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Honda Civic 2002-2003, Service Manual

The Honda Civic 2002-2003 Service Manual is a comprehensive manual that provides detailed instructions and procedures for the maintenance and repair of your vehicle. You can download this manual for free from manualshive.com to ensure your Honda Civic is running at its best.

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Summary of Contents for Civic 2002-2003

Page 1: ......

Page 2: ...al words DANGER WARNING or CAUTION These signal words mean m jW fj tt IIt 1 You WILL be KILLED or SERIOUSLY HURT if you don t follow instructions You CAN be KILLED or SERIOUSLY HURT if you don t follo...

Page 3: ...odes 2002 Model 1 2 Chassis and Paint Codes 2003 Model 1 3 Identification Number Locations 1 4 Warning Caution Label Locations 1 5 Under hood Emission t I Control Label 1 7 Lift and Support Points 1 8...

Page 4: ...bag system Canada e Check Digit f Model Year 2 2002 g Factory Code U Honda of U K Manufacturing in Swindon England h Serial Number U S 300001 Canada 600001 1 2 Vehicle Identification Number and Federa...

Page 5: ...eck Digit f Model Year 3 2003 g Factory Code U Honda of U K Manufacturing in Swindon England h Serial Number U S 400001 Canada 700001 Vehicle Identification Number and Federal Motor Vehicle Safety Sta...

Page 6: ...Generallnformation Identification Number Locations Vehicle Identification Number IVIN Vehicle Identification Number VIN D _ 7 1 4 Engine Number Transmission Number...

Page 7: ...glove box on the U S model Passenger s Compartment SRS INFORMATION U S model SRSWARNING INFORMATION FRONT PASSENGER MOOULE OANGER MONITOR NOTICE SlOE MOOULE DANGER SIDE AIRBAG CAUTION Located on drive...

Page 8: ...tions cont d SERVICE INFORMATION LABEL Under hood Emission Control SRS WARNING Information labelI and ENGINE LABEL COOLANT INFORMATION i _ f i L __ _ _ _ _ __ RADIATOR CAP CAUTION AIR CONDITIONING INF...

Page 9: ...V REGULATIONS APPLICABLE TO 2003 MODEL YEAR NEW PASSENGER CARS AND CALIFORNIA REGULATIONS APPLICABLE TO 2003 MODEL YEAR NEW LEV II LEV PASSENGER CARS Engine and Evaporative Families Engine Family 2 HN...

Page 10: ...the hoist to full height and inspectthe 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 e as for a frame hois...

Page 11: ...way of towing the vehicle 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...

Page 12: ...arts have self adhesive labels Replacement body parts have generic self adhesive labels The original engine or transmission VIN plate is transferred to a replacement engine or transmission and attache...

Page 13: ...anual Transmission and Differential 2 7 Steering 2 9 Suspension 2 9 Brakes 2 10 Air Conditioning 2 10 l Design Specifications Dimensions 2 11 Weight U S A 2 11 Weight CANADA 2 11 Engine 2 11 Starter 2...

Page 14: ...ring 0 0 14 4 mm D S7 in 4 0 mm 0 55 in Brush length 10 5 mm 0 41 in I 1 5 mm 10 06 in 1 Brush spring tension 2 9 3 5 N 0 30 0 36 kgf O 7 0 Blbs Starter Output 1 1 kW Commutator mica depth 0 50 0 80...

Page 15: ...5 445 mm 0 214 in Exhaust 5 450 5 460 mm 0 2146 0 2150 in 5 42 mm 0 213 in Stem ta guide clearance I Intake 0 030 0 055 mm 0 0012 0 0022 in 0 08 mm 0 003 in Exhaust 0 055 0 080 mm 0 0022 0 0031 in 0...

Page 16: ...FEDERAL 0 20 0 70 mm 0 008 0 028 in 0 75 mm 0 030 in 0 80 mm 0 031 in MOGULI 1 c ___ __ _2_1 _96_5mm 1O 8646_0_ _86_48 i n j 1 2 1 95_3_m_m_IO 8_64_3_in_ 1 Pin to piston clearance 0 005 0 002 mm 0 00...

Page 17: ...082 mm 0 0020 0 0032 in 0 10 mm 0 004 in clearance shaft 1 No 1 journal rear shaft 0 050 0 082 mm 0 0020 0 0032 in 0 10 mm 0 004 in No 2 journal front and 0 060 0 120 mm 0 0024 0 0047 in 0 15 mm 0 006...

Page 18: ...Qualification Standard or New Service Limit Clutch pedal Height from the floor 193 mm 7 60 in Stroke 130 140 mm 5 1 5 5 in Play 10 16 mm 0 39 0 63 in Disengagement height from the floor 115 mm 4 53 i...

Page 19: ...of needle bearing contact 35 000 35 015 mm 1 37S0 1 3785 in 34 95 mm 1 376 in area clutch housing side Diameter of distance collar contact 39 937 39 950 mm 1 5723 1 5728 in 39 88 mm 1 570 in area Diam...

Page 20: ...ear Shift fork Finger thickness 7 4 7 6 mm W 29 0 30 in Fork to synchro sleeve clearance 0 35 0 65 mm 0 014 0 026 in 1 0 mm 0 039 in Reverse shift Finger thin _ _ s 13 4 13 7 mm W 527 0 539 in _ fork...

Page 21: ...cked position 5uspenslon Item Measurement Qualification Standard or New I Service limit Wheel alignment Camber Front 0 00 _45 Rear 0 45 __ 45 Caster Front 1Q 33 1 Total Toe I Front O_3mmW 0 12 in Rear...

Page 22: ...4 in Parallelism Front and rear 0 015 mm 0 0006 in Brake pads Thickness Front 10 0 mm 0 39 in 1 6 mm 0 06 in Rear 9 0 mm 0 35 in 1 6 mm 0 06 in A C d Ir on Itlonma Hem Measurement Qualification Standa...

Page 23: ...ratio 9 8 Valve train Chain drive DOHC VTEC 4 valves per cylinder Lubrication system i Forced wet sump with trochoid pump Oil pump displacement At 6 000 engine 54 3 Q 57 4 US qt minute pm Water pump...

Page 24: ...trol Maximum capacity Type Electrical power consumption at 68 F 120 CI Type Capacity Specification Electric Power assisted rack and pinion 15 1 2 835 360 mm 14 2 in Independent strut with stabilizer c...

Page 25: ...Light bulbs Headlight high 12V BOW beam Headlight low 12 V 55 W beam Front turn signal 12 V 21 W lights Front parking lights 12 V 5W Rear turn signal 12V 21W lights Front rear side 12 V 5 W marker li...

Page 26: ...Body Specifications Unit mm in 1 565161 61 _ _ 1 440156 71 I i 1 0 i 0 1 I __ t y i L l I I _ _ r 2 14...

Page 27: ...hedule for Normal Conditions Listed by DistancefTime 3 4 Maintenance Schedule for Severe Conditions Listed by DistancefTime 3 6 Maintenance Schedule Listed by Maintenance Item for Normal Conditions 3...

Page 28: ...anual Silicone grease I transmission 8 Throttle cable end dashboard lower panel hole 9 Brake booster clevis IMulti purpose grease 10 Clutch booster clevis 11 Shift lever pivot 12 Pedal linkage i 13 Ba...

Page 29: ...jj D l J CD 1 3 3...

Page 30: ...A and B 90 000 mil 144 000 kml 5 years Do items in A and C o ooo mil 144 000 km Do item in D 100 000 mi 160 000 km 5 years Do items in A and B 110 000 mi 176 000 km Inspect valve clearance cold see p...

Page 31: ...luding ABS Check the master cylinder proportioning control valve and ABS modulator for damage and leakage Check all fluid levels and condition of fluids check for leaks If necessary add MTF see page 1...

Page 32: ...nd C Do item in A Do item in F Do items in A B and D Do item in A Do items in A B and C Do items in E and H Do item in A Do item in G Do items in A and B Do item in A Do item in F Replace transmission...

Page 33: ...cessary add MTF see page 13 3 engine coolant brake fluid and windshield washer fluid Inspect exhaust system Check catalytic converter heat shield exhaust pipe and muffler for damage leaks and tightnes...

Page 34: ...rbox and boots Suspension components Driveshaft boots I Brake hoses and lines including ABS Ali fluid levels and condition of fluids Exhaust system Fuel lines and connections Inspect and adjust drive...

Page 35: ...ts Suspension components Driveshaft boots Check parking brake adjustment I Visually inspect the following items I Brake hoses and lines including ASS All fluid levels and condition offluids I Exhaust...

Page 36: ...ing System Component Location Index 4 20 Circuit Diagram 4 21 Charging Circuit Troubleshooting 4 22 Drive Belt Inspection 4 26 Drive Belt Replacement 4 26 Drive Belt Auto tensioner Inspection 4 27 Dri...

Page 37: ...Engine Electrical Special Tools Number I Tool Number Description I Qty CD I07746 0010400 Attachment 52 x 55 mm I 1 07749 0010000 Driver 1 I CD 4 2...

Page 38: ...R CUT RELAY Test page 22 51 STARTER D _ I C c c I L_ Starter Circuit Troubleshooting page 4 5 Solenoid Test page 4 7 Performance Test page 4 8 Replacement page 4 9 Overhaul page 4 10 UNDER DASH FUSE R...

Page 39: ...No 20 NO 19 80A WHT W 4 4 IGNITION SWITCH 1 ST 5T HOT in START 1111 BLK WHT I S g U r HT LTGRN S IWi8 M SOLENOID S M Q STARTER BlK L 1 G50 STARTfR CUT RELAY No 20 I40A USA model No 20 ISOA Canada mode...

Page 40: ...condition Check electrical connections at the battery the negative battery cable to body the engine ground cables and the starter for looseness and corrosion Then try starting the engine again Did the...

Page 41: ...e items until you find the cause Starter armature dragging Shorted armature winding Excessive drag in engine 8 Check the engine speed while cranking the engine Is the engine speed above 100 rpm YES Go...

Page 42: ...inal and the armature housing ground There should be continuity If there is continuity go to step 3 If there is no continuity replace the solenoid 3 Check the pull in coil for continuity between the S...

Page 43: ...erly B 8 12V BATTERY r 4 Disconnect the battery from the M terminal If the pinion does not retract the hold in coil of the solenoid is working properly 4 8 B 8 12V BATTERY I M 5 BODY GROUND 5 Disconne...

Page 44: ...cable A from the B terminal on the solenoid then disconnect the BLK WHT wire B from the S terminal 8x1 25mm 9N m 0 9 kgf m 7 Ib ttl 25mm 64N m S S kgf m 47 Ibf ft 6 Remove the two bolts holding the s...

Page 45: ...ssembly BRUSH 4 10 ARMATURE HOUSING ARMATURE STARTER SOLENOID MOIYbdenUm Disulfide G I SOLENOID LEVER Y GEAR HOUSING f C I o lW j J _ IC O v OVERRUNNING I C CLUTCH ASSEMBLY Molybdenum Disulfide END CO...

Page 46: ...ifications in step 5 or recondition with 500 or 600 sandpaper 8 r I I I 5 Check the commutator diameter If the diameter is below the service limit replace the armature Commutator Diameter Standard New...

Page 47: ...008 in 8 Check for continuity between the segments of the commutator If an open circuit exists between any segments replace the armature 4 12 9 Place the armature IA on an armature tester IB Hold a h...

Page 48: ...sing B If there is continuity replace the armature housing Starter Brush Holder Test 14 Check that there is no continuity between the brush holder A and brush holder 8 Iithere is continuity replace th...

Page 49: ...ly Check the condition of the flywheel ring gear Replace it if the starter drive gear teeth are damaged 4 14 Starter Reassembly 20 Pry back each brush spring with a screwdriver then position the brush...

Page 50: ...Ignition System Component Location Index _J o SPARK PLUG Inspection page 4 19 IGNITION COIL Ignition Timing Inspection page 4 17 Removal Installation page 4 18 4 15...

Page 51: ...BAnERY No 19IBOA No ZO WHT AT BL K YEL ECM r r BRN WHT BLU BlJWH BlKL M M looJ l or cv uv No 4 NoJ BLK sr C L G101 ICM Ignition ControlModule 4 16 r BLU RED r 1G1 HOT in ON In and START 1111 BlKWHY e...

Page 52: ...ompts in the SCS menu see the tester operator s manual 5 Connect the timing light to the service loop 6 Point the light toward the pointer Alan the cam chain case Check the ignition timing under no lo...

Page 53: ...val Installation 1 Remove the ignition coil cover A then remove the ignition coils 8 6x 1 0 mm 9 8 N m 11 0 kgf m 7 2Ibf ftl W4F 6 x 1 0 mm r 12N m 11 2 kgf m 8 7Ibf ft 2 Install the ignition coils in...

Page 54: ...amaged gasket _ Cracked insulator J Improper gap L Oil fouling I 0 Carbon deposits Cracked center electrode insulator 2 Do not adjust the gap of iridium tip plugs A replace the spark plug if the gap i...

Page 55: ...t page 4 28 DRIVE BELT Inspection page 4 26 Replacement page 4 26 CHARGING SYSTEM INDICATOR In the gauge assembly UNDER HOOD FUSE RELAY BOX Has built in ELECTRICAL LOAD DETECTOR IELDI UNITI BATTERY Te...

Page 56: ...VV eM BJ BlJ ALTERNATOR B H RECTIAER t i I I I t WHT 1G1 SWITCH IG1 HOT in ON II and START 1111 BLKtyEL No 4 IUNDER DAS lOA FUSE RELAY BOX BLK ORN EeM I WHT GRN BLKrEl WHTBLU C IG L VOLTAGE REGULATOR...

Page 57: ...s indicated by the diagnostic trouble code IDTC Isee step 8 on page 22 172 5 Disconnect the engine wire harness 6P connector from the starter sub harness 6P connector 4 22 6 Measure the voltage at the...

Page 58: ...ngine wire harness 6P connector NO Go to alternator and regulator test r I I I Alternator and Regulator Circuit Test 1 Be sure the battery is sufficiently charged and in good condition see page 22 50...

Page 59: ...ator components Isee page 4 30 4 24 Alternator Control System Test NOTE After troubleshooting perform the engine control module IECM idle learn procedure Isee page 11 139 1 Check for proper operation...

Page 60: ...see page 11 61 If prescribed voltage is now available replace the original ECM 8 Turn the headlights and ignition switch OFF 9 Disconnect ECM connector B 24PI 10 Check for continuity between ECM conn...

Page 61: ...andard range 8 as shown If it is out of the standard range replace the drive belt see page 4 26 fJ f M w i rl A B 4 26 Drive Belt Replacement 1 Move the auto tensioner A to relieve tension from the dr...

Page 62: ...oothly and without any abnormal noise If the tensioner does not move smoothly or there is abnormal noise replace the auto tensioner 5 Remove the auto tensioner Isee page 4 281 6 Install the tensioner...

Page 63: ...page 4 26 2 Remove the idler pulley 6x 1 Omm 12N m 11 2 kgf m 8 7 Ibf ftl x 1 25 mm 22N m 12 2 kgf m 16 Ibf ftl 3 Remove the tensioner pulley 55 N m 15 6 kgf m 41Ibf ft 4 28 4 Remove the auto tensione...

Page 64: ...ve tank from the bracket 6 Remove the drive belt see page 4 261 7 Remove the three bolts securing the alternator 8 Disconnect the alternator connector AI and BLK wire BI from the alternator 9 Remove t...

Page 65: ...Charging System Alternator Overhaul Exploded View I 4 30 FRONT BEARING STATOR THROUGH BOLT SEAL RING DRIVE END HOUSING RECTIFIER ASSEMBLY INSULATOR BUSHING REAR HOUSING ASSEMBLY...

Page 66: ...m see page 4 221 2 Remove the alternator see page 4 29 3 If the front bearing needs replacing remove the pulley locknut with a 10 mm wrench A and a 22 mm wrench B If necessary use an impact wrench B 4...

Page 67: ...eplacing the front bearing and or rear bearing go to step 16 Remove the rotor from the stator drive end housing 10 Inspect the rotor shaft for scoring and inspect the bearing journal surface in the st...

Page 68: ...the bearing using the inner race 13 Remove the front bearing retainer plate f G e4 14 Support the stator housing in a vise and drive out the front bearing with a brass drift and hammer 15 With a hamm...

Page 69: ...assembly IDiodes are not available separately 1 If all the diodes are OK go to step 17 B E BP lI p l p p P E p p Alternator Brush Inspection 17 Measure the length of both brushes IAI with a vernier c...

Page 70: ...continuity between each lead and the coil core IBI If there is no continuity go to step 22 If there is continuity replace the alternator 22 Assemble the alternator in reverse order of disassembly and...

Page 71: ...lacement page 4 44 4 36 CRUISE CONTROL INOICATOR Built into gauge assembly 00 _i CRUISE CONTROL UNIT Input Test page 4 40 BRAKE PEDAL POSITION SWITCH Test page 22 84 Pedal Height Adjustment page 19 6...

Page 72: ...ONlllOL 2 SETI RESUME CANCf l LTGRN SWITCH LTGRN No 20 14OA USA model No 20 ISM Canada model COMBINATION LIGHTSWrrCH I RED BLK REDI YL CRUISE CONTROL MAINSWITCH 3 _ INDICATOR UGHT UGHT 6 84WI O UW 5 R...

Page 73: ...ntrol unit see page 4 40 3 Excessive overshooting 1 Check cruise control actuator see page 4 43 or undershooting when 2 Check vehicle speed sensor VSS see page 22 65 trying to set speed Check cruise c...

Page 74: ...dal Diagnostic procedure 1 Check main switch see page 4 42 2 Check cruise control unit see page 4 40 1 Check SET RESUME CANCEL switch see page 4 42 2 Check cruise control unit see page 4 40 1 Check SE...

Page 75: ...1 should click and output link An open in the wire should be locked I Short to ground arcs when power is connected 2 BLU Ignition switch ON Check for voltage to ground Faulty brake pedal position II m...

Page 76: ...relay box gauge assembly should come Blown cruise indicator bulb Faulty gauge assembly on An open in the wire 12 BLU wHT Ignition switch ON Check for voltage between Faulty VSS II and main switch the...

Page 77: ...replace illumination bulbs C or the switch Terminal 5 2 1 3 4 Position OFF 10 10 rO ON 10 fO 10 rO 4 42 Set Resume Cancel Switch Test Replacement 1 Remove the two screws then remove the switch E Termi...

Page 78: ...ut linkage is not locked replace the cruise control actuator assembly 6 Check the operation of the actuator motor in each output linkage position according to the table You should be able to hear thE...

Page 79: ...e cable from the bracket 2 Disconnect the 4P connector and remove the three bolts securing the cruise control actuator 6x1 0mm 12 N m 11 2 kgf m 8 7Ibf ftl 4 44 3 Remove the actuator cover Ai then rem...

Page 80: ...turn the adjusting nut FI until the free play is as specified then retighten the locknut Clutch Pedal Position Switch Test 1 Disconnect the 2P connector from the clutch pedal position switch AI CLUTCH...

Page 81: ...Engine Mechanical Engine Assembly Engine Removal 5 2 Engine Installation 5 9 Cylinder Head 6 1 Engine Block 7 1 Engine Lubrication 8 1 Intake Manifold Exhaust System 9 1...

Page 82: ...ther parts 1 Secure the hood in the wide open position support rod in the lower hole 2 Make sure you have the anti theft code for the radio then write down the frequencies for the radio s preset butto...

Page 83: ...throttle link and cruise control link by hand then remove the throttle cable A and cruise control cable 8 from the links Loosen the locknuts C and remove the cables from the bracket 11 Relieve fuel p...

Page 84: ...utch line bracket mounting bolt 8 15 Remove the shift cable A and select cable 8 5 4 16 Disconnect the engine control module EeM connectors A and main wire harness connector 8 B j 17 Remove the harnes...

Page 85: ...3 26 Drain the engine oil see page 8 5 27 Disconnect the stabilizer links Isee page 18 18 28 Disconnect the suspension lower arm ball joints see step 3 on page 18 19 29 Remove the driveshafts see pag...

Page 86: ...st 33 Remove the upper hose A and heater hoses 8 34 Remove the radiator see page 10 10 35 Attach the chain hoist to the engine as shown 5 6 36 Remove the transmission mount bracket support bolt and nu...

Page 87: ...bolts 40 Remove the front mount bracket mounting bolt 41 Attach the subframe adapter to front of the subframe then tighten the knurled knob EQS02COOOOll 42 Raise the jack Line up the slots in the arm...

Page 88: ...onnector A then remove the NC compressor 8 without disconnecting the NC hoses 46 Check that the engine transmission is completely free of vacuum hoses fuel and coolant hoses and electrical wiring 47 S...

Page 89: ...rame adapter EQS02C000011 1 Install the accessory brackets and tighten their bolts and nuts to the specified torques ENGINE MOUNT BRACKET 10x 1 25 mm 44 N m 14 5 kgl m 331bf itl l AIC COMPRESSOR BRACK...

Page 90: ...excessive noise and vibration and reduce bushing life 3 Install the NC compressor A and connect the compressor clutch connector 8 8x 1 25 mm 22 N m 2 2 kgl m 161bl ttl 4 Support the subframe with the...

Page 91: ...ft 11 Raise the hoist to full height 12 Tighten the front engine mount bracket mounting bolt 12 x 1 25 mm 64 N m 6 5 kgl m 47Ibl ft e 13 Lower the hoist 14 Remove the chain hoist from the engine 15 I...

Page 92: ...w gaskets B and new self locking nuts C C 10x1 25mm 33 N m 3 4 kgf m 25Ibf lt D 8x1 25mm 22 N m 2 2 kgf m 16Ibf lt 21 Connectthe air fuel ratio A F sensor connector D and secondary heated oxygen senso...

Page 93: ...Connect the ECM connectors IAI and main wire harness connector B B 31 Install the throttle cable Isee page 11 1641 then adjust the cable see page 11 1631 A 32 Install the cruise control cable Isee pa...

Page 94: ...1 0 kgl m 7 2Ibl lt A E e D______ CV C c 36 Install the clutch slave cylinder A and clutch line bracket mounting bolt B 5 14 B 6X1 0mm 9 8N m a 11 0 kgl m ff 7 2 Ibl lt c 37 Install the battery cables...

Page 95: ...he starterl so that the fuel pump runs for about 2 seconds and pressurizes the fuel line Repeat this operation two or three times then check for fuel leakage at any point in the fuel line 47 Refill th...

Page 96: ...22 Cylinder Head Removal 6 23 VTC Actuator Exhaust Camshaft Sprocket Replacement 6 24 Cylinder Head Inspection for Warpage 6 25 Rocker Arm Assembly Removal 6 26 Rocker Arms and Shafts Disassembly Reas...

Page 97: ...A200 07ZAJ PNAA300 J I _oj 07742 0010100 07746 0010400 07749 0010000 CD _ 1 cI Description Oty Air Pressure Regulator I 1 Valve Guide Reamer 5 5 mm 1 Socket 19 mm 1 Holder Handle 1 Holder Attachment 5...

Page 98: ...n page 6 15 ff CAM CHAIN GUIDE B CAM CHAIN GUIDE A 0 O RING O TIMING CONTROL Q VTC OIL SOLENOID I JL VARIABLE VALVE 71 VALVE TENSIONER ARM AUTO TENSIONER Replacement page 6 19 CRANKSHAFT POSITION CKP...

Page 99: ...ION ftMP SENSOR OEADCENTER TOP OR TDC SENS DOWEL PIN 6 4 o Cl CAMSHAFT HOLDER CAM CHAIN GUIDE B DOWEL PIN FT o INTAKE CAMp 1 29 VTC ACTUATO _24 InspectIOn Remova l pa g ge 6 25 Installation p AUST CAM...

Page 100: ...VALVE SPRING RETAINER VALVE EXHAUST VALVE KEEPERS SPRING VALVE SPRING SEAT j VTEC SOLENOID VALVE FILTER CYLINDER HEAD BOLT Inspectton page 6 39 e INTAKE VALVE SPRING INTAKEVALVE SEAL Replacement page...

Page 101: ...ur spark plugs 8 Attach the compression gauge to the spark plug hole 6 6 9 Open the throttle fully then crank the engine with the starter motor and measure the compression Compression Pressure Above 9...

Page 102: ...y rocker arm needs replacing replace the primary and secondary rocker arms as an assembly and test If the intake primary rocker arm moves freely go to step 4 4 Repeat step 3 on the remaining intake pr...

Page 103: ...the camshaft holder mounting bolts to 22 N m 2 2 kgf m 16Ibf ft 14 Tighten the sealing boltto 20 N m 2 0 kgf m 14Ibf ft 15 Install the cylinder head cover see page 6 41 6 8 B 8 Punch a hole through t...

Page 104: ...the valves only when the cylinder head temperature is less than 100 F 138 C 1 Remove the cylinder head cover Isee page 6 22 2 Set the No 1 piston at top dead center ITOCI The punch mark IA on the vari...

Page 105: ...crew 8 and the end of the valve stem and slide it back and forth you should feel a slight amount of drag A B 6 10 5 If you feel too much or too little drag loosen the locknut A and turn the adjusting...

Page 106: ...see page 6 41 Crankshaft Pulley Removal and Installation Special Tools Required Holder handle 07JAB OO1020A Holder attachment 50 mm 07NAB 00l 040A Socket 19 mm 07JAA 001020A or a commercially availab...

Page 107: ...hten the bolt to 245 N m 25 0 kgf m 181 Ibf ft with a torque wrench and 19 mm socket C Do not use an impact wrench 4 Install the splash shield see step 20 on page 5 12 5 Install front tires wheels 6 1...

Page 108: ...rol solenoid valve connector 8 8 Remove the VTC oil control solenoid valve see step 1 on page 11 127 9 Support the engine with a jack and wood block under the oil pan 10 Remove the ground cable A and...

Page 109: ...ankshaft counterclockwise to compress the auto tensioner 15 Align the holes on the lock AI and the auto tensioner 81 then insert a 1 5 mm 0 06 in 1 diameter pin el into the holes Turn the crankshaft c...

Page 110: ...t to top dead center TOe Align the TOe mark A on the crankshaft sprocket with the pointer 8 on the cylinder block A 2 Setthe camshafts to TOe The punch mark A on the variable valve timing control VTe...

Page 111: ...shaft sprocket A B 4 Install the cam chain on the VTC actuator and exhaust camshaft sprocket with the punch marks A aligned with the two colored pieces 8 B A 6 16 5 Install the cam chain guide A A and...

Page 112: ...PIN 08718 0009 evenly to the cylinder block mating surface of the chain case and to the inner threads of the holes Apply liquid gasket along the broken line 13 Apply liquid gasket to the cylinder bloc...

Page 113: ...NOTE When installing the chain case do not slide the bottom surface on the oil pan mounting surface 6x 1 0 mm 12N m A 11 2 kgf m 8 7 Ibf ltl D I 6 18 J 6x 1 0 mm 12N m 11 2 kgf m 8 7 Ibf ltl c 16 Inst...

Page 114: ...TC oil control solenoid valve connector B B A 21 Install the crankshaft pulley see page 6 12 22 Install the cylinder head cover see page 6 41 23 Install the drive belt 24 Install the splash shield R g...

Page 115: ...the auto tensioner IB then insert a 1 5 mm 10 06 in 1 diameter pin lei into the holes Turn the crankshaft clockwise to secure the pin A 4 Remove the auto tensioner 6 20 Installation 1 Install the auto...

Page 116: ...e applying liquid gasket Instead reapply liquid gasket after removing old residue Apply liquid gasket along the broken line 6 Install the chain case cover Chain Case Oil Seal Installation Special Tool...

Page 117: ...er Head Cylinder Head Cover Removal 1 Remove the intake manifold cover 2 Remove the four ignition coils see page 4 18 3 Remove the dipstick A and breather hose 6 1 6 22 A 4 Remove the cylinder head co...

Page 118: ...t see page 4 26 3 Remove the intake manifold see page 9 3 4 Remove the air cleaner housing see step 7 on page 5 2 5 Remove the water bypass hose A A 6 Remove the exhaust manifold see page 9 7 7 Remove...

Page 119: ...til all bolts are loosened CYLINDER HEAD BOLTS LOOSENING SEQUENCE 14 Remove the cylinder head 6 24 VTC Actuator Exhaust Camshaft Sprocket Replacement Removal 1 Remove the cam chain see page 6 121 2 Ho...

Page 120: ...t 4 Install the cam chain see page 6 15 Cylinder Head Inspection for Warpage 1 Remove the cylinder head jsee page 6 23 2 Inspect the camshaft see page 6 29 3 Check the cylinder head for warpage Measur...

Page 121: ...Remove the camshaft holder bolts To prevent damaging the camshafts unscrew the bolts two turns at a time in a crisscross pattern CAMSHAFT HOLDER BOLTS LOOSENING SEQUENCE 6 26 4 Remove the cam chain g...

Page 122: ...e camshaft holder bolts The bolts will keep the holders springs and rocker arms on the shaft o Prior to reassembling clean all the parts in solvent dry them and apply lubricant to any contact points B...

Page 123: ...e Standard New Intake 0 025 0 052 mm 0 0010 0 0020 in Exhaust 0 018 0 056 mm 0 0007 0 0022 in Service Limit 0 08 mm 0 003 in 5 Repeat for all rocker arms and both shafts If the clearance is over the l...

Page 124: ...kgf m 16lbf ftl 6 mm bolts 12 N m 1 2 kgf m 8 7Ibf ftl 6 mm bolts 11 3 Seat the camshaft by pushing it away from the camshaft pulley end of the cylinder head 4 Zero the dial indicator against the end...

Page 125: ...amshaft 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 10 Camshaft to Holder Oil Clearanc...

Page 126: ...that each item can be reinstalled in its original position 1 Remove the cylinder head Isee page 6 231 2 Using an appropriate sized socket IAI and plastic mallet 6 lightly tap the valve retainer to lo...

Page 127: ...it 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 3 Intake...

Page 128: ...r oven to even y heat the cylinder head to 300 F 150 C Monitor the temperature with a cooki ng thermometer Do not get the head hotterthan 30D F 15D C excessive heat may loosen the valve seats 5 Workin...

Page 129: ...Installed Height Intake 15 2 16 2 mm 0 598 0 638 in Exhaust 15 5 16 5 mm 0 610 0 650 in 07742 0010100 6 34 10 Coat both reamer and valve guide with cutting oil 11 Rotate the reamer clockwise the full...

Page 130: ...5 mm 0 049 0 061 in Service Limit 2 00 mm 0 079 in 6 After resurfacing the seat inspect for even valve seating Apply Prussian Blue compound A to the valve face Insert the valve in its original locatio...

Page 131: ...Intake Valve Stem Installed Height Standard New 40 8 41 0 mm 1 606 1 614 in Exhaust Valve Stem Installed Height Standard New 54 6 54 8 mm 2 150 2 157 in 9 If valve stem installed height is over the st...

Page 132: ...l C has a black spring D and the intake valve seal E has a white spring F They are not interchangeable F f E c B A 5 Install the valve spring Place the end of the valve spring with closely wound coils...

Page 133: ...broken line 4 Insert the bolts IAI into the rocker shaft holder then install the rocker arm assembly IBI on the cylinder head 6 38 5 Remove the bolts from the rocker shaft holder 6 Make sure the punc...

Page 134: ...s use a new cylinder head gasket 3 Set the crankshaft to top dead center TDCI Align the TDC mark Alan the crankshaft sprocket with the pointer BI on the cylinder block A 4 Install the cylinder head on...

Page 135: ...orquing it loosen the bolt and retighten it from the first step 9 After torquing tighten all cylinder head bolts in two steps 90 per step If you are using a new cylinder head bolt tighten the bolt an...

Page 136: ...line Repeat this operation two or three times then check for fuel leakage at any point in the fuel line Refill the radiator with engine coolant and bleed air from the cooling system with the heater va...

Page 137: ...slide the cover slightly back and larth to seat the head cover gasket 6 Inspect the cover washers Ie Replace any washer that is damaged or deteriorated 6 42 7 Tighten the bolts in two or three steps I...

Page 138: ...e page 4 18 10 Check that all tubes hoses and connectors are installed correctly 11 Install the intake manifold cover 6Xl 0mm 12 N m 11 2 kgl m 8 7Ibl 1t1 12 After assembly wait at least 30 minutes be...

Page 139: ...lacement 7 8 Oil Pan Removal 7 11 Crankshaft and Piston Removal 7 12 Crankshaft Inspection 7 14 Block and Piston Inspection 7 15 Cylinder Honing 7 17 Piston Pin and Connecting Rod Replacement 7 18 Pis...

Page 140: ...Engine Block Special Tools Ref No Tool Number Description I Qty CD 07ZAD PNAA100 Oil Seal Driver Attachment 96 I 1 07746 0010700 Attachment 24 x 26 mm 1 07749 0010000 Driver I 1 I I CD CD 7 2...

Page 141: ...n Selection ee page 7 6 page 7 6 CRANKSHAFT End pi Runou Y page 7 5 Out of R page7 14 R ound emoval page 7 14 lnstallati page 7 12 n page 7 24 BAFFLE PLATE FLYWHEEL CRANKSH lRANSMI 21 NSDEAL nstaliati...

Page 142: ...7 19 f B CONNECTING ROD If BEARINGS ____ Removal page 7 18 Inspection page 7 19 Installation page 7 20 ENGINE BLOCK Cylinder bore inspection page 7 15 Warpage inspection page 7 15 Cylinder bore honing...

Page 143: ...stall a new connecting rod and recheck If it is still out aI tolerance replace the crankshaft see page 7 121 5 Install a dial indicator as shown Push the crankshaft lirmly away Irom the dial indicator...

Page 144: ...Journal Oil Clearance No 1 2 4 5 Journals Standard New 0 017 0 041 mm 0 0007 0 0016 in Service Limit 0 050 mm 0 0020 in No 3 Journal Standard New 0 025 0 049 mm 0 0010 0 0019 in Service Limit 0 055 m...

Page 145: ...bores Write down the crank bore codes If you can t read the codes because of accumulated dirt and dust do not scrub them with a wire brush or scraper Clean them only with solvent or detergent NO 5 JO...

Page 146: ...lack 1 t Green Brown Brown B Black Black rown Blue Black II Black Blue Blue Smaller main journal Smaller bearing Thicker 7 8 Connecting Rod Bearing Replacement Rod Bearing Clearance Inspection 1 Remov...

Page 147: ...crankshaft and start over Rod Bearing Selection 1 Inspect each connecting rod for cracks and heat damage Connecting Rod Big End Bore Code Locations 2 Each rod has a tolerance range from 0 0 024 mm 0 0...

Page 148: ...select appropriate replacement bearings from the following table NOTE Color code is on the edge of the bearing When using bearing halves of different colors it does not matter which color is used in t...

Page 149: ...tep 39 on page 5 71 4 Remove the front mount mounting bolt see step 40 on page 5 71 5 Use a marker to make alignment marks on the reference lines that align with the centers of the rear subframe mount...

Page 150: ...oil pump Isee page 8 91 5 Remove the cylinder head Isee page 6 231 6 Remove the baffle plates 7 Remove the 8 mm bolts Q I I J 1 7 12 8 Remove the bearing cap bolts To prevent warpage unscrew the bolt...

Page 151: ...eamer manufacturer s instructions If the ridge is not removed it may damage the pistons as they are pushed out 14 Use the wooden handle of a hammer A to drive out the pistons B 15 Reinstall the lower...

Page 152: ...5 Measure taper at the edges 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 0 005 mm 0 0002 in max...

Page 153: ...3 3827 in 11 mm 10 4 in J PISTON DIAMETER O Oversize Piston Diameter 0 25 86 230 86 240 mm 13 3949 3 3953 in 4 Measure wear and taper in direction X and Y at three levels in each cylinder as shown If...

Page 154: ...New 0 07 mm 0 003 in max Service Limit 0 10 mm 0 004 in PRECISION STRAIGHT EDGE 1 7 16 7 Calculate the difference between the cylinder bore diameter and the piston diameter If the clearance is near o...

Page 155: ...Do not use stones that are worn or broken 3 When honing is complete thoroughly clean the engine block of all metal particles Wash the cylinder bores with hot soapy water then dry and oil them immedia...

Page 156: ...oves until the end gaps are lined up with the cutouts in the piston pin bores 8 NOTE Take care not to damage the ring grooves A B I iL 3 Remove both snap rings A Start at the cutout in the piston pin...

Page 157: ...the dial indicator to the piston pin diameter 3 Check the difference between the piston pin diameter and piston pin hole diameter in the piston Piston Pin to Piston Clearance Standard New 0 005 to 0...

Page 158: ...nnecting rod and the piston pin with engine oil 3 Heat the piston to about 158 F 70 C 7 20 4 Install the piston pin A Assemble the piston B and connecting rod C with the arrow D and the embossed mark...

Page 159: ...into the cylinder bore 15 20 mm 10 6 0 8 in 1 from the bottom 15 20 mm 0 6 0 8 in 1 A 5 Measure the piston ring end gap BI with a feeler gauge If the gap is too small check to see if you have the pro...

Page 160: ...e the rings in their grooves to make sure they do not bind 7 22 8 Position the ring end gaps as shown OIL RING GAP TOP RING GAP and SPACER RING GAP About 900 PISTON PIN SECOND RING GAP OIL RING GAP 9...

Page 161: ...nk journal alignment before pushing the piston into place 6 Check the connecting rod bearing clearance with plastigage Isee page 7 81 7 Inspectthe connecting rod bolts Isee page 7 241 8 Apply engine o...

Page 162: ...the connecting rod bolt 7 24 Crankshaft Installation Special Tools Required Driver 07749 00 10000 Attachment 24 x 26 mm 07746 0010700 Oil seal driver attachment 96 07ZAD PNAA100 1 Install the cranksha...

Page 163: ...ockwise and seat the journals into connecting rod No 2 and connecting rod No 3 Line up the mark on the connecting rod and cap then install the caps and bolts finger tight 12 Tighten the connecting rod...

Page 164: ...Cy 19 Tighten the bearing cap bolts an additional 56 20 Tighten the 8 mm bolts in sequence to 22 N m 2 2 kgf m 16Ibf ft 7 26 21 Use the special tools to drive a new oil seal squarely into the block to...

Page 165: ...y the oil pan mating surfaces 3 Apply liquid gasket PIN 08718 0009 evenly to the cylinder block mating surface of the oil pan and to the inner threads of the bolt holes NOTE Do not install the parts i...

Page 166: ...spension lower arm ball joints see step 6 on page 18 19 7 After assembly wait at least 30 minutes belore lilling the engine with oil 7 28 Transmission End Crankshaft Seal Installation In Car Special T...

Page 167: ...Tools 8 2 Component Location Index 8 3 Oil Pressure Switch Test 8 4 Oil Pressure Test 8 4 Engine Oil Replacement 8 5 Engine Oil Filter Replacement 8 6 Oil Filter Feed Pipe Replacement 8 7 Oil Pump Ove...

Page 168: ...Engine Lubrication Special Tools Tool Number Descri tion 07HAA PJ70100 Oil Filter Wrench I I 4 I 41 8 2...

Page 169: ...WASHER oo it 7 Jll 4 y I g7 127 OIL PUMP CHAIN TENSIONER CRANKSHAFT SPROCKET OIL PUMP CHAIN GUIDE I FFLEPLATE OILCONTROL _ y ORIFICE OIL PRESSURE SWITCH Switch Test page 8 4 Oil Pressure test page 8 4...

Page 170: ...ith the engine running check the engine oil level If the oil level is correct 1 Connect a tachometer 2 Remove the engine oil pressure switch and install an oil pressure gauge AI r 3 Start the engine S...

Page 171: ...Ibf t Do not overtighten 3 Reinstall the drain bolt with a new washer 181 4 Refill with the recommended oillsee page 3 21 Capacity 4 04 14 2 US qtl at oil change 4 2414 4 US qtl at oil change includi...

Page 172: ...8 6 5 If 4 numbers or marks 1 to 4 or to 1are printed around the outside of the filter use the following procedure to tighten the filte Spin the filter on until its seal lightly seats against the bloc...

Page 173: ...he oil filter feed pipe 3 Install the two 20 x 1 5 mm nuts AI onto the new oil filter feed pipe Hold the nut with a wrench then tighten the other nut 4 Tighten the oil filter feed pipe to the block to...

Page 174: ...8 7 Ibf ft m d A 10xl 25mm 1 Q f k f m 33 Ibf ft crisP Apply engone od to c RELIEF VALVE Valve must slide freely OUTER ROTOR In housing bore Replace If scored INNER ROTOR SPRING SEALING BOLT 39N m 14...

Page 175: ...Remove and discard the oil pump chain tensioner 4 To hold the rear balancer shaft insert a 6 mm pin driver A into the maintenance hole in the lower balancer shaft holder and through the rear balancer...

Page 176: ...e between the rotor AI and pump housing BI If the housing to rotor axial clearance exceeds the service limit replace the oil pump Housing to Rotor Axial Clearance Standard New 0 02 0 07 mm 0 001 0 003...

Page 177: ...ck and forth and read the end play Balancer Shaft End Play Front Balancer Shaft Standard New 0 070 0 135 mm 0 0028 0 0053 in Service Limit 0 15 mm 0 006 in Rear Balancer Shaft Standard New 0 070 0 135...

Page 178: ...in Service Limit 20 03 mm 0 789 in Rear Standard New 24 000 24 020 mm 0 9449 0 9457 in Service Limit 24 03 mm 0 946 in Front Rear 8 12 5 Measure the diameters of the No 1 journals on the front balance...

Page 179: ...is out of tolerance install the new bearings and recheck It it is still out at tolerance replace the balancer shafts No 2 Journal Oil Clearance Standard New 0 060 0 120 mm 0 0024 0 0047 in I Service L...

Page 180: ...Installation 1 Make sure the No 1 piston is at TOC see step 1 on page 6 121 2 Align the dowel pin Alan the rear balancer shaft with the mark BI on the oil pump 3 To hold the rear balancer shaft inser...

Page 181: ...161bl ltl 5 Loosely install the oil pump 81 then install the oil pump sprocket el 6 Remove the pin driver DI 7 Tighten the oil pump mounting bolts 8 Squeeze the new oil pump chain tensioner AI then i...

Page 182: ...tensioner 11 Install the oil pan see page 7 27J 8 16 Ojl Pressure Swjtch Replacement 1 Disconnect the oil pressure switch connector then remove the oil pressure switch 18N m 11 8 kgf m 13lbf ftJ 2 Ap...

Page 183: ...Engine Mechanical Intake Manifold and Exhaust System Intake Manifold Removal and Installation 9 2 Exhaust Manifold Removal and Installation 9 7 Exhaust Pipe and Muffler Replacement 9 8...

Page 184: ...2 kgf m 16Ibf ft A INTAKE MANIFOLD Replace if cracked or if mating surface is O damaged GASKET Replace INTAKE MANIFOLD PLATE fj 8 Replace if cracked or Q if mating surface is damaged 9 2 6x 1 0 mm 12N...

Page 185: ...take air temperature IAT sensor connector A and remove the breather hose B then remove the air cleaner housing cover intake air duct assembly e A B 4 Fully open the throttle link and cruise control li...

Page 186: ...holder mounting bolt B and harness clamp mounting bolt C 9 4 9 Remove the engine wire harness connectors and wire harness clamps from the intake manifold Four injector connectors Idle air control lAC...

Page 187: ...inner bolt 3 Tighten the bolt securing the intake manifold and bracket 8x1 25mm 22 N m 12 2 kg m 16Ib ft 4 Install the pev hose IA harness holder mounting bolt 18 and harness clamp mounting bolt Ie 5...

Page 188: ...12N m 11 2 kgf m __ a 7Ibf ft 13 Clean up any spilled engine coolant 14 After installation check that all tubes hoses and connectors are installed correctly 15 Inspect for fuel leaks Turn the ignitio...

Page 189: ...eplace EXHAUST MANIFOLD BRACKET SELF LOCKING NUT 10 x 25 mm o 44 N m 4 5 kgf m 33 fbf ttl 1 Replace 10x1 25mm 44N m 14 5 kgf m 33Ibf tt Replace I 4 3 V 8x1 25mm 10 x 1 25 mm 44N m 4 5 kgf m 33 fbf tt...

Page 190: ...s alternating side to side EXHAUST PIPE B ____ 6 x 1 0 mm _________ 9 8 N m 11 0 kgf m 7 2 Ibf ft SELF LOCKING NUT 10 x 1 25 mm J U c 0 W OXYGEN SENSOR J 0 _______ SECONDARy HEATED 33 N m 13 4 kgf m 2...

Page 191: ...Water Outlet Installation Radiator and Fan Replacement Fan Controls 10 2 10 3 10 3 10 4 10 4 10 5 10 5 10 6 10 6 10 8 10 9 10 9 10 10 Component Location Index 10 11 Symptom Troubleshooting Index 10 1...

Page 192: ...WITCH Test page 10 17 Replacement page 10 17 10 2 AIC CONDENSER FAN ASSEMBLY Replacement page 10 10 Fan Motor Test page 10 4 21 j WATER OUTLET Installation page 10 9 CONNECTING PIPE WATER PASSAGE Inst...

Page 193: ...If the pressure drops replace the cap Radiator 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 At...

Page 194: ...ce 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 B...

Page 195: ...61 3 Remove the crankshaft pulley see page 6 11 I 4 Remove the six bolts securing the water pump then remove the water pump AI A 6x 1 0mm 12 N m 1 2 kg m a 7Ib It 5 Inspect and clean the O ring groov...

Page 196: ...he MAX mark and inspect the cooling system for leaks 10 6 Coolant Replacement 1 Start the engine Set the heater temperature control dial to maximum heat then turn off the ignition switch Make sure the...

Page 197: ...ion causing the cooling system to malfunction or fail Honda All Season Antifreeze Coolant Type 2 is a mixture of 50 antifreeze and 50 water Pre mixing is not required Engine Coolant Refill Capacity in...

Page 198: ...hose then remove the thermostat 6x 1 0 mm 9 8N m 11 0 kgf m 7 2Ibf ftl THERMOSTAT O RING Replace 4 Install the thermostat with a new O ring then install the lower hose 5 Install the splash shield see...

Page 199: ...5 minutes or more have elapsed since applying liquid gasket Instead reapply liquid gasket after removing old residue Apply liquid gasket along the broken line 3 Install the water passage IAI with a ne...

Page 200: ...RADIATOR HOSE Q RESERVE TANK Ale CONDENSER FAN ASSEMBLY FAN MOTOR CONNECTORS 6xl 0mm 9 8 N m 1 0 kgf m 7 2Ibf ft RADIATOR FAN SWITCH CONNECTOR 5 Disconnect the fan motor connectors and radiator fan s...

Page 201: ...TOR FAN RELAY l D l J Test page 22 51 I 7 1 r I CONDENSER FAN RELAY Test page 22 51 UNDER HOOD FUSE RELAY BOX RADIATOR FAN SWITCH Test page 10 17 Replacement page 10 17 RADIATOR FAN ASSEMBLY Motor Tes...

Page 202: ...ator fan does not run at all Radiator Fan Circuit Troubleshooting see page 10 14 Radiator fan does not run for engine cooling but it runs Radiator Fan Switch Circuit Troubleshooting Open with AlC ON s...

Page 203: ...DIATOR d FAN FANSWfTCH MOTOR Closed Above 1 1 199 F 93 e 1 BlK BLK 1 GJ G301 No 20 No 20A a il DENSER RELAY I BLU YEL M X DENSER MOTOR 1 BlK G301 IGNITION SWITCH No 20 40A USA model 1 10 20 SOA Canada...

Page 204: ...Terminal side of female terminals Is there battery voltage YES Go to step 4 NO Replace the under hood fuse relay box 10 14 4 Connect the No 1 and No 2 terminals of the radiator fan relay 4P socket wi...

Page 205: ...ween radiator fan motor 2P connector terminal No 1 and body ground If the wire is OK check for a poor ground at G301 9 Reinstall the radiator fan relay 10 Disconnect the radiator fan switch 2P connect...

Page 206: ...ground If the wire is OK check for a poor ground at G301 10 16 Radiator Fan Switch Circuit Troubleshooting Short NOTE After troubleshooting perform the e gine control module IECM idle learn procedure...

Page 207: ...ter Do not let the thermometer B touch the bottom of the hot container 4 Measure the continuity between terminal No 1 and terminal No 2 according to the table Terminal Operation Temperature 2 ON 96 20...

Page 208: ...1 114 11 115 11 115 11 116 11 117 11 118 11 127 11 128 11 128 11 129 11 130 11 133 11 134 11 135 11 137 11 138 11 139 11 140 11 141 11 144 FuelPressureTest 11 145 Fuel Lines Inspection 11 146 Fuel Lin...

Page 209: ...Fuel Pressure Gauge Adapter 1 CD 07NAJ P070 1OA Pressure Gauge Adapter 1 07XAA 001010A Fuel Sender Wrench 1 CD 07ZAJ S5AA200 Hose Oil Pressure 1 1 07406 0020201 AfT Pressure Hose 1 2 07406 0070300 Af...

Page 210: ...an OBD II scan tool to the Data Link Connector DLCI IBI located under the driver s side of the dashboard A B 3 Turn the ignition switch ON III 4 Check the Diagnostic Trouble Code DTCI and note it Also...

Page 211: ...as described above 2 Do the ECM idle learn procedure see page 11 139 3 Turn the ignition switch OFF 4 Disconnect the OBD II scan tool or Honda PGM Tester from the DLC NOTE The ECM is part of the immo...

Page 212: ...re 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...

Page 213: ...e s electrical devices light horn radio etc How to Update the ECM Turn the ignition switch ON II Do not start the engine 2 Connect the Honda Interface Module HIM to the Data Link Connector DLC A locat...

Page 214: ...ae 11 62 P0128 187 P0128 Coolina SYstem Malfunction see oaae 11 64 P0134 41 Air Fuel Ratio lA F Sensor ISensor 1 No Activity Isee page 11 65 I Detected P0137 163 P0137 Secondary Heated Oxygen Sensor I...

Page 215: ...tem Troubleshooting Isee page 22 172 Pll06 13 Pll06 Barometric Pressure IBARO Sensor Range Isee page 11 83 Performance Problem Pll07 13 Barometric Pressure BARO Sensor Circuit Low Isee page 11 83 Volt...

Page 216: ...ee a e11 93 see page 11 95 Camshaft Position CMP Sensor B Top Dead Center see page 11 95 TDC Sensor No Si nal Evaporative Emissions EVAP Control System Leaka e Fuel Tank S stem Evaporative Emissions E...

Page 217: ...ee page 11 1381 3 Inspect adjust the throttle cable Isee page 11 1631 4 Inspect andtestthe throttle body see page 11 1601 Idle speed fluctuates 1 Do the ECM idle learn procedure see page 11 1391 Intak...

Page 218: ...4 Inspect the fuel tank vapor vent tube between the EVAP canister and the fuel tank vapor control valve Also check for Malfunctioning gas station filling nozzle __ __ ______ t oC h e c k th e E V A P...

Page 219: ...of the system to permit minimal driving Self diagnosis When an abnormality occurs in the signal from a sensor the ECM supplies ground for the malfunction indicator lamp MIL and stores the diagnostic t...

Page 220: ...early the same as Pressure atmospheric pressure MAP At idle speed about 20 41 kPa 150 310 mmHg 6 12 in Hg 0 7 1 3 V Engine The ECT sensor converts coolant temperature into voltage With cold engine YES...

Page 221: ...uces the amount of injected fuel This cycle keeps the air fuel ratio close to the stoichiometric ratio when in ctosed loop status Long Term Long term fuel trim is computed from short term fuel trim 0...

Page 222: ...TION 40A No 9 BACK UP 7 5A No 7 HORN STOP 15A NOER OASH U F USE RELAY BOX 7 No 17 FUEL PUMP 15A 8 No 4 ACG 10A No 1 IGN COIL 15A No 10 METER 7 5A 1No 14 A C CLUTCH RELAY 10A No 2 B LAF A F HEATER 20A...

Page 223: ...A19 J 5Gl All No 2 INJECTOR 841NJ2 TPSENSOR VCC2 A20 No 3 INJECTOR TPS A15 B31NJ3 SG2 A10 No 4 INJECTOR B21NJ4 IATSENSOR lAC VALVE IATB17 H A1ZIACV ECTSENSQR EeTB8 KS BAROSENSOR DlTI Built into K A9 _...

Page 224: ...I l E202WBS I SH02SHTC E6 ALT Bl0ALTL LGl A24 813 ALTF LG2A23 B18ALTC LG3 E3 K J L N 1 SECONDARY HOZS SENSOR 2 CMPSENSQR A To k l CMP AA25 on SPARK I I PLUG I I ICM 1 VTC 81 A30lGPlSl ____ l No 1 IGNI...

Page 225: ...WIT e14 FTP 1 I E4SG3 BKSWE22 CH GAUGE ASSEMBLY T SEFMJE24 To MULTIPLEX CONTROL UNIT I r 7c E31 MIL I CPU I To IMoeD E27 IMMOBILIZER UN 0 L IT r I E30WEN r E29SCS DATA LINK CONNECTOR E23 K LINE 1 EPSL...

Page 226: ...PG2 PG1 AFS CKP KS 10 11 12 15 16 18 19 20 21 002 001 IACV TPS AFS VSS MAP VCC2 VCC1 22 23 24 25 26 27 28 29 30 AFS LG2 LG1 CMPA CMPB IGPLS4 IGPLS3 IGPLS2 IGPLS1 HTC TOC Wire side of female terminals...

Page 227: ...oltage With ignition switch ON II about 5 V With ianition switch OFF about 0 V 22 WHT AFSHTC AIR FUEL Detects A F sensor heater With ignition switch ON II battery voltage IRATIO NFl SENSOR voltage HEA...

Page 228: ...0 4 8V TEMPERATURE SENSOR deoendinq on enaine coolanttemoerature 9 BLU BLK VTPSW VTEC OIL Detects VTEC oil pressure With engine at low engine speed about 0 V PRESSURE SWITCH switch sianal With enQine...

Page 229: ...about 0 V 6 BLK WHT S02SHTC ISECONDARY Drives secondary H02S With ignition switch ON II battery voltage HEATED OXYGEN SENSOR heater With fully warmed up engine running duty SECONDARY H02S controlled...

Page 230: ...th brake pedal released about 0 V POSITION SWITCH I oosition switch sianal With brake oedal Dressed battery voltaae 23 LT BLU K LiNE Sends and receives scan With ignition switch ON II pulses or batter...

Page 231: ...ssions Systems System Descriptions cont d Vacuum Hose Routing FRONT OF VEHICLE 11 24 EVAPORATIVE EMISSION IEVAP CANISTER PURGE VALVE INTAKE AIR BYPASS CONTROL THERMAL VALVE To EVAPORATIVE EMISSION IEV...

Page 232: ...THROTTLE BODY INJECTOR FUEL PULSATION DAMPER FUEL FILTER llJ FUEL PRESSURE REGULATOR FUELPUMP FUEL TANK ATMOSPHERE RESONATOR AIR CLEANER POSITIVE CRANKCASE VENTILATION IPCV VALVE THREE WAY CATALYTIC...

Page 233: ...re BARO Sensor SENSOR TERMINALS HEATER TERMINALS The BARD sensor is inside the ECM It converts atmospheric pressure into a voltage signal that the ECM uses to modify the basic duration of the fuel inj...

Page 234: ...ERMINAL PIEZO CERAMIC Malfunction Indicator Lamp IMIL Indication In relation to Readiness Codes The vehicle has certain readiness codes that are part of the on board diagnostics for the emissions syst...

Page 235: ...NALS HEATER TERMINALS When the engine is started the ECM provides a rich mixture by increasing injector duration Throttle Position TPI Sensor The TP sensor is a potentiometer connected to the throttle...

Page 236: ...GH SPEED CAM ENGINE LOAD LOW L ___________________ LOW ENGINE SPEED HIGH Drivin Condition VTC Control Descri tion CD Light load Base Position Medium high load Advance Control Cam angle is retarded to...

Page 237: ...e charging effect Cam angle is reduced at idle to stabilize combustion and reduces engine speed If a malfunction occurs the VTC system control is disabled and the valve timing is fixed at the fully re...

Page 238: ...r BLU WHT VTC RETARD BLK WHT ECM CHAMBER GRN VEL r BLU BLK r J BLK VANE l QJR1 VTEC OIL PISTON PRESSU RE BRN SWITCH VEL VTEC iiu M W SOLENOID SPOOL Io VALVE VALVE ROCKER ARMS Camshaft Position CMP Se...

Page 239: ...he throttle valve closed current to the injectors is cut off to improve fuel economy at engine speeds over 1 030 rpm Fuel cut off action also occurs when engine speed exceeds 6 900 rpm regardless of t...

Page 240: ...the intake air bypass control thermal valve sends air to the injectors VALVE INJECTOR WAX ELEMENT INTAKE AIR BYPASS CONTROL THERMAL VALVE Throttle Body The throttle body is a single barrel side draft...

Page 241: ...de CO and oxides of nitrogen NOx in the exhaust gas to carbon dioxide C02 dinitrogen N2 and water vapor 11 34 FRONT OF VEHICLE HOUSING THREE WAY CATALYST Positive Crankcase Ventilation PCV System The...

Page 242: ...absolute pressure into an electrical input to the ECM during the EVAP leak check SENSOR UNIT ASSEMBLY TERMINAL EVAP Two Way Valve and EVAP Bypass Solenoid Valve The EVAP two way valve is installed be...

Page 243: ...st idle speed The amount of bypassed air is controlled in relation to engine coolant temperature INTAKE MANIFOLD THROTTLE BODY Intake Air System Diagram lAC VALVE INTAKE AIR DUCT AIR CLEANER YEL BlK I...

Page 244: ...vapor pressure in the fuel tank is higher than the set value of the EVAP two way valve the valve opens and regulates the flow of fuel vapor to the EVAP canister During refueling the fuel tank vapor c...

Page 245: ...VE IACV K RED BL T CMPB t 2 IToCI 2 GR T CKP 7 U BL ro SENSOR Built into the ECM 11 38 JUNCTION CONNECTOR I I I I I G101 I G101 VEL BLK YEL BLK VEl BLK YEL BlK YEL BlK BLK VEL BlK BRN YEL YElfBLK BRN...

Page 246: ...WHT VCC2 __ REO BI U __YEL BLU J TPS RED BLK J VEL BLU RED BLK E 1l rGRNIVEL TP r _J n __ nn REDIBLU Cl02 _____ II I f J J g ro fJ l ______ fAg KS RED C Ol REDIVEL g cr WHT BL D i8J J I A FSENSOR tSE...

Page 247: ...RED VEL GRNI VEL GRN VEL GRN YEL r RED VEL U J IAT5ENSOR EeT GRNjVEl r 1 B8r IREDfWHT RED WHT Eel SENSOR C T BRN VEl LG BRN VEL JUNCTION LG2 CONNECTOR BRNfVEL 1 BRN VEL Gl01 BLK VEL CMPA 2 BLU WHT BRN...

Page 248: ...I WHT BLU WHT BLU WHT RED WHT GRN 13 WHT RED __ J BLK VEL 81 ALTC _ A2 IGPLS4 ALT WHT GRN VEl GRN _ 1 BLK W HT r BLK J rc K No 1 IGNITION COIL BLK WHT BLU RED t_t 4 f1 44 BLK J 1irC K No 21GNrTlON COI...

Page 249: ...2 J A Gl01 IGPl VEL BLK IGP2 VEL BLK 1 1 1 r Cl01 F G551 YEl GRN 3 VEl BLK GRN YEl VEL BlK IMOFPR r _ i El GRN YEL PGM FI MAIN RELAV2 T VEL BLK MRLY WHT BLK r 1 E7 RED VEL WHT BLK PGM A MAIN RELAY 1...

Page 250: ...BRNI VEL rfJ C451 BRN YEL _ _ _ PNK elK WHT BlK CRN 53 LTGRN PNK BLK ORN BLK ORN R PNK BLK WHT BlK CRN SECONDARY H02S SeNSOR 2 VEl LU LTGRN PNK FTPSENSQR LTGRN RED BlK DRN EVAP CANISTER VENT SHUT VAL...

Page 251: ...Fuel and Emissions Systems System Descriptions cont d ECM Circuit Diagram Icont d 11 44...

Page 252: ...I G l4_ t t 8 BLK WH CONNECTORJ L WHl GRN f WHTIRED VEL TEST I_ t t BLK TACHOMETER r BLU CONNECTOR CONNECTOR H UNDER HOOD FUSE RELAY BOX DNo 20 IG 40A Canada 50A WNo 14 OPTION 40A No 6 ECU ECM 15A T...

Page 253: ...he ignition switch off during the procedure All readiness codes are cleared when the battery is disconnected or when the ECM is cleared with the OBD II scan tool or Honda PGM Tester Low ambient temper...

Page 254: ...the procedure All readiness codes are cleared when the battery is disconnected or when the ECM is cleared with the OBD II scan tool or Honda PGM Tester Enable Criteria ECT at 140 F 60 C or higher Proc...

Page 255: ...e 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 operat...

Page 256: ...ng page 11 77 Replacement page 11 115 INTAKE AIR TEMPERATURE IIAT SENSOR Troubleshooting page 11 55 Replacement page 11 115 ENGINE COOLANT TEMPERATURE ECT SENSOR Troubleshooting page 11 57 Replacement...

Page 257: ...PGM FI System Component Location Index cont d INJECTORS Replacement page 11 111 11 50...

Page 258: ...NTROL MODULE General Troubleshooting Information page 3 Troubleshooting page 11 96 DATA LINK CONNECTOR IDLC General Troubleshooting Information page 11 3 I I PGM FI MAIN RELAY 1 Troubleshooting page 1...

Page 259: ...ale terminals 11 52 Is there about 5 V YES Repair open in the wire between the ECM A211 and the MAP sensor NO Update the ECM if it does not have the latest software or substitute a known good ECM then...

Page 260: ...V or higher indicated YES Go to step 8 NO Replace the MAP sensor 8 Remove the jumper wire 9 Measure voltage between MAP sensor 3P connectorterminals No 1 and No 3 MAP SENSOR 3P CONNECTOR Wire side of...

Page 261: ...Intermittent failure system is OK at this time NO Replace the MAP sensor 11 54 OTC P1129 MAP Sensor Signal Higher Than Expected 1 Start the engine Hold the engine at 3 000 rpm with no load in neutral...

Page 262: ...body ground IAT SENSOR 2P CONNECTOR Wire side of female terminals Is there continuity YES Repair short in the wire between the ECM BI7 and the IAT sensor NO Update the ECM if it does not have the late...

Page 263: ...nals 6 Turn the ignition switch ON II 11 56 7 Check the IATwith the scan tool Is 4 F 20 C or less or L Limit in Honda mode of PGM Tester or 5 V indicated YES Go to step 8 NO Replace the IAT sensor 8 T...

Page 264: ...the engine Hold the engine at 3 000 rpm with no load in neutral until the radiator fan comes on then let it idle 2 Check the ECT with the scan tool Is 176 212 F 80 100 C or 0 5 0 8 V indicated YES In...

Page 265: ...the scan tool Is 150 C 302 F or higher or H Limit in Honda mode of PGM Tester or 0 V indicated YES Go to step 5 NO Replace the ECT sensor 5 Turn the ignition switch OFF 6 Disconnect ECM connector 8 2...

Page 266: ...gnition switch ON II 7 Check the ECTwith the scan tool Is 20 C 4 F or less or L Limit in Honda mode of PGM Tester or 5 V indicated YES Go to step 8 NO Replace the ECT sensor 8 Turn the ignition switch...

Page 267: ...o 1 and NO 3 TP SENSOR 3P CONNECTOR SG2 IGRN VEL VCC2 IVEL BLU Wire side of female terminals Is there about 5 V YES Go to step 7 NO Go to step 14 7 Turn the ignition switch OFF 11 60 8 At the sensor s...

Page 268: ...erminal No 2 and body ground TP SENSOR 3P CONNECTOR Wire side of female terminals Is there continuity YES Update the ECM il it does not have the latest software or substitute a known good ECM then rec...

Page 269: ...ure voltage between the TP sensor 3P connector terminals No 1 and No 3 TP SENSOR 3P CONNECTOR SG2 IGRN YEL VCC2 IYEL BLU Wire side of female terminals Is there about 5 V YES Replace the throttle body...

Page 270: ...lure system is OK at this time NO Replace the TP sensor Ithe TP sensor is not available separately OTC P1122 TP Sensor Signal Higher Than Expected 1 Turn the ignition switch ON II 2 Check the throttle...

Page 271: ...e DTC P0128 can occasionally set when the hood is opened while the engine is running 1 Check the engine coolant level Is the engine coolant level low YES Refill the engine coolant If necessary repair...

Page 272: ...P0137 Secondary H02S Sensor 2 Circuit Low Voltage 1 Resetthe ECM see page 11 4 2 Start the engine Hold the engine at 3 000 rpm with no load in neutral until the radiator fan comes on 3 Check the seco...

Page 273: ...H02S Sensor 2 Circuit High Voltage 1 Resetthe ECM see page 11 41 2 Start the engine Hold the engine at 3 000 rpm with no load in neutrall until the radiator fan comes on 3 Check the secondary H02S Sen...

Page 274: ...software or substitute a known good ECM then recheck see page 11 61 If the symptom indication goes away with a known good ECM replace the original ECM NO Repair open in the wire between the ECM E2 E4...

Page 275: ...OR 21 4P CONNECTOR 1 2 3 4 Wire side of female terminals Is there about 3 3 Q YES Go to step 6 NO Replace the secondary H02S Sensor 2 11 68 6 Check for continuity between body ground and secondary H02...

Page 276: ...Is there battery voltage YES Gotostep 13 NO Check the No 4 ACG 10AI fuse in the under dash fuse relay box If the fuse is OK repair open in the wire between the secondary H02S Sensor 21 and No 4 ACG l...

Page 277: ...Go to step 2 NO Check these items If the pressure is too high replace the fuel pressure regulator see page 11 1521 If the pressure is too low check the fuel pump the fuel feed pipe the fuel filter and...

Page 278: ...sfire DTC s P0107 P0108 P1128 P1129 Manifold absolute pressure MAP sensor P0171 P0172 Fuel system P0335 P0336 Crankshaft position CKP sensor P0505 Idle control system P1149 P1162 P1163 P1164 P1165 Air...

Page 279: ...poor contact at the ignition coil connectors no misfire at this time Make sure the coil connections are secure 72 7 Determine which cylinder s had the misfire Does the misfire occur in the cylinder wh...

Page 280: ...faulty injector NO Go to step 19 19 Turn the ignition switch OFF 20 Disconnect the ignition coil 3P connector from the problem cylinder 21 Turn the ignition switch ON III 22 Measure voltage between ig...

Page 281: ...female terminals DTC I WIRE COLOR P0301 I YEL GRN P0302 BLU RED P0303 WHT BLU P0304 I BRN 28 Check for continuity between body ground and ECM connector terminal see tablel ECM CONNECTOR A 131PI 9 IGP...

Page 282: ...engine idle for 2 minutes 38 Test drive the vehicle for several minutes in the range of the freeze data or under various conditions ifthere was no freeze data 39 Check for a DTC or Temporary DTC with...

Page 283: ...P0303 B3 BLU No 4 P0304 B2 YEL Is there continuity YES Repair short in the wire between the ECM and the injector NO Go to step 48 11 76 48 Connect injector 2P connector terminal No 2 to body ground wi...

Page 284: ...er subharness 6P connector NO Go to step 7 7 Connect starter subharness 6P connector terminal No 5 to body ground with a jumper wire STARTER SUBHARNESS 6P CONNECTOR KS JUMPER RED BlU W RE Wire side of...

Page 285: ...Gotostep7 NO Repair open in the wire between PGM FI main relay 1 and the CKP sensor 11 78 7 Measure voltage between CKP sensor 3P connector terminal No 1 and body ground CKP SENSOR 3P CONNECTOR Wire s...

Page 286: ...onnect ECM connector A 31P 13 Check for continuity between ECM connector terminal A7 and body ground ECM CONNECTOR A 131P r r CKPIBLU 7 9 Q Wire side of female terminals Is there continuity YES Repair...

Page 287: ...ulse between 0 V and 5 V or between OV and battery voltage YES Update the ECM if it does not have the latest software or substitute a known good ECM then recheck see page 11 6 If the symptom indicatio...

Page 288: ...the ignition switch ON III 8 Measure voltage between ECM connector terminal E7 and body ground ECM CONNECTOR E 131 PI MRlY IRED YEll Wire side of female terminals 5 there battery voltage YES Gotostep...

Page 289: ...rminals A3 and A2 individually ECM CONNECTOR A 31 PI IGP2 VEl BlK 10 11 12 IGP VEl BlKI 222324 2526 Wire side of female terminals Is there battery voltage YES Go to step 18 NO Update the ECM if it doe...

Page 290: ...are or substitute a known good ECM then recheck see page 11 61 If the symptom indication goes away with a known good ECM replace the original ECM NO Intermittent failure system is OK at this time Ole...

Page 291: ...nnect A F sensor Sensor 1 4P connector terminals No 1 and No 2 with a jumper wire 11 84 A F SENSOR ISENSOR 1I 4P CONNECTOR 3 4 AFS t jIBLUI AFS GRNI 1 2 JUMPER WIRE Wire side of female terminals 6 Che...

Page 292: ...ge 11 6 if the symptom indication goes away with a known good ECM replace the original ECM NO Replace the A F sensor Sensor 1 DTe P1158 A F Sensor Sensor 1 AFS Terminal Low Voltage 1 Reset the ECM see...

Page 293: ...see page 11 4 2 Start the engine Is DTC P1159 indicated YES Go to step 3 NO Intermittent failure system is OK at this time Check for poor connections or loose terminals at the A F sensor Sensor 1 and...

Page 294: ...OTe PI159 indicated YES Update the ECM if it does not have the latest software or substitute a known good ECM then recheck see page 11 61 if the symptom indication goes away with a known good ECM repl...

Page 295: ...at this time Check for poor connections or loose terminals at the NF sensor Sensor 11 and at the ECM 11 88 DIC P1164 A F Sensor Sensor 1 Circuit Range Performance Problem 1 Resetthe ECM see page 11 4...

Page 296: ...relay and the fuses NO Go to step 4 4 Measure voltage between ECM connector terminals Aland A24 30 seconds after the ignition switch is turned ON II ECM CONNECTOR A 131 PI AFSHTC IBLK WH T Ir r c 1 W...

Page 297: ...nector A 31 PI and the NF sensor Sensor 11 4P connector 12 Check for continuity between the NF sensor Sensor 11 4P connector terminal NO 3 and body ground 11 90 A F SENSOR ISENSOR 11 4P CONNECTOR AF2H...

Page 298: ...he ECM 3 Turn the ignition switch OFF 4 Disconnect the NF sensor 4P connector and ECM connector A 31 PI 5 Connect the NF sensor Sensor 11 4P connector terminals No 2 and No 1 with a jumper wire A F SE...

Page 299: ...age between body ground and ELD 3P connector terminal No 3 ELD 3P CONNECTOR Wire side of female terminals Is there about 5 V YES Replace the ELD NO Go to step 8 11 92 8 Turn the ignition switch OFF 9...

Page 300: ...of female terminals Is there battery voltage YES Go to step 8 NO Check the No 4 ACG 1 OA fuse in the under dash fuse relay box If the fuse is OK repair open in the wire between the No 4 ACG 10A fuse...

Page 301: ...e ELD 3P connector and ECM connector E 31 PI 14 Start the engine and let it idle 15 While measuring voltage between ECM connector terminals A24 and E1 5 turn the headlights on high ECM CONNECTORS Wire...

Page 302: ...n the wire between the PGM FI main relay 1 and the CMP sensor B ITDC sensorl 7 Measure voltage between CMP sensor B ITDC sensorl 3P connector terminal No 1 and body ground eMP SENSOR B TOe SENSOR 3P C...

Page 303: ...P sensor B TDC sensor NO Update the ECM if it does not have the latest software or substitute a known good ECM then recheck see page 11 6 If the symptom indication goes away with a known good ECM repl...

Page 304: ...IG 40A Canada 50A fuse in the under hood fuse relay box A loose No 6 ECU ECM 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 connect...

Page 305: ...the ECM IE31 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 IECM 115A fuse i...

Page 306: ...ion goes away with a known good ECM replace the original ECM Also replace the NO 6 ECU ECM 15 A fuse 20 Disconnect the connectors of all these components PGM FI main relay 2 ECM connector A 131 P Inje...

Page 307: ...ion goes away with a known good ECM replace the original ECM 26 Remove the PGM FI main relay 2 A 11 100 I I 1 27 Check for continuity between ECM connector terminal E9 and body ground ECM CONNECTOR E1...

Page 308: ...ound FUEl PUMP 5P CONNECTOR Wire side of female terminals s there continuity YES Replace the PGM FI main relay 2 Also replace the No 17 FUEL PUMP 1 5A fuse NO Check the fuel pump and replace it if nec...

Page 309: ...YES Goto step 41 NO Repair open in the wire between the NO 6 ECU ECM 15A luse and the PGM FI main relay 1 41 Check for continuity between PGM FI main relay 1 4P connector terminal NO 3 and ECM connect...

Page 310: ...ground PGM FI MAIN RELAY 1 4P CONNECTOR 2 Wire side of female terminals Is there battery voltage YES Go to step 49 B IWHT BLKI NO Repair open in the wire between the No 6 ECU ECM 15A fuse and the PGM...

Page 311: ...ge between body ground and ECM connector terminal A21 ECM CONNECTOR A 131PI r VCC1 SS S 7r t T r 9 IYEll r c REDI Wire side of female terminals Is there about 5 V YES Go to step 60 NO Go to step 53 11...

Page 312: ...nal ECM 60 Measure voltage between body ground and ECM connector terminal A20 ECM CONNECTOR A 31PI Wire side of female terminals Is there about 5 V YES Go to step 68 NO Go to step 61 9 VCC2 VEll BLUI...

Page 313: ...good ECM then recheck see page 11 6 II the symptom indication goes away with a known good ECM replace the original ECM 11 106 68 Measure voltage between body ground and ECM connector terminal E5 ECM C...

Page 314: ...Repair short in the wire between the ECM E5 and the FTP sensor NO Update the ECM if it does not have the latest software or substitute a known good ECM then recheck see page 11 6 If the symptom indica...

Page 315: ...ECM then recheck see page 11 61 If the symptom indication goes away with a known good ECM replace the original ECM 82 Turn the ignition switch OFF 83 Disconnect ECM connector E 31PI 84 Turn the igniti...

Page 316: ...terminals No 4 and No 16 DATA LINK CONNECTOR DlCI PG BlKI 9 B WHT RED Terminal side offemale terminals Is there battery voltage YES Go to step 3 NO Repair open in the wire between OLe terminal No 4 a...

Page 317: ...titute a known good ECM then recheck Isee page 11 61 If the symptom indication goes away with a known good ECM replace the original ECM NO Repair open in the wire between DLC terminal No 7 and the ECM...

Page 318: ...ble 8 and remove the bracket Ie A c B c 3 Disconnect the quick connect fittings ID o N m 12 2 kgl m 16 bl ltl D F G 4 Remove the fuel rail mounting nuts IE from the fuel rail IF then remove the fuel r...

Page 319: ...e injectors into the fuel rail then install the fuel rail into the intake manifold IG 11 Install the fuel rail mounting nuts ground cable and bracket 12 Connect the connectors to the injectors 13 Conn...

Page 320: ...e the NF sensor 8 B 44N m 14 5 kgf m 33Ibf ft 2 Install the NF sensor in the reverse order of removal Secondary H02S Replacement Special Tools Required 02 sensor wrench Snap on YA8875 SP Tools 93750 o...

Page 321: ...m 11 2 kgf m 8 7Ibf 1t1 4 Install the sensor in the reverse order of removal with a new a ring BI 11 114 CMP Sensor B TOC Sensor Replacement 1 Remove the air cleaner see page 11 1621 2 Disconnect the...

Page 322: ...nstall the sensor in the reverse order of removal Knock Sensor Replacement 1 Remove the intake manifold bracket IAI I rl B I 31 N m 13 2 kgf m 1 1 23lbf ftl l 24N m 12 4 kgf m 17lbf ftl 2 Disconnect t...

Page 323: ...tem CKP Sensor Replacement 1 Disconnect the CKP sensor 3P connector 2 Remove the CKP sensor IAI 12 N m 11 2 kgf m 8 7Ibf ftl A B 3 Install the sensor in the reverse order of removal with a new a ring...

Page 324: ...OIL CONTROL SOLENOID VALVE Troubleshooting page 11 18 Test page 1 127 VTC SOLENOID VALVE Troubleshooting page 11 123 Removal Inspection page 11 128 CAMSHAFT POSITION ICMP SENSOR A Troubleshooting pag...

Page 325: ...for poor connections or loose terminals at the VTC oil control solenoid valve and at the ECM 4 Turn the ignition switch OFF 5 Disconnect the ECM connector 8 24PI 6 Measure resistance between ECM conne...

Page 326: ...rt in the wire between the ECM 81 823 and the VTC oil control solenoid valve NO Replace the VTC oil control solenoid valve see page 11 127 Ole POOll VlC System Malfunction 1 Resetthe ECM see page 11 4...

Page 327: ...ly NOTE Do not jump for more than 1 minute ECM CONNECTORS A 31PI JIGPI VEL BLKI 1 2 3 4 5 6 71 9 10 111121 1 15 161 118119 2021 JUMPER WIRE 22231241 27128129 3D B 24P I 2314151 f6 7 VTC BLUIWHT 8 9 10...

Page 328: ...the fuse is OK repair open in the wire between the CMP sensor A and No 4 ACG lOA fuse 7 Measure voltage between CMP sensor A 3P connector terminal NO 1 and body ground CMP SENSOR A 3P CONNECTOR Wire...

Page 329: ...way with a known good ECM replace the original ECM 11 122 Ole P0341 VTC Phase Gap 1 Reset the ECM see page 11 41 2 Start the engine Is OTC P0341 indicated YES Go to step 3 NO Intermittent failure syst...

Page 330: ...es Is OTe P1259 indicated YES Go to step 5 NO Intermittent failure system is OK at this time Check the oil consumption if oil was added in step 2 Check for poor connections or loose terminals at the V...

Page 331: ...switch and the ECM 89 NO Update the ECM if it does not have the latest software or substitute a known good ECM then recheck see page 11 6 If the symptom indication goes away with a known good ECM rep...

Page 332: ...enoid valve see page 11 128 23 Turn the ignition switch OFF 24 Disconnect the VTEC solenoid valve 2P connector 25 Attach the battery positive terminal to VTEC solenoid valve 2P connector terminal No 2...

Page 333: ...erminal No 2 to body ground with a jumper wire VTEC SOLENOlO VALVE 2P CONNECTOR JUMPER VTS WIRE IGRN YEL Wire side of female terminals 33 Check for continuity between ECM connector terminal B15 and bo...

Page 334: ...d opening 12N m 11 2 kgf m 8 7Ibf ftl 2 Check the VTC oil control solenoid valve filter for clogging If it is clogged replace the VTC oil control solenoid valve 3 Check the clearance between the port...

Page 335: ...pection 1 Disconnect the VTEC solenoid valve 2P connector 2 Measure resistance between VTEC solenoid valve connector terminals No 1 and No 2 Resistance 14 30 Q r 3 If the resistance is within specific...

Page 336: ...Idle Control System Component Location Index IDLE AIR CONTROL lAC VALVE Troubleshooting page 11 131 11 129...

Page 337: ...idle speed is less than 700 rpm go to step 3 if it s 800 rpm or higher go to step 4 3 Disconnect the idle air control lAC valve 3P connector Does the engine speed increase or fluctuate YES Check the...

Page 338: ...de of female terminals Is there battery voltage YES Go to step 7 NO Repair open in the wire between the lAC valve and the PGM FI main relay 1 7 Turn the ignition switch OFF 8 Check for continuity betw...

Page 339: ...nuity YES Go to step 13 NO Repair open in the wire between the lAC valve and the ECM A121 13 Reconnect the lAC valve 3P connector 14 Turn the ignition switch ON III 11 132 15 Measure voltage between b...

Page 340: ...ower switch ON 5 Turn the AlC switch ON Does the Ale operate YES The air conditioning signal is OK NO Update the ECM if it does not have the latest software or substitute a known good ECM then recheck...

Page 341: ...diator fan comes on then let it idle 7 Measure voltage between ECM connector terminals A24 and B13 Does the voltage decrease when the headlights and rear window defogger are turned on YES The alternat...

Page 342: ...n the ignition switch ON III 2 Measure voltage between ECM connector terminals A24 and E16 ECM CONNECTORS A 31P 1 2 I 314 5 6 7lJ 9 10 11112VV 15 16 VI18119 20 21 22 231241 2712812930V LG1 BRN YEL I E...

Page 343: ...PS control unitterminal No 17 and the body ground EPS CONTROL UNIT 20P CONNECTOR 1 2 3 5 6 7 8 10 111315171920 Wire side of female terminals Is there battery Voltage YES Substitute a known good EPS co...

Page 344: ...27 28 29 30 LGl BRN YEL E 31P 1 2 13 14 5 6 7 I 8 T VV114 15 16V118 120 22231241 271 129130 IBKSW WHT BLK Wire side of female terminals Is there battery voltage 9 21 31 YES The brake pedal position s...

Page 345: ...e Honda PGM Tester C or an aBO II scan tool to the data link connector DLC D located under the driver s side of the dashboard A o 11 138 3 Start the engine Hold the engine at 3 000 rpm with no load in...

Page 346: ...elay box Disconnect any of the connectors from the under hood fuse relay box Disconnect the connector between the engine compartment wire harness and ECM wire harness Disconnect the G2 terminal from t...

Page 347: ...est page 11 141 Replacement page 11 153 FUEL FILTER Replacement page 11 152 FUEL GAUGE SENDING UNIT Test page 11 156 Replacement page 11 153 FUEL PRESSUR REGULATOR ePlacement page 11 152 il UV j FUEL...

Page 348: ...Go to step 5 NO Repair open in the wire between the PGM FI main relay 1 and the PGM FI main relay 2 5 Measure voltage between PGM FI main relay 2 5P connector terminal No 1 and body ground PGM FI MAI...

Page 349: ...r the ignition switch was turned ON II 11 142 ECM CONNECTOR E 31P IMOFPR GRN YEl Wire side of female terminals Is there battery voltage YES Update the ECM if it does not have the latest software or su...

Page 350: ...y ground FUEL PUMP 5P CONNECTOR Wire side of female terminals Is there battery voltage YES Replace the PGM FI main relay 2 NO Repair open in the wire between the PGM FI main relay 2 and the fuel pump...

Page 351: ...l quick connect fitting for dirt and clean it if necessary 11 144 9 Place a rag or shop towel over the quick connect fitting IAI 10 Disconnect the quick connect fitting IAI Hold the connector IBI with...

Page 352: ...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 o If...

Page 353: ...Inspection Check the fuel system lines hoses and fuel filter for damage leaks and deterioration Replace any damaged parts Make sure the connection is secure and the quick connect fitting cover is fir...

Page 354: ...o EVAPORATIVE EMISSION IEVAPI CANISTER PURGE VALVE Clamp in the middle There should be no clea n e J 90 D Clamp in the middle There should be no clearance E BASE GASKET Replace C A mark There should b...

Page 355: ...m with a shop towel which was 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 8 fue...

Page 356: ...f easily Do not remove the retainer from the line once removed the retainer must be replaced with a new one D 4 Check the contact area AI of the line BI for dirt and damage o If the surface is dirty c...

Page 357: ...etainer 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 replacing the fuel filter replacing the fuel gauge sendi...

Page 358: ...a small amount of new engine oil on the line end Connection with new retainer Reconnection to existing retainer 5 Make sure the connection is secure and that the pawls are firmly locked into place che...

Page 359: ...40 47 psi after making sure that the fuel pump and the fuel pressure regulator are OK 1 Remove the fuel pump see page 11 153 2 Remove the fuel filter AI E I 3 Install in the reverse order of removal...

Page 360: ...the fuel filter 8 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...

Page 361: ...ise the fuel rail 6 Place a wrench AI on the fuel rail BI 7 Place a wrench el on the fuel pulsation damper DI 8 Remove the pulsation damper 9 Install the fuel pulsation damper in the reverse order of...

Page 362: ...the fuel pipe cover A Disconnect the fuel vapor hose and quick connect fittings Disconnect the hoses Slide back the clamps 8 then twist the hoses as you pull to avoid damaging them B e A 5 Place a ja...

Page 363: ...etest 3 Turn the ignition switch OFF 4 Remove the rear seat cushion see page 20 801 S Remove the access panel AI from the floor B 6 Disconnect the fuel pump SP connector BI 11 156 7 Measure voltage be...

Page 364: ...tool loosen the fuel tank unit locknut A 07XAA 001010A A 93N m 19 5 kgl m 69 Ibl ltl 15 Measure resistance between the No 1 and No 2 terminals with the float at E EMPTY 1 2 HALF FULL and F FULL positi...

Page 365: ...float at the E IEMPTY position If the low fuel indicator is on go to step 4 If the low fuel indicator is not on refer to the low fuel indicator Circuit Diagram Isee page 22 58 and check the circuit 4...

Page 366: ...L VALVE Test page 11 161 THROTTLE BODY Test page 11 160 Removal Installation page 11 165 Disassembly Reassembly page 11 166 THROTTLE CABLE AIR CLEANER Replacement page 11 162 AIR CLEANER ELEMENT Repla...

Page 367: ...11 1631 then go to step 2 2 Move 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...

Page 368: ...hanges If the vacuum reading does not change check for these problems Misrouted leaking broken or clogged intake air bypass control system vacuum lines A cracked or damaged intake air bypass control t...

Page 369: ...ft c 2 Remove the air cleaner C 3 Install in the reverse order of removal 11 162 Air Cleaner Element Replacement 1 Disconnect the PCV hose A A 3N m 10 3 kgl m 2 Ibl ftJ 2 Open the air cJeaner housing...

Page 370: ...8 1 2 in l loosen the locknut IB turn the adjusting nut ICI until the free play is as specified then retighten the locknut 3 With the cable properly adjusted check the throttle valve to be sure it op...

Page 371: ...tral 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 AI Turn the adjusting nut 81 so that its free play is Omm The s...

Page 372: ...cable see page 4 451 The throttle position TPI sensor is not removable THROITLE STOP SCREW Do not adjust THROITLE LEVER There should be no clearance THROITLE CABLE t MANIFOLD ABSOLUTE PRESSURE IMAP SE...

Page 373: ...hrottle Body DisassemblyIReassembly EVAPORATIVE EMISSION EVAP CANISTER PURGE VALVE TPSENSOR 11 166 I N m 0 2 kgf m 1 Ibf ft MAP SENSOR O RING Replace THROTTLE BODY GASKET t Replace I U I ii 3 5 N m 0...

Page 374: ...radiator fan comes on 3 Drive for about 10 minutes without stopping Your speed can vary 4 With the transmission in 4th gear drive at a steady speed between 50 62 mph 80 100 km h for 30 seconds 5 Repe...

Page 375: ...tral until the radiator fan comes on 3 Let the engine idle for at least 40 seconds with the throttle fully closed 4 Check for a DTC P1505 with the scan tool Is OTe P1505 indicated YES Check these part...

Page 376: ...en 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 PC...

Page 377: ...on page 11 175 step 1 on page 11 180 FUEL TANK VAPOR CONTROL VALVE Test page 11 187 Replacement page 11 189 EVAPORATIVE EMISSION EVAPI CANISTER Troubleshooting step 28 on page 11 183 Replacement page...

Page 378: ...he open end of the hose 7 Turn the ignition switch ON II 8 Monitor FTP sensor voltage with the Honda PGM Tester or measure voltage between ECM connector terminals E4 and E14 and carefully squeeze the...

Page 379: ...CM connector terminal E14 ECM CONNECTOR E 13lPI Wire side of female terminals Is there about 2 5 V YES Intermittent failure system is OK at this time Check for poor connections or loose terminals at t...

Page 380: ...d ECM then recheck see page 11 6 If the symptom indication goes away with a known good ECM replace the original ECM DTC P0453 FTP Sensor Circuit High Voltage 1 Check the vacuum lines at the FTP sensor...

Page 381: ...3P connector terminals No 2 and NO 3 FTP SENSOR 3P CONNECTOR FTPILTGRN SG3IPNK Wire side of female terminals Is there about 5 V YES Replace the FTP sensor NO Gotostep 12 12 Measure voltage between EC...

Page 382: ...t creates greater pressure vacuum The optimum condition for testing is fresh fuel and must be less than a full tank If possible to assist in leak detection add 1 gallon of fresh fuel to the tank as lo...

Page 383: ...rge valve and the ECM B211 NO Update the ECM if it does not have the latest software or substitute a known good ECM then recheck Isee page 11 61 If the symptom indication goes away with a known good E...

Page 384: ...S Go to step 18 NO Repair open in the wire between the EVAP bypass solenoid valve and the ECM E201 18 Turn the ignition switch ON II 19 Measure voltage between EVAP bypass solenoid valve 2P connector...

Page 385: ...id valve EVAP two way valve is OK Go to step 22 NO Repairthe leak from the EVAP bypass solenoid valve EVA two way valve or FTPsensor 11 178 EVAP Canister Vent Shut Valve Test 22 Disconnect the vacuum...

Page 386: ...ol valve test see page 11 187 Is the fuel tank vapor control valve OK YES Gotostep31 NO Replace the fuel tank vapor control valve 31 Tighten the fuel cap 3 clicks then monitor the FTPsensor readings w...

Page 387: ...be less than a full tank If possible to assist in leak detection add 1 gallon of fresh fuel to the tank las long as it will not fill the tankl just before starting these procedures EVAP Canister Purg...

Page 388: ...vacuum hoses from the EVAP two way valve A and connect a vacuum pump to the canister port on the two way valve A973X 041 XXXXX A 11 Turn the ignition switch ON II 12 Apply vacuum to the hose Does the...

Page 389: ...tom indication goes away with a known good ECM replace the original ECM 11 182 EVAP Canister Vent Shut Valve Test 18 Disconnect the vacuum hose from the EVAP canister vent filter A and connect a vacuu...

Page 390: ...ONNECTOR Wire side offemale terminals Is there battery voltage YES Replace the EVAP canister vent shut valve AI and the a ring 181 NO Repair open in the wire between the EVAP canister vent shut valve...

Page 391: ...onnect fitting IA from the EVAP canister and plug the canister port B J A973X 041 T _ xxxxx 36 Turn the ignition switch ON II 11 184 37 While monitoring FTPsensorvoltagewiththe Honda PGM Tester or mea...

Page 392: ...ntinue to pump vacuum until the voltage drops to about 1 5V Make sure the engine coolant temperature is still above 95 F 35 C and your vacuum pump has no leak 45 Monitor the voltage continuously for 2...

Page 393: ...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 11 186 4 Move the vacuum pump hose from the vac...

Page 394: ...If the vacuum holds replace the fuel tank vapor control valve Isee page 11 189 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 ful...

Page 395: ...recirculation hose 8 NOTE At either location tiny droplets of fuel are normaL If fuel runs out of the hoses at either location replace the fuel tank vapor control valve If the fuel does not run out o...

Page 396: ...anister lei 4 Install in the reverse order of removal Fuel Tank Vapor Control Valve Replacement 1 Remove the fuel tank Isee page 11 1551 2 Remove the fuel tank vapor control valve IAI from the fuel ta...

Page 397: ...Transaxle Clutch 12 1 Manual Transmission 13 1 MIT Differential 13 52 Driveline Axle 16 1...

Page 398: ...ls Component Location Index Clutch Pedal Clutch Pedal Position Switch and Clutch Interlock Switch Adjustment Clutch Master Cylinder Replacement Slave Cylinder Replacement Clutch Replacement 12 2 12 3...

Page 399: ...s Ref No Tool Number Descri tion I Qk CD 07JAF PM7011A Clutch Alignment Disc I 1 07LAB PV00100 or 07924 PD20003 Ring Gear Holder 1 CD 07ZAF PR8A100 Clutch Alignment Shaft I 1 CD 07936 3710100 Remover...

Page 400: ...ent page 12 5 CLUTCH DISC ________ CLUTCH INTERLOCK SWITCH Adjustment page 12 4 CLUTCH PEDAL POSITION SWITCH Adjustment page 12 4 Removal page 12 9 Installation page 12 12 m ccc O RING t J I RePla ROL...

Page 401: ...sh rod E in or out to get the specified height F stroke G free play H and disengagement height I atthe clutch pedal Clutch Pedal Stroke 130 140 mm 5 12 5 51 in Clutch Pedal Free Play 10 16 mm 0 39 0 6...

Page 402: ...clip 5 Remove the clutch master cylinder IAI and pull it toward the middle of the engine compartment Remove the retaining clip IBI Disconnectthe clutch line lei Plug the end of the clutch line with a...

Page 403: ...of the retaining clip B with a screwdriver B 11 Tighten the master cylinder mounting nuts to 13 N m 1 3 kgf m 9 4lbf ft 12 Bleed the clutch master hydraulic system see step 11 on page 12 8 NOTE The re...

Page 404: ...emove the intake air duct see step 8 on page 5 3 5 Remove the clutch line bracket A 6 Remove the mounting bolts A and the slave cylinder B A 0 7 Remove the roll pins C Disconnect the clutch line D and...

Page 405: ...he movement of the release fork B with a block of wood to remove all the air from the system Tighten the bleed screw to 8 N m 0 8 kgf m 6 Ibf ttl do not overtighten it Refill the clutch master cylinde...

Page 406: ...replace the pressure plate Standard INewl 0 6 mm 0 02 in 1 max Service Limit 0 8 mm 0 03 in 1 07ZAF PRBA100 07936 3710100 07JAF PM7011A 2 Install the special tools 07ZAF PRBA100 07936 3710100 07LAB P...

Page 407: ...ng of the clutch disc for signs of slipping or oil If the clutch disc is burned black or oil soaked replace it 12 10 g Measure the clutch disc thickness If the thickness is less than the service limit...

Page 408: ...lywheel and recheck the runout Resurfacing the flywheel is not recommended Standard New 0 05 mm 0 002 in max Service Limit 0 15 mm 0 006 in A Flywheel Replacement 1 Install the special tool L 07lAB PV...

Page 409: ...7924 PD20003 B 3 Apply super high temp urea grease PIN 08798 9002 to the splines A of the clutch disc B then install the clutch disc using the special tools 4 Install the pressure plate A and the moun...

Page 410: ...earing CI and the release bearing guide DI in the shaded areas C 0 4 1 09 0 01 0 04 ozl B D 1 0 1 69 10 04 0 060zl 0 4 1 09 0 01 0 04 ozl 5 With the release fork slid between the release bearing pawls...

Page 411: ...ft Inspection 13 26 Mainshaft Reassembly 13 28 Countershaft Assembly Clearance Inspection 13 31 Countershaft Disassembly 13 32 Countershaft Inspection 13 33 Countershaft Reassembly 13 34 Synchro Sleev...

Page 412: ...t Base CD 07JAD PL90100 Oil Seal Driver CD 07NAD P20A100 Oil Seal Driver Attachment 1 07736 A01000B Adjustable Bearing Puller 20 40 mm CD 07746 0010300 Attachment 42 x 47 mm CD 07746 0030100 Driver 40...

Page 413: ...r level Oil Capacity 1 5 a 1 6 us qt atfluid change 1 7 a 1 8 us qt at overhaul Always use Honda Manual Transmission Fluid MTF Using motor oil can cause stiffer shifting and noise because it does not...

Page 414: ...e negative cable first then the positive cable from the battery Remove the battery 2 Remove the intake manifold COver see page 9 3 3 Remove the air cleaner housing see page 11 162 4 Remove the intake...

Page 415: ...ss cover A by lifting up on the lock tab 8 then slide the harness forward off the air cleaner housing mounting bracket C 12 Attach the special tool to the threaded hole in the cylinder head 13 Install...

Page 416: ...Drain the transmission fluid Reinstall the drain bolt with a new washer Isee page 13 31 19 Remove the splash shield c i r fr 6 13 6 20 Remove the three way catalytic converter ITWCI assembly Isee ste...

Page 417: ...ence marks IAI on the lront suspension sublrame IBI and mounting bolts lei then remove the front suspension subframe 27 Remove the clutch cover 28 Remove the front engine mount 29 Place the transmissi...

Page 418: ...C000015 Engine hanger VSB02C000018 Engine support hanger A Reds AAR T 12566 Subframe adapter EQS02C000011 Available through the Honda Tool and Equipment Program 888 424 6857 1 Check the two dowel pins...

Page 419: ...m 47 Ibf ftl 7 Install the clutch cover 6 x 1 0 mm 12 N m 1 2 kgf m 9lbf ftl 8 Support the subframe with the subframe adapter and a jack r EQS02C000011 9 Install the front suspension subframe A in it...

Page 420: ...ll the drivershafts see page 16 171 14 Install the three way catalytic converter TWCI assembly see step 17 on page 5 121 13 10 15 Install the transmission mount bracket AI and the transmission mountin...

Page 421: ...ooster and EVAP line bracket mounting bolts A and air cleaner housing bracket mounting bolt 6 Tighten the air cleaner housing bracket mounting bolt e and install the water pipe mounting bolt D A 9 8N...

Page 422: ...r and the clutch line bracket Take care notto bend the clutch line 24 Install the harness clip 13 12 ____ 6xl 0mm 9 8N m 11 0 kgf m 7 2Ibf ftl 25 Install the cable bracket A and cables 8 26 Apply a li...

Page 423: ...nstall the intake manifold cover see step 41 on page 5 15 33 Install the battery Connect the positive cable first then the negative cable to the battery 34 Refill the transmission fluid see page 13 3...

Page 424: ...m WASHER 13 14 L 0 __ CD o _ U _ _ _ i _ _1 I 28mmSPRING WASHER BALL BEARING 4 28 x 43 x 7 mm OIL SEAL Replace j REVERSE GEAR SHAFT 5 REVERSE IDLER GEAR JJ 6 mm SPECIAL BOLT 15 N m 11 5 kgf m 11lbf ft...

Page 425: ...TTER PLATE I I I I I I I o QQ 80 mm SHIM 8x14m CHANGEm DOWEL PIN 6 LEVER ASSEMBLV 12mNm f E BOLT jj DETENT gl m 9 Ibl hl 22 N BOLT m 12 2 kgl m 161bl h 12 mm WASHER Replace SPRING Ql STEEL BALL TRANSM...

Page 426: ...hitting the workbench 1 Remove the detent bolts AI springs steel balls and back up light switch 8 2 Remove the vehicle speed sensor VSS A and O ring 8 13 16 3 Remove the interlock bolt AI the change l...

Page 427: ...sealing cap A 8 Expand the 72 mm snap ring 8 on the countershaft ball bearing and remove it from the groove using a pair of snap ring pliers 9 Remove the transmission housing C and 14 x 20 mm dowel pi...

Page 428: ...ines to protect the seal then remove the mainshaft assembly A and countershaft assembly B with the shift forks e from the clutch housing D F E 14 Remove the 28 mm spring washer E and 28 mm washer F 13...

Page 429: ...stance is within the standard replace the reverse gear with a new one Standard 13 4 13 7 mm 0 527 0 539 in Change Lever Clearance Inspection 1 Measure the clearance between change lever IAI and the se...

Page 430: ...HER CAP Turn the arrow toward the front of the vehicle and install it Stake the screw in place with a center punch 9 8N m DUST SEAL SELECT LEVER f O _ _ RePlac e B e careful notto damage the dust seal...

Page 431: ...the shift fork with a new one If the thickness of the shift fork finger is within the standard replace the synchro sleeve with a new one Standard 7 4 7 6 mm 0 29 0 30 in 3 Measure the clearance betwee...

Page 432: ...sembly Reassembly Prior to reassembling clean all the parts in solvent dry them and apply lubricant to any contact parts 13 22 3 4 SHIFT FORK _____ 5TH SHIFT FORK 5 x 25 mm SPRING PIN Replace c REVERS...

Page 433: ...is less than the service limit replace 3rd gear with a new one If the thickness of 3rd gear is within the service limit replace the 3rd 4th synchro hub with a new one Standard 23 92 23 97 mm 10 941 0...

Page 434: ...more than the service limit go to step 8 If the clearance is within the service limit go to step 10 Standard 0 06 0 16 mm 0 002 0 006 in Service Limit 0 25 mm 0 010 in c 13 24 B 8 Measure distance on...

Page 435: ...I Mainshaft Disassembly 1 Remove the angular ball bearing AI and the tapered cone ring using a commercially available bearing separator BI and a commercially available bearing puller C Be sure the be...

Page 436: ...nd E If any part of the mainshaft is less than the service limit replace it with a new one Standard A Ball bearing surface transmission housing side 27 987 28 000 mm 1 1019 1 1024 in B Distance collar...

Page 437: ...nds of the mainshaft Rotate the mainshaft two complete revolutions when measuring the runout If the runout is more than the service limit replace the mainshaft with a new one Standard 0 02 mm 0 001 in...

Page 438: ...peration 4TH 5TH GEAR DISTANCE COLLAR c AMBALL BEARING Check for wear and operation Note the direction of installation TAPERED CONE RING v D DISTANCE COLLAR 1 SYNCHRO RING SYr CHIRO SPRING SYNCHRO SLE...

Page 439: ...Install the 3rd 4th synchro hub IAI by aligning the synchro ring fingers 181 with 3rd 4th synchro hub grooves ICI 5 Install the 3rd 4th synchro hub IA using the special tool 6 Install the 3rd 4th sync...

Page 440: ...12 Install the 5th synchro hub A using the special tools 07746 0030100 A 13 Install the 5th synchro sleeve 13 30 14 Install the synchro spring AI c D 15 Install the synchro ring BI by aligning the syn...

Page 441: ...with a new one If the thickness is within the standard go to step 3 Standard 23 03 23 08 mm 0 907 0 909 in 1 r 3 Measure the thickness of the 1st gear If the thickness of 1st gear is less than the se...

Page 442: ...less than the service limit replace 2nd gear with a new one If the thickness of 2nd gear is within the service limit replace the 1st 2nd synchro hub with a new one Standard 27 92 27 97 mm 1 099 1 101...

Page 443: ...e service limit replace it with a new one Standard A Ball bearing surface transmission housing side 30 020 30 033 mm 1 1819 1 1824 in B Distance collar surface 39 937 39 950 mm 1 5723 1 5728 in e Need...

Page 444: ...NEEDLE BEARING Check for wear and operation DISTANCE COLLAR __ SPE IAL BOLT Replace 118 N m 112 kgf m 87Ibl lt BALL BEARING Check for wear and operation Note the direction of installation 35mmSHIM CO...

Page 445: ...e synchro cone fingers 181 with 1st gear grooves ICI then install the synchro spring 101 B c 4 Install the 1st 2nd synchro hub IAI by aligning the synchro cone fingers 181 with 1st 2nd synchro hub gro...

Page 446: ...all the 3rd gear 8 using the special tool and a press C Do not exceed the maximum pressure 13 36 14 700 N 1 500 kgt 3 307 bl max 07746 0030100 12 Install the 4th gear A using the special tool and a pr...

Page 447: ...in F 23983 PPP 900 1 07 mm 0 0421 in G 23984 PPP 000 1 11 mm 0 0437 in H 23984 PPP 900 1 15 mm 0 0453 in J 23985 PPP 000 1 19 mm 0 0469 in K 23985 PPP 900 1 23 mm 0 0484 in L 23986 PPP 000 1 27 mm 0...

Page 448: ...n attachment D to press the countershaft E out of the ball bearing 18 If necessary install the 35 mm shim selected in step 16 then recheck the clearance 19 Install the distance collar AI 35 mm shim an...

Page 449: ...Do not install the synchro sleeve with its longer teeth in the 1st 2nd synchro hub slots E because it will damage the spring ring NOTE If replacement is required always replace the synchro sleeve and...

Page 450: ...tween each gear A and its synchro ring B all the way around Hold the synchro ring against the gear evenly while measuring the clearance If the clearance is less than the service limit replace the sync...

Page 451: ...tial assembly 2 Remove the ball bearing A from the clutch housing B using the special tool and a commercially available 3 8 16 slide hammer e c A 3 Remove the oil seal A from the clutch side Be carefu...

Page 452: ...move the bearing set plate A from the clutch housing 8 2 Remove the needle bearing A using the special tool and a commercially available 3 8 16 slide hammer 81 then remove the oil guide plate C 13 42...

Page 453: ...I 3 Install the washer IH on the mainshaft 4 Measure distance CD between the end of the transmission housing and washer with a straight edge and vernier caliper Measure at three locations and average...

Page 454: ...1 0 93 mm 0 0366 in 1 0 96 mm 0 0378 i nl 0 99 mm 0 0390 in I 1 02 mm 0 0402 in 1 1 05 mm 0 0413 in 1 1 08 mm 0 0425 in 1 1 11 mm 0 0437 in 1 1 14 mm 0 0449 in I 1 17 mm 0 0461 in 1 1 20 mm 0 0472 in...

Page 455: ...bolt in until it just contacts the wide surface of the mainshaft base 16 Zero a dial gauge Alan the end of the mainshaft B 07GAJ PG20130 17 Turn the mainshaft holder bolt BI clockwise stop turning wh...

Page 456: ...her A and 28 mm washer 8 over the ball bearing C Note the installation direction of the spring washer A F B 3 Apply vinyl tape to the mainshaft splines D to protectthe seal Install the mainshaft and c...

Page 457: ...housing C 8 Remove the dirt and oil from the tramsmission housing sealing surface Apply liquid gasket PIN 08718 0001 to the sealing surface Be sure to seal the entire circumference of the bolt holes t...

Page 458: ...C Release the snap ring so it seats in the groove of the countershaft bearing 12 Check that the 52 mm snap ring is securely seated in the groove of the countershaft bearing Dimension CD as installed 3...

Page 459: ...mm 12 N m 11 2 kgf m 9Ibf lt o 39N m 14 0 kgf m 29Ibf lt 18 Apply liquid gasket PIN 08718 0001 to the threads of the interlock bolt D and install it on the transmission housing 19 Install the drain pl...

Page 460: ...Manual Transmission Transmission Reassembly cont d 22 Install the vehicle speed sensor VSS A and O ring B 13 50...

Page 461: ...m 2 2 kgl m 16 Ibl lt f SHIFT LEVER KNOB U 8 N m 0 8 kgl m 5 8Ibl lt SHIFT LEVER HOUSING PIN 08798 9002 CLAMP V 7J PIN 08798 9002 COTTER PINS Replace oj Rotate the shift cable toward the opening Remov...

Page 462: ...MIT Differential Component Location Index 13 52 ALDRIVEN GEAR Replacement page 13 53 DIFFERENTIAL CARRIER Backlash Inspection page 13 53 Replacement page 13 53...

Page 463: ...Standard New 0 05 0 15 mm 0 002 0 006 in Final Driven Gear Carrier Replacement 1 Remove the bolts left hand threads in a crisscross pattern in several steps then remove the final driven gear A from th...

Page 464: ...rs show no signs of wear the bearings are OK 2 Remove the carrier bearing A with a commercially available bearing puller B 13 54 3 Install the new bearings A with the special tool and a press Press ea...

Page 465: ...e differential assembly 2 Remove the oil seal A from the transmission housing B 3 Remove the oil seal A from the clutch housing B 4 Install the new oil seal in the transmission housing with the specia...

Page 466: ...clutch housing 13 56 3 Install the transmission housing onto the clutch housing then tighten the 8 mm flange bolts in a crisscross pattern in several steps see step 15 on page 13 481 axl 25mm 27 N m...

Page 467: ...PL3 BOO 1 1 5 mm 10 0591 in G 41447 PL3 BOOl 1 6 mm 0 0630 in H 41448 PL3 BOOl 1 7 mmj 0669 in J 41449 PL3 BOOl I 1 8 mm 10 0709 in K 41450 PL3 BOOO 1 05 mm 0 0413 in L 41451 PL3 BOOO 1 15 mm 10 0453...

Page 468: ...moval 16 3 Driveshafts Disassembly 16 5 Dynamic Damper Replacement 16 8 Driveshafts Reassembly 16 9 Driveshafts Installation 16 17 Intermediate Shaft Removal 16 19 Intermediate Shaft Disassembly 16 20...

Page 469: ...Oil Seal Driver 1 07MAC SL00200 Ball Joint Remover 28 mm 1 07NAF SR30101 Half Shaft Base 1 Cll 07XAC 001010A Threaded Adapter 22 x 1 5 mm 1 07746 00 10400 Attachment 52 x 55 mm 1 07746 0030400 Driver...

Page 470: ...d Sail joint remover 28 mm 07MAC SL00200 1 Loosen the wheel nuts slightly 2 Raise the front of the vehicle and support it with safety stands in the proper locations see page 1 8 3 Remove the wheel nut...

Page 471: ...n page 18 19 Be careful not to dislodge the lower ball joint from the knuckle 9 Pull the knuckle outward and remove the driveshaft outboard joint from the front wheel hub using a plastic hammer 16 4 1...

Page 472: ...joint 2 Remove the boot bands Be careful not to damage the boot and dynamic damper If the boot band is a welded type IAI cut the boot band IBI If the boot band is a double loop type ICI lift up the ba...

Page 473: ...ing them from the inboard joint 4 Make a mark A on the rollers B and spider e to identify the locations of rollers on the spider then remove the rollers A 5 Remove the eirelip D 6 Mark the spider e an...

Page 474: ...A to the inboard joint side Be careful not to damage the boot 3 Wipe off the grease to expose the driveshaft and the outboard joint inner race 4 Make a mark A on the driveshaft B at the same position...

Page 475: ...e cutthe boot band If the boot band is a double loop type lift up the band bend and push it into the clip If the boot band is a low profile type pinch the boot band using a commercially available boot...

Page 476: ...LIP Qf j I IW 0 I OOT Use the grease included in the inboard boot set Right driveshaft DYNAMIC DAMPER t DOUBLE LOOP BAND Replace V DRIVESHAFT DOUBLE LOOP BAND STOP RING Replace i Replace i N rt J EAR...

Page 477: ...e the grease Included I I r In the nboard boot set CJ I l UU Right driveshaft c1 LOWPROFILE BAND _ RePlace Use the grease included in the inboard boot set i l w DOUBLE LOOP BAND Replace i Boot band re...

Page 478: ...aft then remove the vinyl tape Be careful not to damage the inboard boot 3 Install the spider IA onto the driveshaft by aligning the marks IB on the spider and the end of the driveshaft B i _________...

Page 479: ...ld the driveshaft so the inboard joint is pointing up to prevent it from falling off 16 12 A 8 Make sure the ends of the boot are seated in the grooves in the driveshaft and joint then install the boo...

Page 480: ...nd through the nose section of the commercially available boot band tool KD 3191 or equivalent A and into the slot on the winding mandrel B A c 16 Place a wrench on the winding mandrel of the boot ban...

Page 481: ...n 1 tail protruding from the clip I 19 Bend the band end AI by tapping it down with a hammer NOTE Make sure the band and clip do not interfere with anything and the band does not move Remove any greas...

Page 482: ...stop ring into the driveshaft groove A A 4 Insert the driveshaft A into the outboard jOint B until the stop ring e is close to the joint c G Push Push 5 To completely seat the outboard joint pick up t...

Page 483: ...3 7 4 10zl Use the grease included in the outboard boot set 16 16 A 8 Adjust the length of the driveshafts to the figure below then adjust the boots to halfway between full compression and full exten...

Page 484: ...AX 3 0 mm 10 t2 in MAX 12 Repeat steps 10 and 11 forthe band on the other end of the boot Driveshafts Installation 1 Instali a new set ring onto the set ring groove of the driveshaft Ileft driveshaft...

Page 485: ...e ball joint boot Wipe off the grease before tightening the nut at the ball joint Torque the new castle nut e to the lower torque specification then tighten it only far enough to align the slot with t...

Page 486: ...eel then install the front wheel with the wheel nuts 10 Turn the front wheel by hand and make sure the clearance between the driveshaft and circumference parts 11 Refill the transmission with recommen...

Page 487: ...age to the differential oil seal B 16 20 Intermediate Shaft Disassembly Special Tools Required Oil seal driver 07947 5B00100 Half shaft base 07NAF 5R30101 1 Remove the set ring A outer seal B and exte...

Page 488: ...3 Remove the internal snap ring 4 Press the intermediate shaft bearing A out of the bearing support B using the special tools and a press PRESS l47 SB00100 B A o 07NAF SR30101 16 21...

Page 489: ...E SHAFT 16 22 FLANGE BOLT 10 x 1 25 mm 391V m 14 0 kgf m 29Ibf ft oo BEARING SUPPORT DOWEL BOLTS jj OX 25mm 39N m C 14 0 kgf m 29Ibf ft v INTERMEDIATE SHAFT BEARING Replace EXTERNAL SNAP RING o O JJ I...

Page 490: ...ressed air Do not wash the rubber parts with solvent 2 Press the intermediate shaft bearing AI into the bearing support BI using the special tools and a press PRESS B A 3 Install then seat the interna...

Page 491: ...ter seal Intermediate Shaft Installation 1 Use solvent or brake cieaner to thoroughly clean the areas where the intermediate shaft A contacts the transmission differential and dry with compressed air...

Page 492: ...3 Install the heat shield and tighten the three bolts j 8x 1 25mm 22N m 12 2 kgf m 16lbf ftl 4 Install the right driveshaft see page 16 17 16 25...

Page 493: ...17 4 Steering Linkage and Gearbox Inspection 17 5 Steering Wheel Removal 17 6 Steering Wheel Disassembly Reassembly 17 7 Steering Wheel Installation 17 8 Steering Column Removal and Installation 17 9...

Page 494: ...Steering Special Tools Tool Number Descri tion 07MAA SL00200 Locknut Wrench 43 mm o CD I 17 2...

Page 495: ...AIRBAG ASSEMBLY Removal Installation page 23 113 STEERING WHEEL Removal page 17 6 Disassembly Reassembly page 17 7 Installation page 17 8 STEERING COLUMN Steering Column Removal and Installation page...

Page 496: ...stment inspect the steering linkage and gearbox see page 17 51 ROTATIONAL PLAY 0 10 mm 10 0 39 in 1 L r Power Assist Check 1 Start the engine and let it idle 2 Attach a commercially available spring s...

Page 497: ...heck for looseness STEERING GEARBOX Inspect for loose mounting hardware GEARBOX MOUNTING CUSHIONS Inspect for deterioration BALL JOINT BOOT STEERING COLUMN Inspect for loose column mounting hardware S...

Page 498: ...3 Install a commercially available steering wheel puller IA on the steering wheeIIB Free the steering wheel from the steering column shaft by turning the pressure bolt Ie of the puller Note these ite...

Page 499: ...Steering Wheel Disassembly Reassembly CONNECTOR HOLDERS ACCESS PANEL B 17 7...

Page 500: ...eeve Do not tap on the steering wheel or steering column shaft when installing the steering wheel 17 8 3 Install the steering wheel nut IAi and tighten it to the specified torgue A 39 N m 14 0 kgl m 2...

Page 501: ...r see page 20 591 and under cover see page 20 601 4 Remove the column covers AI 8x 1 25 mm 28 N m 12 9 kgl m 21 Ibl ltl 8x 1 25 mm 16 N m 11 6 kgl m 121b1 1t1 5 Disconnect the wire harness connectors...

Page 502: ...Pullan the steering jointto make sure that the steering joint is fully seated Then install the upper joint bolt and tighten it to the specified torque Tighten the lower joint bolt to the specified tor...

Page 503: ...nd proper movement If any bearing is noisy or has excessive play replace the steering column as an assembly Check the absorbing plates IC absorbing plate guides ID stop IE and coating plates IF for di...

Page 504: ...h a 5 mm 3 16 in 1 drill bit Be careful not to damage the switch body when removing the shear bolts A 3 Remove the shear bolts from the switch body 4 Install the switch body without the key inserted 5...

Page 505: ...w A to 25 N m 12 5 kgf m 18Ibf ft then loosen it A 44N m 14 5 kgf m 33Ibf ft 7 Retighten the rack guide screw to 6 N m 10 6 kgf m 4 Ibf ft then back it off to the specified angle Specified Return Angl...

Page 506: ...Troubleshooting Index 17 23 System Description 17 24 Circuit Diagram 17 26 DTC Troubleshooting 17 28 EPS Indicator Circuit Troubleshooting 17 47 Motor Removal Installation 17 49 Steering Gearbox Remov...

Page 507: ...EPS Components Special Tools Ref No Tool Number Description Qty Q 07MAC SLOO200 Ball Joint Remover 28 mm 1 n 070AO POA0100 Attachment 42 mm 1 07ZAA S5A0100 Locknut Wrench 1 Q l I 17 16...

Page 508: ...Unit Removal Installation page 17 67 UNDER DASH FUSE RELAY BOX MOTOR Removal Installation page 17 49 U U O ASSEMBLY DATA LINK CONNECTOR 116P TORQUE SENSOR STEERING GEARBOX Steering Gearbox Removal pag...

Page 509: ...ver when the same DTC is detected more than once the most recent DTC is written over the prior DTC therefore only one occurrence is memorized The DTCs are indicated repeatedly until the ignition switc...

Page 510: ...nectors poor terminal contact etc in the affected circuit before you start troubleshooting 3 After troubleshooting clear the DTC and test drive the vehicle Be sure the EPS indicator does not come on H...

Page 511: ...ed ON II The engine is stopped The ses circuit is shorted to body ground before the ignition switch is turned ON II Example of OTC 23 Long blinks Short blinks two times three times ON lhrihnrl _ l I U...

Page 512: ...S indicator goes off return the steering wheel to the straight ahead driving position and release the steering wheel The EPS indicator comes on again 4 seconds after releasing the steering wheel 6 Wit...

Page 513: ...motor voltage see page 17 361 OTC 42 A problem with the motor driven current open circuit or short to groundl i see page 17 381 OTC 43 A problem with the motor driven current short to powerI see page...

Page 514: ...ndicator does not go EPS Indicator Circuit Troubleshooting see page 17 471 off and no DTC is stored EPS indicator does not stay 1 Check the motor wires between the EPS control unit and the on no DTC i...

Page 515: ...wer source for the 1 Ground Constant Battery voltage Plus batter actuator motor 2 BLK PG Ground for the actuator 2 Ground Power around motor EPS Control Unit Inputs and Outputs at Connector B 2P EPS C...

Page 516: ...ound and spin the voltage about sensor or the ECM 4 pulsel front wheel OV 5V OV 5V Rev 8 BAN SCS Detects service check a Ground SCS not grounded Battery voltage I IService check sianal connector siana...

Page 517: ...___ ________ 0 ________________________ G N YEl ______________ GRN yEL ______________ U ORN BlU ORN jlNTEGRATEj CIRCUIT i llRED YEl RED iO i J ECM 31P CONNECTOR lEI 8 9 2930 31 GAUGE ASSEMBLV 22P CONN...

Page 518: ...N YEl BLU ORN VEL REO _____________________________________ yEL BLK T SIG ______________________________________ _ I G O __ EPS CONTROL UNIT CONNECTOR A 2P F Connectorl EPS CONTROL UNIT CONNECTOR B 2P...

Page 519: ...120PI Wire side of female terminals Is there continuity YES Repair short to body ground in the wire between the torque sensor and EPS control unit NO Go to step 7 17 28 7 Turn the ignition switch ON I...

Page 520: ...nections If the connections are good the system is OK at this time 4 Stop the engine and verify the DTC Is DTC16 indicated YES Go to step 5 NO Perform the appropriate troubleshooting for the code indi...

Page 521: ...orque sensor NO Go to step 9 17 30 9 Turn the ignition switch OFF 10 Check for continuity between the appropriate EPS control unit connector C 20P terminal and the torque sensor terminal see table Ter...

Page 522: ...DTC 2 Start the engine 3 Wait at least 10 seconds Does the EPS indicator come on YES Go to step 4 NO Check for loose wires or poor connections If the connections are good the system is OK at this time...

Page 523: ...p 9 17 32 9 Check for continuity between EPS control unit connector C 20P terminal No 11 and the torque sensor 6P connector terminal No 3 EPS CONTROL UNIT CONNECTOR C 20P TORQUE SENSOR 6P CONNECTOR Vc...

Page 524: ...is running at 280 rpm or below for 3 seconds 1 Start the engine and check the tachometer Is the tachometer working correctly YES Go to step 2 NO Go to step 9 2 Test drive the vehicle above 15 km h 9...

Page 525: ...good EPS control unit and recheck NO Repair open in the wire between the EPS control unit and the ECM 9 Turn the ignition switch OFF and disconnect EPS control unit connector C 20PI 10 Start the engin...

Page 526: ...ol unit the test tachometer connector the gauge assembly and the ECM NO Check for loose ECM control unit connectors If necessary substitute a known good ECM control unit and recheck DTC 37 EPS Control...

Page 527: ...unit connector B 12P terminal No 1 and body ground EPS CONTROL UNIT CONNECTOR B 2PI Wire side of female terminals Is there continuity YES Repair short to body ground in the RED wire between the EPS c...

Page 528: ...tage YES Repair short to power in the circuit wire between the EPS control unit and the motor NO Gotostepll 11 Turn the ignition switch is OFF 12 Substitute a known good EPS control unit and connect a...

Page 529: ...control unit connector B 2P terminal No 1 and body ground EPS CONTROL UNIT CONNECTOR B 12P Wire side of female terminals Is there continuity YES Repair short to body ground in the RED wire between the...

Page 530: ...B 2PI terminal No 2 and body ground EPS CONTROL UNIT CONNECTOR B 2PI Wire side of female terminals Is there battery voltage YES Repair shortto power in the circuit wire between the EPS control unit a...

Page 531: ...eck for loose wires or poor connections if the connections are good substitute a known good EPS control unit and connect all the disconnected connectors 14 Start the engine and turn the steering wheel...

Page 532: ...ctor B 2P terminal No 1 and body ground EPS CONTROL UNIT CONNECTOR B 2PI Wire side of female terminals Is there battery voltage YES Repair short to power in the circuit wire between EPS control unit a...

Page 533: ...nd verify the DTC Is DTC 43 indicated YES Replace the steering gearbox motor and recheck NO Perform the appropriate troubleshooting for the code indicated 17 42 DTe 47 EPS Control Unit Internal Circui...

Page 534: ...replace the original EPS control unit NO Perform the appropriate troubleshooting for the code indicated DTC 51 EPS Control Unit Internal Circuit EEPROM 1 Clear the DlC 2 Start the engine Does the EPS...

Page 535: ...TC 2 Start the engine Does the EPS indicator come on YES Go to step 3 NO Check for loose wires or poor connections If the connections are good the system is OK at this time 3 Stop the engine and verif...

Page 536: ...e original EPS control unit and recheck NO Perform the appropriate troubleshooting for the code indicated OTC 67 Torque Sensor IIF Circuit 1 Clear the DTC 2 Start the engine 3 Turn the steering wheel...

Page 537: ...NO Check for loose wires or poor connections If the connections are good the system is OK at this time 4 Stop the engi ne and verify the DTC Is DTC 69 indicated YES Check for loose or poor connections...

Page 538: ...e on YES Go to step 5 NO Inspect the EPS indicator bulb if the bulb is OK replace the bulb circuit board in the gauge assembly 5 Turn the ignition switch OFF 6 Disconnect EPS control unit connector C...

Page 539: ...nnector A 2P terminal No 1 and body ground EPS CONTROL UNIT CONNECTOR A 12P Wire side offemale terminals Is there battery voltage YES Go to step 17 NO Check for a blown No 18 60A fuse in the under hoo...

Page 540: ...set buttons 2 Disconnect the negative cable from the battery and wait 3 minutes before beginning work 3 Remove the air cleaner assembly AI 4 Remove the connector bracket Alan the gearbox housing and d...

Page 541: ...ight and left about 45 degrees Make sure the motor is evenly seated on the steering gearbox and that the O ring is not pinched between the mating surfaces 12 Install the removed parts in the reverse o...

Page 542: ...over see page 20 60 7 Remove the steering joint bolts A and disconnect the steering joint by moving the steering joint B toward the column I J I I Y A 8 Remove the cotter pin A from the tie rod ball j...

Page 543: ...et C 13 Remove the ground cable terminal A from the steering gearbox housing 17 52 14 Remove the engine wire harness clamps A from the three mounting brackets A 15 Remove the heater hose B from the br...

Page 544: ...eft side of the steering gearbox 19 Remove the steering stiffener B from the right side of the steering gearbox _r 20 Lower the steering gearbox and rotate it so the pinion shaft points upward 21 Remo...

Page 545: ...y to the wheelwell opening on the passenger s side 23 Carefully raise the driver s side pinion sidel of the steering gearbox AI and tie rod BI until clears the master cylinder and under hood fuse rela...

Page 546: ...____________eJ DISC WASHER ____ SPRING BOOT BAND Replace BO iIlO Il f 12 x 125 STOP PLATE J i _o RACK GUIDE SCREW LOCKNUT r7 Nk mmm Replace BRACKET I 54Ibl ft O RINGS LOCK WASHER Replace Replace IE RO...

Page 547: ...to the steering gearbox Removal 1 Remove the steering gearbox see page 17 511 Disassembly 2 Unbend the lock washer AI A 3 Hold the bracket AI with one wrench and unscrew both tie rod ends 61 with anot...

Page 548: ...ts Securely clamp the yoke in a vise as shown Do not clamp the steering gearbox housing in the vise 8 Install the special toollAI on the lock screw IBI securely then loosen and remove the lock screw f...

Page 549: ...ve and discard the stop ring A on the cylinder by expanding it with snap ring pliers Remove and discard the lock screw B 13 Install the new lock screw on the rack housing 14 Install the new stop ring...

Page 550: ...teering gearbox housing 18 Attach the yoke IAI of a universal puller to the gearbox housing mounts with bolts then securely clamp the yoke in a vise as shown Do not clamp the steering gearbox housing...

Page 551: ...ide mating surfaces Slide the steering rack all the way to lelt and place the slider guide on the steering rack by aligning the bolt holes B 17 60 25 Center the steering rack within its stroke and ali...

Page 552: ...n the housing 33 Expand the boot IA by removing the vinyl tape and fit the boot ends IB in the installation grooves on the cylinder housing A 34 Close the ear portion IA of the bands IB with commercia...

Page 553: ...EPS Components Steering Gearbox Overhaul cont d 36 Bend the lock washer against the flat spots on the bracket with a large pair of pliers 37 Adjust the rack guide screw see page 17 131 17 62...

Page 554: ...box Lower the steering gearbox and move it toward the driver s side until the steering gearbox is in position INOTICEI Be careful not to damage the hoses lines and wire harnesses 3 Install the pinion...

Page 555: ...ad and connect the heater valve cable end B to the heater valve arm e Readjust the heater valve cable see page 21 46 c 17 64 B 9 8N m 11 0 kgf m 7 2Ibf ftl 9 Reinstall the heater hose A on the hose br...

Page 556: ...nter the steering rack within its stroke 15 Wipe off any grease contamination from the ball joint tapered section and threads Then reconnect the tie rod ends A to the damper steering arms Install the...

Page 557: ...ted Then install the upper joint bolt and tighten it to the specified torque Tighten the lower joint bolt to the specified torque E 8x1 25mm 28N m 12 9 kgf m 21lbf ftl 19 Install the driver s dashboar...

Page 558: ...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 ri B 0 A t t 3 Pack the interior of the new boot...

Page 559: ...nt 18 11 Ball Joint Boot Replacement 18 16 Stabilizer Bar Replacement 18 17 Stabilizer Link Removal Installation 18 18 Lower Arm Removal Installation 18 19 Damper Spring Replacement 18 20 Rear Suspens...

Page 560: ...Description Qty CD 07GAF SE00100 Hub Dis Assembly Tool 1 CD 07MAC SL00200 Ball Joint Remover 28 mm 1 07746 0010500 Attachment 62 x 68 mm 1 G 07749 0010000 Driver I 1 07965 SA50500 Front Hub Dis Assemb...

Page 561: ...ment page 18 20 STABILIZER BAR Replacement page 18 17 STABILIZER LINK Removal Installation page 18 18 I NlJ Lc fHUIS 1NHccL BEARING Replacement page 1 1 8all Joint Boot Replacement page 18 16 STABILIZ...

Page 562: ...size and tire pressure Tire size Front rear 195 60R15 Tire pressure Front Rear 230 kPa 2 3 kgf ern 33 psi 210 kPa 2 1 kgf ern 30 psi 4 Check the runout of the wheels and tires 5 Check the suspension...

Page 563: ...hole diameter allows a small range of adjustment Damper Pinch Bolt Adjusting Bolt PIN 90188 S5A 000 1 Raise the front of the vehicle and support it with safety stands in the proper location Isee page...

Page 564: ...ont 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...

Page 565: ...cially 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...

Page 566: ...ce 2 Check the toe If it is correct but the turning angle is not within the specification check for bent or damaged suspension components 18 8 Wheel Bearing End Play Inspection 1 Raise the vehicle and...

Page 567: ...imit 2 0 mm 0 08 in 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 in Service limit 1 5 mm 0 06 i...

Page 568: ...10 3 Loosen the pressure bolt A and 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 adjusting bolt B 10m...

Page 569: ...Replace 0 SPLASH GUARD Check for corrosion deformation and damage Replace if rusted HUB Check for deformation damage and cracks BRAKE DISC FLAT SCREWS 6x 1 0 mm 9 8N m 11 0 kgl m 7 2Ibl ft SPINDLE NU...

Page 570: ...ing bolt A v VA 8 x 1 25 mm ci J 22 N m i 12 2 kgl m 261bl ftl B 12 x 1 25 mm 108N m 111 0 kgl m 801bl ftl 4 Remove the caliper bracket mounting bolts B and remove the caliper assembly C from the knuc...

Page 571: ...ock pin into the ball joint pin from the inside to the outside of the vehicle The closed end of the lock pin must be in the range shown A 07MAC SL00200 SJ B 4q 12 x 1 25 mm 59 69N m 16 0 7 0 kgl m 43...

Page 572: ...to keep it from falling when pressed clear 07GAF SE00100 Press J 15 Press the wheel bearing inner race A off olthe hub B using the spetial tool a commercially available bearing separator C and a pres...

Page 573: ...oval 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 torqu...

Page 574: ...l B c 3 Wipe the grease off the tapered section of the pin e and pack fresh grease onto the base D 18 16 4 Install the boot onto the ball joint pin then squeeze it gently to force out any air Do not l...

Page 575: ...emove the flange bolts A and bushing holders B then remove the bushings IC and the stabilizer bar 0 FORWARD A 10 x 1 25 mm 39N m 4 0 kgf m 29lbf ftl B 4 Install the stabilizer bar in the reverse order...

Page 576: ...ir range of movement 18 18 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 an...

Page 577: ...ct the lower arm from the knuckle using the special tool Isee page 18 10 5 Remove the flange bolts IA and remove the lower arm IB 6 Install the lower arm in the reverse order of removal and note these...

Page 578: ...PER MOUNTING BASE Check for deformation m _ UPPERSPRINGSEAT DAMPER MOUNTING _ C BEARING Check for smooth operation _ UPPER SPRING MOUNTING CUSHION Check for deterioration and damage BUMP STOP Check fo...

Page 579: ...he nut BI T 07MAC Sl002000 3 Disconnectthe tie rod end from the steering arm on the damper using the special tool see page 18 101 4 Remove the bolts and remove the wheel senSOr harness bracket AI and...

Page 580: ...move the nut B 2 Release the pressure from the strut spring compressor then disassemble the damper as shown in the Exploded View 18 22 3 Reassemble all the parts except for the upper spring seat and s...

Page 581: ...Install the upper spring seat and the spring on a commercially available strut spring compressor A and compress the spring lightly 5 Insert the damper unit 8 up through the compressed spring 6 Align...

Page 582: ...mper shaft with a hex wrench el and tighten the 12 mm nut to the specified torque A 12 x 1 25 rnm 44N m 14 5 kgf m 33Ibf ft 10 Remove the damper assembly from the strut spring compressor 18 24 Install...

Page 583: ...6 Tighten the damper pinch nuts to the specified torque 7 Install the brake hose bracket A and the wheel sensor harness bracket B onto the damper and tighten the bolt to the specified torque 9 8N m 1...

Page 584: ...6 HUB BEARING UN T Check for faulty movement and wear 6xl 0mm 9 8 N m 1 0 kgf m 71 bf Itl Check for wear and damage j BRAKEDISC 6x 1 0mm 9 8N m 1 0 kgf m 7lbf ltl SPINDLE NUT 22 1 5 mm HUBCAP Replace...

Page 585: ...unting bolt IA B 10 x 1 25 mm 55N m 15 6 kgf m 41lbf ftl A 8x1 25mm 22N m 12 2 kgf m 16 Ibf ft 6 Remove the caliper bracket mounting bolts IB and hang the caliper Ie to one side To prevent damage to t...

Page 586: ...pindle Use a new hub cap on reassembly Before installing the wheel clean the mating surface of the brake disc and the inside of the wheel 18 28 Knuckle Replacement 1 Rai e the rear of the vehicle and...

Page 587: ...s then place a floor jack under the lower arm and raise the suspension to load it with the vehicle s weight before fully tightening the bolts and nuts to the specified torque values Align the cam posi...

Page 588: ...flange bolts A and bushing holders 8 then remove the bushings C and the stabilizer bar D o c 18 30 A 8x 1 25 mm 22N m 12 2 kgf m 16lbf ftl B 4 Ins all the stabilizer bar in the reverse order of remov...

Page 589: ...th the joint pins 0 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...

Page 590: ...m 6 0 kgf m 43lbf ftl 18 32 B A 12 x 1 25 mm 59 N m 16 0 kgf m 43lbf ftl 5 Install the upper arm in the reverse order of removal and note these items First install all the suspension components and li...

Page 591: ...25 rnm 108 N m 111 0 kgf m 80 Ibf ltl 7 Remove the trailing arm rear mounting bolt A INOTICEI Do not loosen the special bolts B on the trailing arm 8 Lower the jack and remove the trailing arm 9 Insta...

Page 592: ...__ RePlaCe cc DAMPER MOUNTING DAMPER MOUNTING BASE RUBBER BUSHING Check for weakness SPRING MOUNTING CUSHION Check for deterioration and damage DAMPER SPRING Check for weakened compression and damage...

Page 593: ...proper location see page 1 8 Remove the rear wheels 2 Remove the flange bolt A from the bottom of the damper 3 Remove the rear bulkhead cover see page 20 51 4 Remove the flange nuts A from the top of...

Page 594: ...er 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...

Page 595: ...o the top of the damper 3 Loosely install the flange bolt A on the bottom of the damper f __ A 12x 1 25 mm 61 N m 6 2 kg m 45 b ftl 4 Raise the suspension with a floor jack to load the vehicle weight...

Page 596: ...19 10 Front Brake Pads Inspection and Replacement 19 11 Front Brake Disc Inspection 19 13 Front Brake Caliper Overhaul 19 14 Master Cylinder Replacement 19 15 Master Cylinder Inspection 19 16 Brake Bo...

Page 597: ...Conventional Brake Components Special Tools Tool Number Descri tion Ot 07JAG SD40100 Pushrad Ad ustment Gau e CD I 19 2...

Page 598: ...Cylinder Inspection page 19 16 Brake Booster Push rod Clearance Adjustment page 19 16 Brake System Bleeding page 19 8 INDICATOR Brake System Indicator Circuit Diagram page 19 9 Parking Brake Switch Te...

Page 599: ...igns of fluid leakage at Line joints Modulator Brake System Test Brake pedal sinks fades when braking 1 Start the engine and let it warm up to operating temperature 2 Attach a 2 inch piece of masking...

Page 600: ...brake drag Is there brake drag at any of the wheels YES Go to step 4 NO Replace the brake booster 4 Without removing the brake lines unbolt and separate the master cylinder from the booster then spin...

Page 601: ...tighten the locknut firmly Do not adjust the pedal height with the pushrod pressed 19 6 Pedal Free Play 4 With the engine off inspect the play A on the pedal pad 8 by pushing the pedal by hand Free Pl...

Page 602: ...en raise the rear of the vehicle and support it with safety stands in the proper location see page 1 81 4 Make sure the parking brake arm AI on the rear brake caliper contacts the brake caliper pin BI...

Page 603: ...wed to contaminate the brake fluid 1 Make sure the brake fluid level in the reservoir is at the MAX upperllevel line AI A 2 Slide a piece of clear plastic hose over the first bleed screw and submerge...

Page 604: ...T III GAUGE ASSEMBLY BRAKE SYSTEM INDICATOR WHT GRN DER OASH UN FUSE RELAY BOX I MULTIPLEX 1 CONTROL UNIT I IMMOBILIZER CONTROL I UNIT RECEIVER GRN ORN r _ r ED GRN RED BLO J G301 I I I I L I GRN R 1...

Page 605: ...there should be continuity With the brake lever down there should be no continuity 19 10 Brake Fluid Level Switch Test Check for continuity between the terminals A with the float in the down position...

Page 606: ...in the proper location see page 1 8 Remove the front wheels 2 Check the thickness of the inner pad A and outer pad B Do not include the thickness of the brake pad backing plate Brake pad thickness Sta...

Page 607: ...s and pad shim correctly Install the pads with the wear indicators ICI on the inside If you are reusing the pads always reinstall the brake pads in their original pOSitions to prevent a momentary loss...

Page 608: ...ace it see page 18 11 A new disc should be refinished if its runout is greater than 0 10 mm 0 004 in Thickness and Parallelism 1 Raise the front of the vehicle and support it with safety stands in the...

Page 609: ...ed 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 brakin...

Page 610: ...r mounting nuts H and washers 8 Remove the master cylinder from the brake booster Se careful not to bend or damage the brake lines when removing the master cylinder 9 Remove the rod seal I from the ma...

Page 611: ...al 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 th...

Page 612: ...02 in 1 6 If the clearance is incorrect loosen the star locknut AI and turn the adjuster 81 in or out to adjust Adjust the clearance while the specified vacuum is applied to the booster Hold the clevi...

Page 613: ...for 30 seconds the vacuum booster is OK If the pedal rises the booster is faulty 2 With the engine stopped press the brake pedal several times using normal pressure When the pedal s first pressed it s...

Page 614: ...e booster mounting nuts C 7 Remove the brake booster A from the engine compartment iNOTICEi Be careful not to damage the booster surfaces and threads of the booster stud bolts Be careful not to bend o...

Page 615: ...ety stands in the proper location see page 1 8 Remove the rear wheels 2 Check the thickness of the inner pad A and outer pad B Do not include the thickness of the brake pad backing plate Brake pad thi...

Page 616: ...ays reinstall the brake pads in their original positions to prevent a momentary loss of braking efficiency 11 Rotate the caliper piston clockwise into the cylinder then align the cutout AI in the pist...

Page 617: ...Refinish Limit 9 0 mm 10 35 in 1 NOTE If the brake disc is beyond the service limit for refinishing replace it Isee page 18 261 A new disc should be refinished if its runout is greater than 0 10 mm 0...

Page 618: ...heir original positions to prevent loss of braking efficiency Do not reuse drained brake fluid Use only clean Honda DOT 3 brake fluid Non Honda brake fluid can cause corrosion and shorten the life of...

Page 619: ...if necessary 4 Check the master cylinder and ABS modulator unit for damage and leakage NOTE Replace the brake hose clip whenever the brake hose is serviced ABS MODULATOR UNIT to BRAKE LINE 15 N m 11 5...

Page 620: ...A and remove the brake hose brackets from the damper o c 4 Remove and discard the hose clip B 5 Remove the banjo bolt C and remove the brake hose D from the caliper 6 Install the brake hose bracket A...

Page 621: ...Exploded View PARKING BRAKE LEVER Check for smooth operation Sliding surface EQUALIZER ________ADJUSTING NUT iil1ll1l JJJlmI EJ Q PARKING BRAKE SWITCH 19 26 if lilt PARKING BRAKE CABLE Check for stif...

Page 622: ...e cable adjusting nut IA A c y 4 Remove the parking brake cable clip IA from the brake cable IB c B 5 Disconnectthe parking brake cable from the lever Ie 6 Remove the parking brake cable mounting hard...

Page 623: ...TC Troubleshooting Index 19 34 Symptom Troubleshooting Index 19 35 System Description 19 36 Circuit Diagram 19 42 DTC Troubleshooting 19 45 ABS Indicator Circuit Troubleshooting 19 52 Brake System Ind...

Page 624: ...9 59 ABS MODULATOR CONTROL UNIT Removal and Installation page 19 57 19 30 UNDER DASH FUSE RELAY BOX RIGHT REAR WHEEL SENSOR Inspection page 9 59 Replacement page 19 59 LEFT REAR WHEEL SENSOR Inspecti...

Page 625: ...53 The ABS indicator goes off when the vehicle is driven again and the system is OK after the ignition switch is turned from OFF to ON II Diagnostic Trouble Code DTC The memory can hold three DTes How...

Page 626: ...ooting is done based on the OTC check for loose connectors poor terminal contact etc before you start troubleshooting 3 After troubleshooting clear the OTC disconnect the Honda PGM Tester and test dri...

Page 627: ...ned ON II The SCS circuit is shorted to body ground belore the ignition switch is turned ON II Example of DTe 15 Long blink I II ON OFF Example of Ole 22 Short blinks five times Long blinks two times...

Page 628: ...age 19 46 OlC 17 Left rear wheel sensor open short to body ground short to power see page 19 45 OlC 18 Faulty left rear wheel sensor pulse signal see page 19 46 OlC 21 Continuous operation chipped pul...

Page 629: ...s not go off and no ABS Indicator Circuit Troubleshooting see step 1 ABS DTC is stored on page 19 531 Brake system indicator does not come Brake System Indicator Circuit Troubleshooting on see age 19...

Page 630: ...s right rear 1 2 YEL wheel sensor 2 GRN RRSI I signal YEL 4 BLU FRS I I Detects right front 4 5 Spin wheel at AC 0 053 V or wheel sensor 1turn second above signal 5 GRN FRSI I Wheel Oscilloscope BLK 0...

Page 631: ...tor assemblv 20 BLU ABS Drives ASS RED indicator 21 BRN EBD Drives brake VEL IElectronic brake system indicator distribution Measurement Terminals Conditions Ignition switch ON llill 14 GND Brake peda...

Page 632: ...ting an extremely unstable condition The ASS precisely controls the slip rate aftha wheels to ensure maximum grip force from the tires thereby ensuring the maneuverability and stability of the vehicle...

Page 633: ...EEL SENSOR SPEEOWHEEL SOLENOID SOLENOID I I I RIGHT FRONT I I RIGtfT FRONT DETECT Jt E ASS DRIVE grlN J lgNT I WHEEL SENSOR I WHEEL SPEED CONTROL SOLENOID I I I LEFT FRONT I I LEFT FRONT DETECT Jt E I...

Page 634: ...NDER MODULATOR UNIT Me2 Mel r I DAMPING CHAMBER DAMPING CHAMBER I MOTOR I PUM I I 7 lLjlJ l J I I I I ACCUMULATO PUMP L _____________ _ _ _ _ _ ____________________________J IN INLET VALVE NORMAllY OP...

Page 635: ...ntrol SPEED VEHICLE SPEeD REFERENCE VEHICLE SPE JL WHEEL SPEED TIME PRESSURElLl0 _ _ OUTLET t VALVE 0 L O J ______ JO L__________ lO L_ INLET t VALVE ON InI I0I OFF L_ L_________ ________________LLLL_...

Page 636: ...K T BlK YEL G1 otl ON 1111 START 1 1 m mONI No 11 7 5A D BLK DRN I INDICATOR BlU RED L l jD G i 01 BLK DRN WHTIGRN _ __________________________________________________________________ WIfT GRN No 10 4...

Page 637: ...MULTIPLEX OONTJlOL UNIT t WHT BLK BAN YEL BLU RED lKIORN WHT GRN WHTIRED lUIORN BRN WHT GRN YEL BtU YEl LTBLU BS CABS MODULATOA CONTAOL UNIT ONTRO UNIT MODULATOA UNIT STOP I B FSR B MR FLO I cont d __...

Page 638: ...MULTIPLEX CONTROL UNIT 13P CONNECTOR 1 2 3 8 10 11 12113114 15 17 6 7 8 9110111 12 19 44 GAUGE ASSEMBLY CONNECTORS CONNECTOR A 22P 1 4 5 111213141516 ABS CONTROL UNIT 31P CONNECTOR DATA LINK CONNECTO...

Page 639: ...lator control unit and the appropriate wheel sensor NO Go to step 4 4 Turn the ignition switch OFF 5 Check for continuity between the appropriate wheel sensor I I circuit terminal and body ground Isee...

Page 640: ...circuit wire between the ASS modulator control unit and the wheel sensor NO Replace the wheel sensor 19 46 OTe 12 14 16 18 Wheel Sensor Pulse Signal NOTE If the ASS indicator comes on lor the reasons...

Page 641: ...it 5 Disconnect the harness 2P connector from the appropriate wheel sensor and check the resistance between the side and the side olthe wheel sensor Is there less than 450 Q YES Replace the wheel sens...

Page 642: ...8 OTC 51 Motor Locked 1 Check the No 10 40A fuse in the under hood fuse relay box Is the fuse OK YES Reinstall the fuse and go to step 2 NO Replace the fuse and recheck 2 Disconnect the ASS control un...

Page 643: ...ABS indicator come on and is OTe 51 indicated YES Replace the ABS modulator control unit NO The system is OK at this time OTe 52 Motor Stuck OFF 1 Check the No 10 40A fuse in the under hood fuse relay...

Page 644: ...the wire between the ABS control unit and body ground G202 19 50 OTe 53 Motor Stuck ON 1 Clearthe DTC then disconnect the Honda PGM Tester 2 Test drive the vehicle Does the ABS indicator come on and i...

Page 645: ...the under hood fuselrelay box DlC 61 IG2 Voltage NOTE Check the No 1 1 7 5A fuse in the under dash fuselrelay box before troubleshooting 1 Clear the DTC then disconnect the Honda PGM tester 2 Test dr...

Page 646: ...the parking brake lever Does the brake system indicator come on YES Go to step 3 NO Repair open in the indicator power source circuit If necassary substitute a known good ASS modulator control unit a...

Page 647: ...etween the gauge assembly and body ground G501 ABS indicator does not go off 1 Check the No 8 20AI fuse in the under hood fuse relay box and reinstall the fuse if it is OK Is the fuse OK YES Go to ste...

Page 648: ...ignition switch ON II 19 54 10 Connectthe ABS control unit 31P connector terminal No 20 and body ground with a jumper wire ABS CONTROL UNIT 3 P CONNECTOR 1 21 4 5167891 11121 1415 16 17 18 19TiDr211 1...

Page 649: ...indicator does not go off 1 Turn the ignition switch ON II 2 Release the parking brake Does the brake system indicator go off after several seconds YES The system is OK at this time NO Go to step 3 3...

Page 650: ...witch OFF 11 Connect the multiplex control unit 13P connector terminal No 1 and body ground with a jumper wire MULTIPLEX CONTROL UNIT 13P CONNECTOR JUMPER WIRE Wire side of female terminals 12 Turn th...

Page 651: ...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 T...

Page 652: ...of the ASS control unit 31 P connector until you hear it click into place then connect the connector 4 Connect the six brake lines 5 Bleed the brake system starting with the front wheels 6 Connect th...

Page 653: ...easure the gap on the rear wheel sensor If the gap exceeds 1 0 mm 0 04 in check for a bent suspension arm Standard Front Rear Front O 4 1 0mm 10 02 0 04 in Rear O 2 1 0mrn 10 01 0 04 in 0 4 1 0 mm 0 0...

Page 654: ...nsole Disassembly Reassembly 20 58 Dashboard Instrument Panel Removal Installation 20 59 Driver s Dashboard Lower Cover Removal Installation 20 59 Driver s Dashboard Under Cover Removal Installation 2...

Page 655: ...ion Index 20 105 Hood Opener Cable Replacement 20 106 Fuel Fill Door Opener Cable Replacement 20 107 Hood Latch Replacement 20 108 Fuel Fill Door Opener Replacement 20 109 Hatch Handle Replacement 20...

Page 656: ...page 20 12 ______ HINGE I REFLECTOR TAPE DOOR SHOULDER PAD 0 I Y DETENT ROD HINGE j J PLASTIC _ DOOR WEATHERSTRIP Replacement page 20 11 c SPEAKER DOOR GLASS INNER WEATHERSTRIP INNER HANDLE POWER WIND...

Page 657: ...IMMOBILIZER LABEL REGULATOR Replacement page 20 9 LATCH Replacement page 20 7 I FRONT LOWER CHANNEL P OUTER HANDLE ROTECTOR 20 3...

Page 658: ...p cover Ie out to release the hook ID and tab IE and pullout the cover to release the tabs IF and hook IG by hand then remove the cover B c J _ F f C 20 4 3 Remove the armrest cover A Take care not to...

Page 659: ...g or breaking it Fastener Locations 95 mm 3 74 in C Clip 9 12mm 0 47 in T I 1mm L 0 04 in r 45 mm 1 77 in A 7 Disconnect the inner handle cable A from the inner handle 18i and disconnect the power doo...

Page 660: ...from the latch protector IB 3 Pull the protector down to release the hook Ie from the door Fastener location Screw 1 c 20 6 4 Disconnect the cylinder rod IA and release the retainer clip IB then remov...

Page 661: ...nstall the lock cylinder 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 is sealed around the c...

Page 662: ...the door Take care not to bend the outer handle rod 8 cylinder rod C lock rod D and inner handle cable E Fastener Locations Screw 3 c j B C t 6x 1 0 mm 5N m 10 5 kgf m 4lbf ftl 20 8 9 Install the latc...

Page 663: ...6 I b f f t l I _ 0 I j j A _ cc B c 4 Remove the bolts C and loosen the bolts D then remove the regulator E through the hole in the door 5 Apply multipurpose grease to all the sliding surfaces of th...

Page 664: ...all the trim in the reverse order of removal 20 10 Door Glass Outer Weatherstrip Replacement NOTE Put on gloves to protect your hands Take care not to scratch the door 1 Remove the power mirror see pa...

Page 665: ...llation Check for water leaks see step 7 on page 20 12 Test drive and check for wind noise Door Glass Adjustment NOTE Check the weatherstrips and glass run channel for damage or deterioration and repl...

Page 666: ...ver and install the door panel see page 20 4 9 Test drive and check for wind noise 20 12 Door Position Adjustment NOTE Check for equal gaps between the front rear and bottom door edges and the body Ch...

Page 667: ...striker nuts are fixed but the striker can be adjusted slightly up or down and in or out 1 Loosen the screws 181 then insert a shop towellCI between the body and striker A B C 8x 1 25 mm 18 N m 11 8 k...

Page 668: ...Mirrors t Location Index Componen 20 14 RACTUATOR POWERMIRRO a e22 118 Replacement p 9 SPRING TWEETER MIRROR MOUNT COVER MIRROR HOLDER e 20 15 Replacement pag REARVIEW IRp R20 16 Replacemen...

Page 669: ...note these items Make sure the connector is plugged in properly Attach the harness clip Mirror Holder Replacement 1 Carefully pull out the bottom edge of the mirror holder A by hand Take care not to...

Page 670: ...mirror A down toward the bottom of the windshield then detach it from the spring 8 in the mount C and remove the rearview mirror Take care notta scratch the mirror base 3 If necessary remove the spri...

Page 671: ...tiP fY 11 _ 8 00 ___RETAINER 6 X aU Jil g 2 __ f i WINDSHIELD _c J Replacement page 20 19 LOWER RUBBE CLIP CLIP 4 Blue SPOILER UPPE ROAM FASTENER 2 R R UBBER DAM 4 CO CO OJ CO o m SIDE UPpDiEOCR FAST...

Page 672: ...d QUARTER GLASS UPPER CLIP FRONT SEAL self adhes ve lypel J RUBBER DAM i ii I I I I LOWER CLIP Setf adhesive type J LEV EMBLEM 03 modell Replacement page 20 100 20 18 QUARTER GLASS Replacement page 20...

Page 673: ...page 20 951 4 Remove the molding IAI from the upper edge of the windshield IBI If necessary cut the molding with a utility knife A A 5 If the old windshield is to be reinstalled make alignment marks...

Page 674: ...bonding surface around the entire windshield opening flange Do not scrape down to the painted surface of the body damaged paint will interfere with proper bonding Remove the rubber dam and fasteners...

Page 675: ...eld where adhesive will be applied 12 5 mm 0 49 in 1 E E B 12 5 mm 0 49 in 1 A 12 5 mm 0 49 in 1 14 Glue the molding IA with adhesive tape IB 13M 4212 or equivalent to the upper edge of the windshield...

Page 676: ...s primer around the edge of the windshield A between the dams B and molding e as shown then lightly wipe it off with gauze or cheesecloth Apply glass primer to the molding Do not apply body primer to...

Page 677: ...ithout air pockets to ensure continuous delivery Put the cartridge in a caulking gun and run a bead of adhesive IAI around the edge of the windshield BI between the dams el and molding DI as shown App...

Page 678: ...NOTE The cowl cover clips may not set properly if the windshield adhesive is too wet 26 Install the clips A 8 on both side trim C If the clip D is damaged replace the side trim and clips as an assembl...

Page 679: ...the old rear window is to be reinstalled make alignment marks across the glass and body with a grease pencil 5 Apply protective tape along the inside and outside edges of the hatch Using an awl make...

Page 680: ...water oil and grease 20 26 11 Glue the side upper fasteners IA and side lower fasteners IB with adhesive tape 13M 5312 or equivalent Glue the upper rubber dams IC with adhesive tape IN TTO 501 M or eq...

Page 681: ...glass primer along the edge of the rear window AI upper rubber dams B and lower rubber dam e as shown then lightly wipe it off with gauze or cheesecloth With the printed dots D on the rear window as a...

Page 682: ...20mm 0 79 in X o n Y I2Q Y 5mm 0 2 in I 2mm 0 08 in 17 Before filling a cartridge cut a V in the end ofthe nozzle AI as shown 12 mm 0 47 in 7 mm 0 27 in 20 28 18 Pack adhesive into the cartridge witho...

Page 683: ...east 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...

Page 684: ...remove the quarter glass 20 30 6 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 scr...

Page 685: ...ower clip IB with the edge of the quarter glass Ie then attach them with adhesive tape INITIO 571 or equivalent to the inside face of the quarter glass and align the center of the rear clip ID with th...

Page 686: ...t 100mm 13 94 in A C Inside G J 20 32 6 mm 10 24 in 3 10 5 mm t 14 In c I e I 45mm 11 77 in 1 13 With a sponge apply a light coat of glass primer along the edge of the rubber dam A and front seal IB...

Page 687: ...d ofthe nozzle A as shown 10 mm 0 39 in A 7 mm 0 27 in 16 Pack adhesive into the cartridge without air pockets to ensure continuous delivery Put the cartridge in a caulking gun and run a bead of adhes...

Page 688: ...use a soft shop towel dampened with alcohol 19 Let the adhesive dry for at least 1 hour then spray water over the quarter glass and check for leaks Mark the leaking areas let the quarter glass dry th...

Page 689: ...48 DRAIN CHANNEL Replacement page 20 39 SUNSHADE Replacement page 20 40 WIND DEFLECTOR Replacement page 20 38 SHIM DRAIN CHANNEL SLIDER Replacement page 20 44 CABLE ASSEMBLY Replacement page 20 44 MO...

Page 690: ...deflector seal and roof panel 2 Check for a insufficient deflector extension 3 Check for a deformed deflector Motor noise 1 Check for a loose motor Check closing force 2 Check for a worn gear or bear...

Page 691: ...0 9 kgf m 7 Ibf ftl 3 If necessary repeat on the opposite side Glass Replacement 1 Close the glass fully 2 Slide the sunshade all the way back 3 Remove the screws A then remove both bracket covers 8...

Page 692: ...reverse order of removal and check that the deflector arm base IB and deflector link pivot base IC line up with the same alignment lines D If necessary adjust them forward or backward so the edge of...

Page 693: ...1 A 3 Release the drain channel AI from both hooks 81 of the drain channel slider by pulling the drain channel forward A 4 Remove the drain channel AI 5 Install the channel in the reverse order of re...

Page 694: ...pacers B Fastener locations Screw 4 3 Remove the screws then remove both spacers 20 40 4 While lifting the front portion of the sunshade A move the sunshade forward until you can see both sunshade rea...

Page 695: ...water run freely from a hose without a nozzle Do not use a high pressure spray Motor Replacement 1 Remove the headliner see page 20 541 2 Put on gloves to protect your hands Disconnect the connector...

Page 696: ...E and remove the moonroof relays F Fastener Locations Bolt 10 6x1 0mm 9 BN m H 1 0 kgf m 7 2Ibf ftl A H J 3 Remove the interior harness G by detaching the harness clips H F D J 4 With an assistant ho...

Page 697: ...in 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...

Page 698: ...E from the cable tube side bracket F and the cable tube mounting screws G from both sides of the frame HI Fastener Locations A Screw 2 B Screw 2 E Bolt 2 C F Screw 2 EP No switch side 6x 1 0 mm C 9 BN...

Page 699: ...ed parts should be replaced Apply multipurpose grease to the glass bracket A and guide rail portion of the frame 8 indicated by the arrows Before reinstalling the motor make sure both link lifters are...

Page 700: ...the glass fit to the roof panel and the glass height see page 20 37 C 5 xO 8 mm 5 N m 10 5 kgl m 4lbl fti 3 With an open end wrench loosen the limit switch mounting bolts C 4 Adjust the limit switch...

Page 701: ...re it at the position where you hear a faint click when the switch cam IF pushes the switch lauto stop Check that the switch plate contacts the switch bracket IG 8 Check the operation of the glass by...

Page 702: ...hen check The gear portion and the inner cable for breakage and damage If the gear portion is broken replace the motor If the inner cable is damaged remove the frame see page 20 421 and replace the ca...

Page 703: ...PER TRIM page 20 50 OOR OPENING TRIM page 20 50 A PILLAR TRIM page 20 50 HEADLINER Removal Installation page 20 54 s KICK PANEL REAR SIDE SHELF page 20 51 REAR SIDE TRIM PANEL page 20 51 page 20 50 CA...

Page 704: ...verse order of removal and note these items Replace any damaged clips Apply liquid thread lock to the anchor bolts before reinstallation Before installing the anchor bolts make sure there are no twist...

Page 705: ...ed in properly If the threads on the rear side trim panel mounting self tapping ET screws are worn out use an oversized self tapping ET screw PIN 90137 S1A E0111 made specifically for this application...

Page 706: ...end or scratch the trim and panels 1 To remove the rear trim panel remove the child seat tether anchor see page 23 111 2 Remove the trim as shown 3 Install the trim in the reverse order of removal and...

Page 707: ...hatch side trim Right hatch side trim Hatch lower trim panel 2 Install the trim in the reverse order of removal and replace any damaged clips Fastener Locations A Clip 4 B Clip 2 E Clip 2 C Clip 12 D...

Page 708: ...necessary see page 20 92 C pillar trim both sides see page 20 51 Moonroof switch see page 22 112 Spotlights see page 22 96 Ceiling light see page 22 96 2 Remove the sunvisor A and holder B from both s...

Page 709: ...tached to the trim Replace any clips that remain in the roof during removal Reinstall the clips back in the headliner before installation Carpet Replacement SRS components are located in this area Rev...

Page 710: ...note these items Take care not to damage wrinkle ortwistthe carpet Make sure the seat harnesses are routed correctly Slip the carpet under the rear side trim panel on each side properly Replace the c...

Page 711: ...ar console up then remove it Fastener Locations B Screw 2 C C Clip 2 o o 2tl B E 2 Remove the front console IA 1 Pullout the dashboard center lower cover 8 to detach the clips IC 2 Disconnect the acce...

Page 712: ...Consoles Front Console Disassembly Reassembly NOTE Take care not to scratch the console and related parts Fastener Locations Screw 8 I I CONSOLE BOX 20 58...

Page 713: ...8 and hooks C 2 Gently pullout the upper portion to release the clips D and hooks E Fastener locations Bt Clip 2 Ot Clip 2 y E 4 Install the panel in the reverse order of removal and push the clip and...

Page 714: ...reverse order of removal and push the clip portion into place securely 20 60 B Driver s Pocket Removal Installation NOTE Put on gloves to protect your hands Take care not to scratch the dashboard and...

Page 715: ...ever trim C from under the trim to release the clips D and hooks E of the left side Fastener Locations 0 Clip 2 E Hook 2 A _ _ _ J 4 Pull out the shift lever trim A by hand to release the remaining cl...

Page 716: ...oard lower cover openings loosen the bolts A securing the center panel 8 Fastener Locations A Bolt 2 20 62 5xO 8mm 5N m 10 5 kgf m 4Ibf ft 4 Pull out the center panel A to release the clips 8 and hook...

Page 717: ...ns into place securely Glove Box Removal Installation SRS components are located in this area Review the SRS component locations see page 23 13 and the precautions and procedures see page 23 14 in the...

Page 718: ...from the dashboard 81 Fastener Locations Screw 7 4 Remove the screws then remove the side vent A Fastener Locations Screw 4 0 5 Install the side vent in the reverse order of removal 20 64 Beverage Hol...

Page 719: ...Screw 3 4 Install the tray in the reverse order of removal Passenger s Tray Removal Installation NOTE Take care not to scratch the dashboard Put on gloves to protect your hands 1 Remove the dashboard...

Page 720: ...buttons 2 Disconnect the negative cable from the battery and wait at least three minutes before beginning work 3 Remove these items Driver s dashboard lower cover see page 20 591 Driver s dashboard u...

Page 721: ...ment wire harness connectors from the under dash fuse relay box J B H Middle portion 8 Disconnect the floor wire harness connectors A and combination subharness connector 8 A Passenger s side 9 From u...

Page 722: ...ore reinstallation Before tightening the bolts make sure each wire harness and control cables are not pinched Make sure the connectors are plugged in properly and the antenna lead is connected properl...

Page 723: ...cruise control main switch connector F Separate the dashboard and steering hanger beam Fastener Locations A Bolt 4 B Screw 9 F E 5xO 8mm 5 N m 0 5 kgf m 4 IbMt 5 Install the beam in the reverse order...

Page 724: ...tch Replacement page 20 81 Seat back Striker Replacement page 20 81 Seat back Cover Replacement page 20 82 Seat Cushion Cover Replacement page 20 84 Removal Installation page 20 71 Disassembly Reassem...

Page 725: ...ge Take care notto scratch the body or tear the seat covers Put on gloves to protect your hands 1 Make sure you have the anti theft code for the radio then write down the frequencies for the preset bu...

Page 726: ...driver s seat is similar except it has no OPDS unit connector E B 6 With the help of an assistant carefully remove the front seat through the front door opening 7 Install the seat in the reverse orde...

Page 727: ...with a flat tip screwdriver wrap it with protective tape to prevent damage Apply mUltipurpose grease to the moving portion of the seat track To prevent wrinkles in the seat cushion cover stretch the m...

Page 728: ...e o Apply multipurpose grease to the moving portion of the seat track To prevent wrinkles in the seat cushion cover stretch the material evenly over the pad Make sure the rear seat access cable is con...

Page 729: ...rrode the sensor causing it to fail Put on gloves to protect your hands Seat back Cover 1 Remove the front seat see page 20 71 I 2 With side airbag From under the seat cushion detach the side airbag c...

Page 730: ...ss ID and the OPDS harness IE Ipassengr s seat out through the guide cover IF and holes IG Take care not to bend the cable A B 20 76 6 With side airbag Remove the side airbag Isee page 23 115 and rele...

Page 731: ...e cover B 10 Install the cover in the reverse order of removal and note these items Fit all the hooks of the headrest front trim into the holes in the headrest rear trim then push on the headrest trim...

Page 732: ...4 on page 23 6 3 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 from the seat cushion frame...

Page 733: ..._ _ _ _ __ I A 8 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...

Page 734: ...n the seat back with the center shoulder belt make sure there are no twists or kinks in the belt Make sure the seat backs lock securely Fastener Locations A Bolt 2 B Bolt C Bolt DC Clip 2 1 pJ Wt 8x1...

Page 735: ...n CI of the latch lever DI from the seat back frame Fastener Locations 801t 2 5 Install the latch in the reverse order of removal and make sure the seat back locks and unlocks properly Rear Seat back...

Page 736: ...e of the latch lever cover A to release the clips and release the cover from the pivot pins 8 of the latch lever e while pulling the latch lever Fastener Locations 1 Clip 2 20 82 5 On right seat back...

Page 737: ...ter shoulder belt pass the center belt C through the hole in the seat back cover 10 Install the cover in the reverse order of removal and note these items To prevent wrinkles when installing a seat ba...

Page 738: ...cushion cover all the way around and release the clips A then remove the seat cushion cover 20 84 A _ _ t _ __ t __ _ t I t t t 4 Install the cover in the reverse order of removal and note these item...

Page 739: ...oth front side marker light connectors are plugged in properly Make sure the front bumper engages the hooks of the side spacers and upper beams on both sides securely_ Replace any damaged clips Fasten...

Page 740: ...items Make sure both rear side marker light connectors are plugged in properly Make sure the rear bumper engages the hooks of the side spacers side brackets and upper brackets on both sides securely...

Page 741: ...inge IBI Turn the hood edge cushions lei as necessary to make the hood fit flush with the body atthe front and side edges 6x 1 0mm 9 8N m 11 0 kgf m 7 2Ibf ftl D A 6x 1 0 mm 9 8N m 11 0 kgf m 7 2Ibf f...

Page 742: ...e to each location of the hood latch and hood hinge as indicated by the arrows 20 88 Hood Seal Replacement 1 Using a clip remover detach the clips then remove the hood seal AI Take care not to scratch...

Page 743: ...ns Clip 10 t B A 2 Using a clip remover detach the clips Release the hooks 18 then remove the hood insulator Ie Take care not to scratch the hood 3 Install the insulator in the reverse order of remova...

Page 744: ...Slightly loosen each bolt and nut 5 Adjust the hatch A alignment in the following sequence Adjust the hatch hinges 8 right and left as well as forward and rearward using the elongated holes Turn the...

Page 745: ...Hatch Support Strut Replacement 1 With the help of an assistant use a flat tip screwdriver A to pry the support strut clips B from each end of the support strut C althe hatch and body then release th...

Page 746: ...ocate the painted alignment mark BI on the hatch weatherstrip Align the painted mark with the alignment tab in the the center of the hatch opening and install the hatch weatherstrip all the way around...

Page 747: ...BI in or out until it s flush with the body and up or down as necessary to equalize the gaps 4 Tighten the hinge mounting bolts 5 Reinstall the fuel fill door spring 6 Check that the fuel fill door op...

Page 748: ...2 Remove the clips D 3 Release the bottom hooks E of the grille 4 Pullout the bottom of the grille to release the upper hooks F 5 Pullout the grille to release the slits G from the ribs H then remove...

Page 749: ...y carefully pulling the passenger s cowl cover D upward to release the hooks E and pull out the cover forward to release the hooks F then remove the cover Take care not to scratch the body 5 Detach th...

Page 750: ...the clip by prying on the A pillar corner trim AI Take care not to scratch the body and related parts Fastener location 1 Clip 1 r JuL 3 Close the door half way 4 Pull the A piller corner trim AI out...

Page 751: ...l up and slide the roof molding to release the front bracket IDI from the pin lEI 3 Pull up the front portion of roof molding 4 Pull up and release the rear bracket IAI from the pin 181 then remove th...

Page 752: ...ock cylinder 8 Fastener Locations Bolt 2 I i B A 6x1 0mm 9 8 N m 11 0 kgf m 7 2Ibf ft 20 98 3 From inside the hatch release the clips lA 8 while holding the rear license trim e then remove the trim Ta...

Page 753: ...while pulling the hatch spoiler IAI away and release the fasteners B then remove the spoiler Take care notto scratch the body Fastener Locations t Clip 2 t B 5 Install the spoiler in the reverse orde...

Page 754: ...i VTEC emblem on the body align the application tape with the edge of the wheel arch then press the emblem into place and remove the application tape 03 model When installing the LEV emblem on the qua...

Page 755: ...DHESIVE TAPE REAR Si EMBLEM t REA R SiR EMBLEM Canada t i 34 11 31 d 49 Z l 109 Edge of the hatch f 49 _ ccc i 11 931 i _AD ESIVETAPE ___ Edge of the hatch CIVIC EMBLEM Edge of the hatch ADHESIVE TAPE...

Page 756: ...nder and remove the clip EI securing the front air spoiler front bumper and front inner fender 3 From the wheel arch remove the clips F GI securing the front inner fender and splash shieldI on the bod...

Page 757: ...h remove the clip AI and release the clip BI then remove the front fender fairing el Fastener locations A Clip 1 B Clip 1 J x _ B 4 Install the fender fairing in the reverse order of removal and note...

Page 758: ...tector in the reverse order of removal and note these items Replace any damaged clips Push the clips into place securely 20 104 Rear Air Outlet Replacement 1 Remove the rear bumper see page 20 861 2 D...

Page 759: ...page 20 106 HATCH LOCK CYLINDER Replacement page 20 11 1 HATCH HANDLE Replacement page20 110 HATCH LATCH Replacement page 20 110 FUEL FILL DOOR LATCH page 20 107 FUEL FILL DOOR OPENER CABLE Replacemen...

Page 760: ...the hood opener cable AI from the hood latch Bllsee page 20 108 and remove the bolts lei then remove the hood release handle IDI from the body Fastener locations C Bolt 2 E I Clip 3 6x 1 0 mm 9 8N m 1...

Page 761: ...arpet back as necessary see page 20 55 3 Disconnect the fuel fill door opener cable A from the opener B see step 3 on page 20 109 Fastener Locations c Cushion tape 1 o t Clip 1 E t Clip 2 I _ F c E __...

Page 762: ...er cable B from the hood latch Take care not to bend the cable 20 108 3 Instali the hood latch in the reverse order of removal and note these items Apply multipurpose grease to each location of the ho...

Page 763: ...uring the fuel fill door opener 2 Remove the left door sill trim see page 20 501 3 Remove the opener AI from the bolt 81 4 Disconnect the fuel fill door opener cable AI then remove the opener 81 Take...

Page 764: ...ens properly 20 110 Hatch Latch Replacement NOTE Put on gloves to protect your hands 1 Remove the hatch lower trim panel see page 20 531 2 Disconnect the hatch opener cable AI cylinder rod BI hatch ac...

Page 765: ...rod A 3 From outside the hatch remove the bolt securing the lock cylinder A From inside the hatch pull the lock cylinder out by releasing the hook B Fastener Location Bolt 1 6x1 0mm 9 8N m 11 0 kgf m...

Page 766: ...ones FRONT SUSPENSION SUBFRAME Reference holes alignment SUBFRAME REFERENCE HOLE Body SideI INSTALLATION REFERENCE HOLE Subframe side INSTALLATION REFERENCE HOLE FRONT SUSPENSION SCREWDRIVER or TAPER...

Page 767: ...e quarter panel SIDE FRAME STIFFENER MIDDLE FLOOR CROSS MEMBER BRACE GUSSET 1 j v SIDE FRAME STIFFENER t 1 8x 1 25mm L 29 N m 13 0 kgf m 221bf 1t1 To body To body U S model 10 x 1 25 mm Canada model 3...

Page 768: ...e mount 013 0 51 For engine mount 013 0 51 For manual transmission mount 013 0 51 For manual transmission mount 013 0 51 For manual transmission mount 13 0 51 1 UNE d e f 9 h For damper mount 011 5 0...

Page 769: ...ating hole 825 0 98 t1 t2 Locating hole 013 0 51 n Locating hole 020 O 79 u for upper arm 013 D S1 0 Trailing arm center v for rear lower arm center p Rear damper center w locating hole 050 1 97 q For...

Page 770: ...For engine mount 013 0 51 For engine mount 13 0 51 For manual transmission mount 013 0 51 For manual transmission mount 013 0 51 For manual transmission mount 13 10 51 d A VERTICAL LINE d For damper...

Page 771: ...For engine mount 013 0 51 For engine mount 13 0 51 For manual transmission mount 013 0 51 For manual transmission mount 013 0 51 For manual transmission mount 13 10 51 d A VERTICAL LINE d For damper...

Page 772: ...pper arm 013 0 51 For trailing arm 013 0 51 s For upper arm bracket center 015 0 59 t1 t2 Locating hole 013 0 51 u For upper arm 013 0 51 v For rear lower arm center w Locating hole 050 1 97 xl Locati...

Page 773: ...haul 21 49 Recirculation Control Motor Compressor Thermal Protector Circuit Troubleshooting 21 25 Replacement 21 51 Heater Control Power and Ground Compressor Relief Valve Circuits Troubleshooting 21...

Page 774: ...HVAC Heating Ventilation and Air Conditioning Special Tools f T oo 1N u m ber _ _ _ o c c D escription 07SAZ 001000A Back robe Set Q I 21 2...

Page 775: ...MPRESSOR SERVICE VALVE HIGH PRESSURE SIDEI RECEIVER DRYER Replacement page 21 47 Clutch Check page 21 48 Clutch Overhaul page 21 49 CONDENSER Replacement page 21 52 Thermal Protector Check page 21 48...

Page 776: ...tion Index cont d RAOIATOR FAN RELAY Test page 22 51 COMPRESSOR CLUTCH RELAY Test page 22 51 BLOWER MOTOR RELAY I _ L Test page 22 51 UNDER HOOD FUSE RELAY BOX CONOENSER FAN RELAY Test page 22 51 I 1...

Page 777: ...E SENSOR Replacement page 21 37 Test page 21 37 BLOWER UNIT COMPONENTS Replacement page 21 41 DUST AND POLLEN FILTER Replacement page 21 39 RECIRCULATION CONTROL MOTOR Test page 21 36 Replacement page...

Page 778: ...move the caps or plugs until just before you reconnect each line Before connecting any hose or line apply a few drops of refrigerant oil to the O ring When tightening or loosening a fitting use a seco...

Page 779: ...mm 9 8 N m 1 0 kgf m 7 2 Ibf ft rJ Receiver line A to the receiver dryer 6 x 1 0 mm 9 8 N m 1 0 kgf m 7 2 Ibf ft Receiver line A to the receiver line B 13 N m 1 3 kgf m 9 4Ibf ft COMPRESSOR 7 Receiver...

Page 780: ...conds later the self diagnosis will finish and the NC indicator goes off If any trouble is found the recirculation indicator blinks the diagnostic trouble code DTC to indicate a faulty circuit or comp...

Page 781: ...l linkage doors or motor see page 21 191 12 A problem in the blower motor circuit see page 21 201 13 A problem in the EEPROM in the heater control panel I see page 21 381 the control panel must be rep...

Page 782: ...301 radiator fan runs with the NC on Troubleshooting Isee page 21 28 Cleanliness and tightness of all I connectors __ Both fans do not run with the NC on Radiator and Condenser Fans Blown fuse No 1 12...

Page 783: ...NT OUTPUT 12 YEL BLK REAR WINDOW DEFOGGER RELAY INPUT _ _ 13 BLK GROUND OUTPUT 14 BLK YEL IG2 Power INPUT CONNECTOR B C 0 on IrcUlt laQram Cavity Wire color 1 Signal 1 2 INPUT 3 BLK RED REAR WINDOW DE...

Page 784: ...D LOW PRESSURE LIQUID LOW PRESSURE VAPOR This vehicle uses HFC 134a IR 134a refrigerant which does not contain chlorofluorocarbons Pay attention to the following service items Do not mix refrigerants...

Page 785: ...f BLU BLK GRNfWHT RADIATOR FAN RELAY 13 CONDENSER FAN RELAY 1 I BLU YEL 3 RED j COMPRESSOR CLUTCH RELAY 1 BLU RED 1 THERMAL fY PROTECTOR I T l I 3JiP SSOR t C ll ACC 1 3 2 j G q 1 lJ SWITCH BLOWER MOT...

Page 786: ...LTGRN S5V S COM AMD P AIR MIX CONmOL ll t V SV GAY _ PNK BLK 16 r GRN 12 LIGHT 11 DRIVING CIRCUIT PNK BLU 11 YEL BLU L 1 r VEL REO v y 20 19 18 17 RED YEl REDIBLU WHT BLU YEL GRN M COOL MOTOR M HOT M...

Page 787: ...ix control motor If the symptom indication continues substitute a known good heater control panel and recheck If the symptom indication goes away replace the original heater control panel NO Repair an...

Page 788: ...ater control panel NO Substitute a known good air mix control motor and recheck If the symptom indication goes away replace the original air mix control motor If the symptom indication continues subst...

Page 789: ...HEATER CONTROL PANEL CONNECTOR A114PI Q LTGRN 1 2 3 4 5 6 Wire side of female terminals HEATER CONTROL PANEL CONNECTOR B 22P Wire side of female terminals Is there continuity YES Repair any shortto b...

Page 790: ...nd B 22P and at the mode control motor 1OP connector If the connections are good substitute a known good mode control motor and recheck If the symptom indication goes away replace the original mode co...

Page 791: ...r wire 6 Disconnect the power transistor 4P connector 21 20 7 Check for continuity between the No 3 terminal of the power transistor 4P connector and body ground POWER TRANSISTOR 4P CONNECTOR 2 3 4 Wi...

Page 792: ...rol panel and the power transistor 15 Reconnect heater control panel connector A 14P 16 Test the power transistor see page 21 38 Is the power transistor OK YES Check for loose wires or poor connection...

Page 793: ...y ground BLOWER MOTOR RELAY 4P SOCKET Is there battery voltage YES Go to step 25 NO Repair open in the wire between the No 14 fuse in the under dash fuse relay box and the blower motor relay 21 22 25...

Page 794: ...tance within the specifications shown on the graph YES Go to step 3 NO Replace the evaporator temperature sensor 3 Disconnect heater control panel connector B 22P 4 Check for continuity between the No...

Page 795: ...NO Repair open in the wire between the heater control panel and the evaporator temperature sensor 21 24 OTe 15 A Short in the Evaporator Temperature Sensor Circuit 1 Remove the evaporator temperature...

Page 796: ...YES Go to step 7 NO Replace the recirculation control motor or repair the linkage and doors 7 Disconnect heater control panel connector A 14P 8 Check for continuity between the No 5 and No 6 terminals...

Page 797: ...side of female terminals Q GRN YEL RECIRCULATION CONTROL MOTOR 5P CONNECTOR Wire side of female terminals Is there continuity YES Check for loose wires or poor connections at heater control panel conn...

Page 798: ...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 conn...

Page 799: ...l of the condenser fan relay 4P socket and body ground CONDENSER FAN RELAV 4P SOCKET 2 4 3 Is there battery voltage YES Go to step 4 NO Replace the under hood fuse relay box 21 28 4 Connectthe No 1 an...

Page 800: ...ondenser Fans Common Circuit Troubleshooting NOTE If both fans and the AlC compressor clutch do not work when the AlC switch is on go to AlC Pressure Switch Circuit Troubleshooting see page 21 32 1 Ch...

Page 801: ...e under hood fuse relay box and the No 14 lOA 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 the throt...

Page 802: ...and the compressor clutch relay 9 Turn the ignition switch OFF 10 Reinstall the compressor clutch relay 11 Make sure the AlC switch is OFF 12 Turn the ignition switch ON II 13 Using the Backprobe Set...

Page 803: ...the wire between the compressor clutch relay and the compressor clutch 21 32 AIC Pressure Switch Circuit Troubleshooting 1 Turn the ignition switch ON 1111 2 Turn the blower switch on and check for bl...

Page 804: ...n good multiplex control unit and a ECM one at a time 10 Disconnect the Ale pressure switch 2P connector and under dash fuse relay box connector F 112PI 11 Check for continuity between the No 2 termin...

Page 805: ...o step 3 AIR MIX CONTROL MOTOR J L 1 2 3 4 5 3 Measure the resistance between the No 4 and No 5 terminals It should be between 2 1 k to 3 9 kQ 4 Reconnect the air mix control motor 5P connector then t...

Page 806: ...runs smoothly go to step 4 4 Use a digital multimeter with an output of 1 mA or less at the 20 k Q range With the mode control motor running as in step 2 check for continuity between the No 4 5 6 7 8...

Page 807: ...control matorfor a long time RECIRCULATION CONTROL MOTOR L 1 2 5 3 If the recirculation control motor does not run in step 2 remove it then check the recirculation control linkage and doors for smooth...

Page 808: ...refully pull out the evaporator temperature B 4 Install the sensor in the reverse order of removal Evaporator Temperature Sensor Test 1 Dip the sensor in ice water and measure the resistance between i...

Page 809: ...r 5 Supply 12 volts to the No 4 cavity with a jumper wire 6 Turn the ignition switch ON II and check that the blower motor runs Ifthe blower motor does not run replace the power transistor If the blow...

Page 810: ...rs in the reverse order of removal Blower Unit Removal and Installation For some models SRS components are located in this area Review the SRS component locations see page 23 131 and precautions and p...

Page 811: ...remove the wire harness clips 8 and the connectors C Remove the self tapping screws and the bracket D A D B c 21 40 10 Disconnect the connector A from the recirculation control motor then remove the...

Page 812: ...or A the power transistor 8 the blower motor e and the dust and pollen filters D can be replaced without removing the blower unit Before reassembly make sure that the recirculation control linkage and...

Page 813: ...g the pipes J 1 1 i _ 11 6 Install the core in the reverse order of removal and note these items II you re installing a new evaporator core add refrigerant oil KEIHIN SP 10 see page 21 6 Replace the G...

Page 814: ...e cable B from the heater valve arm C Turn the heater valve arm to the fully opened position as shown B c J r I i 5 When the engine is cool drain the engine coolant from the radiator see page 10 6 6 S...

Page 815: ...remove the wire harness clips 8 and the connector C Remove the self tapping screw and the cover D Disconnect the heater valve cable E A 21 44 11 Remove the mounting bolts the mounting nuts and the hea...

Page 816: ...e clamps securely Refill the cooling system with engine coolant see page 10 61 Adjust the heater valve cable see page 21 461 Make sure that there is no coolant leakage Make sure that there is no air l...

Page 817: ...kage C 3 Set the temperature control dial on Max Cool with the ignition switch ON II 4 Attach the heater valve cable 8 to the air mix control linkage C as shown above then snap the heater valve cable...

Page 818: ...moval and note these items Before installing the new compressor check for metal or other contamination in the line Replace any contaminated parts If you re installing a new compressor you must calcula...

Page 819: ...1 and add or remove shims as needed to increase or decrease clearance Clearance 0 5 0 15 mm 0 020 0 006 in 1 NOTE The shims are available in four thicknesses 0 1 mm 0 2 mm 0 4 mm and 0 5 mm 21 48 4 Re...

Page 820: ...thickness of shims as necessary then reinstall the armature plate and recheck its clearance see page 21 48 NOTE The shims are available in four thicknesses 0 1 mm 0 2 mm 0 4 mm and 0 5 mm A O B 3 If y...

Page 821: ...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 installati...

Page 822: ...the reverse order of removal Compressor Relief Valve Replacement 1 Recover the refrigerant with a recovery recycling charging station see page 21 53 2 Remove the relief valve A and the O ring 8 Plug t...

Page 823: ...g the condenser 6x 1 0mm 9 8 N m 11 0 kgf m 7 2 Ibf ftl 5 Install the condenser in the reverse order of removal and note these items If you re installing a new condenser add refrigerant oil KEIHIN SP...

Page 824: ...scharge occurs ventilate the 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...

Page 825: ...ufacturers 1 When an AlC 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 syste...

Page 826: ...nnect a R 134a refrigerant recovery recycling charging station AI to the high pressure service port 81 and the low pressure service port C as shown following the equipment manufacturer s instructions...

Page 827: ...e 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 21...

Page 828: ...ompressor off then air flow from vents is restricted check evaporator temperature sensor Expansion valve is frosted Cloooed exoansion valve Clean or reolace Receiver dryer outlet is cool and inlet Clo...

Page 829: ...h compressed air Additional health and safety information may be obtained from the refrigerant and lubricant manufacturers 1 Connect a R 134a refrigerant recover recycling charging station to the high...

Page 830: ...ure The delivery temperature should fall between the two lines Complete the low side pressure test and high side pressure test in the same way Any measurements outside the line may indicate the need f...

Page 831: ...urn Signal Hazard Relay Input Test 22 87 Hazard Warning Switch Test 22 88 Entry Lights Control System Component Location Index 22 89 Circuit Diagram 22 90 Ignition Key Switch Test 22 91 Ignition Key l...

Page 832: ...nt 22 145 Rear Window Wiper Motor Replacement 22 146 Washer Reservoir Replacement 22 146 Washer Tubes Replacement 22 147 Accessory Power Socket Circuit Diagram 22 149 Accessory Power Socket Test Repla...

Page 833: ...Body Electrical Special Tools Ref No Tool Number Description Qty CD 07WAZ 0010l0A MPCS Service Connector 1 07LAJ PT3020A Test Harness i 1 CD 07TAZ 001 020A Back Probe Adapter 1 CD I 22 2...

Page 834: ...nectors 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...

Page 835: ...arnesses Secure wires and wire harnesses to the frame with their respective wire ties at the designated locations Remove clips carefully don t damage their locks A Slip pliers A under the clip base an...

Page 836: ...are pinched underthem When using electrical test equipment foliowthe manufacturer s instructions and those described in this manual If possible insert the probe of the tester from the wire side except...

Page 837: ...osis 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 offailure first Try to make tests at points that are easily...

Page 838: ...r I a J Engine Compartment RADIATOR FAN RELAY HORN RELAY A C COMPRESSOR CLUTCH RELAY CONDENSER FAN RELAY UNDER HOOD FUSE RELAY BOX REAR WINDOW DEFOGGER RELAY BLOWER MOTOR RELAY DO D HEADLIGHT RELAY 1...

Page 839: ...LLIGHT RELAY STARTER CUT RELAY DAYTIME RUNNING LIGHTS RELAY ICanada Wire colors RED RED YEL 1 RED BLK and RED BLU LOW BEAM CUT RELAY ICanada Wire colors RED WHT RED BLK 1 RED YEL and RED BLU KEYLESS R...

Page 840: ...IMMOBILIZER CONTROL UNIT RECEIVER HEATER CONTROL PANEL AUDIO UNIT _ _ J c r I I J conl d 22 9...

Page 841: ...f 0 ECM SRS UNIT 22 10 EPS CONTROL UNIT AIR FUEL RATIO SENSOR RELAY Wire colors WHT WHT RED 1 LORN and BLKJORN PGM FI MAIN RELAY 1 Wire colors VEL BLK 1 WHT BLK WHT BLK and RED yEL PGM FI MAN RELAY 2...

Page 842: ...NROOF CONTROL UNIT t I t I MOONROOF OPEN RELAY Wire colors GRNIYEL GRN 1 RED YEL BLK and YEL GRN MOONROOF CLOSE RELAY Wire colors GRN BLK GRN 1 GRN WHT BLK and YEL GRN REAR WINDOW WIPER INTERMITTENT C...

Page 843: ...Relay and Control Unit Locations Door and Seat Driver s Door i I I I Passenger s Seat 22 12 POWER WINDOW MASTER SWITCH Has built in control unit OPDS UNIT c r i r...

Page 844: ...2 EP subharness C151 and C152 see page 22 24 G151 Dashboard wire harness A C504 through C510 see page 22 26 left branch G501 and G503 Left side turn signal light C506 see page 22 26 sub harness I Dash...

Page 845: ...compartment Gl 1 Left side of engine compartment Body ground via battery Qround cable I I 2 Battery Battery neQative terminal Engine Ground Cable Connector or Terminal Ref Cavities location Connects...

Page 846: ...ine compartment i Front of engine Middle of engine compartment Front of engine compartment Engine wire harness see page 22 16 Front of engine compartment Engine wire harness see poo 22 16 Left side of...

Page 847: ...4 7 3 Middle of engine compartment Injector No 1 25 2 Middle of engine compartment Injector No 2 24 2 Middle of engine compartment Injector No 3 20 2 Middle of engine compartment Injector No 4 19 2 Mi...

Page 848: ...30 29 28 27 26 8 25 21 20 19 23 ENGINE WIRE HARNESS 9 17 18 10 11 r I a J 12 13 14 15 16 22 17...

Page 849: ...side of front bumper Right front parking light 1 2 Behind right headlight Right front side marker light 10 2 Behind right side of front bumper Right front turn signal light 11 2 Behind right headligh...

Page 850: ...ENGINE COM HARNESS PARTMENT WIRE 13 12 11 9 8 7 6 2 3 4 5 r I conl d 22 19...

Page 851: ...nt side marker light 16 2 Behind left side of front bumper Left frontturn signal light 13 2 Behind left headlight Left headlight 20 3 Behind left headlight Left horn 21 1 Behind front bumper Radiator...

Page 852: ...2 3 26 25 24 23 22 21 20 19 __ 5 4 16 18 12 r I L I ENGINE COM HARNESS PARTMENT WIRE 13 14 15 cont d 22 21...

Page 853: ...nector J see page 22 45 C151 12 2 Under right side of dash EPS subharness see page 22 I 241 C401 7 4 Under right side of dash Dashboard wire harness B see page 22 30 C451 8 13 Under right side of dash...

Page 854: ...3 2 16 12 UNDER DASH FUSE RELAY BOX r I t I ENGINE COMPARTMENT WIRE HARNESS 6 7 8 10 11 22 23...

Page 855: ...ontrol unit connector B 1 2 Under right side of dash EPS control unit connector C 3 20 Under right side of dash EPS motor 7 2 Middle of engine compartment EPS torque sensor 8 6 Middle of engine compar...

Page 856: ...5 EPS SUB HARNESS 8 7 r I t I 22 25...

Page 857: ...5 16 13 17 10 12 6 12 13 20 13 2 8 4 6 12 Location Under middle of dash Under left side of dash Under left side of dash Under left side of dash Under left side of dash Under left side of dash Under le...

Page 858: ...4 3 2 34 m EN1 N SIGNAL LIGHT 33 13 7 9 32 30 14 21 DASHBOARD WIRE HARNESS A 17 r I t I 18 19 conl d 22 27...

Page 859: ...side of dash Under right side of dash Under right side of dash Under middle of dash Under middle of dash Under right side of dash Location Behind right side turn signal light Under ri ht side of dash...

Page 860: ...13 12 10 DASHBOARD WIRE HARNESS A 2 3 4 5 6 RIGHT AL LIGHT ARNESS 8 22 29...

Page 861: ...ng column cover Under dash fuse relay box 5 5 Under left side of dash connector A see page 22 45 Under dash fuse relay box 6 6 Under left side of dash connector B see page 22 45 Under dash fuse relay...

Page 862: ...2 1 19 18 17 16 15 6 5 4 _ r c c ___ L cS r rl c r lL L J J Jl U J DASHBOARDWIR E r HARNESS B T 7 8 9 10 11 22 31...

Page 863: ...y box 2 13 In the under dash fuse relay box connector E see page 22 45J Under dash fuse relay box 3 6 In the under dash fuse relay box connector R see page 22 45 C101 4 20 Under right side of dash Eng...

Page 864: ...ECM WIRE HARNESS 15 r _W J LL J JL __ n n __ WUWW __ L 2 3 6 10 11 7 8 r I L I 9 22 33...

Page 865: ...r s seat SRS unit connector B 20 18 Under middle of dash SRS unit connector C 21 8 Under middle of dash Under dash fuse relay box 17 18 Under dash fuse relay box connector P see page 22 45 Under dash...

Page 866: ...23 22 21 20 2 G 18 19 6 7 5 8 9 13 FLOOR WIRE HARNESS 14 15 16 r I t I 10 11 12 cont dl 22 35...

Page 867: ...ar Left taillight brake light 27 3 Left taillight Noise condenser rear window 13 2 Right quarter panel defogger Noise condenser rear window wiper 18 2 Right quarter panel Passenger s door switch 10 1...

Page 868: ...5 6 4 3 26 25 24 ____ c _4_ 23 7 8 9 11 12 18 r I t I FLOOR WIRE HARNESS 10 14 22 37...

Page 869: ...ddle of roof Moonroef motor 4 2 Middle of roof Moonroof open relay 7 5 Middle of roof Moonroof position sensor 1 8 2 Middle of roof Moonroef posiflon sensor 2 5 4 Middle of roof Maenroof switch 1 5 Fr...

Page 870: ...ar window defogger connector B 10 I Rear window wiper motor 6 C553 2 C554 10 9 8 Cavities Location 2 Middle of hatch 2 Middle of hatch 2 Behind high mount brake light 2 Middle of hatch 2 Middle of hat...

Page 871: ...mirror actuator Left tweeter Power window master switch C504 C505 I 10 9 22 40 I I I i Ref Cavities location 9 2 Driver s door 10 3 Driver s door 1 3 Driver s door 7 2 Driver s door 2 4 Driver s door...

Page 872: ...tch 7 5 Right power mirror actuator 4 6 Right tweeter 3 2 C514 2 13 C515 1 6 3 4 8 Location Connects to Passenger s door Passenger s door Passenger s door Passenger s door Passenger s door Passenger s...

Page 873: ...dex cont d OPDS Unit Harness Connector or Terminal Rei Cavities Location Connects to Notes OPOS unit 2 8 In front passenger s seat C552 1 4 Under front passenger s seat Floor wire harness see page 22...

Page 874: ...HARNESS 9 8 Cavities Location 5 Under middle of dash 2 Under right side of dash 2 Under middle of dash 10 Under right side of dash 4 Under right side of dash 5 Under right side of dash 1 Under middle...

Page 875: ...nser fan relay 9 4 D 12 14 Engine compartment wire harness see page 22 18 E 1I 7 Engine compartment wire harness see page 22 18 ELD unit 16 3 Engine compartment wire harness see page 22 18 Headlight r...

Page 876: ...harness A see page 22 26 M 22 12 Dashboard wire harness A see page 22 26 N 27 6 Dashboard wire harness A see page 22 26 a 26 12 Dashboard wire harness A see page 22 26 P 7 18 Floor wire harness see pa...

Page 877: ...control unit ECM BLU RED Horns 8 20A WHT GRN ABS modulator control unit 9 lOA WHT RED Audio unit Data link connector DLCI Gauge assembly Immobilizer control unit receiver Immobilizer indicator light K...

Page 878: ...icle speed sensor Not used Moonroof control unit Moonroof open and close relay Power window relay Moonroof motor Audio unit OPDS unit Rear window wiper motor Rear window washer motor Rear window wiper...

Page 879: ...ft and riqht airbaQ sensors SRS unit G451 Data link connector DLC G501 Clutch interlock switchm Clutch pedal position switch for cruise cantrall Cruise control main switch Cruise control unit Daytime...

Page 880: ...the under dash fuse relay box r I I I 5 Remove the mounting bolt and slide the under dash fuse relay box A down from the bracket 8 6 Disconnect the back side from connectors from the back of the under...

Page 881: ...OK go to step 3 3 Check the indicator EYE If the EYE indicates the battery is charged go to step 4 If the EYE indicates a low charge go to step 7 4 Apply a 300 amp load for 15 seconds to remove the su...

Page 882: ...lights relay Canada PGM FI main relay 1 PGM FI main relay 2 Blower motor relay Normally open Rear window defogger relay type B Moonroof close relay Five terminal Moonroof open relay _ c c type Low be...

Page 883: ...ntinuity between the No 1 and No 3 terminals when power is disconnected Rear window defogger relay Blower motor relay type 1 type 2 22 52 2 3 3 Five terminal type Check for continuity between the term...

Page 884: ...lower cover see page 20 59 2 Disconnect the 5P connector from the under dash fuse relay box Wire side of female terminals BLK YEL 3 Check for continuity between the terminals in each switch position a...

Page 885: ...UNIT page 11 156 VEHICLE SPEED SENSOR IVSS Troubleshooting page 22 65 Replacement page 22 67 22 54 page 8 4 I GAUGE ASSEMBLY Self diagnostic Procedure page 22 56 Gauge Bulb Replacement page 22 63 Rep...

Page 886: ...ONNECTOR A blue B1 ODO TRIP METER 810 822 CONNECTORB green SPEEDOMETER ehicle Speed Signal Circuit roubleshooting page 22 65 COOLANT TEMPERATURE GAUGE Troubleshooting page 22 64 FUEL GAUGE Test page 1...

Page 887: ...and OFF again 5 Within 5 sec release the trip reset button then push and release the button four times repeatedly NOTE o While in the self diagnosis mode the dash lights brightness controller operates...

Page 888: ...l the needles return to the minimum position Self diagnosis ON J mode OFF Trip Reset ON n n rLJl switch OFF Gauge needles ON U LJ OFF Beeper ON OFF 5 sec The Communication Line Check The needles sweep...

Page 889: ...M y h BlU TEST TACHOMETER B4 CONNECTOR 81 COOLANT TEMPERATURE GAUGE IMMOBILIZER CONTROL UNIT To page 22 62 I I No 4110AI FUSE Intheundef dash BLK VEL No lll 2No 4 7 5A r 10A Yl lK f VEHICLE SPUD SENSO...

Page 890: ...l GAUGE ASSEMBLY A TonlXl j so m _ REMINDER 7 SYSTEM DOOR HATCH i HT ATOR ATOR NG LOW UEL rMA TENANCE 01 LEDI HT LIGHT INDICATOR REOUIRED LED LEDI UGHT INDICATOR LEDI LIGHT LED l DRIVE CIRCUIT I I DR...

Page 891: ...ircuit Diagram cont d 22 60 No 211SAI FUSE tin the under hood DASH fuse relay box LIGHTS Y Y RED BlK RED I I i I I i ous 1 c ClC B i i f t i t j ____ page J C I I i 81 I PN I WASHER RUID LEVEl SWITCH...

Page 892: ...EMBLY IT I f 1I ATOR I UGHT I I IlEDI I I i I I I I I SIDE AIRBAG CUTOFF INDICATOR LED J CATORl I LCIRCUIT r ABS INDICATOR LIGHT LED RSUNIT I K 14 r SRS 1 INDICATOR CIRCUIT f I I ____ ____________ 1__...

Page 893: ...HT 11 4W I GRN El GRN VEL A12 G l RIGHTTURN SIGNAL INDICATOR UGHTS D l URN INDICATOR UGHT 14WI From 0 1_____ 1 previous I page J 22 62 No 15 15AI FUSE In the under hoodl fu e relaVbo I REDlYEL A1 D HI...

Page 894: ...URN SIGNAL INDICATOR LIGHT 11 4 WI r I t I CRUISE INDICATOR LIGHT 11 4 WI HIGH BEAM INDICATOR LIGHT 11 4 WI LEFT TURN SIGNAL INDICATOR LIGHT 11 4 WI GAUGE LIGHT 11 4 WI GAUGE LIGHT 11 4 WI IMMOBILIZER...

Page 895: ...t DTC Isee page 22 1681 and recheck NO Go to step 3 3 00 the communication line check with the self J 4 Disconnect the connectors e and remove the diagnosis procedure Isee page 22 561 gauge assembly I...

Page 896: ...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 BI to the positive probe of a voltmeter an...

Page 897: ...ulse from 0 to about 5 V or more YES Gotostep 14 NO Replace the VSS 22 66 14 Disconnect the 22P connector 8 from the gauge assembly GAUGE ASSEMBLY CONNECTOR B 122PI Bl B2 B3 B4 B6 B8 B9 BIO 811 B12 B1...

Page 898: ...placement 1 Remove the intake resonator 2 Disconnect the 3P connector from the vehicle speed sensor VSS A 3 Remove the mounting bolt then remove the VSS 4 Install the VSS in the reverse order of remov...

Page 899: ...ge 22 81 22 68 c HEADLIGHT RELAY 1 Test page 22 51 HEADLIGHT RELAY 2 Test page 22 51 BRAKE PEDAL POSITION SWITCH Test page 22 84 Adjustment page 19 6 SIDE TURN SIGNAL LIGHT Replacement page 22 84 FRON...

Page 900: ...22 82 LICENSE PLATE LIGHTS Replacement page 22 83 tEA _ REAR SIDE MARKER LIGHT Replacement page 22 83 BACK UP LIGHT Replacement page 22 82 TAILLIGHTS and BRAKE LIGHTS Replacement page 22 82 REAR TURN...

Page 901: ...REDIYEL 1 RED BLK and RED BLU Test page 22 51 LOW BEAM CUT RELAY ICanadal Wire colors RED WHT RED BLK 1 RED YEL and RED BLU Test page 22 51 DRL INDICATOR LIGHT ICanadal HIGH BEAM INDICATOR LIGHT Bulb...

Page 902: ...R COMBINATlON LIGHT SWITCH REONEL RED YEL LEFT RIGHT RIGHT PARKING FRONT PARKING FRONT UGHT SIDE UGHT DE 15Wj MARKER 15WI MARKER lIGHT UGHT 5WI 15W BLK BLK I BLK BLK 1 1 1 1 G G10l G30 G26 G26 BLU1ED...

Page 903: ...2 13 y G R N I Y ED 22 72 GRN RED Sf G301 BRAKE FLUID LEVEL SWITCH iClosed IF1oatdown 2No 1 I40A WHT ED No 3 UNDER DASH lOA FUSf RELAV BOX RED BLU IMMOBILIZER CONTROL UNIT RECEIVER y GRN O N GRNIORN P...

Page 904: ...ROL UNIT BtU 13 r I t I DASH FUSE RELAY BOX j REDNEL TAILlIGHT RELAY RE DASH LIGHTS DIMMER JI n a OFF 1 1 12 COMBINATION LIGHT SWITCH RED YEl RED YEL RED VEL RED VEl l llll p p b p LEFT LEFT RIGHT RIG...

Page 905: ...HT GRN 1 22 74 WHT BLK Lm BRAKE UGHT 2 IZ1WI LX 1 G WHT GRN W N WHTBLK WHTBLK WHT BLK BLK I G BRAKE PEDAL HORN POSITION SWITCH SYSTEM Closed Pedal pressed H H MOUNT BRAKE LIGHT 15Wx5 ABSMODULATOR CONT...

Page 906: ...GNITION SWITCH BAT 101 1G1 HOTinON II and START III 1 NO l0 7 5A UNDER DASH FUSE RELAY BOX BACK UP UGHTSWITCH On the transmission 1 lIousing I Closed In position R T GRN UFT P UP 2 21WI BLX T l 1 GRN...

Page 907: ...nit 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 see page 20 60 2 Disconnect the 14...

Page 908: ...between Blown bulb light switch ON No 3 and No 1 terminals Faulty low beam cut relay iilD and Both headlights HIGH and Faulty combination light switch J dimmer switch high beam indicator light Poor gr...

Page 909: ...ned off Before adjusting the headlights Park the vehicle on a level surface Make sure the tire pressures are correct The driver or someone who weighs the same should sit in the driver s seat 1 Clean t...

Page 910: ...ary adjust the headlights to local requirements by turning the vertical adjuster Headlight Replacement r I I I 1 Remove the front bumper Isee page 20 85 2 Disconnect the connectors IA from the headlig...

Page 911: ...bination 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 t...

Page 912: ...n the reverse order of removal Make sure the notches in the bulb align with the tabs in the headlight Front Turn Signal Light Parking Light r I 1 Remove the inner fender Isee page 20 102 2 Disconnectt...

Page 913: ...rclockwise to remove the bulb socket 5 When installing the taillight check the gasket if it is distorted or stays compressed replace it 6 After installing the taillight run water over the taillight to...

Page 914: ...3 Separate the lens 81 and housing C then remove the bulb 4 Install the light in the reverse order of removal r I t I Side Marker Light Replacement 1 Carefully pry the light A out of the rear bumper...

Page 915: ...k 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...

Page 916: ...N SIGNAL SWITCH Test page 22 80 Replacement page 22 80 TURN SIGNAL INDICATOR LIGHTS In the gauge assembly Bulb Replacement page 22 63 _ _ _ I I HAZARD WARNING SWITCH Test page 22 88 Replacement page 2...

Page 917: ...IGNALSWITCH J 10 11 YEll LK __0 _ R HT i lEFT RIGHT GRN RED 10 HAZARD WARNING SWITCH BlK RED GRN VEL BLK RED GRN WHT TURN SIGNAl HAZARD RELAY LEFT TURN SIGNAL LIGHTS RIGHT TURN SIGNAL LIGHTS BlJ BlK L...

Page 918: ...should be continuity An open in the wire 3 Ignition switch ON III Check for voltage to ground Blown No 19 17 5A fuse in the Hazard warning switch There should be battery voltage under dash fuse relay...

Page 919: ...he hazard warning switch 8 3 Push out the hazard warning switch from behind the center paneIIC 4 Check for continuity between the terminals in each switch position according to the table 5 If the cont...

Page 920: ...ION KEY SWITCH Test page 22 91 DRIVER S DOOR SWITCH CEILING LIGHTISPOTLIGHTS Test page 22 96 Replacement page 22 96 REAR CEILING LIGHT Test page 22 96 Replacement page 22 96 FRONT PASSENGER S DOOR SWI...

Page 921: ...BOX IFll e relaybox socket UNOER DASH FUSE RELAY BOX MULnPl XCONTROL UNIT r 03 Q4 GAN LTGRN RED DRIVER S UN LOCK 0 LOCK DOOR DRIVER S DOOR SWITCH Closed I Dooropen PASSfNGER S DOOR L 1 G501 22 90 LOC...

Page 922: ...see page 17 9 2 Disconnect the 6P connector 111 121 ill I 1611 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...

Page 923: ...LU ORN 1 I IJI131 UNDER DASH FUSE RELAY BOX CONNECTOR 0 112P 31 1516171819 101121112 I GRN RED UNDER DASH FUSE RELAY BOX CONNECTOR P 118P UNDER DASH FUSE RELAY BOX CONNECTOR Q 18P UNDER DASH FUSE RELA...

Page 924: ...ssible cause if result is not obtained P18 RED Hatch open Check for voltage to ground POOr ground G552 There should be 1 V or less Faulty hatch latch switch o An open in the wire Hatch closed Check fo...

Page 925: ...hts Component Location Index 22 94 CEILING LIGHTISPOTLIGHTS Test page 22 96 Replacement page 22 96 REAR CEILING LIGHT Test page 22 96 Replacement page 22 96 CARGO AREA LIGHT Test page 22 97 Replacemen...

Page 926: ...1 CEILING LIGHTfSPOTLlGHTS bSPOTLIGHTS D 15Wx21 bCEILING LIGHT 5WI 91 II ON OFF o0 3 Bl GRN M G WHT BLU 2 18W ON OFF yO 1 GRN M MULTIPlEX CONTROL UN MAR UNO LIGHT MULTIPLEX CONTROL UN Y WHT BlU 1 15W...

Page 927: ...ION SPOTLIGHTS R OFF Ceiling light ON IOFF L OFF 6 If the continuity is not as specified check the bulb If the bulb is OK replace the ceiling lighVspotlights 22 96 Rear Ceiling light Test Replacement...

Page 928: ...e is no continuity check the bulb If the bulb is OK replace the cargo area light Hatch Latch Switch Test 1 Open the hatch 2 Remove the hatch lower trim panel see page 20 53 3 Disconnect the 2P connect...

Page 929: ...t page 22 102 22 98 LEFT REAR SPEAKER Replacement page 22 102 AUDIO UNIT Removal Installation page 22 100 Connector Terminals page 22 101 RIGHT DOOR TWEETER Replacement page 22 102 FRONT PASSENGER S D...

Page 930: ...A LEAD No 8 I7 5A t I No 20 14OA USA No 20 150A Canada UNDER DASH FUSE RELAY BOX RED BLK WHT RED VEL GRN VEL RED ANTENNA SUBLEAD I A9 AlO A1 i AUDIO UNIT C L Q Q A 19 rA 1 A A17 BLK l3 DASH UGHTS BRIG...

Page 931: ...llAI o I I i B c 4 Disconnect the audio connector 8 and antenna lead ICI heater control panel connectors IDI and HAVC push switch assembly lEI then remove the center panel 22 100 5 Remove the heater c...

Page 932: ...iaht rear soeaker Left rear soeaker Front oassenaer s door speaker Riaht tweeter Driver s door speaker I Left tweeter Liqhts on siqnal Constant Dower Not used Not used Not used Not used Riaht rear soe...

Page 933: ...far you will damage the lower clips C Then lift the speaker straight up to release the lower clips 3 Disconnect the 2P connector 8 and remove the speaker Tweeter Carefully pry the tweeter A out of th...

Page 934: ...enna Replacement 1 Remove the rear part 01 headliner see page 20 541 2 Disconnect the antenna lead connector A and 1P connector 8 lrom the rool antenna e 3 Remove the mounting nut and the antenna r I...

Page 935: ...is built into the heater control panel UNDER HOOD FUSE RELAY BOX REAR WINDOW DEFOGGER SWITCH REAR WINDOW DEFOGGER RELAY Test page 22 51 _ 0j 22 104 o NOISE CONDENSER Capacity Test page 22 107 REAR WI...

Page 936: ...RELAY BlK VEL VEl BlK 812 Re window defogger s witch and defog er timer circuit built nto HEATER CONTROL PANEL heater control panel BlK YEL BlK VEL REAR WINDOW J NOISE DEFOGGER I CONDENSER BlK BlK 1...

Page 937: ...defogger wire and the negative probe to the negative terminal There should be about 6 V with the ignition switch and the defogger switch ON If the voltage is as specified the defogger wire is OK If th...

Page 938: ...onnector A from the noise condenser Noise condenser capacity 0 47 0 09 microfarads Wire side of female terminals 3 Use a commercially available condenser tester Connect the condenser tester probes and...

Page 939: ...3 MOONROOF SWITCH Test page22 112 Replacement page 22 112 MOONROOF MOTOR Test page 22 112 Replacement page 20 41 r MOONROOF LIMIT SWITCH Test page 22 113 MOONROOF OPEN RELAY Wire colors GRNIYEL GRN 1...

Page 940: ...osition B Closed in the tilt or closed position C Closed in any open not tiltl pOSition D Closed in the tilt position UNDER DASH fUSE RELAY BOX t t 1f YEl GRN q C REO YEt RED YEl r r IOPEN rl MOONROOF...

Page 941: ...5P connector AI from the control unit 81 A 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 cor...

Page 942: ...ty Wire Test condition Test Desired result 3 RED YEL Ignition switch ON II Connect a jumper wire between No 3 and No Sterminals Moonroof motor should run i opened 2 GRNIWHT Ignition switch ON II Conne...

Page 943: ...rminal 3 1 2 4 5 Position CLOSE Oi TILT OPEN 0 0 4 If the continuity is not as specified replace the moonroof switch 22 112 Motor Test 1 Remove the headliner see page 20 54 2 Disconnect the 2P connect...

Page 944: ...specified replace the moonroof limit switch Auto stop Switch Test 1 Remove the headliner see page 20 541 2 Disconnect the 2P connector from the moonroof auto stop switch Terminal side of male termina...

Page 945: ...Location Index 22 114 POWER MIRRORS Function Test page 22 116 Replacement page 20 15 Actuator Test page 22 117 Actuator Replacement page 22 118 POWER MIRROR and MIRROR DEFOGGER SWITCH Test page 22 117...

Page 946: ...SWITCH UP lEFT 11 D UGHT DEFOGGER 1 4WI SWITCH INDICATOR 0 UGHT c _ LILEDI DOWN RED 0 J LEFT RIGHT LEFT DASH LIGHTS 8 5 10 11 BRIGHTNESS CONTROllER r I No 20 14IlA USA NolO ISOA Canada 2 Canada RIGHT...

Page 947: ...tilt down or swing left with the ignition switch ON II If the mirror does nottilt down or does not swing left check for an open in the GRN WHT or BLU WHT wire between the left mirror and the 13P conn...

Page 948: ...gger Switch Canada 1 Terminal 1 8 Position ON 0 OFF 5 If the continuity is not as specified replace the power mirror switch Power Mirror Actuator Test r I t I 1 Remove the door panel see page 20 4 2 D...

Page 949: ...ove 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 screws and separa...

Page 950: ...BLK BLK BLK I I Clmffi Clmffi 1 1 ORN GRV VEL LT GRN BRN PNK Wire side of female terminals Canada 11 Reassemble in the reverse order of disassembly Be careful not to break the mirror holder when rein...

Page 951: ...cation Index 22 120 HORN RELAY Test page 22 51 HORNS Test page 22 122 Replacement page 22 122 c J _ i y y 1_ I 12 1 L I I I J L UNDER HOOD FUSE RELAY BOX HORN SWITCH Test page 22 122 CABLE REEL Replac...

Page 952: ...Circuit Diagram GRN BRAKE UGHTS CRUISE CONTROL SET RESUME CANCEL SWITCH 0 0RN BAmRV 2No 7 t 15AI CABLE REEL HORN SWITCH UNDER HOOD fUSE RELAV BOX j HORN RELAV h 8LU RED H HORN H IiORN 22 121...

Page 953: ...sound replace it 22 122 Horn Switch Test 1 Remove the steering column covers see page 17 91 2 Disconnect the dashboard wire harness 8 5P connector AI from the cable reel 81 B 3 Using a jumper wire f c...

Page 954: ...und If the horns sound go to step 6 B If the horns do not sound replace the cable reel 6 Reconnect the horn switch positive 1Pconector B t I 7 Using a jumper wire connent the steering wheel to body gr...

Page 955: ...page 22 126 Test page 22 128 Replacement page 22 133 _ JLJl __ JL r n UL Uc JL2_ULJ_ rn nr n LL U JUL U_ FRONT PASSENGER S WINDOW SWITCH Input Test page 22 130 Test page 22 132 Replacement page 22 133...

Page 956: ...1No 12 No Z3 120Al I20AI L GRN WHT GRN BlK MASTER SWITCH 2 I PASSENGER S DRIVER S 1 rf 1 lllr OFf 1 P J ON OOWN UP VMPl POWER WINDOW CONTROL UNIT l HT DNG ILED upG MAIN SWITCH 14 13 3 10 BLK RED VEL...

Page 957: ...ndow master switch A see page 22 133 2 Disconnect the 14P connector 8 from the master switch B J ___A Wire side of female terminals BLK RED VEL BLK GRN WHT ORN 3 Inspect the connector and socket termi...

Page 958: ...It should run the driver s An open in the wire I and turn the ignition switch i ON III i window moves down 3 BLU RED Connect the No 2 and No 1 Check for passenger s Faulty passenger s window terminals...

Page 959: ...ccording to the table Driver s Window 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 on pa...

Page 960: ...ction UP e c l DOWN c l e 4 If the motor does not run or fails to run smoothly replace it Pulser Test 1 Reconnect the 4P connector to the driver s window motor and reconnect the 20P connector to the p...

Page 961: ...ystem Cavity Wire Test condition Test Desired result Possible cause if result is not obtained 3 GRN BLK Ignition switch ON Check for voltage to Blown No 6 7 5A fuse in the II ground under dash fuse re...

Page 962: ...ould run the passenger s No 4 terminal to window moves down the No 5 terminal There should be battery and turn the Voltage ignition switch ON II and press the down button on the power window master sw...

Page 963: ...V IV 0 OFF 0 c 0 0 DOWN D 0 0 5 If the continuity is not as specified replace the switch 22 132 Passenger s Window Motor Test 1 Remove the passenger s door panel see page 20 41 2 Disconnect the 2P con...

Page 964: ...connector 81 from the switch 4 Remove the three screws and the switch from the switch panel r I t I Passenger s Window Switch Replacement 1 Remove the door grip see page 20 41 2 Remove the power windo...

Page 965: ...placement page 22 145 WIPER WASHER SWITCH Test page 22 140 Replacement page 22 140 0 v 1 WINDSHIELD WIPER MOTOR Test page 22 143 Replacement page 22 145 22 134 1 I r __J INTERMITTENT WIPER CIRCUIT In...

Page 966: ...FLUID LEVEL SWITCH ICanada Test page 22 144 Replacement page 22 144 WINDSHIELD WASHER MOTOR Test page 22 144 Replacement page 22 146 NOISE CONDENSER Capacity Test page 22 107 REAR WINDOW WIPER INTERMI...

Page 967: ...RN BlK 14 WINDSHIELD WIPER WASHER SWITCH uu u uu orycuu C v j 90 voe HI d lM ST lM T INT LO 6 13 12 5 11 GRNBlK WHT BLU MULTIPLEX BLUIRED CONlllOL Xl UN BlU BlK iHasbuilt iii B1 I intermittent WHT BLU...

Page 968: ...RN Ti No 9 OAI t WHT UNDER DASH fUSE RELAY BOX LTJRN 7 L OFF 8 REO GN W ON 1 LTGRN LTGRN l LTGRNIREO J 9 REAR WINDOW WIPER INTERMmENT CONTROL UNIT i LTGRN 1 NOO fREAR WINDOW M WASHER ICONDENSER MOTOR...

Page 969: ...e rear windowwiper intermittent control unit 81 B Wire side of female terminals LT GRN RED WHTIRED LT GRN G I I BLK 1 t 7Utg I I LT GRN BLK 3 Inspect the connector and socket terminals to be sure they...

Page 970: ...e There should be continuity 6 WHT RED Ignition switch ON Check for voltage to ground 0 Blown No 9 110A fuse in the II and rear There should be battery under dash fuse relay box window washer voltage...

Page 971: ...ws 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...

Page 972: ...ELAY BOX CONNECTOR B 16PI UNDER DASH FUSE RELAY BOX CONNECTOR G IIOP UNDER DASH FUSE RELAY BOX CONNECTOR J IBP WHT BLU B ffi rnml I 1 BLU RED UNDER DASH FUSE RELAY BOX CONNECTOR X IBP I BLK UNDER DASH...

Page 973: ...oltage to ground Blown No 20 20A fuse in the II and washer There should be battery under dash fuse relay box switch ON voltage Faulty wiper washer switch _ __ An open in th_e wire B6 BLU RED Ignition...

Page 974: ...the No 5 terminal and ground and run the motor at low or high speed The voltmeter should indicate 12 V and 4 V or less alternately If it does not replace the motor Rear Window r I I I 1 Open the hatch...

Page 975: ...s not run replace it 22 144 Washer Fluid Level Switch Testl Replacement Canada 1 Partially remove the right inner fender see page 20 102 2 Disconnect the 2P connector A from the washer level switch 3...

Page 976: ...cle until it slides off of the pin IE then remove the assembly r I 5 Scribe a line IA across the link and windshield wiper linkage to show the original adjustment Separate the windshield wiper linkage...

Page 977: ...in the reverse order of removal and note these items c A Apply mUltipurpose grease to the moving parts Before reinstalling the wiper arm turn the wiper switch ON then turn OFF to return the wiper sha...

Page 978: ...Washer Tubes Replacement 1 Remove the right inner fender see page 20 102 2 Remove the washer nozzles and clips then remove the tubes R1 a J conrd 22 147...

Page 979: ...Wipers Washers Washer Tubes Replacement cont d 3 Install in the reverse order of removal Take care not to pinch the washer tubes Check the washer operation 22 148...

Page 980: ...center lower cover 2 Disconnect the 2P connector IB 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 the...

Page 981: ...OL UNIT Input Test page 22 155 22 150 DRIVER S DOOR SWITCH DRIVER S DOOR LOCK ACTUATOR KNOB SWTICH Actuator Test page 22 158 Knob Switch Test page 22 160 KEYLESS RECEIVER UNIT Input Test page 22 153 I...

Page 982: ...KNOB SWITCH BLK 1 GSO UNDER DASH fUSE RELAY BOX No ZO 140A USA NoZO 50AI Canitda BAT No 10 7 5A Fuse relay box socket WHT BlK YEL 10 1 I tGl HOT 0 In N III and START 11111 WHT RED WHTlRED VL 5 3 TRANS...

Page 983: ...2 I l HORN RELAY MULTIPLEX CONTROL UNIT HEADUGIfT RELAY BLU RED F7 03 Q4 GRN LTGRN ED DRIVER S DRIVER S 1 PASSENGER S DOOfI OOOR OQOR LOCK SWITCH SWITCH SWITCH Iosed I Iosed lOooropen lJGOropen L X5 T...

Page 984: ...onnect the 5P connector AI from the keyless receiver unit BI WHT RED Wire side of female terminals 4 Inspect the connector and socket terminals to be sure they are all making good contact If the termi...

Page 985: ...connect 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 keyl...

Page 986: ...R F 12P 1 2 4 5 6 7 8 1 9 10 11 12 BLU RED UNDER DASH FUSE RELAY BOX CONNECTOR M 12P 2 3 6 7 8 9 10 11 12 I YEL BLK YEL BLK YEL YEL UNDER DASH FUSE RELAY BOX CONNECTOR X BP VlZvDDlA 71 8 RED WHT UNDER...

Page 987: ...An aDen in the wire i Driver s door closed Check for voltage to ground o Faulty driver s door switch There should be 5 V or more o Short to around Q4 1 LTGRN Passenger s door open Check for voltage to...

Page 988: ...s receiver unit 5P connector disconnected There should be continuity M7 YELJBLK Connect J7 terminal to M7 Check actuator operation Faulty driver s door lock actuator MS YEL MS terminal and M9 The driv...

Page 989: ...nly momentarily 1 Terminal 1 2 Position LOCK 8 8 c 8 B UNLOCK 4 If the actuator does not operate as specified replace it 22 158 Passenger s door 1 Remove the passenger s door panel see page 20 4 2 Dis...

Page 990: ...nnect the 2P connector from the hatch lock actuator Terminal side of male terminals 4 Check actuator operation by connecting power and ground according to the table To prevent damage to the actuator a...

Page 991: ...is in the UNLOCKED position There should be no continuity when the door lock knob switch is in the LOCKED position 5 If the continuity is not as specified replace the door lock actuator 22 160 Door Lo...

Page 992: ...NOTE It is important to maintain the time limits between the steps Make sure the doors and the hatch are closed 1 Turn the ignition switch ON II 2 Within 1 to 4 sec push the transmitter lock or unlock...

Page 993: ...ATOR LIGHT Bulb Replacement page 22 63 ECM Replacement page 11 4 Substitute known good for testing page 11 5 IMMOBILIZER CONTROL UNIT RECEIVER Troubleshooting page 22 165 Replacement page 22 167 l ___...

Page 994: ...T RECEIVER c ECM IGNITION KEY Has built in transponder KEY CYLINDER FUEL SUPPLY SYSTEM If the proper key has been used the immobilizer indicator light will come on for about 2 seconds then go off If t...

Page 995: ...RN YEl RED YEL El E7 IMOflR MAIN RlY fun P PUMP I G551 BAT IGNITION n 1G1 SWITCH IGI HOT in ON II and START III BLK YEl No 17 IISAI YEL BlI YEl BlK E9 1 UNDER DASH FUSE RELAY BOX h YEl BLK YEL BLK A2...

Page 996: ...eiver then go to step 9 NO Check for these problems then go to step 3 Blown No 9 lOA fuse in the under hood fuse relay box An open in the wire between the gauge assembly and the immobilizer control un...

Page 997: ...control unit receiver 7P connector No 2 terminal and ECM terminal E27 Is there continuity YES Go to step 13 NO Repairthe open in the RED BLU wire 13 Reconnect the 7P connector to the immobilizer cont...

Page 998: ...sconnect the 7P connector A from the immobilizer control unit receiver 8 c 4 Remove the two screws and the immobilizer control unit receiver from the ignition key cylinder e 5 Install the immobilizer...

Page 999: ...Index 22 168 IGNITION KEY LIGHT Test page 22 91 ECM MULTIPLEX CONTROL UNIT Built into the under dash fuse relay box Troubleshooting page 22 172 Input Test page 22 175 REAR CEILING LIGHT Test page 22 9...

Page 1000: ...yEL 1131 HOT in ON III and START 1111 W1IT RED J2 UNDER DASH FUSE RELAY BOX MULTIPLEX CONTROL UNIT i f 03 a GAN LTGR IRED 1c DRIVER S q PASSENGER S DOOR DOOR SWITCH SWITCH Closed I Dooropen I Closed I...

Page 1001: ...6 05 F8 DAYTIME RUNNING F1 lIGHTS CONTROL UNIT ICanadal y GRNj D GRNrO BlU RED T IUSAI SRSUNIT j L GRN RED RED 0 o Canadal 2 BRAKE r DRIVER S SEAT8ELT FLUID SWITCH LEVEL 1 GANIORN I 1 iClosed SWIT 7 U...

Page 1002: ...ECM 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 swi...

Page 1003: ...d ceiling light indicate mode I YES Go to step 8 NO Go to step 7 22 172 7 Check for continuity between terminal 4 of the under dash fuse relay box connector J and body ground Is there continuity YES R...

Page 1004: ...uge assembly 1 Faulty power or ground to the ECM 2 Faulty ECM Before replacing a Faulty ECM PCM make sure it has the latest software revision Update if necessary before swapping or replacing M I I u t...

Page 1005: ...ck way of testing the circuits integrity switch lights blinks when Windshield washer washer switch pulled switch Windshield wiper Switch in the INT pas switch Driver s door switch As door is opened pa...

Page 1006: ...V 7 8 9 11 12 13 V GRN ORN BLU CONNECTOR K 17PI WHT GRN CONNECTOR Q 8P LTGRN RED GRN ORN L 7 j GRN BLU RED BLU RED CONNECTOR E 13P CONNECTOR F 12P GRN RED USA GRN ORN Canada CONNECTOR J 8P WHT RED I m...

Page 1007: ...Check for voltage to ground Faulty driver s door switch There should be 1 V or less An open in the wire Driver s door closed Check for voltage to ground o Faulty driver s door switch There should be 5...

Page 1008: ...There should be less than 1 V Check for voltage to ground There should be 5 V or more Check for voltage to ground There should be battery voltage in the sleep mode and 3 7 volts when awake Check for...

Page 1009: ...n 23 23 DTC Troubleshooting Index 23 28 Symptom Troubleshooting Index 23 30 System Description 23 31 Circuit Diagram 23 34 DTC Troubleshooting 23 36 SRS Indicator Circuit Troubleshooting 23 105 Compon...

Page 1010: ...A SRS Inflator Simulator 1 4 07TAZ SZ5011A SRS Simulator Lead C 1 2 07TAZ 001020A Backprobe Adapter 17 mm 2 07XAZ S1A0200 SRS Simulator Lead E 1 i j 07XAZ SZ30100 SRS Simulator Lead F 1 i 07YAZ S3AA10...

Page 1011: ...REAR CENTER BELT and REAR SEAT BELT BUCKLES step 1 on page 23 8 Inspection page 23 9 SHOULDER ANCHOR ADJUSTER step 8 on page 23 4 FRONT SEAT BELT Replacement page 23 4 Inspection page 23 9 REAR SEAT B...

Page 1012: ...able from the battery and wait at least 3 minutes before beginning work 3 Slide the front seat forward fully 4 Remove the lower anchor cap A and remove the lower anchor bolt BI B 7 16 20 UNF 32 N m 13...

Page 1013: ...ner has been deployed replace the front seat belt protector with a new one o Apply liquid thread lock to the anchor bolts before reinstallation o Before installing the anchor bolts make sure there are...

Page 1014: ...ull the seat belt switch tensioner harness e out through the hole on the seat track 23 6 7 Install the buckle in the reverse order of removal and note these items Assemble the washers on the center an...

Page 1015: ...t BI then remove the rear seat belt CI and retractor DI B 7 16 20 UNF 32 N m 13 3 kgf m 24lbf ltl c D A 6x 1 0mm 3 4 N m 10 35 kgf m 2 5 Ibf ltl 5 Install the seat belt in the reverse order of removal...

Page 1016: ...the seat back cover see page 20 82 5 Remove the seat back pad from the seat back frame see step 3 on page 20 81 B 6 Remove the screw and release the hooks A then remove the retractor cover B Fastener...

Page 1017: ...rs with seat belt tensioners review the SRS component locations see page 23 13 and the precautions and procedures see page 23 14 in the SRS section before performing repairs or service Retractor Front...

Page 1018: ...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 alco...

Page 1019: ...oothed washer IE from the tether anchor 3 Install the anchor in the reverse order of removal Side 1 Remove the rear bulkhead covers from both sides Isee page 20 511 2 Remove the anchor bolt IA then re...

Page 1020: ...acement page 23 113 Disposal page 23 116 FRONT PASSENGER S AIRBAG Replacement page 23 114 Disposal page 23 116 OPOS SENSORI SEAT BACK Replacement page 20 75 FRONT PASSENGER S SIDE AIRBAG Replacement p...

Page 1021: ...ystem If it is not a Honda multimeter make sure its output is 10 mA O OlAI or less when switched to the lowest value in the ohmmeter range A tester with a higher output could cause accidental deployme...

Page 1022: ...rface up Never put anything on the airbag To prevent damage to the airbag keep it free from any oil grease detergent or water Store the removed airbag on a secure flat surface away from any high heat...

Page 1023: ...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 the side impact senso...

Page 1024: ...ations are clean and grounds are securely fastened for optimum metal to metal contact Poor grounding can cause intermittent problems that are difficult to diagnose Precautions for Electrical Inspectio...

Page 1025: ...e 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 c 2 When the connector halves are completely conne...

Page 1026: ...rbags 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 on...

Page 1027: ...nning the following procedures Before disconnecting SRS unit connector A 1 from the SRS unit disconnect the driver s airbag 4P connector 3 the front passenger s airbag 4P connector 4 the driver s seat...

Page 1028: ...from the steering wheel then disconnect the driver s airbag 4P connector B from the cable reel Front Passenger s Airbag 3 Disconnect the front passenger s airbag 4P connector A from dashboard wire ha...

Page 1029: ...at belt tensioner 2P connectors AI from the floor wire harness I I I A Seat Belt Buckle Tensioner 6 Disconnect both seat belt buckle tensioner 4P connectors AI A 23 22 SRS Unit 7 Disconnect SRS unit c...

Page 1030: ...imeter make sure its output is 10 mA O OlA or less when switched to the smallest value in the ohmmeter range A tester with a higher output could damage the airbag circuit or cause accidental airbag de...

Page 1031: ...sconnect the Honda PGM Tester from the OLC 7 Do the troubleshooting procedure for the OTC Patterns of OTC Indications The DTC consists of a main code and subcode s Second 65 35 25 35 1 1 1 I I I I FIl...

Page 1032: ...the system If the SRS indicator does not come on as indicated above always check for an open or a short to ground in the SCS circuit before troubleshooting the system Example of DTC Indications 1 Con...

Page 1033: ...tor within 4 seconds 7 The SRS indicator will blink two times indicating that the memory has been erased 8 Turn the ignition switch OFF and wait for 10 seconds 9 Turn the ignition switch ON II again T...

Page 1034: ...SCS service connector lrom 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 seco...

Page 1035: ...ce in driver s seat belt buckle tensioner see page 23 541 21 3 Short to another wire or decreased resistance in driver s seat belt see page 23 551 buckle tensioner 21 4 Short to power in driver s seat...

Page 1036: ...bag deployed 10 6 Driver s and front passenger s side airbags deployed 10 7 Seat belt and seat belt buckle tensioners and airbag s and driver s and front passenqer s side airbaqs deployed 11 1 Open or...

Page 1037: ...age 23 24 Side airbag cutoff indicator stays Make sure nothing is on the front OTC 15 2 troubleshooting on after bulb check If the passenger s seat indicator stays on it does not set If the side airba...

Page 1038: ...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...

Page 1039: ...n 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 Airbagls...

Page 1040: ...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 uni...

Page 1041: ...SSENGtR S AIRBAG FIRST INfLATOR fRONT PASSENGER S AIRBAG SECOND INFLATOR 1 1 SRSUNIT I I I DRIVl R S SEAT BELl TENSIONER FRONT PASSENGER S SEAT BELT TENSKlNER r RECIYEl RED lK P K v LON flOOR W HARNES...

Page 1042: ...IRBAG INFLATOII i DRIVER S SIDE PACT SENSOR 0 OZMod 1 OlMO 101 rwithsidelirb gJ I PASSENGER S SDEIMPACT SENSOR It L_ _____ 1 SRSUNfT 1 I I 1 LTGRN aLUI EO flOOR W HARNESS 1l 1 LTPLEX IrNDER OAS14 SfGN...

Page 1043: ...4P connector A from the cable reel L _ 07SAZ TB4011A 07XAZ SZ30100 tw 5 Connect the SRS inflator simulator 2 Q connectors and the simulator lead Fto the cable reel 23 36 6 Reconnect the battery negati...

Page 1044: ...ther Wire or Decreased Resistance in Driver s Airbag Inflator Special Tools Required SRS inflator simulator 07SAZ TB4011A SRS simulator lead F 07XAZ SZ30100 1 Erase the DTC memory see page 23 26 2 Tur...

Page 1045: ...nnect the special tool from the cable reel 23 38 14 Check resistance between the No 7 and the No 16 terminals and between the No 6 and the No 15 terminals of SRS unit connector A 18P There should be a...

Page 1046: ...SAZ TB4011A 07XAZ SZ30100 W 5 Connect the SRS inflator simulator 2 Q connectors and the simulator lead F to the cable reeL 6 Reconnect the battery negative cable 7 Erase the DTC memory 8 Read the DTC...

Page 1047: ...rminal and body ground There should be 0 5 V or less Is the voltage as specified YES Replace the cable reel NO Replace dashboard wire harness B 23 40 Ole 5 Short to Ground in Driver s Airbag Inflator...

Page 1048: ...etween the No 7 terminal of SRS unit connector A 18PI and body ground the No 16 terminal and body ground the No 6 terminal and body ground and the No 15 terminal and body ground There should be an ope...

Page 1049: ...4P connector A from dashboard wire harness B A 07SAZ TB4011A i _ I_ 07XAZ SZ30100 5 Connect the SRS inflator simulator 2 Q connectors and the simulator lead F to dashboard wire harness B 6 Reconnect t...

Page 1050: ...ols Required SRS inflator simulator 07SAZ TB4011A SRS simulator lead F 07XAZ SZ30100 1 Erase the DTC memory see page 23 26 2 Turn the ignition switch ON II and check that the SRS indicator comes on fo...

Page 1051: ...tors from the floor wire harness see step 5 on page 23 22 23 44 12 Disconnect SRS unit connector A 18P from the SRS unit see step 7 on page 23 22 13 Disconnect the special tool from dashboard wire har...

Page 1052: ...s 4 Disconnect the front passenger s airbag 4P connector A from dashboard wire harness B A 07SAZ TB4011A 0 07XAZ SZ30100 5 Connect the SRS inflator simulator 2 Q connectors and the simulator lead F to...

Page 1053: ...shboard wire harness B replace dashboard wire harness B 23 46 DTC 2 5 Short to Ground in Front Passenger s Airbag Inflator Special Tools Required SRS inflator simulator 07SAZ TB4011A SRS simulator lea...

Page 1054: ...he floor wire harness Isee step 5 on page 23 22 12 Disconnect SRS unit connector A 118P from the SRS unit Isee step 7 on page 23 22 13 Disconnectthe special tool from dashboard wire harness B 14 Check...

Page 1055: ...4011A FEJ iC C I i _ 1 5 Connect the SRS inflator simulator 12 Q connectorl and simulator lead C to the floor wire harness 23 48 6 Reconnect the battery negative cable 7 Erase the DTC memory 8 Read th...

Page 1056: ...122 NO Open or increased resistance in dashboard wire harness 8 replace dashboard wire harness B DTe 3 3 Short to Another Wire or Decreased Resistance in Driver s Seat Belt Tensioner Special Tools Req...

Page 1057: ...floor wire harness replace the floor wire harness 15 Turn the ignition switch OFF Disconnect the battery negative cable and wait for 3 minutes 23 50 16 Disconnect the driver s airbag connector see st...

Page 1058: ...Connect the SRS inflator simulator 2 connector and simulator lead C to the floor wire harness 6 Reconnect the battery negative cable 7 Erase the DTC memory 8 Read the DTC Is DTC 3 4 indicated YES Go...

Page 1059: ...nit replace the SRS unit see page 23 122 NO Shortto power in dashboard wire harness B replace dashboard wire harness B 23 52 OTe 3 5 Short to Ground in Driver s Seat Belt Tensioner Special Tools Requi...

Page 1060: ...rness replace the floor wire harness 15 Turn the ignition switch OFF Disconnect the battery negative cable and wait for 3 minutes 16 Disconnect the driver s airbag connector see step 2 on page 23 21 f...

Page 1061: ...ry negative cable 7 Erase the DTC memory 23 54 GRN BLK Wire side of female terminals Is the resistance as specified YES Faulty SRS unit or poor contact at SRS unit connector B 18P and the SRS unit Che...

Page 1062: ...lead F to the floor wire harness 6 Reconnect the battery negative cable 7 Erase the DTC memory 8 Read the DTC Is OTe 21 3 indicated YES Go to step 9 NO Short in the driver s seat belt buckle tensione...

Page 1063: ...gative cable and wait for 3 minutes 4 Disconnect the driver s seat belt buckle tensioner 4P connector A from the floor wire harness z A _________ 07XAZ SZ301 00 07SAZ TB4011A f 5 Connect the SRS infla...

Page 1064: ...Belt Buckle Tensioner Special Tools Required SRS inflator simulator 07SAZ TB4011A SRS simulator lead F 07XAZ SZ30100 1 Erase the DTC memory see page 23 26 2 Turn the ignition switch ON II and check t...

Page 1065: ...ecified YES Faulty SRS unit replace the SRS unit Isee page 23 122 NO Short to ground in the floor wire harness replace the floor wire harness 23 58 DTC 4 1 Open in Front Passenger s Seat Belt Tensione...

Page 1066: ...replace the floor wire harness 15 Turn the ignition switch OFF Disconnect the battery negative cable and wait for 3 minutes 16 Disconnect the driver s airbag connector Isee step 2 on page 23 21 front...

Page 1067: ...om the floor wire harness A 07TAZ SZ5011A 5 Connect the SRS inflator simulator 2 Q connectorl and simulator lead C to the floor wire harness 6 Reconnect the battery negative cable 7 Erase the DTC memo...

Page 1068: ...dashboard wire harness B replace dashboard wire harness B Dle 4 4 Short to Power in Front Passenger s Seat Belt Tensioner Special Tools Required SRS inflator simulator 07SAZ TB401 lA SRS simulator le...

Page 1069: ...ness replace the floor wire harness 23 62 15 Turn the ignition switch OFF Disconnect the 16 17 IS 19 20 21 battery negative cable and wait for 3 minutes Disconnect the driver s airbag connector see st...

Page 1070: ...AZ SZSOllA 5 Connect the SRS inflator simulator 2 Q connectorl and simulator lead C to the floor wire harness 6 Reconnect the battery negative cable 7 Erase the DTC memory 8 Read the DTC Is DTC 4 5 in...

Page 1071: ...e 23 1221 NO Short to ground in dashboard wire harness B replace dashboard wire harness B 23 64 Ole 22 1 Open or Increased Resistance in Front Passenger s Seat Belt Buckle lensioner Special Tools Requ...

Page 1072: ...nnector B 18P and the SRS unit Check the connection if the connection is OK replace the SRS unit see page 23 122 NO Open or increased resistance in the floor wire harness replace the floor wire harnes...

Page 1073: ...emale terminals Is the resistance as specified YES Faulty SRS unit replace the SRS unit see page 23 122 NO Short in the floor wire harness replace the floor wire harness 23 66 OTe 22 4 Short to Power...

Page 1074: ...er 4P connector see step 6 on page 23 22 11 Disconnect SRS unit connector B 18P from the SRS unit see step 7 on page 23 22 12 Disconnect the special tool from the floor wire harness 13 Reconnect the b...

Page 1075: ...e banery negative cable 7 Erase the DTC memory 23 68 S Read the DTC Is DTC 22 5 indicated YES Go to step 9 NO Short to ground in the front passenger s seat belt buckle tensioner replace the front pass...

Page 1076: ...ever went dead 1 Erase the DTC memory see page 23 26 2 Turn the ignition switch ON II and check that the SRS indicator comes on for about 6 seconds and then goes off Does the SRS indicator stay on YE...

Page 1077: ...ermittent failure system is OK at this time Go to Troubleshooting Intermittent Failures Isee page 23 26 23 70 OTC 14 1 14 2 Internal Failure of the Front Passenger s Side Impact Sensor 1 Erase the DTC...

Page 1078: ...at belt buckle switch 3P connector A from the floor wire harness a A 6 Buckle the driver s seat belt Check resistance between the No 1 and No 3 terminals of the driver s seat belt buckle switch 3P con...

Page 1079: ...of male terminals Is the resistance as specified YES Go to step 8 NO Replace the driver s seat belt buckle assembly then clear the DTC 23 72 8 Check resistance between the No 1 terminal of the floor...

Page 1080: ...nd the No 3 terminal of the floor wire harness 3P connector There should beO 1 Q FLOOR WIRE HARNESS SRS UNIT CONNECTOR C IBPI 3P CONNECTOR 1 234 5 6 7 8 LTGRN Q LTGRN Wire side of female terminals Is...

Page 1081: ...passenger s seat belt buckle switch 3P connector A from the floor wire harness A 23 74 6 Buckle the front passenger s seat belt Check resistance between the No 1 and No 3 terminals of the front passen...

Page 1082: ...terminals Is the resistance as specified YES Go to step S NO Replace the front passenger s seat belt buckle assembly then clear the DTC S Check resistance between the No 1 terminal of the floor wire h...

Page 1083: ...NO Short to ground in the floor wire harness replace the floor wire harness 23 76 13 Check resistance between the No 7 terminal of SRS unit connector C 8PI and the No 3 terminal of the floor wire har...

Page 1084: ...the ignition switch OFF Disconnect the battery negative cable and wait for 3 minutes 5 Disconnect the driver s airbag 4P connector from the cable reel see step 2 on page 23 21 6 Disconnect the front p...

Page 1085: ...tor and simulator lead Hto the engine compartment wire harness 2P connector A A 07YAZ S3AA100 07SAZ TB4011A tJ Gi 23 78 16 Check resistance between the No 10 and No 1 1 terminals of SRS unit connector...

Page 1086: ...ignition switch OFF Disconnect the battery negative cable and wait for 3 minutes 5 Disconnect the driver s airbag 4P connector from the cable reel see step 2 on page 23 211 6 Disconnect the front pass...

Page 1087: ...connector and simulator lead H to the engine compartment wire harness 2P connector A 07SAZ TB40llA tJ l 23 80 A 16 Check resistance between the No 1 and No 12 terminals of SRS unit connector A 18P Th...

Page 1088: ...negative cable and wait for 3 minutes 4 Disconnect the floor wire harness 2P connector IAI from the driver s side airbag o 5 Connect the SRS inflator simulator 12 Q connectorl and simulator lead E to...

Page 1089: ...82 OTe 3 Short to Another Wire or Decreased Resistance in Driver s Side Airbag Inflator Special Tools Required SRS inflator simulator 07SAZ TB4011A SRS simulator lead E 07XAZ S1A0200 1 Erase the DTC m...

Page 1090: ...male terminals Is the resistance as specified YES Faulty SRS unit replace the SRS unit Isee page 23 1221 NO Short to another wire in the floor wire harness replace the floor wire harness OTe 11 4 Shor...

Page 1091: ...see step 4 on page 23 21 and both seat belt buckle tensioner 4P connectors see step 6 on page 23 22 23 84 11 Disconnect SRS unit connector B 18P from the SRS unit see step 7 on page 23 22 12 Turn the...

Page 1092: ...able 7 Erase the DTC memory B Read the DTC Is OTe 11 5 indicated YES Go to step 9 NO Short to ground in the driver s side airbag inflator replace the driver s side airbag see page 23 115 9 Turn the ig...

Page 1093: ...tery negative cable and wait for 3 minutes 4 Disconnect the floor wire harness 2P connector AI from the front passenger s side airbag 07S A AP i JI 07XAZ S1A0200 5 Connect the SRS inflator simulator 2...

Page 1094: ...OTe 12 3 Short to Another Wire or Decreased Resistance in Front Passenger s Side Airbag Inflator Special Tools Required SRS inflator simulator 07SAZ TB4011A SRS simulator lead E 07XAZ S1A0200 1 Erase...

Page 1095: ...T CONNECTOR B 1SP WHT RED WHT GRN Wire side of female terminals Is the resistance as specified YES Faulty SRS unit replace the SRS unit see page 23 122 NO Short to another wire in the floor wire harne...

Page 1096: ...n page 23 21 and both seat belt buckle tensioner 4P connectors Isee step 6 on page 23 22 11 Disconnect SRS unit connector B 118P from the SRS unit Isee step 7 on page 23 22 12 Turn the ignition switch...

Page 1097: ...attery negative cable 7 Erase the DTC memory 8 Read the DTC Is DTC 12 5 indicated YES Go to step 9 NO Short to ground in the front passenger s side airbag inflator replace the front passenger s side a...

Page 1098: ...connect the battery negative cable and wait for 3 minutes 4 Check the connection between the floor wire harness 2P connector and the driver s side impact sensor Is the connection OK YES Go to step 5 N...

Page 1099: ...loor wire harness replace the floor wire harness 23 92 OTe 13 4 Faulty Power Supply to the Driver s Side Impact Sensor 1 Erase the DTC memory see page 23 26 2 Turn the ignition switch ON II and check...

Page 1100: ...specified YES Go to step 8 NO Short to ground in the floor wire harness replace the floor wire harness 8 Check resistance between the No 8 and No 15 terminals of SRS unit connector B 18P There should...

Page 1101: ...and wait for 3 minutes 4 Check the connection between the floor wire harness 2P connector and the front passenger s side impact sensor s the connection OK YES Go to step 5 NO Poor contact between the...

Page 1102: ...de Impact Sensor 1 Erase the DTC memory see page 23 261 2 Turn the ignition switch ON III and check that the SRS indicator comes on for about 6 seconds and then goes off Does the SRS indicator stay on...

Page 1103: ...ill present replace the SRS unit see page 23 122 NO Short in the floor wire harness replace the floor wire harness 23 96 OTe 15 1 Faulty OPDS Unit NOTE An incorrect OPDS unit can cause DTC 15 1 A new...

Page 1104: ...Go to step 12 12 Replace the No 9 110AI fuse 13 Disconnect OPDS unit harness 8P connector IAI from the OPDS unit o 14 Turn the ignition switch ON 1111 for 30 seconds then turn it off 15 Check the No 9...

Page 1105: ...NIT CONNECTOR B Il8P GRN ORN Wire side of female terminals s the resistance as specified YES Go to step 22 NO Short to ground in the floor wire harness or OPDS unit harness replace the faulty harness...

Page 1106: ...ion switch ON III and check thatthe SRS indicator comes on for about 6 seconds and then goes off Does the SRS indicator stay on YES Turn the ignition switch OFF and go to step 4 NO Intermittent failur...

Page 1107: ...OPDS unit harness SP connector and body ground There should be battery voltage OPOS UNIT HARNESS 8P CONNECTOR Wire side of female terminals Is there battery voltage YES Go to step 11 NO Go to step 23...

Page 1108: ...place the gauge assembly NO Go to step 19 19 Turn the ignition switch OFF 20 Disconnect floor wire harness 6P connector C509 A from the dashboard wire harness A 21 Turn the ignition switch ON II 22 Ch...

Page 1109: ...02 model Check for voltage between the No 4 terminal of dashboard wire harness A 6P connector C509 and body ground There should be battery voltage 03 model Check for voltage between the No 5 terminal...

Page 1110: ...e gauge assembly NO Open in dashboard wire harness A replace dashboard wire harness A 32 Turn the ignition switch OFF 33 Disconnect the OPDS unit harness 8P connector AI from the OPDS unit see page 23...

Page 1111: ...on YES Go to step 3 NO Intermittent failure system is OK atthis time Go to Troubleshooting Intermittent Failures see page 23 26 NOTE Aftermarket devices fluorescent lights laptop computers etc used ne...

Page 1112: ...B 22PI 2 3 4 5 6 8 9 10 11 12 13 17 18 19 21 22 Wire side of female terminals Is the resistance as specified YES Go to step 4 NO Open in the BLK wire of dashboard wire harness A or faulty body ground...

Page 1113: ...Go to step 10 NO Go to step 9 23 106 9 Connect a voltmeter between the No 2 terminal of gauge assembly connector B 22PI and body ground Turn the ignition switch ON III and measure the voltage There s...

Page 1114: ...relay box Is the fuse OK YES Gotostep 19 NO Go to step 3 3 Replace the No 13 lOA fuse 4 Turn the ignition switch ON II and wait for 30 seconds Then turn the ignition switch OFF 5 Check the No 13 lOA f...

Page 1115: ...s airbag 4P connector see step 2 on page 23 211 21 Disconnect the front passenger s airbag 4P connector see step 3 on page 23 211 22 Disconnect both seat belt tensioner 2P connectors see step 5 on pa...

Page 1116: ...ct SRS unit connector C 8P from the SRS unit see step 7 on page 23 22 31 Connect the NO 3 terminal of SRS unit connector A 18P and the No 5 terminal of SRS unit connector C 8P with a jumper wire SRS U...

Page 1117: ...shboard wire harness A replace the faulty harness 23 110 40 Remove the gauge assembly see page 22 64 then disconnect gauge assembly connector A from the gauge assembly A 41 Check resistance between th...

Page 1118: ...ts in the SCS menu see the Tester s operating manual 47 Check resistance between the No 6 terminal of SRS unit connector C BPI and body ground There should be 0 1 0 Q SRS UNIT CONNECTOR C IBPI Wire si...

Page 1119: ...r a collision where the side airbag s deployed replace these items SRS unit Deployed side airbagls Side impact sensor s for the side s that deployed During the repair process inspectthese areas Inspec...

Page 1120: ...driver s airbag C Installation 1 Connect the horn switch connector 1 P to the driver s airbag 2 Place the new driver s airbag A in the steering wheel and secure it with new Torx bolts 8 and install th...

Page 1121: ...ront passenger s airbag BI out of the dashboard NOTE The airbag lid has pawls on its side which attach it to the dashboard 23 114 Installation 1 Place the new front passenger s airbag AI into the dash...

Page 1122: ...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 a...

Page 1123: ...eployed while still in the vehicle The airbags side airbags seat belttensioners and seat belt buckle tensioners should not be considered as salvageable parts and should never be installed in another v...

Page 1124: ...of Damaged Components If the red light on the tool comes on the component is ready to be deployed 11 Push the tool s deployment switch The airbags and tensioners should deploy deployment is both high...

Page 1125: ...eat belt tensioner see page 23 4 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...

Page 1126: ...Al from the cruise control set resume switch then remove the steering wheel bolt BI B 5 Align the front wheels straight ahead then remove the steering wheel with a steering wheel puller see step 3 on...

Page 1127: ...ll off the cable reellAI B 23 120 Installation 1 Before installing the steering wheel align the front wheels straight ahead 2 If not already done disconnect the battery negative cable and wait at leas...

Page 1128: ...he steering wheel and install the steering eel with a new steering wheel bolt A 38N m 13 9 kgf m 28lbf ftl 8 Install the driver s airbag see page 23 113 9 Reconnect the battery negative cable 10 After...

Page 1129: ...2 Installation 1 Install the new SRS unit A with Torx bolts 8 then connect the connectors e to the SRS unit push them into position until they clicks NOTE When tightening the Torx bolts to the specifi...

Page 1130: ...he floor wire harness 2P connector from the side impact sensor 6 Remove the Torx bolt A using a Torx T30 bit then remove the side impact sensor 8 Installation 1 Install the new side impact sensor with...

Page 1131: ...two screws el and the OPDS unit DI 23 124 Installation 1 Place the new OPDS unit AI on the seat back frame Tighten the two screws BI and connect the OPDS unit harness 8P and sensor connectors C to the...

Page 1132: ...Remove the front inner fender see page 20 102 4 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...

Page 1133: ...A pillar Corner Trim Replacement 20 96 ABS Indicator Circuit Troubleshooting 19 52 ABS Modulator control Unit Removal Installation 19 57 ABS TCS Components Component Location Index 19 30 Description...

Page 1134: ...4 Cooling System Component Location Index 10 2 Countershaft Bearings Replacement 13 42 Cowl Cover Replacement 20 95 Crankshaft Removal 7 12 Inspection 7 14 Installation 7 24 Crankshaft Main Bearings R...

Page 1135: ...aporator Heater Unit Replacement Exhaust Manifold Removal I nstallation Exhaust Pipe Replacement F Fan Controls Component Location Index Circuit Diagram Fender Fairing Front Replacement Final Driven G...

Page 1136: ...condary Replacement 11 1 3 Hubs Replacement 18 26 IAT Intake Air Temperature Sensor Replacement 11 115 Idle Control System Component Location Index Inspection Ignition CoiUs Removal Installation Ignit...

Page 1137: ...22 112 Moonroof Wind Deflector Replacement _ _ _ _ _ _ 20 38 Moonroof Sunroof Component Location Index 20 35 22 108 Test 20 48 Circuit Diagram 22 109 MTF Inspection Replacement Multiplex Control Syste...

Page 1138: ...llation 20 71 Disassembly Reassembly 20 73 Seat Front Passenger s Disassembly Reassembly 20 74 Seat Rear Removal Installation Seat back Cover Rear 20 80 Replacement 20 82 Seat back Latch Rear Replacem...

Page 1139: ...Installation 20 50 51 52 53 Troubleshooting See first page of this Index Turn Signal Light Replacement 22 84 Turn Signal Hazard Relay Input Test 22 87 Turn Signal Hazard Warning Lights Component Locat...

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