. Set the clock. 25. Do the ECM/PCM idle learn procedure: ^ Make sure all electrical items (A/C, audio unit, defogger, lights, etc.) are off. ^ Start the engine and let it warm up to its normal operating temperature (the cooling fans cycle twice). ^ Let the engine idle (throttle fully closed and all electrical items off) for 10 minutes. 26. For 2001 2-doors up to VIN 1L016502, do the cruise control learn procedure. Drive the vehicle for 10 minutes at over 40 mph with the cruise control on. Disclaimer Page 332 Main Relay (Computer/Fuel System): Testing and Inspection Power Relay Test Use this chart to identify the type of relay, then do the test listed for it. NOTE: See the turn signal/hazard relay input test. Normally-open type A: Page 9771 62. Power Window Motor, Front Passenger's (Sedan Except DX) 64. Power Window Motor, Passenger's (Coupe Except DX, HX) 144. Power Window Motor, Driver's (except DX, HX) Locations 94. Behind Glove Box (except GX) Page 5654 ^ Start the engine, and let it warm up to its normal operating temperature (the cooling fans cycle twice). ^ Let the engine idle (throttle closed and all electrical items off) for 10 minutes. 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 8487 10. Install the cover in the reverse order of removal, and note these items: - To prevent wrinkles when installing a seat-back cover, make sure the material is stretched evenly over the pad before securing the hooks and clips. - Replace any clips you removed with new ones. Install them with commercially available upholstery ring pliers. Page 9483 Terminals - "T" Shielding Switches Fuses Page 934 12. On Accords and Pilots, install the new seat-back clips on the seat-back panel. Turn the clips so their retaining tabs are horizontal. 13. On Accords and Pilots, install the seat-back panel. 14. On all models except Accords and Pilots, zip the seat-back cover closed. 15. Initialize the OPDS unit. ^ To initialize with the HDS, go to Initializing the OPDS Unit: HDS Method. ^ To initialize with the SCS service connector, go to Initializing the OPDS Unit: Manual Mode. Initializing the OPDS Unit: HDS Method NOTE: Non-Honda seat covers will interfere with the performance of the OPDS and are not recommended. 1. Adjust the front passenger's seat-back to an upright position, then remove anything on or near the seat. 2. Turn the ignition switch to LOCK (0). 3. Connect the HDS to the vehicle's DLC (data link connector). 4. Turn the ignition switch to ON (II), then turn on the HDS. 5. At the screen prompts, enter the VIN and the odometer reading. Also verify the correct date and time. 6. From the System Selection menu, select SRS. Page 6244 2. If the measurement is out of the specification, adjust the preload using the following procedures. - Loosen the tilt lever, and set the steering column in the neutral position. - Remove the 6 mm lock bolt (B), and remove the stop (C). Be careful not to loosen the tilt lever when installing the stop or tightening the 6 mm lock bolt. - Adjust the preload by turning the tilt lock bolt (D) left or right. - Pull up the tilt lever to the uppermost position, and install the stop. Check the preload again. If the measurement is still out of specification, repeat the above procedures to adjust. Drain Channel Replacement Sunroof / Moonroof Drain: Service and Repair Drain Channel Replacement Drain Channel Replacement 1. Remove the glass. 2. With the moonroof wrench, move both glass brackets (A) to the position where the moonroof normally pivots down, and remove the screws securing the drain channel (B). 3. Release the drain channel (A) from both hooks (B) of the drain channel slider by pulling the drain channel forward. 4. Remove the drain channel (A). 5. Install the channel in the reverse order of removal, and note these items: - Push the drain channel onto the hooks until a faint click is heard. - Check the glass height adjustment. 6. Check for water leaks. Let the water run freely from a hose without a nozzle. Do not use a high-pressure spray. Page 8291 19. Using your thumb and forefinger to hold the tumblers, remove the key from the inner cylinder, being careful not to drop any tumblers and springs. 20. *Using the key code from the iN that you have written down at step 2, build a new inner cylinder with new springs, new cylinder, and tumblers from the door lock cylinder kit. Make sure you put the appropriate numbered tumbler in the proper inner cylinder cavity. Apply a thin layer of Permalube to each tumbler to help lubricate and retain it.* NOTE: ^ There are two types of tumblers. The "SUBLOCK" tumbler goes only in cavity A." The "DISC" tumbler goes in cavities "B" through "J." ^ Cavity "E" is empty on all cylinders. Page 5994 2. Remove the terminal. 3. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE B: 1. Remove the secondary lock from the male terminal half. 2. Remove the secondary lock from the female terminal half. Locations Knock Sensor: Locations PGM-FI System - Component Location Index Page 3573 Knock Sensor: Description and Operation Knock Sensor The knock control system adjusts the ignition timing to minimize knock. Service and Repair Thermal Limiting Fuse: Service and Repair Compressor Thermal Protector Replacement 1. Remove the bolt, the ground terminal (A), and the holder (B). Disconnect the field coil connector (C), then remove the thermal protector (D). 2. Replace the thermal protector (A) with a new one, and apply silicone sealant (B) to the bottom of the thermal protector. 3. Install in the reverse order of removal. Page 5114 Splices Components Ground - "G" Page 3689 Wire Color Abbreviations Locations 21. Transmission Housing (A/T) Page 5739 1. Remove the secondary locks. 2. Remove the terminal from the female half. 3. Remove the terminal from the male half. 4. Go to HOW TO INSTALL NEW TERMINALS. Connectors Without a Secondary Lock All examples are shown with the connector lock facing up. The illustrations are examples of connector terminals without a secondary lock; however, the connector you are repairing may vary in size and shape. EXAMPLE A: Page 2299 Service and Repair Vehicle Lifting: Service and Repair Lift and Support Points NOTE: If you are going to remove heavy components such as the suspension or the fuel tank from the rear of the vehicle, first support the front of the vehicle with tall safety stands. When substantial weight is removed from the rear of the vehicle, the center of gravity can change and cause the vehicle to tip forward on the hoist. Frame Hoist 1. Position the hoist lift blocks (A), or safety stands, under the vehicle's front support points (B) and rear support points (C). 2. Raise the hoist a few inches, and rock the vehicle gently to be sure it is firmly supported. 3. Raise the hoist to full height, and inspect the lift points for solid contact with the lift blocks. Safety Stands To support the vehicle on safety stands, use the same support points (B and C) as for a frame hoist. Always use safety stands when working on or under any vehicle that is supported only by a jack. Floor Jack 1. Set the parking brake. 2. Block the wheels that are not being lifted. 3. When lifting the rear of the vehicle, put the gearshift lever in reverse (or the automatic transmission in [P] position). 4. Position the floor jack under the front jacking bracket (A) or rear jacking bracket (B), center the jacking bracket in the jack lift platform (C), and jack up the vehicle high enough to fit the safety stands under it. 5. Position the safety stands under the support points and adjust them so the vehicle will level. 6. Lower the vehicle onto the stands. Automatic Transmission Shift Indicator: Locations Automatic Transmission Component Location Index Specifications Water Pump: Specifications Water pump displacement at 6,000 engine rpm ............................................................................................................................................... 130 L (137 US qt, 114 Imp qt)/minute Page 6330 Stabilizer Link: Service and Repair Rear Removal/Installation 1. Raise the rear of the vehicle, and support it with safety stands in the proper locations. Remove the rear wheels. 2. Remove the self-locking nut (A) and flange nut (B) while holding the respective joint pin (C) with a hex wrench (D), and remove the stabilizer link (E). 3. Install the stabilizer link on the stabilizer bar and trailing arm with the joint pins set at the center of each moving range. 4. Install the self-locking nut and flange nut, and lightly tighten them. NOTE: Use a new self-locking nut on reassembly. 5. Place a jack under the trailing arm at the knuckle side end, and raise the suspension to load it with the vehicle's weight. Page 668 7. Using a jumper wire, connect the steering column. - If the horn sounds, replace the steering column. - If the horn does not sound, replace the horn and contact plate. Page 3590 159. Left Side Of Engine Compartment Page 6884 Seat Occupant Sensor: Service and Repair Initializing the OPDS Unit Initializing the OPDS (Occupant Position Detection System) Special Tools Required SCS service connector 07PAZ-0010100 When the seat-back cover, seat-back cushion, and/or OPDS unit are replaced, initialize the OPDS by following the procedure below. NOTE: Make sure the passenger's seat is dry. Set the seat-back in the normal position, and make sure there is nothing on the front passenger's seat. 1. Make sure the ignition switch is OFF. 2. Connect the Honda PGM Tester (A) to the DLC (16P) (B), and follow the Tester's prompts in the "SCS" menu (see the Honda PGM Tester Operator's Manual). 3. Connect the SCS service connector (A) to the MES connector (2P) (B). Do not use a jumper wire. 4. Turn the ignition switch ON (II). 5. The SRS indicator comes on for about 6 seconds and goes off. Remove the SCS service connector from the MES connector within 4 seconds after the SRS indicator went off. 6. The SRS indicator comes on again. Reconnect the SCS service connector to the MES connector within 4 seconds after the SRS indicator comes on. 7. The SRS indicator goes off. Remove the SCS service connector from the MES connector within 4 seconds. 8. Watch the SRS indicator. - If the indicator blinks two times and then stays on, the OPDS is initialized, but the DTCs need to be erased. Go to step 9, then erase the DTCs. - If the indicator blinks two times and then goes off, the OPDS unit is initialized. Go to step 9. - If the indicator stays on without first blinking, the OPDS is not initialized. Read the DTC, and go to the appropriate page in the DTC Troubleshooting Index. 9. Turn the ignition switch off, and disconnect the PGM Tester. Page 5911 - Before connecting connectors, make sure the terminals (A) are in place and not bent. - Check for loose retainer (A) and rubber seals (B). - The backs of some connectors are packed with dielectric grease. Add grease if necessary. If the grease is contaminated, replace it. - Insert the connector all the way and make sure it is securely locked. - Position wires so that the open end of the cover faces down. Handling Wires and Harnesses - Secure wires and wire harnesses to the frame with their respective wire ties at the designated locations. Page 3942 *MVCI: (Available through the Honda Tool and Equipment Program)* Page 2846 Circuit Diagram - Multiplex Control System (Part 2 Of 2) Page 55 Part 1 5. Reconnect all connections to the under-dash fuse/relay box, and make these input tests at the appropriate connectors on the under-dash fuse/relay box. If any test indicates a problem, find and correct the cause, then recheck the system. - If all the input tests prove OK, go to step 6. Part 2 Page 311 PGM-F1 Main Relay 1, 2 Type 1, 2 Check for continuity between the terminals. - There should be continuity between the No.1 and No.2 terminals when power and ground are connected to the No.3 and No.4 terminals. - There should be no continuity between the No.1 and No.2 terminals when power is disconnected. Normally-open type B: Rear Window Defogger Relay Page 8161 The 1999-00 transmitter is not interchangeable with the 2001-04 transmitter. To tell them apart, look at the FCC ID on the back. 1999-00 - FCC ID: E4EG8DN 2001-04 - FCC ID: OUCG8D-440H-A* Programming the Transmitter NOTES: ^ The system accepts up to three transmitters. The transmitter codes are stored in a stacking-type memory. If a fourth transmitter code is programmed, the code for the first transmitter is erased. ^ Entering the programming mode cancels all learned transmitter codes, so none of the previously programmed transmitters will work. You must reprogram all of the transmitters once you are in the programming mode. You must complete steps 1-6 within 4 seconds of the previous step to keep the system from exiting the programming mode. 1. Turn the ignition switch to ON (II). 2. Press the "Lock" or "Unlock" button on one of the transmitters. (An unprogrammed transmitter can be used for this step.) 3. Turn the ignition switch to LOCK (0). 4. Repeat steps 1, 2, and 3 two more times using the same transmitter used in step 2. 5. Turn the ignition switch to ON (II). 6. Press the "Lock" or "Unlock" button on the same transmitter. Make sure the power door locks cycle to confirm that the system is in programming mode. 7. Within 10 seconds, press the "Lock" or "Unlock" button on each transmitter. Make sure the power door locks cycle after you press each transmitter button to confirm that the system accepted the transmitter's code. 8. Turn the ignition switch to LOCK (0) to exit the programming mode. Ordering a Transmitter Transmitters can be ordered only by authorized Honda dealers. Order them from American Honda using normal parts ordering procedures. Batteries for the Transmitter The battery number is CR2025. Each transmitter uses one battery. 99-01 Prelude With Factory-Installed Keyless Entry System 1999-01 Prelude with factory-installed keyless entry system Page 9135 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. Test Equipment 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. Page 6889 Side Air Bag: Description and Operation Side Airbags The side airbags (E) are in each front seat-back. They help protect the upper torso of the driver or front seat passenger during a moderate to severe side impact. Side impact sensors (F) in each door sill and in the SRS unit detect such an impact and instantly inflate the driver's or the passenger's side airbag. Only one side airbag will deploy during a side impact. If the impact is on the passenger's side, the passenger's side airbag will deploy even if there is no passenger. Seats with Side Airbags Seats with side airbags have a "SIDE AIRBAG" label on the seat-back. Because the component parts (seat-back cover, cushion, etc.) of seats with and without airbags are different, make sure you install only the correct replacement parts. * When cleaning, do not saturate the seat with liquid, and do not spray steam on the seat. * Do not repair a torn or frayed seat-back cover. Replace the seat-back cover. * After a collision in which the side airbag was deployed, replace the side airbag with new parts. If the seat-back cushion is split, it must be replaced. If the seat-back frame is deformed, it must be replaced. * Never put aftermarket accessories on the seat (cover, pads, seat heaters, lights, etc.). Page 5941 Under-dash Fuse/Relay Box Page 9205 3. Strip the insulation off the end of the wire so the wire fits in the new terminal as shown. (If the wire has a wire seal, replace it with a new one from the kit.) NOTE: After stripping the end of the wire, make sure you did not cut any wire strands. If you did, cut the wire off even with the insulation, and strip it again. 4. Position the terminal in the crimping tool slot with the solid portion of the terminal toward the anvil and the open section toward the former. 5. Insert the wire in the terminal to the position shown in step 3. 6. Squeeze the tool with both hands until the stops make contact. 7. Crimp the insulation crimp. - If you do not have a wire seal, then use the next larger size crimp slot. Position the crimping tool over the insulation crimp section of the terminal, then squeeze the tool with both hands until the stops make contact. - If you have a wire seal, position the insulation crimp in the 5.5 crimping slot, then carefully squeeze the crimp closed until its ends are touching and making a full-circle shape. Key Beeper, Light Chime & Ceiling Light Don't Work Key Reminder Switch: Technical Service Bulletins Key Beeper, Light Chime & Ceiling Light Don't Work SOURCE: Honda Service News April 2003 TITLE: Key Beeper, Light Chime, Ceiling Light Don't Work APPLIES TO: 2001-03 Civic, 2002-03 CR-V SERVICE TIP: If the ignition key-in beeper, the headlights-on chime, the ceiling light, and the driver's-dooropen indicator are all on the fritz check the driver's door switch in the doorjamb. A faulty door switch can cause all of these symptoms. Page 4175 Skill Level: Repair Technician INSPECTION PROCEDURE 1. Remove the steering column covers. Refer to section 17 of the appropriate service manual. 2. On the lower side of the ignition switch, look at the interlock cylinder cover: ^ If the cover is square, the ignition switch was already replaced with an updated part, and a key interlock repair kit is not needed. Go to step 3. ^ If the cover is round, go to REPAIR PROCEDURE. 3. Reinstall the steering column covers. 4. Center-punch a completion mark above the seventh character of the engine compartment VIN. REPAIR PROCEDURE Page 1842 3. Position the piston in the cylinder, and tap it in using the wooden handle of a hammer (A). Maintain downward force on the ring compressor (B) to prevent the rings from expanding before entering the cylinder bore. 4. Position all pistons at top dead center. Page 5313 Transmission Speed Sensor: Service and Repair Speed Sensors Replacement 1. Disconnect connectors from the drive pulley speed sensor (A), driven pulley speed sensor (B), CVT speed sensor (C), and CVT speed sensor 2 (D). 2. Remove the 6 mm bolts, then remove the speed sensors. Remove the sensor washer (E) from the vehicle speed sensor (C). 3. Replace the O-rings (F) with new ones before installing the speed sensors. 4. Install the sensor washer on the CVT speed sensor 2, and install them. 5. Install the drive pulley speed sensor, driven pulley speed sensor, and CVT speed sensor. 6. Check the speed sensor connectors for rust, dirt, or oil, then connect the connectors securely. Page 6260 6. Remove the stop washer (A), the 12 mm flange bolts (B), O-rings (C), and bracket (D) from the steering gearbox. 7. Remove the boot guard (A) by removing the 8 mm flange bolt (C) on the rack end. 8. Remove the boot band (D) and clip (E). Pull the boot B away from the end of the steering gearbox. Remove the rack end plug (F) 9. Loosen the locknut (A), then remove the rack guide screw (B), spring (C), and rack guide (D) from the steering gearbox. 10. Remove the snap ring (A) and backup ring (B) from the cylinder of the steering gearbox. Page 6197 46. Install the pulley (A), then loosely install the pulley nut (B). Hold the steering pump in a vise with soft jaws (C). Be careful not to damage the pump housing with the jaws of the vise. 47. Hold the pulley with the special tool, and tighten the pulley nut. 48. Check that the pump turns smoothly by turning the pulley. If it turns hard, loosen the five flange bolts ('01-03 models) or four flange bolts ('04 model) on the cover, then try retightening them again in the same manner as in the step 36. Page 6638 Condenser Fan Motor Relay: Testing and Inspection Power Relay Test Use this chart to identify the type of relay, then do the test listed for it. NOTE: See the turn signal/hazard relay input test. Normally-open type A: Page 5626 Disclaimer Cutting Procedure - By Copying 1. Press the ON/OFF button in the middle of the setting unit keypad. (This powers up the keypad.) 2. Turn the clamp unit lock lever to the left to release the clamp unit, and slide it all the way to the left until it stops. Turn the lever to the right to lock the clamp unit in place. 3. Use the clamp carriage lever to position the clamp unit so the tracer and cutter bit are centered directly over the base of the center and right jaws. 4. Pull the vertical carriage lever toward you until the tracer and the cutter bit just touch the base of each fixed jaw. Watch the arrows on the keypad: ^ If the double-headed arrow in the middle of the keypad lights green, the tracer and cutter bit are properly aligned. ^ If the arrow on the left of the keypad lights red, the cutter bit is not touching the fixed jaw. Turn the micrometric ring nut above the tracer to the left until the double-headed arrow lights green. ^ If the arrow on the right of the keypad lights red, the tracer is not touching the fixed jaw. Turn the micrometric ring nut above the tracer to the right until the double-headed arrow lights green. *5. Turn the micrometric ring nut to the right three clicks so the cutter bit is slightly higher than the tracer. The arrow on the left should light red. Raise the vertical carriage. NOTE: Setting the tracer three clicks lower than the cutter bit has the effect of making the cutter bit cut the duplicated key a little shallower. This will protect the locking jaws from being damaged.* 6. Optional: Loosen the setscrew, and adjust the hand rest to a comfortable position. Tighten the screw. 7. Pull the clamp carriage lever toward you until the clamp carriage clicks into its end-of-run position. Tighten both the lateral and spring tension adjustment knobs. 8. Make sure the center and right jaws are free of any metal shavings or debris. (A soft-bristle toothbrush is ideal for this purpose.) Page 7793 ^ Incorrect: "If a Master Key is to be cut, put a five (5) in the blank space. Use a two (2) if a valet key is needed." ^ Correct: "If a Master Key is to be cut, put an M in the blank space. Use an S if a valet key is needed." Page 2, legend at the bottom: ^ Incorrect: "C. If a Master key is desired, then the number five (5) should be placed in the M/S position. Place the number two (2) in the M/S column if a Sub (Valet) key is needed." ^ Correct: "C. If a Master Key is desired, then an M should be placed in the M/S position. Place an S in the MIS column if a Sub (Valet) key is needed." Page 9364 1. Remove the terminal. 2. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE B: 1. Remove the terminal. 2. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE C: 1. Remove the terminal. 2. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE D: Page 6801 157. Behind Left Side Of Front Bumper Component Locations 55. In Steering Column Cover Service and Repair Strut / Shock Tower: Service and Repair Removal Page 9640 - Remove clips carefully; don't damage their locks (A). - Slip pliers (A) under the clip base and through the hole at an angle, then squeeze the expansion tabs to release the clip. - After installing harness clips, make sure the harness doesn't interfere with any moving parts. - Keep wire harnesses away from exhaust pipes and other hot parts, from sharp edges of brackets and holes, and from exposed screws and bolts. - Seat grommets in their grooves properly (A). Do not leave grommets distorted (B). Testing and Repairs - Do not use wires or harnesses with broken insulation. Replace them or repair them by wrapping the break with electrical tape. - After installing parts, make sure that no wires are pinched under them. - When using electrical test equipment, follow the manufacturer's instructions and those described. - If possible, insert the probe of the tester from the wire side (except waterproof connector). - Use back probe adaptor 07TAZ-001020A. - Refer to the instructions in the Honda Terminal Kit for identification and replacement of connector terminals. Five-Step Troubleshooting Five-Step Troubleshooting 1. Verify The Complaint Locations 75. Behind Recir-A/C-Rear Defogger Switch Assembly Page 9748 2. Disconnect the 14P connector (A) from the master switch (B). 3. Inspect the connector and socket terminals to be sure they are all making good contact. - If the terminals are bent, loose or corroded, repair them as necessary, and recheck the system. - If the terminals look OK, Go to step 4. 4. Reconnect the 14P connector to the power window master switch, and perform the given input tests. Page 5135 1. Remove the terminal. 2. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE B: 1. Remove the terminal. 2. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE C: 1. Remove the terminal. 2. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE D: Page 1909 Valve: Service and Repair Valves, Springs and Valve Seals Installation Installation 1. Coat the valve stems with engine oil. Install the valves in the valve guides. 2. Check that the valves move up and down smoothly. 3. Install the spring seats on the cylinder head. 4. Install the new valve seals (A) using the valve guide seal installer (B). NOTE: Exhaust valve seal (C) has a black spring (D), and intake valve seal (E) has a white spring (F). They are not interchangeable. 5. Install the valve spring and valve retainer. Place the end of the valve spring with closely wound coils toward the cylinder head. 6. Install the valve spring compressor. Compress the spring and install the valve keepers. Page 5064 72. Shift Lock Solenoid (A/T) Page 4038 Shift Solenoid: Testing and Inspection Shift Solenoid Valves A and B Test 1. Disconnect the shift solenoid valves A and B connector. 2. Measure shift solenoid valve A resistance between the No. 1 terminal of the shift solenoid valves A and B connector and body ground, and measure shift solenoid valve B resistance between the No. 2 terminal and body ground. STANDARD: 12 - 25 Ohms 3. Replace the shift solenoid valves A and B if either resistance is out of standard. 4. If the resistance is within the standard, connect the No. 1 terminal of the shift solenoid valve A to the battery positive terminal. A clicking sound should be heard. Connect the No. 2 terminal to the battery positive terminal. A clicking sound should be heard. Replace the shift solenoid valves A and B if no clicking sound is heard when either terminal is connected to the battery terminal. Page 2509 162. Right Side Of Engine Compartment Page 3217 1. Remove the secondary locks. 2. Remove the terminal from the female half. 3. Remove the terminal from the male half. 4. Go to HOW TO INSTALL NEW TERMINALS. Connectors Without a Secondary Lock All examples are shown with the connector lock facing up. The illustrations are examples of connector terminals without a secondary lock; however, the connector you are repairing may vary in size and shape. EXAMPLE A: Page 99 Compressor Clutch Relay: Description and Operation Air Conditioning (A/C) Compressor Clutch Relay When the ECM/PCM receives a demand for cooling from the A/C system, it delays the compressor from being energized, and enriches the mixture to assure smooth transition to the A/C mode. Page 4105 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. Circuits must be operating when checking voltage drop. 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. 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 off, 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 Self-Powered Test Light or DVOM 1. Remove the blown fuse and disconnect the battery and load. Page 9010 Power Distribution schematics show how power is supplied from the positive battery terminal to various circuits in the vehicle. Refer to the Power Distribution diagram set to get a more detailed understanding of how picture is supplied to the circuit you're working on. Individual circuit schematics begin with a fuse. So 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 Ground Distribution Schematics This sample Ground Distribution schematic shows all of the components that share the same ground point. Specifications Page 8154 1991-93 Accord 5-door EX with factory-installed keyless entry or dealer-installed security system Programming the Transmitter The transmitter is not programmable. Ordering a Transmitter Transmitters can be ordered only by authorized Honda dealers. To order a transmitter, you need the vehicle's VIN, the code number from the power door lock control unit, and the ignition key code number. The power door lock code number is a five-digit number etched into the plastic case of the control unit (mounted under the driver's seat). The ignition key code number is a four-digit number stamped on the metal shank of all five original keys delivered with the car. Replacement transmitters are manufactured to match the code of the keyless entry system. The new ignition key is cut to match the vehicle's ignition switch, front door locks, tailgate lock, and glove compartment lock. To order this transmitter, use the controlled parts ordering screen on the iN system. The transmitters are manufactured in Japan; delivery takes 4 to 6 weeks. Batteries for the Transmitter The battery is not replaceable. 91-93 Accord 5-Door LX 1991-93 Accord 5-door LX with dealer-installed security system Programming the Transmitter This transmitter is not programmable. Ordering a Transmitter Transmitters can be ordered directly from Kenwood USA only by authorized Honda dealers. Send a completed order form (copy it from the Accessory Replacement Parts section of the Dealer Parts Price List) along with a dealer check for $30.00 (payable to Kenwood U.S.A. Corp.) to this address: Kenwood Service Corp. P.O. Box 22745 Long Beach, CA 90501-5745 Page 2534 2. Remove the terminal (same procedure for male and female). 3. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE E: 1. Remove the secondary locks. 2. Remove the terminal (same procedure for male and female). 3. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE F: Page 7402 59. Under Left Side Of Dash Page 9137 - 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. Troubleshooting Tests 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 test 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 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. 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 Drop Page 7934 Disclaimer Cutting Procedure - By Copying 1. Press the ON/OFF button in the middle of the setting unit keypad. (This powers up the keypad.) 2. Turn the clamp unit lock lever to the left to release the clamp unit, and slide it all the way to the left until it stops. Turn the lever to the right to lock the clamp unit in place. 3. Use the clamp carriage lever to position the clamp unit so the tracer and cutter bit are centered directly over the base of the center and right jaws. 4. Pull the vertical carriage lever toward you until the tracer and the cutter bit just touch the base of each fixed jaw. Watch the arrows on the keypad: ^ If the double-headed arrow in the middle of the keypad lights green, the tracer and cutter bit are properly aligned. ^ If the arrow on the left of the keypad lights red, the cutter bit is not touching the fixed jaw. Turn the micrometric ring nut above the tracer to the left until the double-headed arrow lights green. ^ If the arrow on the right of the keypad lights red, the tracer is not touching the fixed jaw. Turn the micrometric ring nut above the tracer to the right until the double-headed arrow lights green. *5. Turn the micrometric ring nut to the right three clicks so the cutter bit is slightly higher than the tracer. The arrow on the left should light red. Raise the vertical carriage. NOTE: Setting the tracer three clicks lower than the cutter bit has the effect of making the cutter bit cut the duplicated key a little shallower. This will protect the locking jaws from being damaged.* 6. Optional: Loosen the setscrew, and adjust the hand rest to a comfortable position. Tighten the screw. 7. Pull the clamp carriage lever toward you until the clamp carriage clicks into its end-of-run position. Tighten both the lateral and spring tension adjustment knobs. 8. Make sure the center and right jaws are free of any metal shavings or debris. (A soft-bristle toothbrush is ideal for this purpose.) Page 1865 11. Disconnect the quick-connect fitting (A): Hold the connector (B) with one hand and squeeze the retainer tabs (C) with the other hand to release them from the locking pawls (D). Pull the connector off. NOTE: Prevent the remaining fuel in the fuel feed line or hose from flowing out with a rag or shop towel. - Be careful not to damage the line (E) or other parts. - Do not use tools. - If the connector does not move, keep the retainer tabs pressed down, and alternately pull and push the connector until it comes off easily. - Do not remove the retainer from the line; once removed, the retainer must be replaced with a new one. 12. After disconnecting the quick-connect fitting, check it for dirt or damage (see step 4). Page 3918 7. Verify that the Program ID and the Program Part No. are for the vehicle you are updating, then click on the check mark. 8. Confirm the control module update by Program ID and Program Part No. Make sure this corresponds with any information provided in the service bulletin for the update you are doing. Click on Yes to continue. Within a few seconds, the CM Update software loads the program file onto the GNA600. 9. Click on the check mark to begin the control uniti module update. NOTE: To avoid control unit/module damage, do not interrupt the update. 10. Within 60 seconds of update completion, turn the ignition switch to LOCK (0) and then back to ON (II). 11. Once the software verifies that the control uniti mod ule has been successfully updated, click on Yes to update another identical vehicle, or click on No to exit the update program. GNA600 Updating in Storage Mode 1. If not already done, load the latest HDS PC software onto your iN workstation. For loading instructions, refer to the ISIS publication Installation Instructions for HDS PC Software. Page 642 212. Combination Light Switch Page 2310 DTC P0401 thru P0562 Starting System - Starter Grinds While Engine Cranks Starter Cable: Customer Interest Starting System - Starter Grinds While Engine Cranks 06-025 May 18, 2006 Applies To: 2001-05 Civic 2-door - ALL except CVI 2001-05 Civic 4-door - ALL except Hybrid and GX Starter Grinds While Cranking the Engine SYMPTOM The starter motor intermittently grinds while cranking the engine. PROBABLE CAUSE The female terminal at the starter solenoid may have spread apart, causing a loss of current to the solenoid. CORRECTIVE ACTION Replace the female terminal at the starter solenoid. PARTS INFORMATION Spade Receiver Terminal: P/N 07JAZ-001420A, H/C 8362675 TOOL INFORMATION Terminal Crimping Tool: T/N 07JAZ-001020A WARRANTY CLAIM INFORMATION In warranty: The normal warranty applies. Operation Number: 7370C3 Flat Rate Time: 0.4 hour Failed Part: P/N 31200-PLM-A51 H/C 6452429 Defect Code: 06601 Symptom Code: 09004 Template ID: 06-025A 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. DIAGNOSIS 1. If applicable, make sure you have the anti-theft code for the audio system. Write down the customer's audio unit presets. 2. Disconnect the negative cable from the battery, then disconnect the positive cable. 3. Remove the resonator: Locations Relay And Control Unit Locations - Dashboard Page 9848 - Never touch the primed surfaces with your hands. 19. Cut a "V" in the end of the nozzle (A) on the adhesive cartridge as shown. 20. Put the cartridge in a caulking gun, and run a bead of adhesive (A) around the edge of the rear window (B) and moldings (C) as shown. Apply the adhesive within 30 minutes after applying the glass primer. Make a slightly thicker bead at each corner. 21. Use suction cups to hold the rear window over the opening, align it with the alignment marks you made in step 15 and set it down on the adhesive. Lightly push on the rear window until its edges are fully seated on the adhesive all the way around. Do not open or close the doors until the adhesive is dry. 22. Scrape or wipe any excess adhesive off with a putty knife or towel. To remove adhesive from a painted surface or the rear window, use a soft shop towel dampened with alcohol. 23. Let the adhesive dry for at least 1 hour, then spray water over the rear window and check for leaks. Mark the leaking areas, let the rear window dry, then seal with sealant. Let the vehicle stand for at least 4 hours after rear window installation. If the vehicle has to be used within the first 4 hours, it must be driven slowly. 24. Reinstall all remaining removed parts. NOTE: Advise the customer not to do the following things for 2 to 3 days: Slam the doors with all the windows rolled up. - Twist the body excessively (such as when going in and out of driveways at an angle or driving over rough, uneven roads). Page 7225 Programming the Transmitter 1. Locate the security system control unit under the driver's seat. 2. Rub your finger over the label on the top of the control unit until you find the depression. Once you find it, push your finger through the label to expose the hole underneath. Inside the hole is a square, yellow button; this is the programming button. 3. Turn the ignition switch to ON, then turn it to LOCK. 4. Press and hold the programming button. Check that the security siren emits four separate chirps followed by a five-chirp burst. This confirms that the system is in programming mode. The siren then emits prompting chirps at 3-second intervals. 5. Release the programming button. 6. After a prompting chirp, press the "LOCK" button on the transmitter. Verify that the siren emits a confirmation chirp to confirm that the transmitter's code was accepted by the control unit. If you wait more than 30 seconds after the prompting chirp before programming a transmitter, or wait more than 30 seconds between programming transmitters, the siren emits three chirps and the system exits the programming mode. 7. To program additional transmitters, wait for another prompting chirp, then press the "LOCK" button. (You can program up to four transmitters per vehicle.) 8. To exit the programming mode, turn the ignition switch to ON, then turn it to LOCK. 9. Test all the transmitters. Ordering a Transmitter Transmitters can be ordered only by authorized Honda dealers. Order them from American Honda using normal parts ordering procedures. Batteries for the Transmitter The battery number is 23-144 (Radio Shack), A-23 (Eveready), or MS-21/MN-21 (Duracell). Each transmitter uses one battery. Page 3361 172. EGR Valve And EGR Valve Position Sensor (EX, HX; '04-'05: DX, LX) Keyless Entry - Remote Transmitter Information Technical Service Bulletin # 98-011 Date: 040220 Keyless Entry - Remote Transmitter Information 98-011 February 20, 2004 Applies To: ALL Keyless Remote Transmitter Information (Supersedes 98-011, dated February 6, 2003) Updated information is shown by asterisks and a black bar. This service bulletin gives you information about keyless remote transmitters for most Honda vehicles. Each procedure describes transmitter programming (if applicable), transmitter ordering, and transmitter batteries. A remote transmitter quick reference guide is shown below. Page 560 Cruise Control Switch: Service and Repair Set/Resume/Cancel Switch Set/Resume/Cancel Switch Test/Replacement 1. Remove the two screws, then remove the switch. 2. Check for continuity between the terminals in switch position according to the table. - If there is continuity, and it matches the table, but switch failure is occurred on the cruise control unit input test, check and repair the wire harness on the switch circuit. - If there is no continuity in one or both positions, replace the switch. ECM/PCM Terminal Values Engine Control Module: Testing and Inspection ECM/PCM Terminal Values ECM/PCM Inputs And Outputs At Connector A (31P) Page 9024 1. Remove the secondary locks. 2. Remove the terminal from the female half. 3. Remove the terminal from the male half. 4. Go to HOW TO INSTALL NEW TERMINALS. Connectors Without a Secondary Lock All examples are shown with the connector lock facing up. The illustrations are examples of connector terminals without a secondary lock; however, the connector you are repairing may vary in size and shape. EXAMPLE A: Component Locations Oxygen Sensor: Component Locations PGM-FI System - Component Location Index Page 9373 56. License Plate Light Page 4273 ^ The left end goes behind the notch on the interlock lever. ^ Once the spring is correctly installed, make sure the lever moves freely and returns properly. 10. Insert the plunger into the interlock solenoid, then install the solenoid using a new screw. Make sure the groove of the solenoid plunger is in the fork on the lever. 11. Install a new plastic cover on the interlock solenoid. 12. Check the operation of the ignition switch key interlock: ^ Set the parking brake, and turn the ignition switch to ON (I I). ^ While pressing the brake pedal, shift the transmission to Neutral. ^ Try turning the ignition switch to LOCK (0) - If you cannot turn the switch to LOCK (0), your repair was successful; go to step 15. - If you can turn the switch to LOCK (0), the interlock is not working; go to step 13. Page 9828 5. Disconnect the 5P connector, and make these input tests. Page 5066 Shift Interlock Solenoid: Service and Repair Shift Lock Solenoid Replacement 1. Remove the center console panel and center console. 2. Disconnect the shift lock solenoid connector (2P), and remove it from the shift lever bracket base. 3. Push the lock tab (A), pry the shift lock solenoid (B) to clear the projected tips (C) with a screwdriver, and remove the shift lock solenoid. 4. Install the shift lock solenoid plunger (D) and plunger spring (E) in the new shift lock solenoid. 5. Install the shift lock solenoid by aligning the joint (F) of the shift lock solenoid plunger with the tip (G) of the shift lock stop. 6. Connect the shift lock solenoid connector, and install it on the shift lever bracket base. 7. Install the center console and console panel. Page 5131 1. Remove the secondary lock from the male terminal half. 2. Remove the secondary lock from the female terminal half. 3. Remove the terminal (same procedure for male and female). 4. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE C: 1. Remove the secondary lock. Page 2330 ECM/PCM Inputs And Outputs At Connector B (24P) Page 1343 2. Set the crankshaft to top dead center (TDC). Align the TDC mark (A) on the timing belt drive pulley with the pointer (B) on the oil pump. 3. Clean the camshaft pulley and set it to TDC. -1 The "UP" mark (A) on the camshaft pulley should be at the top. -2 Align the TDC marks (B) on the camshaft pulley with the top edge of the head. 4. Install the timing belt in a counterclockwise sequence, starting with the drive pulley. -1 Drive pulley (A). -2 Tensioner pulley (B). -3 Water pump pulley (C). -4 Camshaft pulley (D). Side Airbag Side Air Bag: Service and Repair Side Airbag Spring-Loaded Lock Connector Spring-loaded Lock Connector Some SRS system connectors have a spring-loaded lock. Side Airbag Connector: Disconnecting To release the lock, pull the spring-loaded sleeve (A) and the slider (B) while holding the opposite half of the connector. Then pull the connector halves apart. Be sure to pull on the sleeve and not on the connector half. Connecting Hold both connector halves, and press them firmly together until the projection (C) of the sleeve-side connector clicks. Removal and Installation Side Airbag Replacement NOTE: Review the seat replacement procedure in the body section before performing repair or service. Removal 1. Disconnect the battery negative cable, and wait at least 3 minutes before beginning work. Page 1944 Engine Oil: Service and Repair Engine Oil Replacement 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. Change interval Every 10,000 miles (16,000 km) or 12 months (Normal conditions) Every 5,000 miles (8,000 km) or 6 months (Severe conditions). 1. Warm up the engine. 2. Remove the drain bolt (A), and drain the engine oil. 3. Reinstall the drain bolt with a new washer (B). 4. Refill with the recommended oil. Capacity D17A2, D17A6 engines: 3.3 L (3.5 US qt.) at oil change. 3.5 L (3.7 US qt.) at oil change including filter. 4.2 L (4.4 US qt.) after engine overhaul. D17A1 engine: 3.0 L (3.2 US qt.) at oil change. 3.2 L (3.4 US qt.) at oil change including filter. 4.2 L (4.4 US qt.) after engine overhaul. 5. Run the engine for more than 3 minutes, then check for oil leakage. Page 5381 2. Remove the terminal (same procedure for male and female). 3. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE E: 1. Remove the secondary locks. 2. Remove the terminal (same procedure for male and female). 3. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE F: Page 2156 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. Circuits must be operating when checking voltage drop. 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. 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 off, 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 Self-Powered Test Light or DVOM 1. Remove the blown fuse and disconnect the battery and load. Page 6754 Do not position yourself in front of the airbag assembly during removal, inspection, or replacement. Refer to the scrapping procedures for disposal of the damaged airbag. Page 8977 Fuel Gauge Sender: Service and Repair Fuel Pump/Fuel Gauge Sending Unit Replacement Special Tools Required Fuel sender wrench 07XAA-001010A 1. Relieve the fuel pressure. 2. Remove the fuel fill cap. 3. Remove the seat cushion. 4. Remove the access panel (A) from the floor. 5. Disconnect the fuel pump 5P connector (B). 6. Disconnect the quick-connect fitting (C) from the fuel tank unit. 7. Using the special tool, loosen the fuel tank unit locknut (A). Page 1693 8. Put the splice connector in the proper size slot in the Crimper Tool, slide it to one end (where the flare begins), and close the crimper handles far enough to hold it in place. To release the ratchet mechanism at any point after the first click, squeeze the handles slightly and push the release lever, then let the handles open. 9. Insert one of the bare wires into the splice connector end that is in the crimper jaws. Push the wire all the way into the splice connector, and squeeze the crimper handles. Keep squeezing until the jaws touch, and hold it at that position until the ratchet clicks again. 10. Crimp the other wire in the same way into the other end of the splice connector. 11. After crimping, gently pull on the wires in the opposite directions to make sure they are secure in the connector. 12. Separate the other wires in the harness from the repaired wire(s), and shield them with nonflammable material. Page 9504 1. Remove the terminal. 2. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE E: 1. Remove the terminal. 2. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE F: Page 7419 Keyless Entry Module: Testing and Inspection Control Unit Input Test 1. Before testing, troubleshoot the multiplex control system. 2. Remove the dashboard lower cover. 3. Disconnect the under-dash fuse/relay box connectors. NOTE: All connectors are wire side of female terminals. 4. Inspect the connector and socket terminals to be sure they are all making good contact. - If the terminals are bent, loose or corroded, repair them as necessary, and recheck the system. - If the terminals look OK, go to step 5. Page 2863 Knock Sensor: Service and Repair Replacement 1. Remove the oil filter with the special oil filter wrench. 2. Disconnect the knock sensor connector, then remove the knock sensor. 3. Install the knock sensor and oil filter. Page 6028 Under-hood Fuse/Relay Box (2-door) Page 4210 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. Below most connector numbers and component names are PHOTO and VIEW numbers. The PHOTO number refers to a photo in the back of the book that shows the connector's location on the car. The VIEW number refers to an illustration in the back of the book that shows the connector terminals, wire colors, connector cavity numbers, and other details. The connector cavity numbering sequence begins at the top left corner of the connector as seen from either of the viewpoints shown on diagram [8] . Except for the DLC (data link 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 C554, for example, means those terminals join in cavity 2 of connector C554. Power Distribution Schematics Power Distribution Schematics Locations Camshaft Position Sensor: Locations PGM-FI System - Component Location Index Compressor Clutch Check Compressor Clutch: Testing and Inspection Compressor Clutch Check Compressor Clutch Check 1. Check the armature plate for discoloration, peeling, or other damage. If there is damage, replace the clutch set. 2. Check the rotor pulley bearing play and drag by rotating the rotor pulley by hand. Replace the clutch set with a new one if it is noisy or has excessive play/drag. 3. Measure the clearance between the rotor pulley (A) and the armature plate (B) all the way around. If the clearance is not within specified limits, remove the armature plate and add or remove shims as needed to increase or decrease clearance. Clearance: 0.5 ± 0.15 mm (0.020 ± 0.006 in.) NOTE: The shims are available in four thicknesses: 0.1 mm, 0.2 mm, 0.4 mm, and 0.5 mm. 01 Model Page 9382 Wire Color Abbreviations Page 5795 234. Under-dash Fuse/Relay Box Part 5 Page 8348 3. Featheredge the paint coat. Sand the body filler surface until the proper dimension are met. Use the double action sander and #24O'#32O #400 disc papers. 3. Air blowing/degreasing Use the alcohol, wax and grease remover. Also clean and degrease the surfaces where masking tape will be attached. Undercoating Undercoating 1. Masking Mask the area surrounding the damage to protect it from the primer surfacer overspray. Use masking tape and paper. 2. Spraying primer surfacer - Spray the primer surfacer over a wider area than the body filler and the exposed surface of the paint film. - Spray 2 - 3 coats to get 30 microns of thickness. - Use the 2-part urethane primer surfacer and a spray gun. - Mix the primer surfacer with the additive and solvent, and in the correct ratio. - Follow the primer surfacer manufacturer's instructions. 3. Drying After spraying primer surfacer, allow for 5 - 10 minutes of normal drying time, then force dry IL with infrared lamps or other industrial dryer. NOTE: Follow the primer surfacer manufacturer's instruction for drying time. Page 8589 24. Remove the key. Reinstall the retainer clip in the door handle, and push the lock cylinder into place. 25. Civic: Reconnect the cylinder rod. 26. CR-V: Reconnect the cylinder rod, the outer handle rod, and the rod protector. 27. Element: Reconnect the cylinder rod, the outer handle rod, and the access seal. Reinstall the lower run channel. 28. Reinstall the plastic covering, and lower the window glass. Install the door panel. 29. Check that the door lock and handle operate smoothly. Disclaimer Page 1528 Power Windows Component Location Index Specifications Exhaust Manifold: Specifications Exhaust Manifold Torques D17A1, D17A6 engines Page 4142 Control Module: Service and Repair Updating the ECM/PCM PCM Updating and Substitution for Testing Special Tools Required Honda Interface Module (HIM) P/N EQS05A35570 Use this procedure when you have to substitute a known-good PCM in a troubleshooting procedure. Update the PCM only if the PCM does not already have the latest software loaded. NOTE: Do not turn the ignition switch OFF while updating; the PCM can be damaged. How to Update the PCM NOTE: To ensure the latest program is installed, do an PCM update whenever the PCM is substituted or replaced. - Before you update the PCM, make sure the vehicle's battery is fully charged. - To prevent PCM damage, do not operate anything electrical (audio system, brakes, A/C, power windows, moon roof, door locks, etc.) during the update. - If you need to diagnose the Honda Interface Module (HIM) because the HIM's red (#3) light came on or was flashing during the update, leave the ignition switch in the ON (II) position when you disconnect the HIM from the Data Link Connector (DLC). This will prevent PCM damage. 1. Turn the ignition switch ON (II). Do not start the engine. 2. Connect the HIM to the DLC (A) located under the driver's side of dashboard. 3. Do the PCM update procedure as described on the HIM label and in the PCM update system. If the software in the PCM is the latest version, replace the PCM. How to End a Troubleshooting Session This procedure must be done after any troubleshooting. 1. Clear the DTC(s) with the Scan Tool or HDS, or reset the PCM by removing the No. 6 (PCM) fuse in the under-hood fuse/relay box for more than 10 seconds. 2. Turn the ignition switch ON (II). 3. Start the engine in the P or N position, and warm it up to normal operating temperature (the radiator fans come on). 4. To verify that the problem is repaired, test-drive the vehicle for several minutes at speeds over 30 mph (50 km/h) or in freeze data range. Page 8136 96-97 Passport With Dealer-Installed Security System 1996-97 Passport with dealer-installed security system NOTES: ^ The system uses a stacking-type memory that accepts up to two transmitters. If you program a third transmitter, the memory for the first transmitter is pushed out, and it will no longer work. ^ To clear a lost or stolen transmitter from the system's memory, program a transmitter two times. This will remove the missing transmitter from memory, since only two transmitter codes can be accepted. ^ Another way to clear a lost or stolen transmitter is to erase all transmitter codes and then reprogram them. To do this, refer to the security system owner's manual. Programming the Transmitter 1. Move the driver's seat forward. Locate the security system control unit mounted on the floor underneath the seat. 2. Turn the ignition switch to ON. 3. Use a pen or pencil to press and hold the green programming button on the side of the control unit. When the security system LED on the instrument panel comes on, release the programming button. (Steps 3 and 4 must be done within 5 seconds of each other.) 4. Press and release the top button on the transmitter. Verify that the LED goes out, the siren chirps once, and the front sidemarker lights flash to confirm that the transmitter's code was accepted by the control unit. 5. Turn the ignition switch to LOCK, then to ON. Page 6019 Power Windows Component Location Index Page 1097 7. Align the cutouts (A) on the rotary-frame with the neutral positioning cutouts (B) on the transmission range switch, then put a 2.0 mm (0.08 inch) feeler gauge blade (C) in the cutouts to hold it in the N position. NOTE: Be sure to use a 2.0 mm (0.08 inch) blade or equivalent to hold the switch in the N position. 8. Install the transmission range switch (A) gently on the control shaft (B) with holding the N position with the 2.0 mm (0.08 inch) blade (C). 9. Tighten the bolts on the transmission range switch while you continue to hold it in the N position. Do not move the transmission range switch when tightening the bolts. Remove the feeler gauge. Removal and Installation Engine Control Module: Service and Repair Removal and Installation How to Remove the ECM/PCM for Testing 1. Remove the passenger's dashboard lower cover, the right kick panel, and the glove box. 2. Remove the bolt. Cut the plastic cross brace in the glove box opening with diagonal cutters in the area shown, and discard it. 3. Remove the relays (A), then remove the bolts and the glove box frame (B). 4. Remove the gray 20P ECM/PCM wire harness connector from the ECM/PCM mounting bracket. Remove the ECM/PCM mounting bolt (A) and the bracket. 5. Remove the nuts, then remove the ECM/PCM (B). 6. Install the ECM/PCM in the reverse order of removal. Page 9325 Diagram 115-2 (Coupe EX) Page 8351 Spraying clear coat Spray the top coat clear evenly over the surface of the top coat enamel. Do not try to cover the surface with one heavy coat. Drying After spraying the clear coat, allow it to dry for 10 minutes, then force dry it with infrared lamps or other industrial dryer. NOTE: Follow the top coat manufacturers instructions for drying times. 3. Polishing/buffing Check that the clear coat has dried thoroughly and that it is coal. 1. Any adhesion or roughness on the top coat should be wet sanded and repaired. Use the #1200 - #2000 and crystal block. 2. Polish any roughness caused by sanding. NOTE: Clean the top coat surface frequently so you don't damage the clear coat with the polishing particles. Use a buffing towel, buffing wool, and compound. 3. Finishes up with buffing. NOTE: - Do not use a power buffer. - Don't polish too much; use light hand pressure. Use the buffing sponge, fine compound, very fine compound, then ultra fine compound. 4. After buffing, remove the masking paper and tape, and thoroughly wash the entire vehicle. Page 3255 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 Short Circuit Locator (Short Finder) 1. Remove the blown fuse. Leave the battery connected. Locations Horn Switch: Locations Horn Component Location Index Page 1456 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. Specifications Firing Order: Specifications Ignition coil Firing order .......................................................................................................................................... ............................................................ 1 - 3 - 4 - 2 Diagrams 39. ECT Sensor Diagrams Page 7277 Power Distribution schematics show how power is supplied from the positive battery terminal to various circuits in the vehicle. Refer to the Power Distribution diagram set to get a more detailed understanding of how picture is supplied to the circuit you're working on. Individual circuit schematics begin with a fuse. So 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 Ground Distribution Schematics This sample Ground Distribution schematic shows all of the components that share the same ground point. Page 353 Air Bag Control Module: Service and Repair OPDS Unit Replacement OPDS Unit Replacement NOTE: Review the seat replacement procedure in the body section before performing repair or service. Removal 1. Disconnect the battery negative cable, and wait at least 3 minutes before beginning work. 2. Disconnect the side airbag harness 2P connector. 3. Remove the seat assembly and seat-back cover. 4. Remove the cover (A), then disconnect the OPDS unit harness 8P and sensor connectors (B) from the OPDS unit. Installation 1. Place the new OPDS unit on the seat-back frame. Tighten the two screws, and connect the OPDS unit harness 8P and sensor connector to the OPDS unit. Reinstall the cover. 2. Install the seat-back cover. 3. Install the seat assembly, then connect the side airbag harness 2P connector. 4. Reconnect the battery negative cable. 5. Set the seat-back in the normal position, and make sure there is nothing on the front passenger's seat. 6. Initialize the OPDS unit. 7. After installing the OPDS unit, confirm proper system operation: Turn the ignition switch ON (II); the SRS indicator should come on for about 6 seconds and then go off. Page 785 Power Steering Pressure Switch: Service and Repair Power Steering Hoses, Lines, and Pressure Switch Replacement Note these items during installation: ^ Connect each hose to the corresponding line securely until it contacts the stop on the line. Install the clamp or adjustable clamp at the specified distance from the hose end as shown. ^ Check all clamps for deterioration or deformation; replace the clamps with new ones, if necessary. ^ Add the recommended power steering fluid to the specified level on the reservoir and check for leaks. Page 9385 Splices Components Ground - "G" Page 8151 The battery number is CR2025. Each transmitter uses one battery. 94-95 Accord, Civic, Del SOL, Prelude & 95 Odyssey 1994-95 Accord with dealer-installed security system 1994-95 Civic with dealer-installed security system 1994-95 del Sol with dealer-installed security system 1994-95 Prelude with dealer-installed security system 1995 Odyssey with dealer-installed security system Programming the Transmitter NOTES: ^ The system uses a stacking-type memory that accepts up to four transmitters. If you program a fifth transmitter, the system's memory for the first transmitter is pushed out, and it will no longer work. ^ To clear a lost or stolen transmitter from the system's memory, program a transmitter four times. This will remove the missing transmitter from memory, since only four transmitter codes can be accepted. ^ Another way to clear a lost or stolen transmitter is to erase all transmitter codes, and then reprogram them. To do this, refer to the security system owner's manual. 1. Turn the ignition switch to ON (II). 2. Press and hold the Valet-Disarm button on the dashboard lower cover. (Continue to hold the button during this procedure, or programming will be cancelled.) The LED on the upper steering column cover flashes when the system is in programming mode. 3. Press the top button on the transmitter. Check that the parking lights flash to confirm that the transmitter's code was accepted. 4. Press the top button on each of the remaining transmitters. Check that the parking lights flash after each transmitter code is accepted. 5. Release the Valet-Disarm button to exit the programming mode. Ordering a Transmitter Transmitters can be ordered only by authorized Honda dealers. Order them from American Honda using normal parts ordering procedures. Batteries for the Transmitter The battery number is CR2025. Each transmitter uses one battery. 96-98 Civic EX & Except EX, Civic 1996-98 Civic EX with factory-installed keyless entry system 1996-98 Civic (except EX) with dealer-installed keyless entry system 1996-98 Civic with dealer-installed security system Page 7279 - Before connecting connectors, make sure the terminals (A) are in place and not bent. - Check for loose retainer (A) and rubber seals (B). - The backs of some connectors are packed with dielectric grease. Add grease if necessary. If the grease is contaminated, replace it. - Insert the connector all the way and make sure it is securely locked. - Position wires so that the open end of the cover faces down. Handling Wires and Harnesses - Secure wires and wire harnesses to the frame with their respective wire ties at the designated locations. Page 5058 Pressure Regulating Solenoid: Testing and Inspection A/T Clutch Pressure Control Solenoid Valves A and B Test 1. Disconnect the connectors from the A/T clutch pressure control solenoid valves A and B. 2. Measure the resistance of the A/T clutch pressure control solenoid valves A and B between the No. 1 and No. 2 terminals of each connector. STANDARD: About 5.0 Ohms 3. If the resistance of either A/T clutch pressure control solenoid is out of standard, replace the A/T clutch pressure control solenoid valves A and B. 4. Connect the No. 1 terminal of the A/T clutch pressure control solenoid valve A (and B) to the battery positive terminal, and connect the No. 2 terminal to the battery negative terminal. A clicking sound should be heard. 5. If no sound is heard, remove the A/T clutch pressure control solenoid valves A and B. 6. Check the fluid passage of the A/T clutch pressure control solenoid valve for dust and dirt. 7. Connect the No. 1 terminal of the A/T clutch pressure control solenoid valves A and B to the battery positive terminal, and connect the No. 2 terminal to the battery negative terminal. Make sure the A/T clutch pressure control solenoid valves A and B move. 8. Disconnect one of the battery terminal and check valve movement. NOTE: You can see valve movement through the fluid passage in the mounting surface of the A/T clutch pressure control solenoid valves A and B body (c). 9. If either valve binds or moves sluggishly, or if the A/T clutch pressure control solenoid does not operate, replace the A/T clutch pressure control solenoid valves A and B. Page 4803 Circuit Diagram Page 6686 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 9661 Vanity Lamp: Electrical Diagrams Diagram 114-0 Page 2401 39. Left Side Of Engine Compartment Page 7444 Power Distribution schematics show how power is supplied from the positive battery terminal to various circuits in the vehicle. Refer to the Power Distribution diagram set to get a more detailed understanding of how picture is supplied to the circuit you're working on. Individual circuit schematics begin with a fuse. So 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 Ground Distribution Schematics This sample Ground Distribution schematic shows all of the components that share the same ground point. Page 7486 Front Bumper: Service and Repair Front Bumper Removal/Installation Front Bumper Removal/Installation '01-03 Models NOTE: - Have an assistant help you when removing and installing the front bumper. - Take care not to scratch the front bumper and body. - Put on gloves to protect your hands. 1. Remove the front bumper as shown. 2. Install the bumper in the reverse order of removal, and note these items: - Make sure the front bumper engages the hooks of the side spacers and upper beams on both sides securely. - Replace any damaged clips. '04-05 Models NOTE: - Have an assistant help you when removing and installing the front bumper. - Take care not to scratch the front bumper and body. - Put on gloves to protect your hands. 1. Remove the front bumper as shown. Page 3245 Circuit Schematics Each schematic represents one circuit. A circuit's wires and components are arranged to show current flow from power at the top of the diagram 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 Page 8615 ^ If no key code can be found on the iN or with the Matrix H High Security key Codes Book, remove one tumbler at a time from the old inner cylinder, and match the number stamped on the old tumbler to a new tumbler from the kit. Insert the new tumbler and spring in the appropriate new inner cylinder cavity. ^ Do not use the old inner cylinder, springs, or tumblers. ^ Using your thumb and forefinger, hold the tumblers in place, insert the key in the cylinder and verify that all tumblers are flush with the cylinder. If not, double-check the key number, the cutting key code, the tumbler numbers, and the cavity locations. NOTE: If the key cannot be inserted, check the tumbler in the "J" cavity. It may be out of position. Fuel Gauge Sending Unit - New Wrench Available Fuel Gauge Sender: Technical Service Bulletins Fuel Gauge Sending Unit - New Wrench Available SOURCE: Honda Service News February 2003 TITLE: New Fuel Gauge Sending Unit Wrench Available APPLIES TO: All Models SERVICE TIP: There's a new fuel gauge sending unit wrench available in Honda parts stock. The new wrench T/N 07AAA-S0XA100) is a beefier version of the old one (T/N 07XAA-001010A) and supersedes it. The new wrench is much less prone to bending when you're removing a stubborn fuel pump/sender assembly locknut. Order it through normal parts ordering channels. Page 9822 2. Disconnect the 14P connector (A) from the master switch (B). 3. Inspect the connector and socket terminals to be sure they are all making good contact. - If the terminals are bent, loose or corroded, repair them as necessary, and recheck the system. - If the terminals look OK, Go to step 4. 4. Reconnect the 14P connector to the power window master switch, and perform the given input tests. Page 1600 26. Remove PGM-FI main relay 2 (A). 27. Check for continuity between ECM/PCM connector terminal E9 and body ground. Is there continuity? YES - Repair short in the wire between the No.17 FUEL PUMP (15A) fuse and the ECM/PCM (E9), or the No.17 FUEL PUMP (15A) fuse and the PGM-FI main relay 2. Also replace the No.17 FUEL PUMP (15A) fuse. NO - Go to step 28. 28. Remove the rear seat cushion. 29. Remove the access panel from the floor. 30. Disconnect the fuel pump 5P connector. 31. Check for continuity between fuel pump 5P connector terminal No.5 and body ground. Is there continuity? YES - Repair short in the wire between the fuel pump and the PGM-FI main relay 2. Also replace the No.17 FUEL PUMP (15A) fuse. NO - Go to step 32. Service and Repair Sunroof / Moonroof Frame: Service and Repair Frame and Drain Tube Replacement 1. Remove these items: - Headliner - Moonroof glass 2. Put on gloves to protect your hands. Disconnect the motor connector (A), open/close-tilt/close switch connector (B), and the drain tubes (C), and remove the moonroof relays (D). 3. Remove the interior harness (E) by detaching the harness clips (F). 4. With an assistant holding the frame (G), remove the bolts, starting at the rear, and release the rear hooks (H) by moving the frame forward, then remove the frame. 5. With the help of an assistant, carefully remove the frame through the front door opening. Take care not to scratch the interior trim and body, or tear the seat covers. 6. To remove a front drain valve (A) from the body, remove the kick panel, left or right, 2-door, 4-door. Tie a string to the end of the drain tube, then pull the front drain tube (B) down out of the A-pillar. Page 8912 41. Check for continuity between PGM-FI main relay 1 4P connector terminal No.3 and ECM/PCM connector terminal E7. Is there continuity? YES - Test PGM-FI main relay 1. If the relay is OK, update the ECM/PCM if it does not have the latest software, or substitute a known good ECM/PCM, then recheck. If the symptom/indication goes away with a known-good ECM/PCM, replace the original ECM/PCM. NO - Repair open in the wire between PGM-FI main relay 1 and the ECM/PCM (E7). 42. Reconnect ECM/PCM connector E (31P). 43. Turn the ignition switch ON (II). 44. Measure voltage between body ground and ECM/PCM connector terminals A2 and A3 individually. Is there battery voltage? YES - Go to step 51. NO - Go to step 45. 45. Turn the ignition switch OFF. 46. Remove PGM-FI main relay 1 (A). 47. Turn the ignition switch ON (II). Page 4848 8. Reassemble the transmission; see page 13-43 (13-59 for Hybrid) of the service manual. 9. Install the new shift fork holder. Check the reverse shift fork clearance; see page 13-19 (13-34 for Hybrid) of the service manual. 10. Reinstall the transmission; see page 13-9 (13-23 for Hybrid) of the service manual. 11. Fill the transmission with MTF. 12. * Test-drive the car; make several right turns (left turns for Hybrid), and check that the clicking noise is gone.* Disclaimer Page 4611 Transmission Position Switch/Sensor: Testing and Inspection Transmission Range Switch Test Transmission Range Switch Test 1. Remove the transmission range switch harness connector (A) from the connector bracket (B), then disconnect the connector. 2. Check for continuity between terminals at the harness connector. There should be continuity between the terminals listed for each switch position. In the P position, between terminals: ^ No. 1 and No. 3 ^ No. 1 and No. 8 ^ No. 3 and No. 8 In the R position, between terminals: ^ No. 1 and No. 9 In the N position and between terminals: ^ No. 1 and No. 3 ^ No. 1 and No. 10 ^ No. 3 and No. 10 In the D position, between terminals: ^ No. 1 and No. 2 ^ No. 1 and No. 4 ^ No.2 and No.4 In the D3 position, between terminals: ^ No. 1 and No. 2 ^ No. 1 and No. 5 ^ No.2 and No.5 In the 2 position, between terminals: ^ No. 1 and No. 6 Page 9809 119. Driver's Door (Coupe Except DX, HX) 120. Driver's Door (Sedan Except DX) Testing and Inspection Power Door Lock Control Module: Testing and Inspection Control Unit Input Test 1. Before testing, troubleshoot the multiplex control system.See: Body Control Systems/Testing and Inspection 2. Remove the dashboard lower cover. 3. Disconnect the under-dash fuse/relay box connectors. NOTE: All connectors are wire side of female terminals. 4. Inspect the connector and socket terminals to be sure they are all making good contact. - If the terminals are bent, loose or corroded, repair them as necessary, and recheck the system. - If the terminals look OK, go to step 5. Page 8273 ^ Incorrect: "If a Master Key is to be cut, put a five (5) in the blank space. Use a two (2) if a valet key is needed." ^ Correct: "If a Master Key is to be cut, put an M in the blank space. Use an S if a valet key is needed." Page 2, legend at the bottom: ^ Incorrect: "C. If a Master key is desired, then the number five (5) should be placed in the M/S position. Place the number two (2) in the M/S column if a Sub (Valet) key is needed." ^ Correct: "C. If a Master Key is desired, then an M should be placed in the M/S position. Place an S in the MIS column if a Sub (Valet) key is needed." Page 4630 Shift Cable: Service and Repair Shift Cable Replacement 1. Raise the vehicle, and make sure it is securely supported. 2. Shift the transmission into the N position. 3. Remove the center console panel and center console. 4. Remove the nut securing the shift cable end (A), then separate the cable end from the shift lever assembly. 5. Rotate the socket holder (A) on the shift cable (B) toward the shift lever a quarter turn, then slide the holder out to remove the shift cable from the shift cable bracket base (C). 6. Disconnect the third HO2S connector, and remove the exhaust pipe A and the heat shield (B). Page 5244 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. Test Equipment 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. Page 5455 Brake Fluid Level Sensor/Switch: Testing and Inspection Brake Fluid Level Switch Test Check for continuity between the terminals (A) with the float in the down position and the up position. ^ Remove the brake fluid completely from the reservoir. With the float down, there should be continuity. ^ Fill the reservoir with brake fluid to MAX (upper) level (B). With the float up, there should be no continuity. Technician Safety Information Air Bag(s) Arming and Disarming: Technician Safety Information Technician Safety Information Page 6705 4. Remove the four horn plate mounting bolts, the mounting bolt felt washers, and the horn plate. The felt washers will not be reused. 5. Remove and discard the felt tape covering the lower two inflator locknuts. 6. Using needle-nose Vise Grips, remove the four locknuts from the inflator and discard them. NOTE: Do not remove the inflator from the airbag until you complete step 7. Page 2703 104. CKP Sensor Page 8603 ^ Incorrect: "If a Master Key is to be cut, put a five (5) in the blank space. Use a two (2) if a valet key is needed." ^ Correct: "If a Master Key is to be cut, put an M in the blank space. Use an S if a valet key is needed." Page 2, legend at the bottom: ^ Incorrect: "C. If a Master key is desired, then the number five (5) should be placed in the M/S position. Place the number two (2) in the M/S column if a Sub (Valet) key is needed." ^ Correct: "C. If a Master Key is desired, then an M should be placed in the M/S position. Place an S in the MIS column if a Sub (Valet) key is needed." Page 7017 Seat Belt: Service and Repair Rear Rear Seat Belt Rear Seat Belt Replacement NOTE: Check the rear seat belts for damage, and replace them if necessary. Be careful not to damage them during removal and installation. Rear Seat Belt 1. Remove the rear seat cushion, 2-door, 4-door. 2. Remove the lower anchor bolt (A). 3. Remove the rear shelf, 2-door, 4-door. 4. Remove the retractor mounting self-tapping ET screw (A), and the retractor bolt (B), then remove the rear seat belt (C) and retractor (D). 5. Install the belt in the reverse order of removal, and note these items: - Apply liquid thread lock to the anchor bolts before reinstallation. - Check that the retractor locking mechanism functions as described. - Before installing the anchor bolt, make sure there are no twists or kinks in the rear seat belt. Rear Seat Belt Buckle Rear Seat Belt Replacement NOTE: Check the rear seat belts for damage, and replace them if necessary. Be careful not to damage them during removal and installation. Center Belt and Seat Belt Buckles 1. Remove the rear seat cushion, 2-door, 4-door. Page 6319 22. Press a new hub bearing unit (A) into the hub (B) using the special tools and a press. 23. Install the knuckle/hub/hub bearing unit in the reverse order of removal, and note these items: ^ Be careful not to damage the ball joint boot when installing the knuckle. ^ Tighten all mounting hardware to the specified torque values. ^ Torque the castle nut to the lower torque specification, then tighten it only far enough to align the slot with the ball joint pin hole. Do not align the castle nut by loosening it. ^ Install a new lock pin on the castle nut after torquing. ^ Use a new spindle nut on reassembly. ^ Before installing the new spindle nut, apply a small amount of engine oil to the seating surface of the nut. After tightening, use a drift to stake the spindle nut shoulder against the driveshaft. ^ Before installing the brake disc, clean the mating surface of the front hub and the inside of the brake disc. ^ Before installing the wheel, clean the mating surface of the brake disc and the inside of the wheel. ^ Check the front wheel alignment, and adjust it if necessary. Page 1063 Terminals - "T" Shielding Switches Fuses Page 1539 69. Under Left Side Of Dash Page 2418 172. EGR Valve And EGR Valve Position Sensor (EX, HX; '04-'05: DX, LX) Specifications Fluid Pan: Specifications CVT ATF pan/bolts Page 2024 Timing Belt Tensioner: Service and Repair Auto-Tensioner Removal/ Installation Removal 1. Remove the timing belt. 2. Remove the auto-tensioner. Installation 1. Clean the timing belt pulleys, and the upper and lower covers. 2. Set the crankshaft to TDC. Align the TDC mark (A) on the timing belt drive pulley with the pointer (B) on the oil pump. 3. Clean the camshaft pulley and set it to TDC. -1 The "UP" mark (A) on the camshaft pulley should be at the top. Page 9685 Power Windows Component Location Index Page 2049 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 Locater) 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. Troubleshooting Precautions Troubleshooting Precautions Before Troubleshooting 1. Check the main fuse and the fuse 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, or you will damage the alternator diodes. - Do not attempt to crank the engine with the ground cable disconnected 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. Page 1677 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 Locater) 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. Troubleshooting Precautions Troubleshooting Precautions Before Troubleshooting 1. Check the main fuse and the fuse 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, or you will damage the alternator diodes. - Do not attempt to crank the engine with the ground cable disconnected 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. Valve Inspection Valve: Testing and Inspection Valve Inspection Inspection Measure the valve in these areas. Intake Valve Dimensions A Standard (New): 29.85 - 30.15 mm (1.175 - 1.187 inch) B Standard (New): 118.27 - 118.87 mm (4.656 - 4.680 inch) C Standard (New): 5.480 - 5.490 mm (0.2157 - 0.2161 inch) C Service Limit: 5.45 mm (0.215 inch) Exhaust Valve Dimensions A Standard (New): 25.85 - 26.15 mm (1.018 - 1.030 inch) B Standard (New): 115.65 116.25 mm (4.553 - 4.577 inch) C Standard (New): 5.450 - 5.460 mm (0.2146 - 0.2150 inch) C Service Limit: 5.42 mm (0.213 inch) Page 1146 Rear Window Defogger Component Location Index Component Locations Shift Solenoid: Component Locations Electronic Controls Location Ignition/Locks - Cutting Sidewinder-Type Keys Technical Service Bulletin # 01-077 Date: 060419 Ignition/Locks - Cutting Sidewinder-Type Keys 01-077 April 19, 2006 Applies To: Models With Sidewinder-Type Keys - All Cutting Sidewinder-Type Keys With the MATRIX H Key Cutting Machine (Supersedes 01-077, dated January 12, 2005) Updated information is noted by asterisks. MATRIX H Key Cutting Machine, manufactured by Silca and supplied by Kaba Ilco Corporation, is a portable, power-operated tool that cuts sidewinder-type automotive keys exclusively. The machine lets you cut these keys either by copying or by code. The code function is designed and built to meet the Honda code requirements. No other similar machine has this capability. This service bulletin gives you information for ordering and servicing this special tool, and guides you through the entire key cutting process from setting up the machine to cutting the key blank. TOOL INFORMATION Order through the Honda Tool and Equipment Program: MATRIX H Key Cutting Machine: Model No. ILCMATRIXSH Cutter Bit: Model No. ILCF3O Fixed Jaw: Model No. ILCMTX-H Mobile Jaw (Right Side): Model No. ILCRTMTX-H Mobile Jaw (Left Side): Model No. ILCLTMTX-H *Remanufactured Clamp Unit: Model No. ILCMATRIXHCR* PARTS INFORMATION *For some models, there are two choices for sidewinder-type key blanks: ^ T-5 sidewinder key blanks ^ Honda sidewinder key blanks For other models, only Honda sidewinder key blanks can be used. See DETERMINING WHICH KEY TO USE to determine which key blank you should choose. Ordering T-5 key blanks through the Honda Tool and Equipment Program: T-5 Programmable Key Blank (Master): P/N ILC-35111-T-5H T-5 Programmable Key Blank (Valet): P/N ILC-35112-T-5H Practice Key Blanks (five per pack): ILC-35111DEMO* NOTE: Do not use practice key blanks for replacement purposes. Practice keys do not have an immobilizer chip. Page 8254 13. Push the top of the retainer clip with a flat-tip screwdriver, and hold it. Release the retainer clip with a hook-shaped tool, then remove the lock cylinder. Go to step 14. 14. With the door lock cylinder out of the door handle remove the E-clip and the arm. 15. Try to insert the key into the cylinder and turn it. ^ If you can insert and turn the key, go to step 18. ^ If you cannot insert the key or turn it, go to step 16. 16. Carefully remove the spring and plastic retainer. Page 2678 36. Left Side Of Engine Compartment (except GX) Page 6067 234. Under-dash Fuse/Relay Box Part 2 Page 2958 Page 179 2. Remove the terminal (same procedure for male and female). 3. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE E: 1. Remove the secondary locks. 2. Remove the terminal (same procedure for male and female). 3. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE F: Page 6468 99. Under Right Side Of Dash Page 4102 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. Test Equipment 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. Page 8417 174. Moonroof Switch (EX) Page 6293 2. Check for the letters "OS" on the top of the lower ball joint. ^ If "OS" is not stamped on the ball joint, go to step 3. ^ If "OS" is stamped on the ball joint, the ball joint has already be replaced, and the knuckle is not usable for another ball joint replacement. Replace the knuckle. Replacement knuckles include a new ball joint. 3. Remove the knuckle on the affected side: ^ Refer to page 18-12 of the 2001-05 Civic Service Manual. ^ Enter keyword KNUCKLE, and select Front Knuckle/Hub/Wheel Bearing Replacement for the appropriate vehicle from the list. 4. Remove the dust boot from the lower ball joint. 5. Clamp the knuckle in a bench vise. 6. Insert pilot adapter G into the C-frame press. 7. Install the remover/installer adapter A over the threaded end of the ball joint, and loosely install the castle nut to the ball joint to hold the adapter in place. 8. Clean the area around the ball joint, then position the base remover adapter C. 9. Position the remover/installer adapter H and the C-frame press. 10. Tighten the C-frame press to press the ball joint out of the knuckle. 11. Clean the knuckle bore with brake cleaner. Page 9084 - Remove clips carefully; don't damage their locks (A). - Slip pliers (A) under the clip base and through the hole at an angle, then squeeze the expansion tabs to release the clip. - After installing harness clips, make sure the harness doesn't interfere with any moving parts. - Keep wire harnesses away from exhaust pipes and other hot parts, from sharp edges of brackets and holes, and from exposed screws and bolts. - Seat grommets in their grooves properly (A). Do not leave grommets distorted (B). Testing and Repairs - Do not use wires or harnesses with broken insulation. Replace them or repair them by wrapping the break with electrical tape. - After installing parts, make sure that no wires are pinched under them. - When using electrical test equipment, follow the manufacturer's instructions and those described. - If possible, insert the probe of the tester from the wire side (except waterproof connector). - Use back probe adaptor 07TAZ-001020A. - Refer to the instructions in the Honda Terminal Kit for identification and replacement of connector terminals. Five-Step Troubleshooting Five-Step Troubleshooting 1. Verify The Complaint Locations SRS Component Location Index Page 414 Control Module: Service and Repair How to Substitute the PCM How to Substitute the PCM 1. Remove the PCM from the vehicle. 2. Install a known-good PCM in the vehicle. 3. Rewrite the immobilizer code with the PCM replacement procedure in the Honda PGM Tester; It allows you to start the engine. 4. After completing your tests, reinstall the original PCM and rewrite the immobilizer code with the PCM replacement procedure in the HDS Tester again. Service and Repair Turn Signal Bulb: Service and Repair Front Turn Signal / Side Marker Lights: Parking Light: 1. Remove the inner fender. 2. Disconnect the connectors (A) from the lights. 3. Turn the bulb sockets (B) 45 ° counterclockwise to remove them from the headlight housing. 4. Install the new bulb(s) in the reverse order of removal. Page 1604 48. Measure voltage between PGM-FI main relay 1 4P connector terminal No.2 and body ground. Is there battery voltage? YES - Go to step 49. NO - Repair open in the wire between the No.6 ECU (ECM/PCM) (15A) fuse and the PGM-FI main relay 1. 49. Turn the ignition switch OFF. 50. Check for continuity between PGM-FI main relay 1 4P connector terminal No.1 and ECM/PCM connector terminals A2 and A3 individually. Is there continuity? YES - Replace the PGM-FI main relay 1. NO - Repair open in the wire between PGM-FI main relay 1 and the ECM/PCM (A2, A3). 51. Measure voltage between body ground and ECM/PCM connector terminals A4, A5, A23, and A24 individually. Is there less than 1.0 V? YES - Go to step 52. NO - Repair open in the wire(s) that had more than 1.0 V between G101 and the ECM/PCM (A4, A5, A23, A24). Page 8685 Cruise Control Servo: Diagrams 138. Cruise Control Actuator (USA: HX; Sedan: LX, EX,GX) 199. Cruise Control Actuator (Coupe: LX, EX) Page 1541 Under-hood Fuse/Relay Box Page 9138 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. Circuits must be operating when checking voltage drop. 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. 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 off, 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 Self-Powered Test Light or DVOM 1. Remove the blown fuse and disconnect the battery and load. Page 4597 143. Park Pin/Shift Switch (A/T) Locations Transmission Position Switch/Sensor: Locations Electronic Controls Location, CVT 25. Transmission Housing (CVT) Page 6131 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. Locations 55. In Steering Column Cover Page 8710 Cruise Control Switch: Service and Repair Set/Resume/Cancel Switch Set/Resume/Cancel Switch Test/Replacement 1. Remove the two screws, then remove the switch. 2. Check for continuity between the terminals in switch position according to the table. - If there is continuity, and it matches the table, but switch failure is occurred on the cruise control unit input test, check and repair the wire harness on the switch circuit. - If there is no continuity in one or both positions, replace the switch. Page 7452 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 Short Circuit Locator (Short Finder) 1. Remove the blown fuse. Leave the battery connected. Page 2154 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 Locater) 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. Troubleshooting Precautions Troubleshooting Precautions Before Troubleshooting 1. Check the main fuse and the fuse 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, or you will damage the alternator diodes. - Do not attempt to crank the engine with the ground cable disconnected 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. Page 8529 Sunroof / Moonroof Limit Switch: Adjustments Limit Switch Adjustment 1. Remove the headliner. 2. With the moonroof wrench, close the glass (A) fully: - Make sure both link lifters (B) are parallel, and in the position shown. - Check the glass fit to the roof panel and the glass height. 3. With an open-end wrench, loosen the limit switch mounting bolts (C). 4. Adjust the limit switch (D): - Move the switch plate (E) a little at a time, then secure it at the position where you hear a faint click when the switch cam (P) pushes the limit switch (open/close). - Check that the switch plate contacts the switch bracket (G). 5. Check the operation of the glass (from the tilt-up position to fully closed position, from the fully open position to the fully closed position) by operating the moonroof switch. Page 9567 160. Fog Light Switch (Honda Accessory) Page 8340 Vehicle Identification Number - Canada Model 2-door Page 1943 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 .................................................................................................................................... Make sure the label says "For Gasoline Engines". From -20°F (-30°C) to over 100°F (40°C) .......................................................................................................................................................... SAE 5W-20 Page 2639 11. Disconnect the quick-connect fitting (A): Hold the connector (B) with one hand and squeeze the retainer tabs (C) with the other hand to release them from the locking pawls (D). Pull the connector off. NOTE: Prevent the remaining fuel in the fuel feed line or hose from flowing out with a rag or shop towel. - Be careful not to damage the line (E) or other parts. - Do not use tools. - If the connector does not move, keep the retainer tabs pressed down, and alternately pull and push the connector until it comes off easily. - Do not remove the retainer from the line; once removed, the retainer must be replaced with a new one. 12. After disconnecting the quick-connect fitting, check it for dirt or damage (see step 4). Page 362 VEHICLES AFFECTED CUSTOMER NOTIFICATION All owners of affected vehicles were mailed a notification of this warranty extension. A example of the customer notification is shown in this service bulletin. CORRECTIVE ACTION Repair the vehicle as indicated by the INSPECTION PROCEDURE. If needed, replace the OPDS unit. In rare cases where an updated OPDS unit was already installed, replace the OPDS sensor. Page 8329 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 68 Electronic Brake Control Module: Testing and Inspection ABS Control Unit Inputs and Outputs for 31P Connector Page 8053 12. Pull the vertical carriage lever toward you while you position the tracer on the right edge of the original key at its head, using the clamp carriage lever. Let the cutter bit cut into the key blank, then stop. Gently twist the lever clockwise to lock the vertical carriage at this height. Do not overtighten the lever. 13. Use the clamp carriage lever and the tracer to follow the contours of the original key. (The cutter bit cuts the same contours into the key blank.) Working from right to left, follow the right edge of the original key from head to tip, then the left edge of the key from tip to head. Turn off the cutter motor. 14. Reposition the tracer on the right edge of the original key at its head, using the clamp carriage lever. Turn on the cutter motor. Retrace the key from head to tip, then from tip to head. (This retracing cleans up the cuts on the key.) Turn off the cutter motor. 15. Release the vertical carriage lever. Open the jaw and remove only the new key. Make sure the jaw is free of any metal shavings or debris, then turn the new key over and slide the key with its blank side up into the jaw up to the key stop. Close the jaw to lock the key into place. 16. Turn on the cutter motor, and repeat steps 12 thru 14 to cut both edges of the other side of the key. 17. When you are finished making the required cuts, turn off the cutter motor, and release the vertical carriage lever. Open the jaws, and remove the keys. 18. Use a wire brush to smooth the cut surfaces on the new key. 19. Make sure the key works in the ignition switch and all the locks. If the key does not work, recut the key, and try it again. 20. Depending on the type of key blank you have used, do this: ^ If you have used a Honda key blank, add the transponder code of the new key to the immobilizer system with the Honda Diagnostic System (HDS). ^ If you have used a T-5 programmable key blank ("T-5" stamped on the shank), code the key's transponder with the Ilco Immobilizer Key Code Duplicator (see S/B 99-053, Ilco Immobilizer key Code Duplicator). Cutting Procedure - By Code 1. Press the ON/OFF button in the middle of the setting unit keypad. (This powers up the keypad.) 2. Turn the clamp unit lock lever to the left to release the clamp unit, and slide it to the right until the bottom left side is flush with the base edge. Turn the lever to the right to lock the clamp unit in place. Loosen the lateral and spring tension adjustment knobs on the clamp carriage. Page 6723 4. Remove the four horn plate mounting bolts, the mounting bolt felt washers, and the horn plate. The felt washers will not be reused. 5. Remove and discard the felt tape covering the lower two inflator locknuts. 6. Using needle-nose Vise Grips, remove the four locknuts from the inflator and discard them. NOTE: Do not remove the inflator from the airbag until you complete step 7. Page 2234 Relay And Control Unit Locations - Engine Compartment Locations Clutch Switch: Locations Starting System Component Location Index Page 1608 70. Measure voltage between body ground and ECM/PCM connector terminal E5. Is there about 5 V? YES - Replace the FTP sensor. NO - Go to step 71. 71. Turn the ignition switch OFF. 72. Disconnect ECM/PCM connector E (31P). 73. Check for continuity between ECM/PCM connector terminal E5 and body ground. Is there continuity? YES - Repair short in the wire between the ECM/PCM (E5) and the FTP sensor. NO - Update the ECM/PCM if it does not have the latest software, or substitute a known-good ECM/PCM, then recheck. If the symptom/indication goes away with a known-good ECM/PCM, replace the original ECM/PCM. 74. Turn the ignition switch OFF. 75. Turn the ignition switch ON (II). 76. Measure voltage between ECM/PCM connector terminal E29 and body ground. Is there about 5 V (or battery voltage)? YES - Go to step 80. Page 4778 Power Distribution schematics show how power is supplied from the positive battery terminal to various circuits in the vehicle. Refer to the Power Distribution diagram set to get a more detailed understanding of how picture is supplied to the circuit you're working on. Individual circuit schematics begin with a fuse. So 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 Ground Distribution Schematics This sample Ground Distribution schematic shows all of the components that share the same ground point. Page 6190 Power Steering Pump: Service and Repair Overhaul Overhaul Replace the pump as an assembly if the parts indicated with asterisk (*) are worn or damaged. Special Tools Required ^ Attachment, 32 x 35 mm 07746-0010100 ^ Driver 07749-0010000 ^ Pulley holder 07ZAB-S5A0100 Disassembly NOTE: Refer to the Exploded View as needed during the following procedure. 1. Remove the power steering pump. 2. Drain the fluid from the pump. Page 8368 Keyless Entry Module: Testing and Inspection Control Unit Input Test 1. Before testing, troubleshoot the multiplex control system. 2. Remove the dashboard lower cover. 3. Disconnect the under-dash fuse/relay box connectors. NOTE: All connectors are wire side of female terminals. 4. Inspect the connector and socket terminals to be sure they are all making good contact. - If the terminals are bent, loose or corroded, repair them as necessary, and recheck the system. - If the terminals look OK, go to step 5. Page 3291 Vehicle Speed Sensor: Testing and Inspection Vehicle Speed Signal Circuit Troubleshooting Special Tools Required: Test Harness 07LAJ-PT3020A Before testing, inspect the No.4 (10 A) and No.10 (7.5 A) fuses in the under-dash fuse/relay box. 1. Disconnect the 3P connector from the vehicle speed sensor (VSS) (A). 2. Connect the test harness only to the engine wire harness. 3. Connect the RED test harness clip (B) to the positive probe of an ohmmeter. Cover the white (C) and green (D) test harness leads with protective tape (E). 4. Check for continuity between the RED test harness clip and body ground. Is there continuity? YES - Go to step 5. NO - Repair open in the BLK wire between the VSS and G101. 5. Connect the WHT test harness clip (B) to the positive probe of a voltmeter, and connect the RED test harness clip (C) to the negative probe. 6. Turn the ignition switch ON (II). Is there battery voltage? YES - Go to step 7. NO - Repair open in the BLK/YEL wire between the VSS and the under-dash fuse/relay box. 7. Disconnect the WHT test harness clip (B). Page 4639 Shift Interlock Solenoid: Service and Repair Shift Lock Solenoid Replacement 1. Remove the center console panel and center console. 2. Disconnect the shift lock solenoid connector (2P), and remove it from the shift lever bracket base. 3. Push the lock tab (A), pry the shift lock solenoid (B) to clear the projected tips (C) with a screwdriver, and remove the shift lock solenoid. 4. Install the shift lock solenoid plunger (D) and plunger spring (E) in the new shift lock solenoid. 5. Install the shift lock solenoid by aligning the joint (F) of the shift lock solenoid plunger with the tip (G) of the shift lock stop. 6. Connect the shift lock solenoid connector, and install it on the shift lever bracket base. 7. Install the center console and console panel. Specifications Valve Clearance: Specifications Valve Clearance Intake ................................................................................................................................................... ...................... 0.18 - 0.22 mm (0.007 - 0.009 inch) Exhaust ............................................................... ....................................................................................................... 0.23 - 0.27 mm (0.009 - 0.011 inch) Page 5238 Circuit Schematics Each schematic represents one circuit. A circuit's wires and components are arranged to show current flow from power at the top of the diagram 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 Recall - Ignition/Shift Interlock Defect Technical Service Bulletin # 10-059 Date: 101001 Recall - Ignition/Shift Interlock Defect 10-059 October 1, 2010 Applies To: See VEHICLES AFFECTED Safety Recall: Accord, Civic, and Element Ignition Switch Key Interlock BACKGROUND Under certain conditions, the interlock lever of the ignition switch may unexpectedly deform. The interlock ensures the transmission is in Park before the ignition key can be removed. Interlock failure may allow the ignition key to be removed when the shift lever is not in Park. If the driver fails to engage the parking brake, the vehicle could roll away, increasing the risk of a crash. VEHICLES AFFECTED Not all vehicles within the VIN ranges are affected by this recall. Before beginning work on a vehicle, verify its eligibility by checking at least one of these items: ^ The customer has a notification letter. Page 4318 Shifter A/T: Service and Repair Shift Lever Installation Shift Lever Installation 1. Install the shift lever assembly. 2. Connect the shift lock solenoid connector (2P) (A) and park pin switch connector (4P) (B). 3. Turn the ignition switch ON (II), and verify that the N position indicator comes on. 4. Install the shift cable to the shift lever. If necessary, adjust the shift cable. Page 2041 Resistor Variable Sensor Solenoid Transistors Circuit Schematics Page 6132 TOOL INFORMATION Centering Tape (enough to diagnose 240 vehicles): T/N O7AAJ-001A300 Steering Drift Set Level: T/N 07AAJ-00100 Steering Drift Set: T/N O7MJ-001A140 Replacement Weight for Steering Drift Set: T/N 07AAJ-001A400 WARRANTY CLAIM INFORMATION In warranty: The normal warranty applies. Failed Part: P/N 53560-SDA-AO1 H/C 7139652 Defect Code: 07406 Symptom Code: 03602 Skill Level: Repair Technician Diagnostic Trouble Code: To create the 15-digit DTC, see the applicable repair procedure. Out of warranty: Any repair performed after warranty expiration may be eligible for goodwill consideration by the District Parts and Service Manager or your Zone Office. You must request consideration, and get a decision, before starting work. TOOL DESCRIPTIONS The holding force gauge measures the amount of pull on the vehicle. It is a bracket that counts as one weight, plus five removable weights. Locations VTEC - Component Location Index Page 4029 72. Shift Lock Solenoid (A/T) Page 4766 Shift Indicator: Locations Continuously Variable Transmission Component Location Index Page 3452 Fuel Supply Line: Testing and Inspection Fuel Line Inspection Part 1 Page 5886 234. Under-dash Fuse/Relay Box Part 5 Page 4058 6. Install the speedometer drive gear (A) with its chamfered side facing the carrier. 7. Align the hooked end (B) of the snap ring (C) with the spring pin (D) in the pinion shaft (E), then install the snap ring in the differential carrier groove. Final Driven Gear Replacement 1. Remove the final driven gear from the differential carrier. The final driven gear bolts have left-hand threads. 2. Install the final driven gear with the chamfered side on the inner bore (A) facing the differential carrier. 3. Tighten the bolts to 103 Nm (10.5 kgf-cm, 75.9 ft. lbs.) in a crisscross pattern. Carrier Bearing Replacement Special Tools Required Driver 40 mm I.D. 07746-0030100 1. Remove the bearings (A) with a commercially available bearing puller (B) and stepper adapter (C). Page 5717 Wires Page 3017 Camshaft Position Sensor: Service and Repair CMP (TDC) Sensor Replacement 1. Remove the grommet (A) from the upper cover, and disconnect the camshaft position (CMP) (top dead center (TDC)) sensor connector (B). 2. Remove the upper cover (C). 3. Remove the CMP (TDC) sensor from the cylinder head. 4. Install the CMP (TDC) sensor in reverse order of removal. Page 4182 Page 805 Circuit Schematics Each schematic represents one circuit. A circuit's wires and components are arranged to show current flow from power at the top of the diagram 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 Removal and Installation Engine Control Module: Service and Repair Removal and Installation How to Remove the ECM/PCM for Testing 1. Remove the passenger's dashboard lower cover, the right kick panel, and the glove box. 2. Remove the bolt. Cut the plastic cross brace in the glove box opening with diagonal cutters in the area shown, and discard it. 3. Remove the relays (A), then remove the bolts and the glove box frame (B). 4. Remove the gray 20P ECM/PCM wire harness connector from the ECM/PCM mounting bracket. Remove the ECM/PCM mounting bolt (A) and the bracket. 5. Remove the nuts, then remove the ECM/PCM (B). 6. Install the ECM/PCM in the reverse order of removal. Pressure Plate and Clutch Disc Removal Clutch Release Bearing: Service and Repair Pressure Plate and Clutch Disc Removal Clutch Replacement Special Tools Required ^ Clutch alignment shaft 07LAF-PT00110 ^ Clutch alignment disc 07JAF-PM7011A ^ Remover handle 07936-3710100 ^ Ring gear holder 07LAB-PV00100 or 07924-PD20003 ^ Attachment, 57 x 40 mm 07746-0010200 ^ Driver 077 49-0010000 Pressure Plate and Clutch Disc Removal 1. Check the diaphragm spring fingers for height using the special tools and a feeler gauge (A). If the height is more than the service limit, replace the pressure plate. Standard (New): 0.6 mm (0.02 inch) max. Service Limit: 1.0 mm (0.04 inch) 2. Install the special tools. 3. To prevent warping, unscrew the pressure plate mounting bolts (A) in a crisscross pattern in several steps, then remove the pressure plate (B). Diagram Information and Instructions Variable Valve Timing Actuator: Diagram Information and Instructions Terminal Numbering System Terminal Numbering System Connector terminals are numbered according to the cavities they're in. The cavities are numbered starting from the upper left, looking at the male terminals from the terminal side or looking at the female terminals from the wire side. Both views are in the same direction so the numbers are the same. All actual cavities are numbered, even if they have no wire terminals in them. NOTE: Data Link Connector (DLC) terminals are numbered according 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 below is #6. Page 4984 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 Short Circuit Locator (Short Finder) 1. Remove the blown fuse. Leave the battery connected. Page 8289 13. Push the top of the retainer clip with a flat-tip screwdriver, and hold it. Release the retainer clip with a hook-shaped tool, then remove the lock cylinder. Go to step 14. 14. With the door lock cylinder out of the door handle remove the E-clip and the arm. 15. Try to insert the key into the cylinder and turn it. ^ If you can insert and turn the key, go to step 18. ^ If you cannot insert the key or turn it, go to step 16. 16. Carefully remove the spring and plastic retainer. Page 1049 Shift Interlock Switch: Service and Repair Park Pin Switch Replacement 1. Remove the center console panel and center console. 2. Remove the screws (A), then remove the shift lever knob (B) 3. Remove the A/T gear position indicator panel light (c) from the A/T gear position indicator panel. 4. Remove the A/T gear position indicator panel and panel bracket as an assembly (D). 5. Disconnect the park pin switch connector (4P) (E), and remove it from the shift lever bracket base (F). 6. Remove the shift lock release (G) and spring (H). 7. Open the lock tabs (A) on the shift lever bracket base, then remove the park pin switch (B). 8. Install the new park pin switch. 9. Install the removed parts in the reverse order of removal. Page 8598 9. Open the jaws with the jaws knob, and slide the original key with its flat side down into the center jaw up to the key stop. Slide the key blank with its flat side down into the right jaw up to the key stop. Close the jaws with the jaws knob to lock the keys into place. Visually inspect both keys for proper alignment in the jaws. 10. Loosen the lateral and spring tension adjustment knobs on the clamp carriage. With the clamp carriage lever, adjust the clamp carriage to position the tracer and the cutter bit over the middle of the two locked key blades. Tighten only the spring tension knob when done. NOTE: The clamp carriage has a spring system that puts lateral pressure on the tracer and cutting bit to make it easier to cut sidewinder-type keys. Do not tighten the lateral tension adjustment knob. This knob should be left loose. 11. Turn on the cutter motor with the motor start switch. [NOTICE] ^ To avoid damaging the locking jaws while cutting, keep your hand off the vertical carriage lever. Pressure on the lever will change the cutting depth. * ^ To avoid breaking the cutter bit, never back up while cutting.* ^ Wear proper eye protection (safety glasses, goggles, etc.) Page 4028 107. Behind A/T Shift Lever (except M/T) Page 9150 8. Inspect the quality of the wire crimp. If it has any of the following NO GOOD crimps, cut it off and start over. 9. Insert the terminal into the connector. Make sure the wire seals are pushed all the way into the connector. Lightly pull on the wires to make sure the terminal is locked into place. 10. Close or insert the secondary terminal lock, if applicable, and reconnect the connector. How to Install Pigtail Terminals HOW TO INSTALL PIGTAIL TERMINALS Pigtail terminals (short pieces of wire with a factory crimped terminal) are used when the wire is too short or when access to the connector is too restricted to make a terminal repair. NOTE: To replace just a connector terminal, go to How to Replace Connector Terminals. IMPORTANT SAFETY INFORMATION: On some models, the SRS wires are in a separate harness. If the SRS harness is damaged, replace the harness; do not repair it. On other models, wire harnesses include yellow SRS wires. If any SRS wire is damaged, replace the entire harness; do not repair it. 1. Remove the damaged or faulty terminal from the connector. Use the proper removal tool from Pin Tool Set. Locations Intake Air System - Component Location Index Page 7627 13. After completing the right edge, push all of the cam blades to the right until they touch the cams, then trace the cam blades from back to front. (The cutter bit cuts the same contours into the left edge of the key from tip to head.) Turn off the cutter motor. 14. Release the vertical carriage lever. Push all the cam blades to the left until they touch the cams. Pull the vertical carriage lever towards you until the tracer touches the flat surface on the right side, at the front of the cams. Gently twist the lever clockwise to lock the vertical carriage at this height. Do not overtighten the lever. 15. Turn on the cutter motor, then retrace the cam blades from front to back. Push all the cam blades to the right until they touch the cams, and then retrace the cam blades from back to front (retracing cleans up the cuts on the key). Turn off the cutter motor. 16. Release the vertical carriage lever. Open the jaw and remove the key. Make sure the jaw is free of any metal shavings or debris. Turn the key over so the blank side is up, then slide it into the jaw up to the key stop. Close the jaw to lock the key in place. 17. Push all the cam blades to the left until they touch the cams. Repeat steps 10 through 15 to cut both edges on the other side of the key. 18. When you are done making the required cuts, release the vertical carriage lever. Open the jaw and remove the key. 19. Make sure the key works in the ignition switch and the locks. If the key does not work, recut the key, and try it again. 20. Depending on the type of key, code the key transponder. Equipment Service and Warranty To service the MATRIX H Key Cutting Machine, refer to section 7 of the MATRIX H Operating Manual. It tells you how to replace parts that commonly wear out such as the drive belt, the work light bulb, and the tension spring on the vertical carriage. It also covers checking and replacing fuses and replacing the printed circuit board for the setting unit keypad. If you have technical questions on the equipment, contact the Ilco Technical Assistance Department. Mail: Kaba Ilco Technical Assistance Department 400 Jeffreys Road Rocky Mount, NC 27804 Phone: 800-452-6872 Ext: 200, 384, 323, 398, 356 Fax: 252-446-4702 The MATRIX H Key Cutting Machine comes with a 3-year limited warranty. This warranty does not cover the cutter bit or the work light bulb. CODE BOOK CORRECTIONS In the code book Honda High Security key Codes, correct these errors: Pages 4 thru 51, code headings: ^ Incorrect: J H G F Z X E D C B M/S X ^ Correct: J H G F A X E D C B M/S X Page 2, last paragraph: Page 7883 3. Using an O-ring pick or similar tool, pull up the outer edge of the molding, and apply 3M Black Super Silicone Sealant under it, along the A-pillars and the upper edge of the windshield. 4. Push down on the molding, and smooth it out until it sits flush with the roof. 5. Wait 5 minutes, then remove the masking tape. 6. Clean up any excess sealant with 3M General Purpose Adhesive Cleaner. Disclaimer Locations Power Steering Pressure Switch: Locations Idle Control System - Component Location Index 34. Left Side Of Engine Compartment Page 4390 1. Remove the terminal. 2. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE G: 1. Remove the terminal. 2. Go to HOW TO INSTALL NEW TERMINALS. How to Install New Terminals HOW TO INSTALL NEW TERMINALS 1. Carefully match the old terminal with a new one from the terminal repair kit. Choose the correct replacement terminal based on the wire size range the terminal will accommodate. NOTE: If the replacement terminal quantities are low, reorder them by using the terminal part number listed on the inside lid of the terminal repair kit. Replacement terminals are available through your parts department using normal parts ordering procedures. 2. Depending on the size of the wire you are repairing, use the proper size slot in the crimping tool. Page 8300 *T-5 Sidewinder Key Applications ^ 2003-05 Civic ^ 2004-05 Civic Hybrid ^ 2003-05 Civic GX (CNG) ^ 2004-05 S2000 ^ 2002-06 CR-V ^ 2003-06 Element ^ 2003-04 Odyssey ^ 2003-04 Pilot Ordering Honda key blanks through normal parts ordering channels: Refer to the parts catalog for correct key(s) for your application. PROGRAMMING KEYS Depending on the type of key blank you use, do this: ^ If you have used a T-5 programmable key blank ("T-5" stamped on the shank), you must code the key's transponder with the Ilco Immobilizer Key Code Duplicator (see S/B 99-053, Ilco Immobilizer key Code Duplicator). ^ If you have used a Honda key blank, add the* transponder code of the new key to the immobilizer system with the Honda Diagnostic System (HDS). ORDERING INFORMATION *To order the MATRIX H Key Cutting Machine, replacement cutter bits, fixed jaws and mobile jaws, T-5 programmable key blanks, and practice key blanks, contact the Honda Tool and Equipment Program by calling 888-424-6857 or using the fax order form provided in your Honda Tool and Equipment Program Catalog.* Order Honda key blanks through normal parts ordering channels. WARRANTY CLAIM INFORMATION None. This service bulletin is for information only. *DETERMINING WHICH KEY TO USE T-5 keys require less time to program and should be the first choice. They can be used as long as the following requirements are met: ^ Do you have the customer's operating key? ^ Does the vehicle fall within the T-5 Sidewinder Key Applications? ^ Does your dealership have an Ilco Immobilizer Key Code Duplicator? If the answer to all three questions on the above is yes, the 1-5 key option is the easier procedure. If you answered no to any of the questions, you should order the key(s) from the parts catalogue, and program it using the HDS.* BEFORE YOU START CUTTING 1. Get the original key or the key number from your customer or from the iN. 2. Get the applicable key blank. 3. If cutting by code, look up the applicable 9-digit cutting code for the key number. Refer to the code book Honda High Security key Codes that comes with the machine. Page 8333 Paint: Service Precautions General Safety Precaution - Most paints contain substances that are harmful if inhaled or swallowed. - The fallowing precautions are important items in order to maintain safe painting work. 1. Wear an approved respirator, and eye protection when painting. 2. Wear approved gloves, and appropriate clothing when painting. Avoid contact with skin. 3. Spray paint only in a well ventilated area. 4. Read the paint label before opening the container. Cover spilled paint with sand, or wipe it up at once. 5. If paint gets in your mouth or your skin, rinse or wash thoroughly with water. If paint gets in your eyes, flush with water and get prompt medical attention. 6. After the painting work is finished, wash your face and gargle with water. 7. Paint is flammable. Store it in a safe place, and keep it away from sparks, flames, or cigarettes. Page 1720 10. Measure cam lobe height. Page 9263 PGM-F1 Main Relay 1, 2 Type 1, 2 Check for continuity between the terminals. - There should be continuity between the No.1 and No.2 terminals when power and ground are connected to the No.3 and No.4 terminals. - There should be no continuity between the No.1 and No.2 terminals when power is disconnected. Normally-open type B: Rear Window Defogger Relay Locations Power Window Relay: Locations Relay And Control Unit Locations - Dashboard Page 2520 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. Below most connector numbers and component names are PHOTO and VIEW numbers. The PHOTO number refers to a photo in the back of the book that shows the connector's location on the car. The VIEW number refers to an illustration in the back of the book that shows the connector terminals, wire colors, connector cavity numbers, and other details. The connector cavity numbering sequence begins at the top left corner of the connector as seen from either of the viewpoints shown on diagram [8] . Except for the DLC (data link 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 C554, for example, means those terminals join in cavity 2 of connector C554. Power Distribution Schematics Power Distribution Schematics Page 567 Oil Pressure Sender: Testing and Inspection Oil Pressure Switch Test 1. Remove the YEL/RED wire (A) from the engine oil pressure switch (B). 2. Check for continuity between the positive terminal (C) and the engine (ground). There should be continuity with the engine stopped. There should be no continuity with the engine running. 3. If the switch fails to operate, check the engine oil level. If the engine oil level is OK, check the engine oil pressure. If the oil pressure is OK, replace the oil pressure switch. Page 6195 33. Place the side plate (A) on the cam ring with its "^" mark (B) facing upward, and align the roll pin set hole (C) in the side plate with the roll pin end (D). 34. Coat the new O-ring (F) with the power steering fluid, then position it into the groove on the side plate. 35. Install the pump housing (A) over the cover assembly (B). 36. Align the bolt holes in the cover (B) with the threaded holes in the pump housing. Install the five flange bolts (C) loosely first, then torque the flange bolts in 2 or more steps with sequence shown. Page 1574 Relay Box: Diagrams 234. Under-dash Fuse/Relay Box Part 1 Page 9489 Interior Lighting Module: Diagnostic Aids General Troubleshooting Information General Troubleshooting Information Tips and Precautions Before Troubleshooting 1. Check applicable fuses in the appropriate fuse/relay box. 2. Check the battery for damage, state of charge, and clean and tight connections. NOTE: 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. Handling Connectors - Make sure the connectors are clean and have no loose wire terminals. - Make sure multiple cavity connectors are packed with dielectric grease (except watertight connectors). - All connectors have push-down release type locks (A). - Some connectors have a clip on their side used to attach them to a mount bracket on the body or on another component. This clip has a pull type lock. - Some mounted connectors cannot be disconnected unless you first release the lock and remove the connector from its mount bracket (A). - Never try to disconnect connectors by pulling on their wires; pull on the connector halves instead. - Always reinstall plastic covers. Page 6076 Under-hood Fuse/Relay Box Page 4275 Page 2090 Idle Speed: Testing and Inspection Idle Speed Inspection NOTE: - Leave the Idle Air Control (IAC) valve connected. - Before checking the idle speed, check these items: The Malfunction Indicator Lamp (MIL) has not been reported on. - Ignition timing - Spark plugs - Air cleaner - PCV system - On Canadian models, pull the parking brake lever up, start the engine, then check that the headlights are off. 1. Disconnect the Evaporative Emission (EVAP) canister purge valve 2P connector. 2. Connect a tachometer. 3. Start the engine. Hold the engine at 3,000 rpm with no load (in neutral) unit the radiator fan comes on, then let it idle. 4. Check the idle speed with no-load conditions: headlights, blower fan, radiator fan, and air conditioner are not operating. 5. Idle the engine for 1 minute with the heater fan switch on HI and air conditioner on, then check the idle speed. NOTE: If the idle speed is not within specification, see the Symptom Chart. 6. Reconnect the EVAP canister purge valve 2P connector. Page 5553 NOTE: You need to make the corrections listed in CODE BOOK CORRECTIONS at the end of this service bulletin. TRACER AND CUTTER BIT INSTALLATION 1. Turn the power switch on the back of the machine to ON. (This turns on the built-in work light.) 2. Use the Allen wrench from the built-in tool drawer to loosen the setscrew on the left sleeve of the vertical carriage. Slide the tracer all the way into the sleeve, and tighten the screw. 3. Turn the plastic shield on the right sleeve of the vertical carriage so you can access the setscrew on the sleeve. Use the Allen wrench to loosen the screw. Slide the cutter bit all the way into the sleeve, and tighten the screw. Turn the plastic shield so the open side is in the back. MACHINE COMPONENTS Page 4158 1. Remove and discard the plastic cover from the ignition switch key interlock solenoid. 2. Note the position of the interlock solenoid plunger; you'll need to install it the same way. 3. Remove the screw from the solenoid, but keep the solenoid attached to its electrical connector. Discard the screw. NOTE: ^ Be careful not to lose the solenoid plunger; it slides out easily. ^ Keep the plunger free of dirt and grease while it's removed from the solenoid. 4. Note the position of the interlock lever spring; you'll need to install the new spring the same way. Technician Safety Information Air Bag(s) Arming and Disarming: Technician Safety Information Technician Safety Information Page 4929 Page 5971 69. Under Left Side Of Dash Page 9276 Horn Relay: Testing and Inspection Power Relay Test Use this chart to identify the type of relay, then do the test listed for it. NOTE: See the turn signal/hazard relay input test. Normally-open type A: Page 1175 127. Left Rear Door (Sedan Except DX) (Right Similar) Page 6060 Relay And Control Unit Locations - Engine Compartment Page 7764 1. Check the depth adjustment of the trunk lid: ^ Refer to page 20-132 of the 2001-04 Civic Service Manual. ^ In ISIS, use the keyword TRUNK ADJUST, and select Trunk Lid Adjustment from the list. 2. Make sure the trunk lid is flush on all sides and corners. ^ If the trunk is misaligned, go to step 3. ^ If the trunk lid is properly aligned on all sides and corners, go to REPAIR PROCEDURE C. 3. Adjust the striker depth position and the trunk lid edge cushions: ^ Refer to page 20-132 of the 2001-04 Civic Service Manual. ^ In ISIS, use the keyword TRUNK ADJUST, and select Trunk Lid Adjustment from the list. 4. Check the trunk operation: ^ If the trunk opens and closes smoothly, return the vehicle to the customer. ^ If the trunk lid is still difficult to close, go to REPAIR PROCEDURE C. REPAIR PROCEDURE C 1. Use a small screwdriver to manually set and release the trunk lid latch. Check the operation of the latch: ^ If the latch is difficult to set or release, go to step 2. ^ If the latch operates properly, go to REPAIR PROCEDURE D. 2. Replace the trunk lid latch: ^ Refer to page 20-157 of the 2001-04 Civic Service Manual. ^ In ISIS, use the keyword LID LATCH, and select Trunk Lid Latch Replacement from the list. 3. Check the trunk operation: ^ If the trunk opens and closes smoothly, return the vehicle to the customer. ^ If the trunk lid is still difficult to close, go to REPAIR PROCEDURE D. REPAIR PROCEDURE D 1. Disconnect the trunk lid opener cable from the trunk lid latch. Check the cable operation: ^ Refer to page 20-157 of the 2001-04 Civic Service Manual. ^ In ISIS, use the keyword LID LATCH, and select Trunk Lid Latch Replacement from the list. 2. Check that there is no friction or binding of the cable by holding the outside casing and pulling back and forth on the inner cable: ^ If the cable is difficult to move or binds, go to step 3. ^ If the cable operates smoothly, go to REPAIR PROCEDURE E. 3. Replace the trunk lid opener cable: ^ Refer to page 20-151 of the 2001-04 Civic Service Manual. ^ In ISIS, use the keyword LID OPEN, and select Trunk Lid Opener/Fuel Fill Door Opener Cable Replacement from the list. 4. Check the trunk operation: Page 5803 Ground To Components Index (2-door) Page 2837 1. Remove the terminal. 2. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE G: 1. Remove the terminal. 2. Go to HOW TO INSTALL NEW TERMINALS. How to Install New Terminals HOW TO INSTALL NEW TERMINALS 1. Carefully match the old terminal with a new one from the terminal repair kit. Choose the correct replacement terminal based on the wire size range the terminal will accommodate. NOTE: If the replacement terminal quantities are low, reorder them by using the terminal part number listed on the inside lid of the terminal repair kit. Replacement terminals are available through your parts department using normal parts ordering procedures. 2. Depending on the size of the wire you are repairing, use the proper size slot in the crimping tool. Page 3412 Fuel Injector: Service and Repair Injector Replacement 1. Relieve the fuel pressure. 2. Remove the air cleaner. 3. Disconnect the connectors from the injectors (A), the manifold absolute pressure (MAP) sensor (B), the evaporative emissions (EVAP) canister purge valve (C), and the throttle position (TP) sensor (D). 4. Disconnect the quick-connect fittings (E). 5. Disconnect the hoses from the fuel rail (F). 6. Remove the fuel rail mounting nuts (G) from the fuel rail. 7. Remove the injector clip (H) from the injector. 8. Remove the injector from the fuel rail. 9. Coat the new O-rings (A) with clean engine oil, and insert the injectors (B) into the fuel rail (C). 10. Install the injector clip (D). 11. Coat the injector O-ring (E) with clean engine oil. Page 2928 Power Steering Pressure Signal: Service and Repair Power Steering Hoses, Lines, and Pressure Switch Replacement Note these items during installation: ^ Connect each hose to the corresponding line securely until it contacts the stop on the line. Install the clamp or adjustable clamp at the specified distance from the hose end as shown. ^ Check all clamps for deterioration or deformation; replace the clamps with new ones, if necessary. ^ Add the recommended power steering fluid to the specified level on the reservoir and check for leaks. Page 5305 10. Connect the connector securely, then install the transmission range switch shaft cap (A). 11. Turn the ignition switch ON (II). Move the shift lever through all gear positions, and check the transmission range switch is synchronization with the A/T gear position indicator. 12. Raise the vehicle, and make sure it is securely supported. 13. Allow the wheels to rotate freely, then start the engine. 14. Move the shift lever through all gear positions, and verify the following: ^ The engine will not start in any position other than N or P. ^ The back-up lights come on when the shift lever is in the R position. Locations Pressure Regulating Solenoid: Locations Electronic Controls Location Page 9291 Wires Page 5493 Vacuum Brake Booster: Adjustments Brake Booster Pushrod Clearance Adjustment Special Tools Required Pushrod adjustment gauge 07JAG-SD40100 NOTE: Brake booster pushrod-to-piston clearance must be checked and adjustments made, if necessary, before installing the master cylinder. 1. Set the special tool (A) on the master cylinder body (B), push in the center shaft (C) until the top of it contacts the end of the secondary piston (D) by turning the adjusting nut (E). 2. Without disturbing the center shaft's position, install the special tool (A) backwards on the booster. 3. Install the master cylinder nuts (B), and tighten to the specified torque. 4. Connect the booster in-line with a vacuum gauge (C) 0 - 101 kPa (0 - 760 mm Hg, 30 inch Hg) to the booster's engine vacuum supply, and maintain an engine speed that will deliver 66 kPa (500 mm Hg, 20 inch Hg) vacuum. 5. With a feeler gauge (A), measure the clearance between the gauge body and the adjusting nut (B) as shown. If the clearance between the gauge body and the adjusting nut is 0.4 mm (0.02 inch), the pushrod-to-piston clearance is 0 mm. However, if the clearance between the gauge body and the adjusting nut is 0 mm, the pushrod-to-piston clearance is 0.4 mm (0.02 inch) or more. Therefore it must be adjusted and rechecked. Clearance: 0 - 0.4 mm (0 - 0.0015 inch) Page 4177 5. Attach the slide hammer to the interlock lever pin, and tighten the slide hammer clamping bolt. Then use the slide hammer to remove the pin. Discard the pin, the lever, and the spring. 6. Wipe off any debris from the lever's sliding surface on the ignition switch with a clean cloth or a cotton swab. NOTE: To keep debris out of the ignition switch, do not clean it with compressed air. 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 4164 Page 2741 111. ELD Unit (USA) Page 8279 1. Check the depth adjustment of the trunk lid: ^ Refer to page 20-132 of the 2001-04 Civic Service Manual. ^ In ISIS, use the keyword TRUNK ADJUST, and select Trunk Lid Adjustment from the list. 2. Make sure the trunk lid is flush on all sides and corners. ^ If the trunk is misaligned, go to step 3. ^ If the trunk lid is properly aligned on all sides and corners, go to REPAIR PROCEDURE C. 3. Adjust the striker depth position and the trunk lid edge cushions: ^ Refer to page 20-132 of the 2001-04 Civic Service Manual. ^ In ISIS, use the keyword TRUNK ADJUST, and select Trunk Lid Adjustment from the list. 4. Check the trunk operation: ^ If the trunk opens and closes smoothly, return the vehicle to the customer. ^ If the trunk lid is still difficult to close, go to REPAIR PROCEDURE C. REPAIR PROCEDURE C 1. Use a small screwdriver to manually set and release the trunk lid latch. Check the operation of the latch: ^ If the latch is difficult to set or release, go to step 2. ^ If the latch operates properly, go to REPAIR PROCEDURE D. 2. Replace the trunk lid latch: ^ Refer to page 20-157 of the 2001-04 Civic Service Manual. ^ In ISIS, use the keyword LID LATCH, and select Trunk Lid Latch Replacement from the list. 3. Check the trunk operation: ^ If the trunk opens and closes smoothly, return the vehicle to the customer. ^ If the trunk lid is still difficult to close, go to REPAIR PROCEDURE D. REPAIR PROCEDURE D 1. Disconnect the trunk lid opener cable from the trunk lid latch. Check the cable operation: ^ Refer to page 20-157 of the 2001-04 Civic Service Manual. ^ In ISIS, use the keyword LID LATCH, and select Trunk Lid Latch Replacement from the list. 2. Check that there is no friction or binding of the cable by holding the outside casing and pulling back and forth on the inner cable: ^ If the cable is difficult to move or binds, go to step 3. ^ If the cable operates smoothly, go to REPAIR PROCEDURE E. 3. Replace the trunk lid opener cable: ^ Refer to page 20-151 of the 2001-04 Civic Service Manual. ^ In ISIS, use the keyword LID OPEN, and select Trunk Lid Opener/Fuel Fill Door Opener Cable Replacement from the list. 4. Check the trunk operation: Page 6108 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 5904 Terminals - "T" Shielding Switches Fuses Page 7551 Front Door Window Motor: Connector Locations 123. Driver's Door (Coupe exc. DX, HX; Sedan exc. DX) 123. Driver's Door (Coupe Exc. DX, HX; Sedan Exc. DX) Page 4398 Transmission Position Switch/Sensor: Electrical Diagrams Circuit Diagram Page 6154 Power Steering Pressure Switch: Description and Operation Power Steering Pressure (PSP) Switch The PSP switch signals the ECM/PCM when the power steering load is high. Page 7312 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 5783 Relay And Control Unit Locations - Engine Compartment Page 4220 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. How to Replace Connector Terminals Terminal Replacement Procedure HOW TO REPLACE CONNECTOR TERMINALS The terminal repair kits provide necessary tools and materials (terminals, wire seals, and splice connectors) to repair many damaged or faulty connector terminals. However, not all terminals for all connectors are available. Refer to the labels on the lids of the repair kits for replacement terminal availability. IMPORTANT SAFETY INFORMATION: On some models, the SRS wires are in a separate harness. If the SRS harness is damaged, replace the harness; do not repair it. On other models, wire harnesses include yellow SRS wires. If any SRS wire is damaged, replace the entire harness; do not repair it. Before you begin, inspect the wire you are about to repair for damage and length. Make sure the wire will be long enough to make a terminal repair without stretching it when you reinstall the terminal in the connector. If the wire is too short, or if access to the connector is too restricted to make a terminal repair, you may need to install a pigtail terminal (a short length of wire with a factory-crimped terminal on it). Refer to HOW TO INSTALL PIGTAIL TERMINALS. Removing the Terminal Page 9406 1. Remove the terminal. 2. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE B: 1. Remove the terminal. 2. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE C: 1. Remove the terminal. 2. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE D: Page 757 Manifold Pressure/Vacuum Sensor: Description and Operation Manifold Absolute Pressure (MAP) Sensor The MAP sensor converts manifold absolute pressure into electrical signals to the ECM/PCM. Page 7696 WARRANTY CLAIM INFORMATION In warranty: The normal warranty applies. Failed Part: P/N 68500-S5P-A90ZZ H/C 6528640 *Defect Code: 07406* Symptom Code: 03220 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 A 1. Check the side-to-side alignment of the trunk lid latch to the striker: ^ Refer to page 20-132 of the 2001-04 Civic Service Manual. ^ In ISIS, use the keyword TRUNK ADJUST, and select Trunk Lid Adjustment from the list. 2. Make sure the gaps of the trunk lid are even on all sides. ^ If the trunk is misaligned, go to step 3. ^ If the trunk lid is properly aligned on all sides, go to REPAIR PROCEDURE B. 3. Adjust the trunk lid hinges: ^ Refer to page 20-132 of the 2001-04 Civic Service Manual. ^ In ISIS, use the keyword TRUNK ADJUST, and select Trunk Lid Adjustment from the list. 4. Check the trunk operation: ^ If the trunk opens and closes smoothly and is properly aligned, return the vehicle to the customer. ^ If the trunk lid is still difficult to close, go to REPAIR PROCEDURE B. REPAIR PROCEDURE B Page 6761 2. Disconnect the side airbag harness 2P connector (A). 3. Remove the seat assembly and seat-back cover. 4. Remove the mounting nut (A) and the side airbag (B). Installation NOTE: - If the side airbag lid is secured by a tape, remove the tape. - Do not open the lid of the side airbag cover. - Use new mounting nuts tightened to the specified torque when you replace a side airbag. - Make sure that the seat-back cover is installed properly. Improper installation may prevent proper deployment. - Be sure to install the harness wires so that they are not pinched or interfering with other parts. 1. Place the new side airbag on the seat back-frame (A). Tighten the side airbag mounting nuts (B). 2. Install the seat-back cover. 3. Install the seat assembly, then connect the side airbag harness 2P connector. 4. Move the front seat and the seat-back through their full ranges of movement, making sure the harness wires are not pinched or interfering with Page 213 Under-dash Fuse/Relay Box Page 7814 24. Remove the key. Reinstall the retainer clip in the door handle, and push the lock cylinder into place. 25. Civic: Reconnect the cylinder rod. 26. CR-V: Reconnect the cylinder rod, the outer handle rod, and the rod protector. 27. Element: Reconnect the cylinder rod, the outer handle rod, and the access seal. Reinstall the lower run channel. 28. Reinstall the plastic covering, and lower the window glass. Install the door panel. 29. Check that the door lock and handle operate smoothly. Disclaimer Connector Views Engine Control Module: Connector Views 228. ECM/PCM Part 1 228. ECM/PCM Part 2 Page 4031 Shift Interlock Solenoid: Service and Repair Shift Lock Solenoid Replacement 1. Remove the center console panel and center console. 2. Disconnect the shift lock solenoid connector (2P), and remove it from the shift lever bracket base. 3. Push the lock tab (A), pry the shift lock solenoid (B) to clear the projected tips (C) with a screwdriver, and remove the shift lock solenoid. 4. Install the shift lock solenoid plunger (D) and plunger spring (E) in the new shift lock solenoid. 5. Install the shift lock solenoid by aligning the joint (F) of the shift lock solenoid plunger with the tip (G) of the shift lock stop. 6. Connect the shift lock solenoid connector, and install it on the shift lever bracket base. 7. Install the center console and console panel. Page 7207 Page 3829 1. Remove the secondary lock from the male terminal half. 2. Remove the secondary lock from the female terminal half. 3. Remove the terminal (same procedure for male and female). 4. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE C: 1. Remove the secondary lock. Page 9004 Splices Components Ground - "G" Page 3879 Transmission Position Switch/Sensor: Testing and Inspection Transmission Range Switch Test Transmission Range Switch Test 1. Remove the transmission range switch harness connector (A) from the connector bracket (B), then disconnect the connector. 2. Check for continuity between terminals at the harness connector. There should be continuity between the terminals listed for each switch position. In the P position, between terminals: ^ No. 1 and No. 3 ^ No. 1 and No. 8 ^ No. 3 and No. 8 In the R position, between terminals: ^ No. 1 and No. 9 In the N position and between terminals: ^ No. 1 and No. 3 ^ No. 1 and No. 10 ^ No. 3 and No. 10 In the D position, between terminals: ^ No. 1 and No. 2 ^ No. 1 and No. 4 ^ No.2 and No.4 In the D3 position, between terminals: ^ No. 1 and No. 2 ^ No. 1 and No. 5 ^ No.2 and No.5 In the 2 position, between terminals: ^ No. 1 and No. 6 Page 3203 Power Distribution schematics show how power is supplied from the positive battery terminal to various circuits in the vehicle. Refer to the Power Distribution diagram set to get a more detailed understanding of how picture is supplied to the circuit you're working on. Individual circuit schematics begin with a fuse. So 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 Ground Distribution Schematics This sample Ground Distribution schematic shows all of the components that share the same ground point. Page 4516 Pressure Plate: Service and Repair Release Bearing Replacement Clutch Replacement Special Tools Required ^ Clutch alignment shaft 07LAF-PT00110 ^ Clutch alignment disc 07JAF-PM7011A ^ Remover handle 07936-3710100 ^ Ring gear holder 07LAB-PV00100 or 07924-PD20003 ^ Attachment, 57 x 40 mm 07746-0010200 ^ Driver 07749-0010000 Release Bearing Replacement 1. Remove the release fork boot (A) from the clutch housing (B). 2. Remove the release fork (C) from the clutch housing (B) by squeezing the release fork set spring (D) with pliers. Remove the release bearing (E). 3. Check the release bearing for play by spinning it by hand. If there is excessive play, replace the release bearing with a new one. NOTE: The release bearing is packed with grease. Do not wash it in solvent. Page 6505 Under-hood Fuse/Relay Box Page 2607 3. Use the clamp carriage lever to position the clamp unit so the tracer is directly over the flat surface of the code device, just ahead of the cam blades. 4. Pull the vertical carriage lever toward you until the tracer just touches the flat surface ahead of the cam blades. Watch the arrows on the keypad: ^ If the double-headed arrow in the middle of the keypad lights green, the tracer and cutter bit are properly aligned. ^ If the arrow on the left of the keypad lights red, the cutter bit is not touching the jaw. Turn the micrometric ring nut above the tracer to the left until the double-headed arrow lights green. ^ If the vertical arrow on the right of the keypad lights red, the tracer is not touching the jaw. Turn the micrometric ring nut above the tracer to the right until the double-headed arrow lights green. *5. Turn the micrometric ring nut to the right five clicks so the cutter bit is slightly higher than the tracer. The arrow on the left should light red. Raise the vertical carriage. NOTE: Setting the tracer five clicks lower than the cutter bit at this point has the effect of making the cutter bit cut the duplicated key a little shallower. This will protect the locking jaws from being damaged.* 6. Optional: Loosen the set screw, and adjust the hand rest to a comfortable position. Tighten the screw. 7. Pull the clamp carriage lever toward you until the clamp carriage clicks into its end-of-run position. 8. Clean any metal shavings or debris out of the center jaw. (A soft-bristle toothbrush is ideal for this purpose.) Then open the jaws with the jaws knob, and slide the key blank with its flat side down into the jaw up to the key stop. Close the jaw with the jaws knob to lock the key blank into place. Visually inspect the key for proper alignment in the jaw. 9. Set and lock the cam sets on the code device. ^ Starting with the left cam set, make sure the lock pin is pulled all the way out. (This releases the cams.) Page 9130 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. Below most connector numbers and component names are PHOTO and VIEW numbers. The PHOTO number refers to a photo in the back of the book that shows the connector's location on the car. The VIEW number refers to an illustration in the back of the book that shows the connector terminals, wire colors, connector cavity numbers, and other details. The connector cavity numbering sequence begins at the top left corner of the connector as seen from either of the viewpoints shown on diagram [8] . Except for the DLC (data link 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 C554, for example, means those terminals join in cavity 2 of connector C554. Power Distribution Schematics Power Distribution Schematics Page 4499 5. Align the hole in the flywheel with the crankshaft dowel pin, and install the flywheel. Install the mounting bolts finger-tight. 6. Install the special tool, then torque the flywheel mounting bolts in a crisscross pattern in several steps. Page 4796 3. Strip the insulation off the end of the wire so the wire fits in the new terminal as shown. (If the wire has a wire seal, replace it with a new one from the kit.) NOTE: After stripping the end of the wire, make sure you did not cut any wire strands. If you did, cut the wire off even with the insulation, and strip it again. 4. Position the terminal in the crimping tool slot with the solid portion of the terminal toward the anvil and the open section toward the former. 5. Insert the wire in the terminal to the position shown in step 3. 6. Squeeze the tool with both hands until the stops make contact. 7. Crimp the insulation crimp. - If you do not have a wire seal, then use the next larger size crimp slot. Position the crimping tool over the insulation crimp section of the terminal, then squeeze the tool with both hands until the stops make contact. - If you have a wire seal, position the insulation crimp in the 5.5 crimping slot, then carefully squeeze the crimp closed until its ends are touching and making a full-circle shape. Page 3264 1. Remove the terminal. 2. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE G: 1. Remove the terminal. 2. Go to HOW TO INSTALL NEW TERMINALS. How to Install New Terminals HOW TO INSTALL NEW TERMINALS 1. Carefully match the old terminal with a new one from the terminal repair kit. Choose the correct replacement terminal based on the wire size range the terminal will accommodate. NOTE: If the replacement terminal quantities are low, reorder them by using the terminal part number listed on the inside lid of the terminal repair kit. Replacement terminals are available through your parts department using normal parts ordering procedures. 2. Depending on the size of the wire you are repairing, use the proper size slot in the crimping tool. Page 4132 Pressure Regulating Solenoid: Diagrams 25. A/T Clutch Pressure Control Solenoid Valve A 26. A/T Clutch Pressure Control Solenoid Valve B Page 5967 Relay And Control Unit Locations - Engine Compartment Page 4744 Flex Plate: Service and Repair Continuously Variable Transmission Drive Plate Removal and Installation 1. Remove the drive plate (A) and washer (B) from the engine crankshaft. 2. Install the drive plate, and install the washer in the direction shown on the engine crankshaft. 3. Tighten the six bolts in a crisscross pattern. Page 3844 Transmission Position Switch/Sensor: Testing and Inspection Transmission Range Switch Test 1. Remove the transmission range switch harness connector (A) from the connector bracket (B), then disconnect the connector. 2. Check for continuity between terminals at the harness connector. There should be continuity between the terminals listed for each switch position. In the P position, between terminals: ^ No. 1 and No. 3 ^ No. 1 and No. 8 ^ No. 3 and No. 8 In the R position, between terminals: ^ No. 1 and No. 9 In the N position and between terminals: ^ No. 1 and No. 3 ^ No. 1 and No. 10 ^ No. 3 and No. 10 In the D position, between terminals: ^ No. 1 and No. 2 ^ No. 1 and No. 4 ^ No.2 and No.4 In the D3 position, between terminals: ^ No. 1 and No. 2 ^ No. 1 and No. 5 ^ No.2 and No.5 In the 2 position, between terminals: ^ No. 1 and No. 6 Page 8022 NOTE: You need to make the corrections listed in CODE BOOK CORRECTIONS at the end of this service bulletin. TRACER AND CUTTER BIT INSTALLATION 1. Turn the power switch on the back of the machine to ON. (This turns on the built-in work light.) 2. Use the Allen wrench from the built-in tool drawer to loosen the setscrew on the left sleeve of the vertical carriage. Slide the tracer all the way into the sleeve, and tighten the screw. 3. Turn the plastic shield on the right sleeve of the vertical carriage so you can access the setscrew on the sleeve. Use the Allen wrench to loosen the screw. Slide the cutter bit all the way into the sleeve, and tighten the screw. Turn the plastic shield so the open side is in the back. MACHINE COMPONENTS Page 5132 2. Remove the terminal from the female half. 3. Remove the terminal from the male half. 4. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE D: 1. Remove the secondary locks. Page 1818 14. Drive the crankshaft oil seal squarely into the engine block end cover. 15. Confirm that the clearance is equal all the way around with a feeler gauge. Clearance: 0.5 - 0.8 mm (0.02 - 0.03 inch) 16. Clean and dry the engine block end cover mating surfaces. 17. Apply liquid gasket, P/N 08718-0001 or 08718-0003, evenly to the block mating surface of the engine block end cover and to the inner threads of the bolt holes. Install the dowel pins (A), and the engine block end cover (B) on the cylinder block. NOTE: Do not install the parts if 5 minutes or more have elapsed since applying the liquid gasket. Instead, reapply liquid gasket after removing the old residue. 18. After assembly, wait at least 30 minutes before filling the engine with oil. 19. Clean and dry the oil pump mating surfaces. Page 6527 Blower Motor Relay Type 1, Type 2 Check for continuity between the terminals. - There should be continuity between the No.1 and No.3 terminals when power and ground are connected to the No.2 and No.4 terminals. - There should be no continuity between the No.1 and No.3 terminals when power is disconnected. Five-terminal type Check for continuity between the terminals. - There should be continuity between the No.1 and No.2 terminals when power and ground are connected to the No.3 and No.5 terminals. - There should be continuity between the No.1 and No.4 terminals when power is disconnected. Page 8780 Page 2523 - Before connecting connectors, make sure the terminals (A) are in place and not bent. - Check for loose retainer (A) and rubber seals (B). - The backs of some connectors are packed with dielectric grease. Add grease if necessary. If the grease is contaminated, replace it. - Insert the connector all the way and make sure it is securely locked. - Position wires so that the open end of the cover faces down. Handling Wires and Harnesses - Secure wires and wire harnesses to the frame with their respective wire ties at the designated locations. Page 6746 131. Airbag First And Second Inflators 132. Airbag First And Second Inflators, Front Passenger's (Sedan) 133. Airbag First And Second Inflators, Passenger's (Coupe) Page 9149 3. Strip the insulation off the end of the wire so the wire fits in the new terminal as shown. (If the wire has a wire seal, replace it with a new one from the kit.) NOTE: After stripping the end of the wire, make sure you did not cut any wire strands. If you did, cut the wire off even with the insulation, and strip it again. 4. Position the terminal in the crimping tool slot with the solid portion of the terminal toward the anvil and the open section toward the former. 5. Insert the wire in the terminal to the position shown in step 3. 6. Squeeze the tool with both hands until the stops make contact. 7. Crimp the insulation crimp. - If you do not have a wire seal, then use the next larger size crimp slot. Position the crimping tool over the insulation crimp section of the terminal, then squeeze the tool with both hands until the stops make contact. - If you have a wire seal, position the insulation crimp in the 5.5 crimping slot, then carefully squeeze the crimp closed until its ends are touching and making a full-circle shape. Page 4943 7. Apply a small amount of Permalube grease to the base of the new lever. Then attach the slide hammer to the new lever pin, insert the lever into the ignition switch, and seat the pin with the slide hammer. 8. Check the installed height of the pin with vernier calipers. If the height is more than 5.0 mm, the pin is not seated. If needed, reattach the slide hammer, and seat the pin. NOTE: It's normal for the interlock lever to be loose, even when the pin is fully seated. 9. Install a new spring on the lever. Make sure you attach the ends of the spring correctly: ^ The right end goes into the slot on the ignition switch. Page 9646 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. How to Replace Connector Terminals Terminal Replacement Procedure HOW TO REPLACE CONNECTOR TERMINALS The terminal repair kits provide necessary tools and materials (terminals, wire seals, and splice connectors) to repair many damaged or faulty connector terminals. However, not all terminals for all connectors are available. Refer to the labels on the lids of the repair kits for replacement terminal availability. IMPORTANT SAFETY INFORMATION: On some models, the SRS wires are in a separate harness. If the SRS harness is damaged, replace the harness; do not repair it. On other models, wire harnesses include yellow SRS wires. If any SRS wire is damaged, replace the entire harness; do not repair it. Before you begin, inspect the wire you are about to repair for damage and length. Make sure the wire will be long enough to make a terminal repair without stretching it when you reinstall the terminal in the connector. If the wire is too short, or if access to the connector is too restricted to make a terminal repair, you may need to install a pigtail terminal (a short length of wire with a factory-crimped terminal on it). Refer to HOW TO INSTALL PIGTAIL TERMINALS. Removing the Terminal Page 1561 Power Windows Component Location Index Page 3052 ^ Start the engine and let it warm up to its normal operating temperature (the cooling fans cycle twice). ^ Let the engine idle (throttle closed and all electrical items off) for 10 minutes. 17. CR-V only: Reset the power window control unit: ^ Turn the ignition switch to ON (II). ^ Make sure the driver's window is fully closed. ^ Push down and hold the window switch until the window goes all the way down. ^ Pull back and hold the window switch until the window goes all the way up, then hold the switch for at least 2 more seconds. 18. Enter the audio unit anti-theft code, and set the clock. Enter the audio presets. Disclaimer Page 7191 1. Remove the driver's dashboard lower cover. (See the body section of the appropriate service manual.) 2. Replace the security control unit. ^ Civic: Remove the security control unit, and install the new security control unit. ^ * CR-V and Element: Remove the security control unit and microphone. Install the new security control unit and new microphone.* 3. Reprogram the keyless receiver unit. NOTE: The codes of up to three transmitters can be stored in the keyless receiver unit memory. If a fourth code is stored, the code that was input first will be erased. It is important to maintain the time limits between the steps. Make sure the doors and the trunk/tailgate/hatch are closed, and that you have all of the remotes the customer wishes to use. ^ Turn the ignition switch to ON (II). ^ Within 1 to 4 seconds, push the transmitter lock or unlock button. ^ Within 1 to 4 seconds, turn the ignition switch to LOCK (0). ^ Within 1 to 4 seconds, turn the ignition to ON (II). ^ Within 1 to 4 seconds, push the transmitter lock or unlock button. ^ Within 1 to 4 seconds, turn the ignition switch to LOCK (0). ^ Within 1 to 4 seconds, turn the ignition switch to ON (II). ^ Within 1 to 4 seconds, push the transmitter lock or unlock button. Page 5399 8. Apply Dow Corning Molykote M77 or Daikalub 528D grease to both sides of the pad shim (A), the back of the pads (B), and the other areas indicated by the arrows. Wipe excess grease off the shim. Contaminated brake discs and pads reduce stopping ability. Keep grease off the discs and pads. 9. Install the brake pads and pad shim correctly. Install the pads with the wear indicators (C) on the inside. If you are reusing the pads, always reinstall the brake pads in their original positions to prevent a momentary loss of braking efficiency. 10. Push in the piston (A) so the caliper will fit over the pads. Make sure the piston boot is in position to prevent damaging it when pivoting the caliper down. 11. Pivot the caliper down into position. Being careful not to damage the pin boots, install the bolt (B), and tighten it to the specified torque. 12. Press the brake pedal several times to make sure the brake works, then test-drive. NOTE: Engagement of the brake may require a greater pedal stroke immediately after the brake pads have been replaced as a set. Several applications of the brake pedal will restore the normal pedal stroke. 13. After installation, check for leaks at hose and line joints or connections, and retighten if necessary. Page 2679 53. IAT Sensor Odometer - Does It Rack Up Miles When Towed Odometer: All Technical Service Bulletins Odometer - Does It Rack Up Miles When Towed SOURCE: Honda Service News April 2003 TITLE: Does a Towed Vehicle's Odometer Rack Up Miles? APPLIES TO: All Models SERVICE TIP: If the vehicle has an electronic speedometer (one that isn't cable-driven), the answer is NO. The odometer doesn't rack up mileage as long as the ignition switch is in the LOCK (0) or the ACC (1) position. Page 5268 Transmission Position Switch/Sensor: Service and Repair Transmission Range Switch Replacement 1. Raise the vehicle, and make sure it is securely supported. 2. Shift to the N position. 3. Remove the transmission range switch cover (A). 4. Disconnect the transmission range switch connector (B). 5. Remove the old transmission range switch, and install the new switch. 6. Make sure that the control shaft is in the N position. If necessary, move the shift lever to the N position. Locations Transmission Position Switch/Sensor: Locations Electronic Controls Location, CVT 25. Transmission Housing (CVT) Page 8399 Sunroof / Moonroof Limit Switch: Adjustments Limit Switch Adjustment 1. Remove the headliner. 2. With the moonroof wrench, close the glass (A) fully: - Make sure both link lifters (B) are parallel, and in the position shown. - Check the glass fit to the roof panel and the glass height. 3. With an open-end wrench, loosen the limit switch mounting bolts (C). 4. Adjust the limit switch (D): - Move the switch plate (E) a little at a time, then secure it at the position where you hear a faint click when the switch cam (P) pushes the limit switch (open/close). - Check that the switch plate contacts the switch bracket (G). 5. Check the operation of the glass (from the tilt-up position to fully closed position, from the fully open position to the fully closed position) by operating the moonroof switch. Page 5786 Fuse Block: Connector Locations 71. Under Left Side Of Dash 70. Under Left Side Of Dash Page 3251 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. Test Equipment 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. Service and Repair Repairs and Inspections Required After a Collision: Service and Repair Component Replacement/Inspection After Deployment NOTE: Before doing any SRS repairs, use the PGM Tester SRS menu method to check for DTCs. After a collision where the seat belt tensioners deployed, replace these items: - Seat belt tensioners - Seat belt buckle tensioner - SRS unit - Front impact sensors After a collision where the front airbag(s) deployed, replace these items: - SRS unit - Deployed airbag(s) - Seat belt tensioners - Seat belt buckle tensioners - Front impact sensors After a collision where the side airbag(s) deployed, replace these items: - SRS unit - Deployed side airbag(s) - Side impact sensor(s) for side(s) deployed During the repair process, inspect these areas: - Inspect all the SRS wire harnesses. Replace, don't repair, any damaged harnesses. - Inspect the cable reel for heat damage. If there is any damage, replace the cable reel. After the vehicle is completely repaired, turn the ignition switch ON (II). If the SRS indicator comes on for about 6 seconds and then goes off, the SRS airbag system is OK. If the indicator does not function properly, use the PGM Tester SRS Menu Method to read the DTC. If this doesn't retrieve any codes, use the Tester's SCS menu method. If you still cannot retrieve a code, go to SRS Indicator Circuit Troubleshooting. Page 7016 8. Install the buckle in the reverse order of removal, and note these items: - Assemble the washers on the center anchor bolt as shown. - Apply liquid thread lock to the center anchor bolt before reinstallation. - If the seat belt tensioner has been deployed, replace the front seat belt protector with a new one. - Apply liquid thread lock to the seat mounting bolts before reinstallation. - Reconnect the negative cable to the battery. - Enter the anti-theft code for the radio, then enter the customer's radio station presets. - Reset the clock. - Do the ECM idle learn procedure. Page 1681 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. How to Replace Connector Terminals Terminal Replacement Procedure HOW TO REPLACE CONNECTOR TERMINALS The terminal repair kits provide necessary tools and materials (terminals, wire seals, and splice connectors) to repair many damaged or faulty connector terminals. However, not all terminals for all connectors are available. Refer to the labels on the lids of the repair kits for replacement terminal availability. IMPORTANT SAFETY INFORMATION: On some models, the SRS wires are in a separate harness. If the SRS harness is damaged, replace the harness; do not repair it. On other models, wire harnesses include yellow SRS wires. If any SRS wire is damaged, replace the entire harness; do not repair it. Before you begin, inspect the wire you are about to repair for damage and length. Make sure the wire will be long enough to make a terminal repair without stretching it when you reinstall the terminal in the connector. If the wire is too short, or if access to the connector is too restricted to make a terminal repair, you may need to install a pigtail terminal (a short length of wire with a factory-crimped terminal on it). Refer to HOW TO INSTALL PIGTAIL TERMINALS. Removing the Terminal Page 2762 Page 9098 1. Remove the terminal. 2. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE G: 1. Remove the terminal. 2. Go to HOW TO INSTALL NEW TERMINALS. How to Install New Terminals HOW TO INSTALL NEW TERMINALS 1. Carefully match the old terminal with a new one from the terminal repair kit. Choose the correct replacement terminal based on the wire size range the terminal will accommodate. NOTE: If the replacement terminal quantities are low, reorder them by using the terminal part number listed on the inside lid of the terminal repair kit. Replacement terminals are available through your parts department using normal parts ordering procedures. 2. Depending on the size of the wire you are repairing, use the proper size slot in the crimping tool. Page 2830 Use the tools from Pin Tool Set. First, check the connector that you are about to repair. - If it has a secondary terminal lock, go to Connectors With a Secondary Lock. A secondary lock, found on most connectors on some models, is an additional locking device on the connector housing as a backup for the primary lock on the terminal. - If the connector does not have a secondary lock, go to Connectors Without a Secondary Lock. Connectors With a Secondary Lock All examples are shown with the connector lock facing up. The illustrations are examples of the secondary terminal locks; however, the connector you are repairing may vary in size. Identify the connector by the type of secondary lock, not by the number of terminal cavities. EXAMPLE A: 1. Release the secondary lock. 2. Remove the terminal. 3. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE B: Page 7342 ^ 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, Under-Dash Fuse/Relay Box Under-dash Fuse/Relay Box Page 4192 Shift Interlock Switch: Service and Repair Park Pin Switch Replacement 1. Remove the center console panel and center console. 2. Remove the screws (A), then remove the shift lever knob (B) 3. Remove the A/T gear position indicator panel light (c) from the A/T gear position indicator panel. 4. Remove the A/T gear position indicator panel and panel bracket as an assembly (D). 5. Disconnect the park pin switch connector (4P) (E), and remove it from the shift lever bracket base (F). 6. Remove the shift lock release (G) and spring (H). 7. Open the lock tabs (A) on the shift lever bracket base, then remove the park pin switch (B). 8. Install the new park pin switch. 9. Install the removed parts in the reverse order of removal. Page 2533 2. Remove the terminal from the female half. 3. Remove the terminal from the male half. 4. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE D: 1. Remove the secondary locks. Locations Power Window Relay: Locations Relay And Control Unit Locations - Dashboard Page 6216 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. SRS Unit, Front Sensors and Side Impact Sensors SRS Unit, Front Sensors and Side Impact Sensors Be careful not to bump or impact the SRS unit, front sensors, or the side impact sensors whenever the ignition switch is ON (II), or for at least 3 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, front sensors, and the side impact sensor. The airbags could accidentally deploy and cause damage or injury. After a collision in which any airbags or seat belt tensioners were deployed, replace the SRS unit, front sensors, and other related components. After a collision in which a side airbag was deployed, replace the side impact sensor on the deployed side 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, front sensors, 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 3 minutes before beginning installation or replacement of the SRS unit, or disconnecting 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 N.m (1.0 kgf.m, 7.2 lbf.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 °G) and dry (less than 80% relative humidity, no moisture) area. Wiring Precautions Wiring Precautions SRS wiring can be identified by special yellow outer covering (except the SRS indicator light circuit). Page 3092 17. Right Side Of Engine Compartment (EX, HX) Page 394 Starter Relay: Testing and Inspection Power Relay Test Use this chart to identify the type of relay, then do the test listed for it. NOTE: See the turn signal/hazard relay input test. Normally-open type A: Check for continuity between the terminals. - There should be continuity between the No.1 and No.2 terminals when power and ground are connected to the No.3 and No.4 terminals. - There should be no continuity between the No.1 and No.2 terminals when power is disconnected. Page 6194 25. Install the outer case (A) by aligning the slot (B) inside the outer case with the cover roll pin hole (C). Be sure that the slit (D) on the outer case faces this direction shown. 26. Apply the power steering fluid to the rubber seal (E) black, and install it in the slot (F) of the outer case. 27. Apply power steering fluid to the slipper seal (G) (white), and install it on top of the rubber seal you lust installed. 28. Align the slot (A) in the outer case with the roll pin hole (B) on the cover. 29. Install the cam ring (C) by aligning the slot (D) with the slot (A) in the outer case. 30. Insert the roll pin (E) into the slots between the cam ring and outer case, then push the roll pin into the set hole. 31. Install the rotor (A) in the cam ring (B). 32. Set the 11 vanes (C) in the grooves in the rotor. Make sure that the round ends (D) of the vanes are in contact with the sliding surface of the cam ring. Page 4012 107. Behind A/T Shift Lever (except M/T) Page 7178 80. Under Middle Of Dash Locations 77. Under Middle of Dash Page 8200 Power Door Lock Switch: Diagrams 109. Door Lock Knob Switch, Driver's (except DX) 110. Door Lock Switch, Driver's Page 1566 Under-dash Fuse/Relay Box (2-door) Page 7346 Page 4214 - Remove clips carefully; don't damage their locks (A). - Slip pliers (A) under the clip base and through the hole at an angle, then squeeze the expansion tabs to release the clip. - After installing harness clips, make sure the harness doesn't interfere with any moving parts. - Keep wire harnesses away from exhaust pipes and other hot parts, from sharp edges of brackets and holes, and from exposed screws and bolts. - Seat grommets in their grooves properly (A). Do not leave grommets distorted (B). Testing and Repairs - Do not use wires or harnesses with broken insulation. Replace them or repair them by wrapping the break with electrical tape. - After installing parts, make sure that no wires are pinched under them. - When using electrical test equipment, follow the manufacturer's instructions and those described. - If possible, insert the probe of the tester from the wire side (except waterproof connector). - Use back probe adaptor 07TAZ-001020A. - Refer to the instructions in the Honda Terminal Kit for identification and replacement of connector terminals. Five-Step Troubleshooting Five-Step Troubleshooting 1. Verify The Complaint Alternator Belt Inspection and Adjustment Drive Belt: Adjustments Alternator Belt Inspection and Adjustment Alternator Belt Inspection and Adjustment Special Tools Required Belt tension gauge 07JGG-001010A Belt Tension Gauge Method Inspection 1. Attach the belt tension gauge to the belt and measure the tension. Follow the gauge manufacturer's instructions. If the belt is worn or damaged, replace it. If the belt needs adjustment, go to step 2. Adjustment 2. Loosen the mounting bolt (A), lock bolt (B) and lower bracket mounting bolt (C). 3. Torque the mounting bolt to 20 N.m (2.0 kgf.m, 14 lbf.ft). 4. Turn the adjusting bolt (D) to obtain the proper belt tension, then retighten the lock bolt, mounting bolt and lower bracket mounting bolt. 5. Recheck the belt tension. 6. If you installed a new belt, run the engine for 5 minutes, then readjust the belt to the used belt specification. 7. Check the power steering pump belt adjustment. Deflection Method Inspection Page 6136 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 3855 Transmission Speed Sensor: Diagrams 34. Output Shaft (Countershaft) Speed Sensor (A/T Except CVT) 57. Input Shaft (Mainshaft) Speed Sensor (A/T Except CVT) Page 7777 ^ If no key code can be found on the iN or with the Matrix H High Security key Codes Book, remove one tumbler at a time from the old inner cylinder, and match the number stamped on the old tumbler to a new tumbler from the kit. Insert the new tumbler and spring in the appropriate new inner cylinder cavity. ^ Do not use the old inner cylinder, springs, or tumblers. ^ Using your thumb and forefinger, hold the tumblers in place, insert the key in the cylinder and verify that all tumblers are flush with the cylinder. If not, double-check the key number, the cutting key code, the tumbler numbers, and the cavity locations. NOTE: If the key cannot be inserted, check the tumbler in the "J" cavity. It may be out of position. Locations Canister Purge Control Valve: Locations EVAP System - Component Location Index Page 7284 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. Circuits must be operating when checking voltage drop. 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. 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 off, 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 Self-Powered Test Light or DVOM 1. Remove the blown fuse and disconnect the battery and load. Page 1900 7. Lightly tap the end of each valve stem two or three times with a plastic mallet (A) to ensure proper seating of the valve and valve keepers. Tap the valve stem only along its axis so you do not bend the stem. Page 77 Blower Motor Relay Type 1, Type 2 Check for continuity between the terminals. - There should be continuity between the No.1 and No.3 terminals when power and ground are connected to the No.2 and No.4 terminals. - There should be no continuity between the No.1 and No.3 terminals when power is disconnected. Five-terminal type Check for continuity between the terminals. - There should be continuity between the No.1 and No.2 terminals when power and ground are connected to the No.3 and No.5 terminals. - There should be continuity between the No.1 and No.4 terminals when power is disconnected. Page 1284 Alignment: Service and Repair Wheel Alignment The suspension can be adjusted for front camber, front toe, and rear toe. However, each of these adjustments are interrelated to each other. For example, when you adjust toe, the camber changes. Therefore, you must adjust the front wheel alignment whenever you adjust camber or toe. Pre-Alignment Checks For proper inspection and adjustment of the wheel alignment, do these checks: 1. Release the parking brake to avoid an incorrect measurement. 2. Make sure the suspension is not modified. 3. Check the tire size and tire pressure. Tire size: Front/rear: P185/70R14 87S P185/65R15 86H P195/60R15 87H Tire pressure: Front/rear:210 kPa (2.1 kgf/cm2, 30 psi) 4. Check the runout of the wheels and tires. 5. Check the suspension ball joints. (Hold a wheel with your hands, and move it up and down and right and left to check for wobbling). 6. Bounce the vehicle up and down several times to stabilize the suspension. Front Caster Inspection Use commercially available computerized four wheel alignment equipment to measure wheel alignment (caster, camber, toe, and turning angle). Follow the equipment manufacturer's instructions. Check the caster angle. If the caster angle is not within the specification, check for bent or damaged suspension components. Front caster angle: 1°33' ± 1° for '01-02 models 2°14' ± 1° for '03-04 models Front Camber Inspection Use commercially available computerized four wheel alignment equipment to measure wheel alignment (caster, camber, toe, and turning angle). Follow the equipment manufacturer's instructions. Check the camber angle. If the camber angle is not within the specification, adjust the camber. Front camber angle: 0°00' ± 45' Front Camber Adjustment The front camber can be adjusted by exchanging one or both of the damper pinch bolts with the smaller diameter adjusting bolt(s). The difference between the adjusting bolt diameter and the pinch bolt hole diameter allows a small range of adjustment. Page 7446 - Before connecting connectors, make sure the terminals (A) are in place and not bent. - Check for loose retainer (A) and rubber seals (B). - The backs of some connectors are packed with dielectric grease. Add grease if necessary. If the grease is contaminated, replace it. - Insert the connector all the way and make sure it is securely locked. - Position wires so that the open end of the cover faces down. Handling Wires and Harnesses - Secure wires and wire harnesses to the frame with their respective wire ties at the designated locations. Page 9657 2. Cut off the wire about an inch back from where it connects to the damaged or faulty terminal, then strip about half of the insulation off that piece. This will be used to size the wire end of the replacement pigtail terminal. NOTE: If you are not sure of the wire size, start with a large enough hole on the stripper that will not nick or cut off any strands of wires. 3. Select a pigtail terminal that matches the original wire at both ends (same kind of terminal and same diameter bare wire). 4. Select the smallest splice connector (yellow, pink, or blue) that will fit onto the stripped end of the original wire. 5. Insert the pigtail terminal into the connector cavity; push it in until it locks in place. 6. Lay the pigtail and the original wire side-by-side, and cut off both ends at once. If you are making more than one splice, do not cut each pigtail at the same location; the resulting "lump" of splice connectors would interfere with rewrapping the harness. Instead, cut the first pigtail close enough to the terminal so you will have room to make each remaining cut about 20 mm (3/4 inch) farther down on the next pigtail. 7. If you are using a yellow splice connector, strip about 6 mm (1/4 inch) of insulation off the ends of both wires. If you are using a pink or blue splice connector, strip off about 8 mm (5/16 inch) of insulation. Diagram Information and Instructions Transmission Position Switch/Sensor: Diagram Information and Instructions Terminal Numbering System Terminal Numbering System Connector terminals are numbered according to the cavities they're in. The cavities are numbered starting from the upper left, looking at the male terminals from the terminal side or looking at the female terminals from the wire side. Both views are in the same direction so the numbers are the same. All actual cavities are numbered, even if they have no wire terminals in them. NOTE: Data Link Connector (DLC) terminals are numbered according 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 below is #6. Page 9513 Diagram 115-1 (except EX) Page 1547 234. Under-dash Fuse/Relay Box Part 5 Page 2779 ECM/PCM Inputs And Outputs At Connector C (22P) Page 2335 Engine Control Module: Service Precautions 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 9858 8. If the old quarter glass will be reinstalled (and either clip is broken off the molding), apply a light coat of primer, then apply butyl tapes (A) and (B) to the molding (C) as shown: Be careful not to touch the quarter glass where adhesive will be applied. - Do not peel the separator off the butyl tapes. 9. If the new quarter glass will be installed, attach the fastener (A) with adhesive tape to the body. Be sure the fastener lines up with the alignment marks (B). Fastener adhesive tape: Thickness 0.8 mm (0.03 in.) Width 7 mm (0.28 in.) Page 3941 ^ Updating with the HIM - HIM Updating in Pass-Thru Mode - HIM Updating in Storage Mode - Diagnosing HIM Error Codes - HIM Self-Test NOTE: Whenever you install a new, reprogrammable control unit/module, check that it has the latest software, and update it if needed. WARRANTY CLAIM INFORMATION Skill Level: Repair Technician Refer to the specific service bulletin for the symptom you are repairing. QUESTIONS ABOUT THE UPDATING EQUIPMENT OR THE INTERACTIVE NETWORK For questions about the Honda-supplied updating equipment, call American Honda's Special Tools hotline. For questions about the iN, call the iN Support Center. REQUIRED TOOLS AND EQUIPMENT NOTE: Updating for most control units/modules can be done with any of the following tools. Page 9844 5. Pull down the rear portion of the headliner (A) by detaching the clips (B). Take care not to bend the headliner excessively, or you may crease or break it. 6. Apply protective tape along the inside and outside edges of the body. Using an awl, make a hole through the adhesive from inside the vehicle at the corner portion of the rear window. Push a piece of piano wire through the hole, and wrap each end around a piece of wood. 7. With a helper on the outside, pull the piano wire (A) back and forth in a sawing motion. Hold the piano wire as close to the rear window (B) as possible to prevent damage to the body, and carefully cut through the adhesive (C) around the entire rear window. 8. Carefully remove the rear window. 9. With a putty knife, scrape the old adhesive smooth to a thickness of about 2 mm (0.08 in.) on the bonding surface around the entire rear window opening flange: Do not scrape down to the painted surface of the body; damaged paint will interfere with proper bonding. - Remove the fasteners from the body. 10. Clean the body bonding surface with a sponge dampened in alcohol. After cleaning, keep oil, grease and water from getting on the surface. 11. If the old rear window will be reinstalled, use a putty knife to scrape off all of the old adhesive, the moldings and the fasteners from the rear window. Clean the inside face and the edge of the rear window with alcohol where new adhesive will be applied. Make sure the bonding surface is kept free of water, oil and grease. Continuously Variable Transmission Shift Interlock Switch: Testing and Inspection Continuously Variable Transmission Park Pin Switch Test 1. Remove the center console panel and center console. 2. Disconnect the park pin switch connector (4P). 3. Shift to the P position, then check for continuity between the No. 3 and No. 4 terminals. There should be no continuity. 4. Shift out of the P position, and check for continuity between terminals No. 3 and No. 4. There should be no continuity. 5. If the park pin switch is faulty, replace it. Page 9579 Horn Switch: Testing and Inspection Horn Switch Test 1. Remove the steering column covers. 2. Disconnect the dashboard wire harness B 5P connector (A) from the cable reel (B). 3. Using a jumper wire, connect the dashboard wire harness B 5P connector (A) No.2 terminal to body ground. - If the horn sounds, go to step 4. - If the horn does not sound, check these items: horn relay - No.7 (15 A) fuse in the under-hood fuse/relay box - Horn. - An open in the wire. 4. Reconnect the dashboard wire harness B 5P connector (A), and disconnect the horn switch positive 1P connector (B). 5. Using a jumper wire, connect the horn switch positive 1P connector (B) to ground. - If the horn sounds, go to step 6. - If the horn does not sound, replace the cable reel. 6. Reconnect the horn switch positive connector (B). Campaign - OPDS Unit Warranty Extension Technical Service Bulletin # 06-009 Date: 080205 Campaign - OPDS Unit Warranty Extension 06-009 February 5, 2008 Applies To: See VEHICLES AFFECTED Warranty Extension: OPDS Unit or OPDS Sensor Triggers SRS DTC(s) 15-1, 15-2, 15-3 (Supersedes 06-009, dated September 21, 2007) Updated information is shown with asterisks. BACKGROUND *NOTE: Because of a class action settlement, the warranty extension coverage for the OPDS unit and the OPDS sensor on 2002 Accords, 2002-04 Civics, 2003-04 Civic Hybrids, 2002-04 CR-Vs, 2003 Elements, 2002 Odysseys, and 2003-04 Pilots purchased or leased between April 13, 2002, and November 7, 2006, is now 10 years or 157,500 miles, whichever occurs first. For more information, refer to Service Bulletin 06-085, Warranty Extension: Vehicle Warranty Mileage.* Several vehicle models may have a problem with the OPDS (occupant position detection system) that causes the SRS indicator to stay on. Typically, one or more of these DTCs will be set: ^ SRS DTC 15-1 (faulty OPDS unit or OPDS not initialized) ^ SRS DTC 15-2 (faulty side airbag indicator circuit) ^ SRS DTC 15-3 (faulty OPDS sensor) To ensure continued reliability with the OPDS, American Honda is extending the warranty on the OPDS unit and the OPDS sensor to 10 years or 150,000 miles, whichever occurs first. This warranty extension does not apply to any vehicle that has ever been declared a total loss, or any that has been issued a salvage, branded, or similar title under any state's law. To check for vehicle eligibility, you must do a VIN status inquiry Page 1177 (Coupe Except DX, HX) 167. Power Window Switch, Front Passenger's (Sedan Except DX) 168. Power Window Switch, Left Rear Or Right Rear (Sedan Except DX) Page 7595 8. Power window: Disconnect and detach the connector (A) from the door. 9. Remove the bolts (B), and loosen the bolts (C), then remove the regulator (D) through the hole in the door. Power window is shown, manual window is similar. 10. Apply multipurpose grease to all the sliding surfaces of the regulator (A) where shown, regardless of the channel shape (B, C). 11. Install the glass and regulator in the reverse order of removal, and note these items: - Roll the glass up and down to see if it moves freely without binding. - Make sure that there is no clearance between the glass and glass run channel when the glass is closed. - Adjust the position of the glass as necessary. - Check for water leaks. - Test-drive and check for wind noise and rattles. - When reinstalling the door panel, make sure the plastic cover is installed properly and sealed around its outside perimeter to seal out water. Page 6235 55. In Steering Column Cover Page 5459 Brake Hose/Line: Service and Repair Brake Hose Replacement NOTE: ^ Do not spill brake fluid on the vehicle; it may damage the paint; if brake fluid gets on the paint, wash it off immediately with water. ^ To prevent dripping, cover disconnected line joints with rags or shop towels. ^ Before reassembling, check that all parts are free of dust and other foreign particles. Replace parts with new ones whenever specified to do so. 1. Replace the brake hose (A) if the hose is twisted, cracked, or if it leaks. 2. Disconnect the brake hose from the brake line (B) using a 10 mm flare-nut wrench (C). 3. Remove the flange bolt (A), and remove the brake hose brackets from the damper. 4. Remove and discard the hose clip (B). 5. Remove the banjo bolt (C), and remove the brake hose from the caliper. 6. Install the brake hose bracket (A) on the damper with the flange bolt (B) first, then connect the brake hose to the caliper with the banjo bolt (C) and new sealing washers (D). Page 3271 Variable Valve Timing Actuator: Electrical Diagrams Diagram 31 (EX, HX) Diagrams: Other diagrams referred to by number (See Diagram ##-#, etc.)within these diagrams can be found at Diagrams by Number. See: Diagrams/Electrical Diagrams/Diagrams By Number Locations: Location photographs (references to PHOTOS) referred to within these diagrams can be found at Locations by Photo Number. See: Locations/Component Locations/Locations By Photo Number Connector Views: Connector terminal views (references to VIEWS) referred to within these diagrams can be found at Connector Views by View Number. See: Diagrams/Connector Views/Connector Views By View Number Service and Repair Rear Door Exterior Handle: Service and Repair Rear Door Outer Handle Replacement 4-door NOTE: Put on gloves to protect your hands. 1. Raise the glass fully. 2. Remove these items: - Door panel - Plastic cover, as necessary 3. Release the inner handle rod (A) and lock rod (B) from the rod holder (C), and with power door lock, remove the screws, then remove the actuator (D) from the door. 4. Remove the clip, and release the hooks (A), then remove the rod protector (B). Recall - Ignition/Shift Interlock Defect Technical Service Bulletin # 10-059 Date: 101001 Recall - Ignition/Shift Interlock Defect 10-059 October 1, 2010 Applies To: See VEHICLES AFFECTED Safety Recall: Accord, Civic, and Element Ignition Switch Key Interlock BACKGROUND Under certain conditions, the interlock lever of the ignition switch may unexpectedly deform. The interlock ensures the transmission is in Park before the ignition key can be removed. Interlock failure may allow the ignition key to be removed when the shift lever is not in Park. If the driver fails to engage the parking brake, the vehicle could roll away, increasing the risk of a crash. VEHICLES AFFECTED Not all vehicles within the VIN ranges are affected by this recall. Before beginning work on a vehicle, verify its eligibility by checking at least one of these items: ^ The customer has a notification letter. Page 4095 Resistor Variable Sensor Solenoid Transistors Circuit Schematics Recall 10V364000: Ignition Interlock Defect Shift Interlock Switch: All Technical Service Bulletins Recall 10V364000: Ignition Interlock Defect VEHICLE MAKE/MODEL: MODEL YEAR(S): Honda/Accord 2003 Honda/Civic 2003 Honda/Element 2003-2004 MANUFACTURER: Honda (American Honda Motor Co.) MFR'S REPORT DATE: August 04, 2010 NHTSA CAMPAIGN ID NUMBER: 10V364000 NHTSA ACTION NUMBER: EA09001 COMPONENT: Electrical System: Ignition POTENTIAL NUMBER OF UNITS AFFECTED: 384220 SUMMARY: Honda is recalling certain model year 2003 Honda Accord, Civic two and four door, and model year 2003-2004 Honda Element vehicles. The interlock lever of the ignition switch may unexpectedly deform, which can allow the interlock function of a vehicle with an automatic transmission to be defeated. CONSEQUENCE: Removal of the ignition key when the gear selector of a vehicle with an automatic transmission has not been shifted to the park position can allow the vehicle to roll away, increasing the risk of a crash. REMEDY: Dealers will remove the original interlock pin and lever within the ignition switch, and replace them with newly, designed components. This service will be performed free of charge. The safety recall is expected to begin on or about September 29, 2010. Owners may contact Honda at 1-800-999-1009. NOTES: Honda safety recall No. R44. 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 3348 Refueling Control Valve: Testing and Inspection Fuel Tank Vapor Control Valve Test Special Tools Required Vacuum Pump/Gauge, 0 - 30 in.Hg A973X-041-XXXXX Float Test 1. Make sure the fuel tank is less than half full. 2. Remove the fuel fill cap to relieve fuel tank pressure, then reinstall the cap. 3. Disconnect the fuel tank vapor recirculation tube (A), and connect a vacuum pump to the vapor recirculation tube. 4. Plug the line (B). 5. Apply vacuum to the fuel tank vapor recirculation tube. - If the vacuum holds, replace the fuel tank vapor control valve. - If the vacuum does not hold, the float is OK. Do the valve test. Valve Test 1. Make sure the fuel tank is less than half full. 2. Remove the fuel fill cap. 3. Disconnect the fuel tank vapor signal tube (A). Page 4324 8. Insert a 6.0 mm (0.24 inch) pin (A) through the positioning hole (B) on the shift lever bracket base and into the positioning hole (C) on the shift lever assembly. The shift lever is secured in the N position. 9. Align the socket holder (A) on the shift cable (B) with the slot in the cable bracket base (C), then slide the holder into the base. Install the shift cable end (D) over the mounting stud (E) by aligning its square hole (F) with the square fitting (G) at the bottom of the stud. Rotate the holder clockwise a quarter turn to secure the shift cable. NOTE: Do not install the shift cable by twisting the shift cable guide (H). 10. Verify that the shift cable end (A) is properly installed on the mounting stud (B). Page 231 Under-dash Fuse/Relay Box (4-door) Page 7271 Splices Components Ground - "G" Page 866 Throttle Position Sensor: Description and Operation Throttle Position (TP) Sensor The TP sensor is a potentiometer connected to the throttle valve shaft. As the throttle position changes, the sensor varies the signal voltage to the ECM/PCM. The TP sensor is not replaceable apart from the throttle body. Page 1955 Oil Pan: Service and Repair Installation Installation Aluminum Oil Pan 1. Clean and dry the oil pan mating surfaces and bolt holes. 2. Apply liquid gasket, part No.08718-0001 or 08718-0003, evenly to the oil pan mating surface of the block and to the inner threads of the bolt holes. NOTE: ^ Apply a 4 mm wide bead of liquid gasket. ^ Apply a second bead where the two ends of the first bead meet. ^ Do not install the parts if 5 minutes or more have elapsed since applying liquid gasket. Instead, reapply liquid gasket after removing old residue. 3. Install the oil pan. 4. Tighten the bolts in two or three steps. In the final step, tighten all bolts, in sequence to 12 Nm (1.2 kgf-cm, 8.7 ft. lbs.). 5. After assembly, wait at least 30 minutes before filling the engine with oil. Steel Oil Pan 1. Clean and dry the oil pan mating surfaces and bolt holes. Page 1551 Fuse Block: Service and Repair Removal and Installation SRS components are located in this area. Review the SRS component locations and precautions and procedures in the SRS section before performing repairs or service. Removal 1. Make sure you have the anti-theft code for the radio, then write down the frequencies for the radio's preset buttons. 2. Disconnect the battery negative cable, then disconnect the positive cable, and wait at least 3 minutes. 3. Remove the dashboard lower cover. 4. Disconnect the connectors from the fuse side of the under-dash fuse/relay box. 5. Remove the mounting bolt and slide the under-dash fuse/relay box (A) down from the bracket (B). 6. Disconnect the connectors from the back side of the under-dash fuse/relay box, and remove the fuse/relay box. NOTE: The SRS connector is a spring-loaded lock type. Installation 1. Install the under-dash fuse/relay box in the reverse order of removal and connect all connectors to the under-dash fuse/relay box. 2. Install the dashboard lower cover. 3. Connect both the negative cable and positive cable to the battery. 4. Enter the anti-theft code for the radio, then enter the customer's radio station presets. 5. Confirm that all systems work properly. 6. Do the ECM/PCM idle learn procedure. Page 6893 5. Reconnect the battery negative cable. 6. After installing the side airbag, confirm proper system operation: Turn the ignition switch ON (II); the SRS indicator should come on for about 6 seconds and then go off. Page 9699 Page 4384 1. Remove the secondary lock from the male terminal half. 2. Remove the secondary lock from the female terminal half. 3. Remove the terminal (same procedure for male and female). 4. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE C: 1. Remove the secondary lock. Page 7347 Page 9649 2. Remove the terminal from the female half. 3. Remove the terminal from the male half. 4. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE D: 1. Remove the secondary locks. Page 8092 Keyless Entry Receiver: Testing and Inspection Keyless Receiver Unit Input Test 1. Remove the dashboard center lower cover. 2. Remove the audio unit. 3. Disconnect the 5P connector (A) from the keyless receiver unit (B). 4. Inspect the connector and socket terminals to be sure they are all making good contact. - If the terminals are bent, loose or corroded, repair them as necessary, and recheck the system. - If the terminals are OK, go to step 5. 5. With the connector still disconnected, make these input tests at the connector. - If any test indicates a problem, find and correct the cause, then recheck the system. - If all the input tests prove OK, go to step 6. 6. Reconnect the 5P connector and make these input tests at the connector. - If any test indicates a problem, find and correct the cause, then recheck the system. - If all the input tests prove OK, replace the keyless receiver unit. Page 7439 Terminals - "T" Shielding Switches Fuses Specifications Connecting Rod Bearing: Specifications Connecting Rod Bearing-to-Journal Oil Clearance: Standard (New): 0.024 - 0.042 mm (0.0009 - 0.0017 inch) Service Limit: 0.05 mm (0.002 inch) Page 9787 Page 9723 3. Using an O-ring pick or similar tool, pull up the outer edge of the molding, and apply 3M Black Super Silicone Sealant under it, along the A-pillars and the upper edge of the windshield. 4. Push down on the molding, and smooth it out until it sits flush with the roof. 5. Wait 5 minutes, then remove the masking tape. 6. Clean up any excess sealant with 3M General Purpose Adhesive Cleaner. Disclaimer Locations Rear Door Window Motor: Locations 129. Left Rear Door (Right Similar) 129. Left Rear Door (Sedan Except DX) (Right Similar) Page 2164 1. Remove the terminal. 2. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE B: 1. Remove the terminal. 2. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE C: 1. Remove the terminal. 2. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE D: Removal and Installation Brake Caliper: Service and Repair Removal and Installation Front Inspection and Replacement CAUTION: Frequent inhalation of brake pad dust, regardless of material composition, could be hazardous to your health. ^ Avoid breathing dust particles. ^ Never use an air hose or brush to clean brake assemblies. Use an OSHA-approved vacuum cleaner. Replacement 1. Remove the bolt (B), and pivot the caliper (C) up out of the way. Check the hose and pin boots for damage and deterioration. 2. Remove the pad shim (A) and pads (B). 3. Remove the pad retainers (A). 4. Clean the caliper thoroughly; remove any rust, and check for grooves and cracks. 5. Check the brake disc for damage and cracks. 6. Apply Dow Corning Molykote M77 grease to the retainers on their mating surfaces against the caliper bracket. 7. Install the pad retainers. Wipe excess grease off the retainers. Contaminated brake discs and pads reduce stopping ability. Keep grease off the discs and pads. Locations Camshaft Position Sensor: Locations PGM-FI System - Component Location Index Locations 77. Under Middle of Dash Page 7994 - To remove the driver's kick panel, remove the footrest. - To remove the seat side trim, remove the rear seat side bolster. - To remove the front side cap and opener lock cylinder, refer to trunk lid opener/fuel fill door opener replacement. 2. Install the parts in the reverse order of removal, and note these items: - Replace any damaged clips. - Apply liquid thread lock to the anchor bolts before installation. - Before installing the anchor bolts, make sure there are no twists or kinks in the seat belts. Page 9530 Blower Motor Relay Type 1, Type 2 Check for continuity between the terminals. - There should be continuity between the No.1 and No.3 terminals when power and ground are connected to the No.2 and No.4 terminals. - There should be no continuity between the No.1 and No.3 terminals when power is disconnected. Five-terminal type Check for continuity between the terminals. - There should be continuity between the No.1 and No.2 terminals when power and ground are connected to the No.3 and No.5 terminals. - There should be continuity between the No.1 and No.4 terminals when power is disconnected. Page 5322 Braking Sensor/Switch: Adjustments Brake Pedal and Brake Pedal Position Switch Adjustment Pedal Height 1. Disconnect the brake pedal position switch connector, turn the brake pedal position switch (A) counterclockwise and pull it back until it is no longer touching the brake pedal. 2. Lift up the carpet (B). At the insulator cutout, measure the pedal height (C) from the middle of the right side of the pedal pad (D). Standard Pedal Height (with carpet removed): M/T: 184 mm (7 4/16 inch) A/T: 188 mm (7 6/16 inch) 3. Loosen the pushrod locknut (A), and screw the pushrod in or out with pliers until the standard pedal height from the floor is reached. After adjustment, tighten the locknut firmly. Do not adjust the pedal height with the pushrod pressed. Pedal Free Play Page 6272 69. Install the new lock screw (A) on the cylinder. 70. Install the new stop ring (B) in the groove (C) on the cylinder by expanding it with snap ring pliers. Be careful not to scratch or damage on the cylinder surface with the stop ring edges. 71. Set the new boot bands (B) on the band installation grooves of the boot A by aligning the tabs (C) with the holes (D} of the band. Do not close the ear portion of the boot band in this step. 72. Compress the boot A by hand, and apply vinyl tape (E) to the bellows so the boots stay collapsed and pulled back. Pass boot A over the cylinder so the smaller diameter end of the boot faces the gearbox housing. 73. Apply multipurpose grease to the sliding surface of the slider guide (A). Slide the steering rack all the way to left, and place the slider guide on the steering rack by aligning the bolt holes (B). Page 5380 2. Remove the terminal from the female half. 3. Remove the terminal from the male half. 4. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE D: 1. Remove the secondary locks. Page 3090 PGM-FI System - Component Location Index Locations Multiplex Control System Component Location Index Page 698 104. CKP Sensor Page 5831 Air Conditioning Component Location Index Page 9577 53. Steering Wheel (Airbag Inflators Removed) Page 6489 Cabin Ventilation Duct: Removal and Replacement Rear Air Outlet Replacement 1. Remove the rear bumper. 2. Detach the hooks (A), then remove the rear air outlet (B) Take care not to scratch the body. 3. Install the air outlet by pushing on the hook portions until the hooks snap into place. Page 9416 Map Light: Electrical Diagrams Diagram 114-2 (except EX) Page 9105 226. Brake Light/Taillight, Left Or Right Page 565 161. Middle Of Engine Compartment Page 329 94. Behind Glove Box (except GX) Page 1923 Drive Belt: Adjustments Alternator - A/C Compressor Belt Inspection and Adjustment Alternator - A/C Compressor Belt Inspection and Adjustment Special Tools Required Belt tension gauge 07JGG-001010A Belt Tension Gauge Method Inspection 1. Attach the belt tension gauge to the belt and measure the tension. Follow the gauge manufacturer's instructions. If the belt is worn or damaged, replace it. If the belt needs adjustment, go to step 2. Adjustment 2. Loosen the mounting bolt (A), lock bolt (B) and lower bracket mounting bolt (C). 3. Torque the mounting bolt to 20 N.m (2.0 kgf.m, 14 lbf.ft). 4. Turn the adjusting bolt (D) to obtain the proper belt tension, then retighten the lock bolt, mounting bolt and lower bracket mounting bolt. 5. Recheck the belt tension. 6. If you installed a new belt, run the engine for 5 minutes, then readjust the belt to the used belt specification. 7. Check the power steering pump belt adjustment. Deflection Method Inspection Multiplex Control System Troubleshooting Information Bus: Testing and Inspection Multiplex Control System Troubleshooting Troubleshooting Mode 1 Test 1. Remove the dashboard lower cover. 2. Check the No.9 (10 A) fuse in the under-hood fuse/relay box and the No.10 (7.5 A) fuse in the under-dash fuse/relay box. Are the fuses OK? YES - Go to step 2. NO - Find and repair the cause of the blown fuse. 3. Turn the ignition switch ON (II). If the driver's seatbelt is unbuckled, the seatbelt reminder will chime 6 times. 4. Set the ceiling light to the center position and close all the doors. 5. Connect the special tool to the multiplex inspection connector. 6. After about 5 seconds the spotlight and ceiling light should come on for 2 seconds, go out, then blink on for 0.2 second to show the system is now in mode 1. Did the spotlight and ceiling light indicate mode 1? YES - Go to step 8. NO - Go to step 7. 7. Check for continuity between terminal 4 of the under-dash fuse/relay box connector J and body ground. Is there continuity? YES - Replace the under-dash fuse/relay box. NO - Repair the open in the wire. If the wire is ok, repair G301. 8. If the are DTCs present, the spotlight and ceiling light will blink to indicate the DTC(s). If more than one DTC is present, the DTCs will be displayed in ascending order. If there are not DTCs the spotlight and ceiling light will no blink again after the mode 1 indication. Page 6817 PARTS INFORMATION TOOL INFORMATION Page 140 Hazard Flasher Relay: Testing and Inspection Turn Signal/Hazard Relay Input Test 1. Remove the turn signal/hazard relay (A) from the under-dash fuse/relay box (B). 2. Inspect the relay and fuse/relay box socket terminals to be sure they are all making good contact. - If the terminals are bent, loose, or corroded, repair them as necessary, and recheck the system. - If the terminals look OK, go to step 3. 3. Make these input tests at the fuse/relay box. - If any test indicates a problem, find and correct the cause, then recheck the system. - If all the input tests prove OK, the turn signal/hazard relay must be faulty; replace it. Page 6223 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 5818 Multiple Junction Connector: Service and Repair How to Install New Terminals HOW TO INSTALL NEW TERMINALS 1. Carefully match the old terminal with a new one from the terminal repair kit. Choose the correct replacement terminal based on the wire size range the terminal will accommodate. NOTE: If the replacement terminal quantities are low, reorder them by using the terminal part number listed on the inside lid of the terminal repair kit. Replacement terminals are available through your parts department using normal parts ordering procedures. 2. Depending on the size of the wire you are repainng, use the proper size slot in the crimping tool. 3. Strip the insulation off the end of the wire so the wire fits in the new terminal as shown. (If the wire has a wire seal, replace it with a new one from the kit.) NOTE: After stripping the end of the wire, make sure you did not cut any wire strands. If you did, cut the wire off even with the insulation, and strip it again. 4. Position the terminal in the crimping tool slot with the solid portion of the terminal toward the anvil and the open section toward the former. 5. Insert the wire in the terminal to the position shown in step 3. 6. Squeeze the tool with both hands until the stops make contact. Page 5257 1. Remove the terminal. 2. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE G: 1. Remove the terminal. 2. Go to HOW TO INSTALL NEW TERMINALS. How to Install New Terminals HOW TO INSTALL NEW TERMINALS 1. Carefully match the old terminal with a new one from the terminal repair kit. Choose the correct replacement terminal based on the wire size range the terminal will accommodate. NOTE: If the replacement terminal quantities are low, reorder them by using the terminal part number listed on the inside lid of the terminal repair kit. Replacement terminals are available through your parts department using normal parts ordering procedures. 2. Depending on the size of the wire you are repairing, use the proper size slot in the crimping tool. Page 936 Page 1721 Camshaft: Service and Repair Camshaft, Rocker Arm, Camshaft Seal and Pulley Installation NOTE: To prevent the rocker arm assembly from coming apart, leave the camshaft holder bolts in the holes. 1. After wiping down the camshaft and the journals in the cylinder head, lubricate both surfaces and install the camshaft. 2. Clean and install the oil control orifice (A) with a new O-ring (B) (D17A2, D17A6 engines). 3. Clean and install the oil control orifice (C) (D17A1 engine). 4. Turn the camshaft until its keyway (D) is facing up (No.1 piston TDC). 5. Loosen all the valve adjusting screws. 6. Apply liquid gasket to the head mating surface (shaded areas) of the No. 1 and No. 5 camshaft holders. 7. Set the rocker arm assembly in place and loosely install the bolts. Make sure that the rocker arms are properly positioned on the valve stems. Page 5185 ^ The vehicle is shown as eligible on a VIN status inquiry. In addition, check for a punch mark above the seventh character of the engine compartment VIN. A punch mark in that location means the ignition switch key interlock has already been inspected/repaired. 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 a VIN status inquiry before selling it. CUSTOMER NOTIFICATION All owners of affected vehicles will be sent a notification of this campaign. An example of the customer notification is at the end of this service bulletin. CORRECTIVE ACTION Inspect the ignition switch and, if needed, install a Key Interlock Repair Kit. PARTS INFORMATION Key Interlock Repair Kit: P/N 06351-SDA-000 REQUIRED SPECIAL TOOLS Interlock Slide Hammer: T/N 07AAC-S84A100 NOTE: ^ An initial quantity of Permalube grease to lubricate the sliding surface of the interlock lever is included with the slide hammer. To order more Permalube, use P/N 08734-0030. ^ To order a replacement clamping bolt for the slide hammer, use T/N 07AAC-S84A400. WARRANTY CLAIM INFORMATION Failed Part: P/N 35100-SDA-A31 Defect Code: 5GC00 Symptom Code: R4400 Page 2163 1. Remove the secondary locks. 2. Remove the terminal from the female half. 3. Remove the terminal from the male half. 4. Go to HOW TO INSTALL NEW TERMINALS. Connectors Without a Secondary Lock All examples are shown with the connector lock facing up. The illustrations are examples of connector terminals without a secondary lock; however, the connector you are repairing may vary in size and shape. EXAMPLE A: Page 6955 PARTS INFORMATION TOOL INFORMATION Page 2521 Power Distribution schematics show how power is supplied from the positive battery terminal to various circuits in the vehicle. Refer to the Power Distribution diagram set to get a more detailed understanding of how picture is supplied to the circuit you're working on. Individual circuit schematics begin with a fuse. So 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 Ground Distribution Schematics This sample Ground Distribution schematic shows all of the components that share the same ground point. Page 3782 Skill Level: Repair Technician INSPECTION PROCEDURE 1. Remove the steering column covers. Refer to section 17 of the appropriate service manual. 2. On the lower side of the ignition switch, look at the interlock cylinder cover: ^ If the cover is square, the ignition switch was already replaced with an updated part, and a key interlock repair kit is not needed. Go to step 3. ^ If the cover is round, go to REPAIR PROCEDURE. 3. Reinstall the steering column covers. 4. Center-punch a completion mark above the seventh character of the engine compartment VIN. REPAIR PROCEDURE Page 7389 7. Remove the four screws that hold the two fuses, and remove the fuses. 8. Release the tab that holds the ELD, and pull up on the ELD to remove it. 9. Remove the bus bar from the ELD, and insert the bar into the new ELD. 10. Install the new ELD and bus bar into the fuse/relay box. 11. Reinstall the two fuses. 12. Reinstall the 3P ELD connector and the lower fusel relay box cover. 13. Reinstall the fuse/relay box onto its holder. CR-V only: Reinstall the wire harness clip onto the holder. 14. Reinstall the fuse/relay box cover. 15. Reconnect the negative battery cable. 16. Do the idle learn procedure: ^ Make sure all electrical items (A/C, audio unit, defogger, lights, etc.) are off. Testing and Inspection Vacuum Brake Booster Check Valve: Testing and Inspection Booster Check Valve Test 1. Disconnect the brake booster vacuum hose (check valve built-in) (A) at the booster (B) side. 2. Start the engine, and let it idle. There should be vacuum available. If no vacuum is available, the check valve is not working properly. Replace the brake booster vacuum hose and check valve, and retest. Page 7639 19. Using your thumb and forefinger to hold the tumblers, remove the key from the inner cylinder, being careful not to drop any tumblers and springs. 20. *Using the key code from the iN that you have written down at step 2, build a new inner cylinder with new springs, new cylinder, and tumblers from the door lock cylinder kit. Make sure you put the appropriate numbered tumbler in the proper inner cylinder cavity. Apply a thin layer of Permalube to each tumbler to help lubricate and retain it.* NOTE: ^ There are two types of tumblers. The "SUBLOCK" tumbler goes only in cavity A." The "DISC" tumbler goes in cavities "B" through "J." ^ Cavity "E" is empty on all cylinders. Connector Views 230. Heater Control Panel Page 3494 Fuel Pump Relay: Testing and Inspection Power Relay Test Use this chart to identify the type of relay, then do the test listed for it. NOTE: See the turn signal/hazard relay input test. Normally-open type A: Page 349 Air Bag Control Module: Testing and Inspection Initializing the OPDS (Occupant Position Detection System) Unit Special Tools Required SCS service connector 07PAZ-0010100 When the seat-back cover, seat-back cushion, and/or OPDS unit is replaced, initialize the OPDS by following the procedure below. NOTE: Make sure the passenger's seat is dry. Set the seat-back in the normal position, and make sure there is nothing on the front passenger's seat. 1. Make sure the ignition switch is OFF. 2. Connect the Honda PGM Tester/HDS (A) to the DLC (16P) (B), and follow the Tester's prompts in the "SCS" menu to ground the SCS line (see the Honda PGM Tester Operator's Manual). 3. Connect the SCS service connector (A) to the MES connector (2P) (B). Do not use a jumper wire. 4. Turn the ignition switch ON (II). 5. The SRS indicator comes on for about 6 seconds and goes off. Remove the SCS service connector from the MES connector within 4 seconds after the SRS indicator went off. 6. The SRS indicator comes on again. Reconnect the SCS service connector to the MES connector within 4 seconds after the SRS indicator comes on. 7. The SRS indicator goes off. Remove the SCS service connector from the MES connector within 4 seconds. 8. Watch the SRS indicator. - If the indicator blinks two times and then stays on, the OPDS is initialized, but the DTCs need to be erased. Go to step 9, then erase the DTCs. - If the indicator blinks two times and then goes off, the OPDS unit is initialized. Go to step 9. - If the indicator stays on without first blinking, the OPDS is not initialized. Read the DTC, if DTC 15-1 is indicated, repeat the initialization procedure. If another DTC is indicated, go to the appropriate DTC Troubleshooting Index. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Descriptions/DTC List - Supplemental Restraint System 9. Turn the ignition switch off, and disconnect the PGM Tester. 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. 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 4233 13. Plug in the heat gun, and turn it on. Start at the middle of the splice connector, and move the gun toward the ends as the tube shrinks. Apply heat evenly by rotating the curved heat spreader around the splice connector. Shrinking is complete when a small amount of sealant appears at each end of the tube. Pigtail Terminal Selection Chart PIGTAIL TERMINAL SELECTION CHART Select the proper size pigtail terminal by matching the replacement terminal part number and the wire size being repaired to the corresponding pigtail terminal part number. Then use the color (size) splice connector listed. In some instances you may also have to match the wire seal style to select the proper pigtail terminal. Pigtail terminals are available through your parts department, in quantities of 10, using normal parts ordering procedures. Checking For Poor Fir of Terminals CHECKING FOR POOR FIT OF TERMINALS Loose terminal fit can cause a number of intermittent problems in electrical circuits. By using the Terminal Inspection Feeler Tool Set you can inspect the terminal fit between the two matching connectors without removing the terminals from the connector body. 1. Find the terminal tool that best matches the male terminal in the mating connector. Page 76 PGM-F1 Main Relay 1, 2 Type 1, 2 Check for continuity between the terminals. - There should be continuity between the No.1 and No.2 terminals when power and ground are connected to the No.3 and No.4 terminals. - There should be no continuity between the No.1 and No.2 terminals when power is disconnected. Normally-open type B: Rear Window Defogger Relay Air Mix Control Motor Test Air Door Actuator / Motor: Testing and Inspection Air Mix Control Motor Test Air Mix Control Motor Test 1. Disconnect the 7P connector from the air mix control motor. 2. Connect battery power to the No.1 terminal of the air mix control motor, and ground the No.2 terminal; the air mix control motor should run, and stop at Max Hot. If it doesn't, reverse the connections; the air mix control motor should run, and stop at Max Cool. If the air mix control motor does not run, remove it, then check the air mix control linkage and door for smooth movement. If the linkage and door move smoothly, replace the air mix control motor. - If the linkage or door stick or bind, repair them as needed, - If the air mix control motor runs smoothly, go to step 3. 3. Measure the resistance between the No.5 and No.7 terminals. It should be between 4.2 k to 7.8 kOhm. 4. Reconnect the air mix control motor 7P connector, then turn the ignition switch ON (II). 5. Using the backprobe set, measure the voltage between the No.3 and No.7 terminals. Max Cool - about 1 V Max Hot - about 4 V 6. If either the resistance or voltage readings are not as specified, replace the air mix control motor. Master Switch Test/Replacement Power Window Switch: Testing and Inspection Master Switch Test/Replacement Master Switch Test/Replacement 4-door 1. Remove the door grip cover. 2. Disconnect the 20P connector from the power window master switch. Page 4379 - 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. Troubleshooting Tests 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 test 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 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. 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 Drop Specifications Spark Plug: Specifications NGK ..................................................................................................................................................... ............................................................... PZFR6F-11 DENSO ................................................................................................................................................ ......................................................... PKJ20CR-M11 Gap ...................................................................................................................................................... ................................. 1.0 -1.1 mm (0.039 - 0.043 in) Torque ................................................................................................................................................. ...................................................... 18 N.m (13 lb.ft) Page 4423 4. Inspect the pressure plate (A) surface for wear, cracks, and burning. 5. Inspect the fingers of the diaphragm spring (B) for wear at the release bearing contact area. 6. Inspect for warpage using a straight edge (A) and feeler gauge (B). Measure across the pressure plate (C). If the warpage is more than the service limit, replace the pressure plate. Standard (New): 0.03 mm (0.001 inch) max. Service Limit: 0.15 mm (0.006 inch) 7. Remove the clutch disc and special tools. 8. Inspect the lining of the clutch disc for signs of slipping or oil. If the clutch disc is burned black or oil soaked, replace it. Page 181 1. Remove the terminal. 2. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE B: 1. Remove the terminal. 2. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE C: 1. Remove the terminal. 2. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE D: Page 9554 212. Combination Light Switch Page 7900 Front Fender Liner: Service and Repair Front Inner Fender Replacement Front Inner Fender Replacement NOTE: Take care not to scratch the body. 1. Remove the front inner fender (A). 1. On the back of the wheel arch, remove the screws (B). If equipped, remove the front splash guard (C). 2. From under the front bumper (D), remove the screw (B) securing the front bumper, splash shield (E), and front inner fender, and remove the clip (F) securing the front bumper and front inner fender. With front air spoiler, remove the clip (G) securing the front air spoiler, front bumper, and front inner fender. 3. From the wheel arch, remove the clips (F, H) securing the front inner fender (and splash shield) on the body. 4. Release the hook (I) of the splash shield, then remove the front inner fender. 2. Install the inner fender in the reverse order of removal, and note these items: - Replace any damaged clips. - Push the clips into place securely. Page 7362 Speaker: Service and Repair Speaker Replacement Tweeter: 1. Remove the door panel. 2. Disconnect the 2P connector (A) from the tweeter (B). 3. Remove the mirror mount cover (C). 4. Remove the screw and tweeter from the mirror mount cover. Door Speaker: 1. Remove the door panel. 2. Pull the top of the speaker (A) straight out to release the upper clip, then lift the speaker straight up to release the lower clips. 3. Disconnect the 2P connector (B), and remove the speaker. Rear Speaker: 4-door 1. Remove the rear shelf. Page 1536 Under-hood Fuse And Relay Box (4-door) Page 6396 22. Press a new hub bearing unit (A) into the hub (B) using the special tools and a press. 23. Install the knuckle/hub/hub bearing unit in the reverse order of removal, and note these items: - Be careful not to damage the ball joint boot when installing the knuckle. - Tighten all mounting hardware to the specified torque values. - Torque the castle nut to the lower torque specification, then tighten it only far enough to align the slot with the ball joint pin hole. Do not align the castle nut by loosening it. - Install a new lock pin on the castle nut after torquing. - Use a new spindle nut on reassembly. - Before installing the new spindle nut, apply a small amount of engine oil to the seating surface of the nut. After tightening, use a drift to stake the spindle nut shoulder against the driveshaft. - Before installing the brake disc, clean the mating surface of the front hub and the inside of the brake disc. - Before installing the wheel, clean the mating surface of the brake disc and the inside of the wheel. - Check the front wheel alignment, and adjust it if necessary. Page 2186 67. Radiator Fan Switch Body - Door Lock Cylinders Bind Tailgate Lock Cylinder: All Technical Service Bulletins Body - Door Lock Cylinders Bind 03-068 October 29, 2004 Applies To: See VEHICLES AFFECTED Door Lock Cylinder Binds (Supersedes 03-068, dated April 20, 2004) Updated information is shown with asterisks and black bars. SYMPTOM The key will not go into the door lock cylinder, or if it goes in, it will not turn. PROBABLE CAUSE The door lock tumblers are damaged or worn. VEHICLES AFFECTED CORRECTIVE ACTION Remove the door lock cylinder, and replace the inner cylinder, springs, and tumblers. Page 4971 Terminals - "T" Shielding Switches Fuses Page 7106 Seat Occupant Sensor: Locations SRS Component Location Index Page 3679 Shift Interlock Solenoid: Service and Repair Shift Lock Solenoid Replacement 1. Remove the center console panel and center console. 2. Disconnect the shift lock solenoid connector (2P), and remove it from the shift lever bracket base. 3. Push the lock tab (A), pry the shift lock solenoid (B) to clear the projected tips (C) with a screwdriver, and remove the shift lock solenoid. 4. Install the shift lock solenoid plunger (D) and plunger spring (E) in the new shift lock solenoid. 5. Install the shift lock solenoid by aligning the joint (F) of the shift lock solenoid plunger with the tip (G) of the shift lock stop. 6. Connect the shift lock solenoid connector, and install it on the shift lever bracket base. 7. Install the center console and console panel. Page 122 Exterior Lights Component Location Index Page 5852 234. Under-dash Fuse/Relay Box Part 5 M/T - Clutch Pedal Squeak/Twang or Notchy Feel Clutch Master Cylinder: Customer Interest M/T - Clutch Pedal Squeak/Twang or Notchy Feel 02-002 January 11, 2005 Applies To: See VEHICLES AFFECTED Squeak at the Clutch Pedal (Supersedes 02-002, dated September 21, 2004) SYMPTOM A squeak, a twang, or a notchy feel when the clutch pedal is pressed. PROBABLE CAUSE The clutch master cylinder spring is rubbing on the outer diameter of the piston when the pedal is pressed, or the master cylinder quick connect is moving. Page 7297 2. Cut off the wire about an inch back from where it connects to the damaged or faulty terminal, then strip about half of the insulation off that piece. This will be used to size the wire end of the replacement pigtail terminal. NOTE: If you are not sure of the wire size, start with a large enough hole on the stripper that will not nick or cut off any strands of wires. 3. Select a pigtail terminal that matches the original wire at both ends (same kind of terminal and same diameter bare wire). 4. Select the smallest splice connector (yellow, pink, or blue) that will fit onto the stripped end of the original wire. 5. Insert the pigtail terminal into the connector cavity; push it in until it locks in place. 6. Lay the pigtail and the original wire side-by-side, and cut off both ends at once. If you are making more than one splice, do not cut each pigtail at the same location; the resulting "lump" of splice connectors would interfere with rewrapping the harness. Instead, cut the first pigtail close enough to the terminal so you will have room to make each remaining cut about 20 mm (3/4 inch) farther down on the next pigtail. 7. If you are using a yellow splice connector, strip about 6 mm (1/4 inch) of insulation off the ends of both wires. If you are using a pink or blue splice connector, strip off about 8 mm (5/16 inch) of insulation. Specifications Page 7226 96-97 Passport With Dealer-Installed Security System 1996-97 Passport with dealer-installed security system NOTES: ^ The system uses a stacking-type memory that accepts up to two transmitters. If you program a third transmitter, the memory for the first transmitter is pushed out, and it will no longer work. ^ To clear a lost or stolen transmitter from the system's memory, program a transmitter two times. This will remove the missing transmitter from memory, since only two transmitter codes can be accepted. ^ Another way to clear a lost or stolen transmitter is to erase all transmitter codes and then reprogram them. To do this, refer to the security system owner's manual. Programming the Transmitter 1. Move the driver's seat forward. Locate the security system control unit mounted on the floor underneath the seat. 2. Turn the ignition switch to ON. 3. Use a pen or pencil to press and hold the green programming button on the side of the control unit. When the security system LED on the instrument panel comes on, release the programming button. (Steps 3 and 4 must be done within 5 seconds of each other.) 4. Press and release the top button on the transmitter. Verify that the LED goes out, the siren chirps once, and the front sidemarker lights flash to confirm that the transmitter's code was accepted by the control unit. 5. Turn the ignition switch to LOCK, then to ON. Page 9278 Blower Motor Relay Type 1, Type 2 Check for continuity between the terminals. - There should be continuity between the No.1 and No.3 terminals when power and ground are connected to the No.2 and No.4 terminals. - There should be no continuity between the No.1 and No.3 terminals when power is disconnected. Five-terminal type Check for continuity between the terminals. - There should be continuity between the No.1 and No.2 terminals when power and ground are connected to the No.3 and No.5 terminals. - There should be continuity between the No.1 and No.4 terminals when power is disconnected. Page 1084 1. Remove the terminal. 2. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE E: 1. Remove the terminal. 2. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE F: Page 1033 1. Remove and discard the plastic cover from the ignition switch key interlock solenoid. 2. Note the position of the interlock solenoid plunger; you'll need to install it the same way. 3. Remove the screw from the solenoid, but keep the solenoid attached to its electrical connector. Discard the screw. NOTE: ^ Be careful not to lose the solenoid plunger; it slides out easily. ^ Keep the plunger free of dirt and grease while it's removed from the solenoid. 4. Note the position of the interlock lever spring; you'll need to install the new spring the same way. Page 8132 Programming the Transmitter NOTES: ^ The system accepts up to three transmitters. The transmitter codes are stored in a stacking-type memory. If a fourth transmitter code is programmed, the code for the first transmitter is erased. ^ Entering the programming mode cancels all learned transmitter codes, so none of the previously programmed transmitters will work. You must reprogram all of the transmitters once you are in the programming mode. ^ You must complete steps 1-6 within 4 seconds of the previous step to keep the system from exiting the programming mode. 1. Turn the ignition switch to ON (II). 2. Press the "Lock" or "Unlock" button on one of the transmitters. (An unprogrammed transmitter can be used for this step.) 3. Turn the ignition switch to LOCK (0). 4. Repeat steps 1, 2, and 3 two more times using the same transmitter used in step 2. 5. Turn the ignition switch to ON (II). 6. Press the "Lock" or "Unlock" button on the same transmitter. Make sure the power door locks cycle to confirm that the system is in programming mode. 7. Within 10 seconds, press the "Lock" or "Unlock" button on each transmitter. Make sure the power door locks cycle after you press each transmitter button to confirm that the system accepted the transmitter's code. 8. Turn the ignition switch to LOCK (0) to exit the programming mode. Ordering a Transmitter Transmitters can be ordered only by authorized Honda dealers. Order them from American Honda using normal parts ordering procedures. Batteries for the Transmitter The battery number is CR2025. Each transmitter uses one battery. 88-91 Prelude With Dealer-Installed Security System 1988-91 Prelude with dealer-installed security system Page 9768 123. Driver's Door (Coupe Exc. DX, HX; Sedan Exc. DX) Page 8428 7. To remove a rear drain valve (A) from the trunk compartment, remove these parts, 2-door, 4-door: - Trunk floor mat and trunk floor - Trunk rear trim panel Pull back the trunk side trim panel and release the rear drain tube (B) from the clip (C), and pull the drain tube out through the hole in the pillar. 8. From inside: Release the rear drain tube (A) from the inside of the vehicle by releasing the clips (B). Remove the rear drain tube. 9. Install the frame and drain tube in the reverse order of removal, and note these items: - Before installing the frame, clear the drain tubes and drain valves using compressed air. - Check the frame seal. - Clean the surface of the frame. - When installing the frame, first attach the rear hooks into the body holes. - Make sure the connectors are plugged in properly. - When installing the rear drain tube to the body at the C-pillar, align the cushion of the tube to the hole in the body, and align the alignment mark of the tube to the clip of the upper portion. - When connecting the drain tube, slide it over the frame nozzle at least 10 mm (0.39 in). - Install the tube clip (A) on the drain tube (B) as shown. 10. Check for water leaks. Let the water run freely from a hose without a nozzle. Do not use a high-pressure spray. Page 2617 Knock Sensor: Description and Operation Knock Sensor The knock control system adjusts the ignition timing to minimize knock. Page 278 ECM/PCM Inputs And Outputs At Connector A (31P) Page 8698 5. Remove the actuator cable from the cruise control actuator. 6. Install the reverse order of removal, and adjust the free play at the throttle linkage after connecting the actuator cable. 2-door D17A1, D17A2 engines: 1. Loosen the locknut (A), then disconnect the actuator cable (B) from the throttle linkage. 2. Disconnect the actuator cable from the cruise control actuator. Page 6804 Impact Sensor: Service Precautions SRS Unit, Front Impact Sensors, and Side Impact Sensors - Be careful not to bump or impact the SRS unit, front impact sensors, or side impact sensors whenever the ignition switch is ON (II), or for at least 3 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, front impact sensors, and side impact sensors. The airbags could accidentally deploy and cause damage or injury. - After a collision in which any airbags or seat belt tensioners were deployed, replace the SRS unit, front impact sensors, and other related components. After a collision in which a side airbag was deployed, replace the side impact sensor on the deployed side 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, front impact sensors, and side impact sensors. If there is any damage, replace the SRS unit, front impact sensors and/or side impact sensors. - Do not disassemble the SRS unit, front impact sensors, or the side impact sensors. - Turn the ignition switch OFF, disconnect the battery negative cable, and wait at least 3 minutes before beginning installation or replacement of the SRS unit, or disconnecting the connectors from the SRS unit. - Be sure the SRS unit, front impact sensors, and side impact sensors are installed securely with the mounting bolts torqued to 9.8 N.m (1.0 kgf.m, 7.2 lbf.ft) - Do not spill water or oil on the SRS unit, front impact sensors, or side impact sensors, and keep them away from dust. - Store the SRS unit, front impact sensors, and side impact sensors in a cool (less than 104 °F/40 °C) and dry (less than 80 % relative humidity, no moisture) area. Page 6007 Multiple Junction Connector: Service and Repair Pigtail Terminal Selection Chart PIGTAIL TERMINAL SELECTION CHART Select the proper size pigtail terminal by matching the replacement terminal part number and the wire size being repaired to the corresponding pigtail terminal part number. Then use the color (size) splice connector listed. In some instances you may also have to match the wire seal style to select the proper pigtail terminal. Pigtail terminals are available through your parts department, in quantities of 10, using normal parts ordering procedures. Page 4723 Wheel Bearing: Testing and Inspection End Play Inspection 1. Raise the vehicle, and support it with safety stands in the proper locations. Remove the wheels. 2. Install suitable flat washers (A) and wheel nuts, and tighten the nuts to the specified torque to hold the brake disc or drum securely against the hub. 3. Set up the dial gauge against the hub flange as shown, and measure the bearing end play moving the brake disc or drum inward and outward. Bearing end play: Standard: Front/Rear: 0 - 0.05 mm (0 - 0.002 inch) 4. If the bearing end play is more than the standard, replace the wheel bearing. Page 2818 Circuit Schematics Each schematic represents one circuit. A circuit's wires and components are arranged to show current flow from power at the top of the diagram 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 Page 5752 Auxiliary Power Outlet: Service and Repair Test/Replacement 1. Carefully pry the accessory power socket (A) out from the center lower cover. 2. Disconnect the 2P connector (B) from the socket. 3. Inspect the connector terminals to be sure they are all making good contact. - If the terminals are bent, loose or corroded, repair them as necessary, and recheck the system. - If the terminals look OK, go to step 4. 4. Turn the ignition switch ACC (I), and check for voltage between the No.1 and No.2 terminals. - There should be battery voltage. - If there is no battery voltage, check for: poor ground (G502). - an open in the wire. - blown No.18 (15 A) fuse in the under-dash fuse/relay box. Crankshaft and Piston Removal Crankshaft: Service and Repair Crankshaft and Piston Removal Removal 1. Remove the engine assembly. 2. Remove the transmission: ^ Manual transmission. ^ Automatic transmission. 3. Remove the cylinder head. 4. Remove the oil pan. 5. Remove the engine block end cover. 6. Remove the oil screen (A), then remove the oil pump (B). Page 2311 DTC P0563 thru P0748 Page 6051 Rear Window Defogger Component Location Index Testing and Inspection Seat Belt Retractor: Testing and Inspection Inspection For front seat belt retractor with seat belt tensioner, review the SRS component locations and the precautions and procedures. In the SRS section before performing repairs or service. Retractor 1. Before installing the retractor, check that the seat belt can be pulled out freely. Page 4115 1. Remove the terminal. 2. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE G: 1. Remove the terminal. 2. Go to HOW TO INSTALL NEW TERMINALS. How to Install New Terminals HOW TO INSTALL NEW TERMINALS 1. Carefully match the old terminal with a new one from the terminal repair kit. Choose the correct replacement terminal based on the wire size range the terminal will accommodate. NOTE: If the replacement terminal quantities are low, reorder them by using the terminal part number listed on the inside lid of the terminal repair kit. Replacement terminals are available through your parts department using normal parts ordering procedures. 2. Depending on the size of the wire you are repairing, use the proper size slot in the crimping tool. Engine Controls - DTC P0171 Set Absolute Pressure Sensor: Technical Service Bulletins Engine Controls - DTC P0171 Set SOURCE: Honda Service News TITLE: Got a DTC P0171? Check the Short-Term Fuel Trim APPLIES TO: 03-04 Accord 01-04 Civic 02-04 CR-V 03-04 Element 02-04 Odyssey 03-04 Pilot SERVICE TIP: Got a vehicle in your shop that purrs like a kitten but it sets a DTC P0171 (fuel system too lean)? Check the short-term fuel trim (ST FUEL TRIM B1). If the value reads higher than 1.05, then check the MAP SENSOR value with the engine turned off and the ignition switch turned to ON (II). - If the MAP SENSOR and BARO SENSOR values match, the MAP sensor is working OK. Do the normal troubleshooting for DTC P0171. - If the MAP SENSOR and BARO SENSOR values don't match, install a known-good MAP sensor, and retest. If the sensor values now match, clear the DTC, and make sure the ST FUEL TRIM B1 value is normal (it reads about 1.0). Page 6621 Air Conditioning Component Location Index Page 3824 - 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. Troubleshooting Tests 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 test 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 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. 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 Drop Specifications Spark Plug: Specifications NGK ..................................................................................................................................................... ............................................................... PZFR6F-11 DENSO ................................................................................................................................................ ......................................................... PKJ20CR-M11 Gap ...................................................................................................................................................... ................................. 1.0 -1.1 mm (0.039 - 0.043 in) Torque ................................................................................................................................................. ...................................................... 18 N.m (13 lb.ft) Page 4199 162. Right Side Of Engine Compartment Page 4791 2. Remove the terminal (same procedure for male and female). 3. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE E: 1. Remove the secondary locks. 2. Remove the terminal (same procedure for male and female). 3. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE F: Page 8471 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. Make sure you have the anti-theft code for the radio, then write down the frequencies for the preset buttons. 2. Disconnect the negative cable from the battery, and wait at least 3 minutes before beginning work. 3. Remove the driver's seat from the vehicle. Refer to page 20-109 of the 2001-05 Civic Service Manual. 4. Remove the recline handle by pulling it forward. 5. Remove the center cap from the height knob. Remove the C-clip that holds the height knob. Then remove the knob. 6. Remove the screw and clips from the recline cover. Remove the recline cover. Page 5208 ^ The left end goes behind the notch on the interlock lever. ^ Once the spring is correctly installed, make sure the lever moves freely and returns properly. 10. Insert the plunger into the interlock solenoid, then install the solenoid using a new screw. Make sure the groove of the solenoid plunger is in the fork on the lever. 11. Install a new plastic cover on the interlock solenoid. 12. Check the operation of the ignition switch key interlock: ^ Set the parking brake, and turn the ignition switch to ON (I I). ^ While pressing the brake pedal, shift the transmission to Neutral. ^ Try turning the ignition switch to LOCK (0) - If you cannot turn the switch to LOCK (0), your repair was successful; go to step 15. - If you can turn the switch to LOCK (0), the interlock is not working; go to step 13. Page 7027 6. Install the belt and buckles in the reverse order of removal, and note these items: - Apply liquid thread lock to the anchor bolts before reinstallation. - Check that the retractor locking mechanism functions. - Assemble the washers on the center anchor bolt as shown. - Before installing the center anchor bolt, make sure there are no twists or kinks in the center belt. Page 7748 VEHICLES AFFECTED CORRECTIVE ACTION Adjust the trunk lid and/or the trunk lid latch, or replace components as needed. PARTS INFORMATION WARRANTY CLAIM INFORMATION In warranty: The normal warranty applies. Failed Part: P/N 68500-S5P-A90ZZ H/C 6528640 *Defect Code: 07406* Symptom Code: 03220 Page 1525 Exterior Lights Component Location Index Page 1461 Refrigerant: Fluid Type Specifications Refrigerant Type ..................................................................................................................................................... ........................................... HFC-134 a (R-134 a) Page 3191 162. Right Side Of Engine Compartment Page 7038 2. Make sure that the seat belt does not lock when the retractor (A) is leaned slowly up to 15 ° from the mounted position. The seat belt should lock when the retractor is leaned over 40 °. Do not attempt to disassemble the retractor. 3. Replace the seat belt with a new assembly if there is any abnormality. Do not disassemble any part of the seat belt for any reason. In-vehicle 1. Check that the seat belt is not twisted or caught on anything. 2. After installing the anchors, check for free movement on the anchor bolts. If necessary, remove the anchor bolts and check that the washers and other parts are not damaged or improperly installed. 3. Check the seat belts for damage or discoloration. Clean with a shop towel if necessary. Use only soap and water to clean. NOTE: Dirt build-up in the loops of the upper anchors can cause the seat belts to retract slowly. Wipe the inside of the loops with a clean cloth dampened in isopropyl alcohol. 4. Check that the seat belt does not lock when pulled out slowly. The seat belt is designed to lock only during a sudden stop or impact. 5. Make sure that the seat belt will retract automatically when released. 6. For each passenger's seat belt, check the seat belt retractor locking mechanism ALR (automatic locking retractor). This function is for securing child seats. -1 Pull the seat belt all the way out to engage the ALR. The seat belt should retract with a ratcheting sound, but not extend. This is normal. -2 To disengage the ALR, release the seat belt and allow it to fully retract, then pull the seat belt out part-way. The seat belt should retract and extend normally. 7. Replace the seat belt with a new assembly if there is any abnormality. Do not disassemble any part of the seat belt for any reason. Page 9411 2. Cut off the wire about an inch back from where it connects to the damaged or faulty terminal, then strip about half of the insulation off that piece. This will be used to size the wire end of the replacement pigtail terminal. NOTE: If you are not sure of the wire size, start with a large enough hole on the stripper that will not nick or cut off any strands of wires. 3. Select a pigtail terminal that matches the original wire at both ends (same kind of terminal and same diameter bare wire). 4. Select the smallest splice connector (yellow, pink, or blue) that will fit onto the stripped end of the original wire. 5. Insert the pigtail terminal into the connector cavity; push it in until it locks in place. 6. Lay the pigtail and the original wire side-by-side, and cut off both ends at once. If you are making more than one splice, do not cut each pigtail at the same location; the resulting "lump" of splice connectors would interfere with rewrapping the harness. Instead, cut the first pigtail close enough to the terminal so you will have room to make each remaining cut about 20 mm (3/4 inch) farther down on the next pigtail. 7. If you are using a yellow splice connector, strip about 6 mm (1/4 inch) of insulation off the ends of both wires. If you are using a pink or blue splice connector, strip off about 8 mm (5/16 inch) of insulation. Page 5269 7. Align the cutouts (A) on the rotary-frame with the neutral positioning cutouts (B) on the transmission range switch, then put a 2.0 mm (0.08 inch) feeler gauge blade (C) in the cutouts to hold it in the N position. NOTE: Be sure to use a 2.0 mm (0.08 inch) blade or equivalent to hold the switch in the N position. 8. Install the transmission range switch (A) gently on the control shaft (B) with holding the N position with the 2.0 mm (0.08 inch) blade (C). 9. Tighten the bolts on the transmission range switch while you continue to hold it in the N position. Do not move the transmission range switch when tightening the bolts. Remove the feeler gauge. Page 6448 Air Door Actuator / Motor: Diagrams 180. Air Mix Control Motor 183. Mode Control Motor 184. Recirculation Control Motor Page 3214 1. Remove the secondary lock from the male terminal half. 2. Remove the secondary lock from the female terminal half. 3. Remove the terminal (same procedure for male and female). 4. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE C: 1. Remove the secondary lock. Page 5610 64. Under Left Side Of Dash (M/T) Page 4396 2. Insert the terminal tool into the female terminal, and then remove the terminal tool. NOTE: Make sure you do not select a terminal tool that is larger than the mating male terminal because it would spread the female terminal and cause a loose fit. 3. Compare the drag to the other terminals in the connector. If the drag is less, replace the terminal with a replacement terminal from the appropriate terminal repair kit. Page 8555 8. Tell the customer not to disturb the front bumper air spoiler for 24 hours to allow the adhesive to cure completely. Disclaimer Component Locations Shift Interlock Switch: Component Locations Component Location Index Page 9620 Turn Signal Relay: Testing and Inspection Turn Signal/Hazard Relay Input Test 1. Remove the turn signal/hazard relay (A) from the under-dash fuse/relay box (B). 2. Inspect the relay and fuse/relay box socket terminals to be sure they are all making good contact. - If the terminals are bent, loose, or corroded, repair them as necessary, and recheck the system. - If the terminals look OK, go to step 3. 3. Make these input tests at the fuse/relay box. - If any test indicates a problem, find and correct the cause, then recheck the system. - If all the input tests prove OK, the turn signal/hazard relay must be faulty; replace it. Page 8472 7. Remove and discard the three nuts, and remove the washers from the outboard link and from the outboard seat track. 8. 2001-02 Models: Remove and discard the spacer from the outboard link. 9. Remove and discard the old bushings. 10. Install the new bushings, and add one spacer as shown. 11. Reassemble the outboard side of the seat track in the reverse order of removal using new nuts. Torque the nuts to 24 N.m (17 lb-ft). 12. Install the recline cover, height knob, and recline handle. 13. Remove the seat belt buckle. Page 9153 13. Plug in the heat gun, and turn it on. Start at the middle of the splice connector, and move the gun toward the ends as the tube shrinks. Apply heat evenly by rotating the curved heat spreader around the splice connector. Shrinking is complete when a small amount of sealant appears at each end of the tube. Pigtail Terminal Selection Chart PIGTAIL TERMINAL SELECTION CHART Select the proper size pigtail terminal by matching the replacement terminal part number and the wire size being repaired to the corresponding pigtail terminal part number. Then use the color (size) splice connector listed. In some instances you may also have to match the wire seal style to select the proper pigtail terminal. Pigtail terminals are available through your parts department, in quantities of 10, using normal parts ordering procedures. Checking For Poor Fir of Terminals CHECKING FOR POOR FIT OF TERMINALS Loose terminal fit can cause a number of intermittent problems in electrical circuits. By using the Terminal Inspection Feeler Tool Set you can inspect the terminal fit between the two matching connectors without removing the terminals from the connector body. 1. Find the terminal tool that best matches the male terminal in the mating connector. Service and Repair Cross-Member: Service and Repair Middle Cross-member Gusset Replacement 2-door NOTE: - Put on gloves to protect your hands. - Take care not to scratch the body. 1. Remove these items: - Rear seat-back - Rear seat cushion - Side trim panel 2. Pull back the rear part of the carpet, as necessary. 3. Detach the floor wire harness clip (A), and remove the cushion tape (B), then release the harness from the middle cross-member gusset (C). 4. Remove the bolts (A) and nuts (B), then remove the middle cross-member gusset (C). Page 1209 Windshield Washer Switch: Testing and Inspection Wiper/Washer Switch Test/Replacement 1. Remove the dashboard lower cover. 2. Remove the steering column covers. 3. Disconnect the 14P connector (A) from the wiper/washer switch (B) 4. Remove the two screws, then pull out the wiper/washer switch. 5. Inspect the connector terminals to be sure they are all making good contact. - If the terminals are bent, loose or corroded, repair them as necessary, and recheck the system. - If the terminals look OK, check for continuity between the terminals in each switch position according to the tables. If the continuity is not as specified, replace the switch. Component Locations Shift Interlock Switch: Component Locations Component Location Index Page 3993 Torque Converter Clutch Solenoid: Testing and Inspection Torque Converter Clutch Solenoid Valve Test 1. Disconnect the torque converter clutch solenoid valve connector. 2. Measure the resistance between the No. 1 and No. 2 terminals of the torque converter solenoid valve connector. STANDARD: 12 - 25 Ohms 3. Replace the torque converter clutch solenoid valve if the resistance is out of standard. 4. If the resistance is within the standard, connect the No. 2 terminal to the battery positive terminal, and connect the No. 1 terminal to the battery negative terminal. A clicking sound should be heard. Replace the torque converter clutch solenoid valve if no sound is heard when connecting the battery positive terminal. Procedures Cabin Ventilation Duct: Procedures Rear Air Outlet Replacement 1. Remove the rear bumper. 2. Detach the hooks (A), then remove the rear air outlet (B). Take care not to scratch the body. 3. Install the air outlet by pushing on the hook portions until the hooks snap into place. Body - Trunk Lid Hard to Close Trunk / Liftgate Lock Cylinder: All Technical Service Bulletins Body - Trunk Lid Hard to Close 02-061 November 5, 2004 Applies To: See VEHICLES AFFECTED Trunk Lid is Difficult to Close (Supersedes 02-061, dated July 23, 2004) Updated information is shown with asterisks. SYMPTOM The trunk lid may be difficult to close or won't latch closed. PROBABLE CAUSE The trunk lid may be misaligned, and the trunk lid opener cable, trunk lid latch, lock cylinder, lock rod, and/or the trunk lid latch striker may need adjustment or replacement. VEHICLES AFFECTED CORRECTIVE ACTION Adjust the trunk lid and/or the trunk lid latch, or replace components as needed. PARTS INFORMATION Page 6708 8. Reinstall the driver's airbag using new Torx bolts: ^ Refer to the appropriate service manual, or ^ Online, enter keywords DRIVER AIR, and select Driver's Airbag Replacement from the list. 9. Center-punch a completion mark below the third character of the engine compartment VIN: 10. Give your warranty clerk the 13-digit inflator serial number you wrote down in step 1. For the warranty claim to be paid, your warranty clerk must enter the appropriate 13-digit serial number in the Diagnostic Trouble Codes field on the warranty claim. INFLATOR PACKING AND GROUND SHIPPING INSTRUCTIONS: DEALERS IN THE 48 CONTIGUOUS STATES NOTE: ^ Do not deploy the original inflator. Claims for deployed inflators will be charged back to your dealership. ^ There is a 48-hour return shipment objective for the inflator. ^ The following ground shipping instructions are also in the return shipping box (the box the new inflator came in) from kit P/N 04770-55A-308. If you're a dealer in Alaska or Hawaii, call the WPI administrative office for FedEx Air shipping documents and instructions. 1. Carefully insert the original inflator into the round opening in the return shipping box (the box that the new inflator came in). Also place a copy of the repair order in the box. 2. Close the top flap on the box, then double-tape the the box closed with 2-inch clear packing tape on the entire front seam and the side seams. Press down on the tape for good adhesion. 3. Fill out the Fed Ex Ground paperwork, and handle it as indicated below: ^ OP-950 Hazardous Materials Certification form: - At the top, fill in the shipper name, address, and date. - At the bottom, sign your name on the signature line. - List the Tracking ID on the right side column of both copies. (The 15-digit Tracking ID is found on the PRP Shipping Label beneath the large bar code to the right of the parenthesis.) - Keep one copy for dealer records and retain it for 1 year; give the second copy to the Fed Ex Ground driver. ^ FedEx Ground PRP Shipping Label: - Complete all fields in the upper section of the label. (The RA number is not required.) - Review the instructions on the back and, when the shipment is ready, call for Fed Ex Ground pick up for business locations at 888-777-6040. ^ OP-900 Hazardous Materials form: - This form requires no further completion; attach the six-part label to the box. 4. Prepare the box and the labels: ^ Remove or black-out any old shipping labels, including the original bar code. Do not remove or black-out any of the hazard marks or labels. ^ Remove the adhesive backing from the PRP and the OP-900 labels, and attach them firmly to the box. Do not cover any of the hazard marks or labels. Page 5944 Fuse: Locations Under-Hood Fuse/Relay Box Under-hood Fuse/Relay Box Page 8627 12. Pull the vertical carriage lever toward you while you position the tracer on the right edge of the original key at its head, using the clamp carriage lever. Let the cutter bit cut into the key blank, then stop. Gently twist the lever clockwise to lock the vertical carriage at this height. Do not overtighten the lever. 13. Use the clamp carriage lever and the tracer to follow the contours of the original key. (The cutter bit cuts the same contours into the key blank.) Working from right to left, follow the right edge of the original key from head to tip, then the left edge of the key from tip to head. Turn off the cutter motor. 14. Reposition the tracer on the right edge of the original key at its head, using the clamp carriage lever. Turn on the cutter motor. Retrace the key from head to tip, then from tip to head. (This retracing cleans up the cuts on the key.) Turn off the cutter motor. 15. Release the vertical carriage lever. Open the jaw and remove only the new key. Make sure the jaw is free of any metal shavings or debris, then turn the new key over and slide the key with its blank side up into the jaw up to the key stop. Close the jaw to lock the key into place. 16. Turn on the cutter motor, and repeat steps 12 thru 14 to cut both edges of the other side of the key. 17. When you are finished making the required cuts, turn off the cutter motor, and release the vertical carriage lever. Open the jaws, and remove the keys. 18. Use a wire brush to smooth the cut surfaces on the new key. 19. Make sure the key works in the ignition switch and all the locks. If the key does not work, recut the key, and try it again. 20. Depending on the type of key blank you have used, do this: ^ If you have used a Honda key blank, add the transponder code of the new key to the immobilizer system with the Honda Diagnostic System (HDS). ^ If you have used a T-5 programmable key blank ("T-5" stamped on the shank), code the key's transponder with the Ilco Immobilizer Key Code Duplicator (see S/B 99-053, Ilco Immobilizer key Code Duplicator). Cutting Procedure - By Code 1. Press the ON/OFF button in the middle of the setting unit keypad. (This powers up the keypad.) 2. Turn the clamp unit lock lever to the left to release the clamp unit, and slide it to the right until the bottom left side is flush with the base edge. Turn the lever to the right to lock the clamp unit in place. Loosen the lateral and spring tension adjustment knobs on the clamp carriage. Page 6273 74. Attach the yoke (A) of a universal puller to the gearbox housing (B) with bolts, then securely clamp the yoke in a vise with jaws. Do not clamp the gearbox housing in a vise. 75. Push the cylinder (A) into the gearbox housing (B) so the notch (C) is aligned with the pin (D) inside of the gearbox housing. 76. Tighten the lock screw (A) by hand first, then install the special tool (B) on the lock screw. Lightly tighten the lock screw. Do not tighten the lock screw to specified torque yet. 77. Remove the special tool and yoke from the steering gearbox. Page 9134 - Remove clips carefully; don't damage their locks (A). - Slip pliers (A) under the clip base and through the hole at an angle, then squeeze the expansion tabs to release the clip. - After installing harness clips, make sure the harness doesn't interfere with any moving parts. - Keep wire harnesses away from exhaust pipes and other hot parts, from sharp edges of brackets and holes, and from exposed screws and bolts. - Seat grommets in their grooves properly (A). Do not leave grommets distorted (B). Testing and Repairs - Do not use wires or harnesses with broken insulation. Replace them or repair them by wrapping the break with electrical tape. - After installing parts, make sure that no wires are pinched under them. - When using electrical test equipment, follow the manufacturer's instructions and those described. - If possible, insert the probe of the tester from the wire side (except waterproof connector). - Use back probe adaptor 07TAZ-001020A. - Refer to the instructions in the Honda Terminal Kit for identification and replacement of connector terminals. Five-Step Troubleshooting Five-Step Troubleshooting 1. Verify The Complaint Page 6769 Air Bag Control Module: Diagrams 231. OPDS Unit Page 4689 195. Tranmission Range Switch Specifications Page 1771 2. Cut off the wire about an inch back from where it connects to the damaged or faulty terminal, then strip about half of the insulation off that piece. This will be used to size the wire end of the replacement pigtail terminal. NOTE: If you are not sure of the wire size, start with a large enough hole on the stripper that will not nick or cut off any strands of wires. 3. Select a pigtail terminal that matches the original wire at both ends (same kind of terminal and same diameter bare wire). 4. Select the smallest splice connector (yellow, pink, or blue) that will fit onto the stripped end of the original wire. 5. Insert the pigtail terminal into the connector cavity; push it in until it locks in place. 6. Lay the pigtail and the original wire side-by-side, and cut off both ends at once. If you are making more than one splice, do not cut each pigtail at the same location; the resulting "lump" of splice connectors would interfere with rewrapping the harness. Instead, cut the first pigtail close enough to the terminal so you will have room to make each remaining cut about 20 mm (3/4 inch) farther down on the next pigtail. 7. If you are using a yellow splice connector, strip about 6 mm (1/4 inch) of insulation off the ends of both wires. If you are using a pink or blue splice connector, strip off about 8 mm (5/16 inch) of insulation. Page 1751 Power Distribution schematics show how power is supplied from the positive battery terminal to various circuits in the vehicle. Refer to the Power Distribution diagram set to get a more detailed understanding of how picture is supplied to the circuit you're working on. Individual circuit schematics begin with a fuse. So 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 Ground Distribution Schematics This sample Ground Distribution schematic shows all of the components that share the same ground point. Page 755 36. Left Side Of Engine Compartment (except GX) Page 9688 PGM-F1 Main Relay 1, 2 Type 1, 2 Check for continuity between the terminals. - There should be continuity between the No.1 and No.2 terminals when power and ground are connected to the No.3 and No.4 terminals. - There should be no continuity between the No.1 and No.2 terminals when power is disconnected. Normally-open type B: Rear Window Defogger Relay Page 2504 125. TP Sensor Page 5781 Under-dash Fuse/Relay Box (2-door) Diagram Information and Instructions Interior Lighting Module: Diagram Information and Instructions Terminal Numbering System Terminal Numbering System Connector terminals are numbered according to the cavities they're in. The cavities are numbered starting from the upper left, looking at the male terminals from the terminal side or looking at the female terminals from the wire side. Both views are in the same direction so the numbers are the same. All actual cavities are numbered, even if they have no wire terminals in them. NOTE: Data Link Connector (DLC) terminals are numbered according 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 below is #6. Page 6193 21. Position the pump drive shaft (A) in the pump housing, then drive it in with the appropriate size socket wrench (B) as shown. 22. Install the 40 mm snap ring (C) with its radiused side facing out. 23. Coat the new 23.8 mm O-ring (A) with power steering fluid, then position it into the groove on the bottom of the pump housing. 24. Coat the new cover seal (A) and 13 mm O-ring (B) with the power steering fluid, then position them into the grooves on the cover (C). Page 5943 Under-dash Fuse/Relay Box (2-door) Page 2479 17. Right Side Of Engine Compartment (EX, HX) Page 7607 8. Release the clip, detach the hook, and remove the lock rod protector. 9. Disconnect the outer handle rod and cylinder rod. Page 2681 Intake Air Temperature Sensor: Service and Repair IAT Sensor Replacement 1. Disconnect the IAT sensor 2P connector. 2. Remove the IAT sensor (A). 3. Install the sensor in the reverse order of removal Page 5962 Wiper/Washer Component Location Index Page 1628 Wheel Bearing: Testing and Inspection End Play Inspection 1. Raise the vehicle, and support it with safety stands in the proper locations. Remove the wheels. 2. Install suitable flat washers (A) and wheel nuts, and tighten the nuts to the specified torque to hold the brake disc or drum securely against the hub. 3. Set up the dial gauge against the hub flange as shown, and measure the bearing end play moving the brake disc or drum inward and outward. Bearing end play: Standard: Front/Rear: 0 - 0.05 mm (0 - 0.002 inch) 4. If the bearing end play is more than the standard, replace the wheel bearing. Page 180 1. Remove the secondary locks. 2. Remove the terminal from the female half. 3. Remove the terminal from the male half. 4. Go to HOW TO INSTALL NEW TERMINALS. Connectors Without a Secondary Lock All examples are shown with the connector lock facing up. The illustrations are examples of connector terminals without a secondary lock; however, the connector you are repairing may vary in size and shape. EXAMPLE A: Page 1265 DIAGNOSTIC WORKSHEET REPAIR PROCEDURE A Page 1079 1. Remove the secondary lock from the male terminal half. 2. Remove the secondary lock from the female terminal half. 3. Remove the terminal (same procedure for male and female). 4. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE C: 1. Remove the secondary lock. Page 291 ECM/PCM Inputs And Outputs At Connector C (22P) Page 5556 12. Pull the vertical carriage lever toward you while you position the tracer on the right edge of the original key at its head, using the clamp carriage lever. Let the cutter bit cut into the key blank, then stop. Gently twist the lever clockwise to lock the vertical carriage at this height. Do not overtighten the lever. 13. Use the clamp carriage lever and the tracer to follow the contours of the original key. (The cutter bit cuts the same contours into the key blank.) Working from right to left, follow the right edge of the original key from head to tip, then the left edge of the key from tip to head. Turn off the cutter motor. 14. Reposition the tracer on the right edge of the original key at its head, using the clamp carriage lever. Turn on the cutter motor. Retrace the key from head to tip, then from tip to head. (This retracing cleans up the cuts on the key.) Turn off the cutter motor. 15. Release the vertical carriage lever. Open the jaw and remove only the new key. Make sure the jaw is free of any metal shavings or debris, then turn the new key over and slide the key with its blank side up into the jaw up to the key stop. Close the jaw to lock the key into place. 16. Turn on the cutter motor, and repeat steps 12 thru 14 to cut both edges of the other side of the key. 17. When you are finished making the required cuts, turn off the cutter motor, and release the vertical carriage lever. Open the jaws, and remove the keys. 18. Use a wire brush to smooth the cut surfaces on the new key. 19. Make sure the key works in the ignition switch and all the locks. If the key does not work, recut the key, and try it again. 20. Depending on the type of key blank you have used, do this: ^ If you have used a Honda key blank, add the transponder code of the new key to the immobilizer system with the Honda Diagnostic System (HDS). ^ If you have used a T-5 programmable key blank ("T-5" stamped on the shank), code the key's transponder with the Ilco Immobilizer Key Code Duplicator (see S/B 99-053, Ilco Immobilizer key Code Duplicator). Cutting Procedure - By Code 1. Press the ON/OFF button in the middle of the setting unit keypad. (This powers up the keypad.) 2. Turn the clamp unit lock lever to the left to release the clamp unit, and slide it to the right until the bottom left side is flush with the base edge. Turn the lever to the right to lock the clamp unit in place. Loosen the lateral and spring tension adjustment knobs on the clamp carriage. Page 1410 9. Remove, drain and reinstall the reservoir. Fill the tank to the MAX mark (A) with Honda All Season Antifreeze/Coolant Type 2. 10. Pour Honda All Season Antifreeze/Coolant Type 2 into the radiator up to the base of the filler neck. NOTE: Always use Honda All Season Antifreeze/Coolant Type 2. Using a non-Honda coolant can result in corrosion, causing the cooling system to malfunction or fail. - Honda All Season Antifreeze/Coolant Type 2 is a mixture of 50% antifreeze and 50% water. Premixing is not required. Engine Coolant Refill Capacity (including the reservoir capacity of 0.4 L (0.4 US qt): M/T: 4.0 L (4.2 US qt.) A/T, CVT: 3.9 L (4.1 US qt.) 11. Install the radiator cap loosely. 12. Install the battery. 13. Start the engine and let it run until it warms up (the radiator fan comes on at least twice). 14. Turn off the engine. Check the level in the radiator, and add Honda All Season Antifreeze/Coolant Type 2 if needed. 15. Put the radiator cap on tightly, then run the engine again and check for leaks. 16. Enter the anti-theft code for the radio, then enter the customer's radio station presets. Page 8679 Cruise Control Module: Testing and Inspection Cruise Control Unit Input Test Except 2-door D17A1, D17A2 engines: SRS components are located in this area. Review the SRS component locations, precautions, and procedures, in the SRS before performing repairs or service. 1. Remove the driver's dashboard lower cover. 2. Disconnect the 14P connector from the control unit. 3. Inspect the connector and socket terminals to be sure they are all making good contact. - If the terminals are bent, loose, or corroded, repair them as necessary, and recheck the system. - If the terminals look OK, go to step 4. Service and Repair Camshaft Gear/Sprocket: Service and Repair Camshaft, Rocker Arm, Camshaft Seal and Pulley Installation NOTE: To prevent the rocker arm assembly from coming apart, leave the camshaft holder bolts in the holes. 1. After wiping down the camshaft and the journals in the cylinder head, lubricate both surfaces and install the camshaft. 2. Clean and install the oil control orifice (A) with a new O-ring (B) (D17A2, D17A6 engines). 3. Clean and install the oil control orifice (C) (D17A1 engine). 4. Turn the camshaft until its keyway (D) is facing up (No.1 piston TDC). 5. Loosen all the valve adjusting screws. 6. Apply liquid gasket to the head mating surface (shaded areas) of the No. 1 and No. 5 camshaft holders. 7. Set the rocker arm assembly in place and loosely install the bolts. Make sure that the rocker arms are properly positioned on the valve stems. Ignition/Locks - Cutting Sidewinder-Type Keys Technical Service Bulletin # 01-077 Date: 060419 Ignition/Locks - Cutting Sidewinder-Type Keys 01-077 April 19, 2006 Applies To: Models With Sidewinder-Type Keys - All Cutting Sidewinder-Type Keys With the MATRIX H Key Cutting Machine (Supersedes 01-077, dated January 12, 2005) Updated information is noted by asterisks. MATRIX H Key Cutting Machine, manufactured by Silca and supplied by Kaba Ilco Corporation, is a portable, power-operated tool that cuts sidewinder-type automotive keys exclusively. The machine lets you cut these keys either by copying or by code. The code function is designed and built to meet the Honda code requirements. No other similar machine has this capability. This service bulletin gives you information for ordering and servicing this special tool, and guides you through the entire key cutting process from setting up the machine to cutting the key blank. TOOL INFORMATION Order through the Honda Tool and Equipment Program: MATRIX H Key Cutting Machine: Model No. ILCMATRIXSH Cutter Bit: Model No. ILCF3O Fixed Jaw: Model No. ILCMTX-H Mobile Jaw (Right Side): Model No. ILCRTMTX-H Mobile Jaw (Left Side): Model No. ILCLTMTX-H *Remanufactured Clamp Unit: Model No. ILCMATRIXHCR* PARTS INFORMATION *For some models, there are two choices for sidewinder-type key blanks: ^ T-5 sidewinder key blanks ^ Honda sidewinder key blanks For other models, only Honda sidewinder key blanks can be used. See DETERMINING WHICH KEY TO USE to determine which key blank you should choose. Ordering T-5 key blanks through the Honda Tool and Equipment Program: T-5 Programmable Key Blank (Master): P/N ILC-35111-T-5H T-5 Programmable Key Blank (Valet): P/N ILC-35112-T-5H Practice Key Blanks (five per pack): ILC-35111DEMO* NOTE: Do not use practice key blanks for replacement purposes. Practice keys do not have an immobilizer chip. Page 5472 6. If the clearance is incorrect, loosen the star locknut (A), and turn the adjuster (B) in or out to adjust. ^ Adjust the clearance while the specified vacuum is applied to the booster. ^ Hold the clevis (C) while adjusting. 7. Tighten the star locknut securely. 8. Remove the special tool (D). 9. Check the pushrod length (A) as shown if the booster is removed. If the length is incorrect, loosen the pushrod locknut (B), and turn the clevis (C) in or out to adjust. 10. Install the master cylinder. Locations Air Bag Control Module: Locations Relay And Control Unit Locations - Dashboard A/T - Vehicle Won't Move/MIL ON/DTC P0730 PROM - Programmable Read Only Memory: All Technical Service Bulletins A/T - Vehicle Won't Move/MIL ON/DTC P0730 04-036 January 7, 2005 Applies To: See VEHICLES AFFECTED Vehicle Does Not Move in Drive; MIL Comes On or D Indicator Blinks With A/T DTC P0730 (Supersedes 04-036, dated September 24, 2004) SYMPTOM The vehicle does not move when you select Drive. The MIL comes on ('01-03 models) or the D indicator blinks ('04 models) with "A" DTC P0730 (shift control system) set. PROBABLE CAUSE Excessive wear in the 2nd clutch. VEHICLES AFFECTED CORRECTIVE ACTION Replace the A/T. Use the Honda Interface Module (HIM) to update the PGM software ('01-03 models only). TOOL INFORMATION To do the repair procedure, you need these items: ^ Interactive Network (iN) CD (July '04 or later) ^ iN Workstation ^ Honda Interface Module (HIM): T/N EQS05A35570 ^ PC Interface Cable (RS232): T/N VET-02002832 [This is the same cable you use to connect the PCM Tester to the iN workstation when updating software or when downloading DTCs to American Honda. The cable is blue with an attached adapter.] ^ AC Adapter (110 VAC/12 VDC Power Supply): T/N VET-02002426 (This is the same adapter used by the PGM Tester.) To order additional HIMs, interface cables, or A/C adapters, call the Honda Tool and Equipment Program or use the fax order form provided in your Honda Tool and Equipment Program Catalog. Phone lines are open Monday through Friday from 7:30 a.m. to 7:00 p.m., Central Time. You can also order through the iN. Click on SERVICE, Service Bay, and then Tool and Equipment, or click on eMail and then Tool and Equipment Program. Page 3329 Evaporative Check Valve: Testing and Inspection EVAP Two Way Valve Test Special Tools Required - Vacuum pump/Gauge, 0 - 30 in.Hg A973X-041-XXXXX - Vacuum/Pressure Gauge, 0 - 4 in.Hg 07JAZ-001000B 1. Remove the fuel fill cap. 2. Disconnect the vapor line from the EVAP two way valve (A). Connect it to a fitting (B) from the vacuum gauge and the vacuum pump as shown. 3. Apply vacuum slowly and continuously while watching the gauge. The vacuum should stabilize momentarily at 0.8 - 2.1 kPa (6 - 16 mmHg, 0.2 0.6 in.Hg). If the vacuum stabilizes (valve opens) below 0.8 kPa (6 mmHg, 0.2 in.Hg) or above 2.1 kPa (16 mmHg, 0.6 in.Hg), install a new valve and retest. 4. Move the vacuum pump hose from the vacuum fining to the pressure fitting, and move the vacuum gauge hose from the vacuum side to the pressure side (A) as shown. 5. Slowly pressurize the vapor line while watching the gauge. The pressure should stabilize momentarily above 1.0 kPa (8 mmHg, 0.3 in.Hg). - If the pressure momentarily stabilizes (valve opens) above 1.0 kPa (8 mmHg, 0.3 in.Hg), the valve is OK. - If the pressure stabilizes below 1.0 kPa (8 mmHg, 0.3 in.Hg), install a new valve and retest. Page 2064 2. Cut off the wire about an inch back from where it connects to the damaged or faulty terminal, then strip about half of the insulation off that piece. This will be used to size the wire end of the replacement pigtail terminal. NOTE: If you are not sure of the wire size, start with a large enough hole on the stripper that will not nick or cut off any strands of wires. 3. Select a pigtail terminal that matches the original wire at both ends (same kind of terminal and same diameter bare wire). 4. Select the smallest splice connector (yellow, pink, or blue) that will fit onto the stripped end of the original wire. 5. Insert the pigtail terminal into the connector cavity; push it in until it locks in place. 6. Lay the pigtail and the original wire side-by-side, and cut off both ends at once. If you are making more than one splice, do not cut each pigtail at the same location; the resulting "lump" of splice connectors would interfere with rewrapping the harness. Instead, cut the first pigtail close enough to the terminal so you will have room to make each remaining cut about 20 mm (3/4 inch) farther down on the next pigtail. 7. If you are using a yellow splice connector, strip about 6 mm (1/4 inch) of insulation off the ends of both wires. If you are using a pink or blue splice connector, strip off about 8 mm (5/16 inch) of insulation. Page 6343 2. Line up the slots in the arms with the bolt holes on the corners of the jack base, then attach the adapter to the jack base with the bolts that came with the jack. Tighten all of the bolts securely. 3. Raise the jack to vehicle height. 4. With the rear bar of the adapter spanning the sides of the subframe, route the adapter's strap around the front of the subframe. Pull the strap as tightly as possible, insert the pin through the appropriate loop, then tighten the wing nut. 5. With all of the vehicle parts properly supported or removed (see Engine or Transmission Removal in the appropriate service manual), carefully lower the subframe using the controls on the jack. Disclaimer Page 1108 Transmission Speed Sensor: Service and Repair Countershaft Speed Sensor Replacement Countershaft Speed Sensor Replacement 1. Disconnect the countershaft speed sensor connector. 2. Remove the countershaft speed sensor (A). 3. Install the new countershaft speed sensor with the new O-ring (B). 4. Check the countershaft speed sensor connector for rust, dirt, or oil, then connect the connector securely. Recall 10V041000: Air Bag Inflator Replacement Air Bag: All Technical Service Bulletins Recall 10V041000: Air Bag Inflator Replacement VEHICLE MAKE/MODEL: MODEL YEAR(S): Acura/3.2CL 2003 Acura/3.2TL 2002-2003 Honda/Accord 2001-2002 Honda/Civic 2001-2003 Honda/CRV 2002 Honda/Odyssey 2002 Honda/Pilot 2003 MANUFACTURER: Honda (American Honda Motor Co.) MFR'S REPORT DATE: February 09, 2010 NHTSA CAMPAIGN ID NUMBER: 10V041000 NHTSA ACTION NUMBER: N/A COMPONENT: Air Bags POTENTIAL NUMBER OF UNITS AFFECTED: 379000 SUMMARY: Honda is recalling certain model year 2001-2002 Honda Accord and Civic, model year 2002 CR-V and Odyssey, model year 2002-2003 Acura 3.2TL and one vehicle for model year 2003 Honda Pilot, Civic and Acura 3.2CL passenger vehicles. The driver's airbag inflator could produce excessive internal pressure. If an affected airbag deploys, the increased internal pressure may cause the inflator to rupture. CONSEQUENCE: Metal fragments could pass through the airbag cushion material possibly causing injury or fatality to vehicle occupants. REMEDY: Dealers will replace the airbag inflator free of charge. The safety recall is expected to begin on or before February 25, 2010. Owners may contact Honda Automobile Customer Service at 1-800-999-1009. NOTES: Honda's recall No. Q96 & Acura's recall No. R13. 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. Main Switch Cruise Control Switch: Testing and Inspection Main Switch Main Switch Test/Replacement 1. Carefully pry the switch panel assembly out of the instrument panel. 2. Disconnect the 5P connector (A) from the main switch (B), then remove the switch. 3. Check for continuity between the terminals in each switch position according to the table. If the continuity is not as specified, replace the illumination bulbs (C) or the switch. Page 9444 Exterior Lights Component Location Index Page 771 Oxygen Sensor: Description and Operation Secondary Heated Oxygen Sensor (Secondary HO2S) Secondary Heated Oxygen Sensor (Secondary HO2S) The secondary HO2S detects the oxygen content in the exhaust gas downstream of the TWC and sends signals to the ECM/PCM which checks the efficiency of the TWC. To stabilize its output, the sensor has an internal heater. The secondary HO2S is installed in the TWC. Page 4648 Shift Interlock Switch: Testing and Inspection Park Pin Switch Test Park Pin Switch Test 1. Remove the center console panel and center console. 2. Disconnect the park pin switch connector (4P). 3. Shift to the P position, then check for continuity between the No. 3 and No. 4 terminals. There should be no continuity. 4. Shift out of the P position, and check for continuity between terminals No. 3 and No. 4. There should be continuity. 5. If the park pin switch is faulty, replace it. Page 4161 ^ The left end goes behind the notch on the interlock lever. ^ Once the spring is correctly installed, make sure the lever moves freely and returns properly. 10. Insert the plunger into the interlock solenoid, then install the solenoid using a new screw. Make sure the groove of the solenoid plunger is in the fork on the lever. 11. Install a new plastic cover on the interlock solenoid. 12. Check the operation of the ignition switch key interlock: ^ Set the parking brake, and turn the ignition switch to ON (I I). ^ While pressing the brake pedal, shift the transmission to Neutral. ^ Try turning the ignition switch to LOCK (0) - If you cannot turn the switch to LOCK (0), your repair was successful; go to step 15. - If you can turn the switch to LOCK (0), the interlock is not working; go to step 13. Page 5383 1. Remove the terminal. 2. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE B: 1. Remove the terminal. 2. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE C: 1. Remove the terminal. 2. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE D: Page 393 Relay And Control Unit Locations - Dashboard Component Locations Shift Interlock Switch: Component Locations Component Location Index Page 7638 17. Using a small screwdriver, push down on the tip of the last tumbler to release it, then remove the cylinder from the housing, being careful not to drop any tumblers and springs. Use your thumb and forefinger to hold the tumblers in place. Then go to step 20. 18. While turning the key left and right and pushing on the rear of the inner cylinder to release the spring, slowly remove the cylinder from the housing. Page 9481 Connectors - "C" Page 4203 Wires Page 9818 6. Separate the master switch plate (A) from the armrest (B). 7. Remove the three screws and replace the switch. 2-door Page 9499 1. Remove the secondary lock from the male terminal half. 2. Remove the secondary lock from the female terminal half. 3. Remove the terminal (same procedure for male and female). 4. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE C: 1. Remove the secondary lock. Page 1060 Wires Page 4368 Terminals - "T" Shielding Switches Fuses Page 9082 Brake Lamp: Diagnostic Aids General Troubleshooting Information General Troubleshooting Information Tips and Precautions Before Troubleshooting 1. Check applicable fuses in the appropriate fuse/relay box. 2. Check the battery for damage, state of charge, and clean and tight connections. NOTE: 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. Handling Connectors - Make sure the connectors are clean and have no loose wire terminals. - Make sure multiple cavity connectors are packed with dielectric grease (except watertight connectors). - All connectors have push-down release type locks (A). - Some connectors have a clip on their side used to attach them to a mount bracket on the body or on another component. This clip has a pull type lock. - Some mounted connectors cannot be disconnected unless you first release the lock and remove the connector from its mount bracket (A). - Never try to disconnect connectors by pulling on their wires; pull on the connector halves instead. - Always reinstall plastic covers. Page 202 Blower Motor Relay Type 1, Type 2 Check for continuity between the terminals. - There should be continuity between the No.1 and No.3 terminals when power and ground are connected to the No.2 and No.4 terminals. - There should be no continuity between the No.1 and No.3 terminals when power is disconnected. Five-terminal type Check for continuity between the terminals. - There should be continuity between the No.1 and No.2 terminals when power and ground are connected to the No.3 and No.5 terminals. - There should be continuity between the No.1 and No.4 terminals when power is disconnected. 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 8691 Cruise Control Servo: Service and Repair Cruise Control Actuator/Cable Replacement Except 2-door D17A1, D17A2 engine: 1. Loosen the lockout (A), then disconnect the actuator cable (B) from the throttle linkage. 2. Disconnect the 4P connector from the cruise control actuator. 3. Remove the two mounting bolts, and remove the cruise control actuator assembly. 4. Remove the cruise control actuator cover from the cruise control actuator. Page 9650 2. Remove the terminal (same procedure for male and female). 3. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE E: 1. Remove the secondary locks. 2. Remove the terminal (same procedure for male and female). 3. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE F: Page 5367 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. Below most connector numbers and component names are PHOTO and VIEW numbers. The PHOTO number refers to a photo in the back of the book that shows the connector's location on the car. The VIEW number refers to an illustration in the back of the book that shows the connector terminals, wire colors, connector cavity numbers, and other details. The connector cavity numbering sequence begins at the top left corner of the connector as seen from either of the viewpoints shown on diagram [8] . Except for the DLC (data link 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 C554, for example, means those terminals join in cavity 2 of connector C554. Power Distribution Schematics Power Distribution Schematics Component Locations 55. In Steering Column Cover Page 8014 21. Leave the key in the cylinder. Reinstall the plastic retainer and spring if you removed them in step 16. Hold the plastic retainer and spring on the housing, and insert the inner cylinder. Rotate it left and right to engage the spring to the inner cylinder. Make sure the spring is properly seated to the inner cylinder. 22. Install the arm with a new cylinder rod clip and a new E-clip. 23. Make sure the key can be inserted and removed easily, and that the cylinder turns with the key. Specifications Page 1996 12. Oil Pressure Switch Page 9633 Diodes Light Emitting Diode (LED) Motor Pressure Sensor Page 6374 3. Position the damper bottom on the knuckle, and install the damper pinch bolts (A) and nuts (B), and lightly tighten the nuts. 4. Place the floor jack under the lower arm ball joint, and raise the suspension to load it with the vehicle's weight. NOTICE: Do not place the jack against the flat section of the lower arm. Lifting the arm in this area might bend it. 5. Tighten the flange nuts on the top of the damper to the specified torque. 6. Tighten the damper pinch nuts to the specified torque. 7. Connect the tie-rod end to the steering arm, and tighten the nut (A) to the specified torque. Install the cotter pin (B) after tightening, and bend its end as shown. 8. Install the brake hose bracket and the flange bolt onto the damper, and tighten the bolt to the specified torque. 9. Clean the mating surface of the brake disc and the inside of the wheel, then install the front wheels. 10. Check the wheel alignment, and adjust it if necessary. Locations Transmission Position Switch/Sensor: Locations Component Location Index, A/T Locations Compressor Clutch Relay: Locations Air Conditioning Component Location Index Page 888 *T-5 Sidewinder Key Applications ^ 2003-05 Civic ^ 2004-05 Civic Hybrid ^ 2003-05 Civic GX (CNG) ^ 2004-05 S2000 ^ 2002-06 CR-V ^ 2003-06 Element ^ 2003-04 Odyssey ^ 2003-04 Pilot Ordering Honda key blanks through normal parts ordering channels: Refer to the parts catalog for correct key(s) for your application. PROGRAMMING KEYS Depending on the type of key blank you use, do this: ^ If you have used a T-5 programmable key blank ("T-5" stamped on the shank), you must code the key's transponder with the Ilco Immobilizer Key Code Duplicator (see S/B 99-053, Ilco Immobilizer key Code Duplicator). ^ If you have used a Honda key blank, add the* transponder code of the new key to the immobilizer system with the Honda Diagnostic System (HDS). ORDERING INFORMATION *To order the MATRIX H Key Cutting Machine, replacement cutter bits, fixed jaws and mobile jaws, T-5 programmable key blanks, and practice key blanks, contact the Honda Tool and Equipment Program by calling 888-424-6857 or using the fax order form provided in your Honda Tool and Equipment Program Catalog.* Order Honda key blanks through normal parts ordering channels. WARRANTY CLAIM INFORMATION None. This service bulletin is for information only. *DETERMINING WHICH KEY TO USE T-5 keys require less time to program and should be the first choice. They can be used as long as the following requirements are met: ^ Do you have the customer's operating key? ^ Does the vehicle fall within the T-5 Sidewinder Key Applications? ^ Does your dealership have an Ilco Immobilizer Key Code Duplicator? If the answer to all three questions on the above is yes, the 1-5 key option is the easier procedure. If you answered no to any of the questions, you should order the key(s) from the parts catalogue, and program it using the HDS.* BEFORE YOU START CUTTING 1. Get the original key or the key number from your customer or from the iN. 2. Get the applicable key blank. 3. If cutting by code, look up the applicable 9-digit cutting code for the key number. Refer to the code book Honda High Security key Codes that comes with the machine. Page 7241 The battery number is CR2025. Each transmitter uses one battery. 94-95 Accord, Civic, Del SOL, Prelude & 95 Odyssey 1994-95 Accord with dealer-installed security system 1994-95 Civic with dealer-installed security system 1994-95 del Sol with dealer-installed security system 1994-95 Prelude with dealer-installed security system 1995 Odyssey with dealer-installed security system Programming the Transmitter NOTES: ^ The system uses a stacking-type memory that accepts up to four transmitters. If you program a fifth transmitter, the system's memory for the first transmitter is pushed out, and it will no longer work. ^ To clear a lost or stolen transmitter from the system's memory, program a transmitter four times. This will remove the missing transmitter from memory, since only four transmitter codes can be accepted. ^ Another way to clear a lost or stolen transmitter is to erase all transmitter codes, and then reprogram them. To do this, refer to the security system owner's manual. 1. Turn the ignition switch to ON (II). 2. Press and hold the Valet-Disarm button on the dashboard lower cover. (Continue to hold the button during this procedure, or programming will be cancelled.) The LED on the upper steering column cover flashes when the system is in programming mode. 3. Press the top button on the transmitter. Check that the parking lights flash to confirm that the transmitter's code was accepted. 4. Press the top button on each of the remaining transmitters. Check that the parking lights flash after each transmitter code is accepted. 5. Release the Valet-Disarm button to exit the programming mode. Ordering a Transmitter Transmitters can be ordered only by authorized Honda dealers. Order them from American Honda using normal parts ordering procedures. Batteries for the Transmitter The battery number is CR2025. Each transmitter uses one battery. 96-98 Civic EX & Except EX, Civic 1996-98 Civic EX with factory-installed keyless entry system 1996-98 Civic (except EX) with dealer-installed keyless entry system 1996-98 Civic with dealer-installed security system Page 7293 1. Remove the terminal. 2. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE E: 1. Remove the terminal. 2. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE F: Page 6584 Power Transistor HVAC: Testing and Inspection Power Transistor Test 1. Disconnect the 4P connector from the power transistor. 2. Measure the resistance between the No.3 and No.4 terminals of the power transistor. It should be about 1.4 - 1.5 kOhm. - If the resistance is within the specifications, go to step 3. - If the resistance is not within the specifications, replace the power transistor. 3. Carefully release the lock tab on the No.1 terminal (BLU/YEL) (A) in the 4P connector, then remove the terminal and insulate it from body ground. 4. Reconnect the 4P connector to the power transistor. 5. Supply 12 volts to the No.1 cavity with a jumper wire. 6. Turn the ignition switch ON (II), and check that the blower motor runs. - If the blower motor does not run, replace the power transistor. - If the blower motor runs, the power transistor is OK. Page 5605 Engine Electrical - Special Tools A/C - Heater Blows Cool Air At Idle Heater Core: Technical Service Bulletins A/C - Heater Blows Cool Air At Idle Heater Blows Cool Air When Coming to a Stop or at Idle Got a 01-05 Civic with a heater that blows warm air while driving but starts blowing Cool air when coming to a stop or at idle? What's most likely causing this problem is air trapped in the heater core. To fix this problem, you've got to bleed the cooling system (replacing the thermostat won't do the trick). Here's how you do it: 1. Fill the reserve tank with Honda All Season Antifreeze/Coolant Type 2 50 the coolant level is between the MIN and MAX marks on the tank. 2. Remove the radiator cap. Make sure the coolant level is up to the base of the filler neck. Add coolant if needed. 3. Loosely install the radiator cap. 4. Set the temperature control knob to maximum. 5. Start the engine, and let it run until it reaches normal operating temperature (the cooling fans cycle twice). Shut off the engine. 6. Remove the radiator cap. Make sure the coolant level is up to the base of the filler neck. Add coolant if needed. 7. Securely install the radiator cap. 8. Start the engine, and check for leaks. Page 1075 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. Circuits must be operating when checking voltage drop. 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. 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 off, 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 Self-Powered Test Light or DVOM 1. Remove the blown fuse and disconnect the battery and load. Page 4787 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. How to Replace Connector Terminals Terminal Replacement Procedure HOW TO REPLACE CONNECTOR TERMINALS The terminal repair kits provide necessary tools and materials (terminals, wire seals, and splice connectors) to repair many damaged or faulty connector terminals. However, not all terminals for all connectors are available. Refer to the labels on the lids of the repair kits for replacement terminal availability. IMPORTANT SAFETY INFORMATION: On some models, the SRS wires are in a separate harness. If the SRS harness is damaged, replace the harness; do not repair it. On other models, wire harnesses include yellow SRS wires. If any SRS wire is damaged, replace the entire harness; do not repair it. Before you begin, inspect the wire you are about to repair for damage and length. Make sure the wire will be long enough to make a terminal repair without stretching it when you reinstall the terminal in the connector. If the wire is too short, or if access to the connector is too restricted to make a terminal repair, you may need to install a pigtail terminal (a short length of wire with a factory-crimped terminal on it). Refer to HOW TO INSTALL PIGTAIL TERMINALS. Removing the Terminal Page 1098 10. Connect the connector securely, then install the transmission range switch cover. 11. Turn the ignition switch ON (II). Move the shift lever through all gear positions, and cheek the transmission range switch synchronization with the A/T gear position indicator. 12. Allow the wheels to rotate freely, then start the engine. 13. Move the shift lever through all gear positions, and verify the following: ^ The engine will not start in any position other than N or P. ^ The back-up lights come on when the shift lever is in the R position. Page 9156 Interior Lights - Circuit Diagram With Moonroof Part 2 Page 1174 125. Passenger's Door (Coupe Except DX, HX) 126. Front Passenger's Door (Sedan Except DX) Page 4996 2. Cut off the wire about an inch back from where it connects to the damaged or faulty terminal, then strip about half of the insulation off that piece. This will be used to size the wire end of the replacement pigtail terminal. NOTE: If you are not sure of the wire size, start with a large enough hole on the stripper that will not nick or cut off any strands of wires. 3. Select a pigtail terminal that matches the original wire at both ends (same kind of terminal and same diameter bare wire). 4. Select the smallest splice connector (yellow, pink, or blue) that will fit onto the stripped end of the original wire. 5. Insert the pigtail terminal into the connector cavity; push it in until it locks in place. 6. Lay the pigtail and the original wire side-by-side, and cut off both ends at once. If you are making more than one splice, do not cut each pigtail at the same location; the resulting "lump" of splice connectors would interfere with rewrapping the harness. Instead, cut the first pigtail close enough to the terminal so you will have room to make each remaining cut about 20 mm (3/4 inch) farther down on the next pigtail. 7. If you are using a yellow splice connector, strip about 6 mm (1/4 inch) of insulation off the ends of both wires. If you are using a pink or blue splice connector, strip off about 8 mm (5/16 inch) of insulation. Page 7208 Page 1597 YES - Repair open in the wire between the No.20 IG (40A) fuse and the gauge assembly. If the wires are OK, test the ignition switch. NO - Repair short in the wire between the No.20 IG (40A) fuse and the under-dash fuse/relay box. Also replace the No.20 IG (40A) fuse. 10. Try to start the engine. Does the engine start? YES - Go to step 11. NO - Go to step 14. 11. Turn the ignition switch OFF. 12. Connect ECM/PCM connector terminal E31 to body ground with a jumper wire. 13. Turn the ignition switch ON (II). Is the MIL on? YES - Update the ECM/PCM if it does not have the latest software, or substitute a known-good ECM/PCM, then recheck. If the symptom/indication goes away with a known-good ECM/PCM, replace the original ECM/PCM. NO - Check for an open in the wire between the ECM/PCM (E31) and the gauge assembly. Also check for a blown MIL bulb. If the wires and the bulb are OK, replace the gauge assembly. 14. Turn the ignition switch OFF. 15. Inspect the No.6 ECU (ECM/PCM) (15A) fuse in the under-hood fuse/relay box. Is the fuse OK? YES - Go to step 22. NO - Go to step 16. 16. Remove the blown No.6 ECU (ECM/PCM) (15A) fuse in the under-dash fuse/relay box 17. Remove the glove box and PGM-FI main relay 1 (A). Page 7224 Programming the Transmitter NOTES: ^ The system accepts up to three transmitters. The transmitter codes are stored in a stacking-type memory. If a fourth transmitter code is programmed, the code for the first transmitter is erased. ^ Entering the programming mode cancels all learned transmitter codes, so none of the previously programmed transmitters will work. You must reprogram all of the transmitters once you are in the programming mode. ^ You must complete steps 1-6 within 4 seconds of the previous step to keep the system from exiting the programming mode. 1. Turn the ignition switch to ON (II). 2. Press the "Lock" or "Unlock" button on one of the transmitters. (An unprogrammed transmitter can be used for this step.) 3. Turn the ignition switch to LOCK (0). 4. Repeat steps 1 2, and 3 two more times using the same transmitter used in step 2. 5. Turn the ignition switch to ON (II). 6. Press the "Lock" or "Unlock" button on the same transmitter. Make sure the power door locks cycle to confirm that the system is in programming mode. 7. Within 10 seconds, press the "Lock" or "Unlock" button on each transmitter. Make sure the power door locks cycle after you press each transmitter button to confirm that the system accepted the transmitter's code. 8. Turn the ignition switch to LOCK (0) to exit the programming mode. Ordering a Transmitter Transmitters can be ordered only by authorized Honda dealers. Order them from American Honda using normal parts ordering procedures. Batteries for the Transmitter The battery number is CR2025. Each transmitter uses one battery. 94-95 Passport (Except 1995-1/2) 1994-95 Passport (except 19951A) with dealer-installed security system NOTES: ^ The system uses a stacking-type memory that accepts up to four transmitters. If you program a fifth transmitter, the memory for the first transmitter is pushed out, and it will no longer work. ^ To clear a lost or stolen transmitter from the system's memory, program a transmitter four times. This will remove the missing transmitter from memory, since only four transmitters can be accepted. Main Switch Cruise Control Switch: Service and Repair Main Switch Main Switch Test/Replacement 1. Carefully pry the switch panel assembly out of the instrument panel. 2. Disconnect the 5P connector (A) from the main switch (B), then remove the switch. 3. Check for continuity between the terminals in each switch position according to the table. If the continuity is not as specified, replace the illumination bulbs (C) or the switch. Page 5379 1. Remove the secondary lock from the male terminal half. 2. Remove the secondary lock from the female terminal half. 3. Remove the terminal (same procedure for male and female). 4. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE C: 1. Remove the secondary lock. Page 8114 Page 9359 Use the tools from Pin Tool Set. First, check the connector that you are about to repair. - If it has a secondary terminal lock, go to Connectors With a Secondary Lock. A secondary lock, found on most connectors on some models, is an additional locking device on the connector housing as a backup for the primary lock on the terminal. - If the connector does not have a secondary lock, go to Connectors Without a Secondary Lock. Connectors With a Secondary Lock All examples are shown with the connector lock facing up. The illustrations are examples of the secondary terminal locks; however, the connector you are repairing may vary in size. Identify the connector by the type of secondary lock, not by the number of terminal cavities. EXAMPLE A: 1. Release the secondary lock. 2. Remove the terminal. 3. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE B: Page 7125 9. Check for continuity between the rear window defogger negative terminal (A) connector and body ground. There should be continuity. If there is no continuity, check for: An open in the BLK wire (B) - An open in the rear window defogger wire - Poor ground (G701) (C) Body - Trunk Lid Hard to Close Trunk / Liftgate Lock: Customer Interest Body - Trunk Lid Hard to Close 02-061 November 5, 2004 Applies To: See VEHICLES AFFECTED Trunk Lid is Difficult to Close (Supersedes 02-061, dated July 23, 2004) Updated information is shown with asterisks. SYMPTOM The trunk lid may be difficult to close or won't latch closed. PROBABLE CAUSE The trunk lid may be misaligned, and the trunk lid opener cable, trunk lid latch, lock cylinder, lock rod, and/or the trunk lid latch striker may need adjustment or replacement. VEHICLES AFFECTED CORRECTIVE ACTION Adjust the trunk lid and/or the trunk lid latch, or replace components as needed. PARTS INFORMATION Page 2820 Power Distribution schematics show how power is supplied from the positive battery terminal to various circuits in the vehicle. Refer to the Power Distribution diagram set to get a more detailed understanding of how picture is supplied to the circuit you're working on. Individual circuit schematics begin with a fuse. So 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 Ground Distribution Schematics This sample Ground Distribution schematic shows all of the components that share the same ground point. Page 5148 Shift Indicator: Testing and Inspection Continuously Variable Transmission Indicator Input Test SRS components are located in this area. Review the SRS component locations, precautions, and procedures in the SRS section before performing repairs or service. 1. If the MIL has been reported, check for a DTC, and repair the system as indicated by DTC. 2. If the MIL does not come on, and the A/T gear position indicator P, N, or R does not come on. Turn the ignition switch off, remove the gauge assembly from the dashboard, then disconnect gauge assembly connector A (22P) and B (22P). 3. Inspect the connectors and connector terminals to be sure they are making good contact. 4. If the terminals are bent, loose, or corroded, repair them as necessary, and recheck the system. 5. Shift to the P position, and check for continuity between AS terminal (BLU/BLK) and ground. There should be continuity in the P position and no continuity in any other shift lever position. If your test results are different, check for a faulty transmission range switch or an open in the wire. 6. Shift to the N position, and check for continuity between AS terminal (BLK/RED) and ground. There should be continuity in the N position and no continuity in any-other shift lever position. If your test results are different, check for a faulty transmission range switch or an open in the wire. 7. Turn the ignition switch ON (II), shift to the R position, and check for voltage between A11 terminal (WHT) and ground. There should be 0 V in the R position. There should be about 5 V in any other shift lever position. If your test results are different, check for a faulty transmission range switch or an open in the wire. 8. Check for voltage between B17 terminal (YEL) and ground with the ignition switch ON (II). There should be battery voltage. If your test results are different, check for a blown No. 10 (7.5A) fuse in the under-dash fuse/relay box or an open in the wire. 9. Turn the ignition switch OFF, and check for continuity between B16terminal (BLK) and ground under all conditions. There should be continuity. If your test results are different, check for a poor ground (G501) or an open in the wire. 10. If all input tests prove OK, but the indicator is faulty, replace the printed circuit board. Locations Shift Interlock Solenoid: Locations 107. Behind A/T Shift Lever (except M/T) Page 1765 1. Remove the secondary locks. 2. Remove the terminal from the female half. 3. Remove the terminal from the male half. 4. Go to HOW TO INSTALL NEW TERMINALS. Connectors Without a Secondary Lock All examples are shown with the connector lock facing up. The illustrations are examples of connector terminals without a secondary lock; however, the connector you are repairing may vary in size and shape. EXAMPLE A: Page 3842 195. Tranmission Range Switch Page 8484 Seat Cover: Service and Repair Rear Seat-Back Cover Replacement Rear Seat-back Cover Replacement NOTE: - Take care not to tear the seams or damage the seat covers. - Put on gloves to protect your hands. 1. Remove the seat-back, 2-door, 4-door. 2. '04-05 models: Remove the headrest. 3. On the left seat-back: Remove the screw, then remove the center belt guide (A). 4. Release the hook (A), and unzip the seat-back cover (B). The left seat-back is shown, the right seat-back is similar. Diagrams 118. Ignition Coils Page 6257 17. Install the steering joint (A), and reconnect the steering shaft (B) and pinion shaft (C). Make sure the steering joint is connected as follows: ^ Insert the upper end of the steering joint onto the steering shaft (line up the bolt hole (D) with the flat portion (E) on the shaft). ^ Slip the lower end of the steering joint onto the pinion shaft (line up the bolt hole (F) with the groove (G) around the shaft), and loosely install the lower joint bolt. Be sure that the lower joint bolt is securely in the groove in the pinion shaft. ^ Pull on the steering joint to make sure that the steering joint is fully seated. Then install the upper joint bolt and tighten it. 18. Install the driver's dashboard lower covers. 19. Center the cable reel by first rotating it clockwise until it stops. Then rotate it counterclockwise (approximately two and half turns) until the arrow mark on the label points straight up. Reinstall the steering wheel. 20. Install the front wheels. 21. Fill the system with power steering fluid, and bleed air from the system. 22. After installation, perform the following checks: ^ Start the engine, allow it to idle, and turn the steering wheel from lock-to-lock several times to warm up the fluid. Check the gearbox for leaks. ^ Perform the front toe inspection. ^ Check the steering wheel spoke angle. Adjust by turning the right and left tie-rods equally, if necessary. Page 4274 13. Remove the solenoid cover, and make sure the solenoid plunger groove is installed in the fork on the lever. ^ If needed, correct the position of the solenoid plunger, then go to step 14. ^ If the solenoid plunger is correctly installed, there is an electrical problem with the key interlock system; refer to the Automatic Transmission section of the appropriate service manual for troubleshooting information. Once the key interlock is working normally, go to step 14. 14. Install the solenoid cover. 15. Reinstall the steering column covers. 16. Center-punch a completion mark above the seventh character of the engine compartment VIN. Disclaimer Page 3786 ^ The left end goes behind the notch on the interlock lever. ^ Once the spring is correctly installed, make sure the lever moves freely and returns properly. 10. Insert the plunger into the interlock solenoid, then install the solenoid using a new screw. Make sure the groove of the solenoid plunger is in the fork on the lever. 11. Install a new plastic cover on the interlock solenoid. 12. Check the operation of the ignition switch key interlock: ^ Set the parking brake, and turn the ignition switch to ON (I I). ^ While pressing the brake pedal, shift the transmission to Neutral. ^ Try turning the ignition switch to LOCK (0) - If you cannot turn the switch to LOCK (0), your repair was successful; go to step 15. - If you can turn the switch to LOCK (0), the interlock is not working; go to step 13. Testing and Inspection Power Mirror Motor: Testing and Inspection Power Mirror Actuator Test 1. Remove the door panel. 2. Disconnect the 8P connector (A) from the power mirror actuator (B). 3. Check actuator operation by connecting power and ground according to the table. 4. If the mirror fails to work properly, replace the mirror actuator. Defogger Test (Canada): 5. Check for continuity between the No.3 and No.4 terminals of the 8P connector. There should be continuity. If there is no continuity, check for an open circuit. Page 5256 1. Remove the terminal. 2. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE E: 1. Remove the terminal. 2. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE F: Locations Intake Air System - Component Location Index Page 7124 Antenna Control Module: Testing and Inspection Antenna Module Input Test 2-door 1. Remove the right C-Pillar trim. 2. Make sure the antenna module mounting bolt (A) is torqued to 9.8 N.m (1.0 kgf.m, 7.2 lbf.ft) 3. Disconnect the 2P connector from the antenna module (C). 4. Turn the ignition switch ON (II), turn the rear window defogger switch ON. Check for voltage between the No.2 terminal and body ground. There should be battery voltage. If there is no voltage, check for: Faulty rear window defogger relay. - Blown No.11 (40 A) fuse or No.19 (80 A) in the under-hood fuse/relay box. - An open in the BLK/YEL wire. 5. With the ignition switch ON (II), turn the radio ON, and turn to an FM station. Check for voltage between the No.1 terminal and body ground. If there is no voltage, check for: An open in the YEL/GRN wire. - A short to ground in the YEL/GRN wire. - Faulty audio unit. 6. Disconnect the rear window defogger (+B OUT) connector (D) from the antenna module. 7. With the ignition switch and the rear window defogger switch ON, check for voltage to ground. If there is no voltage, replace the antenna module. 8. Turn the ignition switch OFF. Page 1968 Engine Oil Pressure: Testing and Inspection Oil Pressure Test If the oil pressure warning light stays on with the engine running, check the engine oil level. If the oil level is correct: 1. Connect a tachometer or a Honda PGM Tester. 2. Remove the engine oil pressure switch, and install an oil pressure gauge (A). 3. Start the engine. Shut it off immediately if the gauge registers no oil pressure. Repair the problem before continuing. 4. Al low the engine to reach operating temperature (fan comes on at least twice). The pressure should be: Engine Oil Temperature: 176°F (80°C) Engine Oil Pressure: At Idle: 70 kPa (0.7 kgf/cm2, 10 psi) minimum At 3,000 rpm: 340 kPa (3.5 kgf/cm2, 50 psi) minimum 5. If oil pressure is NOT within specifications, inspect these items: ^ Check the oil filter for clogging. ^ Check the oil pump. Page 6137 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 8610 8. Release the clip, detach the hook, and remove the lock rod protector. 9. Disconnect the outer handle rod and cylinder rod. Locations 13. Middle Of Engine (EX, HX) Page 2055 1. Remove the secondary lock from the male terminal half. 2. Remove the secondary lock from the female terminal half. 3. Remove the terminal (same procedure for male and female). 4. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE C: 1. Remove the secondary lock. Restraints - Child Seat Anchor Locating Button Missing Child Seat: All Technical Service Bulletins Restraints - Child Seat Anchor Locating Button Missing 05-016 May 17, 2005 Applies To: See VEHICLES AFFECTED Child Seat Anchor Locating Button Is Missing PROBLEM The small button on the rear seat-back cover that marks the location of each child seat LATCH lower anchor is missing. VEHICLES AFFECTED 2001-05 Accord - ALL 2001-05 Civic - ALL 2003-05 Civic Hybrid - ALL 2002-05 Civic Si - ALL 2001-05 CR-V - ALL 2003-05 Element - ALL 2001-05 Odyssey - ALL 2003-05 Pilot - ALL CORRECTIVE ACTION Replace the button. NOTE: Older vehicles have buttons without a child seat icon. The buttons in newer vehicles and the replacement buttons all have an icon. If your customer requests matching buttons, replace all the buttons at the same time as a set. PARTS INFORMATION Child Seat ISOFIX Button Kit: (Kit contains buttons in nine different colors; 10 buttons of each color.) P/N 070AZ-SHJA190, H/C 7979016 Child Seat ISOFIX Button Kit Replacement Parts: Page 4797 8. Inspect the quality of the wire crimp. If it has any of the following NO GOOD crimps, cut it off and start over. 9. Insert the terminal into the connector. Make sure the wire seals are pushed all the way into the connector. Lightly pull on the wires to make sure the terminal is locked into place. 10. Close or insert the secondary terminal lock, if applicable, and reconnect the connector. How to Install Pigtail Terminals HOW TO INSTALL PIGTAIL TERMINALS Pigtail terminals (short pieces of wire with a factory crimped terminal) are used when the wire is too short or when access to the connector is too restricted to make a terminal repair. NOTE: To replace just a connector terminal, go to How to Replace Connector Terminals. IMPORTANT SAFETY INFORMATION: On some models, the SRS wires are in a separate harness. If the SRS harness is damaged, replace the harness; do not repair it. On other models, wire harnesses include yellow SRS wires. If any SRS wire is damaged, replace the entire harness; do not repair it. 1. Remove the damaged or faulty terminal from the connector. Use the proper removal tool from Pin Tool Set. Page 8353 - Check each of the plastic arts for solvent resistance and heat resistance temperatures before you do any repair work. - Select the repair material according to materials of the plastic parts. Page 1287 1. Turn the steering wheel fully to the right and left while applying the brake, and check the turning angles of both front wheels. If the turning angle is not within the specification or the inward turning angles differ between the right and left side, go to step 2. 2. Check the toe. If it is correct, but the turning angle is not within the specification, check for bent or damaged suspension components. Page 2951 DTC P1586 thru P1678 Page 9112 Brake Light Switch: Testing and Inspection Brake Pedal Position Switch Test 1. Disconnect the 4P connector (A) from the brake pedal position switch (B). 2. Check for continuity between the No.1 and No.2 terminals. - There should be continuity when the brake pedal is pressed. - There should be no continuity when the brake pedal is released. 3. Check for continuity between the No.3 and No.4 terminals (with cruise control). - There should be no continuity when the brake pedal is pressed. - There should be continuity when the brake pedal is released. 4. If necessary, adjust or replace the switch, or adjust the pedal height. Page 3292 8. Connect the GRN test harness clip (D) to the positive probe of a voltmeter. Is there 5 V or more? YES - Go to step 9. NO - Repair short or open in the BLU/WHT or WHT/GRN wire between the VSS and the cruise control unit, or the ECM/PCM. 9. Turn the ignition switch OFF. 10. Connect the other test harness connector (A) to the VSS(B). 11. Raise the front of the vehicle, and make sure it is securely supported. 12. Put the vehicle in neutral with the ignition switch ON (II). 13. Slowly rotate one wheel with the other wheel blocked. Does voltage pulse from 0 to about 5 V or more? YES - Go to step 14. NO - Replace the VSS. Page 6871 ^ If the OPDS unit has an original part number, go to step 6. ^ If the OPDS unit has a new part number (refer to PARTS INFORMATION) or higher, go to REPAIR PROCEDURE B: OPDS SENSOR REPLACEMENT. 6. Recline the seat-back to access the OPDS unit mounting screws. 7. Remove the mounting screws from the OPDS unit, and gently pull out the unit. 8. Disconnect the OPDS connectors, then remove the OPDS unit. 9. Install a new OPDS unit, then snap on its cover. 10. Slip the seat-back cover over the OPDS unit. 11. On Accords, check the seat-back clip attachment bosses on the seat-back panel: ^ If the attachment bosses are OK, go to step 12. ^ If the seat-back has a pocket, and the attachment bosses are deformed or damaged, do the repair procedure in S/B 02-010, Seat-Back Panel Is Loose or Detached. Then go to step 12. ^ If the seat-back does not have a pocket, and the attachment bosses are deformed or damaged, replace the seat-back. Then go to step 12. Page 4759 4. Apply super high temp urea grease (P/N 08798-9002) to the release fork (A), the release fork bolt (B), the release bearing (C), and the release bearing guide (D) in the shaded areas. 5. With the release fork slid between the release bearing pawls, install the release bearing on the mainshaft while inserting the release fork through the hole in the clutch housing. 6. Align the detent of the release fork with the release fork bolt, then press the release fork over the release fork bolt squarely. 7. Install the release fork boot (E), make sure the boot seals around the release fork and clutch housing. 8. Move the release fork (A) right and left to make sure that it fits properly against the release bearing (B), and that the release bearing slides smoothly. Page 47 80. Under Middle of Dash Page 909 105. Left B Pillar (Right Similar) 155. Behind Left Side Of Front Bumper Locations Body - Front Bumper Spoiler Loose/Detached Spoiler: Customer Interest Body - Front Bumper Spoiler Loose/Detached 03-010 April 15, 2003 Applies To: 2001-03 Civic DX, HX, LX, EX, GX - ALL Front Bumper Air Spoiler Is Loose or Detached (Supersedes 03-010, dated March 4, 2003) SYMPTOM The front air spoiler is becoming detached from the bumper or it is loose, deformed, or shows gaps between the spoiler and the bumper. PROBABLE CAUSE The spoiler was pushed out of position when the front end of the vehicle was parked over a curb or a parking stop. CORRECTIVE ACTION If the spoiler is damaged or deformed, replace it. If it is loose or out of place, reinstall and secure it using 3M Weatherstrip Adhesive. REQUIRED MATERIALS 3M Weatherstrip Adhesive: 3M P/N 051135-08011 PARTS INFORMATION Front Bumper Air Spoiler: P/N 71110-S5A-A00ZA, H/C 6456784 WARRANTY CLAIM INFORMATION In warranty: The normal warranty applies. Operation Number: 023301 Flat Rate Time: 0.3 hour Failed Part: P/N 71110-S5A-A00ZA H/C 6456784 Defect Code: 004 Contention Code: A01 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. Remove the front bumper air spoiler. Page 5761 Under-hood Fuse And Relay Box (4-door) Locations Turn Signal/Hazard Flasher Component Location Index Page 7935 9. Open the jaws with the jaws knob, and slide the original key with its flat side down into the center jaw up to the key stop. Slide the key blank with its flat side down into the right jaw up to the key stop. Close the jaws with the jaws knob to lock the keys into place. Visually inspect both keys for proper alignment in the jaws. 10. Loosen the lateral and spring tension adjustment knobs on the clamp carriage. With the clamp carriage lever, adjust the clamp carriage to position the tracer and the cutter bit over the middle of the two locked key blades. Tighten only the spring tension knob when done. NOTE: The clamp carriage has a spring system that puts lateral pressure on the tracer and cutting bit to make it easier to cut sidewinder-type keys. Do not tighten the lateral tension adjustment knob. This knob should be left loose. 11. Turn on the cutter motor with the motor start switch. [NOTICE] ^ To avoid damaging the locking jaws while cutting, keep your hand off the vertical carriage lever. Pressure on the lever will change the cutting depth. * ^ To avoid breaking the cutter bit, never back up while cutting.* ^ Wear proper eye protection (safety glasses, goggles, etc.) Page 241 234. Under-dash Fuse/Relay Box Part 2 Page 9225 Door Switch: Locations Entry Light Control System Component Location Index Page 2375 Blower Motor Relay Type 1, Type 2 Check for continuity between the terminals. - There should be continuity between the No.1 and No.3 terminals when power and ground are connected to the No.2 and No.4 terminals. - There should be no continuity between the No.1 and No.3 terminals when power is disconnected. Five-terminal type Check for continuity between the terminals. - There should be continuity between the No.1 and No.2 terminals when power and ground are connected to the No.3 and No.5 terminals. - There should be continuity between the No.1 and No.4 terminals when power is disconnected. Page 469 201. Power Mirror Switch (except DX) Page 9136 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 Locater) 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. Troubleshooting Precautions Troubleshooting Precautions Before Troubleshooting 1. Check the main fuse and the fuse 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, or you will damage the alternator diodes. - Do not attempt to crank the engine with the ground cable disconnected 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. M/T - Clutch Pedal Squeak/Twang or Notchy Feel Clutch Master Cylinder: All Technical Service Bulletins M/T - Clutch Pedal Squeak/Twang or Notchy Feel 02-002 January 11, 2005 Applies To: See VEHICLES AFFECTED Squeak at the Clutch Pedal (Supersedes 02-002, dated September 21, 2004) SYMPTOM A squeak, a twang, or a notchy feel when the clutch pedal is pressed. PROBABLE CAUSE The clutch master cylinder spring is rubbing on the outer diameter of the piston when the pedal is pressed, or the master cylinder quick connect is moving. Page 4178 7. Apply a small amount of Permalube grease to the base of the new lever. Then attach the slide hammer to the new lever pin, insert the lever into the ignition switch, and seat the pin with the slide hammer. 8. Check the installed height of the pin with vernier calipers. If the height is more than 5.0 mm, the pin is not seated. If needed, reattach the slide hammer, and seat the pin. NOTE: It's normal for the interlock lever to be loose, even when the pin is fully seated. 9. Install a new spring on the lever. Make sure you attach the ends of the spring correctly: ^ The right end goes into the slot on the ignition switch. Page 1714 8. Tighten each bolt two turns at a time, in the sequence shown below, to ensure that the rockers do not bind on the valves. Specified torque 8 mm bolts: 20 Nm (2.0 kgf-cm, 14 ft. lbs.) Apply engine oil to the bolt threads. 6 mm bolts: 12 Nm (1.2 kgf-cm, 8.7 ft. lbs.) Apply engine oil to the bolt threads. 6 mm bolts: (11), (12), (13), (14) 9. Align the marks (A) on the new cylinder head plug (B) with the top edge of the head, then install the cylinder head plug in the cylinder head. Locations 61. Under Left Side Of Dash Page 9370 8. Put the splice connector in the proper size slot in the Crimper Tool, slide it to one end (where the flare begins), and close the crimper handles far enough to hold it in place. To release the ratchet mechanism at any point after the first click, squeeze the handles slightly and push the release lever, then let the handles open. 9. Insert one of the bare wires into the splice connector end that is in the crimper jaws. Push the wire all the way into the splice connector, and squeeze the crimper handles. Keep squeezing until the jaws touch, and hold it at that position until the ratchet clicks again. 10. Crimp the other wire in the same way into the other end of the splice connector. 11. After crimping, gently pull on the wires in the opposite directions to make sure they are secure in the connector. 12. Separate the other wires in the harness from the repaired wire(s), and shield them with nonflammable material. Locations Throttle Position Sensor: Locations PGM-FI System - Component Location Index Page 3158 195. Tranmission Range Switch Page 8795 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 9578 11. Horn Switch Technician Safety Information Air Bag(s) Arming and Disarming: Technician Safety Information Technician Safety Information Diagram Information and Instructions License Plate Lamp: Diagram Information and Instructions Terminal Numbering System Terminal Numbering System Connector terminals are numbered according to the cavities they're in. The cavities are numbered starting from the upper left, looking at the male terminals from the terminal side or looking at the female terminals from the wire side. Both views are in the same direction so the numbers are the same. All actual cavities are numbered, even if they have no wire terminals in them. NOTE: Data Link Connector (DLC) terminals are numbered according 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 below is #6. Page 2517 Diodes Light Emitting Diode (LED) Motor Pressure Sensor Page 1550 235. Under-dash Fuse/Relay Box Part 8 Page 4257 72. Shift Lock Solenoid (A/T) Page 606 Fuel Supply System - Component Location Index Page 8198 118. Driver's Door (Coupe Exc. DX, HX; Sedan Exc: DX) 121. Driver's Door (Coupe Except DX) Locations Relay And Control Unit Locations - Dashboard Page 236 Under-hood Fuse/Relay Box (2-door) Page 5847 71. Under Left Side Of Dash Under-hood Fuse/Relay Box Page 8115 Page 7826 ^ Going from front to back, use the middle lock pin to set the first cam to the appropriate key code number in the code book. (The cam is properly set when the number on the cam lines up with the red scribe mark on the clamp unit.) ^ Slide the lock pin through the notch in the cam. (This locks the cam in place.) ^ Keep doing this for each of the remaining cams in the set until all the cams are set and locked, then push the lock pin all the way in. Repeat this process to set and lock the cams for the right cam set. NOTE: Make sure you set the MIS cam in the right cam set for the type of key you are cutting. For a master key, set the cam to M; for a valet key, set it to S. When you are done, push all the cam blades to the left until they touch the cams in the left cam set. 10. Pull the vertical carriage lever toward you until the tracer touches the flat surface on the right side at the front of the cams. Gently twist the lever clockwise to lock the vertical carriage at this height. Do not overtighten the lever. 11. Turn on the cutter motor with the motor start switch. [NOTICE] ^ To avoid damaging the locking jaws while cutting, keep your hand off the vertical carriage lever. Pressure on the lever will change the cutting depth. * ^ To avoid breaking the cutter bit, never back up while cutting.* ^ Wear proper eye protection (safety glasses, goggles, etc.) 12. Use the clamp carriage lever and the tracer to follow the contours of the cam blades from front to back. (The cutter bit cuts the same contours into the right edge of the key blank, from head to tip.) Page 9479 Wire Color Abbreviations Page 145 PGM-F1 Main Relay 1, 2 Type 1, 2 Check for continuity between the terminals. - There should be continuity between the No.1 and No.2 terminals when power and ground are connected to the No.3 and No.4 terminals. - There should be no continuity between the No.1 and No.2 terminals when power is disconnected. Normally-open type B: Rear Window Defogger Relay Page 7118 236. Window Antenna Coil (Sedan) Page 7763 WARRANTY CLAIM INFORMATION In warranty: The normal warranty applies. Failed Part: P/N 68500-S5P-A90ZZ H/C 6528640 *Defect Code: 07406* Symptom Code: 03220 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 A 1. Check the side-to-side alignment of the trunk lid latch to the striker: ^ Refer to page 20-132 of the 2001-04 Civic Service Manual. ^ In ISIS, use the keyword TRUNK ADJUST, and select Trunk Lid Adjustment from the list. 2. Make sure the gaps of the trunk lid are even on all sides. ^ If the trunk is misaligned, go to step 3. ^ If the trunk lid is properly aligned on all sides, go to REPAIR PROCEDURE B. 3. Adjust the trunk lid hinges: ^ Refer to page 20-132 of the 2001-04 Civic Service Manual. ^ In ISIS, use the keyword TRUNK ADJUST, and select Trunk Lid Adjustment from the list. 4. Check the trunk operation: ^ If the trunk opens and closes smoothly and is properly aligned, return the vehicle to the customer. ^ If the trunk lid is still difficult to close, go to REPAIR PROCEDURE B. REPAIR PROCEDURE B Page 8318 8. Route the wire harness (A) of the new actuator through the hole in the bracket (B). 9. Insert the terminals into the connector in the original arrangement as shown. 10. Reassemble in the reverse order of disassembly. Be careful not to break in the mirror holder when reinstalling it to the actuator. 11. Reinstall the mirror assembly to the door. 12. Operate the power mirror to ensure smooth operation. Page 92 Relay And Control Unit Locations - Engine Compartment Page 4301 107. Behind A/T Shift Lever (except M/T) Page 9310 1. Remove the secondary lock from the male terminal half. 2. Remove the secondary lock from the female terminal half. 3. Remove the terminal (same procedure for male and female). 4. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE C: 1. Remove the secondary lock. Locations Horn Switch: Locations Horn Component Location Index Page 3714 1. Remove the terminal. 2. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE E: 1. Remove the terminal. 2. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE F: Page 2341 ECM/PCM Inputs And Outputs At Connector C (22P) Diagrams Page 6016 Exterior Lights Component Location Index Campaign - OPDS Unit Warranty Extension Technical Service Bulletin # 06-009 Date: 080205 Campaign - OPDS Unit Warranty Extension 06-009 February 5, 2008 Applies To: See VEHICLES AFFECTED Warranty Extension: OPDS Unit or OPDS Sensor Triggers SRS DTC(s) 15-1, 15-2, 15-3 (Supersedes 06-009, dated September 21, 2007) Updated information is shown with asterisks. BACKGROUND *NOTE: Because of a class action settlement, the warranty extension coverage for the OPDS unit and the OPDS sensor on 2002 Accords, 2002-04 Civics, 2003-04 Civic Hybrids, 2002-04 CR-Vs, 2003 Elements, 2002 Odysseys, and 2003-04 Pilots purchased or leased between April 13, 2002, and November 7, 2006, is now 10 years or 157,500 miles, whichever occurs first. For more information, refer to Service Bulletin 06-085, Warranty Extension: Vehicle Warranty Mileage.* Several vehicle models may have a problem with the OPDS (occupant position detection system) that causes the SRS indicator to stay on. Typically, one or more of these DTCs will be set: ^ SRS DTC 15-1 (faulty OPDS unit or OPDS not initialized) ^ SRS DTC 15-2 (faulty side airbag indicator circuit) ^ SRS DTC 15-3 (faulty OPDS sensor) To ensure continued reliability with the OPDS, American Honda is extending the warranty on the OPDS unit and the OPDS sensor to 10 years or 150,000 miles, whichever occurs first. This warranty extension does not apply to any vehicle that has ever been declared a total loss, or any that has been issued a salvage, branded, or similar title under any state's law. To check for vehicle eligibility, you must do a VIN status inquiry Specifications Flywheel: Specifications Flywheel Runout on clutch mating surface Standard or New ....................................................................................................................................................... 0.06 mm (0.002 inch) maximum Service Limit .................................................................................... ......................................................................................... 0.15 mm (0.006 inch) Torque the flywheel mounting bolts in a crisscross pattern in several steps. Page 8243 WARRANTY CLAIM INFORMATION In warranty: The normal warranty applies. Failed Part: P/N 68500-S5P-A90ZZ H/C 6528640 *Defect Code: 07406* Symptom Code: 03220 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 A 1. Check the side-to-side alignment of the trunk lid latch to the striker: ^ Refer to page 20-132 of the 2001-04 Civic Service Manual. ^ In ISIS, use the keyword TRUNK ADJUST, and select Trunk Lid Adjustment from the list. 2. Make sure the gaps of the trunk lid are even on all sides. ^ If the trunk is misaligned, go to step 3. ^ If the trunk lid is properly aligned on all sides, go to REPAIR PROCEDURE B. 3. Adjust the trunk lid hinges: ^ Refer to page 20-132 of the 2001-04 Civic Service Manual. ^ In ISIS, use the keyword TRUNK ADJUST, and select Trunk Lid Adjustment from the list. 4. Check the trunk operation: ^ If the trunk opens and closes smoothly and is properly aligned, return the vehicle to the customer. ^ If the trunk lid is still difficult to close, go to REPAIR PROCEDURE B. REPAIR PROCEDURE B Page 1490 - 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. - Refer to the scrapping procedures for disposal of the damaged airbag. 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. 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. Locations Relay And Control Unit Locations - Dashboard Page 60 138. Rear Of Roof (EX) Locations 162. Right Side Of Engine Compartment Locations 162. Right Side Of Engine Compartment Body - Trunk Lid Hard to Close Trunk / Liftgate Lock: All Technical Service Bulletins Body - Trunk Lid Hard to Close 02-061 November 5, 2004 Applies To: See VEHICLES AFFECTED Trunk Lid is Difficult to Close (Supersedes 02-061, dated July 23, 2004) Updated information is shown with asterisks. SYMPTOM The trunk lid may be difficult to close or won't latch closed. PROBABLE CAUSE The trunk lid may be misaligned, and the trunk lid opener cable, trunk lid latch, lock cylinder, lock rod, and/or the trunk lid latch striker may need adjustment or replacement. VEHICLES AFFECTED CORRECTIVE ACTION Adjust the trunk lid and/or the trunk lid latch, or replace components as needed. PARTS INFORMATION Page 7553 62. Power Window Motor, Front Passenger's (Sedan Except DX) 64. Power Window Motor, Passenger's (Coupe Except DX, HX) 144. Power Window Motor, Driver's (except DX, HX) Page 782 Power Steering Pressure Switch: Testing and Inspection PSP Switch Signal Circuit Troubleshooting 1. Turn the ignition switch ON (II). 2. Measure voltage between ECM/PCM connector terminals A24 and E16. Is there less than 1.0 V? YES - Go to step 3. NO - Go to step 6. 3. Start the engine. 4. Turn the steering wheel to the full lock position. 5. Measure voltage between ECM/PCM connector terminals A24 and E16. Is there battery voltage? YES - The PSP switch signal is OK. NO - Go to step 13. 6. Turn the ignition switch OFF. 7. Disconnect the PSP switch 2P connector. 8. Turn the ignition switch ON (II). 9. At the harness side, connect the PSP switch 2P connector terminals No.1 and No.2 with a jumper wire. 10. Measure voltage between ECM/PCM connector terminals A24 and E16. Is there less than 1.0 V? YES - Replace the PSP switch. NO - Go to step 11. 11. Turn the ignition switch OFF. Page 9277 PGM-F1 Main Relay 1, 2 Type 1, 2 Check for continuity between the terminals. - There should be continuity between the No.1 and No.2 terminals when power and ground are connected to the No.3 and No.4 terminals. - There should be no continuity between the No.1 and No.2 terminals when power is disconnected. Normally-open type B: Rear Window Defogger Relay Page 2963 ECM/PCM Inputs And Outputs At Connector A (31P) Page 7519 6. Disconnect the actuator connectors (A) (for some models), and detach the inner handle rod (B) from the rod holder (C). Remove the lock knob (D). 7. Remove the screws, then remove the latch (E) through the hole in the door. Take care not to bend the outer handle rod (F), cylinder rod (G), lock rod (H), and inner handle rod. 8. Install the latch in the reverse order of removal, and note these items: - Make sure the actuator connectors are plugged in properly (with power door lock), and each rod is connected securely. - Make sure the door locks and opens properly. - When reinstalling the door panel, make sure the plastic cover is installed properly and sealed around its outside perimeter to seal out water. Page 7112 Seat Occupant Sensor: Service and Repair Initializing the OPDS Unit Initializing the OPDS (Occupant Position Detection System) Special Tools Required SCS service connector 07PAZ-0010100 When the seat-back cover, seat-back cushion, and/or OPDS unit are replaced, initialize the OPDS by following the procedure below. NOTE: Make sure the passenger's seat is dry. Set the seat-back in the normal position, and make sure there is nothing on the front passenger's seat. 1. Make sure the ignition switch is OFF. 2. Connect the Honda PGM Tester (A) to the DLC (16P) (B), and follow the Tester's prompts in the "SCS" menu (see the Honda PGM Tester Operator's Manual). 3. Connect the SCS service connector (A) to the MES connector (2P) (B). Do not use a jumper wire. 4. Turn the ignition switch ON (II). 5. The SRS indicator comes on for about 6 seconds and goes off. Remove the SCS service connector from the MES connector within 4 seconds after the SRS indicator went off. 6. The SRS indicator comes on again. Reconnect the SCS service connector to the MES connector within 4 seconds after the SRS indicator comes on. 7. The SRS indicator goes off. Remove the SCS service connector from the MES connector within 4 seconds. 8. Watch the SRS indicator. - If the indicator blinks two times and then stays on, the OPDS is initialized, but the DTCs need to be erased. Go to step 9, then erase the DTCs. - If the indicator blinks two times and then goes off, the OPDS unit is initialized. Go to step 9. - If the indicator stays on without first blinking, the OPDS is not initialized. Read the DTC, and go to the appropriate page in the DTC Troubleshooting Index. 9. Turn the ignition switch off, and disconnect the PGM Tester. Page 9840 6. With a helper on the outside, pull the piano wire (A) back and forth in a sawing motion. Hold the piano wire as close to the rear window (B) as possible to prevent damage to the body, and carefully cut through the adhesive (C) around the entire rear window: If the rear window is to be reinstalled, take care not to damage the molding (D). - If the molding is damaged, replace the rear window and molding as an assembly. 7. Carefully remove the rear window. 8. With a putty knife, scrape the old adhesive smooth to a thickness of about 2 mm (0.08 in.) on the bonding surface around the entire rear window opening flange: Do not scrape down to the painted surface of the body; damaged paint will interfere with proper bonding. - Remove the clips or fasteners from the body. 9. Clean the body bonding surface with a sponge dampened in alcohol. After cleaning, keep oil, grease and water from getting on the surface. 10. If the old rear window will be reinstalled, use a putty knife to scrape off all of the old adhesive, the clips or the fasteners from the rear window. Clean the inside face and the edge of the rear window with alcohol where new adhesive will be applied. Make sure the bonding surface is kept free of water, oil and grease. 11. Attach the clips (A) with adhesive tape to the inside face of the rear window (B) as shown: - Be sure the clips and fasteners line up with the alignment marks (C). - Be careful not to touch the rear window where adhesive will be applied. Clips adhesive tape: Thickness 0.2 mm (0.0079 in.) Width 7.5 mm (0.3 in.) Page 5813 1. Remove the secondary locks. 2. Remove the terminal (same procedure for male and female). 3. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE F: 1. Remove the secondary locks. Alternator Belt Inspection and Adjustment Drive Belt: Adjustments Alternator Belt Inspection and Adjustment Alternator Belt Inspection and Adjustment Special Tools Required Belt tension gauge 07JGG-001010A Belt Tension Gauge Method Inspection 1. Attach the belt tension gauge to the belt and measure the tension. Follow the gauge manufacturer's instructions. If the belt is worn or damaged, replace it. If the belt needs adjustment, go to step 2. Adjustment 2. Loosen the mounting bolt (A), lock bolt (B) and lower bracket mounting bolt (C). 3. Torque the mounting bolt to 20 N.m (2.0 kgf.m, 14 lbf.ft). 4. Turn the adjusting bolt (D) to obtain the proper belt tension, then retighten the lock bolt, mounting bolt and lower bracket mounting bolt. 5. Recheck the belt tension. 6. If you installed a new belt, run the engine for 5 minutes, then readjust the belt to the used belt specification. 7. Check the power steering pump belt adjustment. Deflection Method Inspection Page 5228 162. Right Side Of Engine Compartment Locations Radiator Cooling Fan Motor Relay: Locations Under-hood Fuse/Relay Box Page 5145 Circuit Diagram Page 4381 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 Short Circuit Locator (Short Finder) 1. Remove the blown fuse. Leave the battery connected. Page 8176 2. Disconnect the 2P connector from the actuator. 3. Check actuator operation by connecting power and ground according to the table. To prevent damage to the actuator, apply battery voltage only momentarily. 4. If the actuator does not operate as specified, replace it. Page 5125 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 Locater) 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. Troubleshooting Precautions Troubleshooting Precautions Before Troubleshooting 1. Check the main fuse and the fuse 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, or you will damage the alternator diodes. - Do not attempt to crank the engine with the ground cable disconnected 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. Page 1329 Compression Check: Testing and Inspection Engine Compression Inspection 1. Warm up the engine to normal operating temperature (cooling fan comes on). 2. Turn the ignition switch OFF. 3. Remove the air cleaner housing. 4. Disconnect all four injector connectors. 5. Remove the four ignition coils. 6. Remove the four spark plugs. 7. Attach the compression gauge to the spark plug hole. 8. Connect a tachometer. 9. Open the throttle fully, then crank the engine with the starter motor and measure the compression. Compression Pressure: Above 930 kPa (9.5 kgf/cm2, 135 psi) 10. Measure the compression on the remaining cylinders. Maximum variation: Within 200 kPa (2.0 kgf/cm2, 28 psi) 11. If the compression is not within specifications, check the following items, then re-measure the compression. ^ Damaged or worn valves and seats ^ Damaged cylinder head gasket ^ Damaged or worn piston rings ^ Damaged or worn piston and cylinder bore Page 5727 - Before connecting connectors, make sure the terminals (A) are in place and not bent. - Check for loose retainer (A) and rubber seals (B). - The backs of some connectors are packed with dielectric grease. Add grease if necessary. If the grease is contaminated, replace it. - Insert the connector all the way and make sure it is securely locked. - Position wires so that the open end of the cover faces down. Handling Wires and Harnesses - Secure wires and wire harnesses to the frame with their respective wire ties at the designated locations. Page 3698 Power Distribution schematics show how power is supplied from the positive battery terminal to various circuits in the vehicle. Refer to the Power Distribution diagram set to get a more detailed understanding of how picture is supplied to the circuit you're working on. Individual circuit schematics begin with a fuse. So 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 Ground Distribution Schematics This sample Ground Distribution schematic shows all of the components that share the same ground point. Page 2322 Engine Control Module: Locations Multiplex Control System Component Location Index Page 3246 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. Below most connector numbers and component names are PHOTO and VIEW numbers. The PHOTO number refers to a photo in the back of the book that shows the connector's location on the car. The VIEW number refers to an illustration in the back of the book that shows the connector terminals, wire colors, connector cavity numbers, and other details. The connector cavity numbering sequence begins at the top left corner of the connector as seen from either of the viewpoints shown on diagram [8] . Except for the DLC (data link 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 C554, for example, means those terminals join in cavity 2 of connector C554. Power Distribution Schematics Power Distribution Schematics Page 238 69. Under Left Side Of Dash 70. Under Left Side Of Dash Locations SRS Component Location Index Page 4775 Resistor Variable Sensor Solenoid Transistors Circuit Schematics Page 4207 Diodes Light Emitting Diode (LED) Motor Pressure Sensor Page 836 7. Align the cutouts (A) on the rotary-frame with the neutral positioning cutouts (B) on the transmission range switch, then put a 2.0 mm (0.08 inch) feeler gauge blade (C) in the cutouts to hold it in the N position. NOTE: Be sure to use a 2.0 mm (0.08 inch) blade or equivalent to hold the switch in the N position. 8. Install the transmission range switch (A) gently on the control shaft (B) with holding the N position with the 2.0 mm (0.08 inch) blade (C). 9. Tighten the bolts on the transmission range switch while you continue to hold it in the N position. Do not move the transmission range switch when tightening the bolts. Remove the feeler gauge. Page 1264 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 8302 Disclaimer Cutting Procedure - By Copying 1. Press the ON/OFF button in the middle of the setting unit keypad. (This powers up the keypad.) 2. Turn the clamp unit lock lever to the left to release the clamp unit, and slide it all the way to the left until it stops. Turn the lever to the right to lock the clamp unit in place. 3. Use the clamp carriage lever to position the clamp unit so the tracer and cutter bit are centered directly over the base of the center and right jaws. 4. Pull the vertical carriage lever toward you until the tracer and the cutter bit just touch the base of each fixed jaw. Watch the arrows on the keypad: ^ If the double-headed arrow in the middle of the keypad lights green, the tracer and cutter bit are properly aligned. ^ If the arrow on the left of the keypad lights red, the cutter bit is not touching the fixed jaw. Turn the micrometric ring nut above the tracer to the left until the double-headed arrow lights green. ^ If the arrow on the right of the keypad lights red, the tracer is not touching the fixed jaw. Turn the micrometric ring nut above the tracer to the right until the double-headed arrow lights green. *5. Turn the micrometric ring nut to the right three clicks so the cutter bit is slightly higher than the tracer. The arrow on the left should light red. Raise the vertical carriage. NOTE: Setting the tracer three clicks lower than the cutter bit has the effect of making the cutter bit cut the duplicated key a little shallower. This will protect the locking jaws from being damaged.* 6. Optional: Loosen the setscrew, and adjust the hand rest to a comfortable position. Tighten the screw. 7. Pull the clamp carriage lever toward you until the clamp carriage clicks into its end-of-run position. Tighten both the lateral and spring tension adjustment knobs. 8. Make sure the center and right jaws are free of any metal shavings or debris. (A soft-bristle toothbrush is ideal for this purpose.) Page 7823 9. Open the jaws with the jaws knob, and slide the original key with its flat side down into the center jaw up to the key stop. Slide the key blank with its flat side down into the right jaw up to the key stop. Close the jaws with the jaws knob to lock the keys into place. Visually inspect both keys for proper alignment in the jaws. 10. Loosen the lateral and spring tension adjustment knobs on the clamp carriage. With the clamp carriage lever, adjust the clamp carriage to position the tracer and the cutter bit over the middle of the two locked key blades. Tighten only the spring tension knob when done. NOTE: The clamp carriage has a spring system that puts lateral pressure on the tracer and cutting bit to make it easier to cut sidewinder-type keys. Do not tighten the lateral tension adjustment knob. This knob should be left loose. 11. Turn on the cutter motor with the motor start switch. [NOTICE] ^ To avoid damaging the locking jaws while cutting, keep your hand off the vertical carriage lever. Pressure on the lever will change the cutting depth. * ^ To avoid breaking the cutter bit, never back up while cutting.* ^ Wear proper eye protection (safety glasses, goggles, etc.) Page 1501 Air Bag(s) Arming and Disarming: Service and Repair Connector Disconnection / Connection Disconnecting System Connectors Before removing a front airbag, side airbag, or other SRS related devices (the SRS unit, the cable reel, front sensor, the side impact sensors, the seat belt buckle tensioners, and the seat belt tensioner connector), disconnecting connectors from related devices, or removing the dashboard or the steering column, disconnect the airbag connectors or the side airbag connectors to prevent accidental deployment. Turn the ignition switch OFF, disconnect the negative cable from the battery, and wait at least 3 minutes before beginning the following procedures. - Before disconnecting SRS unit connector A (A) from the SRS unit, disconnect the driver's airbag 4P connector (C), the front passenger's airbag 4P connector (D), the driver's seat belt tensioner 2P connector (F), and the front passenger's seat belt tensioner 2P connector (G). - Before disconnecting SRS unit connector B (1) from the SRS unit, disconnect both side airbag 2P connectors (L, M) and both seat belt buckle tensioner 4P connectors (J, K). - Before disconnecting the cable reel 4P connector (B), disconnect the driver's airbag 4P connector (C). - Before disconnecting the floor wire harness 4P connector (E), disconnect both seat belt tensioner 2P connectors (F, G). 1. Disconnect the battery negative cable, and wait at least 3 minutes. Driver's Airbag Page 2343 ECM/PCM Inputs And Outputs At Connector E (31P) Page 4092 Splices Components Ground - "G" Page 2056 2. Remove the terminal from the female half. 3. Remove the terminal from the male half. 4. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE D: 1. Remove the secondary locks. Electrical - DTC P1298 Stored in ECM/PCM Electric Load Sensor: Customer Interest Electrical - DTC P1298 Stored in ECM/PCM 05-006 May 6, 2005 Updated information is noted by asterisks. Applies To: 2001-05 Civic - ALL *2002-04 CR-V - ALL* DTC P1298 Is Stored in the ECM/PCM (Supersedes 05-006, dated February 25, 2005, to change the CR-V model-year range) SYMPTOM DTC P1298 (electrical load detector (ELD) circuit high voltage) is stored in the ECM/PCM. PROBABLE CAUSE The electronic load detector (ELD) has a faulty solder joint. CORRECTIVE ACTION Replace the ELD. NOTE: Previously, if an ELD required replacement, you had to replace the under-hood fuse/relay box. To reduce repair costs, replacement ELDs are now available. PARTS INFORMATION Electronic Load Detector: P/N 38255-S5A-003, H/C 7987571 WARRANTY CLAIM INFORMATION In warranty: The normal warranty applies. Operation Number: 121195 Flat Rate Time: 0.4 hour Failed Part: Civic P/N 38250-S5A-A03 H/C 7472277 CR-V P/N 38250-S9A-A01 H/C 6890594 Defect Code: 06402 Symptom Code: 01201 Template ID: 05-006A 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 6316 8. Remove the flange bolt (A) and wheel sensor (B) from the knuckle. Do not disconnect the wheel sensor connector. 9. Remove the flange nut (A) while holding the joint pin (B) with a hex wrench (C), and disconnect the stabilizer link (D) from the lower arm (E). 10. Remove the lock pin (A) from the lower arm ball joint, and remove the castle nut (B). NOTE: During installation, insert the lock pin into the ball joint pin in the range of 180 degrees or below from the inside of the vehicle. Insert the lock pin from the inside to the outside of the vehicle. 11. Disconnect the lower arm from the knuckle using the special too. Page 1770 8. Inspect the quality of the wire crimp. If it has any of the following NO GOOD crimps, cut it off and start over. 9. Insert the terminal into the connector. Make sure the wire seals are pushed all the way into the connector. Lightly pull on the wires to make sure the terminal is locked into place. 10. Close or insert the secondary terminal lock, if applicable, and reconnect the connector. How to Install Pigtail Terminals HOW TO INSTALL PIGTAIL TERMINALS Pigtail terminals (short pieces of wire with a factory crimped terminal) are used when the wire is too short or when access to the connector is too restricted to make a terminal repair. NOTE: To replace just a connector terminal, go to How to Replace Connector Terminals. IMPORTANT SAFETY INFORMATION: On some models, the SRS wires are in a separate harness. If the SRS harness is damaged, replace the harness; do not repair it. On other models, wire harnesses include yellow SRS wires. If any SRS wire is damaged, replace the entire harness; do not repair it. 1. Remove the damaged or faulty terminal from the connector. Use the proper removal tool from Pin Tool Set. Page 1852 Piston Ring: Service and Repair Replacement 1. Remove the piston from the cylinder block. 2. Using a ring expander (A), remove the old piston rings (B). 3. Clean all ring grooves thoroughly with a squared off broken ring or ring groove cleaner with a blade to fit the piston grooves. The top ring groove is 1.0 mm (0.04 inch) wide. The second ring groove is 1.2 mm (0.05 inch wide. The oil ring groove is 2.0 mm (0.08 inch) wide. File down a blade if necessary. Do not use a wire brush to clean the ring grooves, or cut the ring grooves deeper with cleaning tools. NOTE: If the piston is to be separated from the connecting rod, do not install new rings yet. 4. Using a piston, push a new ring (A) into the cylinder bore 15 - 20 mm (0.6 - 0.8 inch) from the bottom. 5. Measure the piston ring end-gap (B) with a feeler gauge: ^ If the gap is too small, check to see if you have the proper rings for your engine. ^ If the gap is too large, recheck the cylinder bore diameter against the wear limits. ^ If the bore is over the service limit, the cylinder block must be rebored. Piston Ring End-Gap: Top Ring Standard (New): 0.15 - 0.30 mm (0.006 - 0.012 inch) Service Limit: 0.60 mm (0.024 inch) Second Ring Standard (New): 0.30 - 0.45 mm (0.012 - 0.018 inch) Service Limit: 0.60 mm (0.024 inch) Oil Ring Standard (New): 0.20 - 0.70 mm (0.008 - 0.028 inch) Service Limit: 0.80 mm (0.031 inch) Locations Brake Fluid Level Sensor/Switch: Locations Gauges Component Location Index (Part 1 Of 4)